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SEN00919-02

Shop
Manual

D275AX-5E0
BULLDOZER
SERIAL NUMBERS

D275AX-5E0 30001 and up

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2007 Komatsu


Printed in U.S.A.
Komatsu America Corp.
May 2007

SEN00921-02

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

00 Index and foreword

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4

D275AX-5E0

SEN00921-02

00 Index and foreword

Composition of shop manual

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

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00919-02

00 Index and foreword


Index
Foreword and general information

SEN00920-02
SEN00921-02 q
SEN00922-01 q

01 Specification
Specification and technical data

SEN00923-00
SEN00924-00

10 Structure, function and maintenance standard


Engine and cooling system
Power train system, Part 1
Power train system, Part 2
Undercarriage and frame
Hydraulic system, Part 1
Hydraulic system, Part 2
Hydraulic system, Part 3
Work equipment
Cab and its attachments
Electrical system

SEN00925-00
SEN00926-00
SEN00927-00
SEN00928-00
SEN00929-00
SEN00930-00
SEN00931-00
SEN00932-00
SEN00933-00
SEN00934-00
SEN00935-00

20 Standard value table


Standard service value table

SEN00936-00
SEN01413-00

30 Testing and adjusting


Testing and adjusting, Part 1
Testing and adjusting, Part 2
Testing and adjusting, Part 3
Testing and adjusting, Part 4

SEN00937-00
SEN01414-00
SEN01415-00
SEN01416-00
SEN01417-00

40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure and error codes, Part 1
Troubleshooting by failure and error codes, Part 2
Troubleshooting by failure and error codes, Part 3

SEN00938-00
SEN01767-00
SEN01768-00
SEN01655-00
SEN01656-00
SEN01657-00

D275AX-5E0

00 Index and foreword

Troubleshooting by failure and error codes, Part 4


Troubleshooting by failure and error codes, Part 5
Troubleshooting by failure and error codes, Part 6
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

SEN00921-02

SEN01658-00
SEN01659-00
SEN01878-00
SEN01646-00
SEN01647-00
SEN01648-00

50 Disassembly and assembly


General information on disassembly and assembly
Engine and cooling system
Engine
Power train, Part 1
Power train, Part 2
Undercarriage and frame, Part 1
Undercarriage and frame, Part 2
Hydraulic system
Work equipment
Cab and its attachments
Electrical system

SEN00939-00
SEN02340-00
SEN02341-00
SEN02342-00
SEN02343-00
SEN02344-00
SEN02345-00
SEN02346-00
SEN02347-00
SEN02348-00
SEN02349-00
SEN02350-00

90 Diagrams and drawings


Hydraulic diagrams and drawings
Electrical diagrams and drawings

SEN00940-01
SEN00941-00
SEN00942-01 q

D275AX-5E0

Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q

SEN00921-02

00 Index and foreword

Table of contents

00 Index and foreword


Index
SEN00921-02
Composition of shop manual.......................................................................................................
2
Table of contents .........................................................................................................................
4
Foreword and general information
SEN00922-01
Safety notice................................................................................................................................
2
How to read the shop manual .....................................................................................................
7
Explanation of terms for maintenance standard..........................................................................
9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data
SEN00924-00
Specification and technical data ..................................................................................................
2
Specefication dimension drawings...........................................................................................
2
Specifications...........................................................................................................................
3
Weight table .............................................................................................................................
9
Table of fuel, coolant and lubricants ........................................................................................ 11
10 Structure, function and maintenance standard
Engine and cooling system
SEN00926-00
Engine and cooling system .........................................................................................................
2
Engine mount...........................................................................................................................
2
Cooling system ........................................................................................................................
4
Cooling fan pump.....................................................................................................................
6
Cooling fan motor .................................................................................................................... 14
Power train system, Part 1
SEN00927-00
Power train system, Part 1 ..........................................................................................................
2
Power train skeleton ................................................................................................................
2
HSS system .............................................................................................................................
4
Overall drawing of power train unit ..........................................................................................
6
Power train hydraulic piping drawing .......................................................................................
8
Transmission control................................................................................................................
9
Steering, brake control............................................................................................................. 10
Damper, universal joint ............................................................................................................ 12
Torque converter, PTO............................................................................................................. 14
Transmission............................................................................................................................ 28
Tranmission ECMV .................................................................................................................. 40
Main relief valve and torque convertor relif valve .................................................................... 46
Torque converter valve ............................................................................................................ 50
Lubrication relief valve ............................................................................................................. 58
Power train system, Part 2
SEN00928-00
Power train system, Part 2 ..........................................................................................................
3
Bevel gear shaft, HSS, brake ..................................................................................................
3
Brake valve .............................................................................................................................. 16
Brake ECMV ............................................................................................................................ 17
Parking brake valve ................................................................................................................. 23
Sudden brake prevention valve ............................................................................................... 24
Final drive ................................................................................................................................ 25

D275AX-5E0

00 Index and foreword

SEN00921-02

Sprocket................................................................................................................................... 30
Undercarriage and frame
SEN00929-00
Undercarriage and frame ............................................................................................................
2
Track frame..............................................................................................................................
2
Recoil spring............................................................................................................................
4
Idler..........................................................................................................................................
6
Track roller...............................................................................................................................
8
Track roller bogie ..................................................................................................................... 10
Carrier roller............................................................................................................................. 12
Track shoe ............................................................................................................................... 14
Main frame............................................................................................................................... 16
Suspension.............................................................................................................................. 18
Hydraulic system, Part 1
SEN00930-00
Hydraulic system, Part 1 .............................................................................................................
2
Work equipment hydraulic piping diagram ..............................................................................
2
PPC control piping diagram.....................................................................................................
6
Work equipment control...........................................................................................................
8
Hydraulic tank.......................................................................................................................... 10
Scavenging pump.................................................................................................................... 12
Work equipment pump ............................................................................................................ 14
Power train pump, steering lubrication pump .......................................................................... 30
HSS pump ............................................................................................................................... 31
HSS motor ............................................................................................................................... 47
PPC, HSS charge filter ............................................................................................................ 56
Hydraulic system, Part 2
SEN00931-00
Hydraulic system, Part 2 .............................................................................................................
2
Control valve............................................................................................................................
2
Self pressure reducing valve ................................................................................................... 31
Hydraulic system, Part 3
SEN00932-00
Hydraulic system, Part 3 .............................................................................................................
2
HSS charge filter bypass .........................................................................................................
2
HSS oil cooler bypass valve ....................................................................................................
4
PPC valve................................................................................................................................
6
PCCS lever.............................................................................................................................. 18
PPC lock valve ........................................................................................................................ 21
Work equipment cylinder ......................................................................................................... 22
Piston valve ............................................................................................................................. 25
Quick drop valve...................................................................................................................... 26
Pin puller switch....................................................................................................................... 27
Pin puller solenoid valve.......................................................................................................... 28
Blade control knob................................................................................................................... 30
Pitch, dual tilt solenoid valve ................................................................................................... 31
Accumulator............................................................................................................................. 32
Work equipment
SEN00933-00
Work equipment ..........................................................................................................................
2
Cylinder stay ............................................................................................................................
2
Blade .......................................................................................................................................
4
Cutting edge, end bit ...............................................................................................................
8
Ripper ...................................................................................................................................... 10
Cab and its attachments
SEN00934-00
Cab and its attachments..............................................................................................................
2
Cab mount ...............................................................................................................................
2
Cab ..........................................................................................................................................
3
Air conditioner..........................................................................................................................
5

D275AX-5E0

SEN00921-02

00 Index and foreword

Electrical system
SEN00935-00
Electrical system .........................................................................................................................
2
Engine control..........................................................................................................................
2
Engine control system ............................................................................................................
3
Engine controller......................................................................................................................
4
Deceleration potentiometer...................................................................................................... 11
CRI engine control system....................................................................................................... 12
Monitor system ........................................................................................................................ 14
Monitor panel ........................................................................................................................... 16
Sensors.................................................................................................................................... 20
Mode selection system ............................................................................................................ 24
Electrical equipment ................................................................................................................ 30
Palm Command Control System ............................................................................................. 33
KOMTRAX terminal system..................................................................................................... 35
20 Standard value table
Standard service value table
SEN01413-00
Standard value table for engine...................................................................................................
2
Standard value table for machine................................................................................................
3
30 Testing and adjusting
Testing and adjusting, Part 1
SEN01414-00
Tools for testing, adjusting, and troubleshooting .........................................................................
3
Testing engine speed ..................................................................................................................
6
Testing intake air pressure (Boost pressure) ...............................................................................
9
Testing exhaust temperature ....................................................................................................... 11
Testing exhaust gas color............................................................................................................ 13
Adjusting valve clearance............................................................................................................ 15
Testing compression pressure..................................................................................................... 17
Testing blow-by pressure............................................................................................................. 19
Testing engine oil pressure.......................................................................................................... 20
Handling of fuel system devices.................................................................................................. 21
Releasing residual pressure from fuel system ............................................................................ 21
Testing fuel pressure ................................................................................................................... 22
Testing fuel return rate and fuel leakage ..................................................................................... 23
Bleeding air from fuel circuit ........................................................................................................ 27
Testing fuel circuit for leakage ..................................................................................................... 29
Testing and adjusting alternator belt tension ............................................................................... 30
Testing and adjusting air conditioner compressor belt ................................................................ 31
Testing fan speed ........................................................................................................................ 32
Testing fan circuit oil pressure ..................................................................................................... 33
Bleeding air from fan pump ......................................................................................................... 34
Adjusting fuel control dial and decelerator pedal......................................................................... 35
Testing and adjusting, Part 2
SEN01415-00
Testing power train oil pressure...................................................................................................
3
Testing and adjusting HSS oil pressure....................................................................................... 12
Adjusting transmission speed sensor.......................................................................................... 17
Bleeding air from HSS pump ...................................................................................................... 18
Simple method of testing brake performance.............................................................................. 18
Adjusting brake pedal and parking brake lever ........................................................................... 19
Adjusting PCCS lever console position ....................................................................................... 22
Emergency escape method when power train has trouble ......................................................... 23
Adjusting clearance of idler ......................................................................................................... 26
Inspecting wear of sprocket......................................................................................................... 26
Testing and adjusting track shoe tension .................................................................................... 27
Testing and adjusting work equipment oil pressure..................................................................... 28

D275AX-5E0

00 Index and foreword

SEN00921-02

Testing control circuit main pressure........................................................................................... 32


Testing PPC valve output pressure ............................................................................................. 33
Adjusting play of PPC valve ........................................................................................................ 35
Testing outlet pressure of ripper pin puller solenoid valve .......................................................... 36
Testing parts which cause hydraulic drift of blade and ripper...................................................... 37
Testing internal leakage of work equipment cylinder................................................................... 38
Releasing residual pressure from work equipment cylinder........................................................ 39
Bleeding air from work equipment cylinder ................................................................................. 39
Adjusting ripper lever position ..................................................................................................... 40
Adjusting work equipment lock lever........................................................................................... 41
Adjusting blade............................................................................................................................ 42
Testing and adjusting operator's cab........................................................................................... 44
Testing and adjusting, Part 3
SEN01416-00
Special functions of machine monitor (EMMS) ...........................................................................
2
Testing and adjusting, Part 4
SEN01417-00
Adjustment method when controller has been replaced .............................................................
2
Method of starting use of KOMTRAX terminal ............................................................................
4
Indication by KOMTRAX terminal lamps .....................................................................................
7
Preparation work for troubleshooting for electric system ............................................................ 10
Handling of optional devices ....................................................................................................... 13
Pm Clinic ..................................................................................................................................... 14
40 Troubleshooting
Failure code table and fuse locations
SEN01767-00
Failure codes table ......................................................................................................................
2
Fuse locations ............................................................................................................................. 10
General information on troubleshooting
SEN01768-00
Points to remember when troubleshooting..................................................................................
2
Sequence of events in troubleshooting .......................................................................................
3
Check before troubleshooting .....................................................................................................
4
Classification and procedures for troubleshooting ......................................................................
5
Contents of troubleshooting table................................................................................................
8
Connection table for connector pin numbers .............................................................................. 10
T-adapter box and T-adapter table .............................................................................................. 39
Troubleshooting by failure and error codes, Part 1
SEN01655-00
Failure code [1500L0] Transmission clutch dual engagement ....................................................
3
Failure code [15SAL1] Forward clutch oil pressure 1 .................................................................
4
Failure code [15SALH] Forward clutch oil pressure 2.................................................................
6
Failure code [15SBL1] Reverse clutch oil pressure 1 .................................................................
8
Failure code [15SBLH] Reverse clutch oil pressure 2................................................................. 10
Failure code [15SEL1] 1st clutch oil pressure 1.......................................................................... 12
Failure code [15SELH] 1st clutch oil pressure 2 ......................................................................... 13
Failure code [15SFL1] 2nd clutch oil pressure 1......................................................................... 14
Failure code [15SFLH] 2nd clutch oil pressure 2 ........................................................................ 15
Failure code [15SGL1] 3rd clutch oil pressure 1 ......................................................................... 16
Failure code [15SGLH] 3rd clutch oil pressure 2 ........................................................................ 17
Failure code [1800MW] Power train clutch slip ........................................................................... 18
Failure code [2300NR] Brake thermal load ................................................................................. 19
Failure code [2301L1] Right steering brake oil pressure 1.......................................................... 20
Failure code [2301LH] Right steering brake oil pressure 2 ......................................................... 22
Failure code [2301NR] Right steering brake thermal load .......................................................... 24
Failure code [2302L1] Left steering brake oil pressure 1 ............................................................ 26
Failure code [2302LH] Left steering brake oil pressure 2 ........................................................... 28
Failure code [2302NR] Left steering brake thermal load............................................................. 30
Failure code [A000NS] Engine overheat..................................................................................... 30
Failure code [AA10NX] Air cleaner clogging ............................................................................... 32
D275AX-5E0

SEN00921-02

00 Index and foreword

Failure code [AB00MA] Battery charge abnormal ....................................................................... 34


Failure code [B@BAZG] Eng oil press low.................................................................................. 36
Failure code [B@BAZK] Eng oil level low ................................................................................... 37
Failure code [B@BCNS] Eng coolant overheat........................................................................... 38
Failure code [B@BCZK] Radiator coolant level low .................................................................... 38
Failure code [B@BEBF] Water gets mixed with fuel ................................................................... 39
Failure code [B@BFZK] Fuel level abnormal reduction .............................................................. 39
Failure code [B@CENS] Torque converter oil overheat .............................................................. 40
Failure code [B@CHZG] HSS charge oil pressure reduction...................................................... 41
Failure code [B@CHZK] Power train oil oil level reduction ......................................................... 41
Failure code [B@GAZK] Battery electrolyte level reduction........................................................ 42
Failure code [B@HANS] Hyd oil overheat................................................................................... 42
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................. 43
Troubleshooting by failure and error codes, Part 2
SEN01656-00
Failure code [CA111] EMC critical internal failure .......................................................................
4
Failure code [CA115] Eng Ne and Bkup speed sens error..........................................................
6
Failure code [CA122] Chg air press sensor high error ................................................................
8
Failure code [CA123] Chg air press sensor low error ................................................................. 10
Failure code [CA131] Throttle sensor high error ......................................................................... 12
Failure code [CA132] Throttle sensor low error........................................................................... 14
Failure code [CA135] Eng oil press sensor high error................................................................. 16
Failure code [CA141] Eng oil press sensor low error .................................................................. 18
Failure code [CA144] Coolant temp sens high error ................................................................... 20
Failure code [CA145] Coolant temp sens low error..................................................................... 22
Failure code [CA153] Chg air temp sensor high error................................................................. 24
Failure code [CA154] Chg air temp sensor low error .................................................................. 26
Failure code [CA187] Sens supply 2 volt low error ..................................................................... 26
Failure code [CA221] Ambient press sens high error.................................................................. 28
Failure code [CA222] Ambient press sens low error ................................................................... 30
Failure code [CA227] Sens supply 2 volt high error .................................................................... 32
Failure code [CA234] Eng overspeed ......................................................................................... 34
Failure code [CA238] Ne speed sens supply volt error ............................................................... 36
Failure code [CA263] Fuel temp sensor high error ..................................................................... 38
Failure code [CA265] Fuel temp sensor low error....................................................................... 39
Failure code [CA271] PCV1 short error....................................................................................... 40
Failure code [CA272] PCV1 open error....................................................................................... 41
Failure code [CA273] PCV2 short error....................................................................................... 42
Failure code [CA274] PCV2 open error....................................................................................... 43
Failure code [CA322] Inj #1 (L#1) open/short error..................................................................... 44
Failure code [CA323] Inj #5 (L#5) open/short error..................................................................... 45
Failure code [CA324] Inj #3 (L#3) open/short error..................................................................... 46
Failure code [CA325] Inj #6 (L#6) open/short error..................................................................... 47
Failure code [CA331] Inj #2 (L#2) open/short error..................................................................... 48
Failure code [CA332] Inj #4 (L#4) open/short error..................................................................... 49
Failure code [CA342] Calibration code incompatibility ................................................................ 50
Failure code [CA351] Injectors drive circuit error ........................................................................ 52
Failure code [CA352] Sens supply 1 volt low error ..................................................................... 54
Failure code [CA386] Sens supply 1 volt high error .................................................................... 56
Failure code [CA441] Battery voltage low error........................................................................... 58
Failure code [CA442] Battery voltage high error ......................................................................... 58
Failure code [CA449] Rail press very high error ......................................................................... 59
Failure code [CA451] Rail press sensor high error ..................................................................... 60
Failure code [CA452] Rail press sensor low error....................................................................... 62
Failure code [CA553] Rail press high error ................................................................................. 62
Failure code [CA554] Rail press sensor in range error ............................................................... 63
Failure code [CA559] Rail press low error................................................................................... 64
Failure code [CA689] Eng Ne speed sensor error ...................................................................... 68

D275AX-5E0

00 Index and foreword

SEN00921-02

Troubleshooting by failure and error codes, Part 3


SEN01657-00
Failure code [CA731] Eng Bkup speed sens phase error ...........................................................
3
Failure code [CA757] All continuous data lost error ....................................................................
3
Failure code [CA778] Eng Bkup speed sensor error...................................................................
4
Failure code [CA1228] EGR valve servo error 1.........................................................................
6
Failure code [CA1625] EGR valve servo error 2.........................................................................
7
Failure code [CA1626] BP valve sol current high error ...............................................................
8
Failure code [CA1627] BP valve sol current low error ................................................................ 10
Failure code [CA1628] Bypass valve servo error 1 ..................................................................... 11
Failure code [CA1629] Bypass valve servo error 2 ..................................................................... 12
Failure code [CA1631] BP valve pos sens high error ................................................................. 14
Failure code [CA1632] BP valve pos sens low error................................................................... 16
Failure code [CA1633] KOMNET datalink timeout error ............................................................. 18
Failure code [CA1642] EGR inlet press sens low error............................................................... 20
Failure code [CA1653] EGR inlet press sens high error ............................................................. 22
Failure code [CA2185] Throt sens sup volt high error................................................................. 24
Failure code [CA2186] Throt sens sup volt low error .................................................................. 26
Failure code [CA2249] Rail press very low error......................................................................... 26
Failure code [CA2271] EGR valve pos sens high error .............................................................. 28
Failure code [CA2272] EGR valve pos sens low error................................................................ 30
Failure code [CA2351] EGR valve sol current high error ............................................................ 32
Failure code [CA2352] EGR valve sol current low error ............................................................. 34
Failure code [CA2555] Grid htr relay volt low error ..................................................................... 35
Failure code [CA2556] Grid htr relay volt high error.................................................................... 36
Failure code [D110KA] Battery relay holding disconnection ....................................................... 38
Failure code [D110KB] Battery relay drive short circuit ............................................................... 40
Failure code [D130KA] Neutral safety relay disconnection ......................................................... 42
Failure code [D130KB] Neutral safety relay short circuit............................................................. 44
Failure code [D161KA] Back-up alarm relay disconnection ........................................................ 46
Failure code [D161KB] Back-up alarm relay short circuit............................................................ 48
Failure code [D190KA] Engine controller ACC signal cut relay .................................................. 50
Failure code [D190KB] Engine controller ACC signal cut relay short ......................................... 52
Failure code [D811KR] KOMTRAX controller CAN defective communication ............................ 54
Failure code [DAFRKR] Machine monitor CAN communication defective communication......... 56
Troubleshooting by failure and error codes, Part 4
SEN01658-00
Failure code [DAQ0KT] Transmission controller internal abnormality.........................................
3
Failure code [DAQ1KK] Transmission controller main source voltage reduction ........................
4
Failure code [DAQ2KK] Transmission controller load voltage reduction.....................................
6
Failure code [DAQ5KK] Transmission controller sensor 5 V power source (1) power supply
source voltage reduction......................................................................................................
8
Failure code [DAQ6KK] Transmission controller sensor 24 V power supply source voltage
reduction .............................................................................................................................. 10
Failure code [DAQ7KK] Transmission controller sensor 5 V power supply source (2)
power source voltage reduction ........................................................................................... 11
Failure code [DAQ9KQ] Transmission controller type collation
(Type select signal inconsistency) ....................................................................................... 12
Failure code [DAQRKR] Transmission controller CAN defective communication
(Abnormality in objective component system) ..................................................................... 14
Failure code [DAQSKR] Transmission controller S-NET defective communication
(Abnormality in objective component system) ..................................................................... 16
Failure code [DB2RKR] Engine controller CAN defective communication.................................. 18
Failure code [DB30KT] Steering controller abnormality in controller........................................... 20
Failure code [DB31KK] Steering controller main power supply source voltage reduction .......... 22
Failure code [DB32KK] Load power source of steering controller power source voltage drop ... 24
Failure code [DB35KK] Steering controller sensor 5 V power source (1) power source
voltage drop ......................................................................................................................... 26
Failure code [DB36KK] Steering controller sensor 24 V power supply source voltage
reduction .............................................................................................................................. 28
D275AX-5E0

SEN00921-02

00 Index and foreword

Failure code [DB37KK] Steering controller sensor 5 V power source (2) power source
voltage drop ......................................................................................................................... 30
Failure code [DB39KQ] Steering controller type collation (Type select signal inconsistency)..... 32
Failure code [DB3RKR] Steering controller CAN defective communication
(Abnormality in objective component system)...................................................................... 34
Failure code [DB3SKR] Steering controller S-NET defective communication
(Abnormality in objective component system)...................................................................... 36
Failure code [DD12KA] Shift up switch disconnection ................................................................ 38
Failure code [DD12KB] Shift up switch short circuit .................................................................... 40
Failure code [DD13KA] Shift down switch disconnection............................................................ 42
Failure code [DD13KB] Shift down switch short circuit ............................................................... 44
Failure code [DD14KA] Parking brake lever switch disconnection.............................................. 46
Failure code [DD14KB] Parking brake lever switch short circuit ................................................. 48
Failure code [DDB9L4] Reverse switch disagreement................................................................ 50
Failure code [DDK3L4] Forward switch disagreement ................................................................ 51
Failure code [DDK5KA] Gearshift switch disconnection.............................................................. 52
Failure code [DDK5KB] Gearshift switch short circuit ................................................................. 53
Failure code [DDN7KA] Blade pitch switch disconnection .......................................................... 54
Failure code [DDN7KB] Blade pitch switch short circuit.............................................................. 56
Failure code [DDN9KA] Blade tilt switch disconnection .............................................................. 58
Failure code [DDN9KB] Blade tilt switch short circuit.................................................................. 60
Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON for long time................. 62
Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON for long time................ 63
Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON for long time................. 64
Failure code [DDQ2KA] Parking brake lever switch disconnection............................................. 66
Failure code [DDQ2KB] Parking brake lever switch short circuit ................................................ 68
Failure code [DDQ2L4] Parking brake lever switch disagreement.............................................. 70
Failure code [DDT5KA] Neutral switch disconnection................................................................. 71
Failure code [DDT5KB] Neutral switch short circuit .................................................................... 72
Failure code [DDT5KQ] Lever specification selection (Model selection signal disagreement) ... 73
Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is out of normal range ... 74
Troubleshooting by failure and error codes, Part 5
SEN01659-00
Failure code [DGT1KA] Power train oil temp sensor disconnection ............................................
4
Failure code [DGT1KX] Power train oil temp sensor out of input signal range ...........................
6
Failure code [DH21KB] Work equipment pump oil pressure sensor short circuit........................
8
Failure code [DH22KA] Work equipment pump oil pressure sensor disconnection .................... 10
Failure code [DH22KB] Work equipment pump oil pressure sensor short circuit........................ 12
Failure code [DHH3KA] HSS pump oil pressure sensor A disconnection................................... 14
Failure code [DHH3KB] HSS pump oil pressure sensor A short circuit ...................................... 16
Failure code [DHH4KA] HSS pump oil pressure sensor B disconnection................................... 18
Failure code [DHH4KB] HSS pump oil pressure sensor B short circuit ...................................... 20
Failure code [DK10KA] Fuel control dial disconnection .............................................................. 22
Failure code [DK10KB] Fuel control dial short circuit .................................................................. 24
Failure code [DK30KA] Steering potentiometer (1) disconnection .............................................. 26
Failure code [DK30KB] Steering potentiometer (1) short circuit.................................................. 28
Failure code [DK30KX] Steering potentiometer (1) out of input signal range.............................. 30
Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit....................... 31
Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree......................... 32
Failure code [DK31KA] Steering potentiometer (2) disconnection .............................................. 34
Failure code [DK31KB] Steering potentiometer (2) short circuit.................................................. 36
Failure code [DK40KA] Brake potentiometer disconnection ....................................................... 38
Failure code [DK40KB] Brake potentiometer short circuit ........................................................... 40
Failure code [DK55KX] Directional potentiometer out of input signal range ............................... 42
Failure code [DK55KZ] Directional potentiometer disconnection or short circuit ........................ 43
Failure code [DK55L8] Directional potentiometer analog signals do not agree .......................... 44
Failure code [DK56KA] F-R potentiometer (1) disconnection ..................................................... 46
Failure code [DK56KB] F-R potentiometer (1) short circuit ......................................................... 48
Failure code [DK57KA] F-R potentiometer (2) disconnection ..................................................... 50

10

D275AX-5E0

00 Index and foreword

SEN00921-02

Failure code [DK57KB] F-R potentiometer (2) short circuit......................................................... 52


Failure code [DK60KA] Acceleration sensor disconnection ........................................................ 54
Failure code [DK60KB] Acceleration sensor short circuit............................................................ 56
Failure code [DKH1KA] Pitch angle sensor disconnection ......................................................... 58
Failure code [DKH1KB] Pitch angle sensor short circuit ............................................................. 60
Failure code [DKH1KX] Pitch angle sensor out of input signal range ......................................... 62
Failure code [DLT3KA] Transmission out-speed sensor disconnection ...................................... 64
Failure code [DLT3KB] Transmission out-speed sensor abnormal ............................................. 66
Failure code [DV00KB] Caution buzzer short circuit ................................................................... 67
Failure code [DW59KA] Blade dual selector solenoid disconnection.......................................... 68
Failure code [DW59KB] Blade dual selector solenoid short circuit ............................................. 70
Failure code [DW59KY] Blade dual selector solenoid hot short.................................................. 72
Failure code [DW5AKA] Blade pitch selector solenoid disconnection ........................................ 73
Failure code [DW5AKB] Blade pitch selector solenoid short circuit ............................................ 74
Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit .................................... 76
Troubleshooting by failure and error codes, Part 6
SEN01878-00
Failure code [DW7BKA] Fan rev EPC disconnection..................................................................
3
Failure code [DW7BKB] Fan rev EPC short circuit .....................................................................
4
Failure code [DW7BKY] Fan reverse solenoid hot short circuit ..................................................
5
Failure code [DWN1KA] HSS pump solenoid right disconnection ..............................................
6
Failure code [DWN1KB] HSS pump solenoid right short circuit..................................................
8
Failure code [DWN1KY] HSS pump solenoid right hot short ...................................................... 10
Failure code [DWN2KA] HSS pump solenoid left disconnection ................................................ 12
Failure code [DWN2KB] HSS pump solenoid left short circuit .................................................... 14
Failure code [DWN2KY] HSS pump solenoid left short circuit .................................................... 16
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.................................. 18
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit ..................................... 20
Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit ............................... 22
Failure code [DWN4KA] HSS motor free solenoid disconnection............................................... 23
Failure code [DWN4KB] HSS motor free solenoid short circuit .................................................. 24
Failure code [DWN5KA] Fan pump solenoid disconnection ....................................................... 26
Failure code [DWN5KB] Fan pump solenoid short circuit ........................................................... 28
Failure code [DWN5KY] Fan pump solenoid hot short circuit ..................................................... 30
Failure code [DXH1KA] Lock-up solenoid disconnection............................................................ 32
Failure code [DXH1KB] Lock-up solenoid short circuit ............................................................... 34
Failure code [DXH1KY] Lock-up solenoid hot short.................................................................... 36
Failure code [DXH4KA] 1st clutch ECMV disconnection ............................................................ 38
Failure code [DXH4KB] 1st clutch ECMV short circuit ................................................................ 40
Failure code [DXH4KY] 1st clutch ECMV hot short circuit .......................................................... 42
Failure code [DXH5KA] 2nd clutch ECMV disconnection ........................................................... 44
Failure code [DXH5KB] 2nd clutch ECMV short circuit............................................................... 46
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit......................................................... 48
Failure code [DXH6KA] 3rd clutch ECMV disconnection ............................................................ 50
Failure code [DXH6KB] 3rd clutch ECMV short circuit................................................................ 52
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit.......................................................... 54
Failure code [DXH7KA] Reverse clutch ECMV disconnection.................................................... 56
Failure code [DXH7KB] Reverse clutch ECMV short circuit ....................................................... 58
Failure code [DXH7KY] R clutch ECMV hot short circuit ............................................................ 60
Failure code [DXH8KA] Forward clutch ECMV disconnection .................................................... 62
Failure code [DXH8KB] Forward clutch ECMV short circuit........................................................ 64
Failure code [DXH8KY] F clutch ECMV hot short circuit............................................................. 66
Failure code [DXHBKA] Right brake ECMV disconnection......................................................... 68
Failure code [DXHBKB] Right brake ECMV short circuit ............................................................ 70
Failure code [DXHBKY] Right brake ECMV hot short circuit ...................................................... 72
Failure code [DXHCKA] Left brake ECMV disconnection ........................................................... 74
Failure code [DXHCKB] Left brake ECMV short circuit............................................................... 76
Failure code [DXHCKY] Left brake ECMV hot short circuit......................................................... 78

D275AX-5E0

11

SEN00921-02

00 Index and foreword

Troubleshooting of electrical system (E-mode)


SEN01646-00
Information in troubleshooting table ............................................................................................
3
E-1 The engine does not start .....................................................................................................
4
E-2 The preheater does not operate (Manual preheating function) ............................................
7
E-3 The ripper pin puller cylinder does not operate .................................................................... 10
E-4 The machine monitor does not come on at all when the starting switch is turned ON ......... 12
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted
and does not go out ............................................................................................................. 14
E-6 When the starting switch is turned ON, the basic check items flash .................................... 15
E-7 While the engine is operating, any caution item flashes....................................................... 16
E-8 While the engine is operating, the emergency warning item flashes.................................... 19
E-9 While the preheater is operating, the preheating pilot lamp does not come on.................... 24
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on
(Dual tilt-mounted machine) ................................................................................................. 26
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp
does not come on................................................................................................................. 26
E-12 The engine coolant temperature gauge does not indicate normally ................................... 26
E-13 Indication of the power train temperature gauge is abnormal............................................. 27
E-14 The hydraulic oil temperature gauge does not indicate normally ....................................... 27
E-15 Indication of the fuel gauge is abnormal ............................................................................. 28
E-16 Indications of gear speed and engine speed are abnormal................................................ 29
E-17 Indication of the shift mode service meter is abnormal....................................................... 29
E-18 The switch module cannot be operated.............................................................................. 30
E-19 The warning lamp does not flash or does not go out.......................................................... 31
E-20 The alarm buzzer does not sound or does not stop ........................................................... 32
E-21 Auto shift down is not possible or is not released............................................................... 33
E-22 Pivot turn is not possible or is not released ........................................................................ 34
E-23 The alarm buzzer cannot be cancelled............................................................................... 35
E-24 The operator mode cannot be operated ............................................................................. 36
E-25 The service mode cannot be operated ............................................................................... 38
E-26 The back-up alarm does not sound .................................................................................... 40
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel
do not come on .................................................................................................................... 42
E-28 The air conditioner does not operate .................................................................................. 48
E-29 KOMTRAX system does not operate normally ................................................................... 54
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN01647-00
Information in troubleshooting table ............................................................................................
3
H-1 No travel power (No drawbar pull)........................................................................................
4
H-2 Machine does not move (At 2nd or 3rd speed) ....................................................................
5
H-3 Machine does not move in any speed range........................................................................
6
H-4 Machine travels only in one direction forward or in reverse .................................................
7
H-5 When gear is shifted or travel direction is changed, large time lag is made.........................
8
H-6 Machine does not turn (Not turned rightward or leftward) ....................................................
9
H-7 Steering speed or power is low............................................................................................. 10
H-8 Brake does not work............................................................................................................. 11
H-9 Torque converter does not lock-up ....................................................................................... 12
H-10 Overheat of power train oil temperature ............................................................................. 13
H-11 Abnormal sound around HSS pump or HSS motor ............................................................ 14
H-12 All work equipment speeds are slow .................................................................................. 15
H-13 Work equipment does not move......................................................................................... 16
H-14 Blade lift speed is slow or lacks power ............................................................................... 17
H-15 Blade tilt speed is slow or lacks power ............................................................................... 18
H-16 Ripper lift speed is slow or lacks power.............................................................................. 19
H-17 Ripper tilt speed is slow or lacks power.............................................................................. 20
H-18 Excessive hydraulic drift of blade lift................................................................................... 21
H-19 Excessive hydraulic drift of blade tilt................................................................................... 22
H-20 Excessive hydraulic drift of ripper lift .................................................................................. 23
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ..................... 24

12

D275AX-5E0

00 Index and foreword

SEN00921-02

H-22 Blade pitch does not work (Dual tilt attachment machine) ................................................. 25
H-23 Abnormal sound comes out from around work equipment pump....................................... 26
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or
engine overheats). ............................................................................................................... 27
Troubleshooting of engine (S-mode)
SEN01648-00
Method of using troubleshooting chart ........................................................................................
3
S-1 Starting performance of engine is poor.................................................................................
6
S-2 Engine does not start............................................................................................................
8
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operation .............................................................................................. 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lack output (or lacks power) ..................................................................................... 15
S-7 Exhaust gas is black (incomplete combustion)..................................................................... 16
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 18
S-9 Oil becomes dirty quickly...................................................................................................... 19
S-10 Fuel consumption is excessive........................................................................................... 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 21
S-12 Oil pressure drops .............................................................................................................. 22
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 24
S-14 Coolant temperature becomes too high (Overheating) ...................................................... 26
S-15 Abnormal noise is made ..................................................................................................... 27
S-16 Vibration is excessive ......................................................................................................... 28
50 Disassembly and assembly
General information on disassembly and assembly
SEN02340-00
How to read this manual .............................................................................................................
2
List of adhesives .........................................................................................................................
4
Special tool list ............................................................................................................................
7
Sketchs of special tools............................................................................................................... 15
Engine and cooling system
SEN02341-00
Removal and installation of engine assembly .............................................................................
2
Removal and installation of radiator assembly (including hydraulic oil cooler assembly and
aftercooler assembly) ..................................................................................................................
7
Removal and installation of hydraulic oil cooler assembly .......................................................... 10
Removal and installation of aftercooler assembly ....................................................................... 12
Removal and installation of radiator guard assembly ................................................................. 14
Removal and installation of fuel tank assembly .......................................................................... 19
Removal and installation of engine hood assembly .................................................................... 20
Removal and installation of fan drive assembly .......................................................................... 22
Removal and installation of fan motor assembly......................................................................... 24
Engine
SEN02342-00
Removal and installation of fuel supply pump assembly.............................................................
2
Removal and installation of common rail ....................................................................................
6
Removal and installation of cylinder head assembly ..................................................................
9
Removal and installation of fuel injector assembly ..................................................................... 20
Removal and installation of engine front seal ............................................................................. 24
Removal and installation of engine rear seal .............................................................................. 26
Power train, Part 1
SEN02343-00
Removal and installation of damper assembly............................................................................
2
Disassembly and assembly of damper assembly .......................................................................
5
Removal and installation of power train unit assembly ............................................................... 10
Disconnection and connection of power train unit assembly ...................................................... 15
Disassembly and assembly of PTO assembly ............................................................................ 26
Disassembly and assembly of torque converter assembly ......................................................... 33
Disassembly and assembly of torqflow transmission assembly.................................................. 43

D275AX-5E0

13

SEN00921-02

00 Index and foreword

Power train, Part 2


SEN02344-00
Removal and installation of scavenging pump ............................................................................
2
Disassembly and assembly of HSS case assembly....................................................................
3
Removal and installation of final drive assembly......................................................................... 23
Disassembly and assembly of final drive assembly .................................................................... 26
Undercarriage and frame, Part 1
SEN02345-00
Removal and installation of track frame assembly ......................................................................
2
Removal and installation of recoil spring assembly.....................................................................
7
Disassembly and assembly of recoil spring assembly ................................................................ 11
Removal and installation of idler assembly ................................................................................. 13
Disassembly and assembly of idler assembly............................................................................. 14
Removal and installation of track roller assembly ....................................................................... 18
Disassembly and assembly of track roller assembly................................................................... 21
Removal and installation of carrier roller assembly..................................................................... 25
Disassembly and assembly of carrier roller assembly ................................................................ 26
Removal and installation of 1st bogie assembly ......................................................................... 30
Removal and installation of 2nd, 3rd and 4th bogie assembly .................................................... 36
Disassembly and assembly of bogie assembly........................................................................... 44
Undercarriage and frame, Part 2
SEN02346-00
Expanding and installing track shoe assembly............................................................................
2
Whole disassembly and whole assembly of track shoe assembly ..............................................
5
Removal and installation of pivot shaft assembly........................................................................ 27
Removal and installation of equalizer bar assembly ................................................................... 28
Disassembly and assembly of equalizer bar bushing ................................................................. 32
Hydraulic system
SEN02347-00
Removal and installation of HSS pump assembly.......................................................................
2
Removal and installation of work equipment and HSS charge pump assembly .........................
4
Removal and installation of power train and lubricating oil pump assembly ...............................
6
Removal and installation of HSS motor assembly ......................................................................
8
Removal and installation of fan pump assembly .........................................................................
9
Removal and installation of control valve assembly.................................................................... 11
Disassembly and assembly of work equipment control valve assembly ..................................... 15
Disassembly and assembly of hydraulic cylinder assembly........................................................ 16
Work equipment
SEN02348-00
Removal and installation of blade assembly ...............................................................................
2
Disassembly and assembly of ripper assembly ..........................................................................
4
Cab and its attachments
SEN02349-00
Removal and installation of ROPS guard....................................................................................
2
Removal and installation of operator's cab assembly .................................................................
3
Removal and installation of operator's cab glass (Stuck glass)...................................................
5
Removal and installation of floor frame assembly ....................................................................... 14
Electrical system
SEN02350-00
Removal and installation of transmission controller assembly ....................................................
2
Removal and installation of steering controller assembly ...........................................................
3
Removal and installation of engine controller assembly .............................................................
4
Removal and installation of air conditioner unit assembly...........................................................
5
Removal and installation of monitor panel assembly ..................................................................
8
90 Diagrams and drawings
Hydraulic diagrams and drawings
SEN00941-00
Hydraulic diagrams and drawings ...............................................................................................
3
Hydraulic circuit diagram .........................................................................................................
3
Power train hydraulic circuit diagram.......................................................................................
5

14

D275AX-5E0

00 Index and foreword

SEN00921-02

Electrical diagrams and drawings


SEN00942-01
Electrical circuit diagram (1/12)...................................................................................................
3
Electrical circuit diagram (2/12)...................................................................................................
5
Electrical circuit diagram (3/12)...................................................................................................
7
Electrical circuit diagram (4/12)...................................................................................................
9
Electrical circuit diagram (5/12)................................................................................................... 11
Electrical circuit diagram (6/12)................................................................................................... 13
Electrical circuit diagram (7/12)................................................................................................... 15
Electrical circuit diagram (8/12)................................................................................................... 17
Electrical circuit diagram (9/12)................................................................................................... 19
Electrical circuit diagram (10/12)................................................................................................. 21
Electrical circuit diagram (11/12) ................................................................................................. 23
Electrical circuit diagram (12/12)................................................................................................. 25
Electrical circuit diagram for inside cab ...................................................................................... 27
Air conditioner unit electrical circuit diagram............................................................................... 29
Connectors table and arrangement drawing ............................................................................... 31

D275AX-5E0

15

SEN00921-02

00 Index and foreword

D275AX-5E0 Bulldozer
Form No. SEN00921-02

16

D275AX-5E0

SEN00922-01

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

00 Index and foreword

Foreword and general information


Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36

D275AX-5E0

SEN00922-01

Safety notice

00 Index and foreword

(Rev. 2007/02)

Important safety notice


Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.

General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always


have a trained and experienced welder
carry out the work. When carrying out
weld in g wo rk , al way s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.

Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5

Prohibition of operation and handling by


unlicensed workers

6 Safety check before starting work


7

Wearing protective goggles


(for cleaning or grinding work)

Wearing shielding goggles and protectors


(for welding work)

9 Good physical condition and preparation


10

2.

Precautions against work which you are


not used to or you are used to too much

Preparations for work


1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.

D275AX-5E0

00 Index and foreword

3)
4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or


stands before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.

Precautions during work


1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.

D275AX-5E0

SEN00922-01

8)

9)
10)

11)

12)

13)
14)
15)

16)

When removing piping, stop the fuel or oil


from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

SEN00922-01

4.

Precautions for sling work and making


signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.

00 Index and foreword

8)

When installing wire ropes to an angular


load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes.


12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.

D275AX-5E0

00 Index and foreword

If the load is unstable or the wire rope


or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.

SEN00922-01

13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.

5.

6.

Precautions for using mobile crane


a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.

D275AX-5E0

7.

Selecting wire ropes


1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.

Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4

The allowable load is one-sixth of the


breaking strength of the rope used
(Safety coefficient: 6).

SEN00922-01

8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k

2)

Collect the air conditioner refrigerant


(R134a) from the air conditioner circuit
in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or filling
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.

Example of O-ring (Fitted to every joint of


hoses and tubes)

For tightening torque, see the precautions for


installation in each section of "Disassembly
and assembly".

00 Index and foreword

D275AX-5E0

00 Index and foreword

How to read the shop manual


q
q
q

1.

SEN00922-01

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

D275AX-5E0

SEN00922-01

3.

4.

00 Index and foreword

Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q

Revised edition mark


When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )

Revisions
Revised brochures are shown in the shop manual composition table.

Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol

Item

Safety

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when


selecting hoisting wire, or when working posture is important, etc.

Tightening
torque

Coat

Oil, coolant

Drain

Remarks
Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during


assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.

5.

Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

D275AX-5E0

00 Index and foreword

SEN00922-01

Explanation of terms for maintenance standard

The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.

Standard size and tolerance


To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
q

Example:
Standard size
120

Tolerance
0.022
0.126

The tolerance may be indicated in the text


and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)

Usually, the size of a hole and the size of


the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Standard size
60

D275AX-5E0

Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0

SEN00922-01

2.

Standard clearance and standard value


The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.

00 Index and foreword

5.

3.

4.

Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q

6.

Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q

Repair limit and allowable value


The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit must be
replaced or repaired.
q
The performance and function of a product lowers while it is used. A value below
which the product can be used without
causing a problem is called the allowable
value.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
q

10

D275AX-5E0

00 Index and foreword

Handling electric equipment and hydraulic component

SEN00922-01

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric
equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.

Main failures occurring in wiring harness


1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)

Defective crimping or soldering of connectors


The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

D275AX-5E0

11

SEN00922-01

12

3)

Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.

4)

High-pressure water entering connector


The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.

5)

Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.

00 Index and foreword

D275AX-5E0

00 Index and foreword

3.

SEN00922-01

Removing, installing, and drying connectors and wiring harnesses


1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q

When removing from clips


Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.

When removing a connector from a


clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.

3]

Action to take after removing connectors


After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.

D275AX-5E0

13

SEN00922-01

2)

14

00 Index and foreword

Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.

D275AX-5E0

00 Index and foreword

3)

Heavy duty wire connector (DT 8-pole, 12pole)


Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

D275AX-5E0

SEN00922-01

Disconnection

Connection (Example of
incomplete setting of (a))

15

SEN00922-01

4)

16

00 Index and foreword

Drying wiring harness


If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

D275AX-5E0

00 Index and foreword

4.

Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5.

Points to remember when troubleshooting


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

D275AX-5E0

SEN00922-01

17

SEN00922-01

00 Index and foreword

Points to remember when handling hydraulic equipment


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

Be careful of the operating environment.


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

2.

Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.

3.

Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

4.

Do not let any dirt or dust get in during


refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

18

D275AX-5E0

00 Index and foreword

5.

Change hydraulic oil when the temperature


is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6.

Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

7.

Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.

D275AX-5E0

SEN00922-01

19

SEN00922-01

00 Index and foreword

Connectors newly used for Tier 3 engines


1.

Slide lock type


(FRAMATOME-3, FRAMATOME-2)
q
107 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(107 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)

2.

Pull lock type (PACKARD-2)


107 170, 12V140 engine
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.

Disconnect connector (1) according to the following procedure.


1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.

20

D275AX-5E0

00 Index and foreword

3.

SEN00922-01

Push lock type


q
107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q

114 engine

107, 114 engine


Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3)

While pressing lock (D), pull out connector


(4) in the direction of the arrow.

107 engine

2)

If the lock is on the underside, use


flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

D275AX-5E0

21

SEN00922-01

4)

125 170, 12V140 engine


While pressing lock (E) of the connector,
pullout connector (5) in the direction of the
arrow.
Example)
Fuel pressure in common rail: PFUEL etc.
(AMP-3)

00 Index and foreword

4.

Turn-housing type (Round green connector)


140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

1)

Disconnect connector (6) according to the


following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring harness side.

2)

Connect the connector according to the


following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.

Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)

Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

22

D275AX-5E0

00 Index and foreword

SEN00922-01

How to read electric wire code


a

The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile

Symbol
AV

AVS

Heat-resistant low-voltAEX
age wire for
automobile

D275AX-5E0

Material
Conductor
Insulator
Conductor

Annealed copper for electric appliance


Soft polyvinyl chloride
Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance


Heat-resistant crosslinked
polyethylene

Insulator

Using
temperature
range (C)

Example of use
General wiring
(Nominal No. 5 and above)

30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place

23

SEN00922-01

2.

00 Index and foreword

Dimensions

(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6

CovAV
Standard

4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1

3.8
4.6

Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7

5.5
5.3

4.8

7.0
7.0

6.0

8.2
8.2

8.0

10.8
10.8

8.6

11.4
11.4

9.8

13.0
13.0

10.4

13.6
13.6

12.0

16.0
16.0

13.6

17.6
17.6

108/0.80 127/0.80 169/0.80 217/0.80

f of nominal No. denotes flexible.

24

D275AX-5E0

00 Index and foreword

3.

SEN00922-01

Color codes table

(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR

Color of wire

Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW

Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red

Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.

Types of circuits and color codes

(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others

D275AX-5E0

AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch

AEX

R
B
R
D
Y
G
L

WG

RB
YR
GW
LW
BrW
LgR

RY
YB
GR
LR
BrR
LgY

RG
YG
GY
LY
BrY
LgB

RL
YL
GB
LB
BrB
LgW

YW
GL

Gr
Br

25

SEN00922-01

00 Index and foreword

Precautions when carrying out operation

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

Precautions when carrying out removal work


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

26

Sleeve nut (elbow end)

07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234

02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234

Split flange type hoses and tubes


Nominal
number
04
05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400
07379-00500

07378-10400
07378-10500

07371-30400
07371-30500

If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number

Part Number

06
08
10
12
14
16
18
20
22
24

07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430

Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30

27

07049-02734

27

22.5

34

D275AX-5E0

00 Index and foreword

2.
q
q
q
q
q
q
q
q
q
q
q
q
q

a
3.

SEN00922-01

Precautions when carrying out installation work


Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.

D275AX-5E0

27

SEN00922-01

4)

5)

28

00 Index and foreword

Checking muffler and exhaust pipe for damage and looseness


1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.

D275AX-5E0

00 Index and foreword

SEN00922-01

Method of disassembling and connecting push-pull type coupler


k
k

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1
1.

Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.

2.

Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.

D275AX-5E0

29

SEN00922-01

00 Index and foreword

Type 2
1.

Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)

2.

Connection
q
Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

30

D275AX-5E0

00 Index and foreword

SEN00922-01

Type 3
1.

Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)

2.

Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

D275AX-5E0

31

SEN00922-01

00 Index and foreword

Standard tightening torque table


1.

Table of tightening torques for bolts and nuts


a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt


mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a

a Fig. A

Width across flats


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

Tightening torque
Nm
kgm
11.8 14.7
1.2 1.5
27 34
2.8 3.5
59 74
6.0 7.5
98 123
10.0 12.5
153 190
15.5 19.5
235 285
23.5 29.5
320 400
33.0 41.0
455 565
46.5 58.0
610 765
62.5 78.0
785 980
80.0 100.0
1,150 1,440
118 147
1,520 1,910
155 195
1,960 2,450
200 250
2,450 3,040
250 310
2,890 3,630
295 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt


mm
6
8
10
12

32

Width across flats


mm
10
13
14
27

Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2

kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2

a Fig. B

D275AX-5E0

00 Index and foreword

2.

Table of tightening torques for split flange bolts


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

Thread diameter of bolt


mm
10
12
16

3.

Width across flats


mm
14
17
22

Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5

Table of tightening torques for O-ring boss piping joints


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

Nominal No.
02
03,04
05,06
10,12
14

4.

SEN00922-01

Thread diameter
mm
14
20
24
33
42

Width across flats


mm

Tightening torque Nm {kgm}


Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}

Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52

D275AX-5E0

Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52

Width across flats


mm
14
17
19
22
24
27
30
32
32

36

Tightening torque Nm {kgm}


Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}

33

SEN00922-01

5.

00 Index and foreword

Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm}

Nominal
No. of
hose

Width
across
flats

02

19

03
04
05
06
(10)
(12)
(14)

6.

22
24
27
32
36
41
46
55

Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}

Target

44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}

mm
6
8
10
12
14

14

18
22
24
30
33
36
42

Tightening torque
Bolts and nuts
Nm
10 2
24 4
43 6
77 12

kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22

Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14

34

Thread size
(mm)

Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3

11/16-16UN
17.5

13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Thread size

7.

Taper seal

Tightening torque
Nm
82
10 2
12 2
24 4
36 5

kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51

D275AX-5E0

00 Index and foreword

8.

SEN00922-01

Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1

D275AX-5E0

Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9

kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92

35

SEN00922-01

00 Index and foreword

Conversion table

Method of using the conversion table


The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.

Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2.

Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

36

(B)

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740

6
0.236
0.630
1.024
1.417
1.811

7
0.276
0.669
1.063
1.457
1.850

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

D275AX-5E0

00 Index and foreword

SEN00922-01

Millimeters to inches

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

5
0.197
0.591
0.984
1.378
1.772

6
0.236
0.630
1.024
1.417
1.811

1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

2.165
2.559
2.953
3.346
3.740

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03

2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

Kilogram to pound

0
10
20
30
40

0
0
22.05
44.09
66.14
88.18

1
2.20
24.25
46.30
68.34
90.39

2
4.41
26.46
48.50
70.55
92.59

3
6.61
28.66
50.71
72.75
94.80

4
8.82
30.86
51.91
74.96
97.00

5
11.02
33.07
55.12
77.16
99.21

50
60
70
80
90

110.23
132.28
154.32
176.37
198.42

112.44
134.48
156.53
178.57
200.62

114.64
136.69
158.73
180.78
202.83

116.85
138.89
160.94
182.98
205.03

119.05
141.10
163.14
185.19
207.24

121.25
143.30
165.35
187.39
209.44

123.46
145.51
167.55
189.60
211.64

125.66
147.71
169.76
191.80
213.85

127.87
149.91
171.96
194.01
216.05

130.07
152.12
174.17
196.21
218.26

Liters to U.S. Gallons

0
10
20
30
40

0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095

3
0.793
3.434
6.076
8.718
11.359

4
1.057
3.698
6.340
8.982
11.624

1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944

50
60
70
80
90

13.209
15.850
18.492
21.134
23.775

14.001
16.643
19.285
21.926
24.568

14.265
16.907
19.549
22.190
24.832

14.529
17.171
19.813
22.455
25.096

D275AX-5E0

13.473
16.115
18.756
21.398
24.040

13.737
16.379
19.020
21.662
24.304

14.795
17.435
20.077
22.719
25.361

15.058
17.700
20.341
22.983
25.625

15.322
17.964
20.605
23.247
25.889

15.586
18.228
20.870
23.511
26.153

37

SEN00922-01

00 Index and foreword

Liters to U.K. Gallons

0
10
20
30
40

0
0
2.200
4.399
6.599
8.799

1
0.220
2.420
4.619
6.819
9.019

2
0.440
2.640
4.839
7.039
9.239

3
0.660
2.860
5.059
7.259
9.459

4
0.880
3.080
5.279
7.479
9.679

5
1.100
3.300
5.499
7.699
9.899

50
60
70
80
90

10.998
13.198
15.398
17.598
19.797

11.281
13.418
15.618
17.818
20.017

11.438
13.638
15.838
18.037
20.237

11.658
13.858
16.058
18.257
20.457

11.878
14.078
16.278
18.477
20.677

12.098
14.298
16.498
18.697
20.897

1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117

12.528
14.738
16.938
19.137
21.337

12.758
14.958
17.158
19.357
21.557

12.978
15.178
17.378
19.577
21.777

kgm to ft.lb

0
10
20
30
40

0
0
72.3
144.7
217.0
289.3

1
7.2
79.6
151.9
224.2
296.6

2
14.5
86.8
159.1
231.5
303.8

3
21.7
94.0
166.4
238.7
311.0

4
28.9
101.3
173.6
245.9
318.3

5
36.2
108.5
180.8
253.2
325.5

6
43.4
115.7
188.1
260.4
332.7

1 kgm = 7.233 ft.lb


7
8
9
50.6
57.9
65.1
123.0
130.2
137.4
195.3
202.5
209.8
267.6
274.9
282.1
340.0
347.2
354.4

50
60
70
80
90

361.7
434.0
506.3
578.6
651.0

368.9
441.2
513.5
585.9
658.2

376.1
448.5
520.8
593.1
665.4

383.4
455.7
528.0
600.3
672.7

390.6
462.9
535.2
607.6
679.9

397.8
470.2
542.5
614.8
687.1

405.1
477.4
549.7
622.0
694.4

412.3
484.6
556.9
629.3
701.6

419.5
491.8
564.2
636.5
708.8

426.8
499.1
571.4
643.7
716.1

100
110
120
130
140

723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150
160
170
180
190

1084.9
1157.3
1129.6
1301.9
1374.3

38

1092.2
1164.5
1236.8
1309.2
1381.5

1099.4
1171.7
1244.1
1316.4
1388.7

1106.6
1179.0
1251.3
1323.6
1396.0

1113.9
1186.2
1258.5
1330.9
1403.2

1121.1
1193.4
1265.8
1338.1
1410.4

1128.3
1200.7
1273.0
1345.3
1417.7

1135.6
1207.9
1280.1
1352.6
1424.9

1142.8
1215.1
1287.5
1359.8
1432.1

1150.0
1222.4
1294.7
1367.0
1439.4

D275AX-5E0

00 Index and foreword

SEN00922-01

kg/cm2 to lb/in2

0
10
20
30
40

0
0
142.2
284.5
426.7
568.9

1
14.2
156.5
298.7
440.9
583.2

2
28.4
170.7
312.9
455.1
597.4

3
42.7
184.9
327.1
469.4
611.6

4
56.9
199.1
341.4
483.6
625.8

5
71.1
213.4
355.6
497.8
640.1

6
85.3
227.6
369.8
512.0
654.3

1 kg/cm2 = 14.2233 lb/in2


7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9

50
60
70
80
90

711.2
853.4
995.6
1,138
1,280

725.4
867.6
1,010
1,152
1,294

739.6
881.8
1,024
1,166
1,309

753.8
896.1
1,038
1,181
1,323

768.1
910.3
1,053
1,195
1,337

782.3
924.5
1,067
1,209
1,351

796.5
938.7
1,081
1,223
1,365

810.7
953.0
1,095
1,237
1,380

825.0
967.2
1,109
1,252
1,394

839.2
981.4
1,124
1,266
1,408

100
110
120
130
140

1,422
1,565
1,707
1,849
1,991

1,437
1,579
1,721
1,863
2,005

1,451
1,593
1,735
1,877
2,020

1,465
1,607
1,749
1,892
2,034

1,479
1,621
1,764
1,906
2,048

1,493
1,636
1,778
1,920
2,062

1,508
1,650
1,792
1,934
2,077

1,522
1,664
1,806
1,949
2,091

1,536
1,678
1,821
1,963
2,105

1,550
1,693
1,835
1,977
2,119

150
160
170
180
190

2,134
2,276
2,418
2,560
2,702

2,148
2,290
2,432
2,574
2,717

2,162
2,304
2,446
2,589
2,731

2,176
2,318
2,460
2,603
2,745

2,190
2,333
2,475
2,617
2,759

2,205
2,347
2,489
2,631
2,773

2,219
2,361
2,503
2,646
2,788

2,233
2,375
2,518
2,660
2,802

2,247
2,389
2,532
2,674
2,816

2,262
2,404
2,546
2,688
2,830

200
210
220
230
240

2,845
2,987
3,129
3,271
3,414

2,859
3,001
3,143
3,286
3,428

2,873
3,015
3,158
3,300
3,442

2,887
3,030
3,172
3,314
3,456

2,901
3,044
3,186
3,328
3,470

2,916
3,058
3,200
3,343
3,485

2,930
3,072
3,214
3,357
3,499

2,944
3,086
3,229
3,371
3,513

2,958
3,101
3,243
3,385
3,527

2,973
3,115
3,257
3,399
3,542

D275AX-5E0

39

SEN00922-01

00 Index and foreword

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F
F

40.4
37.2
34.4
31.7
28.9

40
35
30
25
20

40.0
31.0
22.0
13.0
4.0

11.7
11.1
10.6
10.0
9.4

11
12
13
14
15

51.8
53.6
55.4
57.2
59.0

7.8
8.3
8.9
9.4
10.0

46
47
48
49
50

114.8
116.6
118.4
120.2
122.0

27.2
27.8
28.3
28.9
29.4

81
82
83
84
85

177.8
179.6
181.4
183.2
185.0

28.3
27.8
27.2
26.7
26.1

19
18
17
16
15

2.2
0.4
1.4
3.2
5.0

8.9
8.3
7.8
7.2
6.7

16
17
18
19
20

60.8
62.6
64.4
66.2
68.0

10.6
11.1
11.7
12.2
12.8

51
52
53
54
55

123.8
125.6
127.4
129.2
131.0

30.0
30.6
31.1
31.7
32.2

86
87
88
89
90

186.8
188.6
190.4
192.2
194.0

25.6
25.0
24.4
23.9
23.3

14
13
12
11
10

6.8
8.6
10.4
12.2
14.0

6.1
5.6
5.0
4.4
3.9

21
22
23
24
25

69.8
71.6
73.4
75.2
77.0

13.3
13.9
14.4
15.0
15.6

56
57
58
59
60

132.8
134.6
136.4
138.2
140.0

32.8
33.3
33.9
34.4
35.0

91
92
93
94
95

195.8
197.6
199.4
201.2
203.0

22.8
22.2
21.7
21.1
20.6

9
8
7
6
5

15.8
17.6
19.4
21.2
23.0

3.3
2.8
2.2
1.7
1.1

26
27
28
29
30

78.8
80.6
82.4
84.2
86.0

16.1
16.7
17.2
17.8
18.3

61
62
63
64
65

141.8
143.6
145.4
147.2
149.0

35.6
36.1
36.7
37.2
37.8

96
97
98
99
100

204.8
206.6
208.4
210.2
212.0

20.0
19.4
18.9
18.3
17.8

4
3
2
1
0

24.8
26.6
28.4
30.2
32.0

0.6
0
0.6
1.1
1.7

31
32
33
34
35

87.8
89.6
91.4
93.2
95.0

18.9
19.4
20.0
20.6
21.1

66
67
68
69
70

150.8
152.6
154.4
156.2
158.0

40.6
43.3
46.1
48.9
51.7

105
110
115
120
125

221.0
230.0
239.0
248.0
257.0

17.2
16.7
16.1
15.6
15.0

1
2
3
4
5

33.8
35.6
37.4
39.2
41.0

2.2
2.8
3.3
3.9
4.4

36
37
38
39
40

96.8
98.6
100.4
102.2
104.0

21.7
22.2
22.8
23.3
23.9

71
72
73
74
75

159.8
161.6
163.4
165.2
167.0

54.4
57.2
60.0
62.7
65.6

130
135
140
145
150

266.0
275.0
284.0
293.0
302.0

14.4
13.9
13.3
12.8
12.2

6
7
8
9
10

42.8
44.6
46.4
48.2
50.0

5.0
5.6
6.1
6.7
7.2

41
42
43
44
45

105.8
107.6
109.4
111.2
113.0

24.4
25.0
25.6
26.1
26.7

76
77
78
79
80

168.8
170.6
172.4
174.2
176.0

68.3
71.1
73.9
76.7
79.4

155
160
165
170
175

311.0
320.0
329.0
338.0
347.0

40

D275AX-5E0

00 Index and foreword

D275AX-5E0

SEN00922-01

41

SEN00922-01

00 Index and foreword

D275AX-5E0 Bulldozer
Form No. SEN00922-01

42

D275AX-5E0

SEN00924-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

01 Specification

Specification and technical data


Specification and technical data...................................................................................................................... 2
Specefication dimension drawings........................................................................................................ 2
Specifications........................................................................................................................................ 3
Weight table .......................................................................................................................................... 9
Table of fuel, coolant and lubricants ....................................................................................................11

D275AX-5E0

SEN00924-00

01 Specification

Specification and technical data


Specefication dimension drawings

Item

Unit

Semi U-tilt dozer +


Giant ripper

U-tilt dozer +
Giant ripper

Semi U-tilt dozer +


Multi-shank ripper

U-tilt dozer+
Multi-shank ripper

Overall
length

mm

9,260

9,595

8,905

9,245

Overall
height
(with ROPS)

mm

3,915
(3,990)

3,915
(3,990)

3,915
(3,990)

3,915
(3,990)

Overall
width

mm

4,300

4,615

4,300

4,615

D275AX-5E0

01 Specification

SEN00924-00

Machine model

D275AX-5E0

Serial number

30001 and up

Machine weight
Bare tractor

Transmission speed ranges


Overall height Overall width Overall length

Dimensions

Ground pressure

Performance

Min. turning radius


Gradeability
Stability (front, rear, left, right)

kg

50,800

m
deg.
deg.

3,9 (Pivot turn)


30
35

Forward

Above with semi U-dozer + variable multishank ripper + ROPS + cab + air conditioner + side cover

38,430

1st speed
2nd speed
3rd speed

km/h

3.6
6.7
11.2

Reverse

Weight

Specifications

1st speed
2nd speed
3rd speed

km/h

4.7
8.7
14.9

Bare tractor
With semi U-dozer + variable multishank ripper
With ROPS + cab + air conditioner +
side cover
With U-dozer + variable multi-shank
ripper + ROPS + cab + air conditioner
+ side cover
Bare tractor (To top of lift cylinder)
With Semi U-dozer + variable multishank ripper
With U-dozer + variable multi-shank
ripper

88.26 {0.90}
kPa {kg/cm2}

119.63 {1.22}

5,570
8,905
mm
9,245

Bare tractor (To top of lift cylinder)


With Semi U-dozer + variable multishank ripper
With U-dozer + variable multi-shank
ripper

mm

To top of exhaust pipe


To top of air intake duct
(To top of control lever)

mm

D275AX-5E0

117.67 {1.20}

2,925
4,300
4,615

3,915
3,153

Overall height

Dimensions

SEN00924-00

01 Specification

Machine model

D275AX-5E0

Serial number

30001 and up

With cab
With ROPS canopy
With canopy

Track gauge
Length of track on ground
Track shoe width (Standard)
Minimum ground clearance
(To the bottom of under cover)

mm

mm

Name

Performance

Engine

Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption ratio

Starting motor
Alternator
Battery

Power train system

Radiator core type

Torque converter

Transmission

2,260
3,480
610
510

SAA6D140E-5

Type of engine

Number of cylinders = Bore Stroke


Piston displacement

3,915
3,990
3,985

4-cycle, water-cooled, in-line vertical type,


direct injection type with turbocharger and aftercooler
mm
l {cc}

6140 x 165
15.24 {15,240}

kw{HP}/rpm
Nm{kgm}/rpm
rpm
rpm
g/kwh {g/HPh}

306{410}/2,000
1,989{203}/1,400
2,150
700
215 {160}
24V, 11kW
24V, 75A
12V, 170Ah x 2
Rectangle wave fin
3-element, 1-stage, 1-phase
Planetary gear type, multiple disc clutch type,
hydraulically actuated type (electric),
force-feed lubrication gear pump type,
forward 3-speed, reverse 3-speed,
electrically operated type

D275AX-5E0

01 Specification

SEN00924-00

Machine model

D275AX-5E0

Serial number

30001 and up

HSS pump

Variable swash plate type (HPV180)


Max. discharge pressure: 41.2 {420}

l/min/rpm

Logical discharge pressure: 411/2,286

MPa
{kg/cm2}

Fixed swash plate type (HMF180)


Max. allowable working pressure: 41.2 {420}
Spiral bevel gear type, force-feed lubrication
gear pump type

Bevel gear shaft

HSS steering system

Differential planetary gear type, hydraulic motor actuated type, electric motorized type, hydraulically actuated type

Master brake

Wet type, multiple disc clutch type, spring-boosted


type, hydraulically actuated type, pedal operated type

HSS

Power train system

HSS motor

MPa
{kg/cm2}

Spur gear 1-stage, planetary gear 1-stage type,


splash type lubrication

Undercarriage

Final drive
Suspension

Rigid, balancing beam type

Carrier roller

2 on each side

Track roller

7 on each side
Assembly type, single grouser, 39 each side Pitch:
260.6 mm

Track shoe (610 mm)


Power train + lubrication pump (tandem)

Gear type (BAR(3)100+50)

Variable in-line pump type

Work equipment
hydraulic system

Scavenging pump

Work equipment pump

Cooling fan pump

Cooling fan motor

D275AX-5E0

Gear type (BAR(3)160)


MPa
{kg/cm2}

Variable swash plate type (HPV112)


Max. discharge pressure: 27.4 {280}

l/min/rpm

Logical discharge pressure: 256/2,286

MPa
{kg/cm2}

Variable swash plate type: (LPV64)


Max. discharge pressure: 18.6 {190}

l/min/rpm

Logical discharge pressure: 146/2,286

MPa
{kg/cm2}

Fixed swash plate type (LMF110)


Max. allowable working pressure: 18.6 {190}

Main control
valve

SEN00924-00

01 Specification

Machine model

D275AX-5E0

Serial number

30001 and up

Type
For blade lift
For blade tilt
For ripper lift
For ripper tilt

Double + single + single type, spool type,


hydraulic assisted type Ripper tilt + ripper lift +
blade lift + blade tilt

Dimension of riper Dimension of ripper Dimension of blade Dimension of blade Dimension of blade
tilt cylinder
lift cylinder
tilt + pitch cylinder
tilt cylinder
lift cylinder

Hydraulic cylinder

Work equipment hydraulic system

Type

Double acting piston type


Cylinder bore
Piston rod outside diameter
Piston stroke (Max.)
Max. distance between pins
Min. distance between pins

mm
mm
mm
mm
mm

120
80
1,495
2,470
985

Cylinder bore
Piston rod outside diameter
Piston stroke (Max.)
Max. distance between pins
Min. distance between pins

mm
mm
mm
mm
mm

180
100
190
1,555
1,365

Cylinder bore
Piston rod outside diameter
Piston stroke (Max.)
Max. distance between pins
Min. distance between pins

mm
mm
mm
mm
mm

180
100
190
1,555
1,365

Cylinder bore
Piston rod outside diameter
Piston stroke (Max.)
Max. distance between pins
Min. distance between pins

mm
mm
mm
mm
mm

180
100
465
1,565
1,100

Cylinder bore
Piston rod outside diameter
Piston stroke (Max.)
Max. distance between pins
Min. distance between pins

mm
mm
mm
mm
mm

160
90
455
1,570
1,115

Hydraulic tank

Box type(Control valve externally installed type)

D275AX-5E0

01 Specification

SEN00924-00

Machine model

D275AX-5E0

Serial number

30001 and up

Type

Hydraulic semi U-tilt dozer,Hydraulic U-tilt dozer

mm

1,450

Performance

mm

640

mm
deg.
m3

1,000
6
13.7

Dimensions

Blade width
Blade height
Blade cutting angle

mm
mm
deg.

4,300
1,960
52

Max. lifting blade height


(from ground level)
Max. lowering blade depth
(from ground level)
Max. tilt
Blade cutting angle variation
Blade capacity (SAE)

mm

1,450

Performance

Brace type (Right-side tilt cylinder)

Max. lifting blade height


(from ground level)
Max. lowering blade depth
(from ground level)
Max. tilt
Blade cutting angle variation
Blade capacity (SAE)

mm

640

mm
deg.
m3

1,070
6
16.6

Blade width
Blade height
Blade cutting angle

mm
mm
deg.

4,615
1,973
52

Max. tilt
Max. pitch angle
Max. pitch-back angle

mm
deg.
deg.

1,140
6
6

Max. tilt
Max. pitch angle
Max. pitch-back angle

mm
deg.
deg.

1,220
6
6

Dimensions Performance Dimensions

U-dozer
U-dozer

Semi U-dozer

Work equipment

Semi U-dozer

Blade support method

D275AX-5E0

01 Specification

Machine model

D275AX-5E0

Serial number

30001 and up

Type
Weight
Beam length
Number of shanks

kg
mm
unit
deg.

Cutting depth
Max. digging depth
Max. lifting height

mm
mm

Type
Weight
Beam length
Number of shanks
Cutting angle (Standard)

kg
mm
unit
deg.

Cutting depth
Max. digging depth
Max. lifting height

mm
mm

Performance

Cutting angle (Standard)

Performance

Variable multi-shank ripper


Variable giant ripper

Work equipment

SEN00924-00

Variable cutting angle type,parallelogram type


4,490
2,495
3
51.7 (Stepless adjustment is possible between 38.9
and 61.2 deg.)
Two Switch-Selectable
900
955
Variable cutting angle type, parallelogram type
3,640
1,252
1
52.7 (Stepless adjustment is possible between 38.7
and 62.2)
Three Switch-Selectable
1,300
870

D275AX-5E0

01 Specification

SEN00924-00

Weight table
a

This weight table is for reference in handling or transporting components.


Unit: kg
Machine model

D275AX-5E0

Serial number

30001 and up

Engine
Engine assembly
Damper assembly
Universal joint
Engine mounting parts (Wiring)

1,850
135
25
5

Radiator assembly
(Including built-in oil cooler)
Aftercooler assembly
Hydraulic cooler
Fuel tank assembly (When empty)
Fuel tank assembly (When full)

49
25
385
1,090

Power train unit assembly (Including HSS pump, motor)


Torque converter, PTO assembly
Transmission assembly
HSS assembly
Brake valve assembly
HSS charging filter assembly
HSS cooler bypass valve assembly
Power train filter assembly
Scavenging pump
Power train, lubricating pump
Work equipment pump + HSS charging pump
HSS motor
HSS pump
Cooling fan pump
Cooling fan motor

2,615
534
645
996
14
25
5
23 x 2
19
27
78
64
103
40
25

Final drive assembly


Sprocket teeth
Hull frame assembly
Track group assembly (each side)
Track frame
Idler assembly
Recoil spring assembly
First bogie and track roller assembly
Second-fourth bogies and track roller assembly
Track roller assembly (Single flange x 1)
Track roller assembly (Double flange x 1)
Carrier roller assembly

D275AX-5E0

451

1,720 x 2
(25 x 5) x 2
4,054
5,021
1,396
333
352
231
527 x 3
149 x 2
161 x 5
58 x 2

SEN00924-00

01 Specification

Unit: kg
Machine model

D275AX-5E0

Serial number

30001 and up

Track shoe assembly (610mm width, wet type)


Pivot shaft assembly
Equalizer bar

3,405 x 2
142 x 2
273

Hydraulic tank assembly


Main control valve
(Blade lift + blade tilt + ripper lift + ripper tilt)

166

Engine underguard
Transmission underguard
Operator seat

250
312
41

Semi U-tilt dozer assembly


Blade
Straight frame
Tilt brace
Center brace
Tilt cylinder assembly

6,750
4,150
967 x 2
153 x 1
141 x 2
230

Semi U-tilt + pitch dozer assembly


Blade
Straight frame
Center brace
Pitch cylinder assembly

6,827
4,150
967 x 2
141 x 2
230 x 2

Radiator guard assembly (Including cylinder yoke + lattice mask)


Blade lift cylinder assembly

1,336
235 x 2

Multi-shank ripper assembly


Shank
Lift cylinder assembly
Tilt cylinder assembly

4,462
350 x 3
184 x 2
155 x 2

Giant ripper assembly


Shank
Lift cylinder assembly
Tilt cylinder assembly
Pin puller cylinder assembly

3,600
500 x 1
184 x 2
155 x 2
7

ROPS assembly (Specification with cab)


Cab assembly
ROPS canopy
Dash board
Floor frame assembly
Air conditioner assembly (Including air conditioner unit assembly)
Operator seat assembly

10

99

605
455
650
83
591
87
64

D275AX-5E0

01 Specification

SEN00924-00

Table of fuel, coolant and lubricants


a

For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.

D275AX-5E0

11

SEN00924-00

01 Specification

Unit: l
Refilling points

D275AX-5E0
Specified capacity

Refill capacity

Engine oil pan

55

50

Damper case

1.5

1.5

Power train case

150

90

Fainal drive case (each)

40

40

Hydraulic system
(with blade, without ripper)

270

130

Cooling system
(including reservoir tank)

110

Fuel tank

840

12

D275AX-5E0

SEN00924-00

01 Specification

D275AX-5E0 Bulldozer
Form No. SEN00924-00

14

D275AX-5E0

SEN00926-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Engine and cooling system


Engine and cooling system ............................................................................................................................. 2
Engine mount ....................................................................................................................................... 2
Cooling system..................................................................................................................................... 4
Cooling fan pump ................................................................................................................................. 6
Cooling fan motor............................................................................................................................... 14

D275AX-5E0

SEN00926-00

10 Structure, function and maintenance standard

Engine and cooling system

Engine mount

Unit: mm
No.

Check item
Clearance between bracket
and cushion

Free height of mount rubber

Criteria
Standard
size
60

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

0.100
0.300

+0.046
+0.046

0.100
0.346

0.4

Standard clearance

Repair limit

90

84

Replace

D275AX-5E0

SEN00926-00

Cooling system

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

A:
B:
C:
D:

Power train oil cooler inlet


Power train oil cooler outlet
Hydraulic oil cooler inlet
Hydraulic oil cooler outlet

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Hydraulic oil cooler


Radiator cap
Aftercooler outlet hose
Radiator inlet hose
Aftercooler inlet hose
Radiator
Aftercooler
Power train oil cooler
Radiator outlet hose
Drain plug
Cooling fan motor
Cooling fan
Reservoir tank

SEN00926-00

Specifications
Radiator

Power train
oil cooler

Hydraulic oil cooler

Aftercooler

Rectangle wave fin

PTO-OL

J4

Rectangle straight fin

8.0/2

4.0

8.0/2

Total heat dissipation surface (m2)

41.99 x 3

3.741

8.52

25.82

Cracking pressure of pressure valve (kPa{kg/cm2})

88.3 14.7
{0.9 0.15}

Cracking pressure of vacuum valve (kPa {kg/cm2})

0 4.9
{0 0.05}

Core type
Fin pitch (mm)

D275AX-5E0

SEN00926-00

Cooling fan pump

10 Structure, function and maintenance standard

LPV64

P1:
PS:
PA:
PE:

Pump discharge port


Pump suction port
Pump control basic pressure
Pump control pressure

P1C: Pump pressure detection port


PEN: Pump control pressure detection port
PD: Pump drain port
PD2: Pump drain port

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.

Shaft
Oil seal
Case
Rocker cam
Shoe
Piston

D275AX-5E0

SEN00926-00

7.
8.
9.
10.
11.
12.

Cylinder block
Valve plate
Spring
Servo piston
Ball
End cap

SEN00926-00

Function
q
The rotation and torque of the engine are
transmitted to the shaft of this pump and converted into hydraulic energy in this pump. This
pump discharges the pressurized oil according
to the load.
q
The discharge of this pump can be changed by
changing the swash plate angle in it.

10 Structure, function and maintenance standard

Structure
q
Cylinder block (7) is supported on shaft (1)
through spline (B). Shaft (1) is supported by
the front and rear bearings.
q
The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6)
and shoe (5) form a spherical bearing.
q
Rocker cam (4) has plane (A). Shoe (5) is kept
pressed against plane (A) and slid circularly.
Rocker cam (4) slides around ball (11).
q
Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q
Cylinder block (7) rotates relatively against
valve plate (8), sealing the pressurized oil, and
the hydraulic balance is maintained properly.
q
The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).

D275AX-5E0

10 Structure, function and maintenance standard

SEN00926-00

Operation
1. Operation of pump
q
Cylinder block (7) rotates together with shaft
(1) and shoe (5) slides on plane (A). At this
time, rocker cam (4) tilts around ball (11). As a
result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block
(7) changes. Angle (a) is called the swash
plate angle.
q
If angle (a) is made between center line (X) of
rocker cam (7) and the axis of cylinder block
(7), plane (A) works as a cam for shoe (5).
q
Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
resurlt, each piston (6) sucks and discharges
oil by (F) (E).
q
In other words, if cylinder block (7) rotates and
the volume of chamber (E) is decreased, the
oil is discharged from chamber (E). On the
other hand, the volume of chamber (F) is
increased and the oil is sucked in chamber (F).
(In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.)
q
If center line (X) of rocker cam (4) is equal to
the axis of cylinder block (7) (the swash plate
angle is 0), there is not a difference between
volumes (E) and (F) in cylinder block (7) and
oil is not sucked or discharged. (The swash
plate angle is not set to 0 actually, however.)
q
In short, swash plate angle (a) is in proportion
to the pump discharge.

D275AX-5E0

SEN00926-00

2.
q

10

10 Structure, function and maintenance standard

Control of discharge
If swash plate angle (a) is increased, the difference between volumes (E) and (F) is
increased, and so discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
Servo piston (10) reciprocates straight according to the signal pressure of the servo valve.
This straight motion is transmitted to rocker
cam (4).
Then, rocker cam (4) supported on ball (11)
slides around ball (11).

D275AX-5E0

10 Structure, function and maintenance standard

SEN00926-00

Servo valve

P:
T:
PE:
PH:

EPC valve basic pressure


Drain
Control piston pressure
Pump discharge pressure

1.
2.
3.
4.
5.
6.
7.

Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve

D275AX-5E0

11

SEN00926-00

Function
q
The servo valve controls the current (i) input to
the EPC valve and the swash plate angle (a) of
the pump so that they will be related as shown
in the figure below.

12

10 Structure, function and maintenance standard

The relationship between the input current (i)


to the EPC valve and the output pressure of
EPC valve (F) is as follows.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00926-00

Operation
q
The output pressure of the EPC valve is
applied to the piston chamber to push piston
(6). Piston (6) pushes spool (5) until it is balanced with the spring.
q
Then, the land (PE) of the servo piston pressure passage is connected to the pump discharge passages by the cut of spool (5) and
the discharge pressure is led to the servo piston.
q
The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
q
If spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are
shut off.
q
The pressure in the servo piston chamber lowers and the rocker cam returns toward the
maximum swash plate angle.
q
These processes are repeated until the swash
plate is fixed to a position where the EPC output pressure is balanced with the spring force.
q
Accordingly as the EPC output pressure is
heightened, the swash plate angle is
decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.

D275AX-5E0

13

SEN00926-00

Cooling fan motor

10 Structure, function and maintenance standard

Type: LMF110(65)

P: From fan pump


T: From cooler to tank
TC: To tank

14

Specifications
Type: LMF110(65)
Capacity: 65.1 cc/rev
Rated speed: 1,250 rpm
Rated flow: 81.4 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.

Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate

SEN00926-00

7.
8.
9.
10.
11.
12.

End cover
Center spring
Check valve
Pilot valve
Spool for reversible valve
Safety valve
Unit: mm

No.

Check item

Criteria

Remedy

Standard size
13 Spool return spring

14 Check valve spring

D275AX-5E0

Free length x Installation


outer diameter
length

Repair limit
Installation
load

Free
length

62.66 x 19.8

53.5

146 N
{14.9 kg}

16.4 x 8.9

11.5

13.7 N
{1.4 kg}

Installation
load
Replace spring
if damaged or
117 N
{11.9 kg} deformed.
11.0 N
{1.12 kg}

15

SEN00926-00

10 Structure, function and maintenance standard

1. Hydraulic motor
Function
q
This hydraulic motor is called a swash platetype axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q
The oil sent to one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and generates force (F1)[F1 = P x xD2/4].
q
This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft(1), the force is
divided into components (F2) and (F3).
q
The radial component (F3) generates torque
[Ti = F3 x ri] against the (Y-Y) line connecting
the top dead center and bottom dead center.
q
The result of this torque [T = Ti] rotates cylinder block (5) through the piston.
q
Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to transmit the torque.
q

16

D275AX-5E0

10 Structure, function and maintenance standard

2. Suction valve
Function
q
If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor continues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q
When the oil stops flowing in from inlet port (P),
suction valve (1) sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.

SEN00926-00

2)
q

When the pump is stopped


If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the pressurized oil from the pump is not supplied to
port (P) any more. As the pressurized oil is not
supplied to the (MA) side of the motor, the
motor speed lowers gradually to stop.
If the motor shaft is revolved by the force of
inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent
by the suction valve (1) to the (MA) side to prevent cavitation.

Operation
1) When pump is started
q
If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution.The pressurized oil
on the motor outlet (MB) side of the motor
returns through port (T) to the tank.

D275AX-5E0

17

SEN00926-00

3. Operation of reversible valve


1)
q

q
q

18

When the ON-OFF solenoid is de-energized.


If ON-OFF solenoid (1) is de-energized, the
pressurized oil from the pump is blocked by
ON-OFF selector valve (2), and port (C) opens
for the tank circuit.
Spool (3) is pushed to the right by spring (4).
Motor port (MA) opens and pressurized oil
flows in to revolve the motor in forward (clockwise).

10 Structure, function and maintenance standard

2)
q

q
q

When the ON-OFF solenoid is energized.


If ON-OFF solenoid (1) is energized, ONOFF selector valve (2) changes to let the pressurized oil from the pump flow through port (C)
into spool chamber (D).
The pressurized oil in chamber (D) pushes
valve spool (3) to the left against spring (4).
Motor port (MB) opens and pressurized oil
flows in to revolve the motor in reverse (counterclockwise).

D275AX-5E0

10 Structure, function and maintenance standard

SEN00926-00

4. Safety valve

Function
q
When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q
Safety valve (1) is installed to protect the fan
system circuit.
Operation
If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pressurized oil into port (T).
q
By this operation, generation of abnormal pressure in port (P) is prevented.
q

D275AX-5E0

19

SEN00926-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00926-00

20

D275AX-5E0

SEN00927-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Power train system, Part 1


Power train system, Part 1.............................................................................................................................. 2
Power train skeleton............................................................................................................................. 2
HSS system ......................................................................................................................................... 4
Overall drawing of power train unit....................................................................................................... 6
Power train hydraulic piping drawing ................................................................................................... 8
Transmission control ............................................................................................................................ 9
Steering, brake control ....................................................................................................................... 10
Damper, universal joint....................................................................................................................... 12
Torque converter, PTO ....................................................................................................................... 14
Transmission ...................................................................................................................................... 28
Tranmission ECMV ............................................................................................................................ 40
Main relief valve and torque convertor relif valve............................................................................... 46
Torque converter valve....................................................................................................................... 50
Lubrication relief valve ....................................................................................................................... 58

D275AX-5E0

SEN00927-00

10 Structure, function and maintenance standard

Power train system, Part 1


Power train skeleton

1
1

Outline
q
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3), and is
transmitted to torque converter (10).
q
The power from the engine is transmitted
through the oil by torque converter (10) to the
transmission input shaft (turbine shaft) in
accordance with the change in load.
q
Transmission (11) uses a combination of a
planetary gear system and hydraulic clutches
to reduce the speed and shift the gears (3 forward gears and 3 reverse gears). It connects
2 sets of clutches selected according to the
change in load, and transmits the power to
bevel gear (12) from the bevel pinion at the
rear end of the transmission.
q
The power transmitted to the bevel gear shaft
is transmitted to HSS (Hydrostatic Steering
System) (13). HSS pump (10) is driven by
PTO (7), and output oil of the HSS pump drives
HSS motor (14). The rotation of the pair of the
HSS gears on the right and left is controlled by
HSS motor (14). The steering is carried out by
generating a difference in speed on the right
and left.

It is also possible to use the HSS mechanism


to rotate the right and left sides in opposite
directions to carry out pivot turns.
Brake (15) of the HSS is used for braking the
machine. Brake (15) is a wet, multiple disc
clutch, spring boosted type. If brake (15) on
only 1 side is applied, the machine can carry
out pivot turns. The power sent from brake
(15) is transmitted to final drive (16).
Final drive (16) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (17)
to drive track shoe (18) and move the machine.
It also rotates fan motor (21) with the oil discharged from fan pump (19) driven with PTO
(7).

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.

Engine (SAA6D140E-5)
Damper
Universal joint
Scavenging pump
[BAR(3)-160]
HSS charge pump [SAL(3)-72]
Work equipment pump (HPV112)
PTO

D275AX-5E0

8.
9.
10.
11.
12.
13.
14.

Power train pump


[SAR(3)-100]
Steering lubricating oil pump
[SAR(3)-50]
Torque converter
Transmission
Bevel gear
HSS unit
HSS motor (HMF180)

SEN00927-00

15.
16.
17.
18.
19.
20.
21.

Brake
Final drive
Sprocket
Track shoe
Cooling fan pump (LPV64)
HSS pump (HPV180)
Cooling fan motor (LMF110)

SEN00927-00

HSS system

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

PCCS lever
HSS controller
Servo valve
HSS pump
Engine
Hydraulic pump
Hydraulic valve
Sproket
Final drive
HSS motor
HSS closed circuit
Motor free solenoid

SEN00927-00

A:
B:
C:
D:
E:
F:
G:

Travel REVERSE signal 2


Travel; REVERSE signal 1
Steering signal 1,2
Engine speed signal
Hydraulic pressure signal
Steering circuit pressure signal A
Steering circuit pressure signal B

Outline
q
The HSS system is a hydraulic system; HSS
stands for hydraulic Steering System.
q
The HSS system consists of a set of piston
pump and piston motor as shown in the diagram. With this system, it is possible to turn
continuously by generating a difference in
speed between the left and right tracks.
There is no need to reduce speed.
q
The HSS controller controls the angle of the
swash plate in the HSS pump according to the
angle of operation of the monolever, and controls the speed and directional of rotation of the
HSS motor.
The HSS motor uses the planetary gear system of the bevel gear shaft to create a differe n c e i n t h e s p e e d o f t h e l e ft a n d r i g h t
sprockets, and this turns the machine.
q
The HSS controller detects the speed of the
engine and the hydraulic pressure at all parts,
and controls the swash plate angle of the HSS
pump to ptevent the engine from stalling.
q
If the pivot turn mode is selected and the steering lever is operated to the stroke end, the
motor-free solenoid operates to open the HSS
circuit and the steering brake on one side operates.
As a result, the machine makes a pivot turn.

D275AX-5E0

SEN00927-00

Overall drawing of power train unit

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

HSS charge pump [SAL(3)-72]


Work equipment pump (HPV112)
Torque converter, PTO
Power train pump [SAR(3)-100]
Steering lubricating oil pump [SAR(3)-50]
Transmission
Parking brake valve
Left brake ECMV
Right brake ECMV
Sudden brake prevention valve
Cooling fan pump (LPV64)
HSS pump (HPV180)
HSS motor (HMF180)
HSS unit
Main relief valve
Power train oil strainer
Scavenging pump [BAR(3)-160]

D275AX-5E0

SEN00927-00

Outline
q
The power train unit consists of the main components of torque converter (3), transmission
(6), and HSS unit (14). Accordingly, after the
power train unit is removed, it can be divided
into the torque converter, transmission unit,
and HSS unit.
q
The HSS unit consists of the bevel pinion unit,
bevel gear shaft, HSS motor, planetary gear
system, and brake.

SEN00927-00

10 Structure, function and maintenance standard

Power train hydraulic piping drawing

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Scavenging pump [BAR(3)-160]


HSS charge pump [SAL(3)-72]
Power train oil filter
Power train lubrication oil filter
Work equipment pump (HPV112)
Centralized pressure pick-up ports
Power train pump [SAR(3)-100]
Steering lubricating oil pump [SAR(3)-50]
HSS charge filter
Brake control valve
HSS motor (HMF180)
Main relief valve
HSS pump (HPV180)
Power train oil cooler
(built in radiator lower tank)
15. Transmission ECMV
A:
B:

Left brake oil pressure pick-up port (LB)


Right brake oil pressure pick-up port (RB)

C:

Transmission 1st clutch oil pressure pick-up


port (1st)
D: Transmission 2nd clutch oil pressure pick-up
port (2ND)
E: Transmission 3rd clutch oil pressure pick-up
port (2RD)
F: Transmission R clutch oil pressure pick-up port
(R)
G: Transmission F clutch oil pressure pick-up port
(FWD)
H: Transmission main relief pressure pick-up port
(TM)
J: Torque converter stator clutch pressure pick-up
port (SC)
K: Torque converter lock-up clutch pressure pickup port (LU)
L: Torque converter outlet pressure pick-up port
(OUT)
M: Torque converter inlet pressure pick-up port (IN)

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Transmission control

For steering operation concerned to operation


of PCCS lever, see "Steering and brake control".

1.
2.
3.

Brake pedal
Lock lever
PCCS lever (Forward-Reverse,
Gear shift)
UP switch
(Gear is shifted up each time this
switch is pressed.)
DOWN switch
(Gear is shifted down each time
this switch is pressed.)
Transmission neutral safety
switch
Cable
Transmission control valve

4.
5.
6.
7.
8.

D275AX-5E0

Lever positions
(A): Neutral
(B): Forward
(C): Reverse
(D): OFF
(E): Shift UP
(F): Shift DOWN
(G): Free
(H): Lock

PCCS: Abbreviation for Palm Command Control System.

Outline
q
The transmission is controlled with PCCS
lever (3).
The PCCS lever is used to select the travel
direction and shift the gear.
q
Since the safety mechanism is employed,
transmission neutral safety switch (6) does
not work and the engine does not start
unless lock lever (2) is in the LOCK position.

SEN00927-00

Steering, brake control


q

10

10 Structure, function and maintenance standard

Regarding the transmission-related description


of the operation of the PCCS lever, refer to the
transmission control.
PCCS: Palm Command Control System

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Brake pedal
Lock lever
PCCS lever (Steering)
Steering controller
Limit switch
Steering ECMV
Brake valve
Parking brake lever (From lock lever)
Cable
Rod (From brake pedal)
Potentiometer

Outline
q
PCCS lever (3) sends electric signals to steering controller (4). Upon receiving those signals, steering controller (4) sends signals to
HSS Pump servo to changes the discharge of
the pump to operate the starting motor.
q
Brake pedal (1) sends electric signals through
potentiometer (11) to steering controller (4).
Upon receiving this signal, steering controller
(4) sends proportional current to ECMV (6) to
operate the brake. Rod (10), as a redundant
device, operates the brake through brake valve
(7) (only in the complete braking mode).

D275AX-5E0

SEN00927-00

Positions of levers and pedals


A: Neutral
B: Forward straight
C: Reverse straight
D: Left clutch OFF
E: Left clutch OFF
Left brake ON
F: Right clutch OFF
G: Right clutch OFF
Right brake ON
H: Brake OFF
J: Brake ON
K: Free
L: Lock

Lock lever (2) is connected to parking brake


lever (8) and used as the parking brake lever,
too.

11

SEN00927-00

Damper, universal joint

12

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

SEN00927-00

Breather
Oil level gauge
Drain plug
Output shaft
Flywheel
Outer body
Coupling
Universal joint
Cover
Rubber coupling
Inner body

Outline
The damper dampens the torsional vibration
caused by the change in engine torque and the
impact torque generated when accelerating suddenly or when carrying out heavy-duty digging. In
this way it acts to protect the torque converter,
transmission, and other parts of the power train.
This damper has few component parts: it uses a
rubber coupling, so the vibration is absorbed by the
damping effect of the rubber material.
Operation
q
This motive force from the engine passes
through flywheel (5) and it transmitted to outer
body (6).
q
The torsional vibration of the engine is
absorbed by rubber coupling (10), and the
power is transmitted to inner body (11). It
passes through universal joint (8), and is then
transmitted to the torque converter and transmission.
Unit: mm

No.

Check item

Clearance between flywheel


12
housing and cover

13

Clearance between flywheel


and damper

14

Outer circumference of coupling oil seal contact surface

D275AX-5E0

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

511.18

0.022
0.092

+ 0.070
+ 0.070

0.022
0.162

0.2

466.72

0.020
0.083

+ 0.063
+ 0.063

0.020
0.146

0.2

Standard size

Tolerance

Repair limit

90

0.087
0.087

89.8

Replace

13

SEN00927-00

Torque converter, PTO

14

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

D275AX-5E0

SEN00927-00

15

SEN00927-00

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

16

Work equipment pump, HSS charge pump


mounting port
HSS pump mounting port
Power train oil strainer
Scavenging pump mounting port
Fan pump mounting port
PTO lubrication tube
Power train, Steering lubricating oil pump
mounting port
Coupling
Input shaft [PTO drive gear (56 teeth)]
Idler gear (77 teeth)
Idler gear shaft
Torque converter case
Drive case
Turbine
Stator
Stator boss
Pump
Retainer
Shaft
Stator clutch rear housing
Stator clutch front housing
Stator shaft
Stator shaft boss (90 teeth)
Return spring
Stator clutch plate
Stator clutch disc
Stator clutch piston
Transmission input shaft
Turbine boss (90 teeth)
Lock-up clutch plate
Lock-up clutch disc
Lock-up clutch piston
Lock-up clutch housing
Pump drive gear (49 teeth)
(Work equipment, HSS charge pump, power
train, and steering lubricating oil pump)
HSS, Fan pump drive gear (49 teeth)
Scavenging pump drive gear (57 teeth)
Power train oil strainer

10 Structure, function and maintenance standard

A:
B:
C:
D:
E:
F:

From power train pump (to torque converter


valve, transmission ECMV, and steering brake
ECMV)
To oil cooler
Torque converter oil inlet
To transmission case (From torque converter
case)
To transmission case (To scavenging pump)
From steering case and transmission case
(Oil pan pass)

D275AX-5E0

10 Structure, function and maintenance standard

Outline
q
The torque converter is the 3-element, 1-stage,
and 1-phase type, which is combined with the
transmission into 1 unit. It is equipped with a
torque converter lock-up device of the wet and
multiple disc type and a stator clutch to reduce
the fuel consumption and increase the operability and reduce the horsepower consumption
by the engine.
q
For higher efficiency of continuous dozing and
leveling work, the engine power should be
transmitted directly to the input shaft of the
transmission. For this reason, the hydraulic
lock-up clutch is built in the torque converter.
When the torque converter is locked up (the
pump and turbine is combined into 1 unit), the
oil supplied from the torque converter relief
valve does not stop. Accordingly, the oil flowing from the pump through the turbine is given
an unnecessary directional property and
resists the revolution of the pump and turbine
(agitates the oil).
To avoid this, a stator clutch similar to the lockup clutch is installed so that the stator can
rotate freely together with the pump and turbine when the torque converter is locked up.
As a result, the oil discharged from the pump
and turbine is returned to the pump against
less resistance.
a

The torque converter is set in the lock-up


range and torque converter range under the
following conditions.

SEN00927-00

Structure
q
Pump (17) is combined with coupling (8), shaft
(9), clutch housing (33), and drive case (13)
into 1 unit and rotated by the engine power.
q
Turbine (14) is combined with turbine boss (29)
and transmission input shaft (turbine shaft)
(28) into 1 unit and rotated by the engine
power.
q
Stator (15) is combined with stator boss (16),
stator shaft (22), and stator shaft boss (23) into
1 unit and fixed to front housing (21) and rear
housing (20) through the stator clutch unit.
q
The lock-up clutch unit consists of clutch plate
(30) meshed with drive case (13), clutch disc
(31) meshed with turbine boss (29), and clutch
piston (32) which slides inside housing (33)
combined with the drive case into 1 unit.
q
The stator clutch unit consists of clutch disc
(26) meshed with boss (23) coupled with stator
shaft (22) by the spline, clutch plate (25) supported by the pins on front housing (21) and
rear housing (20) of the clutch, and clutch piston (27) which slides inside the front housing.
The front hosing and rear housing of the stator
clutch are bolted to the front housing of the
transmission R clutch.
q
The PTO unit consists of input shaft (9), idler
gear (10), scavenging pump drive gear (36),
work equipment pump and power train pump
drive gear (34), and HSS pump and fan pump
drive gear (35).

Unit: rpm

Lock-up range

Torque converter range

F1

Min. 1,471

Max. 1,433

F2

Min. 1,440

Max. 1,419

F3

Min. 1,420

Max. 1,407

R1

Min. 1,419

Max. 1,392

R2

Min. 1,420

Max. 1,404

R3

Min. 1,417

Max. 1,408

While the transmission gear is being shifted,


the torque converter is set in the torque converter range.

D275AX-5E0

17

SEN00927-00

18

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Unit: mm
No.

Check item

Criteria
Tolerance

Repair limit

120

0.054
0.054

119.8
150.5
90.5

Outside diameter of coupling


oil seal contact surface

Inside diameter of retainer seal


ring contact surface

150

+ 0.040
+ 0.040

Inside diameter of sleeve seal


ring contact surface

90

+ 0.035
+ 0.035

Backlash between PTO drive


gear and scavenging pump
drive gear

Backlash between PTO drive


gear and driven gear

Wear of stator shaft seal ring

Stator clutch Lock-up clutch

Standard clearance

Clearance limit

0.204 0.512

0.204 0.512

Standard size

Repair limit

Width: 4.5
Height: 5.5

Width: 4.05
Height: 4.95

Thickness of disk

5.0

4.5

Thickness of plate

5.0

4.5

Thickness of
overall assembly

15.0

13.9

Thickness of disk

5.0

4.5

Thickness of plate

5.0

4.5

15.0

13.9

Thickness of
overall assembly

Standard size
9

Remedy

Standard size

Stator clutch spring

D275AX-5E0

Repair hard
chrome plating or
replace

Replace

Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

35

27.2

83.5 N
{8.5 kg}

34.0

79.3 N
{8.1 kg}

19

SEN00927-00

10 Structure, function and maintenance standard

Power train route


1.

When lock-up clutch is OFF


and stator clutch is ON
If the lock-up clutch is OFF,
drive case (13) and turbine (14)
are disconnected from each
other. If stator clutch is ON at
this time, rear housing (20) and
stator shaft (22) are connected
to each other to fix stator (15)
and the lock-up torque converter works as an ordinary
torque converter. The engine
power is transmitted through
the damper and universal joint
to coupling (8) and rotates input
shaft (9), clutch housing (33),
drive case (13), and pump (17)
as 1 unit. The power of the
p u m p r o ta t e s t u r b i n e ( 1 4 )
through oil and is transmitted to
transmission input shaft (28)
combined with the turbine into 1
unit.

2.

When lock-up clutch is ON


and stator clutch is OFF
If the lock-up clutch is ON, drive
case (13) and turbine (14) are
connected to each other. If stator clutch is OFF at this time,
rear housing (20) and stator
shaft (22) are disconnected
from each other and stator (15)
is dragged and rotated by pump
(17) and tur bine ( 14) . T he
engine power is transmitted
through the damper and universal joint to coupling (8) and
rotates input shaft (9), clutch
housing (33), drive case (13),
and pump (17) as 1 unit. Since
drive case and turbine (14) are
connected by the clutch, the
power is transmitted directly to
transmission input shaft (28)
without using the oil.

20

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Flow of oil
q

The oil pressure is regulated to


below 1.0 MPa {10.2 kg/cm2} by the
torque converter relief valve and the
oil flows through port (C) and oil hole
of stator clutch front housing (21) into
p u m p ( 1 7 ) . S i n c e th e p u m p i s
rotated constantly by the engine
power, the oil in the pump is given a
centrifugal force and put in turbine
(14), then the turbine is rotated by
the centrifugal force of the oil. Since
the turbine is combined with transmission input shaft (28), the power
received by the turbine is transmitted
the transmission. The oil discharged
from the turbine is sent to stator (15)
and put in the pump again, but some
of it is sent from the stator through
port (B) to the oil cooler.

D275AX-5E0

21

SEN00927-00

10 Structure, function and maintenance standard

Torque converter lock-up control system


System diagram

Operation
q
The torque converter lock-up control system
controls the lock-up operation of the torque
converter automatically with a sensor signal
and the controller in it according to the load on
the machine. When the torque converter is
locked up, the pilot lamp on the monitor panel
lights up.
q
The signal of the transmission outlet speed
sensor is input to the transmission controller.
q
The lock-up mode is set with the mode selection panel.
q
The machine controller receives the transmission outlet speed sensor signal etc. and turns
ON and OFF the lockup system by controlling
the lockup solenoid and pilot lamp according to
the machine condition.

22

D275AX-5E0

10 Structure, function and maintenance standard

1.

SEN00927-00

When traveling in torque converter range

While the machine is in the "torque converter


range", the solenoid valve is deactivated and
plunger (29) is returned up by the oil pressure
and the seats of valve (22) and ball (23) are
separated and ports (P) and (N) are opened.
Since the drain circuit of port (N) is open, oil in
port (M) is also drained.
Since lock-up changeover valve (20) is pushed
to the right by spring (19), the passages
between ports (Q) and (L) and between (S)
and (T) are closed and the passages between
(Q) and (S) and between (L) and (R) are
opened. Then, the oil from the pump flows
through port (Q) into port (S) and applies back
pressure to the stator clutch piston and excited
the stator clutch when the circuit oil pressure
rises. At the same time, the oil which has been
applying back pressure to the lock-up clutch
piston is drained through port (L) into (R) and
the lock-up clutch is deactivated. The oil from
the pump flows in port (P), too. It is drained
through throttle (A), however, since the solenoid is deactivated. The oil pressure in port
D275AX-5E0

(Q) is secured by throttle (A) and regulated by


modulating valve (5).

23

SEN00927-00

2.

10 Structure, function and maintenance standard

When traveling in direct range

While the machine is in the "direct range", the solenoid valve is excited and plunger (29) is pushed
back down and the seats of valve (22) is closed and
ports (P) and (M) are opened and the drain circuit
of port (N) is closed. The oil from (M) moves piston
(21) and lock-up changeover valve (20) to the left to
close the passages between ports (Q) and (S) and
between ports (L) and (R) and open the passages
between ports (Q) and (L) and between ports (S)
and (T). Then, the oil from the pump flows through
port (Q) into port (L) and applies back pressure to
the lock-up clutch piston and excited the lock-up
clutch when the circuit oil pressure rises. At the
same time, the oil which has been applying back
pressure to the stator clutch piston is drained
through port (S) into (T) and the stator clutch is
deactivated. The oil pressure in port (L) is regulated by modulating valve (10).

24

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Operation of modulation valves of stator clutch and lock-up clutch


q

1.

The modulating valves are in the circuits


between the lock-up changeover valve and the
inlet of the 2 clutches. When each clutch is
turned ON, the modulating valve in its circuit
heightens the oil pressure applied to the piston
gradually to the specified level to excited the
clutch smoothly and reduce the impacts given
to the torque converter and transmission.
The following is the explanation of the modulating valve for the stator clutch. Although the
modulating valve for the lock-up clutch operates similarly to that for the stator clutch, the oil
flow into the clutches in the direct range and
torque converter range is reversed, however.
When traveling in direct range
While the machine is in the "direct range", the
solenoid valve is excited and the oil in port (M)
of lock-up changeover valve (24) pushes piston (21) and valve (20) to the left. Lock-up
changeover valve (20) is pushed to the left by
the oil pressure higher than the tension of
spring (19) and the passage between ports (Q)
and (S) is closed and the passage between
ports (S) and (T) is opened to drain the oil from
port (S) through port (T). If the oil pressure in
port (S) is lost, modulating valve (5) is returned
to the right by the tension of spring (2) to open
part (B) of port (S) fully. At this time, the operating oil of the stator clutch is drained from port
(S) to port (T) and the clutch is deactivated.
The oil from the pump flows through port (Q) to
port (L) and the lock-up clutch is turned ON.

D275AX-5E0

25

SEN00927-00

2.

10 Structure, function and maintenance standard

When traveling in torque converter range


While the machine is in the "torque converter
range", the solenoid valve is deactivated and
the oil from the pump and in port (M) is
drained.
Valve (22) is moved to the right by the tension
of spring (19) and the passages between ports
(Q) and (L) and between ports (S) and (T) are
closed and the passage between port (Q) and
(S) is opened. As a result, the circuit is connected from port (Q) through modulating valve
(5) to the stator clutch.
The oil from the pump flows through port (Q) to
the stator clutch and the oil pressure in the circuit starts rising.
If the circuit pressure rises, the oil flowing
through orifice (d) of modulating valve (5)
pushes piston (7). The reaction force of piston
(7) moves the modulating valve to the left to
narrow part (B) of port (S).
Port (S) is connected to port (U) to apply back
pressure to load piston (3). Load piston (3) is
moved to the right to compress spring (2) and
the tension of the spring opens part (B) of port
(S). This operation is repeated intermittently to
increase the load on spring (2). During this
operation, the oil pressure rises gradually until
part (B) of port (S) is closed. Then, rise of the
oil pressure is completed.
At this time, the stator clutch pressure is 2.65
0.1 MPa {27.0 1 kg/cm2}
The lock-up clutch pressure is 1.3 +0.1
MPa
0
{13 +10 kg/cm2}.

26

D275AX-5E0

SEN00927-00

Transmission

28

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

A:
B:
C:
D:
E:
F:
G:
H:
J:
K:

To forward clutch
To reverse clutch
To 3rd clutch
To 2nd clutch
To 1st clutch
To torque converter case
From torque converter case
To scavenging pump
To torque converter case
From scavenging pump

D275AX-5E0

SEN00927-00

L:
M:
N:
P:
Q:
R:
S:
T:
U:
V:

From power train pump


To steering valve
To steering case
From steering case
Transmission lubrication oil inlet
Transmission 1st clutch pressure pick-up port
Transmission 3rd clutch pressure pick-up port
Transmission R clutch pressure pick-up port
Transmission 2nd clutch pressure pick-up port
Transmission F clutch pressure pick-up port

29

SEN00927-00

30

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Main relief valve


Transmission case
Transmission control valve and valve cover
assembly
Lubricating oil relief valve
Input shaft
Reverse clutch sungear (34 teeth)
Pinion shaft
Ring gear of reverse travel (86 teeth)
Planetary pinion for reverse travel (26 teeth)
Disc
Plate
Piston
Planetary pinion for forward travel (27 teeth)
Planetary pinion for 3rd gear speed (36 teeth)
Ring gear for 3rd gear speed (Number of internal teeth: 91, Number of external teeth: 109)
Sun gear for 2nd gear speed (39 teeth)
Planetary pinion for 1st gear speed (21 teeth)
Sun gear for 1st gear speed (49 teeth)
Output shaft (Number of teeth of sun gear for
3rd gear speed: 20)
Ring gear for 1st gear speed (Number of internal teeth: 91, Number of external teeth: 105)
1st clutch carrier (90 teeth)
Clutch housing for 1st gear speed
Clutch housing for 2nd gear speed
Planetary pinion for 2nd gear speed (26 teeth)
Ring gear for 2nd gear speed (Number of internal teeth: 90, Number of external teeth: 105)
Clutch housing for 3rd gear speed
Carrier for 2nd and 3rd gear speeds
Clutch housing for forward travel
Sun gear for forward travel (37 teeth)
Ring gear for forward travel (Number of internal teeth: 91, Number of external teeth: 105)
Carrier for forward travel (86 teeth)
Clutch housing for reverse travel
Return spring
Ring gear for reverse travel (Number of internal teeth: 90, Number of external teeth: 105)
Pin
Carrier for reverse travel (90 teeth)

D275AX-5E0

SEN00927-00

Outline
q
The transmission consists of planetary gear
systems and disc clutches and has "3 forward
gear speeds and 3 reverse gear speeds".
q
Among the 5 sets of planetary gear system
and disc clutch of the transmission, 2 clutches
are fixed hydraulically with control valves to
select 1 rotating direction and rotating speed.
q
Clutches No. 1, No. 2, No. 3, No. 4, and No. 5
are fixed respectively when the reverse, forward, 3rd, 2nd, and 1st gears are selected.
Number of plates and discs
Clutch No.
No.1
No.2
No.3
No.4
No.5

Number of discs Number of plates


6
8
4
4
3

6
7
5
5
4

Gear speeds and operated clutches


Gear speed

Operated clutches (Turned ON)

Forward 1st
Forward 2nd
Forward 3rd
Neutral
Reverse 1st
Reverse 2nd
Reverse 3rd

No.2No.5
No.2No.4
No.2No.3
*1. No.5
No.1No.5
No.1No.4
No.1No.3

*1: While the transmission is in neutral, the 1st


clutch is filled with low-pressure oil and
engaged so that the machine can start without
a time lag.

31

SEN00927-00

32

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Unit: mm
No.

Check item

Criteria
Standard size

No. 1 clutch spring (12 pcs.)

Remedy
Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

91

71.2

174.6 N
{17.8 kg}

88.3

165.7N
{16.9 kg}

No. 2 clutch spring (12 pcs.)

84

79.8

53.0 N
{5.4 kg}

81.5

50.0 N
{5.1 kg}

No. 3 clutch spring (12 pcs.)

68

59.5

95.1 N
{9.7 kg}

66.0

90.2 N
{9.2 kg}

No. 4 clutch spring (12 pcs.)

70

51

93.2 N
{9.5 kg}

67.9

88.3 N
{9.0 kg}

No. 5 clutch spring (12 pcs.)

70

53

83.4 N
{8.5 kg}

67.9

79.4 N
{8.1 kg}

Thickness of clutch disc


(No. 1, 2 clutches)

Standard size

Tolerance

Repair limit

5.4

0.1

4.9

Thickness of clutch disc


(No. 3 - 5 clutches)

5.4

0.1

4.6

Thickness of clutch plate


(No. 1 - 5 clutches)

3.2

0.1

2.9

Total thickness of No. 1 clutch

51.6

0.3

48.8

10 Total thickness of No. 2 clutch

65.6

0.4

58.2

11 Total thickness of No. 3 clutch

37.6

0.3

35.6

12 Total thickness of No. 4 clutch

37.6

0.3

35.6

13 Total thickness of No. 5 clutch

29.0

0.3

27.3

Standard clearance

Clearance limit

0.14 0.35

Backlash between each planetary gear and internal teeth of


15
ring gear (Forward, reverse,
1st and 2nd gear speeds)

0.15 0.38

Backlash between planetary


16 pinion and internal teeth of ring
gear (3rd gear speed)

0.16 0.41

Backlash between carrier and


17 internal teeth of ring gear
(Reverse)

0.18 0.54

Backlash between each carrier


18 and internal teeth of ring gear
(Forward, 1st gear speed)

0.18 0.48

Backlash between each sun


gear and planetary pinion
14
(Forward, reverse, 1st - 3rd
gear speeds)

D275AX-5E0

Replace

33

SEN00927-00

10 Structure, function and maintenance standard

Operation
1. Operation of disc clutch
q
To lock ring gear (8) a disc clutch is used. The
clutch consists of piston (12), plates (11), discs
(10), pin (35) and piston return springs (33).
The internal teeth of the disc engage with the
external teeth of the ring gear.
The teeth on the outside diameter of the plate
engage with pins (35) secured by housing (32).

Clutch engaged (locked)


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

Clutch disengaged (free)


When the supply of pressure oil from the control valve is shut off, piston (12) is returned to
its original position by the force of piston return
spring (33). This relieves the frictional force
between plates (11) and discs (10), making the
ring (8) free.

34

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Oil circuit of 1st clutch


Since the 1st clutch is the farthest from the control
valve and has the longest circuit to the cylinder, it
takes the longest time to fill the circuit.
To solve this problem, the oil is supplied to the 1st
clutch even if the gear shift lever is in the NEUTRAL position,
Accordingly, when the gear shift lever is shifted
from the NEUTRAL position to the F1 position, the
pump is required to supply oil of only quantity to fill
the forward clutch.
When the gear shift switch is changed from the F1
to F2, the pump is required to supply fill of only
quantity to fill the 2nd clutch since the forward
clutch has been filled with the oil.
The time lag in the gear shifting operation is
reduced by using the oil as explained above.

D275AX-5E0

35

SEN00927-00

2.
q

36

Forward 1st
When the transmission is set to FORWARD
1st, the No. 2 clutch and No. 5 clutch are
engaged. The motive force from the torque
converter transmitted to input shaft (5) is then
transmitted to output shaft (19).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring
gear (30) in position. No. 5 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and engages ring gear (20).
The motive force from the torque converter is
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (29)
and is transmitted to planet pinion (13).
Ring gear (30) is held in position by No. 2
clutch, so the rotation of planet pinion (13)
rotates carrier (31), which is on the inside of
ring gear (30).
Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).

10 Structure, function and maintenance standard

Carrier (21) is meshed with ring gear (25), and


rotates as one unit, so the rotation is transmitted to planet pinion (17).
Ring gear (20) is being held in position by No.
5 clutch, so the rotation of planet pinion (17)
rotates sun gear (18), and this rotates output
shaft (19).

D275AX-5E0

10 Structure, function and maintenance standard

3.
q

Forward 2nd
When the transmission is set to FORWARD
2nd the No. 2 clutch and No. 4 clutch are
engaged. The motive force from the torque
converter transmitted to input shaft (5) is then
transmitted to output shaft (19).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring
gear (30) in position. No. 4 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and engages ring gear (25).
The motive force from the torque converter is
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (29)
and is transmitted to planet pinion (13).
Ring gear (30) is held in position by No. 2
clutch, so the rotation of planet pinion (13)
rotates carrier (31), which is on the inside of
ring gear (30).

D275AX-5E0

SEN00927-00

Carrier (31) and carrier (27) are joined by a


spline, and rotate as one unit, so the rotation is
transmitted to planet pinion (24).
Ring gear (25) is being held in position by No.
4 clutch, so the rotation of planet pinion (24)
rotates sun gear (16), and this rotates output
shaft (19).

37

SEN00927-00

4.
q

38

Forward 3rd
When the transmission is set to FORWARD
3rd the No. 2 clutch and No. 3 clutch are
engaged. The motive force from the torque
converter transmitted to input shaft (5) is then
transmitted to output shaft (19).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring
gear (30) in position. No. 5 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and engages ring gear (15).
The motive force from the torque converter is
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (29)
and is transmitted to planet pinion (13).
Ring gear (30) is held in position by No. 2
clutch, so the rotation of planet pinion (13)
rotates carrier (31), which is on the inside of
ring gear (30).

10 Structure, function and maintenance standard

Carrier (31) and carrier (27) are joined by a


spline, and rotate as one unit, so the rotation is
transmitted to planet pinion (14).
Ring gear (15) is being held in position by No.
3 clutch, so the rotation of planet pinion (14)
rotates output shaft (19).

D275AX-5E0

10 Structure, function and maintenance standard

5.
q

Reverse 1st
When the transmission is set to REVERSE 1st,
the No. 1 clutch and No. 5 clutch are engaged.
The motive force from the torque converter
transmitted to input shaft (5) is then transmitted to output shaft (19).
No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds
carrier (36) in position. No. 5 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and engages ring gear (20).
The motive force from the torque converter is
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (6)
and is transmitted to planet pinion (9).
Carrier (36) is held in position by No. 1 clutch,
so the rotation of planet pinion (9) rotates ring
gear (8).
Ring gear (8) rotates in the opposite direction
from the input shaft, and rotates carrier (31).
Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).

D275AX-5E0

SEN00927-00

Carrier (21) is meshed with ring gear (25), and


rotates as one unit, so the rotation is transmitted to planet pinion (17).
Ring gear (20) is being held in position by No.
5 clutch, so the rotation of planet pinion (17)
rotates sun gear (18), and this rotates output
shaft (19).

39

SEN00927-00

Tranmission ECMV

10 Structure, function and maintenance standard

(Electronic Control Modulation Valve)

40

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Proportional solenoid valve for 3rd clutch ECMV


Proportional solenoid valve for 1st clutch ECMV
Proportional solenoid valve for R clutch ECMV
Proportional solenoid valve for 2nd clutch ECMV
Proportional solenoid valve for F clutch ECMV
Fill switch for 3rd clutch
Fill switch for 2nd clutch
Fill switch for 1st clutch
Fill switch for R clutch
Fill switch for F clutch
Connector for 1st proportional solenoid valve
Connector for 3rd proportional solenoid valve
Connector for R proportional solenoid valve
Connector for 2nd proportional solenoid valve
Connector for F proportional solenoid valve
Connector for 3rd fill switch
Connector for 2nd fill switch
Connector for 1st fill switch
Connector for R fill switch
Connector for F fill switch
Filter
Pressure control valve
Oil pressure detection valve
Pressure control valve spring

A:
B:
C:
D:
E:
F:
P:
T:

1st clutch operating pressure pick-up port


3rd clutch operating pressure pick-up port
R clutch operating pressure pick-up port
2nd clutch operating pressure pick-up port
F clutch operating pressure pick-up port
To clutch
From pump
Drain

D275AX-5E0

SEN00927-00

41

SEN00927-00

10 Structure, function and maintenance standard

Outline of ECMV
q

The ECMV (Electronic Control Modulation


Valve) consists of the following two units, a
pressure control valve and fill switch.
Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
Fill switch
Detects that the clutch is filled with oil. It has
the functions below.
1) It outputs a signal (fill signal) to the controller as soon as the clutch is filled with oil
to report the completion of filling.
2) It outputs a signal (fill signal) to the controller while an oil pressure is applied to
the clutch to report the presence/absence
of oil pressure.
A region: Before gear shift (When draining)
B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling

ECMV and proportional solenoid


q

One proportional solenoid is attached to one


ECMV. After receiving the command current
from the controller, it produces thrust in the
right figure.
By making the proportional solenoid-produced
thrust act on the pressure control valve spool,
it produces an oil pressure shown in the right
figure. By controlling the amount of command
current, the thrust is changed to operate the
pressure control valve, controlling the oil flow
and oil pressure.

ECMV and fill switch


q

42

One fill switch is attached to one ECMV. When


the clutch completes filling, the pressure of the
clutch turns "ON" the fill switch. By this signal,
the oil pressure starts build-up.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Operation of ECMV
q

The ECMV is controlled by the command current sent from the controller to the proportional
solenoid and the fill switch output signal.
The relation among the proportional solenoid
command current of the ECMV, the clutch
input pressure, and fill switch output signal is
as shown in the figure to the right.
A region: Before gear shift (When draining)
B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling

The clutch is crimped by the piston when shifting the gear with the gear shift switch. If a high
oil pressure is applied suddenly, however, the
piston connects to the clutch suddenly, causing
the machine to make a sudden start and give
an excessive shock to the machine.
To prevent them, it is designed so that if you
connect the ECMV to shift gears with the gear
shift switch, the oil pressure to the clutch may
be gradually increased up to the specified
level. By this design, the clutch is excited
smoothly to eliminate the shock at the start,
improve the durability of the power transfer
system, and also provide operator comfort.

1.

Before gear shift (Region A in the diagram)


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

D275AX-5E0

43

SEN00927-00

2.

44

When filling (When inputting the trigger


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

10 Structure, function and maintenance standard

3.

Pressure regulation (D region in the diagram)


If you flow a current to the proportional solenoid (1), the solenoid produces thrust proportional to the current. Pressure is regulated by
striking a balance among the thrust of the solenoid, the thrust of the oil pressure of the clutch
port, and reaction force of the pressure control
spring (5).

D275AX-5E0

SEN00927-00

10 Structure, function and maintenance standard

Main relief valve and torque convertor relif valve

1.
2.
3.
4.
5.
6.
7.
8.
9.

Body
Torque converter relief valve
Valve spring
Piston
Piston spring
Main relief valve
Valve spring
Piston spring
Piston

A:
B:
C:
D:
E:
P1:
P8:

Drain port (for torque converter relief)


Drain port
From pump
Drain port
To torque converter
Main relief oil pressure detection port
Torque converter relief oil pressure detection
port

46

Outline
1. Main relief valve
Main relief valve (6) sets the set pressure of
the oil pressure for the transmission, steering
clutch, and brake.
2. Torque converter relief valve
Torque converter relief valve (2) acts to protect
the torque converter from abnormally high
pressure by relieving the circuit if the torque
converter inlet port pressure rises above the
set pressure.
Unit: MPa {kg/cm2}
Set pressure
Main relief pressure

3.2 0.1 {32.7 1.0}

Torque converter relief


pressure

0.98 0.05 {10.2 0.5}

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Unit: mm
No.

Check item

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

28

0.035
0.045

+ 0.013
+ 0.013

0.035
0.058

0.08

Clearance between main relief


valve and piston

19

0.020
0.030

+ 0.018
+ 0.018

0.020
0.048

0.07

Clearance between torque


12 converter relief valve and valve
body

22

0.035
0.045

+ 0.013
+ 0.013

0.035
0.068

0.08

Clearance between torque


converter relief valve and piston

15

0.020
0.030

+ 0.021
+ 0.021

0.020
0.051

0.07

Clearance between main relief


10
valve and valve body

11

13

Standard size
14

15

Main relief valve spring


(outside)

Main relief valve spring


(inside)

16 Main relief valve piston spring

Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

122

78

481 N
{49 kg}

118.3

457 N
{46.6 kg}

108

78

368 N
{37.5 kg}

104.8

349 N
{35.6 kg}

30

25

7.32 N
{0.746 kg}

29.1

6.96 N
{0.71 kg}

17

Torque converter relief valve


spring

50

41.5

182 N
{18.6 kg}

48.5

174 N
{17.7 kg}

18

Torque converter relief valve


piston spring

26

20

4.87 N
{0.497 kg}

25.2

4.61 N
{0.47 kg}

D275AX-5E0

Replace

47

SEN00927-00

Operation of main relief valve


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

48

10 Structure, function and maintenance standard

Operation of torque converter relief valve


q
The oil relieved by the main relief valve flows
from port (C) to the torque converter, and at
the same time, passes through orifice (b) and
enters port (D).
When the passage to the torque converter is
filled with oil, the oil pressure starts to rise.
q
As the oil pressure to the torque converter
rises, the oil entering port (D) pushes piston
(9). The reaction compresses spring (3),
moves relief valve (2) to the right in the arrow
direction, and opens ports (C) and (E).
Then, the oil from port (C) is relieved to port (E)
and is drained to the oil tank.
The oil pressure at port (C) at this point is 1.0
0.05 MPa {10.2 0.5 kg/cm2}.

D275AX-5E0

SEN00927-00

Torque converter valve

50

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Cover
Valve spring
Load piston
Valve body
Stator clutch modulating valve
Piston
Piston
Piston spring (small)
Cover
Lock-up clutch modulating valve
Valve spring (inside)
Valve spring (outside)
Shaft
Stopper
Load piston
Cover
Plug
Valve body
Valve spring
Lock-up changeover valve
Piston
Valve
Ball
Valve
Coil
Base
Case
Cap
Plunger
Shaft

D275AX-5E0

SEN00927-00

A:
P:
P3:
P8:

From pump
Stator clutch pressure pick-up port
Lock-up clutch pressure pick-up port
Main relief pressure pick-up port

51

SEN00927-00

Outline
q
The torque converter valve is installed to the
top of the torque converter case and consists
of valves of the following 4 types.
1. Torque converter lock-up valve
Lock-up changeover valve (20) turns ON and
OFF the lock-up clutch and stator clutch.
2. Torque converter lock-up solenoid valve
The solenoid valve receives electric signals
from the controller and changes the pilot pressure for lock-up changeover valve (20) to turn
ON and OFF the 2 clutches.

52

10 Structure, function and maintenance standard

3.

4.

Stator clutch modulating valve


Modulating valve (5) regulates the clutch pressure to 2.55 2.75 MPa {26 28 kg/cm2} to
protect the stator clutch from abnormally high
pressure and heightens the pressure of the oil
from lock-up changeover valve (20) gradually
to the specified level.
Lock-up clutch modulating valve
Modulating valve (10) regulates the clutch
pressure to 1.27 1.37 MPa {13 14 kg/cm2}
similarly to stator clutch modulating valve (5).

D275AX-5E0

SEN00927-00

54

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Unit: mm
No.

Check item
Clearance between stator
clutch modulating valve and
valve body

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

25

0.035
0.045

+ 0.013
+ 0.013

0.035
0.058

0.08

Clearance between lock-up


clutch modulating valve and
valve body

25

0.035
0.045

+ 0.013
+ 0.013

0.035
0.058

0.08

Clearance between lock-up


valve and valve body

25

0.035
0.045

+ 0.013
+ 0.013

0.035
0.058

0.08

Standard size
4

Stator clutch modulating


valve spring

Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

103.5

92.7

197.0 N
{20.10 kg}

100.4

187.2 N
{19.10 kg}

Lock-up clutch modulating


valve spring (outside)

141.4

88.7

158.6 N
{16.18 kg}

137.16

150.7 N
{15.37 kg}

Lock-up clutch modulating


valve spring (inside)

80.5

80.5

78.09

Lock-up valve spring

66

54.0

55.9 N
{5.7 kg}

64.0

53.1 N
{5.42 kg}

D275AX-5E0

Replace

55

SEN00927-00

10 Structure, function and maintenance standard

Operation of torque converter lock-up


valve and solenoid valve
q

56

The torque converter lock-up valve supplies oil


for turning ON and OFF the lock-up clutch and
stator clutch installed in the torque converter.
The lock-up valve is operated by the pilot oil
pressure of the solenoid valve which operates
according to the electric signals from the lockup controller.
If the electricity flows in the solenoid valve, the
drain circuit is closed to raise the pilot pressure
in the lock-up valve and operate the valve to
lock up the torque converter.
If the lock-up valve operates, the oil in the stator clutch is drained and the stator clutch
becomes free.

D275AX-5E0

SEN00927-00

Lubrication relief valve

1.
2.
3.

Forward clutch housing


Spring
Piston

A:
B:
C:

From oil cooler


Drain
Drain

10 Structure, function and maintenance standard

Outline
q
The oil leaving the torque converter passes
through the oil cooler built in the radiator lower
tank. It then goes through the lubrication relief
valve and lubricates the transmission and
PTO.

58

The lubrication relief valve is installed to the


right side face of the forward clutch housing.
And prevents any abnormal pressure in the
lubrication oil.
Unit: MPa {kg/cm2}
Set pressure

Pressure when normal

0.14 0.05 {1.4 0.5}

Cracking pressure

0.30 0.03 {3.0 0.3}

D275AX-5E0

10 Structure, function and maintenance standard

SEN00927-00

Unit: mm
No.

Check item

Criteria
Standard size

Lubrication relief valve spring

D275AX-5E0

Remedy
Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

26

23.6

12.5 N
{1.27 kg}

25.2

11.9 N
{1.21 kg}

Replace

59

SEN00927-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00927-00

60

D275AX-5E0

SEN00928-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Power train system, Part 2


Power train system, Part 2.............................................................................................................................. 3
Bevel gear shaft, HSS, brake............................................................................................................... 3
Brake valve ........................................................................................................................................ 16
Brake ECMV ...................................................................................................................................... 17
Parking brake valve............................................................................................................................ 23
Sudden brake prevention valve.......................................................................................................... 24
Final drive........................................................................................................................................... 25
Sprocket ............................................................................................................................................. 30

D275AX-5E0

10 Structure, function and maintenance standard

Power train system, Part 2


Bevel gear shaft, HSS, brake

D275AX-5E0

SEN00928-00

1
1

SEN00928-00

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Cover
Output shaft
Bearing cage
Spring
Brake piston (140 teeth)
Return spring
Brake plate (6 pcs. on each side)
Brake disc (7 pcs. on each side)
Brake outer drum (140 teeth)
Brake inner drum
Bearing cage
Shim (For adjustment of bevel gear)
Bearing A
Bevel gear shaft
Bevel gear (40 teeth)
Bearing B
Carrier
Ring gear (111 teeth)
Planetary pinion (35 teeth)
Hub (111 teeth)
Sun gear (41 teeth)
Shim (For adjustment of bevel pinion)
Bearing cage
Bearing
Nut (For adjustment of preload on bearing)
Bevel pinion (21 teeth)
Gear E (For driving right sun gear) (50 teeth)
Gear D (16 teeth)
Shaft
HSS motor
Pinion (20 teeth)
Gear A (34 teeth)
Gear C (16 teeth)
Gear B (For driving left sun gear) (50 teeth)

D275AX-5E0

SEN00928-00

A:
B:
C:
D:
E:
F:
G:

To transmission case (power train pump)


From transmission case (scavenging pump)
To pin puller solenoid valve
From pin puller solenoid valve
Drain plug
Left brake oil pressure pick-up port
Right brake oil pressure pick-up port

SEN00928-00

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

2.9

2.6

Tolerance

Repair limit

Max. 0.3

0.4

Standard size

Repair limit

4.5

4.0

Tolerance

Repair limit

Max. 0.3

0.4

Total thickness of brake plates


and discs

Standard size

Repair limit

48.9

45.3

38

Backlash between brake disc


and brake inner drum

Standard clearance

Clearance limit

0.42 0.72

1.0

39

Backlash between sun gear


and planetary pinion

0.14 0.39

0.60

Backlash between planetary


40
pinion and ring gear

0.16 0.40

Thickness of brake plate


35
Strain of brake plate
Thickness of brake disc
36
Strain of brake disc
37

41

42

Sealing fitting face of small end


of brake piston
Backlash between gear A and
pinion

Repair or replace
Replace
Repair or replace

Replace

Standard
size
220

0.70

Tolerance
Shaft

Hole

Standard
clearance

0.100
0.172

+ 0.072
+ 0.072

0.100
0.244

Clearance
limit

Standard clearance

Clearance limit

0.20 0.48

0.70

Backlash between gear A and


43
gear C

0.08 0.72

0.70

44

Backlash between gear D and


gear E

0.19 0.46

0.80

45

Backlash between gear A and


gear B

0.10 0.58

0.80

46

Backlash between bevel gear


and pinion

0.25 0.33

0.50

D275AX-5E0

Replace

Replace

Adjust or replace

SEN00928-00

Outline
Bevel gear shaft
q
The bevel gear shaft device changes the output power of the transmission by a right angle
to the lateral directions and reduce the output
speed by using a bevel pinion and a bevel
gear.
q
The bevel gear shaft device has a spiral bevel
pinion and spiral bevel gear and is lubricated
forcibly with pressurized oil.
q
The bevel gear shaft device consists of bevel
pinion (26) meshed with bevel gear (15), bevel
gear shaft (14), and bearings (13) and (16) to
support the bevel gear shaft.
HSS
q
The HSS (Hydrostatic Steering System) consists of the transfer unit which reverses the
rotating direction of HSS motor (30) and transmits it to sun gear (21) and the planetary unit
whic h adjusts and outputs the input. It
changes the turning direction of the machine
by stopping or reversing the rotation of the
HSS motor.
q
The transfer unit has a spur gear speed reducing mechanism.
q
The transfer unit is lubricated forcibly with the
oil sent from the steering lubricating oil pump.
q
The planetary unit is lubricated forcibly with the
oil sent from the steering lubricating oil pump.
q
The transfer unit consists of HSS motor pinion
(31), gear A (32), gear C (33), shaft (29), gear
D (28), gear E (27), gear B (34), and cover (1)
to support those parts.
q
The planetary unit consists of sun gear (21),
planetary pinion (19), and hub (20), carrier (17)
[connected to brake inner drum (10)].

10 Structure, function and maintenance standard

Brake
q
The brake is installed specially to stop the
machine and connected to brake inner drum
(10).
q
The brake is the wet, multiple disc clutch, and
spring boosted type, which is operated hydraulically with the oil from the brake valve connected to the brake pedal.
q
The brake is lubricated forcibly with oil sent
from the steering lubricating oil pump through
the housing, cage, discs, and plates.
q
The brake consists of inner drum (10) [connected to brake outer drum (9) and carrier
(17)], discs (8), plates (7), brake outer drum
(9), piston (5), spring (4), bearing cage (3) to
support those parts, brake cover (1), and output shaft (2).
Brake outer drum (9) and brake cover (1) are
fixed to the HSS case.
Output shaft (2) is connected to brake inner
drum (10) by spline.
q
If the engine is stopped, the back pressure on
the brake piston lowers and the brake is turned
ON automatically. If the engine is started
again, the oil pressure in the circuit rises and
the brake is deactivated. Since this is dangerous, be sure to set the parking brake lever to
the LOCK position.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00
Mechanical power
Hydraulic power
Conbined power

Flow of power for HSS

The power from the transmission passes


through bevel pinion (26) and bevel gear (15),
and is transmitted to bevel gear shaft (14). It
then goes from bevel gear shaft (14) through
hub (20), ring gear (18), carrier (17), and brake
inner drum (10), and is transmitted to left and
right output shafts (2).
When the steering is operated, HSS motor (30)
rotates and the power is transmitted from pinion (31) to gear A (32), where it is divided to
the left and right. The power sent to the left is
transmitted from gear A (32) to gear B (34),
sun gear (21), and planet pinion (19). It is combined with the power from the transmission at
the planetary gear portion, and is transmitted
from carrier (17) to output shaft (2). The power
sent to the right is transmitted from gear A (32)
through gear C (33), gear D (28), and gear E
(27) to right sun gear (21) in order to reverse
the rotation of the power from the HSS motor.
(The flow of power beyond this point is the
same as on the left side.)

D275AX-5E0

The braking force is applied by braking the


rotation of inner drum (10) (which is interconnected with carrier (17)) at brake outer drum
(9), which is fixed to the HSS case.

SEN00928-00

10 Structure, function and maintenance standard

Operation of HSS
1. When PCCS lever is at NEUTRAL (Traveling straight forward)
a

The direction of rotation of the HSS motor and gears is as seen from the left side of the machine.

Traveling straight forward


When the PCCS lever is at the NEUTRAL position,
HST motor (30), and transfer gear (33) and left and
right sun gears (21) of the planetary gear portion,
which are interconnected with the HSS motor, are
stopped.
In this condition, the power from bevel gear shaft
(14) is input to hub (20), passes through ring gear
(18) and planet pinion (19), and is transmitted to
carrier (17). It then passes through brake inner
drum (10), which forms one unit with the carrier,
and is transmitted to output shaft (2).
Therefore, the left and right output speeds are the
same and the machine travels in a straight line.
q
Direction of rotation of HSS motor.
PCCS lever steering position
PCCS lever directional position

Neutral
Any

Rotation direction seen from left


Stopped
of machine

[1]
[2]
[3]
[4]

Transmission output speed


Left bevel gear shaft output speed
Transmission output speed
Right bevel gear shaft output speed
: Transmission power

Right turn
Left turn
*Neutral Forward Reverse *Neutral Forward Reverse
CW

CW

CCW

CCW

CCW

CW

* Counter rotation turn

10

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00

2. PCCS lever operated to RIGHT TURN

[1] Transmission output speed


[2] Acceleration from HSS motor
[3] Left bevel gear shaft output
speed ([1] + [2])

[4] Transmission output speed


[5] Deceleration from HSS speed
[6] Right bevel gear shaft output
speed ([4] [5])

Forward
When the machine is traveling forward, bevel gear
shaft (14) and hub (20), which is connected to it,
rotate clockwise.
If the PCCS lever is operated to the RIGHT TURN
position when the machine is traveling forward,
HSS motor (30) rotates clockwise, the rotation
passes through gear A (32), and gear B (34) on the
left side of the machine rotates clockwise, while
gear E (27) in the right side of the machine is
rotated counterclockwise by gear C (33).
In other words, the rotation of the HSS motor is
transmitted to sun gears (21) as rotation in opposite
directions on the left and right by the transfer portion.

D275AX-5E0

: Transmission power
: HSS motor power
: Combined power

This rotation acts on the left and right planetary


gear mechanisms. The speed of carrier (17) on the
left is accelerated from the speed when traveling in
a straight line by the amount of the power from the
HSS motor.
On the other hand, the speed of carrier (17) on the
right is decelerated from the speed when traveling
in a straight line, so a difference in rotation is generated in the output on the left and right. The output
speed in the right is lower, so as a result, the
machine travels forward and turns to the right.

11

SEN00928-00

[1] Transmission output speed


[2] Acceleration from HSS motor
[3] Left bevel gear shaft output
speed ([1] + [2])

10 Structure, function and maintenance standard

[4] Transmission output speed


[5] Deceleration from HSS speed
[6] Right bevel gear shaft output
speed ([4] [5])

Reverse
When the machine is traveling in reverse, bevel
gear shaft (14) and hub (20), which is connected to
it, rotate counterclockwise.
If the PCCS lever is operated to the RIGHT TURN
position when the machine is traveling in reverse,
HSS motor (30) is rotated counterclockwise in the
opposite direction from when traveling forward by
the function of the HSS controller.
The rotation passes through gear A (32), and gear
B (34) on the left side of the machine rotates
counter-clockwise, while gear E (27) on the right
side of the machine is rotated clockwise by gear C
(33).
In other words, the rotation of the HSS motor is
transmitted to sun gears (21) as rotation in opposite
directions on the left and right by the transfer portion.

12

: Transmission power
: HSS motor power
: Combined power

This rotation acts on the left and right planetary


gear mechanisms. The speed of carrier (17) on the
left is accelerated from the speed when traveling in
a straight line by the amount of the power from the
HSS motor. On the other hand, the speed of carrier
(17) on the right is decelerated from the speed
when traveling in a straight line, so a difference in
rotation is generated in the output on the left and
right. The output speed in the right is lower, so as a
result, the machine travels in reverse and turns to
the right.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00

3. PCCS lever operated to LEFT TURN

[1] Transmission output speed


[2] Deceleration from HSS motor
[3] Left bevel gear shaft output
speed ([1] [2])

[4] Transmission output speed


[5] Acceleration from HSS speed
[6] Right bevel gear shaft output
speed ([4] + [5])

Forward
When the machine is traveling forward, bevel gear
shaft (14) and hub (20), which is connected to it,
rotate clockwise.
If the PCCS lever is operated to the LEFT TURN
position when the machine is traveling forward,
HSS motor (30) rotates counterclockwise, the rotation passes through gear A (32), and gear B (34) on
the left side of the machine rotates counterclockwise, while gear E (27) on the right side of the
machine is rotated clockwise by gear C (33).
In other words, the rotation of the HSS motor is
transmitted to sun gears (21) as rotation in opposite
directions on the left and right by the transfer portion.
This rotation acts on the left and right planetary
gear mechanisms.

D275AX-5E0

: Transmission power
: HSS motor power
: Combined power

The speed of carrier (17) on the right is accelerated


from the speed when traveling in a straight line by
the amount of the power from the HSS motor. On
the other hand, the speed of carrier (17) on the left
is decelerated from the speed when traveling in a
straight line, so a difference in rotation is generated
in the output on the left and right. The output speed
in the left is lower, so as a result, the machine travels forward and turns to the left.

13

SEN00928-00

[1] Transmission output speed


[2] Deceleration from HSS motor
[3] Left bevel gear shaft output
speed ([1] [2])

10 Structure, function and maintenance standard

[4] Transmission output speed


[5] Acceleration from HSS speed
[6] Right bevel gear shaft output
speed ([4] + [5])

Reverse
When the machine is traveling in reverse, bevel
gear shaft (14) and hub (20), which is connected to
it, rotate counterclockwise.
If the PCCS lever is operated to the TURN LEFT
position when the machine is traveling in reverse,
HSS motor (30) is rotates clockwise in the opposite
direction from when traveling forward by the function of the HSS controller. The rotation passes
through gear A (32), and gear B (34) on the left side
of the machine rotates clockwise, while gear E (27)
on the right side of the machine is rotated counterclockwise by gear C (33).
In other words, the rotation of the HSS motor is
transmitted to sun gears (21) as rotation in opposite
directions on the left and right by the transfer portion.
This rotation acts on the left and right planetary
gear mechanisms.

14

: Transmission power
: HSS motor power
: Combined power

The speed of carrier (17) on the right is accelerated


from the speed when traveling in a straight line by
the amount of the power from the HSS motor. On
the other hand, the speed of carrier (17) on the left
is decelerated from the speed when traveling in a
straight line, so a difference in rotation is generated
in the output on the left and right. The output speed
in the left is lower, so as a result, the machine travels in reverse and turns to the left.

D275AX-5E0

10 Structure, function and maintenance standard

Operation of brake
1.

Brake released
When the brake pedal is at the RELEASED
position, the brake valve is also at the NEUTRAL position, so oil flows to back pressure
port (A) of brake piston (5).
When the oil pressure rises, the piston is
pushed to the left in the direction of the arrow,
compresses spring (4), and releases the pressure pushing disc (8) and plate (7) into tight
contact. When this happens, the power transmitted from bevel gear shaft (14) through the
HSS to brake inner drum (10) is transmitted to
output shaft (2), and is then transmitted to the
final drive.

D275AX-5E0

SEN00928-00

2.

Brake applied (brake pedal depressed)


When the brake pedal is depressed, the brake
valve is switched, and the oil at port (A), which
was applying back pressure to piston (5), is
connected to the drain circuit.
In this condition, piston (5) is pushed to the
right in the direction of the arrow by the tension
of spring (4), so disc (8) and plate (7) are
brought into tight contact with the stopper of
brake outer drum (9). The brake outer drum is
joined to the HSS case and is locked in position.
Therefore, the rotation of brake inner drum
(10) (in other words, output shaft (2)) is braked
when the disc and plate are brought into tight
contact.
By adjusting the amount the brake pedal is
depressed, it is possible to adjust the hydraulic
pressure applied to piston (5), thereby adjusting the braking force.

15

SEN00928-00

10 Structure, function and maintenance standard

Brake valve

1.
2.
3.
4.
5.
6.

Parking brake valve


Right brake ECMV
Left brake ECMV
Filter
Sudden brake prevention
valve
Valve seat

A:
B:
C:
D:
E:

Left brake operating pressure


pick-up port
Right brake operating pressure
pick-up port
To right brake
To left lubrication
To right lubrication

Outline
q
The brake valve is installed through the main
relief valve between the power train pump and
the brake piston in the HSS unit. It consists of
2 sets of brake ECMV (Right and left), parking
brake valve, and sudden brake prevention
valve.
Each valve is installed as an assembly on the
valve seat.
q
If the brake pedal is pressed, the oil pressure
applied to the brake piston is shut off and the
brake piston fits the discs and plates with the
spring force to excited the brake. Since the
brake is used to only stop the machine in the
HSS, both brakes are applied simultaneously.
q
The sudden brake prevention valve is installed
to p r ev e nt th e br a ke fr om s to pp i ng th e
machine suddenly because of a trouble in the
electric system.

16

F: To right brake
G: From steering lubricating oil
pump
H: To transmission lubrication
J: From power train pump
K: To pin puller solenoid valve

When the parking brake lever is set to the


LOCK position, the port of the parking brake
valve is changed to drain the oil between the
ECMV for both brakes and the brakes and
excited the brakes. The parking brake valve is
connected to the brake pedal by the linkage.
The steering ECMV operates to excited the
brake so that the machine can make a pivot
turn when the turning operation stroke of the
PCCS lever is 80 100%.

D275AX-5E0

10 Structure, function and maintenance standard

Brake ECMV

SEN00928-00

(Electronic control modulation valve)

A:
T:
Dr:
P:
P1:

To brake
Drain
Drain
From pump
Brake oil pressure pick-up port

D275AX-5E0

1.
2.
3.
4.
5.
6.

Connector for fill switch


Connector for proportional solenoid
Oil pressure detection valve
Fill switch
Proportional solenoid
Pressure control valve

17

SEN00928-00

Outline of ECMV
q

The ECMV (Electronic Control Modulating valve)


consists of a pressure control valve and a fill
switch.
Pressure control valve
This valve allows a proportional solenoid to
receive a current sent from a steering controller and converts it to oil pressure.
Fill switch
This component detects that a clutch is filled
with oil and has the following functions.
1) When the clutch is filled with the oil, at the
same time, a signal (fill signal) is output to
the controller and transmits filling termination.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the controller and transmits the presence of oil
pressure.

10 Structure, function and maintenance standard

Operation of ECMV
q

The ECMV is controlled using the command


current from the controller to the proportional
solenoid and a fill switch output signal.

Outline
q
This valve sets the steering clutch oil pressure
or the steering brake oil pressure to a set pressure and switches a circuit to the clutch chamber and the brake chamber.

ECMV and proportional solenoid


q

18

One proportional solenoid is mounted for each


ECMV. A thrust is generated according to the
command current of the controller.
The thrust generated by the proportional solenoid is actuated on a pressure control valve
spool and generates oil pressure. Accordingly,
by controlling an amount of the command current, the thrust changes and the pressure control valve is actuated, then a flow of oil and the
oil pressure is controlled.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00

Operation
1.

When PCCS lever is in NEUTRAL and brake pedal is RELEASED (During straight travel and
when PCCS lever is moved from NEUTRAL to 80% of stroke)
When brake pedal is RELEASED (During gradual turn: Both brakes are OFF and parking brake is
OFF)

If the PCCS lever is in NEUTRAL and the


brake pedal is OFF, proportional solenoid valve
(1) of the brake ECMV is excited and pushes
ball (2) to the left to close the seal. The oil in
pump port (Pb) flows in port (A) and pushes
valve (3) to the left to open the passage
between ports (Pb) and (B) and close the passage between ports (B) and (Dr).
The oil in port (Pb) flows through port (B) to the
back pressure port of the brake piston. If the
circuit pressure rises, the brake piston moves
to the left to compress the brake spring and
RELEASE the brake.
If the parking brake is deactivated, the parking
brake valve is closed and the oil in the brake
circuit is not drained.

D275AX-5E0

19

SEN00928-00

10 Structure, function and maintenance standard

2.

When PCCS lever is moved to left more than 80% of stroke (Pivot turn: Left brake is turned "ON",
right brake is deactivated, and parking brake is deactivated)

If the PCCS lever is moved to the left more


than 80% of the stroke in the state in 1 above,
the proportional solenoid valve (1) of the left
brake ECMV is deactivated and ball (2)
becomes free and the seal is opened. Since
oil in port (A) is drained through the seal, valve
(3) is moved to the right by the tension of
spring (4).
At this time, the passage between ports (Pb)
and (B) is closed and the passage between
ports (B) and drain port (Dr) is opened.
The oil from the power train pump is drained
through port (Pb), throttle (a), and the seal of
ball (2).
The oil which has been flowing in the brake
piston port to apply back pressure is drained
through port (B) to (Dr).

20

q
q

The left brake is turned "ON" by the tension of


the brake spring.
If the parking brake is turned "OFF", the parking brake valve is closed and the oil in the
brake circuit is not drained.

D275AX-5E0

10 Structure, function and maintenance standard

3.

When brake pedal is PRESSED


(Brake is "ON" and parking brake is "OFF")

If the brake pedal is pressed, proportional solenoid valves (1) of both brake ECMV's are
deactivated.
The controller outputs a command current to
proportional solenoid valves (1) according to
the pressing stroke of the brake pedal. If a current flows in proportional solenoid valves (1),
the solenoid generates trust in proportion to
the current. The oil pressure, or the braking
force, is regulated by this trust of the solenoids,
oil pressure in the brake port, and reaction
force of pressure control valve spring (4).

D275AX-5E0

SEN00928-00

If the brake pedal is pressed, the parking brake


valve connected by the linkage operates and
drains the oil from the brake circuit.

21

SEN00928-00

10 Structure, function and maintenance standard

4.

When parking brake is turned ON


(Brake is "ON", PCCS lever is in "NEUTRAL", brake pedal is "RELEASED")

If the lock lever for the PCCS lever is set to the


"LOCK" position, parking brake valve (1)
moves to the left and the ports (A) and (B) are
connected to between port (C). The oil which
has been flowing in the brake piston port to
apply back pressure is drained through ports
(A), (B), and (C). As a result, the back pressure in the brake piston port keeps lowering
and the brake is turned "ON" completely and
kept as it is.
When the engine is started again, ports (A)
and (B) are kept connected to drain port (C).
Accordingly, the brake is kept turned "ON".
If the parking brake is turned "OFF", parking
brake valve (1) moves to the right. Ports (A)
and (B) are disconnected from between drain
port (C) and the brake is turned "RELEASED"
by the oil pressure.

22

D275AX-5E0

10 Structure, function and maintenance standard

Parking brake valve

SEN00928-00

Unit: mm
No.

Check item
Clearance between parking
brake valve spool and valve
body
Outside diameter of sliding
parts fitting to dust seal and
V-packing (Spool)

Criteria
Standard
size
14

Tolerance
Shaft

Hole

Standard
clearance

0.020
0.030

+ 0.011
0

0.020
0.041

Parking brake valve spool


spring

Free length
65

D275AX-5E0

Clearance
limit
0.05

Tolerance

Clearance limit

0.020
0.030

13.9

14

Standard size
3

Remedy

Using
length
47.7

Replace

Repair by hard
chromium plating
or replace

Repair limit
Using load Free length Using load
38.2 N
{3.9 kg}

63.1

Replace

36.3 N
{3.71 kg}

23

SEN00928-00

10 Structure, function and maintenance standard

Sudden brake prevention valve 1

Outline
q
The sudden brake prevention valve is installed
to p r ev e nt th e br a ke fr om s to pp i ng th e
machine suddenly because of a trouble in the
electric system.
q
Sudden brake prevention valve (1) is installed
in the brake ECMV drain circuit. If brake
ECMV solenoid valve (2) is deactivated, the oil
is drained from the brake circuit and the brake
is applied suddenly. To prevent this, if solenoid
valve (3) of sudden brake prevention valve (1)
is deactivated, the circuit of throttle (a) is
formed. As a result, pilot pressure drain circuit
( D) i s c h o k e d a n d t h e b r a k e i s " S E M I RELEASED".

24

D275AX-5E0

10 Structure, function and maintenance standard

Final drive

SEN00928-00

Outline
q
The final drive is a single stage spur gear, single stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and installed as a single unit.
q
Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubricating oil.

D275AX-5E0

25

SEN00928-00

26

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Floating seal
Sun gear
Carrier
Hub
Cover
Sprocket boss
Sprocket teeth
Floating seal guard
Cover
Planetary gear
Ring gear

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

SEN00928-00

Cover
No.1 pinion
Final drive case
Bearing cage
No.1 gear
No.1 gear hub
Boss
Shaft
Wear guard
Pivot shaft

Unit: mm
No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

0.28 0.93

0.93

22

Backlash between No.1 pinion


and No.1 gear

23

Backlash between sun gear


and planet pinion

0.22 0.81

0.81

24

Backlash between planet pinion and ring gear

0.25 0.90

0.90

25

Outside diameter of No.1 pinion oil seal contact surface

26

Thickness of thrust collar of


roller bearing

Clearance between outer diameter of planet gear shaft and in27


ner diameter of carrier hole.
(Small diameter)
Clearance between outer diameter of planet gear shaft and in28
ner diameter of carrier hole.
(Large diameter)
29

Standard size

Tolerance

30
Standard
size

D275AX-5E0

94.913

Repair or
replace

29.95
Tolerance

Shaft

Hole

Standard
clearance

Clearance
limit

85

0.036
0.058

0.024
0.059

0.023
0.034

0.034

105

0.036
0.058

0.072
0.107

0.071
0.014

0.014

Standard shim thickness for


No.1 pinion bearing cage

30 Wear of wear guard

Repair limit

0
0.087

95

Replace

Replace

Adjust

Standard size

Repair limit

72

18

Repair or
replace

27

SEN00928-00

10 Structure, function and maintenance standard

Path of power transmission

28

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00

The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (13) to
rotate 1st gear (16) meshed with the 1st pinion
and sun gear (2) meshed with the 1st gear.
The rotation of sun gear (2) is transmitted to
planetary pinion (10). Since ring gear (11)
meshed with the planetary pinion is fixed to
cover (9), the planetary pinion rotates along
the ring gear and revolves around the sun
gear.
Then, the rotating force of sun gear (2) forms
the rotating force of carrier (3), which supports
the planet pinion via hub (4), and is transmitted
to sprocket hub (6).
The rotating direction of carrier (3) is the same
with sun gear (2).
The rotational force transmitted to sprocket
hub (6) is further transmitted to sprocket teeth
(7).

D275AX-5E0

29

SEN00928-00

Sprocket

10 Structure, function and maintenance standard

Unit: mm
No.

Check item

Wear of tooth tip

Thickness of tooth root

30

Criteria

Remedy

Standard clearance

Repair limit

402.4

386

23.2

17

Repair or
replace

D275AX-5E0

10 Structure, function and maintenance standard

SEN00928-00

Sprocket tooth shape of real dimension

The above drawing is reduced to 35%. Enlarge it to 280% to return it to the full scale and make a copy
on an OHP sheet.

D275AX-5E0

31

SEN00928-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00928-00

32

D275AX-5E0

SEN00929-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Undercarriage and frame


Undercarriage and frame ................................................................................................................................ 2
Track frame .......................................................................................................................................... 2
Recoil spring ........................................................................................................................................ 4
Idler ...................................................................................................................................................... 6
Track roller ........................................................................................................................................... 8
Track roller bogie................................................................................................................................ 10
Carrier roller ....................................................................................................................................... 12
Track shoe.......................................................................................................................................... 14
Main frame ......................................................................................................................................... 16
Suspension ........................................................................................................................................ 18

D275AX-5E0

SEN00929-00

10 Structure, function and maintenance standard

Undercarriage and frame


Track frame

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Idler
Recoil spring assembly
Carrier roller
Track frame
Sprocket
Sprocket cover guard
Track roller bogie
Track roller
Track roller support guard
Pivot shaft
Cylinder
Guide

1
1

Outline
q
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.
q
The K-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
Track roller, bogie
Track roller flange type and bogie arrangement
1st

2nd

3rd

4th

5th

6th

7th

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Criteria
Item

12

Clearance between idler bogie


and guide

13 Press-fitting force for cartridge

D275AX-5E0

Repair limit

Curvature

7 (for length of 3,000)

Twisting

3 (for level length of 300)

Dents (pipe portion)

12

Deformation of track frame outer pipe

Clearance between inner pipe


11 and adjustment cylinder protrusion

Remedy

Standard
size
50

Tolerance
Shaft

Hole

0.15
0.35

+ 0.1
+ 0.1

Standard
clearance

Clearance
limit

0.15 0.45

2.0

Standard clearance

Clearance limit

0 0.5

3.0

275 530 kN {28 54 ton}

Repair or replace

Replace

Adjust

SEN00929-00

Recoil spring

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

10 Structure, function and maintenance standard

Yoke
Nut
Retainer
Recoil spring
Rod
Spring cylinder
Retainer
Holder
Piston
Lubricator (for pumping in and releasing grease)
Grease chamber cylinder

Outline
q
Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from
lubricator (10) to move rod (5) forward or backward. The recoil spring (4) also acts to dampen
any sudden shock brought to bear on the idler.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Criteria
Standard size

12 Recoil spring

Clearance between inner cylin13 der and outer cylinder of outer


cylinder bushing
14

Clearance between adjustment


cylinder and bushing

Remedy
Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

1,231

1,045

372.7 kN
{38,000 kg}

1.415

345.1 kN
{35,185 kg}

Standard
size

Shaft

Hole

Standard
clearance

340

0.055
0.228

+ 0.317
+ 0.060

0.115
0.545

0.8

110

0.100
1.350

+ 0.054
+ 0.054

0.100
0.404

Tolerance

Press-fitting force for outer cyl15 inder bushing (outer cylinder


side)

42.1 96.1 kN {4.3 9.8 ton}

Press-fitting force for outer cyl16 inder bushing (inner cylinder


side)

44.1 228.6 kN {4.5 23.3 ton}

17

Clearance between recoil


spring mount nut and lock plate

D275AX-5E0

Clearance Replace
limit

Adjust

0 1.0

SEN00929-00

Idler

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Outside diameter of protruding


part

Outside diameter of tread surface

Width of protruding part

Criteria

Remedy

Standard size

Repair limit

822

780

755

121

Width of tread

77

85.5

Overall tread

275

Thickness of tread

25.5

13

Width of shaft flange

242

Clearance between shaft and


bushing

Interference between shaft and


seal guard

Standard
size
147
Standard
size
84

10 Play in axial direction of shaft

D275AX-5E0

Tolerance

Rebuild or
replace

Shaft

Hole

Standard
clearance

Clearance
limit

0.350
0.413

+ 0.170
0.010

0.340
0.583

Interference limit

Tolerance
Shaft

Hole

Standard
interference

+ 0.046
+ 0.046

0.150
0.200

0.150
0.246

Standard clearance

Clearance limit

0.5 1.0

Replace bushing

Replace

SEN00929-00

Track roller

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

291

277

single flange

255

185

double flange

255

195

single flange

65

30

double flange

65

35

Outside diameter of flange


(outside of single flange)

Outside diameter of flange


(inside of double flange)

Outside diameter

Thickness of
tread

Overall width

336

Width of tread (single flange)

80

Width of tread (double flange)

80

Width of flange (double flange


of outside)

27.5

12.5

Width of flange (double flange


of inside)

24

28.5

10 Width of shaft flange

11

12

Clearance between shaft and


bushing

Interference between shaft and


seal guard

Standard
size
115
Standard
size
65

13 Play in axial direction of shaft

D275AX-5E0

Tolerance

Rebuild or
replace

Replace

Shaft

Hole

Standard
clearance

0.350
0.413

+ 0.225
+ 0.007

0.343
0.038

Interference limit

Tolerance
Shaft

Hole

Standard
interference

+ 0.046
+ 0.046

0.150
0.200

0.150
0.246

Clearance
limit

Standard clearance

Clearance limit

0.44 0.91

Replace bushing

Replace

SEN00929-00

Track roller bogie

1.
2.
3.
4.
5.
6.
7.
8.
9.

10

Guide
Cap
Track roller assembly (double)
Large bogie
Rubber mount
Small bogie
Track roller assembly
Cover
Cartridge pin

10 Structure, function and maintenance standard

Outline
q
The track roller are installed to small bogie (6).
The track rollers and track shoes are always in
contact.
q
The vibration of the machine from the ground
surface is absorbed by rubber mount (5).

D275AX-5E0

SEN00929-00

Carrier roller

12

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Outside diameter of flange

Outside diameter of carrier roller tread

Thickness of tread

Width of carrier roller tread

Width of flange

Clearance between shaft and


support

Interference between shaft and


seal guard

Criteria

Play in axial direction of shaft

D275AX-5E0

Standard size

Repair limit

232

200

175

40

27.5

Standard
size
76
Standard
size
77

Remedy

76.5

23

12
Tolerance

Shaft

Hole

0
0.2

+ 0.35
0

Tolerance
Shaft
+ 0.210
+ 0.150

Hole
+ 0.030
0

Rebuild or
replace

Standard
clearance

Clearance
limit

0
0.550

Standard
interference

Interference limit

0.120
0.210

Standard clearance

Clearance limit

0 0.22

Replace bushing

Replace

13

SEN00929-00

Track shoe

14

10 Structure, function and maintenance standard

Portion P shows the link on the side where the bushing is pressed fitted.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

260.6

263.6

88

30

Thickness of plate

20

Link height

166

148

Thickness of link metal

51.7

33.7

Link pitch

Height of grouser

Reverse or
replace
Lug welding
rebuild or replace
Rebuild or
replace

Bushing outside diameter

90.5

82 (Standard ground)
84.5 (Heavy duty ground)

Thickness of bushing metal

17.1

8.6 (Standard ground)


11.1 (Heavy duty ground)

Shaft

Hole

Standard
interference

90

+ 0.602
+ 0.372

+ 0.087
+ 0.087

0.285
0.602

Interference between pin and


link (without wedge ring)

55.5

+ 0.296
+ 0.236

0.206
0.280

0.442
0.576

Interference between pin and


link (with wedge ring)

55.5

+ 0.296
+ 0.236

0.034
0.096

0.270
0.392

Interference between bushing


and link

Clearance between link and


10
link
11

Tightening torque for regular


bolt

12

Tightening torque for master


bolt

D275AX-5E0

Tolerance

Standard
size

Standard clearance
Each side

Both sides

1.4

2.8

Interference limit Reverse or


replace
0.10

Clearance limit
Both sides

Tightening torque

Additional tightening

784 78 Nm {80 8 kgm}

120 10

490 49 Nm {50 5 kgm}

180 10

Replace

15

SEN00929-00

Main frame

16

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.

SEN00929-00

Main frame
Cage
Clamp
Cover
Seal
Clamp
Cap
Plate
Unit: mm

No.

Check item

Clearance between radiator


guard mounting pin and bushing

Clearance between radiator


10 guard mounting pin and bushing

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

80

0.030
0.076

+ 0.257
+ 0.170

0.410
0.555

0 more than

80

0.030
0.076

+ 0.257
+ 0.170

0.343
0.405

1.0
Replace

11

Clearance between ripper


beam mount pin and bushing

110

0.036
0.090

+ 0.267
+ 0.180

0.098
0.254

1.5

12

Clearance between ripper cylinder mounting pin and bushing

90

0.036
0.090

+ 0.257
+ 0.170

0.064
0.256

1.5

13

Clearance between equalizer


bar shaft and bushing

120

0.036
0.090

0.109
0.260

1.5

14

Press-fitting force for radiator


guard mount bushing

6.08 138.3 kN {6.2 14.1 ton}

15

Press-fitting force for radiator


guard mount bushing

68.7 155.0 kN {7.0 15.8 ton}

16

Press-fitting force for ripper


beam mount bushing

69.7 37.3 kN {7.1 14.0 ton}

17

Press-fitting force for ripper cylinder mount bushing

57.9 114.8 kN {5.9 11.7 ton}

18

Press-fitting force for equalizer


bar shaft bushing

31.4 105.9 kN {2 13 ton}

D275AX-5E0

Adjust

17

SEN00929-00

10 Structure, function and maintenance standard

Suspension

1.
2.
3.
4.
5.
6.
7.

18

Equalizer bar
Pivot shaft assembly
Cover
Thrust plate
Thrust plate
Pivot shaft
Seal cage

8.
9.
10.
11.
12.

Seal
Bushing
Side pin
Center pin
Bushing

Outline
q
The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1) rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).

D275AX-5E0

10 Structure, function and maintenance standard

SEN00929-00

Unit: mm
No.

Check item

Clearance between center pin


13
and bushing

14

15

Clearance between side pin


and bushing

Interference between side pin


boss and bushing

Criteria
Standard
size

Shaft

Hole

Standard
clearance

Clearance
limit

105

0.030
0.060

+ 0.247
0.166

0.196
0.307

1.0

75

0.030
0.060

+ 0.046
+ 0.046

0.030
0.106

1.0
Interference
limit

Standard
size
140

16

Press-fitting force for center pin


bushing

Press-fitting force for side pin


17
bushing

D275AX-5E0

Tolerance

Remedy

Tolerance
Shaft

Hole

Standard
interference

0.018
0.018

0.088
0.098

0.098
0.106

Replace bushing

32.4 225.6 kN {3.3 23 ton}

34.3 68.7 kN {3.5 7.0 ton}

19

SEN00929-00

10 Structure, function and maintenance standard

*1. Indicates the left of the blade single tilt specifications.


*2. Indicates the right of the blade single tilt specifications.

No.

Check item

Interference between
18
thrust washer and seal

Criteria
Standard
size

Tolerance

Remedy
Standard Interference
interference
limit

Shaft

Hole

210

+ 0.213
+ 0.098

0.180
0.226

0.278
0.439

Replace

19

Interference between thrust


washer and seal

140

+ 0.140
+ 0.100

0.061
0.124

0.161
0.264

20

Interference between pivot


shaft and seal

194

+ 0.096
+ 0.050

0.075
0.147

0.125
0.243

Clearance between pivot


21
shaft and bushing

22

20

Clearance between pivot


shaft and bushing

Standard
size

Tolerance
Shaft

Hole

Standard
clearance

Clearance
limit

155

0.145
0.208

+ 0.132
+ 0.059

0.204
0.340

1.0

190

0.170
0.242

+ 0.144
+ 0.059

0.229
0.386

1.0

Replacing
bushing

D275AX-5E0

SEN00929-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00929-00

22

D275AX-5E0

SEN00930-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Hydraulic system, Part 1


Hydraulic system, Part 1 ................................................................................................................................. 2
Work equipment hydraulic piping diagram............................................................................................ 2
PPC control piping diagram .................................................................................................................. 6
Work equipment control........................................................................................................................ 8
Hydraulic tank ..................................................................................................................................... 10
Scavenging pump ............................................................................................................................... 12
Work equipment pump........................................................................................................................ 14
Power train pump, steering lubrication pump ..................................................................................... 30
HSS pump .......................................................................................................................................... 31
HSS motor .......................................................................................................................................... 47
PPC, HSS charge filter ....................................................................................................................... 56

D275AX-5E0

SEN00930-00

10 Structure, function and maintenance standard

Hydraulic system, Part 1

Work equipment hydraulic piping diagram

Semi U-dozer

1.
2.
3.
4.
5.
6.

Blade tilt cylinder


R.H. blade lift cylinder
HSS charge filter bypass valve
HSS charge filter
Control valve
Accumulator

7.
8.
9.
10.
11.
12.

Hydraulic tank
Oil cooler bypass valve
Work equipment pump
HSS charge pump
L.H. blade lift cylinder
Oil cooler

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

U-Dozer + dual tilt

1.
2.
3.
4.
5.
6.
7.

Blade tilt cylinder


R.H. blade lift cylinder
HSS charge filter bypass valve
HSS charge filter
Control valve
Accumulator
Dual tilt solenoid valve

D275AX-5E0

8.
9.
10.
11.
12.
13.
14.

Hydraulic tank
Oil cooler bypass valve
Work equipment pump
HSS charge pump
L.H. blade lift cylinder
Blade pitch cylinder
Oil cooler

SEN00930-00

10 Structure, function and maintenance standard

Multi-shank ripper

1.
2.
3.
4.

Control valve
Divider block
Ripper tilt cylinder
Ripper lift cylinder

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

Giant ripper
q

The diagram shows a machine equipped with a pin puller cylinder

1.
2.
3.
4.
5.

Control valve
Divider block
Ripper tilt cylinder (right)
Ripper lift cylinder (right)
Pin puller cylinder

D275AX-5E0

6.
7.
8.
9.
10.

Ripper lift cylinder (left)


Ripper tilt cylinder (left)
Pin puller solenoid valve
Steering case
Brake valve

SEN00930-00

10 Structure, function and maintenance standard

PPC control piping diagram

PPC control piping diagram

1.
2.
3.
4.
5.

HSS charge filter bypass valve


HSS charge filter
Blade control PPC valve
Control valve
Accumulator

6.
7.
8.
9.
10.

Ripper control PPC valve


PPC lock valve
Work equipment lock lever
Work equipment pump
HSS charge pump

D275AX-5E0

SEN00930-00

10 Structure, function and maintenance standard

Work equipment control


q

The diagram shows a machine equipped with pitch dozer and pin puller cylinder.

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.

SEN00930-00

Work equipment lock lever


Blade control valve
Pitch button
Tilt switch
Ripper control lever
Pin puller switch
PPC lock valve

Lever and switch positions


A: Blade HOLD
B: Blade LOWER
C: Blade FLOAT
D: Blade RAISE
E: Blade LEFT TILT/PITCH
F: Blade RIGHT TILT/PITCH
G: Ripper HOLD
H: Ripper RAISE
J: Ripper LOWER
K: Ripper TILT IN
L: Ripper TILT BACK
M: FREE
N: LOCK
P: Single tilt
Q: Dual tilt
R: Pitch OFF
S: Pitch ON
T: Pin puller switch PUSH IN
U: Pin puller switch PUSH OUT
Outline
q
The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
q
Work equipment lock lever (1) is interconnected with PPC lock valve (7), and at the
LOCK position, the oil in the PPC circuit is
stopped.

D275AX-5E0

SEN00930-00

10 Structure, function and maintenance standard

Hydraulic tank

1.
2.
3.
4.
5.
6.

10

Oil filler cap


Hydraulic filter element
Spring
Suction valve
Cover
Cover

7.
8.
9.
10.
11.
12.

Hydraulic tank
Strainer
Sight gauge
Pressure valve
Drain valve
Drain plug

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

Specified value
Tank capacity (l)
Hydraulic
Level inside
tank
tank

Breather
cap

200

Hi (l)

149

Center (l)

135

Low (l)

117

Cracking pressure
(KPa {kg/cm2})

16.7 6.9
{0.17 0.07}

Vacuum valve actuating


pressure
(KPa {kg/cm2})

0 0.49
{0 0.005 }

D275AX-5E0

Specified value
102.9 19.6
{1.05 0.2}

Cracking pressure
(KPa {kg/cm2})
Hydraulic Mesh size
filter
Filtering area

Strainer

(m)

30/8

(cm2)

13,600

Filtering oil flow (l/min)

245

Mesh size

105

Filtering area

(m)
(cm2)

1,850

11

SEN00930-00

10 Structure, function and maintenance standard

Scavenging pump

BAR (3) 160

A.
B.

Discharge port
Suction port
Unit: mm

No.
1

Check item
Spline shaft rotation torque
Delivery

12

Criteria

(Oil: EO30 - CD
Oil temperature: 45 50C)

Remedy

Type

Rotating
speed
(rpm)

Discharge
pressure
MPa
({kg/cm2})

Standard
discharge
amount
(l/min)

Permissible
discharge
amount
(l/min)

BAR160

1,250

2.94
{30}

D275AX-5E0

SEN00930-00

10 Structure, function and maintenance standard

Work equipment pump

Type: HPV112 (112-cm3/rev specification)


Outline
This pump consists of a swash plate-type variable-capacity piston pump and an LS valve.

14

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.

SEN00930-00

Piston pump
Control assembly
Gear pump

PA:
PA2:
PD1:
PD2:
PS1:
PS2:
PLS1:
PLS2:
PNC2:

Pump discharge
Gear pump discharge
Pump drain
Pump drain
Pump suction
Gear pump suction
Load pressure input
Load pressure pick-up
Control pressure pick-up

Specifications
Model: HPV112 (112 cm3/rev)
Theoretical displacement: 112 1 cm3/rev
Rated speed: 2,286 rpm
Max. cut-off pressure: 31.9 MPa {325 kg/cm2}

D275AX-5E0

15

SEN00930-00

PA:
Pump discharge
PA1: Pump pressure signal
PD1: Pump drain

16

10 Structure, function and maintenance standard

PD2: Pump drain


PS1: Pump suction
PNC1: Control pressure

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.

Shaft
Case
Cradle
Rocker cam
Shoe
Servo piston
Lod

D275AX-5E0

SEN00930-00

8.
9.
10.
11.
12.
13.

Piston
Cylinder block
Valve plate
End cap
Impeller
Spline

17

SEN00930-00

Outline
q
The engine rotation and torque transmitted to
the pump shaft is converted to hydraulic
energy and pressurized oil is discharged
according to the load.
q
It is possible to change the discharge amount
by changing the swash plate angle.

10 Structure, function and maintenance standard

Structure
Cylinder block (9) is supported to shaft (1) by a
spline (13), and shaft (1) is supported by the
front and rear bearings.
q
The end of piston (8) has a concave ball shape
and shoe (5) is caulked to it to form one unit.
Piston (8) and shoe (5) form a spherical bearing.
q
Rocker cam (4) holds plane (A), and shoe (5)
is always pressed against this surface as it
slides in a circle.
q

18

Rocker cam (4) forms a static bearing sending


high pressure oil at cylindrical surface (B) of
cradle (3), which is fixed to the case, and carries out a sliding movement.
Piston (8) carries out motion relative to the
axial direction inside each cylinder chamber of
cylinder block (9).
The cylinder block (9) carries out rotation relative to valve plate (10) while sealing the pressurized oil, and this surface ensures that the
hydraulic balance is maintained correctly.
The oil inside each cylinder chamber of cylinder block (9) is sucked in and discharged
through valve plate (10).
Impeller (12) is fixed to shaft (1), and rotates
together with the shaft, it makes it easier for
the oil sucked in from the suction port to be
sucked in and sends it into the cylinder chamber by centrifugal force.

D275AX-5E0

10 Structure, function and maintenance standard

OPERATION
1.
q

Operation of pump
Cylinder block (9) rotates together with shaft
(1), and shoe (5) slides on plane (A). When
this happens, rocker cam (4) moves along
cylindrical surface (B), so angle (a) of center
line (X) of rocker cam (4) to the axial direction
of cylinder block (9) changes. This angle (a) is
called the swash plate angle.

SEN00930-00

When center line (X) of rocker cam (4) is the


same as the axial direction of cylinder block (9)
(s wash plate angle = 0) , the differ enc e
between volumes (E') and (F') inside cylinder
block (9) is 0, so pump does not suction and
discharge, and no pumping's carried out. Actually swash plate angle does not become 0.)
The swash plate angle (a) is proportional to
pump discharge volume.

With swash plate angle (a) formed by the angle


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

D275AX-5E0

19

SEN00930-00

1.
q

20

10 Structure, function and maintenance standard

Control of discharge amount


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

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

Control assembly

PP:
Pump pressure signal
PT:
Drain
PLS1: Load pressure signal
PLS2: Load pressure pick-up
PNV1: Control pressure
PNV2: Control pressure pick-up

D275AX-5E0

21

SEN00930-00

1.
2.
3.
4.
5.
6.
7.

22

Valve body
LS valve
Variable throttle valve
Plug
Spool
Spring
Plug

10 Structure, function and maintenance standard

8.
9.
10.
11.
12.
13.

Locknut
Locknut
Plug
Spring
Spool
Plug

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

1. Operation of LS valve
1)

When the control valve is at HOLD position

Operation
q
The LS valve is a 3-way selector valve, and
main pump pressure (PP) and pressure (PLS)
(LS pressure) from the outlet port of the control
valve are applied to (d) port and (a) port.
q
Spool (4) of this LS valve is pushed by the
force of spring (3) from the end receiving the
LS pressure, and the position of the spool (4)
is determined by the LS pressure (PLS) +
spring force (F) and the size of main pump
pressure (PP).
q
Main pump pressure (PP) always effects to
ports (d) and (e). LS pressure (PLS) enters
chamber (g) from port (a).
q
Before the engine is started, servo piston (1) is
pushed to the right by spring (5) of rod (2).
(See the diagram on the right)
q
After the engine is started, lf the control lever is
at "HOLD" position, the LS pressure (PLS) is 0
MPa {0kg/cm2}. (The circuit is connected to the
drain circuit through the passage inside the
control valve spool.)
q
When this happens, spool (4) is pushed to the
left, and port (d) and port (c) are connected.
Pump pressure (PP) enters the large diameter
piston end from port(f), and the difference in
area of piston (1) to the left so that the swash
plate angle becomes minimum.

D275AX-5E0

23

SEN00930-00

2)

Movement in direction to increase pump discharge ( to the right)

Operation
q
When LS differential pressure ( PLS), which
is the difference in pressure between main
pump pressure (PP) and LS pressure (PLS),
becomes smaller (for example, the area of
opening of the control valve becomes larger
and pump pressure (PP) is reduced), spool (4)
is pushed to the right under the combined force
of the LS pressure (PLS) and the force of
spring (3). Main pump pressure (PP) enters
chamber (h). The combined force of spring (3)
and the force of LS pressure (PLS) is greater
than the force of main pump pressure (PP), so
spool (4) is pushed to the right.
q
Because of the movement of spool (4), port (c)
and port (b) are connected, and circuit (c) - (f)
become drain pressure (PT).

24

10 Structure, function and maintenance standard

Circuits (c) (f), which are the pressure of (f)


port at the large diameter piston end of servo
piston (1), become the drain pressure, so
servo piston (1) is pushed from the small diameter piston end to the large diameter piston
end.
Rod (2) also moves to the right because of this
movement, and changes the swash plate
angle.

D275AX-5E0

10 Structure, function and maintenance standard

3)

SEN00930-00

Movement in direction to reduce pump discharge (to the left)

Operation
q
The following explains the situation when
servo piston (1) moves to the left (the direction
to make the discharge amount smaller). If LS
differential pressure ( PLS) becomes larger
(for example, the area of opening of the control
valve becomes smaller and pump pressure
(PP) increases), spool (4) is pushed to the left
by pump pressure (PP).
q
Because of the movement of spool (4), main
pump pressure (PP) flows into port (c), and
main pump pressure (PP) enters the large
diameter piston end from port (f).

D275AX-5E0

Main pump pressure (PP) also enters the small


diameter piston end, but servo piston (1) is
pushed from the large diameter piston end to
the small diameter piston end because of the
difference in area between the large diameter
piston end and the small diameter piston end.
As a result, rod (2) moves in the direction to
make the swash plate angle smaller (to the
left).

25

SEN00930-00

4)

When servo piston is balanced

Operation
q
In the LS valve, lf main pump pressure (PP) is
balanced with the combined force of LS pressure (PLS) at chamber (g) and force (F) of
spring (3), servo piston (1) stops at the intermediate position for the swash plate angle.
[Force (F) of spring (3) converted to the
hydraulic power: Approx. 1.96 MPa {20kg/
cm2}].
q
If an LS pressure (main pump pressure force
of spring) that fulfills the above conditions for
balancing enters ports (a), main pump pressure (PP) entering from port (d) and combined
force (F) of spring (3) and the force from LS
pressure (PLS) are balanced, and pressure of
a certain size enters port (f) from port (c).

26

10 Structure, function and maintenance standard

When this happens, the force pushing the


small diameter piston and the force pushing
the large diameter piston are balanced, so
servo piston (1) stops. In other words, the following condition is reached.
Pump pressure (PP) x area receiving pressure
at small diameter piston end = hydraulic pressure (PNC) at the large diameter piston end x
area receiving pressure at large diameter piston end.
The difference I area between the large diameter piston and small diameter piston is normally
approx. 2:1, so the pressure at the large diameter piston end is approx. 1/2 of pump pressure (PP).

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

2. Operation of variable throttle valve


1)
q

Properties of variable throttle valve


Because the main pump controls its own pressure, there is a tendency for the response
speed of the swash plate to be quick at high
pressure and slow at low pressure.
The variable throttle valve has been installed
between the LS valve and the port at the large
diameter end of the servo piston for the following reasons.
i
To reduce the swash plate speed between
MIN and MAX at high pressure; to reduce
the impact force on the rod and other parts
of the main pump; and to prevent excessive response.
ii
To prevent cavitation at the suction port
caused by the sudden increase in the suction volume when changing from MIN to
MAX.
The characteristics of the variable throttle
valve are as shown in the diagram below.
It has the function and property of maintaining
the response during operations at low pressure
by making the area (A) of the opening smaller
at high pressure and the area (A) of the opening larger at low pressure, and by preventing
the above problems i and ii at high pressure.

D275AX-5E0

27

SEN00930-00

2)

10 Structure, function and maintenance standard

Pump discharge pressure at high pressure

Operation
q
In the variable throttle valve (6), main pump
pressure (PP) from LS valve (5) passes
through port (b) and enters port (f).
q
When main pump pressure (PP) is high, if it is
greater than the force of spring (3) because of
the difference in area of the land portion diameters at both ends of chamber (f), spool (4) is
moved to the left.
q
If spool (4) moves to the left, the area of the
opening from port (a) to port (c) is throttled, so
the flow of oil entering the large diameter end
of servo piston (1) from port (d) is reduced and
the speed of movement of servo piston (1)
becomes slower.

28

D275AX-5E0

10 Structure, function and maintenance standard

3)

SEN00930-00

Pump discharge pressure at low pressure

Operation
q
When main pressure (PP) is low, even if it
enters chamber (f) from port (b), the pressure
is low, so it does not become greater than the
force of spring (3), and spool (4) remains
pushed to the right.
q
The area of the opening from port (a) to port (c)
becomes larger, so output pressure (PNC)
from the LS valve (5) is transmitted as it is.

D275AX-5E0

29

SEN00930-00

10 Structure, function and maintenance standard

Power train pump, steering lubrication pump

SAR (3) 100 + 50

Unit: mm
No.

Check item

Criteria
Type

Clearance limit

SAR (3) 100

0.13 0.18

0.22

SAR (3) 50

0.10 0.15

0.19

0.060 0.149

0.20

Standard size

Tolerance

14

0
0.5

Side clearance

SAR (3) 100

Clearance between plain


bearing inner diameter and gear
shaft outer diameter

Pin driving depth

SAR (3) 100

SAR (3) 50
Type
SAR (3) 50

Spline shaft rotation torque


Delivery

(Oil: EO10-CD
Oil temperature: 45 50C)

Replace

13.7 73.5Nm{1.4 2.4kgm}


Type
SAR (3) 100
SAR (3) 50

30

Remedy

Standard
clearance

Speed
(rpm)

2,300rpm

Delivery
pressure
MPa
{kg/cm2}

Standard
delivery
(l/min)

Delivery
limit
(l/min)

32.71

188

174

30.3

94

86

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

HSS pump

HPV160

1.
2.
3.
4.

Servo valve connector


Piston pump
Servo piston
Servo valve

5.
6.
7.

Suction safety valve


Charge safety valve
Plug for measuring (PA and PB pump pressure)

Outline
q
The pump is composed of variable displacement piston pump with swash plate, servo
valve, suction safety valve, and charge safety
valve.

D275AX-5E0

31

SEN00930-00

10 Structure, function and maintenance standard

1. Piston pump
a

A figure shows the state where the Servo valve was removed from the HSS pump.

PSVO:Servo valve source pressure


PB:
Pump inlet and outlet port
PA:
Pump inlet and outlet port
PD2: Pump drain port
PR: Charge safety valve relief pressure

32

PSVA: Servo valve output


PSVB: Servo valve output
PSV1: Servo valve source pressure
PC: Charge pressure

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.

Shaft
Case
Cradle
Rocker cam
Servo piston
Slider
Shoe

Outline
q
The rotation torque transmitted to the pump
shaft is converted to hydraulic energy and
pressurized oil is discharged according to the
load.
q
It is possible to charge the delivery amount
(normal delivery i
o0i
o reverse delivery) by
changing the swash plate angle.
Structure
q
Cylinder block (9) is supported to shaft (1) by a
spline (13), and shaft (1) is supported by front
and rear bearings (12) and (14).
q
The end of piston (8) has a concave ball
shape, and shoe (7) is caulked to it to form one
unit. Piston (8) and shoe (7) form a spherical
bearing.

SEN00930-00

8.
9.
10.
11.
12.
13.
14.

Piston
Cylinder block
Valve plate
End cap
Bearing
Spline
Bearing

Rocker cam (4) has plane (A), and shoe (7) is


always pressed against this surface as it slides
in a circle.
Rocker cam (4) sends high pressure oil to the
space between cylindrical surface (B) and cradle (3) fixed to the case (2), to form a hydrostatic bearing and carries out a rocking
movement.
Piston (8) carries out motion relative to the
axial direction inside each cylinder chamber of
cylinder block (9).
Cylinder block (9) carries out rotation relative
to valve plate (10) while sealing the pressurized oil, and this surface ensures that the
hydraulic balance is maintained correctly. The
oil inside each cylinder chamber of cylinder
block (9) is sucked in and discharged through
valve plate (10).

Piston

D275AX-5E0

33

SEN00930-00

Operation
1. Operation of pump
q
Cylinder block (9) rotates together with shaft
(1), and shoe (7) slides on plane (A).
When this happens, angle of center line (X)
of rocker cam (4) to the axial direction of cylinder block (9) changes. This angle (a) is called
the swash plate angle.
1) With swash plate angle a formed by the angle between center line (X) of rocker cam
(4) to the axial direction of cylinder block
(9), plane (A) acts as a cam for shoe (7). In
this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is
generated between volumes (E) and (F) inside the cylinder block. The amount of suction and discharge is equal to difference
(F) - (E).
In other words, cylinder block (9) rotates,
and the volume of chamber (F) becomes
smaller, so oil is discharged during this process. At the same time, the volume of
chamber (E) becomes larger and oil is
sucked in as the volume increases.

2)

34

10 Structure, function and maintenance standard

3)

With swash plate angle a formed by the angle between center line (X) of rocker cam
(4) to the axial direction of cylinder block
(9), plane (A) acts as a cam for shoe (7). In
this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is
generated between volumes (E'') and (F'')
inside the cylinder block. The amount of
suction and discharge is equal to difference (F'') (E'').
In other words, cylinder block (9) rotates,
and the volume of chamber (E'') becomes
smaller, so oil is discharged during this process. At the same time, the volume of
chamber (F'') becomes larger and oil is
sucked in as the volume increases. When
the swash plate angle changes, the suction/discharge action of ports (PA) and
(PB) is reversed.

When center line (X) of rocker cam (4) is


the same as the axial direction of cylinder
block (9) (swash plate angel = 0), the difference between volumes (E') and (F') inside
cylinder block (9) is 0, so no oil flows in or
out, and no pumping is carried out.

D275AX-5E0

10 Structure, function and maintenance standard

2.

SEN00930-00

Control of discharge amount


1) If swash plate angle (a) becomes larger,
the difference between volumes (E) and
(F) becomes large, and oil delivery (Q) is
increased. Swash plate angle ( ) is
changed by servo piston (5).
Servo piston (5) carries out reciprocal
movement in a straight line (i
o) according
to the command from the valve. This
straight-line movement is transmitted to
rocker cam (4) through slider (6), and rocker cam (4), which is supported on the cylindrical surface by cradle (2) slides on the
cylindrical surface (direction).
In the case of the pump, swash plate angle
( ) is a maximum of 19.

D275AX-5E0

35

SEN00930-00

10 Structure, function and maintenance standard

2. Servo valve

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

36

Connector
Solenoid valve B
Connector
Solenoid valve A
Shaft
Coil
Base
Lever 1
Spring
Lever 2
Body
Screw
Arm
Spool

PSV1: Servo valve source pressure


PSVB: Servo valve outlet pressure
PSVA: Servo valve outlet pressure

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

Operation
1) When pressurized oil (servo source pressure) does not enter from the charge
pump or when is no current flowing to
solenoid valve coil (6), the servo valve and
servo piston (15) are not actuated.

D275AX-5E0

37

SEN00930-00

2)

3)

38

10 Structure, function and maintenance standard

When the current flows to solenoid valve


coil (6) and coil is excited, solenoid propulsion force (f1) is generated and shaft (5)
pushes spool (14) to the right in the direction of the arrow. Lever 2 (10), which is
interconnected with spool (14), uses
screw (12) as a fulcrum and rotates clockwise while pulling spring (9).
When spool (14) moves, the passages
between ports (A) and (B) and ports (D)
and (E) open, and pressurized oil from the
charge pump passes through ports (A)
and (B) and flows to port (F) of servo piston (15).
At the same time, the oil at port (G)
passes through ports (D) and (E), and is
drained.

D275AX-5E0

10 Structure, function and maintenance standard

4)

SEN00930-00

Servo piston (15) is moved to the right in


the direction of the arrow by the pressurized oil entering port (F), and the swash
plate angle of the variable pump becomes
larger by an amount equal to stroke (a) of
the servo piston. At the same time, arm
(13), which is connected to servo piston
(15) rotates arm (13) around screw (12) as
a fulcrum, and lever 1 (8) is moved to the
left. Servo piston (15) stops in a position
where solenoid propulsion force (f1) is balanced with spring force (f2).

D275AX-5E0

39

SEN00930-00

5)

40

10 Structure, function and maintenance standard

The stroke of the servo piston, which


changes the delivery amount of the variable pump, is controlled by the servo
valve. The relationship between the stroke
of the servo piston and the current of the
solenoid valve is as shown in the diagram.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

3. Suction safety valve

1.
2.
3.
4.
5.

Charge pump
HSS pump
Oil cooler
Charge safety valve
Suction safety valve
5A. Valve
5B. Piston
5C. Sleeve
5D. Poppet
5E. Valve seat
5F. Spring
5G. Pressure adjustment screw: one turn
adjusts pressure by approx. 13.7 MPa
{140kg/cm2}
6. HSS motor

D275AX-5E0

Function
q
There are two suction safety valves installed to
the HSS pump, and they have the following
functions.
1) High pressure relief valve
The valve restricts the maximum pressure
inside the HSS circuit in order to protect
the HSS circuit and to restrict the maximum steering foree of the machine.
2) Suction safety valve
The valve ensures the flow of charge oil to
the HSS circuit and prevents the charge
oil from flowing into the pump high pressure side (delivery side).

41

SEN00930-00

Operation when acting as high pressure relief


valve (Valve at piston pump delivery side)

Port (A) is connected to the piston pump circuit


and port (B) is connected to the charge circuit.
The pressurized oil also fills port (C) through drill
hole (a) in piston (5B). In addition, poppet (5D)
is in tight contact with valve seat (5E).

If abnormal pressure is generated in the piston


pump circuit and the oil pressure at port (A) and
(C) reaches the pressure set by spring (5F),
poppet (5D) is pushed to the right in the direction of the arrow, and the oil at port (C) is relieved from port (D) to port (B) to reduce the oil
pressure at port (C).

42

10 Structure, function and maintenance standard

When the oil pressure at port (C) goes down, a


differential pressure is generated between port
(A) and port (C) by orifice b in piston (5B). Valve
(5A) is pushed to the right in the direction of the
arrow by the oil pressure at port (A), and the oil
at port (A) is relieved to port (B). In this way, the
piston pump circuit is prevented from reaching
any higher pressure.

D275AX-5E0

10 Structure, function and maintenance standard

Operation when acting as suction safety valve


1. When HSS pump delivery is 0
q
The HSS circuit is closed, and the charge pressure oil does not flow into the HSS circuit.
Therefore, the charge pressure oil from the
charge pump all passes through charge safety
valve (with coin filter) (4) and is drained
through oil cooler (3) to the tank.

D275AX-5E0

SEN00930-00

2.

When HSS pump delivery is discharged


from port PA
1) Valve at piston pump delivery side
q
When pressure oil is discharged from
port (PA) of HSS pump (2), port (PA)
becomes the high pressure side. This
pressure oil at port (PA) passes
through drill hole a in piston (5B) and
flows to port (A). When this happens,
valve (5A) is pushed to the left in the
direction of the arrow against sleeve
(5C) because of the difference in area
(A1>A2). Therefore, the pressure oil
from charge pump (1) is prevented
from flowing into the HSS closed circuit.

43

SEN00930-00

2)

44

10 Structure, function and maintenance standard

Valve at piston pump suction side


q
Port (PB) becomes the suction side,
so it becomes the low pressure side.
Because of the difference in area
(A1>A2), valve (5A) is pushed to the
right in the direction of the arrow by
the charge pressure oil and the seat
of sleeve (5C) opens. As a result, the
charge pressure oil at port (B) passes
through the gap and flows to port
(PB) to carry out the charge function
for the HSS circuit.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

4. Charge safety valve

1.
2.
3.
4.

Charge pump
HSS pump
Oil cooler
Charge safety valve
4A. Valve
4B. Spring
4C. Valve seat
4D. Poppet
4E. Spring
4F. Pressure adjustment screw
5. Suction safety valve
6. HSS motor

D275AX-5E0

Function
q
The charge safety valve is installed to the HSS
pump between the suction safety valve and the
oil cooler. It acts to restrict the maximum pressure in the charge circuit.
a Set pressure:
3.7 MPa {38kg/cm2} at 204 l/min

45

SEN00930-00

Operation
q
Port (A) is connected to the charge circuit, and
port (B) is connected to the tank drain circuit.
The pressure oil passes through orifice (a) in
valve (4A) and fills (C). Poppet (4D) is in tight
contact with valve seat (4C).

46

10 Structure, function and maintenance standard

When the pressure of the oil at port (C) goes


down, a differential pressure is created
between ports (A) and (C) because of orifice
(a) in valve (4A). Valve (4A) is pushed to the
right in the direction of the arrow by the oil
pressure at port (A), and the oil at port (A) is
relieved to port (B). In this way, the pressure in
the charge circuit is prevented from going any
higher.

Drain port (D) at the poppet portion is drained


to the HSS pump case, so the back pressure
of drain port (B) is not added to the charge
relief pressure, and the valve always displays
the set relief characteristics.

If abnormal pressure is generated in the circuit


or the shuttle valve of the HSS motor is at neutral, and the pressure oil at ports (A) and (C)
reaches the pressure set by spring (4E), poppet (4D) is pushed to the right in the direction
of the arrow, and the oil at (C) is relieved to
port (D) to reduce the pressure of the oil at (C).

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

HSS motor

HMF180
1. Piston motor
Outline
q
Motor is composed of fixed capacity, fixed swash plate type piston motor, flashing shuttle valve, bypass
valve and charge relief valve.

1.
2.
3.
4.

HSS motor assembly


Flashing shuttle valve
Bypass valve
Charge relief valve

C: From charge pump


T: To hydraulic tank
P: From pivot turn solenoid
CA: Pressure sensor mounting port
CB: Pressure sensor mounting port
CD: To hydraulic tank
MA: From HSS pump PA port
MB: From HSS pump PB port

D275AX-5E0

Specifications
Model

HMF180

Theoretical displacement
(cc/rev)

181

Rated output pressure


MPa{kg/cm2}

41.2{420}

Rated speed

(rpm)

2,078

47

SEN00930-00

1.
2.
3.
4.
5.
6.
7.
8.
9.

10 Structure, function and maintenance standard

Output shaft
Motor case
Swash plate
Piston
Cylinder block
Valve plate
End cover
Cover
Return spring

10.
11.
12.
13.
14.
15.
16.
17.
18.

Flashing shuttle valve


Plug
Spool return spring
Bypass valve
Charge relief valve
Bearing (rear)
Spline
Shoe
Bearing (front)
Unit: mm

No.

Check item

Criteria

Remedy

Standard size
19 Spool return spring

20 Spool return spring

48

Free length
OD

Repair limit

Installed
length

Installed
load

43.5 28.7
48.5 21

Free length

Installed
load

36.0

530N
{54kg}

498N
{50.8kg}

41.0

294N
{30kg}

297N
{38.2kg}

Replace spring
if damaged or
deformed

D275AX-5E0

10 Structure, function and maintenance standard

SEN00930-00

Outline
q
Pressurized oil sent from pump is converted to
rotation energy and is transmitted to output
shaft.
Structure
q
Cylinder block (5) is supported to shaft (1) by a
spline (14), and shaft (1) is supported by front
and rear bearings (16) and (13).
q
The end of piston (4) has a concave ball
shape, and shoe (15) is caulked to it to form
one unit.
q
Piston (4) and shoe (15) form a spherical bearing.
q
Piston (4) carries out motion relative to the
axial direction inside each cylinder chamber of
cylinder block (5).
q
Cylinder block (5) carries out rotation relative
to valve plate (6) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly. The oil inside
each cylinder chamber of cylinder block (5) is
sucked in and discharged through valve plate
(6).

D275AX-5E0

49

SEN00930-00

Operation
1. Operation of motor
q
The pressurized oil sent from the pump
enters cylinder block (5) and pushes piston (4) from the back face.
In the case of the motor, the center line of
plate (3) is always at an angle (swash
plate angle a to the axial direction of cylinder block (5). As a result, if we take the
example of one of pistons (4), oil pressure
is applied to the back face of the right, and
piston axial force (FO) is generated.

50

10 Structure, function and maintenance standard

2.

Rotation speed and torque control


q
As flow (Q) from the HSS pump is
increased, motor speed (N) is heightened.
q
Since the swash plate angle of the HSS
motor is fixed (a is constant), torque (T) is
proportional to pressure (P).
q
Swash plate angle ( ) is 19.
Q=qN
(q = E F)
T=

Pq

2x

Q: Total flow
q: Flow per 1 turn
N: Rotation speed
P: Pressure
T: Rotating torque

With shoe (15), which is joined to piston (4)


by the spherical surface, reaction force (FR)
in a direction at right angles to plane (A) is
generated. The combined force of (FO) and
(FR) is (FP), and this becomes the force to
rotate cylinder block (5).
Shaft (1), which is meshed to cylinder block
(5) by spline (14) transmits this rotation
torque to the output side. Cylinder block (5)
rotates, and while the condition changes
from volume (E) to volume (F), pressurized
oil from the pump flows into the cylinder
chamber, and pressure (P) is generated according to the load. On the other hand, when
the condition goes beyond volume (F) and
changes to volume (E), the oil is pushed out
and returned to the pump.

D275AX-5E0

10 Structure, function and maintenance standard

2. Flushing shuttle valve


Function
q
The shuttle valve acts to switch the shuttle
valve spool according to the pressurized oil in
the HSS high-pressure circuit, and to return
the oil in the HSS low-pressure circuit through
the oil cooler to the tank. The shuttle valve is
installed to the HSS motor assembly.
Operation
(1) When HSS pump swash plate angle is at
neutral position
q
The swash plate angle of the pump is at the
neutral position, so the delivery from HSS
pump (2) is 0. When this happens, the same oil
pressure is applied to ports (A) and (B) at both
ends of shuttle valve spool (7), so spool (7)
remains at the neutral position.
q
When this happens, the relationship of the set
pressure of charge relief valve (8) is as follows.
Set pressure of
charge safety valve
(4)
q

SEN00930-00

(2) When HSS pump is discharging oil from


port PA
q
The pressurized oil from HSS pump (2) enters
port (MA) from port (PA), passes through orifice (a) of shuttle valve spool (7), then enters
port (A). Spool (7) is pushed to the right in the
direction of the arrow by the pressurized oil at
port (A), so the passage between ports (MB)
and (D) is opened and the oil is connected to
charge relief valve (8).
q
When this happens, the relationship of the set
pressure of charge relief valve is as follows.
Set pressure of
charge safety valve
(4)
q

Set pressure of
charge relief valve
(8)
As a result, the pressurized oil from charge
pump (1) flows from port (D) through charge
relief valve (8), where the set pressure is lower.
It is then relieved and is drained from oil cooler
(3) to the tank.

>

Set pressure of
charge relief valve
(8)
As a result, the pressurized oil from charge
pump (1) flows from port (C) of the motor
through charge relief valve (8), where the set
pressure is lower. It is then relieved and
drained from oil cooler (3) to the tank.

D275AX-5E0

>

51

SEN00930-00

10 Structure, function and maintenance standard

(3) When HSS pump is discharging oil from


port PB
q
The pressurized oil from HSS pump (2) enters
port (MB) from port (PB), passes through orifice (b) of shuttle valve spool (7), then enters
port (B). Spool (7) is pushed to the left in the
direction of the arrow by the pressurized oil at
port (B), so the passage between ports (MA)
and (E) is opened and the oil is connected to
charge relief valve (8).
q
When this happens, the relationship of the set
pressure of charge relief valve (8) is as follows.
Set pressure of
charge safety valve
(4)
q

52

Set pressure of
charge relief valve
(8)
As a result, the pressurized oil from charge
pump (1) flows from port (E) through charge
relief valve (8), where the set pressure is lower.
It is then relieved and drained from oil cooler
(3) to the tank.

>

D275AX-5E0

10 Structure, function and maintenance standard

3. Bypass valve
Function
q
When the machine carries out a pivot turn, the
HSS motor receives a reverse force from the
steering brake and is rotated at high speed. At
this time, the bypass valve is changed according to the signals from the pivot turn solenoid
to add a passage so that the oil will circulate
inside the motor and the load on the HSS
motor rotating at high speed will be reduced.

SEN00930-00

(2) When the pivot turn solenoid is turned ON


q
Bypass valve spool (1) is pushed to the right
as indicated by the arrow and (MA) and (MB)
are connected to each other and the oil circulates inside the motor. Quantity (Q1) of the oil
circulating in the HSS circuit is the difference
between discharge (Q) of the motor and flow
rate (Q2) of the oil circulating inside the motor.
Q1 = Q Q2

Operation
(1) When the pivot turn solenoid is deactivated
q
Bypass valve spool (1) is in neutral. The quantity of the oil circulating in the HSS circuit is
equivalent to discharge (Q) of the motor.

D275AX-5E0

53

SEN00930-00

10 Structure, function and maintenance standard

4. Charge relief valve

1.
2.
3.
4.
5.
6.
7.
8.

54

Charge pump
HSS pump
Oil cooler
Charge safety valve
Suction safety valve
HSS motor
Shuttle valve
Charge relief valve
8A: Valve
8B: Spring
8C: Valve seat
8D: Puppet
8E: Spring
8F: Pressure adjustment screw
8G: Filter

Function
q
The charge relief valve is installed to the HSS
motor. It maintains the minimum pressure on
the low pressure side of the circuit to secure
the suction performance of the HSS pump.
a Set pressure:
2.3 MPa {23kg/cm2} (at 120 l/min)

D275AX-5E0

10 Structure, function and maintenance standard

Operation
q
While the HSS pump is discharging oil through
port (PA) or (PB), the oil on the low pressure
side of the HSS circuit flows through port (MA)
or (MB) and shuttle valve (7) to inlet port (A) of
charge relief valve (8).
q

SEN00930-00

If the oil pressure in port (C) lowers, differential


pressure is generated between ports (A) and
(C) because of orifice (a). As a result, valve
(8A) is pushed to the right as indicated by the
arrow and the oil in port (A) is relieved to port
(B).
By this operation, the oil pressure in the charge
circuit is kept at the set pressure of charge
relief valve (8). This charge pressure keeps
supplying the oil to the closed HSS circuit.

Since drain port (D) of the puppet is joined to


the drain part of the HSS motor, the back pressure on drain port (B) is not added to the
charge relief pressure and the specified relief
characteristics are maintained.

The oil in port (A) also fills port (C) through orifice (a) of valve (8A). At this time, puppet (8D)
is fitted to valve seat (8C).

If the oil pressure in port (C) rises to the level


set with spring (8E), puppet (8D) is pushed to
the right as indicated by the arrow and the oil in
port (C) is relieved to port (D), thus the oil pressure in port (C) lowers.

D275AX-5E0

55

SEN00930-00

10 Structure, function and maintenance standard

PPC, HSS charge filter

1.
2.
3.
4.
5.
6.

56

Plug
Cover
Spring
Plate
Element
Case

A: To HSS motor
B: To filter bypass valve
C: From charge pump

Performance
Mesh size (mm)

30/8

Filtering area (cm2)

5,400

Oil flow (l/min)

138

D275AX-5E0

SEN00930-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00930-00

58

D275AX-5E0

SEN00931-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Hydraulic system, Part 2


Hydraulic system, Part 2 ................................................................................................................................. 2
Control valve ........................................................................................................................................ 2
Self pressure reducing valve.............................................................................................................. 31

D275AX-5E0

SEN00931-00

10 Structure, function and maintenance standard

Hydraulic system, Part 2

Control valve

Standard specification
Cautions for tightening bolts marked with *
Tighten the 3 bolts in the following 3 steps so that they will be tightened equally.
1st time: 58.8 9.8 Nm {6 1 kgm}
2nd time:137.3 9.8 Nm {14 1 kgm}
3rd time: 186.3 9.8 Nm {19 1 kgm}

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

A: Pump pressure pick-up port


B: LS pressure pick-up port
C: PPC main pressure
T:
Drain
A1: To blade tilt right cylinder head
A2: To blade lift cylinder head
A3: To ripper lift cylinder head
A4: To ripper tilt cylinder bottom
B1: To blade tilt right cylinder bottom
B2: To blade lift cylinder bottom
B3: To ripper lift cylinder bottom
B4: To ripper tilt cylinder head
LS: To HSS pump LS valve
P1: From pump
PR: PPC output
TS: Seal drain
PA1: From blade PPC valve port P3
PA2: From blade PPC valve port P1
PA3: From ripper PPC valve port P3
PA4: From ripper PPC valve port P1
PB1: From blade PPC valve port P4
PB2: From blade PPC valve port P2
PB3: From ripper PPC valve port P4
PB4: From ripper PPC valve port P2

D275AX-5E0

SEN00931-00

1.
2.
3.
4.

10 Structure, function and maintenance standard

Valve block
Ripper tilt spool
Ripper lift spool
Blade lift spool

5.
6.
7.
8.

Blade tilt spool


Valve body
Load check valve
Pressure compensation valve
Unit: mm

No.

Check item

Criteria
Standard size

Spool return spring


(only for blade lift)

10 Spool return spring

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

76.3 x 30

68.5

209.37N
{21.35kg}

167.50N
{17.08kg}

51.7 x 31.3

50

140.1N
{14.3kg}

111.7N
{11.4kg}

173.5N
{17.7kg}

Spool return spring


11
(for blade lift FLOAT)

54.7 x 36.5

32.5

216.6N
{22.1kg}

12 Load check valve spring

20.8 x 10.2

13.5

12.7N
{1.3kg}

9.8N
{1.0kg}

108.3 x 29.5

81

562N
{57.3kg}

449N
{45.8kg}

86.7 x 30

66

192.4N
{19.63kg}

154N
{15.7kg}

13

Pressure compensation valve


spring

14 Unload spring

Replace

If damaged or
deformed,
replace spring

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.

LS check valve
Main relief valve
LS relief valve

SEN00931-00

4.
5.
6.

Unload valve
Suction valve
Check valve (built in spool)
Unit: mm

No.

Check item

Criteria
Standard size

Suction valve spring

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

64.9 x 12.5

56

6.37N
{0.65kg}

5.1N
{0.52kg}

Check valve spring in spool

27.9 x 6.5

22.5

14.7N
{1.5kg}

11.8N
{1.2kg}

Check valve spring in spool

9.4 x 4.6

8.5

0.29N
{0.03kg}

0.20N
{0.02kg}

D275AX-5E0

Replace

If damaged or
deformed,
replace spring

SEN00931-00

10 Structure, function and maintenance standard

1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
No.

Check item

Criteria
Standard size

Suction valve spring

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

46.8 x 7.5

40.6

5.49N
{0.56kg}

4.4N
{0.45kg}

If damaged or
deformed,
replace spring

D275AX-5E0

SEN00931-00

10 Structure, function and maintenance standard

Dual tilt specification


Cautions for tightening bolts marked with*
Tighten the 3 bolts in the following 3 steps so that they will be tightened equally.
1st time: 58.8 9.8 Nm {6 1 kgm}
2nd time:137.3 9.8 Nm {14 1 kgm}
3rd time: 186.3 9.8 Nm {19 1 kgm}

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

A: Pump pressure pick-up port


B: LS pressure pick-up port
C: PPC main pressure
T:
Drain
A1: To blade tilt right cylinder head
A2: To blade lift cylinder head
A3: To blade tilt left cylinder head
A4: To ripper lift cylinder head
A5: To ripper tilt cylinder bottom
B1: To blade tilt right cylinder bottom
B2: To blade lift cylinder bottom
B3: To blade tilt left cylinder bottom
B4: To ripper lift cylinder bottom
B5: To ripper tilt cylinder head
LS: To HSS pump LS valve
P1: From pump
PR: PPC output
TS: Seal drain
PA1: From dual tilt and pitch changeover valve
PA2: From blade PPC valve port P1
PA3: From dual tilt and pitch changeover valve
PA4: From ripper PPC valve port P3
PA5: From ripper PPC valve port P1
PB1: From dual tilt and pitch changeover valve
PB2: From blade PPC valve port P2
PB3: From dual tilt and pitch changeover valve
PB4: From ripper PPC valve port P4
PB5: From ripper PPC valve port P2

D275AX-5E0

SEN00931-00

1.
2.
3.
4.
5.

10 Structure, function and maintenance standard

Valve block
Ripper tilt spool
Ripper lift spool
Blade tilt left spool
Blade lift spool

6.
7.
8.
9.

Blade tilt right spool


Valve body
Load check valve
Pressure compensation valve spool
Unit: mm

No.

Check item

Criteria
Standard size

Spool return spring


10
(only for blade lift)

11 Spool return spring

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

76.3 x 30

68.5

209.37N
{21.35kg}

167.50N
{17.08kg}

51.7 x 31.3

50

140.1N
{14.3kg}

111.7N
{11.4kg}

173.5N
{17.7kg}

Spool return spring


12
(for blade lift FLOAT)

54.7 x 36.5

33.5

216.6N
{22.1kg}

13 Load check valve spring

20.8 x 10.2

13.5

12.7N
{1.3kg}

9.8N
{1.0kg}

108.3 x 29.5

81

562N
{57.3kg}

449N
{45.8kg}

86.7 x 30

66

192.4N
{19.63kg}

154N
{15.7kg}

14

Pressure compensation valve


spring

15 Unload spring

10

Replace

If damaged or
deformed,
replace spring

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.

LS check valve
Main relief valve
LS relief valve

SEN00931-00

4.
5.
6.

Unload valve
Suction valve
Check valve (built in spool)
Unit: mm

No.

Check item

Criteria
Standard size

Suction valve spring

Remedy
Repair limit

Free length
Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

64.9 x 12.5

56

6.37N
{0.65kg}

5.1N
{0.52kg}

Check valve spring in spool

27.9 x 6.5

22.5

14.7N
{1.5kg}

11.8N
{1.2kg}

Check valve spring in spool

9.4 x 4.6

8.5

0.29N
{0.03kg}

0.20N
{0.02kg}

D275AX-5E0

Replace

If damaged or
deformed,
replace spring

11

SEN00931-00

10 Structure, function and maintenance standard

1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
No.

Check item

Criteria
Standard size

12

Suction valve spring

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

46.8 x 7.5

40.6

5.49N
{0.56kg}

4.4N
{0.45kg}

If damaged or
deformed,
replace spring

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

Operation of control valve

Function
q
When the main spool is at the HOLD position,
it drains the excess oil discharged by the
pump, and prevents the pressure from being
formed in the circuit from rising.
Operation
1. At hold (Operation of unload valve)
(1) When the main spool is at the HOLD position, the pump pressure passes from
chamber (A) through oriffice (4) to chamber (D). Chambers (C) and (C') are connected to the drain circuit.
(2) When oil is supplied from the pump, the
pressure in chamber (D) rises, and spool
(1) is pushed to the right by pressure (FO)
which is determined by the cross-sectional
area of piston (3) receiving the pressure.

D275AX-5E0

(3) When (FO) becomes larger than set load


(FS) of spring (2), the spool moves to the
right and connects the passage between
chamber (A) and chamber (B), so the oil
from the pump is drained. Therefore,
spool (1) is balanced at a position that
matches the supply of oil from the pump.
Actually, the amount of oil supplied from
the pump is small, so the pressure in the
circuit is almost the same as the set load
of spring (2).

13

SEN00931-00

10 Structure, function and maintenance standard

2. Control of oil flow


(1) Work equipment valve (Following explanation
is for blade right tilt cylinder circuit)
q
Use of the CLSS circuit (Closed Center Load
Sensing System) makes it possible to control
the oil flow by adjusting the area of opening of
the spool driven by the PPC valve, regardless
of the load.
1) At HOLD

When the spool is at the HOLD position, the


pump pressure is sent from chamber (A)
through the notch in spool (3) of the pressure
compensation valve, and passes through
chamber (B) to chamber (C). Chamber (G) is
drained through chamber (H) to chamber (F).
When this happens, the pump pressure is acting on the left end of spool (3) of the pressure

14

compensation valve, so it pushes against the


load of spring (4) and moves to the right to the
maximum stroke position. In this condition, the
area of the opening to spool (1) of the blade tilt
valve is at its minimum.

D275AX-5E0

10 Structure, function and maintenance standard

2)

SEN00931-00

At blade right tilt

[1] When the tilt lever is operated to right tilt, pilot


pressure (PB1) acts on the right end of spool
(1) through the PPC valve, and when the pressure becomes greater than the set load of
spring (2), the spool starts to move to the left. It
is balanced at a position corresponding to PPC
output pressure (PB1).

D275AX-5E0

q
q
q

PLS = differential pressure between ports


(K) and (J) = 1.96 MPa {20kg/cm2}
PLS' = differential pressure between ports
(I) and (D)
PLS C PLS'

15

SEN00931-00

10 Structure, function and maintenance standard

[2] Chamber (C) and chamber (D) are connected,


and the oil from the pump flows through ports
(A), (B), (C), and (D) to tilt cylinder (6). At the
same time, the load pressure in chamber (D)
passes through LS orifice (5) and chamber (H),
and is sent to chamber (G). It is also sent from
the LS circuit (O) to pump servo valve (7).
[3] The condition of the pressure of spool (3) is
chamber (B) pressure C chamber (C) pressure,
and chamber (G) pressure C chamber (D)
pressure, so spool (3) is controlled by the differential pressure of spool (1) (chamber (C)
pressure Chamber (D) pressure), and balances with spring (4).
In other words, if the oil flow is too large, the
differential pressure of spool (1) becomes
larger, so spool (3) moves in the direction to
throttle the oil flow; on the other hand, if the oil
flow is too small, spool (3) moves in the direction to increase the oil flow.
[4] In addition, pump servo valve (7) is controlled
so that the differential pressure between pump
pressure (P) and LS pressure (LS) (LS differential pressure: ( PLS) remains constant, so
a suitable amount of oil flows to ensure that the
loss of pressure at the control valve ( PLS') is
equal to ( PLS). The loss of pressure in the
control valve is determined by the area of the
opening of the main spool, so the oil flow
matches the opening of the spool.
[5] The return oil flow from the tilt cylinder passes
through chamber (E) and chamber (F), and is
drained.

16

D275AX-5E0

SEN00931-00

3)

18

10 Structure, function and maintenance standard

Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)

D275AX-5E0

10 Structure, function and maintenance standard

In the case where the blade falls owing to the


weight of the blade, the return flow from a cylinder is controlled according to the opening
area of main spool (1).

Oil flows from the suction valve (2) to a cylinder so that it prevents the circuit from being
evacuated.
1)

2)

SEN00931-00

When a spool port opens with PPC output


pressure at (PA2), oil on the cylinder head
side passes through ports (A), (B) and (D)
and then drains into the tank owing to the
weight of the blade. At this time, the openin g ar ea be twee n por ts (A ) a nd ( B)
squeezes the return flow from a lift cylinder in order to control the drop speed.
In the case where the blade falls owing to
the weight of the blade, oil on the cylinder
head side passes through a drain circuit
and the suction valve (2) and then it is
supplied to the cylinder bottom side. At the
same time, the output flow from the pump
passes through ports (A1), (B1), (C1),
(D1) and (E1) and then it is supplied to the
cylinder bottom side.

D275AX-5E0

19

SEN00931-00

4)

20

10 Structure, function and maintenance standard

Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

When the lift valve is at FLOAT, the cylinder


port and drain port are connected to put the circuit in a no-load condition.
When the lift valve is in the FLOAT condition,
the pump passage and cylinder ports (A3) and
(B3) are separated so that the other control
valves can be operated.
1) When the work equipment control lever is
at the FLOAT position, if pressure (PA3)
becomes 3.4 MPa (35 kg/cm2) or more, lift
spool (1) is moved to the maximum stroke
position.
2) In this condition, ports (A3) and (B3) and
the LS passage (O) are all connected to
the drain circuit, so there is no load on the
lift cylinder.
3) If the cylinder is driven by the weight of the
blade, the oil entering from (A3) flows to
ports (A), (B), (B1) and (A1), while the rest
of the oil flows through port (D), and is
drained. The oil from suction valve (9)
flows to port (B3). When this happens, the
oil flow is throttled by the area of opening
between ports (A) and (B) of spool (1),
and the cylinder speed is controlled.
4) The pump circuit chamber (E) and ports
(A3) and (B3) are separated, and pump
pressure (P) is formed, so it is possible to
carry out compound operations with other
control valves.

D275AX-5E0

21

SEN00931-00

10 Structure, function and maintenance standard

3. At relief
(1) Blade lift, blade tilt, ripper lift, ripper tilt
a The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke
end.

q
q
q

22

P1 = P3 + P4 = Differential pressure
between ports (M) and (P)
P2 = Differential pressure between ports (P)
and (N)
P3 = Differential pressure between ports (M)
and (B)

q
q

P4 = Differential pressure between ports (B)


and (P)
LS = ( P1) + ( P2) = Differential pressure
between ports (M) and (N) = 1.96 MPa {20 kg/
cm2}

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

1) If blade tilt valve (1) is moved, and the pressure of tilt cylinder (8) becomes higher, work
equipment LS relief valve (5) will crack and
oil will be drained from LS circuit (O). (Ports
(P), (F), (G), (J), and (K)). As a result, there
will be a drop in pressure in LS passage (O)
starting from LS sensing hole (F), and ( P2)
will become larger.
2) For the same reason, if the pressure in
chamber (I) and (H) drops, spool (2) will
push against spring (3) and move to the
right, and will make the opening between
chambers (B) and (C) smaller, so the flow
between chambers (B) and (C) will be throttled and ( P4) will become larger.
3) Because of the pump swash plate control,
the system circuit is balanced at a circuit
pressure which makes the pressure loss
generated by the flow at work equipment LS
relief valve (5) ( P1) + ( P2) equal to LS
differential pressure ( LS). When this happens, pump LS valve (6) detects the differential pressure generated by LS relief valve
(5), and moves the pump swash plate from
the maximum to the minimum position
where the LS differential pressure is 1.96
MPa {20 kg/cm2}.
4) When the pump is at the minimum swash
plate angle (minimum oil flow), if the minimum oil flow is greater than the LS relief oil
flow + leakage at any part, the pressure is
confined in the pump circuit (the pump and
chambers (A) and chamber (B) through
pressure compensation valve (7)), so the LS
differential pressure rises. If this differential
pressure goes above the set pressure for
unload valve (4), the unload valve is actuated to relieve the excess oil flow and balance
the circuit.

D275AX-5E0

23

SEN00931-00

10 Structure, function and maintenance standard

(2) Compound operation of work equipment valve


a The diagram shows the condition when the blade lift and tilt valves are operated at the same time.

24

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

It consists of a parallel circuit, so when compound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
1)

Tilt spool (1) and lift spool (2) are actuated


by PPC valve output pressure (PA1) and
(PB2), and each is balanced at a position
that matches its own pilot pressure.

2)

When pump pressure (P2) (P3)


Lift valve load pressure (P3) is sent to
pump LS valve (4) through LS passage
(O).

[1] When pump swash plate does not reach


maximum angle
When the maximum flow of oil from the
pump is greater than the total of the oil
flow demanded by the tilt valve and lift
valve, an oil flow that matches the opening
of the spool flows to both the tilt valve and
lift valve.
[2] When pump swash plate is at maximum
angle
When the maximum flow of oil from the
pump is smaller than the total of the oil
flow demanded by the tilt valve and lift
valve, the flow of oil to the tilt valve and lift
valve is divided according to differential
pressure (PO) (P2) and differential pressure (PO) (P3). In other words, more oil
flows to (P2) where the load is small.
a

In cases where the blade is raised in the


air and the tilt valve and lift valve (for
raise) are operated at the same time, the
tilt valve load pressure is smaller than the
lift valve load pressure, so the flow of oil to
the tilt valve is given priority. In addition,
the oil flow demanded by the tilt valve is
smaller, so the condition is just as if priority was given to the oil flow for the tilt
valve.

3)

When pump pressure (P2) = pump pressure (P3)


(P) (P2) C (P) (P3), so an oil flow proportional to the size of the spool opening
is distributed to each spool.

D275AX-5E0

25

SEN00931-00

10 Structure, function and maintenance standard

(3) Unload valve preset system


a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.

26

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

This improves the response of the system


including the pump swash plate and pressure
compensation valve by sending the pilot pressure (basic pressure of PPC valve) to the LS
circuit, and compensating the rise of the LS circuit pressure.

(1) When lift spool (1) is at the HOLD position, pilot


pressure (P1) (basic pressure of PPC valve) is
sent through preset check valve (3) to the
chamber (F) of the pressure compensation
valve. This pressure is called preset pressure
(P2). At the same time, unload pressure (P) is
being sent to chamber (B), but (P1) + (FO) > (P)
((FO): load of spring (4)), so pressure compensation spool (2) moves to the left and the size of
the opening between (A) and (B) becomes the
maximum.
(2) When spool (1) is switched, unload pressure
(P) flows immediately through chamber (A),
(B), (C), (D), and (E) to lift cylinder (8), so the
pressure at the port starts to rise and the time
lag becomes smaller.
(3) At the same time, preset pressure (P2) is supplied to LS circuit (O) by the timing of the spool,
and the pressure in the LS circuit rises. Because of this, unload valve (7) closes, and oil is
sent further to pump LS valve (6) to improve the
response of the pump swash plate angle. This
makes it possible to reduce the response time
for giving the necessary oil flow. Check valve
(5) is built in the spool to prevent preset pressure (P2) from venting in force from the cylinder
port.
(4) When cylinder port pressure (P3) rises and becomes greater than preset pressure (P2), it
pushed up check valve (5), and oil is sent to
chamber (F) of the pressure compensation
valve and pump LS valve (6) to give the basic
( PLS) control.
When this happens, pressure (P3) at the cylinder port is prevented from entering the PPC
pump circuit by preset check valve (3).

D275AX-5E0

27

SEN00931-00

10 Structure, function and maintenance standard

(4) Dual tilt and pitch system


a A machine with the dual tilt specification has the dual tilt and pitch system circuit.
1) When single tilt operation is carried out

28

In the single tilt mode, solenoid valve (1) is in


the neutral position and connected to (PA3)
and (PB3) of the control valve as shown in the
figure. PPC circuits (2) and (3) are separated
from output circuits (4) and (5) of the PPC
valve.
Accordingly, the right tilt cylinder does not
move and only the left tilt cylinder moves to
carry out the single tilt operation.
D275AX-5E0

10 Structure, function and maintenance standard

2)

When dual tilt operation is carried out

In the dual tilt mode, solenoid valve (1) is


changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB1)
of the control valve is connected to output circuit (4) of the PPC valve.
PPC circuit (3) connected to (PA1) of the control valve is connected to output circuit (5) of
the PPC valve.
Accordingly, both tilt cylinders move in the
opposite directions to carry out the dual tilt
operation.

D275AX-5E0

SEN00931-00

29

SEN00931-00

3)

When pitch operation is carried out

In the pitch mode, solenoid valve (1) is


changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB1)
of the control valve is connected to output circuit (5) of the PPC valve.
PPC circuit (3) connected to (PA1) of the control valve is connected to output circuit (4) of
the PPC valve.
Accordingly, both tilt cylinders move in the
same direction to carry out the pitch operation.

30

10 Structure, function and maintenance standard

D275AX-5E0

10 Structure, function and maintenance standard

Self pressure reducing valve

T:
P1:
P2:
PR:

SEN00931-00

To hydraulic tank
From cooling fan pump
To cooling fan motor
Supply to PPC valve and EPC valve

D275AX-5E0

31

SEN00931-00

1.
2.
3.
4.
5.

32

Valve (sequence valve)


Spring
Screw
Poppet
Spring (pressure reducing valve pilot)

10 Structure, function and maintenance standard

6.
7.
8.
9.
10.

Spring (pressure reducing valve main)


Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

Unit: mm
No.

11

Check item
Spring
(pressure reduction main)

12

Spring
(pressure reduction valve pilot)

13

Spring

14

Spring (safety valve)

Criteria
Standard size
Free length Installed
Installed
x O.D.
length
load
19.6
19.2 x 7.20
16.1
{2.0 kg}
28 N
17.8 x 7.20
12.7
{2.90 kg}
200 N
71.0 x 18.0
59.0
{20.4 kg}
61.7 N
16.1 x 7.80
13.4
{6.30 kg}

Remedy
Repair limit
Free length Installed
load
17.7 N

{1.80 kg}
25.6 N

{2.60 kg}
186 N

{19.0 kg}
58.8 N

{6.0 kg}

Replace
spring if any
damages or
deformations are
found

Function
The self pressure reducing valves reduces the discharge pressure of the cooling fan pump and supplies it to the PPC valve, the EPC valve, etc. as the
control pressure.

D275AX-5E0

33

SEN00931-00

10 Structure, function and maintenance standard

Operation
1. At engine stop (total low pressure)

34

The spring (6) pushes the poppet (5) the seat,


and the circuit between the ports (PR) and (T)
is closed.
The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports (P1)
and (PR) is open.
The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports (P1)
and (P2) is closed.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00931-00

2.

When the load pressure P2 is lower than the output pressure PR of the self pressure reducing
valve.

The spring (3) and the (PR) pressure (0 MPa


{0 kg/cm2} at the time of engine stop) pushes
the valve (2) in the direction to close the circuit
between the ports (P1) and (P2). When the
hydraulic oil enters the (P1) port, the expression ((P1) pressure
Spring (7) force + ((d)
area x (PR) pressure)) holds, and the self pressure reducing valve will adjust the openings of
the ports (P1) and (P2) so that the (P1) pressure can be maintained higher than the (PR)
pressure.
When the (PR) pressure rises above the set
pressure, the poppet (5) will open and the
hydraulic oil flows through the route from the
(PR) port, the hole a in the spool (8), the poppet (5) opening to the tank port (T).

D275AX-5E0

Therefore, there will occur a differential pressure around the hold a in the spool (8) and the
spool will move in the direction to close the
port (P1) and the (PR) opening. Then, the (P1)
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.

35

SEN00931-00

3.

At raise of load pressure P2

When the load pressure (P2) rises due to digging or other operations, the pump delivery will
increase and the (P1) pressure will rise.
Then, the expression ((P1) pressure > Spring
(7) force + ( (d) area x (PR) pressure)) will
hold, and the valve (2) will move to the right
side till the stroke end. As a result, the opening between the ports (P1) and (P2) will
increase, the passage resistance will become
smaller to reduce engine loss horsepower.

36

10 Structure, function and maintenance standard

When the (PR) pressure rises above the set


pressure, the poppet (5) will open and the
hydraulic oil will flow through the route from the
(PR) port, the hole (a) in the spool (8), the poppet (5) opening to the tank port (T).
Therefore, there will occur a differential pressure around the hold (a) in the spool (8) and
the spool will move in the direction to close the
port (P1) and the (PR) opening. Then, the (P1)
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.

D275AX-5E0

10 Structure, function and maintenance standard

4.

At occurrence of abnormal high pressure

When the (PR) pressure of the self pressure


reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports (PR)
(T) so as to reduce the
(PR) pressure. Then, the equipment (PPC
valve, solenoid valve, etc.), to which the oil
pressure is supplied, is protected from the
abnormal high pressure.

D275AX-5E0

SEN00931-00

37

SEN00931-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00931-00

38

D275AX-5E0

SEN00932-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Hydraulic system, Part 3


Hydraulic system, Part 3 ................................................................................................................................. 2
HSS charge filter bypass...................................................................................................................... 2
HSS oil cooler bypass valve................................................................................................................. 4
PPC valve ............................................................................................................................................ 6
PCCS lever ........................................................................................................................................ 18
PPC lock valve ................................................................................................................................... 21
Work equipment cylinder.................................................................................................................... 22
Piston valve........................................................................................................................................ 25
Quick drop valve ................................................................................................................................ 26
Pin puller switch ................................................................................................................................. 27
Pin puller solenoid valve .................................................................................................................... 28
Blade control knob ............................................................................................................................. 30
Pitch, dual tilt solenoid valve .............................................................................................................. 31
Accumulator ....................................................................................................................................... 32

D275AX-5E0

SEN00932-00

10 Structure, function and maintenance standard

Hydraulic system, Part 3


HSS charge filter bypass

C1:
C2:
P:
P1:
T:

1
1

Outline
When the difference between the charge inlet pressure and charge outlet pressure is increased, the
HSS charge filter bypass valve drains the oil into
the tank without sending it to the HSS charge circuit.
(Cracking differential pressure:
490 98 kPa {5 1 kg/cm2})

To HSS motor
To HSS pump
Charge filter outlet
Charge filter inlet
To hydraulic tank

Unit: mm
No.

Check item

Clearance between filter


bypass valve and valve body

Clearance between filter


bypass valve and piston

Filter bypass valve spring

Criteria
Tolerance
Shaft
Hole
0.035
+ 0.013
28
0.045
+ 0.013
0.020
+ 0.018
15
0.030
+ 0.018
Standard size
Installed
Installed
Free length
length
load
71.15
N
70.3
64.3
{7.26 kg}
Standard
size

Remedy
Standard
Clearance
clearance
limit
0.035
0.08
0.058
0.020
0.06
Replace
0.048
Repair limit
Installed
Free length
load

D275AX-5E0

SEN00932-00

10 Structure, function and maintenance standard

HSS oil cooler bypass valve

1.
2.
3.
4.
5.
6.

Plug
Valve
Shim
Plug
Spring
Body

A:
B:
C:
D:
E:

From charge relief valve


To hydraulic tank
From oil cooler
To oil cooler
From charge safety valve

Outline
q
This valve is installed in the circuit between the
HSS pump and HSS motor charge relief valve
oil return circuit and the oil cooler. If any abnormal pressure is generated in the oil flowing to
the oil cooler, this valve acts to return the oil
directly to the hydraulic tank.
Set pressure
Cracking pressure
(MPa {kg/cm2 })

0.487 {4.97}

D275AX-5E0

10 Structure, function and maintenance standard

SEN00932-00

Unit: mm
No.

Check item

Clearance between oil cooler


bypass valve and valve body

Criteria
Standard
size
22

Tolerance
Shaft

Hole

Standard
clearance

Clearance
limit

0.035
0.045

+ 0.013
+ 0.013

0.035
0.058

0.08

Standard size
2

Spring

D275AX-5E0

Remedy

Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

52

46

156.9 N
{16 kg}

149.1 N
{15.2 kg}

Replace

SEN00932-00

PPC valve

10 Structure, function and maintenance standard

1. Blade PPC valve

P: From self pressure reducing valve


P1: To blade lift valve (LOWER) PPC port
P2: To blade lift valve (RAISE) PPC port

P3: To blade tilt valve (LEFT TILT) PPC port


P4: To blade tilt valve (RIGHT TILT) PPC port
T: To hydraulic tank

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.

Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connecting lever)

D275AX-5E0

SEN00932-00

7.
8.
9.
10.
11.

Joint
Plate
Retainer
Body
Filter

SEN00932-00

10 Structure, function and maintenance standard

Unit: mm
No.

Check item

Criteria
Standard size

Centering spring
12
(For port P1)

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free length

Installed
load

34.0 x 15.5

31.9

94 N
{9.6 kg}

75.2 N
{7.68 kg}

13

Centering spring
(For port P2)

43.2 x 15.5

34.0

78.5 N
{8 kg}

62.8 N
{6.4 kg}

14

Centering spring
(For ports P3 and P4)

48.57 x 15.5

32.5

107.9 N
{11 kg}

86.3 N
{8.8 kg}

15

Metering spring
(For port P1)

29.27 x 8.15

25.4

16.7 N
{1.70 kg}

13.3 N
{1.36 kg}

16

Metering spring
(For port P2)

26.3 x 8.15

24.1

16.7 N
{1.70 kg}

13.3 N
{1.36 kg}

17

Metering spring
(For ports P3 and P4)

26.53 x 8.15

24.9

16.7 N
{1.70 kg}

13.3 N
{1.36 kg}

If spring is
damaged or
deformed,
replace it

D275AX-5E0

10 Structure, function and maintenance standard

Operation
1) When in neutral
(1) For lifting blade
q
Ports (A) and (B) of the blade lift valve of thecontrol valve and ports (P1) and (P2) of
thePPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).

D275AX-5E0

SEN00932-00

(2) For tilting blade


q
Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D).

SEN00932-00

2)
q

10

10 Structure, function and maintenance standard

When in fine control


(Neutral o Fine control)
If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simultaneously to release the pressure in port (P1).
As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
The positional relationship between spool (1)
and body (10) [where fine control hole (f) is
between drain chamber (D) and pump pressure chamber (PP)] does not change until
retainer (9) comes in contact with spool (1).
Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with
the force of the control valve spool return
spring.

D275AX-5E0

10 Structure, function and maintenance standard

3)
q

When in fine control


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

D275AX-5E0

SEN00932-00

4)
q

When lever is operated to stroke end


If disc (5) pushes down piston (4) and retainer
(9) pushes down spool (1), fine control hole (f)
is disconnected from drain chamber (D) and
connected to pump pressure chamber (PP).
Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and
pushes the control valve spool.
The oil returning from port (A) flows through
port (P2) and fine control (f) into drain chamber (D).

11

SEN00932-00

5)
q

q
q

q
q

12

When blade is floated


If piston (4) on the LOWER side of port (P1)
is pushed down by disc (5), ball (11) touches
projection (a) of the piston in the middle of the
stroke (The detent starts to operate).
If piston (4) is pushed in further, ball (11)
pushes up collar (12) supported on detent
spring (13) and escapes out to go over projection (a) of the piston.
At this time, piston (4') on the opposite side is
pushed up by spring (14).
As a result, the oil in chamber (F) flows
through (b) and (c) to chamber (E) and piston
(4') follows disc (5). Since passage (d) is connected to port (P1), almost the same pressure
is applied to passage (d) and port (P1).
Chamber (E) is normally connected to drain
chamber (D). If ball (11) goes over projection
(a) of the piston, passage (d) and chamber (E)
are connected and the oil starts flowing.
At this time, the control valve moves to the
FLOAT position and the blade is floated.
Since piston (4') is pushed up by the pressure
in chamber (E), the FLOAT state is kept even
if the lever is released.

10 Structure, function and maintenance standard

6)
q

When FLOAT state of blade is reset


Disc (5) is pushed down with a force larger
than the oil pressure in chamber (E) to return
from the FLOAT position.
As a result, chamber (E) is disconnected from
passage (d) and connected to the drain chamber. Accordingly, the oil pressure in chamber
(E) is lost and the FLOAT state is reset.

D275AX-5E0

SEN00932-00

10 Structure, function and maintenance standard

2. Ripper PPC valve

P:
P1:
P2:
P3:
P4:
T:

14

From self pressure reducing valve


To ripper tilt valve PPC port
To ripper tilt valve PPC port
To ripper lift valve PPC port
To ripper lift valve PPC port
To tank

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connecting lever)
Joint
Plate
Retainer
Body
Filter

D275AX-5E0

10 Structure, function and maintenance standard

SEN00932-00

Unit: mm
No.

Check item

Criteria
Standard size

12

13

Centering spring
(For ports P3 and P4)

Centering spring
(For ports P1 and P2)

14 Metering spring

D275AX-5E0

Remedy
Repair limit

Free length
x Outside
diameter

Installed
length

Installed
load

Free
length

Installed
load

50.4 x 15.5

34.0

55.9 N
{5.7 kg}

44.7 N
{4.56 kg}

50.1 x 15.5

34.0

71.4 N
{7.28 kg}

56.9 N
{5.8 kg}

26.5 x 8.20

24.9

16.7 N
{1.70 kg}

13.3 N
{1.36 kg}

If spring is
damaged or
deformed,
replace it

15

SEN00932-00

Operation
1) When in neutral
q
Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected
through fine control hole (f) of spool (1) to drain
chamber (D).

2)
q

16

10 Structure, function and maintenance standard

Since metering spring (2) is compressed in


proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in chamber (A)
[equal to the pressure in port (P1)] is balanced
with the force of the control valve spool return
spring.

When in fine control


(Neutral o Fine control)
If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (A).
If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simultaneously to release the pressure in port (P1).
As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional relationship between spool (1) and body (10)
[where fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)] does not change until retainer (9) comes
in contact with spool (1).

D275AX-5E0

10 Structure, function and maintenance standard

3)
q

When in fine control


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

D275AX-5E0

SEN00932-00

4)
q

When lever is operated to stroke end


If disc (5) pushes down piston (4) and retainer
(9) pushes down spool (1), fine control hole (f)
is disconnected from drain chamber (D) and
connected to pump pressure chamber (PP).
Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into chamber (A) and
pushes the control valve spool.
The oil returning from chamber (B) flows
through port (P2) and fine control (f) into drain
chamber (D).

17

SEN00932-00

10 Structure, function and maintenance standard

PCCS lever

Travel and steering PCCS lever


a

Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operating effort characteristics will need to be adjusted.

1.
2.
3.
4.

Bellows
Bracket
Plate
Bolt

18

5.
6.
7.

Screw
Lever
Connector

D275AX-5E0

10 Structure, function and maintenance standard

Function
1. Operating effort characteristics
1) Operation for forward and reverse travel
q
The control lever is held at 3 positions of Forward, Neutral, and Reverse.

D275AX-5E0

SEN00932-00

2)
q

Operation for steering


Free return.

19

SEN00932-00

2.
q

20

10 Structure, function and maintenance standard

Output voltage characteristics


The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
The operating angle (stroke) of the control
lever is sensed with potentiometers and signal
voltages are output to the transmission and
steering controller.
A potentiometer is installed in each of longitudinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the figure at right.

D275AX-5E0

10 Structure, function and maintenance standard

PPC lock valve

1.
2.
3.
4.
5.

SEN00932-00

Lever
End cap
Ball
Seat
Body

Outline
q
The PPC lock valve is installed in the PPC circuit between the PPC, HSS charge valve and
PPC valve. If the work equipment lock lever is
placed at the LOCK position, the PPC lock
valve is actuated together with the work equipment lock lever. This stops the oil in the PPC
circuit and makes it impossible to operate the
work equipment.

D275AX-5E0

21

SEN00932-00

Work equipment cylinder

10 Structure, function and maintenance standard

Blade lift cylinder

Blade tilt cylinder

Ripper lift cylinder

22

D275AX-5E0

10 Structure, function and maintenance standard

SEN00932-00

Ripper tilt cylinder

Unit: mm
No.

Check item

Criteria
Standard
size

Shaft

Hole

Standard
clearance

Clearance
limit

Blade lift

80

+ 0.258
+ 0.048

0.078
0.334

0.745

Clearance between
piston rod and bush- Blade tilt
ing

0.030
0.076

100

0.036
0.090

+ 0.257
+ 0.047

0.084
0.347

0.693

Ripper lift

100

0.036
0.090

+ 0.257
+ 0.047

0.084
0.347

0.693

Ripper tilt

90

0.036
0.090

+ 0.257
+ 0.047

0.084
0.347

0.693

100
(Ball)

+ 0.300
0

1.0

Blade lift

90

1.0

Clearance between
piston rod spherical Blade tilt
shaft and bushing

+ 0.207
+ 0.120

70

+ 0.200
0

1.0

90

+ 0.207
+ 0.120

1.0

Clearance between
cylinder support
Blade lift
shaft bushing and
yoke

95

0.120
0.207

+ 0.035
0

0.120
0.242

1.0

Blade tilt

70

+ 0.174
+ 0.100

2.0

90

+ 0.207
+ 0.120

1.0

90

+ 0.207
+ 0.120

1.0

Clearance between
piston rod spherical
Blade lift
surface and blade
ball portion

Ripper lift

Tolerance

Remedy

Clearance between
cylinder bottom supRipper lift
port shaft and bushing
Ripper tilt
Thickness of standard shim between
Blade lift
tip of piston rod and
cap

D275AX-5E0

4.0

Replace

Adjust

23

SEN00932-00

10 Structure, function and maintenance standard

Dual tilt cylinder (If equipped)

Pin puller cylinder (If equipped)

Unit: mm
No.

Check item

Criteria

Clearance between
piston rod and bush- Dual tilt
ing
Pin puller

Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

100

0.036
0.090

+ 0.257
+ 0.047

0.084
0.347

0.693

30

0.065
0.117

+ 0.133
+ 0.007

0.072
0.250

0.55

70

+ 0.200
0

1.0

Clearance between piston rod


support shaft and bushing

Clearance between piston rod


spherical surface and bushing

29

0.100
0.200

Clearance between cylinder


bottom support shaft and bushing

70

+ 0.174
+ 0.100

2.0

Clearance between cylinder


bottom support shaft and bushing

26

+ 0.100
0.100

24

Replace

D275AX-5E0

10 Structure, function and maintenance standard

Piston valve

SEN00932-00

For blade lift cylinder


Outline
q
The piston valve is installed on the piston in
the blade lift cylinder. When the piston reaches
its stroke end, the valve releases the oil from
the hydraulic pump to reduce the oil pressure
being exerted on the piston.
When the blade is tilted, the blade is subject to
a tortional force owing to the uneven position
of the pistons in the two cylinders; that is the
piston one side is still moving while the piston
on the other side has reached its stroke end.
The piston valves are installed to prevent the
tortional force from occurring. When one of the
pistons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact with the cylinder head or the bottom and
serves to redure the subsequent surge pressure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its
stroke end.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction
of the arrow until piston valve seat (4) comes
into snug contact with the tapered section,
thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow.
2.

Piston valve OPEN


Just before piston rod (1) reaches the end of
its stroke, the tip of valve (6) contacts the cylinder bottom, so valve (6) and piston valve (3)
stop at that position and do not move further.
Only piston (2) moves further.
When this happens, the oil at the cylinder
head, which was sealed by piston valve (3),
escapes from piston valve seats (4) and (5),
and the pressure inside the cylinder stops rising.

D275AX-5E0

25

SEN00932-00

10 Structure, function and maintenance standard

Quick drop valve

For blade lift cylinder

Unit: mm
No.

Check item

Clearance between spool and


valve body

Criteria
Standard
size
38.0

Tolerance
Shaft

Hole

Standard
clearance

Clearance
limit

0.011
0.016

+ 0.010
+ 0.010

0.011
0.026

0.03

Standard size
2

26

Valve spring

Remedy

Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

75.2

55.9

136.3 N
{13.9 kg}

67.7

122.6 N
{12.5 kg}

Replace

D275AX-5E0

10 Structure, function and maintenance standard

Pin puller switch

1.
2.
3.
4.

SEN00932-00

Connector
Wire
Switch
Knob

Function
q
The pin puller solenoid valve is controlled by
turning the pin puller switch ON/OFF. This
changes the oil circuit to the pin puller cylinder
and sets the shank mounting pin to the PUSH
IN or PULL OUT position.

D275AX-5E0

27

SEN00932-00

Pin puller solenoid valve

1.
2.
3.
4.
5.
6.
7.
8.
9.

28

Plug
Spring
Spring retainer
Valve body
Spool
Spring retainer
Spring
Push in
Solenoid assembly

10 Structure, function and maintenance standard

A:
B:
P:
T:

To pin puller cylinder bottom


To pin puller cylinder head
From power train pump
To HSS case

D275AX-5E0

10 Structure, function and maintenance standard

SEN00932-00

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

2.

Pin puller switch at PULL OUT position


When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9)
and it is excited. Then, the solenoid pushes out
push pin (8) and spool (5) moves to the left in
the arrow direction.
At this point, ports (P) and (A) and ports (B)
and (T) close, and ports (P) and (B) and ports
(A) and (T) open, so the oil from the power
train pump flows from port (P) to port (B) and
enters the head end of pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder
retracts and pulls shank mounting pin (11) out
of shank (12).

D275AX-5E0

29

SEN00932-00

Blade control knob

1.
2.
3.
4.
5.

10 Structure, function and maintenance standard

Switch (dual-single selector switch)


Switch (pitch)
Cover
Connector (male)
Connector (femele)

Outline
q
If the blade control knob is tilted forward, backward, to the right, or to the left, the blade is
raised, lowered, tilted to the right, or tilted to
the left. If switch (1) is set to the DUAL position and the lever is tilted to the right or left,
dual tilt operation is carried out. If the lever is
tilted to the right or left while (2) is pressed and
held, pitching operation is carried out.

30

If switch (2) is pressed and the lever is operated, the blade is pitched. If the lever is tilted
to the left, the blade is pitched back. If the
former is tilted to the right, the latter is pitched
forward.
If switch (1) is set to the DUAL position and the
lever is operated, blade carries out dual tilt
operation. If the lever is tilted to the left, the
blade carries out left dual tilt operation. If the
lever is tilted to the right, the blade carries out
right dual tilt operation.
If switch (1) is set in either DUAL or SINGLE
position and the lever is tilted to the right or left
while switch (2) is pressed and held, the blade
is pitched.

D275AX-5E0

10 Structure, function and maintenance standard

Pitch, dual tilt solenoid valve


P3

SEN00932-00

1
PA1

P3 P4

PB2 PA1

PB1

1.
2.
3.
4.
5.

Connector
Solenoid (b)
Valve
Solenoid (a)
Manual push pin

P3: To PPC valve port, hydraulic tank


P4: To PPC valve port, control valve P3 port
PB1:To control valve port
PA1: To control valve port

D275AX-5E0

P4

Outline
q
The pitch switch solenoid valve is located
between the PPC valve and the blade valve,
and at the downstream of the pitch tilt switch
solenoid valve, and its function is to switch the
PPC pilot pressure.
q
By operating the pitch back switch or the pitch
dump switch of the blade control lever, the pilot
pressure can be delivered to the left pitch cylinder and the right pitch cylinder, and it enables
to switch from the tilt to the pitch.
q
In addition, the pitch solenoid valve is operated
by the controller.

31

SEN00932-00

10 Structure, function and maintenance standard

Accumulator
For PPC valve

1
Function
q
The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the
engine is stopped with the work equipment still
raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B).
q
When the PPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas in
chamber (A) expands the bladder, so the oil in
chamber (B) acts as the pilot pressure and
actuates the main control valve.
q

1.
2.
3.
4.
5.
6.

Glass plug
Shell
Poppet
Holder
Bladder
Oil port

Specificetions:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1 MPa {32 kg/cm2}
Max. actuation pressure: 1.2 MPa {12 kg/cm2}

32

D275AX-5E0

SEN00932-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00932-00

34

D275AX-5E0

SEN00933-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Work equipment
Work equipment .............................................................................................................................................. 2
Cylinder stay ........................................................................................................................................ 2
Blade .................................................................................................................................................... 4
Cutting edge, end bit ............................................................................................................................ 8
Ripper................................................................................................................................................. 10

D275AX-5E0

SEN00933-00

10 Structure, function and maintenance standard

Work equipment

Cylinder stay

1.
2.
3.

Yoke
Oil seal
Bushing

4.
5.

Bushing
Air Breather plug

Unit: mm
No.

Check item

Criteria

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

140

0.172
0.235

+ 0.088
+ 0.046

0.218
0.323

Clearance between cylinder


yoke and bushing

105

0.160
0.214

+ 0.075
+ 0.039

0.199
0.289

Clearance between lift cylinder support shaft and bushing

95

0.120
0.207

+ 0.035
+ 0.046

0.120
0.242

0.5

Clearance between cylinder


yoke and bushing

Standard
size

Tolerance

Replace

D275AX-5E0

SEN00933-00

Blade

10 Structure, function and maintenance standard

Semi U-dozer

D275AX-5E0

10 Structure, function and maintenance standard

SEN00933-00

Unit: mm
No.

Check item

Clearance between brace and


brace

Criteria
Standard
size

Tolerance

Remedy
Standard
clearance

Clearance
limit

+ 0.5
+ 0.3

0.6 1.0

Shaft

Hole

70

0.3
0.5

Clearance between brace pin


and bracket

70

0.3
0.5

+ 0.5
+ 0.3

0.6 1.0

Clearance between brace


spherical surface and cap

115

0.2
0.3

+ 0.3
0

0.2 0.6

Clearance between center


brace spherical surface and
cap

130

0.2
0.3

+ 0.3
0

0.2 0.6

Clearance between joint and


blade bracket

120

0.2
0.7

+ 0.5
+ 0.3

0.5 1.2

Clearance between joint and


frame

120

0.2
0.7

+ 0.5
+ 0.3

0.5 1.2

Clearance between frame pin


and joint

60

0.3
0.5

+ 0.3
0

0.3 0.8

Clearance between frame pin


and frame

60

0.3
0.5

+ 0.3
0

0.3 0.8

Clearance between blade


bracket pin and joint

60

0.3
0.5

+ 0.3
0

0.3 0.8

Clearance between blade


10 bracket pin and blade bracket

60

0.3
0.5

+ 0.3
0

0.3 0.8

Clearance between center


11 brace spherical surface and
cap

130

0.2
0.3

+ 0.3
0

0.2 0.6

Clearance between center link


12 pin and center link

115

0.04
0.10

+ 0.3
+ 1.0

0.14 0.40

Clearance between center link


13 pin and blade bracket

115

0.04
0.10

+ 0.3
+ 1.0

0.14 0.40

Clearance between center link


14
and blade bracket

400

0.2
0.4

+ 0.5
0

0.2 0.9

Clearance between trunnion


15 and cap spherical surface

195

0.5
1.0

+ 1.0
0

0.5 2.0

D275AX-5E0

Replace

Adjust shim or
replace

Replace

Adjust shim or
replace

Replace

SEN00933-00

10 Structure, function and maintenance standard

U-dozer

D275AX-5E0

10 Structure, function and maintenance standard

SEN00933-00

Unit: mm
No.

Check item

Clearance between brace and


brace

Criteria
Standard
size

Tolerance

Remedy
Standard
clearance

Clearance
limit

+ 0.5
+ 0.3

0.6 1.0

Shaft

Hole

70

0.3
0.5

Clearance between brace pin


and bracket

70

0.3
0.5

+ 0.5
+ 0.3

0.6 1.0

Clearance between brace


spherical surface and cap

115

0.2
0.3

+ 0.3
0

0.2 0.6

Clearance between center


brace spherical surface and
cap

130

0.2
0.3

+ 0.3
0

0.2 0.6

Clearance between joint and


blade bracket

120

0.2
0.7

+ 0.5
+ 0.3

0.5 1.2

Clearance between joint and


frame

120

0.2
0.7

+ 0.5
+ 0.3

0.5 1.2

Clearance between frame pin


and joint

60

0.3
0.5

+ 0.3
0

0.3 0.8

Clearance between frame pin


and frame

60

0.3
0.5

+ 0.3
0

0.3 0.8

Clearance between blade


bracket pin and joint

60

0.3
0.5

+ 0.3
0

0.3 0.8

10

Clearance between blade


bracket pin and blade bracket

60

0.3
0.5

+ 0.3
0

0.3 0.8

130

0.2
0.3

+ 0.3
0

0.2 0.6

Clearance between center


11 brace spherical surface and
cap
Clearance between center link
pin and center link

115

0.04
0.10

+ 0.3
+ 1.0

0.14 0.40

13

Clearance between center link


pin and blade bracket

115

0.04
0.10

+ 0.3
+ 0.1

0.14 0.40

400

0.2
0.4

+ 0.5
0

0.2 0.9

195

0.5
1.0

+ 1.0
0

0.5 2.0

15

Clearance between trunnion


and cap spherical surface

D275AX-5E0

Adjust shim or
replace

Replace

12

Clearance between center link


14
and blade bracket

Replace

Adjust shim or
replace

Replace

SEN00933-00

Cutting edge, end bit

10 Structure, function and maintenance standard

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

415

300

Width of end bit

662

500

Height of inside of end bit

330

260

Height of cutting edge

330

260 (215 to turning)

Height of outside of end bit

Replace

Turn or replace

D275AX-5E0

SEN00933-00

Ripper

10 Structure, function and maintenance standard

Variable multiple shank ripper

10

D275AX-5E0

10 Structure, function and maintenance standard

SEN00933-00

Giant ripper

Unit: mm
No.

Check item
Clearance between bushing
and bracket and arm mount pin

Clearance between bushing


and beam and arm mount pin

Clearance between cylinder


mount pin and bushing

Clearance between shank and


mount pin

Wear of point

Wear of protector

D275AX-5E0

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

110

0.036
0.090

+ 0.207
+ 0.120

0.156
0.297

1.5

120

0.036
0.090

+ 0.207
+ 0.120

0.156
0.297

1.5

90

0.036
0.090

+ 0.207
+ 0.120

0.156
0.297

1.5

Standard size

Tolerance

Repair limit

82

0.3

Standard size

Repair limit

420

255

155

115

Replace

11

SEN00933-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00933-00

12

D275AX-5E0

SEN00934-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Cab and its attachments


Cab and its attachments ................................................................................................................................. 2
Cab mount............................................................................................................................................ 2
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 5

D275AX-5E0

SEN00934-00

10 Structure, function and maintenance standard

Cab and its attachments


Cab mount

1.
2.
3.

Support
Damper mount (front)
Damper mount (rear)

1
1

Outline
q
Viscous mounts are installed at two places at
the front and two places at the rear to secure
the floor frame and cab.
q
An oil-filled damper mount is used to absorb
the vibration.

D275AX-5E0

10 Structure, function and maintenance standard

Cab

SEN00934-00

Cab assembly

1.
2.
3.
4.

Front wiper
Front glass
Rear wiper
Door

D275AX-5E0

SEN00934-00

10 Structure, function and maintenance standard

ROPS guard

1.

ROPS guard

D275AX-5E0

10 Structure, function and maintenance standard

Air conditioner

SEN00934-00

Air conditioner piping

1.
2.
3.
4.
5.
6.
7.
8.
9.

Air conditioner compressor


Condenser
Window defroster
Side defroster
Air conditioner control unit
Vent
Blower motor
Hot water pick-up piping
Valve (hot water outlet)

D275AX-5E0

10.
11.
12.
13.

Receiver tank
Hot water return piping
Valve (hot water inlet)
Refrigerant piping

A:
B:
C:

Fresh air
Recirculated air
Hot air/cold air

SEN00934-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00934-00

D275AX-5E0

SEN00935-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

10 Structure, function and


maintenance standard

Electrical system
Electrical system ............................................................................................................................................. 2
Engine control ...................................................................................................................................... 2
Engine control system ......................................................................................................................... 3
Engine controller .................................................................................................................................. 4
Deceleration potentiometer .................................................................................................................11
CRI engine control system ................................................................................................................. 12
Monitor system................................................................................................................................... 14
Monitor panel ..................................................................................................................................... 16
Sensors .............................................................................................................................................. 20
Mode selection system....................................................................................................................... 24
Electrical equipment........................................................................................................................... 30
Palm Command Control System........................................................................................................ 33
KOMTRAX terminal system ............................................................................................................... 35

D275AX-5E0

SEN00935-00

10 Structure, function and maintenance standard

Electrical system

Engine control

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Decelerator pedal
Decelerator potentiometer
Starter switch
Transmission controller
Steering controller
Fuel control dial
Battery
Breaker
Battery relay
Starter
Engine throttle controller
Alternator

Outline
q
The throttle signals of the fuel control dial are
input to the steering controller and transmission controller and processed together with the
other information, then the result is sent as the
throttle command to the engine controller. The
engine throttle controller controls the fuel supply pump according to the command.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Engine control system

Outline
q
The engine throttle controller receives the 1st
and 2nd throttle signal which is the manual signal and the 3rd throttle signals which is the
control signals from the machine body, then
selects the lower engine speed and controls
the fuel supply pump.
The 3rd throttle control signals contain the following.
q
SSC (Shoe Slip Control) control
q
Automatic deceleration (F3, R3, R2)
q

The information of the engine controller is used


commonly by the all controllers through the
network for the optimum control of the engine
and machine body.
The automatic deceleration function sets the
engine speed to 1,000 rpm temporarily when
the travel direction is changed from F3, R3, or
R2 (to protect the transmission clutch).

The steering controller selects the lowest


engine speed from these information and
transmits to the engine controller.

D275AX-5E0

SEN00935-00

10 Structure, function and maintenance standard

Engine controller

Meanings of signal classes in the terminal


table shown below are as follows.
A: Power Supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication

CN-CE01
Input/
output
1
NC(*)

2
NC(*)

3
Atmosphere sensor
D
4
Supply pump #1 (+)
B
5
Supply pump #1 ()
C
6
CAN()
C
7
NC(*)

8
CAN(+)
B
9
Supply pump #2 (+)
B
10
Supply pump #2 ()
C
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.

Signal name

CN-CE01
Input/
output
11
EGR val ve
C
12
NC(*)

13
Engine oil pressure sensor
D
14
NC(*)

15
Coolant temperature sensor
D
16
5V electric power supply for sensor
A
17
NC(*)

18
NC(*)

19
EGR valve position sensor
D
20
EGR inlet pressure sensor
B
21
NC(*)

22
EGR valve (+)
B
23
Boost temperature sensor
D
24
NC(*)

25
Common rail pressure sensor
D
26
Buckup sensor
D
27
NE sensor (+)
D
28
NC(*)

29
Bypass valve position sensor
B
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.

Signal name

D275AX-5E0

10 Structure, function and maintenance standard

CN-CE01

CN-CE02

Input/
output
30
Fuel temperature sensor
D
31
Bypass valve (+)
D
32
NC(*)

33
5 V electric power supply for sensor
A
34
NC(*)

35
NC(*)

36
NC(*)

37
5 V electric power supply for sensor
A
38
GND
C
39
NC(*)

40
NC(*)

41
NC(*)

42
NC(*)

43
NC(*)

44
Boost pressure sensor
D
45
Injector #1 (+)
B
46
Injector #5 (+)
B
47
Sensor GND
C
48
Ne sensor ()
C
49
NC(*)

50
NC(*)

51
Injector #2 ()
C
52
Injector #3 ()
C
53
Injector #1 ()
C
54
Injector #2 (+)
B
55
Injector #3 (+)
B
56
Injector #4 (+)
B
57
Injector #6 (+)
B
58
Injector #4 ()
C
59
Injector #6 ()
C
60
Injector #5 ()
C
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.

Signal name

CN-CE02
Input/
output
1
NC(*)
B
2
NC(*)
B
3
NC(*)
B
4
NC(*)
B
5
NC(*)
B
6
NC(*)
B
7
NC(*)
B
8
NC(*)
B
9
Decelerator signal
B
10
NC(*)
E
11
NC(*)
B
12
NC(*)
B
13
NC(*)
B
14
NC(*)
B
15
NC(*)
B
16
NC(*)
B
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.

D275AX-5E0

SEN00935-00

Signal name

Input/
output
17
NC(*)
B
18
NC(*)
B
19
NC(*)
B
20
NC(*)
E
21
NC(*)
A
22
5V electric power supply for sensor
A
23
GND
C
24
NC(*)
B
25
NC(*)
B
26
NC(*)
B
27
NC(*)
B
28
NC(*)
B
29
NC(*)
C
30
NC(*)
B
31
NC(*)
B
32
NC(*)
C
33
GND
C
34
NC(*)
C
35
NC(*)
B
36
NC(*)
B
37
CAN shield
C
38
NC(*)
D
39
Key switch (ACC)
B
40
Electrical intake air heater relay drive
D
41
NC(*)
D
42
Electrical intake air heater relay return
C
43
NC(*)
D
44
NC(*)
D
45
NC(*)

46
CAN(+)
E
47
CAN()
E
48
NC(*)
D
PWM OUTPUT
49
D
(Power train relay output)
50
NC(*)
D
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.

Signal name

CN-CE03
Pin No.
1
2

Signal name

Input/
output
C
C

GND
NC(*)
Electric power supply
3
A
(+24V constantly)
4
NC(*)
A
*: Never connect to NC or malfunctions or failures will
occur.

SEN00935-00

EGR inlet pressure sensor


q

This sensor is used to sense the EGR pressure.

10 Structure, function and maintenance standard

Fuel temperature sensor


q

The fuel temperature sensor senses the fuel


temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.

The following graph shows the output characteristics of the EGR inlet pressure sensor.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

EGR valve position sensor


Bypass valve position sensor
q

These sensors sense the opening and closing positions of the EGR valve and bypass valve.

1.

EGR and bypass valve position sensors

The following graph shows the output characteristics of the position sensor.

D275AX-5E0

SEN00935-00

Engine controller
NE speed sensor (Crank angle sensor)
q
q

10 Structure, function and maintenance standard

Common rail pressure sensor


Oil pressure sensor

If the signal hole made on the flywheel passes


the sensor, the magnetic line of force changes.
If the magnetic line of force changes, the output of the Hall element sensor changes linearly
and it is converted into pulse of 0 5 V by the
wave form shaping circuit in the sensor, and
then output.

Atmospheric pressure sensor


q

This sensor is used to correct altitude.

D275AX-5E0

10 Structure, function and maintenance standard

Bkup speed sensor (G sensor)


(Cylinder No. sensor)
q

Similarly to the NE speed sensor, this sensor


utilizes the pulses of 0 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120.
In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine.
The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.

D275AX-5E0

SEN00935-00

Charge pressure sensor


q

This sensor is used to sense the charge pressure (boost pressure).

SEN00935-00

Charge temperature sensor


q

10

The charge temperature sensor senses the


intake air temperature (boost temperature) and
sends it to the engine controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.

10 Structure, function and maintenance standard

Coolant temperature sensor


q

The coolant temperature sensor senses the


coolant temperature and sends it to the engine
controller.
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.

D275AX-5E0

10 Structure, function and maintenance standard

Deceleration potentiometer

1.
2.
3.
4.
5.
6.
7.

Connector
Lever
Body
Potentiometer
Coupling
Shaft
Stopper

D275AX-5E0

SEN00935-00

Outline
q
The deceleration potentiometer is installed to
the front lower part of the operator's cab and
connected to the decelerator pedal by linkage.
q

If the decelerator pedal is pressed, the throttle


potentiometer shaft rotates by the linkage and
the potentiometer resistance changes.
Constant voltage is applied between pins A
and C of the potentiometer and an electric signal is sent through pin B to the steering controller according to the position of the
decelerator pedal.

11

SEN00935-00

10 Structure, function and maintenance standard

CRI engine control system


a

"CRI" is an abbreviation for Common Rail Injection.

System diagram

12

D275AX-5E0

10 Structure, function and maintenance standard

1.
2.
3.

4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

16.

NE speed sensor
Engine throttle controller
Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
Fuel cooler
Fuel tank
Strainer
Pre fuel filter (with water separator)
Priming pump
Fuel filter
Engine throttle controller cooler
Pressure limiter
Flow damper
High pressure injection pipe
Common rail
Fuel supply pump assembly
15A. PCV
15B. High pressure pump
15C. Priming pump
15D. Feed pump
15E. Bypass valve
15F. Bkup speed sensor (G sensor)
Overflow valve

Outline
q
The signals detected by various sensors are
input to the engine controller.
q
The input signals are processed by the controller and output to each actuator to control the
fuel injection rate and fuel injection timing.

D275AX-5E0

SEN00935-00

System configuration
q
The CRI system consists of fuel supply pump
(15), common rail (14), injector (3), engine
throttle controller (2) to control them, and sensors.
q
The fuel supply pump generates fuel pressure
in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply
pump. The discharge rate is controlled by
turning on and off PCV (discharge control
valve) (15A) of the fuel supply pump according
to the electric signals from the engine throttle
controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common
rail fuel pressure sensor installed to the common rail and controlled by the feedback
method so that the actual fuel pressure will
match to the command pressure set according
to the engine speed and the load on the
engine.
The fuel pressure in the common rail is applied
to the nozzle (3E) side of the injector and control chamber (3B) through the fuel injection
pipe of each cylinder.
q
The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve). If the TWV is
turned on, the fuel circuit is so changed that
the high-pressure fuel in the control chamber
will flow through orifice (3A). The needle valve
is raised to start fuel injection by the nozzle
cracking pressure applied as the high-pressure
fuel on the nozzle side. If the TWV is turned
off, the fuel circuit is so change that the highpressure fuel will be applied to the control
chamber through the orifice. As a result, the
needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and
fuel injection rate are controlled respectively by
the timing to turn on the TWV and the length of
the turn-on time of the TWV.

13

SEN00935-00

10 Structure, function and maintenance standard

Monitor system

The monitor system monitors the machine condition with the sensors installed to various
parts of the machine and processes and displays the obtained information on the panel
quickly to notify the operator of the machine
condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm
when the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids.

In the monitor panel, there are various mode


selector switches of the SSC (Shoe Slip Control), which are used to operate the machine
control system.

14

The monitor panel has functions of displaying


data and selecting the SSC mode.
The CPU (Central Processing Unit) in it processes, displays, and outputs the information.
The display unit is LCD (Liquid Crystal Display)
and the switches are seat switches.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Processing in monitor system (Common to all specifications)


Display of monitor panel
(1) Contents and conditions of processing
1)

(2) Method

(3) Flow of signals

Display of travel direction and gear speed.


F1, R3, etc. are notified by CAN according to information of transmission controller.

Transmission controllerSteering
controllerMonitor panel

2)

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

3)

CAN
Display of troubleshooting
When the machine has a trouble, the corresponding
failure code is notified to the monitor panel by CAN.
Which one should be turned on, the buzzer or the caution lamp, is notified, too.
(1) In normal state
User code
(2) In trouble history display mode
The service code (6-digit code) and the follow
ingitems are displayed
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrences
The monitor panel displays the code on the hour meter
section.

Each sensor/solenoidControllerMonitor panel

Display of monitoring condition


(1) Contents and conditions of processing
1)

(2) Method

(3) Flow of signals

The communication conditions of each sensor, each CAN


solenoid, and CAN are displayed.
The item Nos. and device conditions are notified to the
monitor panel by CAN.
The monitor panel displays the items and each value
on its multi-information section.

Each sensorControllerMonitor
panel

2) Each items is selected by using the cursor switches,


selector switches, buzzer cancel switch, and shift UP/
DOWN switches.

Monitor panelControllerMonitor panel

Other items
(1) Contents and conditions of processing
1)

2)
3)

4)

Function selection mode (Displayed each time cancel


switch is turned to left)
(1) Replacement periods of oil filter and oil are displayed.
(2) Engine speed, oil pressure in work equipment circuit, etc. are displayed.
(3) Failure codes related to electronic control are dis
played.
(4) Brightness of display, etc. are adjusted.
Mode to change replacement periods of maintenance
mode
Mode to display failure codes related to machine body
such as overheating, abnormal coolant temperature,
etc.
Mode to display service meter and information related
to load on machine

D275AX-5E0

(2) Method

(3) Flow of signals

15

SEN00935-00

10 Structure, function and maintenance standard

Monitor panel

Monitor portion

1.
2.
3.
4.
5.
6.
7.
8.

Display plate (Speed range display)


Charge lamp
Power train oil temperature gauge
Engine coolant temperature gauge
Fuel gauge
Hydraulic oil temperature gauge
Hydraulic oil temperature caution lamp
HSS charge pressure caution lamp

Outline
q
The monitor portion consists of a monitor that
issues an alarm when an error occurred in a
vehicle, a gauge that always displays the state
of the vehicle, and the service meter.
The monitor portion installs a microcomputer
and processes and displays signals from each
sensor.
Besides, the items displayed on the monitor
portion and gauge portion are listed in the table
on the next page.
Operation
1. When the power turns on (When the starter
switch is ON)
1) All items of the gauge and monitor portions come on for three seconds.
2) The alarm lamp comes on for two seconds.
2.

16

9.
10.
11.
12.
13.
14.
15.
16.

Power train oil temperature caution lamp


Engine coolant temperature caution lamp
Dual tilt display lamp
Engine oil pressure caution lamp
Maintenance caution lamp
Preheat pilot lamp
Radiator water level check lamp
Display plate (Multi information)
2)

3.

a
a

If the engine is started, the check items


before starting go off. (If the engine is running is judged by the signal (CAN) from
the engine controller.)

Cautions
Caution items are checked until the engine
stops after the engine starts.
If an error occurs, the error is displayed by
flashing and the alarm lamp synchronously
flashes.
Further, if an emergency item flashes, the
alarm buzzer also sounds synchronously.
Flashing of the monitor and alarm lamp is
repeated. They come on and off for about 0.8
second.
The flashing period of the monitor slightly
changes when atmospheric temperature is low
(below about 10C), but this case in not
abnormal.

Star-up inspection
1) After all lighting of Section 1 is terminated,
if there is an error in a start-up inspection
item, the item flashes.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Monitor panel displa


Symbol

Display item

Caution 1
Caution 2

Display method

Radiator water level

Below low level

Engine oil pressure

When sensor is abnormal or when wiring harness is disconnected

Display when normal: OFF


Display when abnormal: ON

Battery charge

When charge is defective

Displays when starting switch is ON and


engine is running
Display when normal: OFF
Display when abnormal: Flashes
CAUTION lamp also flashes

Engine oil pressure

Below 49.0kPa
{0.5kg/cm2}

Radiator water level

Below low level

SAP00522

Displays when starting switch is ON and


engine is running
Display when normal: OFF
Display when abnormal: Flashes
CAUTION lamp also flashes
Alarm buzzer sounds

Displays when starting switch is ON and


engine is running.
When in red range of
102C 107C (when at 1st level of red
Engine coolant tempera- coolant temperature
range) : Flashes
Min. 108C (when at 2nd level of red
ture
gauge
range): Flashes
(102C or above)
CAUTION lamp also flashes
Alarm buzzer sounds
Displays when starting switch is ON and
engine is running.
When in red range of
120C 129C (when at 1st level of red
Torque converter oil tem- power train oil tempera- range) : Flashes
Min. 130C (when at 2nd level of red
perature
ture gauge
range): Flashes
(120C or above)
CAUTION lamp also flashes
Alarm buzzer sounds
Displays when starting switch is ON and
engine is running.
When in red range of hy- 100C 109C (when at 1st level of red
draulic oil temperature range) : Flashes
Hydraulic oil temperature
Min. 110C (when at 2nd level of red
gauge
range): Flashes
(100C or above)
CAUTION lamp also flashes
Alarm buzzer sounds

HSS charge pressure

Maintenance

D275AX-5E0

Display range

Displays when engine is stopped and


starting switch is ON
Display when normal: OFF
Display when abnormal: Flashes

Check

Display
category

When HSS charge


pressure is reduced

Displays when starting switch is ON and


engine is running
Display when normal: OFF
Display when abnormal: Flashes
When replacement time CAUTION lamp also flashes
of filter or oil has been
Alarm buzzer sounds
passed

17

SEN00935-00

Display
category

Symbol

10 Structure, function and maintenance standard

Display item

Dual tilt

Display method

When preheating

When preheating: ON
(Engine controller determined at the time of preheat
by coolant temperature or
switch at preheat position
(turning it counterclockwise)
start the preheating.)

At the time of operation

Display lights at the time of


operation.
It goes off at the time of nonoperation.

Pilot

Preheating

Display range

Engine coolant temperature

One place lights up to show


applicable level

Gauges

Torque converter oil


temperature

Hydraulic oil temperature

All lamps light up below applicable level

Multi information

Fuel level

18

Service meter
(Hours meter)

From 0 to 99999

Actuated when the engine is


rotating

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

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 specifications.

SSC specifications

Without SSC specifications

Economy mode function


In a field, such as a rock-bed place where many
shoe slips are generated, the following power is
output in each mode so that the frequency of decelerator operation can decrease.
q
Economy mode 1 o Set to about 90% of the
full power.
q
Economy mode 2 o Set to about 70% of the
full power.
q
Reverse slow mode o Set to about 80% of the
full travel speed at reverse time.

D275AX-5E0

2.

Initial Setup at key ON


The function the operator desires according to
the situation of an operating place is selected
and all functions shall be set to the OFF state.

19

SEN00935-00

10 Structure, function and maintenance standard

Sensors

Type of sensor

Sensor method

When normal

When abnormal

Torque converter
oil temperature

Resistance

Hydraulic oil temperature

Resistance

Radiator water level

Contact

ON

OFF

Fuel level

Resistance

HSS charge pressure

Contact

ON

OFF

20

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Torque converter oil temperature sensor


Hydraulic oil temperature sensor

Radiator water level sensor

1.
2.
3.

Float
Sensor
Tube

D275AX-5E0

4.
5.

Wire
Connector

21

SEN00935-00

10 Structure, function and maintenance standard

Fuel level sensor

1.
2.
3.
4.
5.
6.
7.

22

Connector
Float
Arm
Body
Spring
Contact
Spacer

Function
q
The fuel sensor is installed to the side face of
the fuel tank. The float moves up and down
according go to the fuel level. This movement
of the float is transmitted by the arm and actuates a variable resistance. This sends a signal
to the monitor panel to indicate the remaining
fuel level. When the display on the monitor
panel reaches a certain level, a warning lamp
flashes.

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

HSS charging pressure sensor

1.
2.
3.
4.

Switch
Case
Wire
Connector

D275AX-5E0

23

SEN00935-00

10 Structure, function and maintenance standard

Mode selection system

(SSC (Shoe Slip Control) System)


System diagram

Outline
q
The mode selection system automatically carries out engine control to match the operating
mode selected by the operator, and acts to
reduce fuel consumption, extend the life of the
track shoes, and reduce the frequency of operation of the deceleration.
q
The engine control modes consist of the economy mode control used when dozing, the SSC
(shoe ship control) used when ripping, and the
reverse slow mode control, which can be used
for either operation.

24

The lock-up control mode is the same as the


conventional lock-up function. It cannot be
selected in combination with the above modes.

D275AX-5E0

10 Structure, function and maintenance standard

Function of model selection system


q

This system consists of the mode selection


panel (containing a microcomputer) to select
working condition, steering controller (containing a microcomputer) to control the engine,
engine controller to receive the commands
from the steering controller and controls the
fuel supply pump, transmission controller to
turn on and off the lock-up system of the torque
converter according to the signals from the
transmission output speed sensor, and various
sensors.
The function of each controller is explained
below.

SEN00935-00

Function of engine controller


1.

The engine controller controls the fuel supply


pump according to the lowest engine speed
(highest voltage) in the 3 signals of the manual
command input from the deceleration potentiometer, manual signal of the throttle dial, and
the SSC command signal.

Functions of steering controller and


transmission controller
1.

2.

3.

4.

The steering controller calculates the travel


speed to the ground from the signals of the
acceleration sensor and inputs the transmission output speed sensor signal to it to calculate the shoe speed, then obtains the shoe slip
rate.
If the engine speed sensor signal and transmission output speed sensor signal are input,
the steering controller calculates the traction
force.
The steering controller calculates the optimum
engine speed from the results of 1 and 2
above, mode set signal of the monitor panel,
and speed information from the transmission
controller, then sends it as the SSC command
to the engine controller.
The transmission controller sends the lock-up
signal to the lock-up solenoid valve, judging
from the input gear speed information of the
transmission controller.
a See "Operation of torque converter lockup control system".

D275AX-5E0

25

SEN00935-00

10 Structure, function and maintenance standard

Operation of mode selection system


q
Work can be performed under the optimum conditions by simply or simultaneously selecting five modes
in accordance with the contents of work
Work

Single
Mode
switch selection

Simultaneous
selection

Mode work condition

ON/OFF switching is automatically per- 1.


formed in accordance with a load.

Economy

1.

Low
High
speedside speedside

T/Coutput
shaftspeed

Dozing

Lock-up

Speednumber
ofgearratios

Mode operation, characteristic

F1

F2,F3,
R1,R2,R3

ON

1,230rpm
ormore

1,260rpm
ormore

2.
3.

OFF

1,200rpm
ormore

1,230rpm
ormore

4.

2,140rpm
ormore

ON
OFF

2,200rpm
ormore

When F1 is shifted with the economy 1.


mode switch [1] or [2] ON

2.

Reverse slow

3.
1.

When R1, R2, and R3 are shifted

1.
2.

SSC (Shoe Slip Control)

Ripping

The following conditions are satisfied:


1.
[1] When F1 is shifted.
[2] After the ripper down, ripper tilt levers
are actuated and the switch is set to ON
2.

3.

Rock-bed
selection

4.

26

When the torque converter approaches to


the stall area or performs gear shaft operation, lock-up is set to OFF. When the torque
converter reaches a light lode, lock-up is set
to ON.
Can be used in all number of gear ratios.
Simultaneous selection disabled with another mode
Suitable for dozing work of comparatively a
few load fluctuations

Set to ON in connection with SSC

1.
2.

When the economy mode ([1] or [2]) and


SSC are set simultaneously, the F1 shift
economy control is performed. When the ripper lever is actuated and the switch is turned
on, the slip control is performed.
The engine output can be suppressed in two
stages without performing the decelerator
operation of the engine.
Mode [1]: 90% (at 1.5 km/h)
Mode [2]: 65% (at 1.5 km/h)
At neutral time, the engine speed can be
suppressed partially
The engine speed can be suppressed without performing the decelerator operation of
the engine.
Target travel speed at reverse time
R1
R2 70% at full operation
R3
At start, to prevent rashing out, the modulating valve is actuated. At this time, the steering controller performs index characteristic
down of about 40% and performs the engine
outpuut control if a ripper down signal is input.
The seering controller performs the engine
output control in accordance with the index
force characteristic (refer to the rock-bed selection shown below) selected by the operator among the index force characteristics set
in five stages and suppresses the generation of a slip.
The steering controller regards the index
force immediately before the slip (exceeding
the shoe ripping ratio of 30% is generated,
as the maximum, and performs the engine
output control. At this time, the steering controller performs index characteristic down of
about 30 to 80% and performs the engine
outpuut control if a ripper tilt or ripper up signal is input.
At neutral time, the engine speed is suppressed partially.
When the SSC is set to ON, the selection
mode 3 comes on.
1i
o3 i
o 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.
D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Sensors
Transmission output shaft speed sensor

1.
2.
3.
4.
5.

Magnet
Terminal
Case
Boots
Connector

D275AX-5E0

27

SEN00935-00

10 Structure, function and maintenance standard

Acceleration sensor

1.
2.
3.

Sensor portion
Wire
Connector

Outline
q
The acceleration sensor is installed under the
front of the operator's cab.
q
With the acceleration sensor, the position of
the ball inside the sensor changes according to
the acceleration.
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
steering controller.
q
The input and output characteristics of the sensor are shown in the diagram on the right.

28

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Pitch angle sensor

1.
2.
3.
4.

Body
Tube
Wire
Connector

D275AX-5E0

29

SEN00935-00

Electrical equipment

10 Structure, function and maintenance standard

Relay box

30

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Operation of lamp system

Lamp system circuit diagram

D275AX-5E0

31

SEN00935-00

10 Structure, function and maintenance standard

Preheat (Electrical intake air heater) control

Preheat circuit

32

D275AX-5E0

10 Structure, function and maintenance standard

SEN00935-00

Palm Command Control System

1.
2.
3.
4.
5.

Monitor panel (Multi-information)


Auto shift-down switch
Engine throttle controller
Transmission controller
Steering controller

D275AX-5E0

6.
7.
8.
9.

Steering control valve


Transmission output speed sensor
Transmission control valve
Engine speed sensor

33

SEN00935-00

1.

2.

3.

10 Structure, function and maintenance standard

Shift Mode Function


Function
If you shift the lever to the forward or reverse,
the gear speed selected from the shift mode is
turned on.
q
Shift mode 1
q
Shift mode 2
Type of Modes
[1] F1-R2
[2] F2-R2
[3] F1-R1 (Manual mode)
Selecting method
Shift the steering or forward-reverse lever to N.
Shift up switch ON
Manual mode

Shit up switch ON
Shift mode 1

Shift down switch ON

4.

Displaying method
Monitor panel

Auto Shift-down Function


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.
Selecting method
Turn the auto shift-down switch (1) ON.
Operation and features of the mode
1) This function turns on the shift-down automatically by calculating the drawbar pull
(load to the machine body) based the
engine speed, transmission speed and
throttle information from the steering controller.
2) Once the machine is automatically shifted
down, shit-up wont be turned on automatically (shift up from the manual switch is
available, though).
3) This function is available for both the forward and reverse travel.

1.

2.
3.

34

Shift mode 2
Shift down switch ON

D275AX-5E0

10 Structure, function and maintenance standard

KOMTRAX terminal system

SEN00935-00

The KOMTRAX terminal system transmits various kinds of machine information wirelessly.
Persons to operate the KOMTRAX can refer to
the information at office to provide various
kinds of services for customers.
* Information transmittable from the KOMTRAX
terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.

D275AX-5E0

35

SEN00935-00

10 Structure, function and maintenance standard

KOMTRAX terminal

1.
2.
3.

Communication antenna connection


GPS antenna connection
DRC connector connection (40 poles)

Input and output signals


DRC conector
Pin No.
Signal name
Input/output
1
NC(*)

2
NC(*)

3
NC(*)

4
NC(*)

5
NC(*)

6
CAN shield GND

7
CAN signal (L)
Input/output
8
CAN signal (H)
Input/output
9
NC(*)

10
NC(*)
Input/output
11
NC(*)

12
NC(*)

13
NC(*)

14
NC(*)

15
NC(*)

16
NC(*)

17
NC(*)

18
NC(*)

19
NC(*)

20
Engine control output
Output
21
Action mode select 1
Input
22
Action mode select 2
Input
23
NC(*)

24
NC(*)

25
NC(*)

*: Never connect to NC or malfunctions or failures will


occur.

36

The KOMTRAX terminal obtains various kinds


of machine information from the network signals and input signal in the machine and transmits them via the wireless communication
antenna. It contains a CPU (Central Processing Unit) and has wireless communication
function and GPS function.
q
This terminal has an LED lamp unit and a 7segment display lamp unit used for inspection
and troubleshooting.
DRC conector
q

Pin No.
26
27
28
29
30
31
32
33
34
35
36
37
38

Signal name
Input/output
NC(*)

C-terminal input
Input
R-terminal input
Input
NC(*)

NC(*)

NC(*)

NC(*)

NC(*)

NC(*)

NC(*)

ACC input
Input
Power GND

Power GND

Electric power supply


39
Input
(+24V constantly)
Electric power supply
40
Input
(+24V constantly)
*: Never connect to NC or malfunctions or failures will
occur.

D275AX-5E0

SEN00935-00

10 Structure, function and maintenance standard

D275AX-5E0 Bulldozer
Form No. SEN00935-00

38

D275AX-5E0

SEN01413-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

20 Standard value table


Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 3

D275AX-5E0

SEN01413-00

20 Standard value table

Standard value table for engine

Category

Item

Speed

Machine model

D275AX-5E0

Engine

SAA6D140E-5

Measurement conditions
High idle
Engine coolant temperaLow idle
ture: Within operating
range
Rated speed

Unit

Standard value
for new machine

Service limit
value

rpm

2,150 25

2,150 25

rpm

700 50

700 50

rpm

2,000

2,000

Min. 169
{Min. 1,270}

144
{1,080}

Max. 620

670

%
(Bosch
index)

Max. 25
{Max. 2.5}

35
{3.5}

(Bosch
index)

Max. 1.0

2.0

Engine coolant temperature:


Within operating range
Intake air pressure
kPa
Power train oil temperature:
(Boost pressure)
{mmHg}
Within operating range
Torque converter: Stalled
Exhaust temperature

Whole speed range


(Outside temperature: 20C)

Exhaust gas color

At sharp accel Engine coolant tempera- eration


ture: Within operating
range
High idle
Intake valve

mm

0.35

Exhaust valve

mm

0.57

MPa
{kg/cm2}

Min. 4.1
{Min 42}

2.8
{29}

rpm

200 250

200 250

Max. 2.94
{Max. 300}

3.92
{400}

MPa
{kg/cm2}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

MPa
{kg/cm2}

Min. 0.10
{Min. 1.0}

0.08
{0.8}

90 110

120

Between water pump pulley alternator


Alternator belt tenpulley
sion
Deflection under finger pressure of 98 N
{10 kg}

mm

13 16

13 16

Between compressor pulley fan pulley


Air compressor belt
Deflection under finger pressure of 59 N
tension
{6 kg}

mm

Approx. 10

Approx. 10

Engine

Valve clearance

Normal temperature

Compression
Compression pres- Engine oil temperature: pressure
sure
40 60C
Engine speed

Blow-by pressure

Engine coolant temperature:


Within operating range
kPa
Power train oil temperature:
{mmH2O}
Within operating range
Torque converter: Stalled

SAE0W30EOS,
SAE5W40EOS,
High idle
SAE10W30DH,
Engine oil pressure
SAE15W40DH
SAE30DH Oil
Engine oil temperature: Low idle
Min. 80 C
Oil temperature

Whole speed range (In oil pan)

D275AX-5E0

20 Standard value table

SEN01413-00

Standard value table for machine

Machine model
Category

Item

Engine speed

Decelerator pedal
speed
Auto deceleration
speed
Torque converter
stall speed

Stroke of control lever/pedal

PCCS lever

Torque converter
stall + Work equipment relief speed

Measurement conditions
Engine coolant temperature:
Within operating range
Torque converter oil temperature:
Within operating range
Hydraulic oil temperature:
Within operating range
Decelerator pedal speed: Press pedal.
Auto deceleration speed:
Set all equipment in neutral.
Torque converter stall speed: F3
Torque converter stall + Work equipment relief speed: F3 + Ripper RAISE

Stop engine.
Operation of lever knob
Steering

900 50

2,000 25

2,000 25

1,620 50

1,510

1,580 50

1,450

30 10

30 10

30 10

30 10

Neutral o Left

40 10
(Play: Max. 3)

40 10
(Play: Max. 3)

Neutral o
Right

40 10
(Play: Max. 3)

40 10
(Play: Max. 3)

47 5

47 5

75 8

75 8

61 10

61 10

60 10
(84 10)

60 10
(84 10)

53 10

53 10

85 10

85 10

85 10

85 10

56.9 6.9
{5.8 0.7}

56.9 6.9
{5.8 0.7}

51 6.9
{5.2 0.7}

51 6.9
{5.2 0.7}

25.5 4.9
{2.6 0.5}

25.5 4.9
{2.6 0.5}

28.4 4.9
{2.9 0.5}

28.4 4.9
{2.9 0.5}

Neutral o
Reverse

Stop engine.
Pressing pedal

Brake pedal

Engine: Low idle


Pressing pedal

Blade lever

Neutral
Engine: Low idle
Raise/Lower
Hydraulic oil tempera(Float)
ture: Within operating
range
Neutral
Operation of lever knob Left/Right tilt

PCCS lever

Steering

Standard value for


Service limit value
new machine
900 50

Decelerator pedal

Forward and
reverse

Unit

rpm

Neutral o
Forward

Forward and
reverse

Ripper lever

Operating effort of control lever/pedal

D275AX-5E0

mm

mm
All stroke
Stroke to 0 of
oil pressure

Neutral
Engine: Low idle
Raise/Lower
Hydraulic oil temperature: Within operating
Neutral
range
Forward/
Operation of lever knob
Reverse tilt

mm

mm

mm

Neutral o
Forward/
Reverse
Forward/
Reverse o
Stop engine.
Neutral
Operation of lever knob
Neutral o
Left

N
{kg}

Neutral o
Right

Decelerator pedal

Stop engine.
Pressing pedal

N
{kg}

49.0 9.8
{5.0 1.0}

49.0 9.8
{5.0 1.0}

Brake pedal

Engine: Low idle


Pressing pedal

N
{kg}

490.0 49.0
{50.0 5.0}

490.0 49.0
{50.0 5.0}

D275AX-5E0

SEN01413-00

20 Standard value table

Machine model

Operating effort of control lever/pedal

Category

Item

Blade lever

Ripper lever

Measurement conditions

Power train oil pressure

Torque converter
stator clutch
pressure

Transmission main
relief pressure

Transmission F
clutch pressure

Transmission R
clutch pressure

Transmission 1st
clutch pressure

Transmission 2nd
clutch pressure

Torque converter oil


temperature: Within
operating range

Torque converter oil


temperature: Within
operating range

Standard value for


Service limit value
new machine
39.2 9.8
{4.0 1.0}

77.6 13.9
{7.9 1.4}

77.6 13.9
{7.9 1.4}

29.4 9.8
{3.0 1.0}

29.4 9.8
{3.0 1.0}

24.5 9.8
{2.5 1.0}

24.5 9.8
{2.5 1.0}

24.5 9.8
{2.5 1.0}

24.5 9.8
{2.5 1.0}

Engine:
Low idle

Max. 0.2
{Max. 2}

Max. 0.2
{Max. 2}

Engine:
High idle

0.49 1.0
{5 10}

0.49 1.0
{5 10}

Engine:
Low idle

Max. 0.2
{Max. 2}

Max. 0.2
{Max. 2}

0.49 0.1
{5 1}

0.49 0.1
{5 1}

1.27 0.2
{13 2}

1.27 0.2
{13 2}

Engine:
High idle

1.27 0.2
{13 2}

1.27 0.2
{13 2}

Engine:
Low idle

2.65 0.2
{27 2}

2.65 0.2
{27 2}

Engine:
High idle

2.65 0.2
{27 2}

2.65 0.2
{27 2}

Engine:
Low idle

2.74 3.06
{28 31.2}

Min. 2.65
{Min. 27}

Engine:
High idle

3.04 3.30
{31 33.7}

Min. 2.94
{Min. 30}

Engine:
Low idle

2.84 3.14
{29 32}

Min. 2.65
{Min. 27}

Engine:
High idle

3.14 3.43
{32 35}

Min. 2.94
{Min. 30}

Engine:
Low idle

2.84 3.14
{29 32}

Min. 2.65
{Min. 27}

3.14 3.43
{32 35}

Min. 2.94
{Min. 30}

Engine:
Low idle

2.84 3.14
{29 32}

Min. 2.65
{Min. 27}

Engine:
High idle

3.14 3.43
{32 35}

Min. 2.94
{Min. 30}

Engine:
Low idle

2.84 3.14
{29 32}

Min. 2.65
{Min. 27}

Engine:
High idle

3.14 3.43
{32 35}

Min. 2.94
{Min. 30}

Neutral o
Engine: Low idle
Raise/Lower
Hydraulic oil temperature: Within operating
range
Neutral o
Operation of lever knob
Tilt in/out

Torque converter
outlet pressure

Unit

39.2 9.8
{4.0 1.0}

Neutral o
Engine: Low idle
Raise/Lower
Hydraulic oil temperaNeutral o
ture: Within operating
Float
range
Operation of lever knob Neutral o
Left/Right tilt

Torque converter
inlet pressure

Torque converter
lock-up clutch
pressure

D275AX-5E0

Engine:
High idle
Engine:
Low idle

N
{kg}

N
{kg}

MPa
{kg/cm2}

MPa
{kg/cm2}
Engine:
High idle

D275AX-5E0

20 Standard value table

SEN01413-00

Machine model
Category

Item

Measurement conditions

Power train oil pressure

Transmission 3rd
clutch pressure
Transmission lubricating oil pressure
(For reference)
Steering left brake
pressure

Torque converter oil


temperature: Within
operating range

Steering right brake


pressure

Performance of power train

HSS
pressure

Ripper pin puller


operating pressure
HSS main relief
pressure
HSS charge relief
pressure

Travel speed

D275AX-5E0
Unit

Engine:
Low idle

2.84 3.14
{29 32}

Min. 2.65
{Min. 27}

Engine:
High idle

3.14 3.43
{32 35}

Min. 2.94
{Min. 30}

Engine:
High idle

0.05 0.29
{0.5 3.0}

0.05 0.29
{0.5 3.0}

2.84 3.14
{29 32}

Min. 2.26
{Min. 23}

3.14 3.43
{32 35}

Min. 2.45
{Min. 25}

Engine:
Low idle

2.84 3.14
{29 32}

Min. 2.26
{Min. 23}

Engine:
High idle

3.14 3.43
{32 35}

Min. 2.45
{Min. 25}

Engine:
High idle

3.14 3.43
{32 35}

Min. 2.45
{Min. 25}

38.2 41.7
{390 425}

38.2 41.7
{390 425}

2.6 3.4
{27 35}

2.6 3.4
{27 35}

F1

3.5 0.2

3.5 0.2

F2
Lock-up
F3
switch:
OFF R1
R2

6.6 0.3

6.6 0.3

10.6 0.6

10.6 0.6

4.6 0.2

4.6 0.2

8.5 0.4

8.5 0.4

R3

14.3 0.7

14.3 0.7

F1

3.6 0.2

3.6 0.2

Engine:
Low idle
Engine:
High idle

MPa
{kg/cm2}

Hydraulic oil temperature:


MPa
Within operating range
{kg/cm2}
Engine: High idle

Flat road
Engine coolant temperature: Within operating
range
Torque converter oil
temperature: Within
operating range
Engine: High idle
Run up distance:
10 30 m
Measuring distance:
20 m

F2
Lock-up
F3
switch:
ON R1
R2

km/h

km/h

R3

Work equipment oil pressure

Engine:
Low idle
Unload pressure

Blade lift relief


pressure

Blade tilt relief


pressure

D275AX-5E0

Hydraulic oil temperature: Within operating


range
Unload pressure: Set all
equipment in neutral.
Relief pressure: Set cylinder to stroke end.
LS pressure: Set cylinder to stroke end.

Standard value for


Service limit value
new machine

6.7 0.3

6.7 0.3

11.2 0.6

11.2 0.6

4.7 0.2

4.7 0.2

8.7 0.4

8.7 0.4

14.9 0.7

14.9 0.7

+1.37

2.45 +0

Engine:
High idle

{25

+14
+0 }

+1.37

2.45 +0
{25

+14
+0 }

27.44 1.37
{280 14}

27.44 1.37
{280 14}

27.44 1.37
{280 14}

27.44 1.37
{280 14}

Engine:
Low idle

27.44 1.37
{280 14}

27.44 1.37
{280 14}

Engine:
High idle

27.44 1.37
{280 14}

27.44 1.37
{280 14}

Engine:
Low idle
Engine:
High idle

MPa
{kg/cm2}

SEN01413-00

20 Standard value table

Machine model
Category

Item

Ripper tilt relief


pressure

LS pressure
(Load sensing
pressure)

Measurement conditions

Hydraulic oil temperature: Within operating


range
Unload pressure: Set all
equipment in neutral.
Relief pressure: Set cylinder to stroke end.
LS pressure: Set cylinder to stroke end.

Unit

Standard value for


Service limit value
new machine

Engine:
Low idle

27.44 1.37
{280 14}

27.44 1.37
{280 14}

Engine:
High idle

27.44 1.37
{280 14}

27.44 1.37
{280 14}

27.44 1.37
{280 14}

27.44 1.37
{280 14}

27.44 1.37
{280 14}

27.44 1.37
{280 14}

Engine:
Low idle

25.48 1.27
{260 13}

25.48 1.27
{260 13}

Engine:
High idle

25.48 1.27
{260 13}

25.48 1.27
{260 13}

3.43 +0.49
+0

+0.49
3.43 0.20

{35 +5
+0 }

+5
{35 2
}

3.14 3.92
{32 40}

3.14 3.92
{32 40}

Low idle

8 15

20

High idle

35

Low idle

1 1.5

High idle

1 1.5

Low idle

35

High idle

2.8 0.5

3.5

Low idle

35

High idle

2.8 0.5

3.5

Engine:
Low idle
Engine:
High idle

MPa
{kg/cm2}

Control circuit main


pressure
Hydraulic oil temperature:
(HSS, PPC, fan)
MPa
Within operating range
{kg/cm2}
Engine: High idle
PPC valve output
pressure

Raise

Work equipment oil pressure

Ripper lift relief


pressure

D275AX-5E0

Left tilt

Lower

sec
Hydraulic oil temperature: 45 55C
Apply no load to blade.
Between ground level
and rising end of blade

Work equipment speed

Work equipment

Blade lift

Blade tilt
Hydraulic oil temperature: 45 55C
Apply no load to blade.
Between left tilt end and
right tilt end

Right tilt

sec

D275AX-5E0

20 Standard value table

SEN01413-00

Machine model
Category

Measurement conditions

Unit

Standard value for


Service limit value
new machine

Low idle

58

10

High idle

2.8 0.5

3.5

Low idle

58

10

High idle

2.8 0.5

3.5

Low idle

69

12

High idle

2.8 0.5

3.5

Low idle

58

10

High idle

2.8 0.5

3.5

Low idle

7 10

13

High idle

2.8 0.5

3.5

Low idle

3.3 4.3

High idle

3.5 0.5

4.5

Low idle

12 18

21

High idle

4.5 0.5

5.5

Low idle

8 14

17

High idle

3.5 0.5

4.5

Left tilt

Item

D275AX-5E0

sec

Forward

Hydraulic oil temperature: 45 55C


Apply no load to blade.
Between left tilt end and
right tilt end

Right tilt

Blade dual tilt

sec
Backward

Hydraulic oil temperature: 45 55C


Apply no load to blade.
Between forward end
and backward end

Raise

Work equipment speed

Hydraulic oil temperature: 45 55C


Apply no load to ripper.
Between ground level
and rising end of blade

sec

Tilt in

Ripper lift

Lower

Work equipment

Blade pitch

D275AX-5E0

Hydraulic oil temperature: 45 55C


Apply no load to ripper.
Between tilt-in end and
tilt-out end

sec
Tilt out

Ripper tilt

SEN01413-00

20 Standard value table

Machine model
Category

Item

Time lag

Blade

Ripper

D275AX-5E0

Measurement conditions
Hydraulic oil temperature:
45 55C
Move lever to stroke end.
Lower blade from max. rising position and measure
time after blade comes in
contact with ground until
idler is lifted.
Hydraulic oil temperature:
45 55C
Move lever to stroke end.
Lower ripper from max. rising position and measure
time after ripper comes in
contact with ground until
sprocket is lifted.

Unit

Standard value for


Service limit value
new machine

Low idle

Max. 8

11

High idle

Max. 1.8

2.5

Low idle

Max. 6

High idle

Max. 1.5

2.5

Max. 200/15
minutes

300/15 minutes

Max. 50/5 minutes

100/15 minutes

Max. 50/5 minutes

100/15 minutes

sec

Hydraulic drift
of lifted blade

Hydraulic drift

Work equipment

Hydraulic oil temperature: 45 55C


Engine: Stopped
Measure reduction of blade bottom
height h (for 15 minutes).

Hydraulic drift
of machine
lifted by blade

mm

Hydraulic oil temperature: 45 55C


Engine: Stopped
Measure reduction of idler center height
h (for 5 minutes).

Hydraulic drift
of machine
tilted by blade
Hydraulic oil temperature: 45 55C
Engine: Stopped
Measure reduction of idler center height
h (for 5 minutes).

D275AX-5E0

20 Standard value table

SEN01413-00

Machine model
Category

Item

D275AX-5E0

Measurement conditions

Unit

Hydraulic oil temperature: 45 55C


Engine: Stopped
Measure reduction of shank bottom
height h (for 15 minutes).

Hydraulic drift

Work equipment

Hydraulic drift
of lifted ripper

Standard value for


Service limit value
new machine

Max. 80/15
minutes

160/15 minutes

Max. 30/5 minutes

60/5 minutes

16

16

16

450 30

400

1,450 50

1,350

16.17 19.11
{165 195}

16.17 19.11
{165 195}

mm

Hydraulic drift
of machine
lifted by ripper

Cooling fan

Leakage from cylinder

Hydraulic oil temperature: 45 55C


Engine: Stopped
Measure reduction of sprocket center
height h (for 5 minutes).
Blade tilt
cylinder
Ripper lift
cylinder
Ripper tilt
cylinder

Fan speed

Fan pump oil


pressure

D275AX-5E0

Engine: High idle


Hydraulic oil temperature: 45 55C
Relieve cylinder and measure leakage
for 1 minute.

Fan: 100% speed mode


Engine: Low idle

Min.
speed

Fan: 100% speed mode


Engine: High idle

Max.
speed

Fan: 100% speed mode


Engine: High idle

cc/min

rpm

MPa
{kg/cm2}

SEN01413-00

20 Standard value table

D275AX-5E0 Bulldozer
Form No. SEN01413-00

10

D275AX-5E0

SEN01414-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

30 Testing and adjusting

Testing and adjusting, Part 1


Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 6
Testing intake air pressure (Boost pressure) .................................................................................................. 9
Testing exhaust temperature..........................................................................................................................11
Testing exhaust gas color ............................................................................................................................. 13
Adjusting valve clearance ............................................................................................................................. 15
Testing compression pressure ...................................................................................................................... 17
Testing blow-by pressure .............................................................................................................................. 19
Testing engine oil pressure ........................................................................................................................... 20
Handling of fuel system devices ................................................................................................................... 21
Releasing residual pressure from fuel system .............................................................................................. 21
Testing fuel pressure..................................................................................................................................... 22
Testing fuel return rate and fuel leakage....................................................................................................... 23
Bleeding air from fuel circuit.......................................................................................................................... 27
Testing fuel circuit for leakage....................................................................................................................... 29
Testing and adjusting alternator belt tension................................................................................................. 30

D275AX-5E0

SEN01414-00

30 Testing and adjusting

Testing and adjusting air conditioner compressor belt .................................................................................. 31


Testing fan speed .......................................................................................................................................... 32
Testing fan circuit oil pressure....................................................................................................................... 33
Bleeding air from fan pump ........................................................................................................................... 34
Adjusting fuel control dial and decelerator pedal .......................................................................................... 35

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing and adjusting item

Symbol

Testing intake air


pressure (boost pressure)

Testing exhaust
temperature
Testing exhaust gas color

799-201-2202 Boost gauge kit

Commercially
Thickness gauge
available

E
2
F

101 200 kPa


{760 1,500 mmHg}
1 99.9 1,299C
1 For Pm clinic specification
1 Pollution level: 0 70%
(With standard color)
1 (Pollution level x 1/10 C Bosch index)
1

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

2 799-401-2320 Hydraulic tester

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

2 799-401-2320 Hydraulic tester


3
1
2
3
Testing fuel return rate
and fuel leakage

J 4
5
6

Testing fan speed

795-471-1450
07005-00812
6151-51-8490
6206-71-1770
Commercially
available
Commercially
available
Commercially
available

1
8 1.25 mm o R1/8
1
1 Inside diameter: 14 mm
1 Inside diameter of joint: 10 mm

Hose

1 5 mm 2 3 m

Hose

1 15 mm 2 3 m

Measuring cylinder

Commercially
Stopwatch
available
795-205-1100 Tachometer kit

1 6.0 99999.9 rpm

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester


2 799-401-3400 Adapter
799-101-5220 Nipple
3
07002-11023 O-ring

D275AX-5E0

Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
{600 kg/cm2}
Pressure gauge: 0.98 MPa
{10 kg/cm2}
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
{600 kg/cm2}
Pressure gauge: 0.98 MPa
{10 kg/cm2}

Adapter
Gasket
Spacer
Joint

1
Testing fan circuit
pressure

Air intake: 0.35 mm,


Exhaust: 0.57 mm

795-471-1330 Adapter
6261-71-6150 Gasket
799-201-1504 Blow-by checker

1
Testing fuel pressure

Remarks

1
G

2
1 0 6.9 MPa {0 70 kg/cm }
KIT No.: 795-502-1205
1
1
1

1 795-502-1590 Compression gauge

Testing blow-by pressure

Testing engine oil


pressure

Part name

B
799-101-1502 Digital thermometer

799-201-1150 Adapter connector


1 799-201-9001 Handy smoke checker
C
Commercially
2
Smoke meter
available

Adjusting valve clearance

Testing compression
pressure

Part No.

Q'ty

Tools for testing, adjusting, and troubleshooting

1
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}
1 Size: 05

1 Size: 10 1.25 mm

Testing and adjusting item

30 Testing and adjusting

Symbol

Part No.

Part name

799-101-5220 Nipple
07002-11023 O-ring
799-101-5002 Hydraulic tester

1
790-261-1204 Digital hydraulic tester

2 799-401-2320 Hydraulic tester


3

799-101-5220 Nipple
07002-11023 O-ring
799-101-5002 Hydraulic tester

Testing and adjusting HSS


P
oil pressure

1
790-261-1204 Digital hydraulic tester

799-101-5220
07002-11023
19M-06-32820
1 7824-66-6430
Emergency escape when
Q
power train has trouble
17M-06-41530
2 790-190-1600
2

Nipple
O-ring
Switch assembly
Resistor
Wiring harness
Pump assembly

799-101-5002 Hydraulic tester


Testing and adjusting work
R
equipment oil pressure

1
790-261-1204 Digital hydraulic tester
2

1
Testing control circuit
basic pressure

790-261-1204 Digital hydraulic tester

S
2

Testing ripper pin puller


solenoid valve outlet
pressure

799-101-5002 Hydraulic tester

1 Size: 02
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}

Oil pressure pickup


adapter
02896-11008 O-ring
Oil pressure pickup
799-401-3200
adapter
3
02896-11009 O-ring

799-101-5002 Hydraulic tester

799-401-3100

1
790-261-1204 Digital hydraulic tester

U
2

Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}

790-261-1204 Digital hydraulic tester


T

Oil pressure pickup


adapter
02896-11008 O-ring

799-401-3100

1
Testing PPC valve output
pressure

Remarks

Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}
Pressure gauge: 0.98 MPa
1
{10 kg/cm2}
1 Size: 10 1.25 mm
1
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}
1 Size: 10 1.25 mm
1
1
1
1
1
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
1
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}
1 Size: 10 1.25 mm
1

799-101-5002 Hydraulic tester

Testing power train oil


pressure

Q'ty

SEN01414-00

Oil pressure pickup


adapter
02896-11009 O-ring

799-401-3200

1 Size: 02
1
1 Size: 03
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 58.8 MPa
1
{600 kg/cm2}

1 Size: 03
1

D275AX-5E0

30 Testing and adjusting

Testing leakage in work


equipment cylinder
Testing coolant
temperature and oil
temperature
Testing operating effort
and pressing force
Testing stroke and
hydraulic drift
Testing work equipment
speed
Testing voltage and
resistance

Symbol

Part name

Q'ty

Testing and adjusting item

SEN01414-00

Commercially
Measuring cylinder
available

799-101-1502 Digital thermometer

1 99.9 1,299C

79A-264-0021
79A-264-0091
Commercially
available
Commercially
available

Push-pull scale
Push-pull scale

1 0 294 N {0 30 kg}
1 0 490 N {0 50 kg}

Ruler

Stopwatch

Part No.

Commercially
Circuit tester
available

Remarks

For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see Troubleshooting (Information related to troubleshooting), "List of T-boxes and T-adapters".

D275AX-5E0

SEN01414-00

Testing engine speed


k

1.

2.

30 Testing and adjusting

3.

Testing high idle speed


1) Start the engine and set the fuel control
dial in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and test the engine
speed.
a The high idle speed tested in the "Monitoring mode" or in the "Pm Clinic auxiliary
mode" is the auto-deceleration speed.
a When testing the high idle speed of the
engine, use the "Adjustment mode".
Adjustment code:
0007 (Engine decelerator cut mode)

4.

Testing decelerator pedal speed


1) Start the engine and set the fuel control
dial in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and press the
decelerator pedal and test the engine
speed.

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the engine speed under the following condition.
q
Engine coolant temperature:
Within operating range
q
Hydraulic oil temperature:
Within operating range
q
Power train oil temperature:
Within operating range
Preparation work
Turn the starting switch ON and set the
machine monitor in the "Monitoring mode" to
prepare for test of the engine speed.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
q
Monitoring code: 01000 (Engine speed)

Testing low idle speed


1) Start the engine and set the fuel control
dial in the low idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and test the engine
speed.

D275AX-5E0

30 Testing and adjusting

5.

Testing torque converter stall speed


q
Adjustment mode:
0530 (Stall speed check mode)
k This machine is equipped with the
cooling fan speed control function to
protect the radiator when the engine is
not fully warmed up. Since that function does not work while this mode is
used, warm up the engine fully before
using this mode.
1) Start the engine and set the fuel control
dial in the low idle position.
2) With the brake pedal depressed securely
and the parking brake lever in the free
position, set the PCCS lever in the forward and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the monitor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
5) Just after the power train oil temperature
gauge reaches position (a) of the green
range, return the direction of the PCCS
lever into neutral.

6)
7)

SEN01414-00
a
6.

After finishing measurement, finish


the Adjustment mode.

Measuring torque converter stall + work


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

Repeat above steps 2) 5) 3 times.


Perform steps 2) 4) again and measure
the engine speed when the power train oil
temperature gauge reaches position (a) of
the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.

D275AX-5E0

SEN01414-00

7)
8)

Repeat above steps 2) 6) 3 times.


Perform steps 2) 4) and also operate ripper RAISE relief and pitch back relief and
measure the engine speed when the
power train oil temperature gauge reaches
position (a) of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
a After finishing measurement, finish
the Adjustment mode.

30 Testing and adjusting


a

The engine speed can be tested in the "Pm


Clinic auxiliary mode" of the machine monitor
(Test the high idle speed of the engine in the
"Adjustment mode", however).

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing intake air pressure (Boost


pressure)
1
a

Install nipple [1] of boost gauge kit A and connect gauge [2].

4.

Run the engine at medium or higher speed and


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

5.

Run the engine at high idle and stall the torque


converter and test the intake air pressure
(boost pressure) at this time.
a For the procedure for stalling the torque
converter, see "Testing engine speed".
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is operated at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque converter.

6.

After finishing test, remove the testing instrument and return the removed parts.

Testing instruments for intake air pressure


(boost pressure)

Symbol

Part No.

799-201-2202

a
k

3.

Part name
Boost gauge kit

A nipple (quick coupler) is installed to the


intake air pressure (boost pressure) testing
port of the Pm clinic specification machine.
Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
When installing and removing the testing
instrument, take care not to touch a hot
part.
Test the intake air pressure (boost pressure)
under the following condition.
q
Engine coolant temperature:
Within operating range
q
Torque converter oil temperature:
Within operating range
q
Hydraulic oil temperature:
Within operating range

1.

Open the right side cover of the engine.

2.

Remove boost pressure testing plug (1).

D275AX-5E0

SEN01414-00
a

The boost pressure can be tested in the "Pm


Clinic auxiliary mode" of the machine monitor.

The boost pressure displayed in the Pm clinic


auxiliary mode is absolute pressure.

10

30 Testing and adjusting

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing exhaust temperature


a

3.

Install sensor [1] of digital thermometer B and


connect them to meter [2].
a Clamp the wiring harness of the digital
thermometer so that it will not touch a hot
part during measurement.

4.

Procedure for testing maximum exhaust temperature for troubleshooting


Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital thermometer.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q
Corrected value [C] = Measured value
+ 2 x (20 Outside air temperature)

Testing instrument for exhaust temperature

Symbol

Part No.

799-101-1502

Part name
Digital thermometer

Testing instruments for exhaust temperature


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

Symbol

Part No.

799-101-1502

Digital thermometer

799-201-1150

Adapter connector

Part name

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Install and remove the testing instrument
after the exhaust manifold is cooled.
Test the exhaust temperature under the following condition.
q
Engine coolant temperature:
Within operating range
q
Torque converter oil temperature:
Within operating range
q
Hydraulic oil temperature:
Within operating range

1.

Open the engine right side cover.

2.

Remove 1 exhaust temperature pickup plug (1)


under the turbocharger.
a You may remove either of the right and left
plugs.

D275AX-5E0

11

SEN01414-00

5.

12

Procedure for measuring exhaust temperature


periodically for preventive maintenance (Pm
clinic)
a If the torque converter is stalled simply,
the torque converter oil temperature is
overheated before the exhaust temperature is stabilized. Accordingly, test according to the following procedure.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650C
according to the following procedure
(Condition a in the figure).
i) Start the engine and set the fuel control dial to the low idle position. Raise
the ripper lift cylinder to the stroke
end with the ripper lever.
ii) Press the brake pedal securely and
set the PCCS lever in the FORWARD
3rd gear speed position.
iii) Press the decelerator pedal and set
the fuel control dial to the high idle
position.
iv) Return the decelerator pedal slowly to
stall the torque converter and relieve
the ripper in raising direction with the
engine at high idle.
k Press the brake pedal securely and
keep your right foot on the decelerator pedal for safety until the work
is finished.
2) Stop only relieving the ripper and lower
the exhaust temperature by only stalling
the torque converter (Condition b in the
figure).
a If the temperature does not lower but
rises, set the temperature in step 1).
3) After the temperature lowers and is stabilized, measure it (Condition c in the figure).

30 Testing and adjusting


k

6.

Just after the torque converter oil temperature gauge reads the red range,
return the direction of the PCCS lever
into neutral and lower the torque converter oil temperature.

After finishing test, remove the testing instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing exhaust gas color


a

Testing instrument for exhaust gas color

Symbol
C
k

1.

Part No.

Part name

799-201-9001

Handy smoke checker

Commercially
available

Smoke meter

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
When installing and removing the testing
instrument, take care not to touch a hot
part.
If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
Test the exhaust gas color under the following
condition.
q
Engine coolant temperature:
Within operating range
Measuring with handy smoke checker C1
1) Stock a sheet of filter paper to C1.
2) Insert the exhaust gas intake pipe in the
exhaust pipe.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas.

5)
6)

2.

Testing with smoke meter C2


1) Insert probe [1] of smoke meter C2 in the
outlet of the exhaust pipe and fix it to the
exhaust pipe with a clip.

2)

3)

4)

5)

Connect the probe hose, receptacle of the


accelerator switch, and air hose to smoke
meter C2.
a Limit the supplied air pressure to 1.5
MPa {15kg/cm2}.
Connect the power cable to a receptacle
of AC power supply.
a Before connecting the cable, check
that the power switch of the smoke
meter is turned off.
Before connecting the cable, check that
the power switch of the smoke meter is
turned off.
a Fit the filter paper securely so that the
exhaust gas will not leak.
Turn on the power switch of smoke meter
C2.

Remove the filter paper and compare it


with the attached scale.
After finishing test, remove the testing
instrument and return the removed parts.

D275AX-5E0

13

SEN01414-00

6)
7)

8)

9)

14

30 Testing and adjusting

Start the engine.


Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter C2 and collect the
exhaust gas into the filter paper.
Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
After finishing test, remove the testing
instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Adjusting valve clearance


a

Adjusting instrument for valve clearance

Symbol

Part No.

Commercially
available

1.

2.

3.

Part name
Thickness gauge

When the No. 1 cylinder piston is at the


compression top dead center, the No. 1
cylinder rocker arm can be moved with the
hand by the valve clearance. If the rocker
arm does not move, the piston is not at the
compression top dead center. In this case,
revolve the crankshaft 1 more turn.

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Open the inspection cover under the universal
joint (1) and disconnect universal joint (1) from
the engine.

4.

While fixing adjustment screw (6), loosen locknut (7).


a After setting the No. 1 cylinder to the compression top dead center, adjust its valve
clearance.

5.

Insert thickness gauge D in clearance (b)


between rocker arm (4) and cross head (5) and
adjust the valve clearance with adjustment
screw (6).
a Adjust the adjustment screw with the
thickness gauge inserted so that the filler
gauge can be moved lightly.

6.

Fix adjustment screw (6) and tighten locknut


(7).
3 Locknut:
45.1 51.0 Nm {4.6 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.

Open the right side cover of the engine and


remove all cylinder head covers (2).

Rotate the crankshaft forward and set line (a)


of "1.6TOP" of the damper to pointer (3) to set
the No. 1 cylinder piston to the compression
top dead center.
a Rotate the hexagonal part (c) of the water
pump drive shaft end to crank the engine.

D275AX-5E0

15

SEN01414-00

7.

Rotate the crankshaft forward by 120 and


repeat steps 3 6 for each cylinder in the firing
order.
q
Firing order: 1 5 3 6 2 4

8.

After finishing adjustment, return the removed


parts.
3 Cylinder head cover mounting bolt:
29.4 34.3 Nm {3.0 3.5 kgm}
3 Universal joint mounting bolt:
98.0 122.5 Nm {10.0 12.5 kgm}

16

30 Testing and adjusting

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing compression pressure


a

Testing tools for compression pressure

Symbol
1
E
k

1.

Part No.

Part name

795-502-1590

Compression gauge

795-471-1310

Adapter

6261-71-6150

Gasket

Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
remove the injector wiring harness
(Loosen the 2 terminal nuts alternately).
Pass a wire under the fuel path projected
sideways and pull up the injector (Do not
pry the injector top up).

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
When testing the compression pressure,
take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Test the compression pressure under the following conditions.
q
Engine oil temperature: 40 60 C
Remove the engine hood assembly and air
cleaner together.
4

2.

5.

Install adapter E2 to the mounting hole on the


injector and connect compression gauge E1.
a Be sure to fit the gasket to the injector
end.
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.

6.

Install rocker arm assembly (2) and adjust the


valve clearance.
3 Rocker arm mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a See "Adjusting valve clearance".

Engine hood assembly: 170 kg

Remove cylinder head cover (1) of the cylinder


to test the compression pressure.

3.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a For the procedure for bringing each cylinder to the compression top dead center,
see "Adjusting valve clearance".

4.

Disconnect fuel high-pressure tube (3) and


injector wiring harness (4) and remove injector
(5) and wiring harness.

D275AX-5E0

17

SEN01414-00

7.

8.

Disconnect power supply connector EGC3 (6)


of the engine controller.
k If this connector is not disconnected,
the engine will start during test and will
be dangerous. Accordingly, be sure to
disconnect this connector.
k Cover the controller side and wiring
harness side with vinyl sheets, etc. to
prevent electric leakage and ground
fault.
a If the starting switch is turned ON while
the connector is disconnected, errors are
made in the engine controller CAN communication etc.

Turn the starting switch ON and set the


machine monitor to real-time monitoring mode
of the service mode.
q
Monitoring code: 01000 Engine Speed
a For the operating method, see "Special
functions of machine monitor (EMMS)".

30 Testing and adjusting

9.

Rotate the engine with the starting motor and


test the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
a When testing the compression pressure,
check that the engine speed is in the
range of the test condition.

10. After finishing test, remove the testing instruments and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
a Before installing the injector, replace the
copper gasket and O-ring with new ones.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) temporarily.
2 Spherical part of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt: 58.8 73.5 Nm {6 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}

a
1)

2)
3)
4)

18

Install the injector wiring harness according to the following procedure.


Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate.
Fix the intermediate clamp with the clip.
Tighten the nut on the injector side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
Secure the clamp and spacer with the
bolt.
3 Rocker arm assembly mounting
bolt: 93 103 Nm {9.5 10.5 kgm}
Adjust the valve clearance. For details,
see "Adjusting valve clearance".
3 Cylinder head cover mounting bolt:
29.4 34.3 kgm {3.0 3.5 kgm}

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing blow-by pressure


a

Testing instrument for blow-by pressure

Symbol

Part No.

799-201-1504

Part name
Blow-by checker

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the blow-by pressure under the following
condition.
q
Engine coolant temperature:
Within operating range
q
Torque converter oil temperature:
Within operating range
q
Hydraulic oil temperature:
Within operating range

1.

Open the left side cover of the engine and pull


out blow-by hose (1).

2.

Install nozzle [1] of blow-by checker F to the


end of blow-by hose (1).

3.

Connect hose [2] and then connect it to gauge


[3].

4.

Run the engine at high idle, stall the torque


converter, and test the blow-by pressure.
a For the procedure for stalling the torque
converter, see "Testing engine speed".
a Normally, the blow-by pressure should be
tested while the engine is operated at the
rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
test while the engine is running at high
idle. The value obtained in this case is
about 80% of the blow-by pressure at the
rated output.

D275AX-5E0

5.

The blow-by pressure may vary largely


with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterioration speed of oil, etc. which are related
to the abnormal blow-by pressure.

After finishing test, remove the testing instrument and return the removed parts.

19

SEN01414-00

30 Testing and adjusting

Testing engine oil pressure


a

1
2

a
a

Part No.

Run the engine at low idle and high idle and


measure the engine oil pressure in each
speed.

4.

After finishing test, remove the testing instruments and return the removed parts.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
A nipple (quick coupler) is installed to the
engine oil pressure switch mounting part of the
Pm clinic specification machine.
Measure the engine oil pressure under the following condition.
q
Engine coolant temperature:
Within operating range

1.

Open the engine left side cover and remove


engine oil pressure pickup plug (1) from the
cylinder block.

2.

Install nipples [1] and [2] of hydraulic tester G1


and connect them to hydraulic tester G2.
a Since the size of plug holes is R 1/4, you
may use quick nipples (799-101-5210)
instead of nipples [1] and [2].

20

3.

Testing instruments for engine oil pressure

Symbol
G

D275AX-5E0

30 Testing and adjusting

Handling of fuel system devices 1


a

Precautions for testing and adjusting fuel system


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

D275AX-5E0

SEN01414-00

Releasing residual pressure from


fuel system
1
a

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

21

SEN01414-00

30 Testing and adjusting

Testing fuel pressure


a

1
2
3
k

a
k

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

795-471-1450

Adapter

07005-00812

Gasket

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be tested.

1.

Open the engine left side cover and remove


fuel pressure pickup plug (1) from the top of
the fuel filter.

2.

Install adapter H3 and elbow [1] and nipple [2]


of hydraulic tester H1 and connect them to
hydraulic tester H2.

22

3.

Testing instruments for fuel pressure

Symbol

4.

Run the engine at high idle and test the fuel


pressure.
a If the fuel pressure is in the following
range, it is normal.
Engine speed

Fuel pressure

High idle

0.15 0.3 MPa


{1.5 3 kg/cm}

After finishing test, remove the testing instruments and return the removed parts.
3 Plug (1): 7.84 9.8 Nm {0.8 1.0 kgm}

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing fuel return rate and fuel leakage

Testing instruments for return rate and fuel


leakage

Symbol

a
k

Part No.

Part name

6151-51-8490

Spacer

6206-71-1770

Joint

Commercially available Hose

Commercially available Hose

Commercially available Measuring cylinder

Commercially available Stopwatch

Prepare an oil pan of about 20 l to receive the


fuel flowing out during the test.
Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.

D275AX-5E0

23

SEN01414-00

1.

30 Testing and adjusting

Preparation work
1) Open the engine left side cover and left
mudguard.
2) Remove tube (3) between supply pump
(1) and common rail (2).
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Disconnect both ends of the tube,
loosen the clamp, and move the tube
to the opposite side of the cylinder
block.

5)

2.

24

3)

Insert spacer J1 on supply pump (1) side


and tighten the removed joint bolt again.
a Connect the return pipe to the fuel
tank again, too.
a Be sure to fit the gaskets to both ends
of the spacer.

4)

Insert joint J2 on common rail (2) side and


tighten the removed joint bolt again.
a In the figure, 1 oil filter is removed
temporarily from the common rail
side.
a Be sure to fit the gaskets to both ends
of the joint.

Connect test hose J3 to the end of joint


J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.

Testing leakage from pressure limiter


1) Lay test hose J3 so that it will not slacken
and put its end in the oil pan.
2) Warm up the machine sufficiently.
k If it is not, the radiator may be broken.
3) Turn the starting switch ON and set the
machine monitor to Monitoring function of
the service mode.
q
Adjustment code:
0530 (Stall speed check mode)
a For the operating method, see "Special functions of machine monitor
(EMMS)".

4)

Run the engine at high idle and stall the


torque converter. After the engine speed
is stabilized, measure the leakage in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see "Testing torque
converter stall speed" of "Testing
engine speed".
a You may test the leakage for 20 seconds and judge by multiplying the
result by 3.
D275AX-5E0

30 Testing and adjusting


a

If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
Install torque

converter

5)
3.

SEN01414-00

4)

Turn the starting switch ON set the


machine monitor to Adjusting function of
the service mode.
q
Adjustment code:
0530 (Stall speed check mode)
a For the operating method, see "Special functions of machine monitor
(EMMS)".

5)

Run the engine at high idle and stall the


torque converter. After the engine speed
is stabilized, measure the return rate in 1
minute with measuring cylinder J5.
a For the procedure for stalling the
torque converter, see "Testing engine
speed".
a You may measure the return rate for
20 seconds and judge by multiplying
the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.

Leakage
(cc/min)
Max. 10

After finishing test, stop the engine.

Testing return rate from injector


a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injector.
1) Disconnect return hose (5) of return block
(4) and connect test hose J4.
a Stop the return hose with a plug, etc.
and fix it to the fuel tank.
Plug: 07376-70315
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose J4 so that it will not slacken
and put its end in the oil pan.

Torque converter
stall speed (rpm)

3)

Limit of return rate


(spill) (cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1.200

Warm up the machine sufficiently.


If it is not, the radiator may be broken.

D275AX-5E0

25

SEN01414-00

6)
4.

26

30 Testing and adjusting

After finishing testing, stop the engine.

Work after finishing testing


After finishing all testing, remove the testing
instruments and return the removed parts.

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Bleeding air from fuel circuit

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure.

1.

Open the engine left side cover.

2.

Remove fuel prefilter (1) and fill it with fuel.


a Fill the fuel prefilter with clean fuel and
take care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel prefilter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the fuel prefilter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the prefilter but fill it with the fuel
by operating priming pump (4).
a Do not add fuel to fuel main filter (2) from
outside.

D275AX-5E0

3.

Install fuel prefilter (1) to the filter head.


a Apply engine oil thinly over the packing on
the fuel prefilter side.
a After the packing of the fuel prefilter
touches the sealing face of the filter head,
tighten the fuel prefilter 3/4 turns.

27

SEN01414-00

30 Testing and adjusting

7.

4.

Remove air bleed plug (3) of fuel main filter (2)


and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}

5.

Remove air bleed plug (5) of the fuel main filter


and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleed plug:
7.8 9.8 Nm {0.8 1.0 kgm}

6.

Loosen air bleeder (6) of the supply pump and


operate priming pump (4) 90 100 times.
a Operate the priming pump until the fuel
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
a Air bleeder: 4.9 6.9 kgm {0.5 0.7 kgm}

28

Start the engine with the starting motor.


a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 4.

D275AX-5E0

30 Testing and adjusting

Testing fuel circuit for leakage


k

a
a

SEN01414-00

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing and
installing its parts, test it for fuel leakage
according to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.

1.

Spray color checker (developer) over the joints


of the fuel supply pump, common rail, fuel
injector, and high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and


stop it after its speed is stabilized.

3.

Check the fuel piping and devices for fuel leakage.


a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

4.

Run the engine at low idle.

5.

Check the fuel piping and devices for fuel leakage.


a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

6.

Run the engine at high idle.

7.

Check the fuel piping and devices for fuel leakage.


a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.

8.

Run the engine at high idle and load it.


a Relieve the ripper circuit by raising the ripper.

D275AX-5E0

9.

Check the fuel piping and devices for fuel leakage.


a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
a If no fuel leakage is detected, inspection is
completed.

29

SEN01414-00

Testing and adjusting alternator


belt tension
1
k

30 Testing and adjusting

6.

Install belt cover (1) with the 2 mounting bolts.


a Check for breakage of the pulleys, wear of
the V-grooves, contact of the belts and Vgrooves, and contact of the belt covers
and rotating parts.
a If the belt is lengthened to the adjustment
limit, cut, or cracked, replace it with new
one.
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
a After tightening the bolts, check that the
belt tension is normal according to the
above procedure.

7.

After testing and adjusting, return the removed


parts.

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.

Testing
1. Open the engine right side cover and remove
the inspection plate on the right of the radiator
guard.
2.

Press the intermediate point of the belt


between alternator pulley and water pump pulley with a finger and measure deflection (a) of
the belt.
a Pressing force:
Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 16 mm

Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1.

Remove the 2 mounting bolts and belt cover


(1).
a Remove the belt cover only when replacing the belt.

2.

Loosen 2 mounting bolts (3) of alternator (2),


and then loosen lock bolt (4) of the adjustment
rod.

3.

Loosen locknut (5) of the adjustment rod and


move alternator (2) with adjustment nut (6) to
adjust the tension of the belt.

4.

While fixing adjustment nut (6), tighten locknut


(5).

5.

Tighten locknut (4) of the adjustment rod and 2


mounting bolts (3) of alternator (2).

30

D275AX-5E0

30 Testing and adjusting

Testing and adjusting air


conditioner compressor belt
k

SEN01414-00
a

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.

After tightening the bolts, check that the


belt tension is normal according to the
above procedure.

Testing
1. Open the left engine side cover and remove
the left mudguard.
2.

Press the intermediate point of the belt between


the drive pulley and compressor pulley with a
finger and measure deflection (a) of the belt.
a Pressing force:
Approx. 59 N {Approx. 6 kg}
a Deflection (a): 10 mm

5.

After testing and adjusting, return the removed


parts.

Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1.

Loosen the locknut of bolt (1).

2.

Loosen locknuts (2) and (3) and move compressor (5) and bracket as a unit with adjustment nut (4) to adjust the belt tension.

3.

While fixing adjustment nut (4), tighten locknuts (3) and (2).

4.

Tighten the locknut of bolt (1).


a Check for breakage of the pulleys, wear of
the V-grooves and contact of the belts and
V-groove.
a If the belt is lengthened to the adjustment
limit, cut or cracked, replace it with new
one.
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.

D275AX-5E0

31

SEN01414-00

30 Testing and adjusting

Testing fan speed


a

5.

Start the engine and set the machine monitor


to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accordance with the engine speed, regardless
of the state of the machine.

6.

While running the engine at low idle and high


idle, test the fan speed

7.

After finishing test, remove the testing instruments and return the removed parts.

Testing instrument for fan speed

Symbol

Part No.

795-205-1100

Part name
Tachometer kit

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the fan motor speed under the following
condition.
q
Hydraulic oil temperature: Within operating range
q
Engine coolant temperature: Within operating range
q
Power train oil temperature: Within operating range
k Warm up the machine sufficiently to
prevent breakage of the radiator.

1.

Open the radiator mask and remove the fan


net.

2.

Stick 1 reflection tape [1] of tachometer kit K to


fan (1)

3.

Set probe [2] to the reflection tape with stand


[3] and connect it to tachometer [4].
k

a
a

4.

32

Take care that the probe will not interfere with the fan.
Rotate the fan with the hand and check
that the probe can sense the rotation of
the reflection tape.
Set probe [1] 100 200 mm apart from the
fan to stabilize the measured value.

Close the radiator mask.


k

Before starting the engine, be sure to


close the radiator mask. Do not start
the engine while the radiator mask is
open.

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Testing fan circuit oil pressure


a

Testing instruments for fan circuit oil pressure

Symbol
1
L

2
3

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3400

Adapter (05)

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the fan circuit oil pressure under the following condition.
q
Hydraulic oil temperature: Within operating range
q
Engine coolant temperature: Within operating range
q
Power train oil temperature: Within operating range
k Warm up the machine sufficiently to
prevent breakage of the radiator.

1.

Open the radiator mask and remove the fan


net.

2.

Disconnect supply hose (1) of the fan motor.

3.

Install adapter L2 and connect the disconnected hose again.

4.

Install nipple L3 and connect it to oil pressure


gauge [2].
a When using an analog oil pressure gauge,
use one of 39.2 MPa {400 kg/cm}.

D275AX-5E0

5.

6.

Close the radiator mask.


k

Before starting the engine, be sure to


close the radiator mask. Do not start
the engine while the radiator mask is
open.

Start the engine and set the machine monitor


to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accordance with the engine speed, regardless
of the state of the machine.

33

SEN01414-00

7.

While running the engine at high idle, test the


fan circuit oil pressure.

30 Testing and adjusting

Bleeding air from fan pump


a

8.

34

If the fan pump is removed and installed or its


piping is disconnected and connected, bleed
air from the fan pump case according to the
following procedure.
Before starting the following work, check that
the hydraulic oil level is normal.

1.

Remove the floor inspection cover.

2.

Loosen air bleeder (1) and leave it for 15 minutes.

3.

After 15 minutes, start the engine and run it at


low idle.

4.

After oil flows out of air bleeder (1), tighten air


bleeder (1) and stop the engine.
3 Air bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}

After finishing test, remove the testing instruments and return the removed parts.

D275AX-5E0

30 Testing and adjusting

SEN01414-00

Adjusting fuel control dial and decelerator pedal

1.

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Outline of fuel control system
q
The following signals are inputted as rotation command signals to the engine controller.
q
Decelerator pedal potentiometer signal
q
3rd throttle signal
The engine controller controls the fuel
control system of the engine (CRI system)
according to the lowest engine speed signal among those input signals.
q
Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.

D275AX-5E0

[1] Fuel control dial (2nd throttle signal)


[2] Engine controller
[3] Steering controller
[4] Decelerator pedal (1st throttle signal)
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] Machine control signal
(3rd throttle signal)
[8] Rod

35

SEN01414-00

2.

Preparatory work
1) Start the engine, set the monitor panel in
the Adjustment mode, and prepare to
measure the engine speed.
a For the operation method, see Special functions of monitor panel
(EMMS).
q
Adjustment code: 0007
(Engine deceleration cut mode)
a The engine speed is displayed by 1 rpm.

3.

Adjusting decelerator pedal speed


Set the fuel control dial at the high idle position,
depress decelerator pedal (2) until it contacts
the stopper, and check that the decelerator
pedal speed is normal.
q
Decelerator pedal speed: 900 50 rpm
a If the engine speed is not correct, adjust
installation dimension (a) of rod (1).
q
Installation dimension (a): 123 mm

4.

Adjusting high idle speed


Set the fuel control dial to the high idle position
and check that the high idle speed is correct.
q
High idle speed: 2,150 25 rpm
a If engine speed is too high:
To remove the play in the decelerator
pedal, set the engine speed to less than
1,900 rpm with stopper bolt (3), then
adjust it to the high idle speed.

36

30 Testing and adjusting


a

If engine speed is too low:


Adjust the high idle speed with stopper
bolt (3).

5.

Check of decelerator position (decelerator


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

6.

Check of final accelerator position


a Finish the check in 5 above in advance.
a Measure the final accelerator position in
the real-time monitoring mode.
q
Monitoring code: 31706
(Final accelerator position)
While the decelerator pedal is released, set the
fuel control dial to the MAX position, set the
parking brake lever in the FREE position, set
the PCCS lever in the F or R position, and
check that the displayed position is 100%.
If the displayed position is less than 100%,
check the voltage signal of the fuel circuit for
error.
If this adjustment is not made perfectly, the
engine control function etc. may not operate
normally. Accordingly, be sure to check the displayed position.
a The accelerator position can be checked
while the engine is stopped.

D275AX-5E0

SEN01414-00

30 Testing and adjusting

D275AX-5E0 Bulldozer
Form No. SEN01414-00

38

D275AX-5E0

SEN01415-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

30 Testing and adjusting

Testing and adjusting, Part 2


Testing power train oil pressure ...................................................................................................................... 3
Testing and adjusting HSS oil pressure ........................................................................................................ 12
Adjusting transmission speed sensor ........................................................................................................... 17
Bleeding air from HSS pump ....................................................................................................................... 18
Simple method of testing brake performance ............................................................................................... 18
Adjusting brake pedal and parking brake lever ............................................................................................. 19
Adjusting PCCS lever console position......................................................................................................... 22
Emergency escape method when power train has trouble ........................................................................... 23
Adjusting clearance of idler........................................................................................................................... 26
Inspecting wear of sprocket .......................................................................................................................... 26
Testing and adjusting track shoe tension ...................................................................................................... 27
Testing and adjusting work equipment oil pressure ...................................................................................... 28
Testing control circuit main pressure............................................................................................................. 32
Testing PPC valve output pressure............................................................................................................... 33
Adjusting play of PPC valve.......................................................................................................................... 35
Testing outlet pressure of ripper pin puller solenoid valve ............................................................................ 36

D275AX-5E0

SEN01415-00

30 Testing and adjusting

Testing parts which cause hydraulic drift of blade and ripper........................................................................ 37


Testing internal leakage of work equipment cylinder..................................................................................... 38
Releasing residual pressure from work equipment cylinder.......................................................................... 39
Bleeding air from work equipment cylinder ................................................................................................... 39
Adjusting ripper lever position ....................................................................................................................... 40
Adjusting work equipment lock lever............................................................................................................. 41
Adjusting blade.............................................................................................................................................. 42
Testing and adjusting operator's cab............................................................................................................. 44

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Testing power train oil pressure 1


a

Testing instruments for power train oil pressure

Symbol
1
N

2
3

a
k

Part No.
799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester
(0.98 MPa {10 kg/cm2})

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

A nipple (quick coupler) is installed to the


transmission lubricating oil pressure pickup
port of the Pm clinic specification machine.
Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the power train oil pressure under the following condition.
q
Torque converter oil pressure:
Within operating range
Centralized pressure pickup ports (1) (12)
are installed inside the inspection cover on the
right outside of the operators cab and transmission lubricating oil pressure pickup port
(13) is installed to the top of the power train filter.
List of oil pressure pickup nipples and gauges
used
Oil pressure
gauge
(MPa {kg/cm2})
IN Torque converter inlet oil pressure
2.5 {25}
0.98 {10}
OUT Torque converter outlet oil pressure

No. Stamp
1
2

Part name

Oil pressure to be tested

LU

Torque converter lockup clutch


pressure

2.5 {25}

SC

Torque converter stator clutch


pressure

5.9 {60}

TM

Transmission main relief pressure

5.9 {60}

6
7

Transmission forward clutch oil


FWD
pressure

5.9 {60}

Transmission reverse clutch oil


pressure

5.9 {60}

1ST Transmission 1st clutch oil pressure

5.9 {60}

Transmission 2nd clutch oil


2ND
pressure

5.9 {60}

10
11
12

3RD Transmission 3rd clutch oil pressure


LB Steering left clutch oil pressure
RB Steering right brake oil pressure

5.9 {60}
5.9 {60}
5.9 {60}

13

Transmission lubricating oil


pressure

0.98 {10}

14

Output pressure of sudden stop


prevention valve

5.9 {60}

D275AX-5E0

SEN01415-00

1.

Testing torque converter inlet pressure (IN)


1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(1).
a Use an oil pressure gauge of 2.5 MPa
{25 kg/cm2}.

2)
3)

4)

30 Testing and adjusting

2.

Testing torque converter outlet pressure


(OUT)
1) Connect hydraulic tester N2 to oil pressure testing nipple (2).
a Use an oil pressure gauge of 0.98
MPa {10 kg/cm2}.

Start the engine and set the PCCS lever in


the full neutral position.
Test the oil pressure while the engine is
running at low idle and high idle.

2)

After finishing test, remove the testing


instrument and return the removed parts.

4)

3)

Start the engine and set the PCCS lever in


the full neutral position.
Test the oil pressure while the engine is
running at low idle and high idle.

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting

3.

SEN01415-00

Testing torque converter lock-up clutch


pressure (LU)
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure test nipple (3).
a Use an oil pressure gauge of 2.5 MPa
{25 kg/cm2}.

6)

2)

Run the engine and lift up the machine


body with the blade and ripper so that the
track shoes can run idle.
k After lifting up the machine, set the
work equipment lock lever in the
LOCK position.

3)
4)

Turn on the lock-up mode switch.


Set the PCCS lever in the FORWARD and
1st gear speed position and make the
shoes run idle.
k Take care not to be caught in the
track shoes during testing.
Raise the engine speed gradually and test
the oil pressure when the lock-up pilot
lamp lights up.

5)

D275AX-5E0

After finishing test, remove the testing


instrument and return the removed parts.

SEN01415-00

4.

Testing torque converter stator clutch pressure (SC)


1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(4).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

2)
3)

4)

30 Testing and adjusting

5.

Testing transmission main relief pressure


(TM)
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(5).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

Run the engine and set the PCCS lever in


the full neutral position.
Test the oil pressure while the engine is
running at low idle and high idle.

2)

After finishing test, remove the testing


instrument and return the removed parts.

4)

3)

Run the engine and set the PCCS lever in


the full neutral position.
Test the oil pressure while the engine is
running at low idle and high idle.

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting

6.

Testing transmission forward clutch pressure (FWD)


1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(6).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

2)
3)

4)

5)

SEN01415-00

7.

Testing transmission reverse clutch pressure (R)


1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(7).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

Run the engine and set the parking brake


lever in the FREE position.
Press the brake pedal and set the PCCS
lever in the FORWARD and 3rd gear
speed position.
Test the oil pressure while the engine is
running at low idle.
k 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.

2)

After finishing test, remove the testing


instrument and return the removed parts.

5)

D275AX-5E0

3)

4)

Run the engine and set the parking brake


lever in the FREE position.
Press the brake pedal and set the PCCS
lever in the REVERSE 3rd gear speed
position.
Test the oil pressure while the engine is
running at low idle.
k 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.

After finishing test, remove the testing


instrument and return the removed parts.

SEN01415-00

8.

Testing transmission 1st clutch pressure


(1ST)
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(8).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

2)
3)

4)

5)

30 Testing and adjusting

9.

Testing transmission 2nd clutch pressure


(2ND)
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(9).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

Run the engine and set the parking brake


lever in the FREE position.
Press the brake pedal and set the PCCS
lever in the FORWARD and 1st gear
speed position.
Test the oil pressure while the engine is
running at low idle.
k Since the torque converter will be
stalled, keep pressing the brake
pedal securely.
k Do not raise the engine speed to
high idle during testing.

2)

After finishing test, remove the testing


instrument and return the removed parts.

5)

3)

4)

Run the engine and set the parking brake


lever in the FREE position.
Press the brake pedal and set the PCCS
lever in the FORWARD and 2nd gear
speed position.
Test the oil pressure while the engine is
running at low idle.
k Since the torque converter will be
stalled, keep pressing the brake
pedal securely.
k Do not raise the engine speed to
high idle during testing.

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting

10. Testing transmission 3rd clutch pressure


(3RD)
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(10).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

SEN01415-00

11. Testing steering left brake pressure (LB)


1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(11).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

2)
2)
3)

4)

5)

Run the engine and set the parking brake


lever in the FREE position.
Press the brake pedal and set the PCCS
lever in the FORWARD and 3rd gear
speed position.
Test the oil pressure while the engine is
running at low idle.
k Since the torque converter will be
stalled, keep pressing the brake
pedal securely.
k Do not raise the engine speed to
high idle during testing.

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

3)

4)

Run the engine and set the parking brake


lever in the FREE position.
Test the oil pressure while the engine is
running at low idle and high idle.
a Turn the pivot turn mode switch ON
and drive the machine in FORWARD
and 1st (F1) actually and check that
the oil pressure lowers to 0 when the
PCCS lever is moved to the left steering stroke end.
a Check that the oil pressure lowers to
0 when the brake pedal is pressed or
the parking brake lever is set in the
LOCK position.

After finishing test, remove the testing


instrument and return the removed parts.

SEN01415-00

12. Testing steering right brake pressure (RB)


1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipple
(12).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

2)
3)

4)

10

Run the engine and set the parking brake


lever in the FREE position.
Test the oil pressure while the engine is
running at low idle and high idle.
a Turn the pivot turn mode switch ON
and drive the machine in FORWARD
and 1st (F1) actually and check that
the oil pressure lowers to 0 when the
PCCS lever is moved to the right
steering stroke end.
a Check that the oil pressure lowers to
0 when the brake pedal is pressed or
the parking brake lever is set in the
LOCK position.

After finishing test, remove the testing


instrument and return the removed parts.

30 Testing and adjusting

13. Testing transmission lubricating oil pressure


1) Remove oil pressure testing plug (13).

2)

Install nipple N3 and connect hydraulic


tester N2.
a Use an oil pressure gauge of 0.98
MPa {10 kg/cm2}.

3)

Run the engine at high idle and test the oil


pressure.

4)

After finishing test, remove the testing


instruments and return the removed parts.

D275AX-5E0

30 Testing and adjusting

14. Testing output pressure of sudden stop


prevention valve
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure testing nipples
(11) and (12).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
q
(11): For steering left brake oil pressure

2)

3)

SEN01415-00

4)

Test the oil pressure while the engine is


running at low idle.
a If the brake pressure is as follows when
the sudden stop prevention valve operates, it is normal.
q
1.13 1.57 MPa {11.5 16.0 kg/cm2}

5)

After finishing test, remove the testing


instruments and return the removed parts.

(12):
For steering right brake oil pressure

Run the engine and set the machine monitor in the adjustment mode.
a For the method of operating the
adjustment mode, see "Special functions of machine monitor (EMMS)".
a Adjustment code: 9995
(Operation mode of emergency stop
prevention valve)
Set the parking brake lever in the FREE
position and set the all PCCS levers in the
NEUTRAL position.

D275AX-5E0

11

SEN01415-00

30 Testing and adjusting

Testing and adjusting HSS oil


pressure
a

Install nipple P2 and connect oil pressure


gauge [1] of hydraulic tester P1.
a Use an oil pressure gauge of 58.8
MPa {600 kg/cm2}.

4)

Run the engine and set the parking brake


lever in the FREE position and press the
brake pedal.
k Since the steering circuit will be
stalled, keep pressing the brake
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
Run the engine at high idle and steer to
the right or left with the PCCS lever. When
the steering circuit is relieved, test the oil
pressure.
a Since a pivot turn will be made with
only the steering system, set the
direction of the PCCS lever into neutral.

Testing and adjusting instrument for HSS oil


pressure

Symbol
1
P
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Testing
k Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Test the HSS oil pressure under the following
condition.
q
Hydraulic oil temperature:
Within operating range
1.

3)

Testing HSS main relief pressure


1) Remove the floor inspection cover.
2) Remove oil pressure testing plug (1) or
(2).
q
(1): For left steering (Port PA)
q
(2): For right steering (Port PB)

5)

6)

12

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting


a

HSS main relief pressure (A) can be tested in


the "Pm Clinic auxiliary mode" of the machine
monitor.

D275AX-5E0

SEN01415-00
a

HSS main relief pressure (B) can be tested in


the "Pm Clinic auxiliary mode" of the machine
monitor.

13

SEN01415-00

2.

Testing HSS charge relief pressure


1) Open the right fender inspection cover.
2) Remove oil pressure testing plug (3).

3)

4)

14

30 Testing and adjusting

Install nipple P2 and connect oil pressure


gauge [1] of hydraulic tester P1.
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

3.

5)

Test the oil pressure while the engine is


running at high idle.

6)

After finishing test, remove the testing


instrument and return the removed parts.

Testing HSS servo charge pressure


a The control circuit main pressure from the
self-pressure reducing valve of the control
valve is used as the HSS servo charge
pressure commonly for work equipment
PPC and fan pump control.
a For the testing method, see "Testing control circuit main pressure".

Run the engine and set the PCCS lever in


the full neutral position.

D275AX-5E0

30 Testing and adjusting

Adjusting
1. Adjusting HSS main relief pressure
a If the HSS main relief pressure is abnormal, adjust it with main relief valve (4) or
(5) of the HSS pump according to the following procedure.
q
(4): For left steering (Port PA)
q
(5): For right steering (Port PB)
1) Open the inspection cover under the universal joint.

SEN01415-00

2.

Adjusting HSS charge relief pressure (when


pressure is low)
a If the HSS charge relief pressure is low,
adjust the charge relief valve (8) of the
HSS motor to heighten the HSS charge
relief pressure.
1) Remove the fuel tank.

2)
3)
2)
3)

4)

Fixing adjustment nut (6), loosen locknut


(7).
Turn the adjustment nut (6) to adjust the
pressure.
a If the adjustment nut is
q
turned to the right, the pressure
rises.
q
turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment nut:
Approx. 13.7MPa {Approx. 140kg/cm2}
Fixing adjustment nut (6), tighten locknut
(7).
3 Locknut: 29 39 Nm {3 4 kgm}

4)

5)

5)

Fixing adjustment nut (9), loosen locknut


(10).
Turn the adjustment nut (9) to adjust the
pressure.
a If the adjustment nut is
q
turned to the right, the pressure
rises.
q
turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment nut: 1 MPa {10.4 kg/cm2}
Fixing adjustment nut (9), tighten locknut
(10).
3 Locknut:
58.8 78.5 Nm {6 8 kgm}

After finishing adjustment, check the oil


pressure again according to the procedure
for measurement described above.

After finishing measurement, check the oil


pressure according to the above measuring method.

D275AX-5E0

15

SEN01415-00

3.

Adjusting HSS charge relief pressure (when


pressure is high)
a If the HSS charge relief pressure is high,
adjust the charge safety valve (11) of the
HSS pump to lower the HSS charge relief
pressure.
1) Remove the inspection cover under the
universal joint.

2)
3)

4)

16

30 Testing and adjusting

5)

After finishing adjustment, check the oil


pressure again according to the procedure
for measurement described above.

Fixing adjustment nut (14), loosen locknut


(13).
Turn the adjustment nut (14) to adjust the
pressure.
a If the adjustment nut is
q
turned to the right, the pressure
rises.
q
turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment nut:
1.55 MPa {15.88 kg/cm2}
Fixing adjustment nut (14), tighten locknut
(13).
3 Locknut:
58.8 78.5 Nm {6 8 kgm}

D275AX-5E0

30 Testing and adjusting

Adjusting transmission speed


sensor
1.

SEN01415-00

Remove sensor (1) and flange (2) together and


secure them with nut (3).
a Take care not to change the adjustment
angle of the sensor.
3 Nut: 49.0 68.6 Nm {5 7 kgm}

7.

Install flange (2) and sensor to the HSS case


with the mark of "HSS UP" directed to the
upper side of the HSS case.

8.

After finishing adjustment, set the machine


monitor in the "Monitoring display mode" and
check that it displays the transmission speed
normally.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a Monitoring code:
31400 (Transmission output speed)

Remove the undercover of the fuel tank and


then remove transmission speed sensor (1)
and flange together.
a Before adjusting transmission speed sensor (1), remove it and check that its tip is
free from steel chips and flaws, then install
it again.
a Before installing, separate sensor (1),
flange (2), and nut (3).

2.

Install flange (2) to the HSS case temporarily


with the mark of "HSS UP" directed to the
upper side of the HSS case.

3.

Look at bevel gear (4) through the hole of


flange (2) and check that a tooth tip is at the
center of the hole.
a If the tooth tip is not at the center of the
hole, run the engine and move the
machine forward or in reverse to adjust
the position of the tooth tip.

4.

Tighten sensor (1) until its tip comes in contact


with the tooth tip of gear (4).
2 Threads of sensor:
Gasket sealant (LG-5)

5.

Return sensor (1) by the specified angle.


a Returning angle of sensor: 1/2 1 turn
a Adjust clearance (b) between the sensor
tip and gear tooth tip to 0.75 1.50 mm.

D275AX-5E0

6.

17

SEN01415-00

Bleeding air from HSS pump


a

30 Testing and adjusting

If the HSS pump is removed and installed or its


piping is disconnected and connected, bleed
air from the pump case according to the following procedure.
Before bleeding air, check that the hydraulic oil
level is proper.

1.

Remove the floor inspection cover.

2.

Loosen air bleeder (1) and leave it for 15 minutes.

3.

After 15 minutes, run the engine at low idle.


a After starting the engine, do not move the
PCCS lever from the full neutral position.

4.

After oil flows out of air bleeder (1), tighten air


bleeder (1).

18

Simple method of testing brake


performance
1
a

Carry out the simple test of brake performance


under the following condition.
q
Torque converter oil temperature:
Within operating range

1.

Set the blade and ripper in the travel position


on a level place.

2.

Run the engine and set the parking brake lever


in the FREE position.

3.

Run the engine at low idle and press the brake


pedal and set the PCCS lever in the FORWARD and 2nd gear speed position.
k 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 gear speed.
a Set the steering unit in neutral.

4.

Press the decelerator pedal and set the fuel


control dial in the high idle position.

5.

Return the decelerator pedal slowly and check


that the machine does not start when the
engine speed reaches the high idle level.
k Since the torque converter will be
stalled, press the brake pedal securely
and keep your right foot on the decelerator pedal for safety until the work is
finished.

D275AX-5E0

30 Testing and adjusting

Adjusting brake pedal and parking brake lever

SEN01415-00

Brake pedal

Parking lever

D275AX-5E0

19

SEN01415-00

Adjusting brake pedal side


1. Adjusting brake pedal stroke
Adjust stroke (a) of brake pedal (1) by adjusting installed dimension (b) of stopper bolt (2).
a Adjust the brake pedal stroke with the
brake rod disconnected from the pedal.
q
Pedal stroke (a): 74 mm
q
Installed dimension (b) of stopper bolt:
42 mm
2.

Adjusting installed length of brake rod


1) Install brake rod (3) and leave brake pedal
(1) free [Do not press brake pedal (1)].
2) Adjust installed dimensions (c) and (d) of
brake rod (3) with turnbuckle (5) so that
the spool of brake valve (4) will be at the
OFF position.
a The locknut screw of the turnbuckle
o n t h e b r a k e p e d a l s i d e i s l e ft handed.
q
Installed dimension (c): 32 mm
q
Installed dimension (d): 14 mm
3 Locknut:
34.3 58.8 Nm {3.5 6.0 kgm}

3.

Checking brake pedal stroke


1) Press brake pedal (1) and check that its
stroke is as adjusted in step 1 above.
2) Press brake pedal (1) and check that it is
stopped at stopper (6).
3) Press brake pedal (1) and check that
spool stroke (e) of brake valve (4) is in the
normal range at this time.
q
Spool stroke (e): 19 23 mm

4.

Checking brake oil pressure


1) Run the engine and set the machine monitor in the adjustment mode.
a For the method of operating the
adjustment mode, see "Special functions of machine monitor (EMMS)".
a Adjustment code: 9996
(Mechanical brake operation check)
2) Press the brake pedal fully with the parking brake lever in the FREE position and
check that the brake oil pressure on both
right and left sides is 0.
a For the point to measure the brake oil
pressure, see "Testing power train oil
pressure".

20

30 Testing and adjusting

5.

Setting brake potentiometer to initial position


Turn the starting switch ON and set the
machine monitor in the adjustment mode and
set the brake potentiometer to the initial position.
a For the method of operating the adjustment mode, see "Special functions of
machine monitor (EMMS)".
a Adjustment code:
0005 (Brake pedal standard value)

Adjusting parking brake lever side


6.

Assembly and installation of lever assembly


1) Assemble lever assembly (7) and adjust
the operation of limit switch (8).
a Assemble the lever assembly with the
parking brake cable (9) disconnected from
the lever.
q
When lever is at upper position: OFF, at
lower position: ON
q
Operating stroke of limit switch: 3 mm
2) Install lever assembly (7).

7.

Adjusting installed length of parking brake


cable
1) Connect parking brake cable (9) to the
lever side and valve side, and then adjust
installed dimensions (f) and (g).
q
Installed dimension (f) of cable:
112.8 mm
q
Installed dimension (g) of cable:
14.0 mm
2) Operate parking brake lever (10) between
the FREE position and LOCK position and
adjust the position of rod end (11) so that
spool stroke (h) of brake valve (4) will be
normal.
q
Spool stroke (h): 23.0 mm

8.

Checking brake oil pressure


Run the engine and set the parking brake lever
in the FREE position and LOCK position and
check that the brake oil pressure will be as follows.
a For the measuring point of the brake oil
pressure, see "Testing power train oil
pressure".
q
LOCK position: 0, FREE position: Specified pressure

D275AX-5E0

30 Testing and adjusting

9.

SEN01415-00

Checking limit switch


1) Turn the starting switch ON and set the
machine monitor in the display mode.
a For the method of operating the display mode, see "Special functions of
machine monitor (EMMS)".
q
Monitoring code: 40910
(Steering controller input signal 1)
2) Set the parking brake lever in the FREE
position and LOCK position and check
that the limit switch signals are input normally.

D275AX-5E0

21

SEN01415-00

Adjusting PCCS lever console position

1.

Set operators seat (1) in the forward (dozing)


position.

2.

Under this condition, check that console (2) is


in parallel with operators seat (1).
a If the console is not parallel with the operators seat, adjust dimension (a) of rod (3).
q
Standard dimensions (a): 179mm
a The locknut on the rear side of the turnbuckle is a left-handed (reversing) screw.

22

30 Testing and adjusting

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Emergency escape method when


power train has trouble
1

Devices used for emergency escape

Symbol

Part No.

Part name

Since the female side of connector


PL2 is kept disconnected, mask it
with a vinyl sheet, etc.
Put switch assembly [1] in the cab
through the cab window.

19M-06-32820 Switch assembly


Q

Register

17M-06-41530 Wiring harness


2

1.

7824-66-6430
790-190-1600

Pump assembly

Escape with switch box (Use Q1)


a If the machine cannot be moved because
of a trouble in the electric system of the
power train control unit (travel direction,
gear speed, steering), escape according
to the following procedure.
a The engine must be startable for the following procedure. If the engine cannot be
started, see "Emergency escape with
brake releasing device".
1) Connect switch assembly [1] and register
[2] to wiring harness [3] of emergency
escape device Q1.
k Since register [2] controls the drive
voltage of the solenoid, connect it
to the wiring harness before connecting to the machine.
k Set the all gear speed switches of
switch assembly [1] in the OFF
position and the direction switch in
the P position to prevent the
machine from starting suddenly.

2)

3)

Disconnect neutral safety relay (NSF) in


the fuse room and connect pins [3] and [5]
of the connector on the wiring harness
side.
k If the engine is started by this
method, the neutral safety function
does not work. Accordingly, before
starting the engine, set the parking
brake lever in the LOCK position
and set the PCCS lever in the full
neutral position.
k Start the engine by this method
only in an emergency. If the engine
does not start in another case, be
sure to carry out troubleshooting
and repair the trouble.

Open the left fender inspection cover and


connect wiring harness [3] to connectors
PL1 (1) and PL2 (2).
q
Connector PL1 (1):
Connect to male side and female side.
q
Connector PL2 (2):
Connect to male side.

D275AX-5E0

23

SEN01415-00

4)
5)

24

Start the engine and set the parking brake


lever in the FREE position.
Operate switch assembly [1] and move
the machine to a safe place.
a The gear speed switch is so made
that the switch on the lower gear
speed will be operated first.

30 Testing and adjusting

2.

Escape with brake releasing device (Use


Q2)
a If the engine cannot be started and the
parking brake cannot be released, escape
according to the following procedure.
1) Assemble pump assembly Q2.

2)

Install volume pump [4] of pump assembly


Q2 to the outside of the operators cab.

3)

Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller
solenoid valve.

D275AX-5E0

30 Testing and adjusting

4)

Connect end hose [5] of pump assembly


Q2 to the supply hose.
a Block the solenoid valve side with
plug [6].

5)

Turn the starting switch ON and set the


parking brake lever in the FREE position.
Operate the vacuum pump to raise the
brake releasing oil pressure to the initial
pressure.
q
Initial pressure:
Approx. 2.74 MPa {28 kg/cm2}
a Since an accumulator is installed in
the circuit, the handle must be operated 30 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
Tow the machine to a safe place.
a The brake releasing oil pressure lowers gradually because of internal
leakage and the brake is applied
again about 1 minutes after. Accordingly, work quickly.
a If the brake releasing pressure lowers
to about 1.5 MPa {16 kg/cm 2 }, the
brake is applied. In this case, operate
the volume pump again to raise the
brake releasing pressure to the initial
pressure.

6)

7)

D275AX-5E0

SEN01415-00

25

SEN01415-00

Adjusting clearance of idler

30 Testing and adjusting

If the idler runs out or tilts because of wear of


the side guide, upper and lower guides, and
guide plate, adjust according to the following
procedure.

1.

Drive the machine for 1 2m on a level place,


then measure clearance (a) (on the inside and
outside).

2.

If clearance (a) is more than 3mm, remove bolt


(1) and reduce shims (2).
q
Standard clearance (a) on each side:
0 0.5 mm
q
Thicknesses of shim: 0.5 mm, 1.0 mm
a When the machine is new, the total thickness of the shims on each side is 7 mm.
a Reduce the shims on the inside and outside equally.
3 Mounting bolt:
490 608 Nm {50 62 kgm}

26

Inspecting wear of sprocket


a

As the wear measurement gauge for the


sprocket, use the "Full-scale drawing of
sprocket tooth profile" in "Structure, function
and maintenance standard", "Sprocket".
Make a copy of the "Full-scale drawing of
sprocket tooth profile" on a transparent sheet
and apply it to the sprocket directly to see if the
sprocket is serviceable.

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Testing and adjusting track shoe


tension
1
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2.

Place straight steel bar (1) between the idler


and front carrier roller and measure clearance
(a) between the bottom of the steel bar and
shoe grouser.
q
Standard clearance (a): 20 30 mm

Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
1.

Remove cover (2).

2.

When the tension is too high


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

3.

When tension is low


Add grease through grease fitting (4).
a If the track shoe is not tensed well, drive
the machine forward and in reverse
slowly.

D275AX-5E0

27

SEN01415-00

30 Testing and adjusting

Testing and adjusting work


equipment oil pressure
a

Testing and adjusting instruments for work


equipment oil pressure

Symbol
1
R
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

Measuring
k Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Test the work equipment oil pressure under the
following condition.
q
Hydraulic oil temperature:
Within operating range
1.

Run the engine at high idle and set the


blade lever and ripper lever in neutral and
test the oil pressure.

5)

After finishing test, remove the testing


instrument and return the removed parts.

Testing unload pressure


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

3)

28

4)

Install nipple R2 and connect oil pressure


gauge [1] of hydraulic tester R1.
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

D275AX-5E0

30 Testing and adjusting

2.

Testing main relief pressure


a Test the main relief pressure at the same
point with the unload pressure.
a Use an oil pressure gauge of 39.2 MPa
{400 kg/cm2}.

1)
2)

3)

SEN01415-00
a

The unload pressure and main relief pressure


can be tested in the "Pm Clinic auxiliary mode"
of the machine monitor.

Start the engine and set the work iquipment lock lever in the FREE position.
Run the engine at high idle and operate
the blade lever and ripper lever to relieve
each cylinder at a stroke end and test the
oil pressure.

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

29

SEN01415-00

3.

30 Testing and adjusting

Testing LS pressure (Load Sensing pressure)


1) Open the right fender inspection cover.
2) Remove oil pressure testing port (2).

6)

3)

Install nipple R2 and connect oil pressure


gauge [1] of hydraulic tester R1.
a Use an oil pressure gauge of 39.2
MPa {400 kg/cm2}.

4)

Start the engine and set the work equipment lock lever in the FREE position.
Run the engine at high idle and operate
the blade lever and ripper lever to relieve
each cylinder at a stroke end and test the
oil pressure.

5)

30

After finishing test, remove the testing


instrument and return the removed parts.

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Adjusting
a The unload pressure cannot be adjusted.
1.

Adjusting main relief pressure


a If the main relief pressure is abnormal,
adjust LS relief valve (3) of the control
valve according to the following procedure.
a If the LS relief valve is adjusted, the LS
pressure (load sensing pressure) is
changed, too.

1)
2)

3)

4)

2.

After finishing adjustment, check both


main relief pressure and LS pressure
(load sensing pressure) again according
to the procedure for measurement
described above.

Adjusting LS pressure (load sensing pressure)


a If the LS pressure (load sensing pressure)
is abnormal, adjust LS relief valve (3) of
the control valve.
a If the LS relief valve is adjusted, the main
relief pressure is changed, too.
a Adjust the LS pressure similarly to the
main relief pressure.
a After finishing adjustment, check both LS
pressure (load sensing pressure) and
main relief pressure again according to
the procedure for measurement described
above.

Fixing adjustment nut (4), loosen locknut


(5).
Turn the adjustment nut (4) to adjust the
pressure.
k Do not remove the adjustment nut.
If it is removed, the internal parts
may come off.
a If the adjustment nut is
q
turned to the right, the pressure
rises.
q
turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment nut: Approx. 19.6 MPa
{Approx. 200 kg/cm2}
Fixing adjustment nut (4), tighten locknut
(5).
3 Locknut: 39 49 Nm {4 5 kgm}

D275AX-5E0

31

SEN01415-00

30 Testing and adjusting

Testing control circuit main


pressure
a

1
S
2

5.

Run the engine at high idle and set the blade


lever and ripper lever in neutral and test the oil
pressure.

6.

After finishing test, remove the testing instrument and return the removed parts.
a The control circuit basic pressure cannot
be adjusted.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3100

Oil pressure pickup adapter


(Size 02)

02896-11008

O-ring

A nipple (quick coupler) is installed to the control valve outlet hose of the Pm clinic specification machine.
The control circuit main pressure is the pressure lowered by the self-pressure reducing
valve of the fan pump. It is used commonly for
HSS servo charge, work equipment PPC, and
fan pump control.
Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the control circuit main pressure under the
following condition.
q
Hydraulic oil temperature:
Within operating range

1.

Open the right fender inspection cover.

2.

Disconnect hose (1).

3.

Install oil pressure pickup adapter S2 and connect the disconnected hose again.

32

Install nipple [1] of hydraulic tester S1 and connect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa {60
kg/cm2}.

Testing instrument for control circuit main pressure

Symbol

4.

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Testing PPC valve output


pressure
a

3
k

a
a

Install nipple [1] of hydraulic tester T1 and connect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa {60
kg/cm2}.

4.

Start the engine and set the work equipment


lock lever in the FREE position.

5.

Run the engine at high idle and operate the


control lever of the circuit to be tested and test
the oil pressure.
a Test the oil pressure with the lever at a
stroke end.
a When testing the blade circuit, operate the
lever until the blade floats.

6.

After finishing test, remove the testing instrument and return the removed parts.

Testing instruments for PPC valve output pressure

Symbol

3.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3100

Oil pressure pickup adapter


(Size 02)

02896-11008

O-ring

799-401-3200

Oil pressure pickup adapter


(Size 03)

02896-11009

O-ring

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Before testing the PPC valve output pressure,
check that the control circuit main pressure is
normal.
Test the PPC valve output pressure under the
following condition.
q
Hydraulic oil temperature:
Within operating range

1.

Open the right side cover.

2.

Remove the pressure switch or pressure testing plug (1) of the circuit to be tested.
a For the circuit to be tested, see the drawing on the next page.
a If a circuit does not have a pressure switch
or a pressure testing plug, install pick-up
adapter T2 or T3.

D275AX-5E0

33

SEN01415-00

34

30 Testing and adjusting

D275AX-5E0

30 Testing and adjusting

Adjusting play of PPC valve


a
a
q

SEN01415-00

If the end play of the blade lever and ripper


lever is excessive, adjust it with their PPC
valves according to the following procedure.
This figure shows the PPC valve for the ripper.
Standard play (a):
0.5 3.0 mm at 200 mm from revolution center
of lever (in both longitudinal and lateral directions)

1.

Remove boot (1).

2.

Loosen locknut (2) and turn disc (3) to adjust


the play.
a Do not move the piston at this time.

3.

Fix disc (3) and tighten locknut (2).


3 Locknut: 98 127 Nm {10 13 kgm}

4.

Install boot (1).

D275AX-5E0

35

SEN01415-00

30 Testing and adjusting

Testing outlet pressure of ripper


pin puller solenoid valve
1
a

Testing instruments for outlet pressure of ripper pin puller solenoid valve

Symbol
1
U
2
k

1.

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-3200

Oil pressure pickup adapter


(Size 03)

02896-11009

O-ring

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the outlet pressure of the ripper pin puller
solenoid valve under the following condition.
q
Torque converter oil temperature:
Within operating range

Run the engine at high idle and operate the ripper pin puller switch and test the oil pressure.

5.

After finishing test, remove the testing instrument and return the removed parts.

Disconnect pin puller cylinder hose (1) or (2).

2.

Install oil pressure pickup adapter U2 and connect the disconnected hose again.

3.

Install nipple [1] of hydraulic tester U1 and connect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa {60
kg/cm2}.

36

4.

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Testing parts which cause


hydraulic drift of blade and ripper1
a

If the blade or ripper drifts hydraulically, check


to see if the cause is on the cylinder packing
side or control valve side according to the following procedure.

1.

Set the cylinders to be tested in the following


positions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of
the machine body.
a Since the blade lift cylinder is equipped
with a piston valve, do not extend it to
the stroke end.

2)

Blade tilt cylinder


Extract the tilt cylinder to the stroke end
and brace the blade to push up the right
side of the machine body.

3)

Ripper lift cylinder


Brace the ripper to push up the rear side
of the machine body.

D275AX-5E0

2.

Turn the starting switch ON and set the work


equipment lock lever in the FREE position.

3.

Extend the cylinder to be tested with the corresponding lever and check its movement.
q
If the lowering speed is increased, the cylinder packing is defective.
q
If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.

[Reference]
Reason why the lowering speed is increased
when the cylinder packing is the cause of the
hydraulic drift:
1. If the machine is set in the above position
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom side
to the head side. Since the volume on the head
side is less than that on the bottom side by the
volume of the rod, the pressure in the head
side is increased by the oil flowing in from the
bottom side.
2. As the pressure in the head side is increased,
it is balanced at a certain level (which depends
on the leakage), then the lowering speed is
lowered.
3. If the circuit on the head side is opened to the
drain circuit by the above operation of the lever
(the bottom side is closed by the check valve
at this time), the oil on the head side flows in
the drain circuit. As a result, the pressure is
unbalanced and the lowering speed is
increased.

37

SEN01415-00

30 Testing and adjusting

Testing internal leakage of work


equipment cylinder
1
a

3.

Run the engine at high idle and apply the relief


pressure to the cylinder bottom side.
q
Blade tilt cylinder:
Operate to extend the cylinder to
be tested.
q
Ripper lift cylinder:
Operate to lower ripper.
q
Ripper Tilt cylinder:
Operate to tilt ripper forward.

4.

After 30 second, test leakage in 1 minute by


the measuring cylinder V.

5.

After finishing test, return the removed parts.


a Referring to "Bleeding air from work equipment cylinder", bleed air from the cylinder
circuit.

Testing instruments for internal leakage of


work equipment cylinder

Symbol

Part No.

Commercially
available

a
a

Part name
Measuring cylinder

Stop the machine on level ground, lower


the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock position.
Test the internal leakage of work equipment
cylinder under the following condition.
q
Hydraulic oil temperature: 45 55C
Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be
tested.

1.

Extend the cylinder to be tested to the stroke


end and set the machine in the testing position.
1) Blade tilt cylinder
Extend the cylinder to be tested to the
stroke end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper
to the end.
3) Ripper tilt cylinder
Tilt the ripper forward to the end.

2.

Disconnect hose on the cylinder head side and


block the hose side with a plug.
a Remove the hose cover of the blade tilt
cylinder.
k Take care not to disconnect the hose
on the bottom side.

38

D275AX-5E0

30 Testing and adjusting

SEN01415-00

Releasing residual pressure from


work equipment cylinder
1

Bleeding air from work equipment


cylinder
1

1.

When disconnecting the piping between the


control valve and work equipment cylinder,
release the residual pressure from the circuit
according to the following procedure.
Stop the machine on level ground, lower
the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the LOCK
position.

a
1.

Run the engine at low idle for about 5 minutes.

2.

While running the engine at low idle, extend


and retract the cylinder to be bled 4 5 times.
a Move the piston rod to about 100 mm
before the stroke end and never relieve
the oil.

3.

While running the engine at high idle, carry out


the operation in step 2.

4.

While running the engine at low idle, move the


cylinder to the stroke end to relieve the oil.

Loosen oil filler cap (1) of the hydraulic tank


gradually to release the residual pressure from
the tank.

2.

Turn the starting switch ON and set the work


equipment lock lever in the FREE position.

3.

Operate the blade control lever and ripper


control lever to each direction.
a If the control lever is operated 2 3 times,
the residual pressure in the accumulator is
released.

4.

Run the engine at low idle for about 10 seconds to increase the pressure in the accumulator, then stop it.

5.

Repeat steps 2 4 above 2 3 times.

D275AX-5E0

If the work equipment cylinder is removed and


installed or its piping is disconnected and connected, bleed air from its circuit according to
the following procedure.
Before performing the following operation,
check that the hydraulic oil level is normal.

39

SEN01415-00

Adjusting ripper lever position

a
a

30 Testing and adjusting

Adjust the ripper lever to the best position


according to the following procedure.
The ripper lever can be adjusted forward and
in reverse within the range of 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 180 it.
3) Install lever (2) to lever (5) and set it to the
best position.
4) Tighten lock bolt (1) to secure lever (2).

40

5)
6)
7)

Loosen nut (3).


Reverse 180 knob (4).
Tighten nut (3) to secure knob (4).

D275AX-5E0

30 Testing and adjusting

Adjusting work equipment lock lever

1.

Adjust dimension (a) between pins of rod (1).


q
Dimension (a) between pins: 444mm

2.

Connect rod (1) to work equipment lock lever


(2) and PPC lock valve (3).
a Install connecting pin (4) on the work
equipment lock lever side with the cotter
pin on the outside of the machine.

D275AX-5E0

SEN01415-00

41

SEN01415-00

30 Testing and adjusting

Adjusting blade

1.

If the blade is removed and installed or disassembled and reassemble, adjust it according
to the following procedure.
Adjusting shims for assembly
1) Adjust the shim of center (1).
Adjusted
point

Adjusted
clearance

Standard
clearance

Standard
shim
thickness

See note.

4.5 mm

2)

Adjust the shim of lift (2).


Adjusted
point

Adjusted
clearance

Standard
clearance

Standard
shim
thickness

Max. 1mm

4.0mm

Note: Adjust the shim so that the play of


the ball in the axial direction will be
less than 1mm and the ball can rotate smoothly.

42

D275AX-5E0

30 Testing and adjusting

3)

2.

SEN01415-00

Adjust the shim of trunnion (3).

Adjusted
point

Adjusted
clearance

Standard
clearance

Standard
shim
thickness

1.56 0.65mm
(Total
thickness)

12 mm

Adjusting blade tilt distance


1) Adjust dimension (d) of brace (4) with the
handle.
q
Dimension (d) of brace: 1,460 mm
2) Measure right and left tilt distances (e1)
and (e2).
q
Right tilt distance (e1):
Approx. 700 mm
q
Left tilt distance (e2):
Approx. 700 mm
3) If both tilt distances are not the same,
adjust dimension (d) of brace (4) according to the following procedure.
q
(e1) > (e2):
Increase dimension (d) finely.
q
(e1) < (e2):
Decrease dimension (d) finely.

D275AX-5E0

43

SEN01415-00

30 Testing and adjusting


a

Testing and adjusting operator's


cab
1
a

If the operator's cab is removed and installed


or disassembled and transported and assembled in the field, test and adjust it according to
the following procedure.

1.

Testing pressure in cab


q
Criterion:
Measured value X 78.5 Pa {8 mmH2O}
q
Engine speed: High idle
q
Fan speed: 100% mode
(Refer to service mode on machine monitor)
q
Air conditioner fan switch: High
q
Air conditioner Fresh/Recirculation switch:
Fresh air position
a If the measured value is lower than the
standard value, check the seals of the
holes for wiring harnesses and optional
parts in the cab.
1)

A simple method of measuring the internal


pressure is as follows.
i) Prepare a transparent vinyl hose.
q
Inside diameter: 6 mm,
Length: 3,000 mm
ii) Secure the inside end of the hose to
the top of the back seat with a tape.
iii) Remove bolt (1) under the left console box. Pass the other end of the
hose through the bolt hole and take it
out of inspection cover (2) on the left
side of the cab.

2.

[a] side: Inside of cab (Pressurized)


[b] side: Out of cab
(Atmospheric pressure)

Check of searing performance


1) Close the all openings of the cab.
2) Splash water around the hatched part of
the cab at the rate of about 19 l/min for 10
minutes.
q
At this time, it is not necessary to
splash pressurized water.
3) Splash water horizontally from a hose over
sealing surface (4).
4) Check around the dashboard carefully.
a If water leaks, caulk the leaking part and
check again.

iv) Seal the hole of bolt (1) with tape (3).


v) Pour water in the hose up to about
half, then bent the hose to U - shape.
vi) Set the water level in the vinyl hose
out of the cab to that in the cab.
vii) Run the engine at high idle and measure water level difference (c).
(Value (c): Pa {mmH2O})

44

D275AX-5E0

SEN01415-00

30 Testing and adjusting

D275AX-5E0 Bulldozer
Form No. SEN01415-00

46

D275AX-5E0

SEN01416-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

30 Testing and adjusting

Testing and adjusting, Part 3


Special functions of machine monitor (EMMS) ............................................................................................... 2

D275AX-5E0

SEN01416-00

30 Testing and adjusting

Special functions of machine monitor (EMMS)

Display section of special func- Operation section 1 of special


tions
functions
(Basic operation)
1. Gear speed display section
3. Service switch
2. Multi-information section

Operation section 2 of special


functions
(Changeover operation)
4.
5.
6.
7.

Buzzer cancel switch


Information switch
Shift-up switch
Shift-down switch

EMMS: Equipment Management Monitoring System

D275AX-5E0

30 Testing and adjusting

SEN01416-00

Normal function and special functions of machine monitor (EMMS)


The machine monitor (EMMS) has the normal function and special functions and displays information of various types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function 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)

Maintenance mode

Pm clinic auxiliary mode

[U]
(W)

Error code display mode

[T]

Adjustment mode

Maintenance mode

[>]
Travel direction/Gear speed
+
Shift mode/Service meter

[>]
[>]
[>]

(Automatic)

Maintenance item: 12 items

[<]
Auxiliary menu: 11 items

[<]
[<]
Adjustment menu: 5 items

[<]

Action code display function


[ON] & [U](W)

[T]

Service mode

Maintenance interval change


mode
[>]

Maintenance item: 12 items

[<]

Electric system error code


display mode
[>]

[<]

Mechanical system error code


7
display mode
[>]
8

[<]

Adjustment mode
[>]

[<]

9 Load memory display mode


[>]

Adjustment menu: 21 items


Display menu: 3 items

[<]

10 Real-time monitoring mode


[>]

[<]

11 Dual display monitoring mode


[>]

[<]

Maintenance interval change


5
mode

D275AX-5E0

[ON]
[U]:
[T]:
[ > ]:
[ < ]:
(W):

Service switch
Buzzer cancel switch (Left)
Buzzer cancel switch (Right)
Information switch (Right)
Information switch (Left)
Min. 2.5 sec

SEN01416-00

Operation and display in operator mode


(Outline)
a

In this section, only the outline of the operation


mode is described. For the details of the contents and operation method of each function
and mode, see "Operation Manual".

Normal display mode (Default)


The monitor panel displays the following information normally.
Gear speed display section (1):
q
Left side: Travel direction (P N F R)
q
Right side: Gear speed (1 2 3)
q
Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 characters each.
q
Left side:
Gear shift mode (F1-R1 F1-R2 F2-R2)
q
Right side:
Service meter (Unit: 0.1h)
a To change the normal display mode to the
operator mode, hold buzzer cancel switch (4)
in the [U] position for 3 seconds.

30 Testing and adjusting

1.

Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replacement of oils and filters is displayed on the
multi-information section (2) and to update the
maintenance history.
a Gear speed display section (1) keeps displaying normally.
Order

Display

Item

01:ENG OIL

Engine oil

02:ENG FILT

Engine oil filter

03:FUEL FILT

Fuel main filter

04:HYD FILT

Hydraulic oil filter

06:CORR RES

Corrosion resistor

07:DAMP OIL

Damper oil

08:FNL OIL

Final drive oil

10:HYD OIL

Hydraulic oil

12:HSS FILT

Charge filter

10

19:POWL OIL

Power train oil

11

20:POWL FILT

Power train oil filter

12

41:F. PRE-FLT

Fuel pre-filter

The displayed numbers are specific to the


corresponding items. (Some of them may
not be used in some models.)

D275AX-5E0

30 Testing and adjusting

2.

Pm clinic auxiliary mode


(2-PM CLINIC MODE)
In this mode, the condition of the machine is
displayed on multi-information section (2) as
an auxiliary function of the periodic diagnoses
such as the Pm clinic, even if any measuring
instrument is not connected.
a Gear speed display section (1) keeps displaying normally.

OrDisplay
der
1 01-ENG SPEED
2
3
4
5
6
7
8
9
10
11

SEN01416-00

Item

Engine speed
Engine coolant tempera02-COOLANT TEMP.
ture
03-ENG OIL PRESS Engine oil pressure
05-BOOST PRESS.
Boost pressure
06-BOOST TEMP.
Boost temperature
Torque converter oil tem07-T/C TEMP.
perature
08-HYD TEMP.
Hydraulic oil temperature
09-HYD PRESS.
Hydraulic oil pressure
HSS circuit oil pressure
11-HSS PRESS. A
A
HSS circuit oil pressure
12-HSS PRESS. B
B
13-BATTERY VOLT.
Battery voltage mV

a
a

Unit
rpm
C
kPa
kPa
C
C
C
MPa
MPa
MPa
mV

The displayed numbers are specific to the


corresponding items. (Some of them may
not be used in some models.)
The boost pressure is indicated by the
absolute pressure.

D275AX-5E0

3.

Error code display mode


(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the
machine are displayed by a 6-character error
code on the multi-information section (2).
When the user or the operator needs to be
notified of the error code of each fault, this
mode is applied.
a Gear speed display section (1) keeps displaying normally.
a When a serviceman needs to check the
error codes for troubleshooting, the Electric system error code display mode and
the Mechanical system error code display
mode should be used for more detailed
information.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [U]
position on the screen shown at right, and
the all error codes detected currently are
displayed at the interval of about 2 seconds. (To finish displaying, turn the buzzer
cancel switch to the [T] position.)
a For details of the displayed failure code,
see Troubleshooting Volume, "Failure
code table".

SEN01416-00

4.

30 Testing and adjusting

Adjustment mode (4-USER ADJUST MODE)


In this mode, the display condition of the
machine monitor can be adjusted and the fan
speed (for cleaning the radiator) can be
changed on the multi-information section (2).
a Gear speed display section (1) keeps displaying normally.
Order

Display

01:LCD BRIGHTNES

Adjustment of display
02:DSP BRIGHTNES
brightness

03:DSP CONTRAST

Fan 100% speed


04:FAN 100%SPEED mode (For cleaning
radiator)

05:NO INJECTION

1)

Brightness of LCD
This function is used to adjust the brightness of the back light of the LCD gauge
unit (See the operation manual).

2)

Brightness of display
This function is used to adjust the brightness of the back light of the multi-information unit (See the operation manual).

3)

Contrast of display
This function is used to adjust the contrast
of the LCD of the multi-information unit
(See the operation manual).

4)

Fan 100% mode


This function is to control rotation speed of
the cooling fan forcedly at approximately
100% of the maximum speed.
1] This mode is selected by operating
the information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] position.
3] The function is effective under this
condition and the rotation speed of
the cooling fan is controlled to
approximately 100% of the maximum
speed.
a Exiting this mode disables the
function.

Item
Adjustment of LCD
brightness

Adjustment of display
contrast

Non-injection cranking mode

D275AX-5E0

30 Testing and adjusting

5)

No-injection cranking mode


This function is used to stop fuel injection
into all the cylinders of the engine to lubricate the engine parts simply before starting the engine after a long-time stop.
i) Operate the information switch to
select this mode.
ii) Set the buzzer cancel switch in the
[U] position to settle the mode.

iii)

D275AX-5E0

SEN01416-00

iv) Under this condition, set the starting


switch in the START position to perform non-injection cranking.
v) Return the starting switch to the ON
position and set the buzzer cancel
switch in the [t] position to reset the
mode.
a If the system gets out of the mode,
this function is set ineffective.
k Limit the continuous no-injection
cranking to 20 seconds to protect
the starting motor.
k This function is set ineffective for
safety while the engine is running.
At this time, "NOT AVAILABLE" is
displayed on the lower line to indicate that the mode is ineffective.

After about 3 seconds, "WAIT" displayed on the lower line changes to


"ACTIVE" and the mode becomes
effective.

SEN01416-00

30 Testing and adjusting

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).
a Gear speed display section (1) keeps displaying normally.
a The phone No. is displayed only when an action
code of high importance is displayed. The figure shown at right is an example (The display
style of the phone No. depends on its input
style).
a If an important action code is displayed, the
caution lamp flashes and the caution buzzer
sounds.
<Reference>
An action code is displayed only when a serious
fault occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a error code in the "Electric system error
code display mode" and "Mechanical system error
code display mode" of the service mode.

Action codes table


Action
code

E01

E02

Indication method of fault

Only action code is displayed.

Action code is displayed.


Caution lamp flashes.
Caution buzzer sounds.

Example of contents of fault

Remedy

Torque converter is not locked


up.
Blade dual tilt mechanism does
not work.

Automatic function stops or normal function stops partially but


machine can work.
Call your Komatsu distributor for
repair.

Gear is not shifted up or down.


Blade tilt is not limited.
Blade pitch mechanism does not
work.

Stop engine and start it again,


and you can operate machine
without limiting function. You
must take care, however.
Call your Komatsu distributor for
repair.

Action code is displayed.


CALL E03 Caution lamp flashes.
Caution buzzer sounds.

Engine coolant temperature is


defective.
Usable gear speeds are limited.
Move machine to safe place.
Engine speed does not rise fully.
Call your Komatsu distributor for
Gear shifting shocks become
repair.
large.
Steering performance lowers.
Brake shocks become large.

Action code is displayed.


CALL E04 Caution lamp flashes.
Caution buzzer sounds.

Engine cannot be controlled.


Machine cannot travel.
Machine stops.

Stop machine immediately.


Call your Komatsu distributor for
repair.

D275AX-5E0

30 Testing and adjusting

Operation and display in service mode

SEN01416-00

2)

Method of changing to service mode


a When using the service mode, change the
screen by the following special operation.
1)

Special operation of switches


Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel
switch (4).
a While keeping the service switch in the
ON position (hold it up), keep the buzzer
cancel switch in the [U] position for a minimum of 3 seconds.
a If the multi-information section changes to
the mode display shown below, the system is in the service mode.
a The mode displayed first depends on each
case.

Gear
Order speed
display

3)

D275AX-5E0

Selecting and executing mode to be used


Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
q
[ > ]: Next mode No.
q
[ < ]: Previous mode No.
q
[U]: Execute mode.
a For the details of operation in each mode,
see the following pages.

1C

EE

bE

Cb

Ld

5R

dR

Display and item


5-EXCHG, INTVAL INTERVAL MODE
Maintenance interval change mode
6-ELEC. FAULT CODE MODE
Electric system fault code display mode
7-MACHINE CHECK CODE MODE
Mechanical system fault code display mode

8-SERVICE ADJUST MODE


Adjustment mode
9-LOAD MAP DISPLEY MODE
Load memory display mode
10-REAL TIME MONITORING MODE
Real time monitoring mode
11-DUAL DISPLAY MONITORING MODE
Dual display monitoring mode

Finishing mode and function


The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
[1] When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating
buzzer cancel switch (4).
q
[T]: Screen returns.
[2] When finishing the all operation:
Turn off the starting switch.

SEN01416-00

5.

Maintenance interval change mode


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

10

30 Testing and adjusting

2)

Selecting and displaying maintenance


item
i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
q
[ > ]: Next code
q
[ < ]: Previous code
ii) Display the maintenance item selection screen by operating buzzer cancel switch (4).
q
[U]: Execute item.

3)

Contents of information section


The following items are displayed on the
information section.
[1]: Code
[2]: Maintenance item
[3]: Replacement interval time (Set time)
a The items shown at right are examples.
a If the replacement interval does not
need to be changed, finish the operation on this screen.
a If the replacement interval needs to
be changed, go to step 4).

Selecting and executing mode


i) Select "Maintenance interval change
mode" on the mode selection screen.
a If the mode is selected, code
(1C) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the maintenance item selection screen by operating buzzer cancel switch (4).
q
[U]: Execute mode.

D275AX-5E0

30 Testing and adjusting

4)

Changing replacement interval time


i) Change the set time by operating
information switch (5), shift-up switch
(6), and shift-down switch (7).
q
[ > ]: Move cursor to right.
q
[ < ]: Move cursor to left.
q
[UP]: Increase number.
q
[DOWN]: Decrease number.

D275AX-5E0

If you do not use the maintenance function, set the all times
to 0.

SEN01416-00

ii)

If the input time is correct, enter the


change of setting by operating buzzer
cancel switch (4).
q
[U]: Enter change.
a If the change is finished normally,
the information display screen
appears after the screen shown
at right.

If the change is not finished normally, the information display


screen before the change
appears after the screen shown
at right. In this case, execute the
above operation again.

11

SEN01416-00

30 Testing and adjusting

Maintenance items table


Order

Display

Item

1st time
(Cannot be changed)

2nd time and after


(Can be changed)

01:ENG OIL

Engine oil

0500h

0500h

02:ENG FILT

Engine oil filter

0500h

0500h

03:FUEL FILT

Fuel main filter

1000h

1000h

04:HYD FILT

Hydraulic oil filter

0250h

2000h

06:CORR RES

Corrosion resistor

1000h

1000h

07:DAMP OIL

Damper oil

2000h

2000h

08:FNL OIL

Final drive oil

0250h

2000h

10:HYD OIL

Hydraulic oil

0250h

2000h

12:HSS FILT

Charge filter

1000h

1000h

10

19:POWL OIL

Power train oil

0250h

1000h

11

20:POWL FILT

Power train oil filter

0250h

0500h

12

41:F. PRE-FLT

Fuel prefilter

0500h

0500h

a
a

12

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.
The displayed numbers are the ID numbers specific to the corresponding items and are not the display
order numbers. Some of them may not be used in some models. In addition there is a thing becoming
a missing number by a model.

D275AX-5E0

30 Testing and adjusting

6.

Electric system error code display mode


(6-ELEC. ERROR CODE MODE)
In this mode, you can check the past electric
system error codes.
1)

SEN01416-00

2)

Display in the case where no codes are


recorded
If no error codes have been output up to
now, the information section displays as
shown below.

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 below.
[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
[5]: Time measured by service meter after
last occurrence
a The items shown below are examples.
a For the details of displayed error
codes, see the errors code table in
"Troubleshooting when error code is
indicated (Error code)".

Selecting and executing mode


i) Select "Electric system error code
display mode" on the mode selection
screen.
a If the mode is selected, code
(EE) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the error code display screen
by operating buzzer cancel switch (4).
q
[U]: Execute mode.

D275AX-5E0

13

SEN01416-00
a

14

30 Testing and adjusting

Flashing and lighting of error code


Flashing:
Code is being output currently.
Lighting:
Code is not being output currently.
Condition for detecting and keeping
error code
If an error code of any item other than
communication is output, it keeps
flashing until the starting switch is
turned off. After the starting switch is
turn on or the engine is started again,
the error code keeps lighting until the
same fault is detected.
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
information switch (5).
q
[ > ]: Next code
q
[ < ]: Previous code
a The error codes are displayed from
the oldest one in order of length of
time after they were output.

5)

Method of deleting error code


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

D275AX-5E0

30 Testing and adjusting

7.

Mechanical system error code display mode


(7-MACHINE CHECK CODE MODE)
In this mode, you can check the past mechanical system error codes.
1)

SEN01416-00

2)

Display in the case where no codes are


recorded
If no error codes have been output up to
now, the information section displays as
shown below.

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 below.
[1]: Record No. (Up to 15)
[2]: Error code (Code being output currently is flashing)
[3]: Number of past occurrences
[4]: Time measured by service meter after
first occurrence
[5]: Time measured by service meter after
last occurrence
a The items shown below are examples.
a For the details of displayed error
codes, see the errors code table in
"Troubleshooting when error code is
indicated (Error code)".

Selecting and executing mode


i) Select "Mechanical system error code
display mode" on the mode selection
screen.
a If the mode is selected, code
(bE) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the error code display screen
by operating buzzer cancel switch (4).
q
[U]: Execute mode.

D275AX-5E0

15

SEN01416-00
a

16

30 Testing and adjusting

Flashing and lighting of error code


Flashing:
Code is being output currently.
Lighting:
Code is not being output currently.
Condition for detecting and keeping
error code
If an error code of any item other than
communication is output, it keeps
flashing until the starting switch is
turned off. After the starting switch is
turn on or the engine is started again,
the error code keeps lighting until the
same fault is detected.
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
information switch (5).
q
[ > ]: Next code
q
[ < ]: Previous code

5)

Method of deleting error code


The mechanical system error codes cannot be deleted.

D275AX-5E0

30 Testing and adjusting

8.

Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.
1)

SEN01416-00

2)

Selecting adjustment items


On the adjustment code input screen,
input the 4-digit code of the item to be
adjusted by operating information switch
(5), shift-up switch (6), and shift-down
switch (7).
q
[ > ]: Move cursor to right.
q
[ < ]: Move cursor to left.
q
[UP]: Increase number.
q
[DOWN]: Decrease number.
a Input a 4-digit code and set buzzer
cancel switch (4) to the [U] position,
and the information on that item is
displayed.

3)

Contents of display on adjustment screen


[1]: Code
[2]: Adjustment item
[3]: Related information
a For the detailed information and
adjustment procedure, see "Adjustment mode table and adjustment procedure".

Selecting and executing mode


i) Select "Adjustment mode" on the
mode selection screen.
a If the mode is selected, code
(Cb) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the adjustment code input
screen by operating buzzer cancel
switch (4).
q
[U]: Execute mode.

D275AX-5E0

17

SEN01416-00
a

4)

18

If an incorrect code is input, the


adjustment code input screen
appears again after the screen shown
below. In this case, execute the
above operation again.

When operating machine in adjustment


mode
If the parking brake lever is set in the
FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
a To select another screen, return the
parking brake lever to the LOCK position and perform the necessary procedure.
k Since the operation may be different from the usual, take extreme
care when operating.

30 Testing and adjusting

5)

Automatic selection of adjustment item


(Limited function)
After one of some adjustment items is
selected, if the information switch is operated, the next adjustment item is selected
automatically, even if the code of the next
adjustment item is not input.
q
[ > ]: Code is increased
q
[ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Automatic selection column of the Adjustment mode table. Those items are
selected in the order of their numbers.
a Note that this operation is not effective while the parking brake lever is in
the RESET position.
a You may return to the screen for
inputting codes and enter a code
without using this function.

D275AX-5E0

30 Testing and adjusting

SEN01416-00

Adjustment mode table and adjustment procedure


No.

Adjustment
code

[1]

0001

INP TEL NO.

Phone No. input mode

[2]

0002

S/T S. CODE

[3]

0003

[4]

Disassembly/ Automatic
Assembly selection

Displayed data

Unit

Phone No.

(None)

Steering controller model code setting

Code

Character

T/M S. CODE

Transmission controller model code setting

Code

Character

0004

BODY TYPE

Machine specification code setting

Code

Character

[5]

0005

BRAKE BASE

Brake pedal standard value set

Voltage offset
quantity

mV

[6]

0006

PUMP N. AJST

HSS pump neutral adjustment

Pressure

MPa

[7]

0007

ENG. FULL CH

Engine decelerator cut mode

Engine speed

rpm

[8]

0008

INJ->123456

Reduced cylinder mode

Engine speed/Injection quantity

rpm/mg

[9]

0009

PITCH SENS.

Pitch angle sensor standard value set

Voltage offset
quantity

mV

[10]

0010

FAN 70%MODE

Fan 70% mode

Adjustment
quantity

(None)

[11]

0021

KMTRX INST

KOMTRAX specification setting

Setting
condition

Character

[12]

0530

STALL CHECK

Stall speed check mode

Engine speed

rpm

[13]

1005

FAN 100%MODE Fan 100% mode

Adjustment
quantity

(None)

10

[14]

1012

S/T N-SET

Steering lever neutral value set

Steering lever
voltage

mV

[15]

1013

S/T M. L-SET

Steering lever left max. value set

Steering lever
voltage

mV

[16]

1014

S/T M. R-SET

Steering lever right max. value set

Steering lever
voltage

mV

[17]

2222

HSS ADJUST

HSS initial current adjustment mode

Adjustment
quantity

mA

[18]

2223

R SLOW CUT

Reverse slow cut function setting

Setting
condition

Character

[19]

9995

LOCK BRAKE

Sudden stop prevention valve operation


mode

Brake potentiometer voltage

mV

[20]

9996

MECHA BRAKE

Mechanical brake operation check mode

Brake potentiometer voltage

mV

[21]

9997

HI IDLE SET

High idle limit setting

Adjustment
quantity

rpm

[22]

9998

SFT INHIBIT

3rd gear speed cut setting

Setting
condition

Character

Adjustment item

7
9

Items marked with q in the Disassembly/Assembly column of the above table must be adjusted
after the machine is assembled or any controller is replaced. (For the adjustment procedure, see
"Adjustment after replacement of controller".)

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19

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[1] 0001: Phone number input mode


q
This code inputs or changes a phone number
to be displayed simultaneously with when the
user code is displayed.
q
The lower part displays a phone number and
symbols.
q
Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
q
Instructions for use:
By operating the information switch (5), shift up
switch (6), and shift down switch (7), input a
phone number and symbols.
q
[ > ]: Moves the cursor rightward.
q
[ < ]: Moves the cursor leftward.
q
[UP]: Advance the numeric character or
character (in the order of available
characters).
q
[DOWN]:Reverse the numeric character
or character (in the reverse order
of available characters).
a Sixteen digits of numeric characters are
provided. To avoid confusion, input symbols other than numeric characters at digits you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory.
a The setting is enabled even after ending
this code.

20

30 Testing and adjusting

[2] 0002: Steering controller model code setting


q
This code is used to initialize the model codes
recognized by the steering controller and the
set values of the memory in the controller.
q
The model code is displayed on the lower line.
q
Adjustment method:
1) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
2) Check that the displayed model code has
changed from [6*6] to [666].
a If model code [666] is not displayed, the
controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting
is effective.

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30 Testing and adjusting

[3] 0003:Transmission controller model code setting


q
This code is used to initialize the model codes
recognized by the transmission controller and
the set values of the memory in the controller.
q
The model code is displayed on the lower line.
q
Adjustment method:
1) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
2) Check that the displayed model code has
changed from [5*5] to [555].
a If model code [555] is not displayed, the
controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting
is effective.

SEN01416-00

[4] 0004: Machine specification code setting


q
This code is used to have the machine specification recognized by the controllers which
compose the system.
q
The specifications of the work equipment, SSC
and travel lever are set with this code.
a Since setting of this code is reset when "Transmission controller specification setting" is executed, adjust it after that.
q
Adjustment procedure
1) Select code 0004 in the adjustment mode.
(a): Indicates specification of travel lever
(1st place)
(b): Indicates specification of work equipment (2nd place)
(c): Indicates specification of SSC (3rd
place)

2)

D275AX-5E0

Each time shift-up switch (6) is pressed,


display of the 2nd place and 3rd place
changes. Select proper specifications of
the work equipment and SSC.
a If the SSC is installed to the machine,
be sure to select Power setting 1 (do
not select Power setting 2).
q
Example of operation
Upper line: Indicates specifications of
single tilt and without-SSC.
Lower line: Indicates specifications of
dual tilt and with-SSC.

21

SEN01416-00

30 Testing and adjusting

List of specifications of work equipment


and SSC
No.
X00
X01
X02
X10
X11
X12

Specification of
work equipment
Single tilt
Single tilt
Single tilt
Dual tilt
Dual tilt
Dual tilt

Specification of SSC
Without SSC
SSC power setting 1
SSC power setting 2
Without SSC
SSC power setting 1
SSC power setting 2

Note) "X" indicates the travel lever code.


3)

Each time shift-down switch (7) is pressed,


display of the 1st place changes. Select a
proper specification (standard specification
or optional specification) of the travel lever.
q
Example of operation
Upper line: Indicates standard specification of travel lever.
Lower line: Indicates optional specification of travel lever.
a Be sure to select the standard travel
lever specification. (Do not select the
optional travel lever specification.)

[5] 0005: Brake pedal standard value setting


q
This code is used to adjust the zero point of the
brake pedal potentiometer.
q
The deviation from the standard value is indicated by voltage on the lower line (Indication
range: 2,500 2,500).
q
Adjustment method:
1) Check that the brake pedal is in neutral (it
is not pressed).
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to
adjust the effect of the brake.
a Even if this adjustment is performed, the
indication on the lower line does not
change.
a Even if this code is turned off, the setting
is effective.

Travel lever specification table


Code
8XX
9XX

Travel lever specification


Standard travel lever specification
Optional travel lever specification

Note) XX indicates the work equipment and


SSC code.
4)

22

Set buzzer cancel switch (4) in the [U]


position to save the machine specification.
a When the buzzer cancel switch is
operated, the alarm buzzer sounds.
k If the actual machine specification
is different from the setting in the
controller, the machine may move
unexpectedly or an error is made.
Accordingly, be sure to set the
machine specification correctly.
Even if this code is turned OFF, the setting
is effective.
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30 Testing and adjusting

[6] 0006: HSS pump neutral adjustment


(HSS specification)
q
This code is used to solve a problem in the
straight travel performance of the HSS steering.
q
The HSS oil pressure is indicated on the lower
line.
q
Adjustment method 1 (Check of HSS differential pressure and deviation direction):
a Before performing this adjustment, check
the differential pressure of the HSS pump
to see if the straight travel performance
needs to be adjusted.
1) Run the engine at high idle with the parking brake lever in the LOCK position.
2) Set the machine monitor in the real-time
monitoring mode (5R) and set it to the following code.
q
Monitoring code:
50500 (HSS differential oil pressure)
3) Check the indicated differential pressure
to see if the straight travel performance
needs to be adjusted.
a If the differential pressure is 2 MPa or
lower, the straight travel performance
does not need to be adjusted. In this
case, finish the work.
a If the differential pressure is higher
than 2 MPa, perform the following
adjustment step.
4) Run the engine at high idle and tilt the
PCCS lever to the right end and return it
and measure the differential pressure and
tilt it to the left end and return it and measure the differential pressure, and then
judge the deviation direction from the
measured differential pressure.
a The machine deviates during travel in
the lever operation direction in which
the differential pressure is higher.

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SEN01416-00

Adjustment method 2 (Adjustment of neutral


position of HSS):
k Since the steering circuit will be
relieved, take care of safety around the
machine and keep pressing the brake
pedal securely during adjustment.
1) Set the machine monitor in the adjustment
mode.
2) Set the parking brake lever in the FREE
position and keep pressing the brake
pedal securely and run the engine at high
idle.
3) Turn the PCCS lever fully in the opposite
direction to the deviating direction and
keep it that position.
4) Set the buzzer cancel switch (4) in the [U]
position and return the PCCS lever to the
neutral position.
a It takes about 1 minutes to complete
the adjustment (The progress of the
adjustment is displayed graphically
on the engine speed display section
of the monitor panel).
5) When the adjustment is completed, the all
segments of the engine speed display
section of the monitor panel light up and
start flashing.

23

SEN01416-00

24

Adjustment procedure 3 (Check of adjustment):


Check that the differential pressure in the HSS
pump is in the normal range according to
Adjustment method 1 above.
q
Monitoring code:
50500 (HSS differential pressure)
q
Normal range: Max. 2 MPa
a Even if this code is turned off, the setting
is effective.

30 Testing and adjusting

[7] 0007: Engine deceleration-cut mode


q
This code is used to stop the auto-deceleration
function of the engine and check the high idle
speed of the engine singly.
q
The engine speed is displayed on the lower
line (Display range: 0 3000).
q
Using method:
While this code is displayed, its function is
turned on and the auto-deceleration function is
turned off.
a If this code is turned off, its function is
turned off.

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30 Testing and adjusting

[8] 0008: Reduced cylinder mode


a When the engine common rail system seems
to be faulty, this code is used to stop injecting
fuel into 1 or more cylinders (reduce the number of effective cylinders) while the engine is
running and find out a faulty cylinder from the
change of the engine speed and fuel injection
quantity.
a Since a fault is detected by the difference of
the engine speed and fuel injection quantity in
the reduced cylinder mode operation from that
in the normal mode operation, use this function
while the engine is running.
q
Engine speed (A) and fuel injection quantity
(B) are displayed on the lower line.

D275AX-5E0

SEN01416-00

Using method:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylinders again, too.
q
[ > ]: Move cursor to right.
q
[ < ]: Move cursor to left.
q
[U]: Execute or stop reduced cylinder mode
operation.
a The figure at below is an example that No.
2 cylinder is turned off for reduced cylinder
mode operation and turned on again (The
cylinder No. lamp is turned off in the
reduced cylinder mode operation and on
in the normal mode operation).
a Only one or more cylinders can be turned
off for the reduced cylinder mode operation.
a If this code is turned off, its function is
turned off.
k Since this mode is for troubleshooting,
do not carry out work in this mode.

25

SEN01416-00

[9] 0009: Pitch angle sensor standard value set


q
This code is used to adjust the zero point and
correct the installation error of the pitch angle
sensor.
q
The deviation from the standard neutral position is displayed by voltage on the lower line
(Display range: 2500 2500).
q
Adjustment method:
i) Stop the machine on level ground.
ii) Buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a Even after adjustment, the display of the
lower line does not change.
a Even if this code is turned off, the setting
is effective.

30 Testing and adjusting

[11] 0021: KOMTRAX specification setting


q
This code is used to select installation condition of the KOMTRAX terminal.
a Set this specification before starting the
operation of the KOMTRAX.
q
The installation condition of the KOMTRAX terminal is displayed on the lower line.
q
ACTIVE: KOMTRAX is installed.
q
DEACTIVE: KOMTRAX is not installed.
q
Setting method
1) Select installation condition of the
KOMTRAX terminal with shift-up switch
(6) and shift-down switch (7).
2) After selecting the installation condition of
the terminal correctly, set buzzer cancel
switch (4) in the [U] position and check
that the alarm buzzer sounds.
a Even if this code is turned OFF, the setting
is effective.
a After replacing the controller, be sure to
perform (check) the setting.

[10] 0010: Fan 70% mode


q
This code forcedly sets the rpm of cooling fan
at approximately 70% of the maximum speed.
q
The lower part displays data for adjustment.
q
Instructions for use:
The function is enabled with this code displayed to control the rpm of cooling fan to
approximately 70% of the maximum speed.
a Ending this code disables the function.

26

D275AX-5E0

30 Testing and adjusting

[12] 0530: Stall speed check mode


q
This code is used to obtain the torque converter stall speed while keeping the cooling fan
speed to the maximum.
k This machine is equipped with the cooling
fan speed control function to protect the
radiator when the engine is not fully
warmed up. Since the protective function
does not work while this mode is used,
warm up the engine fully before using this
mode.
k If the machine is not warmed up sufficiently, durability of the radiator may be
reduced.
Rough standard of warming up: All of the
hydraulic oil temperature, engine coolant
temperature and power train oil temperature are within the operating range.
q
The engine speed is displayed on the lower
line. (Display range: 0 3,000)
q
Using method
While this code is displayed, its function is
effective and the cooling fan speed is set to the
maximum.
a Adjust the cooling fan maximum speed in
advance in the fan maximum speed adjustment mode (ID: 1005).
a After this code is turned OFF, its function
becomes ineffective.

D275AX-5E0

SEN01416-00

[13] 1005: Fan 100% mode


q
This code forcedly sets the rpm of cooling fan
at approximately 100% of the maximum speed.
It is also used to set the adjustment value of
the maximum speed.
q
The lower part displays data for adjustment.
q
Instructions for use:
a The function is enabled with this code displayed to control the rpm of cooling fan to
approximately 100% of the maximum
speed.
i) Change the adjustment value of the maximum speed by operating shift-up switch
(6) and shift-down switch (7).
q
[UP]: Increase the adjustment value.
q
[DOWN]: Decrease the adjustment
value.
ii) To settle the adjustment value, set buzzer
cancel switch (4) in the [U] position and
check that the alarm buzzer sounds.
k When using this mode, warm up the
machine sufficiently. If the machine is
not warmed up sufficiently, durability
of the radiator may be reduced.
Rough standard of warming up: All of
the hydraulic oil temperature, engine
coolant temperature and power train oil
temperature are within the operating
range.
a If this code is finished, the function
becomes ineffective but the set adjustment value is effective.

27

SEN01416-00

[14] 1012: Steering lever neutral value setting


q
This code is used to adjust the steering potentiometer neutral position of the PCCS lever.
q
The output signal of steering potentiometer
from displayed by voltage on the lower line
(Display range: 0 5000).
q
Adjustment method:
i) Shift the PCCS lever in the steering neutral position.
ii) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a Even after adjustment, the display of the
lower line does not change.
a Even if this code is turned off, the setting
is effective.
a This code is not for adjustment of the
steering performance, etc.

28

30 Testing and adjusting

[15] 1013: Steering lever left maximum value se


q
This code is used to adjust the maximum left
steering potentiometer position of the PCCS
lever.
q
The output signal of the steering potentiometer
from displayed by voltage on the lower line
(Display range: 0 5000).
q
Adjustment method:
i) Set the PCCS lever to the left steering
stroke end.
ii) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a Even after adjustment, the display of the
lower line does not change.
a Even if this code is turned off, the setting
is effective.
a This code is not for adjustment of the
steering performance, etc.

D275AX-5E0

30 Testing and adjusting

[16] 1014: Steering lever right maximum value set


q
This code is used to adjust the maximum right
steering potentiometer position of the PCCS
lever.
q
The output signal of steering potentiometer from
displayed by voltage on the lower line (Display
range: 0 5000).
q
Adjustment method:
i) Set the PCCS lever to the right steering
stroke end.
ii) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a Even after adjustment, the display of the
lower line does not change.
a Even if this code is turned off, the setting
is effective.
a This code is not for adjustment of the
steering performance, etc.

SEN01416-00

[17] 2222: HSS initial current adjustment mode


q
When the steering start feeling is different by
the steering direction, this code is used to
adjust the turning radius at the start of steering.
q
The current to drive the HSS pump solenoid is
displayed on the lower line [Display range:
350 (Left end) 0 350 (Right end)].

D275AX-5E0

Adjustment method:
1) Turning the PCCS lever to the left or right,
display and keep the current to be set.
q
If the lever is turned to the left, the
current becomes negative.
q
If the lever is turned to the right, the
current becomes positive.
2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a As the set current is increased in the positive or negative direction, the turning
radius at the start of steering is decreased
(the machine turns more quickly).
a The figure is an example that the set current for steering to the left is reduced to
increase the turning radius.
a: Max. steering point
b: Steering start point
c: Steering start point
d: Max. steering point
a Even if this code is turned off, the setting
is effective.

29

SEN01416-00

[18] 2223: Reverse slow cut function setting


q
This code is used to forcibly stop the reverse
slow function in the R1 gear speed, regardless
of the switch operations of the machine monitor.
q
This code does not affect the reverse slow
function in the R2 and R3 gear speeds.
q
Whether the reverse slow cut function is turned
on is displayed by letters on the lower line.
q
Adjustment method:
Change the setting by operating information
switch (5).
q
[ < ], [ > ]: Change setting.
q
[DEACTIVE]: Turn off reverse slow cut function.
q
[ACTIVE]: Turn on reverse slow cut function.
a If the reverse slow function is stopped, the
reverse speed is not slowed down in the
R1 gear speed even if the reverse slow
mode switch on the machine monitor is
turned ON.
a Even if this code is turned off, the setting
is effective.

30 Testing and adjusting

[19] 9995: Operation mode of emergency stop prevention valve


q
This code is used to check that the sudden
stop prevention valve works normally.
q
The voltage of the brake potentiometer is displayed on the lower line.
q
Using method:
While this code is displayed, its function is
effective and the emergency stop prevention
valve keeps operating.
Under this condition, operate the brake pedal
or parking brake lever and check the brake oil
pressure.
a If this code is turned off, its function is
turned off.

[20] 9996: Mechanical brake operation check mode


This code is used to check the operation of the
mechanical brake.
q
The voltage of the brake potentiometer is displayed on the lower line.
q
Using method:
While this code is displayed, its function is
turned on and the electric brake is normally
released.
Under this condition, operate the brake pedal
or parking brake lever and check the brake oil
pressure.
a If this code is turned off, its function is
turned off.
q

30

D275AX-5E0

30 Testing and adjusting

[21] 9997: High idle limit setting


q
This code is used to limit the use high idle
speed.
q
The engine speed limit adjustment value is displayed on the lower line.
q
Limit range: High idle speed 400rpm
q
Using method:
1) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] position.
2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a If the high idle speed is limited, the engine
speed is not set to the normal high idle
even if the fuel control dial is set to the
maximum position.
a Even if this code is turned off, the setting
is effective.

D275AX-5E0

SEN01416-00

[22] 9998: 3rd gear speed cut setting


q
This code is used to limit the use of the 3 gear
speeds.
q
The usable gear speeds are displayed by bits
on the lower line (in the order of the 3rd, 2nd,
and 1st from the left).
q
Using method:
Limit or allow the use of the maximum gear
speed by operating information switch (5) and
buzzer cancel switch (4).
q
[ < ], [ > ]: Display changes.
q
[U]: Enter setting.
q
Display on lower line [ o ]:
Gear speed is effective.
q
Display on lower line [ _ ]:
Gear speed is not effective.
a If the use of a gear speed is limited, the
transmission is not shifted to that gear
speed even if the gear shift-up switch is
operated.
a Even if this code is turned off, the setting
is effective.

31

SEN01416-00

9.

Load memory display mode


(9-LOAD MAP DISPLAY MODE)
In this mode, you can check the load on the
machine, forward odometer, and reverse
odometer.
1)

Selecting and executing mode


i) Select "Load memory display mode"
on the mode selection screen.
a If the mode is selected, code (Ld)
is displayed on gear speed display section (1) and the title is
displayed on multi-information
section (2).
ii) Display the information screen by
operating buzzer cancel switch (4).
q
[U]: Execute mode.

30 Testing and adjusting

2)

No.

3)

32

Changing information screen


Change the information screen by operating information switch (5).
q
[ > ]: Next screen.
q
[ < ]: Previous screen.
Display

Item

01-1000 rpm SMR

1000 rpm service


meter

02-FOWARD ODO M

Forward travel
distance

03-REVERSE ODO M

Reverse travel
distance

04-F1 ODO Meter

F1 travel distance

05-F2 ODO Meter

F2 travel distance

06-F3 ODO Meter

F3 travel distance

07-R1 ODO Meter

R1 travel distance

08-R2 ODO Meter

R2 travel distance

09-R3 ODO Meter

R3 travel distance

Displayed information of 1000 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.
a The data cannot be reset.

D275AX-5E0

30 Testing and adjusting

SEN01416-00

4)

Displayed information of forward odometer (02)


On this screen, the integrated forward
travel distance is displayed.
a The data cannot be reset.

7)

Display of F2 odometer (05)


On this screen, the integrated F2 (forward
2nd gear speed) travel distance is displayed.
a The data cannot be reset.

5)

Display of reverse odometer (03)


On this screen, the integrated reverse
travel distance is displayed.
a The data cannot be reset.

8)

Display of F3 odometer (06)


On this screen, the integrated F3 (forward
3rd gear speed) travel distance is displayed.
a The data cannot be reset.

6)

Display of F1 odometer (04)


On this screen, the integrated F1 (forward
1st gear speed) travel distance is displayed.
a The data cannot be reset.

9)

Display of R1 odometer (07)


On this screen, the integrated R1 (reverse
1st gear speed) travel distance is displayed.
a The data cannot be reset.

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33

SEN01416-00

10) Display of R2 odometer (08)


On this screen, the integrated R2 (reverse
2nd gear speed) travel distance is displayed.
a The data cannot be reset.

30 Testing and adjusting

12) When operating machine in load memory


display mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) displays normally and the machine can be
operated normally.
a To select another screen, return the
parking brake lever to the LOCK position and perform the necessary procedure.

11) Display of R3 odometer (09)


On this screen, the integrated R3 (reverse
3rd gear speed) travel distance is displayed.
a The data cannot be reset.

34

D275AX-5E0

30 Testing and adjusting

10. Real-time monitoring mode


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

SEN01416-00

2)

Selecting and entering monitored items


i) On the code input screen, input the 5digit code of the item to be monitored
by operating information switch (5),
shift-up switch (6), and shift-down
switch (7).
q
[ > ]: Move cursor to right.
q
[ < ]: Move cursor to left.
q
[UP]: Increase number.
q
[DOWN]:Decrease number.

Selecting and executing mode


i) Select "Real-time monitoring mode"
on the mode selection screen.
a If the mode is selected, the title is
displayed on multi-information
section (2).
ii) Display the monitoring code input
screen by operating buzzer cancel
switch (4).
q
[U]: Execute mode.

ii)

D275AX-5E0

After inputting the code, display the


m o n ito ring scree n by op erating
buzzer cancel switch (4).
q
[U]: Enter input code.
a If the input code is correct, the
monitoring screen shown at right
appears.

35

SEN01416-00
a

3)

36

30 Testing and adjusting

If the input code is abnormal, the


code input screen appears again
after the screen shown.

Contents of display on monitoring screen


(Figure shows examples)
[1] Code
[2] Monitoring item
[3] Information
[4] Unit (Not displayed for some items)
a For the details, see the "Monitoring mode table".

4)

Function of holding monitoring information


If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be
held and released by operating buzzer
cancel switch (4).
q
[U]: Hold and release.
a While the monitored item is held, the
letter "H" is displayed at the left end of
the lower line.

5)

When operating machine in monitoring


mode
If the parking brake lever is set in the
FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
a To select another screen, return the
parking brake lever to the FREE position and perform the necessary procedure.

D275AX-5E0

30 Testing and adjusting

6)

SEN01416-00

Automatic selection of monitoring item


(Limited function)
After one of some monitoring items is
selected, if the information switch is operated, the next monitoring item is selected
automatically, even if the code of the next
monitoring item is not input.
q
[ > ]: Code is increased
q
[ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Automatic selection column of the Monitoring mode table. Those items are
selected in the order of their numbers.
a Note that this operation is not effective while the parking brake lever is in
the RESET position.
a You may return to the screen for
inputting codes and enter a code
without using this function.

D275AX-5E0

37

SEN01416-00

30 Testing and adjusting

Monitoring mode table


No.

Code

Monitoring item

Unit

Remarks

Automatic
selection

00201 ENG M ID

Engine controller model name

01000 ENG REV

Engine speed

01603 Remote Th

2nd throttle position

03000 FUEL DIAL

Fuel control dial voltage

mV

25

03200 BATTERY

Battery voltage

mV

39

03201 S/T ACC

Steering controller ACC input voltage

mV

03202 S/T PWR2

Steering controller load power supply


voltage

mV

03203 E-ECM PW

Engine controller power supply voltage

mV

03207 S/T PWR1

Steering controller unswitched power


supply voltage

mV

10

03208 T/M PWR1

Transmission controller unswitched


power supply voltage

mV

11

03212 T/M ACC

Transmission controller ACC input


voltage

mV

12

03216 T/M PWR2

Transmission controller load power


supply voltage

mV

13

04104 COOLANT TP

Engine coolant temperature

04105 COOLANT TP

Engine coolant temperature sensor


voltage

mV

14

Character

rpm

15

04200 FUEL SENS

Fuel level sensor voltage

mV

37

16

04401 HYD. TEMP.

Hydraulic oil temperature

17

08100 HSI BREAK

HSI line Brake point

rpm

18

08200 TQ Sel

Torque curve selection

Character

19

08300 Droop Type

Droop type selection

Character

20

08400 Droop SW

Droop switch selection

Character

21

08500 Droop Trim

Droop trim selection

Character

22

10500 S/T 5V PW1

Steering controller sensor 5V power


supply voltage (for potentiometer)

mV

23

10501 T/M 5V PW1

Transmission controller sensor 5V power


supply voltage (for potentiometer)

mV

24

10505 S/T 5V PW2

Steering controller sensor 5V power


supply voltage 2

mV

25

10506 T/M 5V PW2

Transmission controller sensor 5V power


supply voltage 2

mV

26

10700 S/T 24V PW

Steering controller sensor 24V power


supply voltage

mV

27

10701 T/M 24V PW

Transmission controller sensor 24V


power supply voltage

mV

28

14200 FUEL TMP

Fuel temperature

29

14201 FUEL TMP

Fuel temperature sensor voltage

mV

30

17201 PCV TMG

PCV opening timing

CA

31

17500 ENG MODE

Engine controller mode selection

Character

32

18000 EGR IN PRS

EGR valve inlet pressure

MPa

33

18001 EGR IN PRS

EGR valve inlet pressure sensor voltage

mV

34

18100 EGR VALVE

EGR valve position

mm

35

18101 EGR VALVE

EGR valve position sensor voltage

mV

38

D275AX-5E0

30 Testing and adjusting

SEN01416-00

Monitoring item

Unit

Remarks

Automatic
selection

No.

Code

36

18200 BPS VALVE

BYPAS valve position

mm

37

18201 BPS VALVE

BYPAS valve position sensor voltage

mV

38

18300 ENG IVSW 1

Engine controller idle validation switch 1

bit

See detailed information

39

18301 ENG IVSW 2

Engine controller idle validation switch 2

bit

See detailed information

40

18500 BOOST TMP

Boost temperature

41

18501 BOOST TMP

Boost temperature sensor voltage

mV

42

18600 INJECT CMD

Final injection quantity command

mg/st

43

18700 ENG TRUQUE Engine output torque

Nm

44

18900 E-ECM TP

45

20201 T/M. PROGRM Transmission controller program version Character

46

20202 S/T. PROGRM

Steering controller program version

Character

47

20216 ENG BLD

Engine controller build version

Character

48

20217 ENG CAL

Engine controller calibration data version Character

49

20300 KOMTRAX

KOMTRAX LED monitor

LED

40

50

20400 E-ECM SN

Engine controller ECM serial No.

Character

51

30100 T/C TEMP.

Torque converter oil temperature

52

31400 T/M OUT

Transmission controller output speed

rpm

53

31520 T/M-FILL

Transmission controller fill switch input


condition

bit

See detailed information

54

31521 S/T FILL

Steering controller fill switch input


condition

bit

See detailed information

55

31602 1st CLUTCH

1st clutch ECMV current command value

mA

56

31603 2nd CLUTCH

2nd clutch ECMV current command


value

mA

57

31604 3rd CLUTCH

3rd clutch ECMV current command value

mA

58

31606 Rev CLUTCH

Reverse clutch ECMV current command


value

mA

59

31608 Frd CLUTCH

Forward clutch ECMV current command


value

mA

60

31612 1 CLUTCH F

1st clutch ECMV output current


(Feedback value)

mA

33

61

31613 2 CLUTCH F

2nd clutch ECMV output current


(Feedback value)

mA

34

62

31614 3 CLUTCH F

3rd clutch ECMV output current


(Feedback value)

mA

35

63

31616 R CLUTCH F

Reverse clutch ECMV output current


(Feedback value)

mA

32

64

31618 BRAKE R. H.

Right brake ECMV output current


(Feedback value)

mA

27

65

31619 BRAKE L. H.

Left brake ECMV output current


(Feedback value)

mA

26

66

31620 BRAKE R. H.

Right brake ECMV current command


value

mA

67

31621 BRAKE L. H.

Left brake ECMV current command


value

mA

68

31622 F CLUTCH F

Forward clutch ECMV output current


(Feedback value)

mA

31

69

31623 FAN PUMP. O

Fan pump EPC current command value

mA

D275AX-5E0

Engine controller engine internal


temperature

39

SEN01416-00

30 Testing and adjusting

Monitoring item

Unit

Automatic
selection

No.

Code

Remarks

70

31624 FAN PUMP. F

Fan pump EPC output current


(Feedback value)

mA

71

31625 PITCH SOL.

Pitch solenoid current

mA

72

31626 HSS M. FREE

Motor free solenoid voltage

mV

73

31627 L/U SOL

Lockup solenoid current

mA

36

74

31628 E. BRAKE SL

Emergency stop prevention solenoid


current

mA

28

75

31701 DECEL

Decelerator position

76

31703 DECEL

Decelerator pedal potentiometer voltage

mV

24

77

31706 F THROTTLE

Final accelerator position

78

32900 BODY ANGLE

Machine pitch angle

deg

18

79

36001 Accel Adj

Throttle correction value

MPa

CA

80

36200 PRESS CMD

Final common rail command

81

36300 INJECT CMD

Final injection timing command

82

36400 RAIL PR

Common rail pressure

MPa

11

83

36401 RAIL PR

Common rail pressure sensor voltage

mV

84

36500 BOOST PRS

Boost pressure

kPa

85

36501 BOOST PRS

Boost pressure sensor voltage

mV

86

36700 ENG TORQUE Engine conversion torque

13

87

37200 EG OIL PRS

Engine oil pressure

kPa

10

88

37201 EG OIL PRS

Engine oil pressure sensor voltage

mV

89

37301 FUEL RATE

Momentary fuel consumption

L/h

90

37400 AMB PRESS

Ambient pressure

kPa

91

37401 AMB PRESS

Ambient pressure sensor voltage

mV

92

40001 VEHICLE SP

Theoretical travel speed

km/h

93

40905 T/M-SW1

Transmission controller switch input


signal 1

bit

See detailed information

94

40906 T/M-SW2

Transmission controller switch input


signal 2

bit

See detailed information

95

40907 T/M OP SIG

Transmission controller operation input


signal

bit

See detailed information

96

40908 T/M HYD SW

Transmission controller blade lever oil


pressure switch input signal

bit

See detailed information

97

40909 T/M SOL. 2

Transmission controller ON/OFF output


signal 2

bit

See detailed information

98

40910 S/T-SW1

Steering controller switch input signal 1

bit

See detailed information

99

40911 S/T-SW2

Steering controller switch input signal 2

bit

See detailed information

100 40913 S/T-SW5

Steering controller switch input signal 5

bit

See detailed information

101 40914 S/T SOL. 1

Steering controller ON/OFF output


signal 1

bit

See detailed information

102 40915 S/T SOL. 2

Steering controller ON/OFF output


signal 2

bit

See detailed information

103 43502 IdleCancel

Warm-up operation cancel flag

bit

See detailed information

104 44202 Accel Up

Throttle upper limit value data

105 44203 Accel Low

Throttle lower limit value data

106 50200 T/M LEVR 1

FR lever potentiometer 1 voltage

mV

19

107 50201 T/M LEVR 2

FR lever potentiometer 2 voltage

mV

20

108 50300 S/T LEVR 1

Steering lever potentiometer 1 voltage

mV

21

40

(Absolute pressure)

12

D275AX-5E0

30 Testing and adjusting

No.

Code

SEN01416-00

Monitoring item

Unit

Remarks

Automatic
selection

109 50301 S/T LEVR 2

Steering lever potentiometer 2 voltage

mV

22

110 50400 BRAKE PEDL

Brake pedal potentiometer voltage

mV

23

111 50500 HSS PUMP D

HSS differential oil pressure

MPa

15

112 50501 HSS PUMP A

HSS oil pressure A

MPa

16

113 50502 HSS PUMP B

HSS oil pressure B

MPa

17

114 50503 HSS PUMP A

HSS oil pressure A sensor voltage

mV

115 50504 HSS PUMP B

HSS oil pressure B sensor voltage

mV

116 50600 HSS L. H. F

Left HSS pump EPC output current


(Feedback value)

mA

29

117 50601 HSS R. H. F

Right HSS pump EPC output current


(Feedback value)

mA

30

118 50602 HSS L. H. O

Left HSS pump EPC current command


value

mA

119 50603 HSS R. H. O

Right HSS pump EPC current command


value

mA

120 50900 N-SAFTY

Neutral safety relay drive voltage

mV

38

121 51000 ENG REG

Regulation circuit command value

rpm

122 51100 FUEL DIAL

Fuel control dial command speed

rpm

123 60000 TRACTION

Theoretical traction force

124 60100 BODY ANGLE

Pitch angle sensor voltage

mV

125 60200 ACCELERATN Acceleration sensor voltage

mV

126 60300 SSC ORDER

SSC command value

rpm

127 60400 S/T-SW6

Steering controller SW input signal 6

bit

Engine controller ACC cut relay drive


128 60500 ENG. CON. PW
voltage

mV

129 60600 BR HOLD

Steering controller battery relay drive


voltage

mV

130 60700 S/T MODE

Steering condition variable

Character

131 60800 FILL MODE

Fill condition setting variable

Character

132 60909 MOD. MODE

Modulation condition setting variable

Character

133 70000 CHG. P. MODE Gearshift point condition setting variable Character

134 70200 T/M OUT

Transmission output speed sensor


voltage

mV

135 70300 B. KNOB SW

Transmission controller blade lever knob


switch input signal

bit

136 70304 T/M SOL. 1

Transmission controller ON/OFF output


signal 1

bit

See detailed information

See detailed information

137 70305 T/M RIPER2

Ripper lever oil pressure switch input

bit

138 70400 BACK ALARM

Backup alarm relay drive voltage

mV

139 70600 DUAL SOL.

Dual tilt solenoid current

mA

140 70700 HYD. PUMP 1

Work equipment oil pressure 1

MPa

14

141 70701 HYD. PUMP 1

Work equipment oil pressure 1 sensor


voltage

mV

142 92100 F1 SMR

F1 travel integrated time

143 92101 F2 SMR

F2 travel integrated time

144 92102 F3 SMR

F3 travel integrated time

145 92200 R1 SMR

R1 travel integrated time

146 92201 R2 SMR

R2 travel integrated time

D275AX-5E0

See detailed information

41

SEN01416-00

No.

Code

30 Testing and adjusting

Automatic
selection

Monitoring item

Unit

Remarks

147 92202 R3 SMR

R3 travel integrated time

148 99901 TRIG T F

Trigger time F

msec

149 99902 TRIG T R

Trigger time R

msec

150 99903 TRIG T 1

Trigger time 1

msec

151 99904 TRIG T 2

Trigger time 2

msec

152 99905 TRIG T 3

Trigger time 3

msec

153 99906 TM SFT

Transmission shift condition

154 99907 LU

Lockup condition

bit

155 99908 TM IN TRQ

Transmission input torque

Nm

156 99909 DOZING h

Dozing time

157 99910 RIPPING h

Ripping time

158 99911 PATH NUM

Number of path

path

159 99913 TC IN TRQ

Torque converter input torque

Nm

160 99914 H. P 1 TRQ

Work equipment pump 1 input torque

Nm

161 99917 BR L PRESS

Left brake command pressure

MPa

162 99918 BR R PRESS

Right brake command pressure

MPa

42

Character

See detailed information

D275AX-5E0

30 Testing and adjusting

SEN01416-00

Detailed information on bit display codes


Examples of display of bit information
a The display position of the bit information in the
"Real-time monitoring mode (Display of only 1
item)" is different from that in the "Dual display
monitoring mode (Simultaneous display of 2
items)".
a The bit information is displayed by [ _ ] for OFF
and [ o ] for ON in the places 1 8.
a The state of each item shown below is the condition for turning on the bit.

18300: Engine controller idle validation switch 1


1: Idle validation switch: When detected
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)

D275AX-5E0

18301: Engine controller idle validation switch 2


1: Idle validation switch: When detected
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)

31520: Input state of transmission controller related


fill switch
1: Forward clutch fill switch: ON
2: Reverse clutch fill switch: ON
3: 1st clutch fill switch: ON
4: 2nd clutch fill switch: ON
5: 3rd clutch fill switch: ON
6: (Unused)
7: (Unused)
8: (Unused)

43

SEN01416-00

31521: Input state of steering controller fill switch


1: Left brake fill switch: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: Right brake fill switch: ON
7: (Unused)
8: (Unused)

40905: Transmission controller input signal 1


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

44

30 Testing and adjusting

40906: Transmission controller input signal 2


1: Automatic gear shift-down switch: ON
2: Neutral switch: ON
3: Neutral switch: OFF
4: Shift mode switch: ON
5: Shift mode switch: OFF
6: (Unused)
7: (Unused)
8: (Unused)
a Items 2 and 5 are for optional specifications.

40907: Transmission controller operation input signal


1: ACC signal
2: (Unused)
3: R signal
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)

D275AX-5E0

30 Testing and adjusting

40908: Input signal of transmission controller blade


lever oil pressure switch
1: Blade raise switch: ON
2: Blade lower switch: ON
3: (Unused)
4: (Unused)
5: Blade left tilt switch: ON
6: Blade right tilt switch: ON
7: (Unused)
8: (Unused)
a This item is for optional specifications.

40909: Transmission controller ON/OFF output


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

D275AX-5E0

SEN01416-00

40910: Steering controller switch input signal 1


1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: Parking brake lever switch: FREE
6: Parking brake lever switch: LOCK
7: (Unused)
8: (Unused)

40911: Steering controller switch input signal 2


1: Buzzer cancel switch: T position (Right)
2: Buzzer cancel switch: U position (Left)
3: Information switch: > position (Right)
4: Information switch: < position (Left)
5: Service switch: ON
6: Pivot turn mode switch: ON
7: (Unused)
8: (Unused)

45

SEN01416-00

30 Testing and adjusting

40913: Steering controller switch input signal 5


1: ACC signal: ON
2: Pre-lubricating oil pressure switch: ON
3: R signal
4: (Unused)
5: Fan reverse mode switch: ON
6: Fan clean mode switch: ON
7: (Unused)
8: (Unused)
a Items 2 and 5 are for optional specifications.

40915: Steering controller ON/OFF output signal 2


1: Pre-lubrication motor relay drive: ON
2: Engine ACC cut relay drive: (ON)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
a This item is for optional specifications.

40914: Output signal of steering controller ON/OFF


1: HSS MOTOR FREE solenoid: ON
2: Snap shot signal: ON
3: Fan reverse solenoid: ON
4: (Unused)
5: Battery relay drive output: ON
6: Sudden stop prevention valve: ON
7: (Unused)
8: (Unused)
a Item 2 is for optional specifications.

43502: Warm-up operation cancel flag


1: Warm-up operation cancel flag: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)

46

D275AX-5E0

30 Testing and adjusting

60400: Steering controller switch input signal 6


1: (Unused)
2: C-signal: ON
3: Engine low idle: ON
4: Engine stop signal: ON
5: Hydraulic oil level switch signal: ON
6: Pre-lubrication motor drive signal: ON
7: (Unused)
8: (Unused)
a Items 3 and 6 are for optional specifications.

70300: Input signal of transmission controller blade


lever knob switch
1: Blade lever tilt switch: Single tilt
2: Blade lever tilt switch: Dual tilt
3: Blade lever pitch switch: When ON
4: Blade lever pitch switch: When OFF
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)

D275AX-5E0

SEN01416-00

70304: Transmission controller ON/OFF output signal


1: Dual tilt solenoid: ON
2: Pitch solenoid: ON
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)

70305: Input signal of ripper lever oil pressur


switch
1: (Unused)
2: Ripper lift RAISE oil pressure switch:
ON (Operated)
3: Ripper lift LOWER oil pressure switch:
ON (Operated)
4: Ripper lift TILT-IN oil pressure switch:
ON (Operated)
5: Ripper lift TILT-OUT oil pressure switch:
ON (Operated)
6: (Unused)
7: (Unused)
8: (Unused)
a Item 5 is for the optional specification.

47

SEN01416-00

30 Testing and adjusting

99907: Lockup condition


1: Forward clutch outputing
2: Reverse clutch outputing
3: 1st clutch outputing
4: 2nd clutch outputing
5: 3rd clutch outputing
6: Modulating
7: Lockup clutch outputing
8: Neutral

48

D275AX-5E0

30 Testing and adjusting

11. Dual display monitoring mode


(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be displayed simultaneously.
a Note that only codes and monitoring information are displayed in this mode since
the usable display columns are limited.
(Item names and units cannot be displayed.)
1)

Selecting and executing mode


i) Select "Dual display monitoring mode"
on the mode selection screen.
a If the mode is selected, code
(dR) is displayed on gear speed
display section (1) and the title is
displayed.
ii) Display the monitoring code input
screen by operating buzzer cancel
switch (4).
q
[U]: Execute mode.

SEN01416-00

2)

Selecting and entering monitored items


i) On the code input screen, input the 5digit codes of the items to be monitored to the upper and lower lines by
operating information switch (5), shiftup switch (6), and shift-down switch
(7).
q
[ > ]: Move cursor to right.
q
[ < ]: Move cursor to left.
q
[UP]: Increase number.
q
[DOWN]: Decrease number.
ii) After inputting the codes, display the
m o n ito ring scree n by op erating
buzzer cancel switch (4).
q
[U]: Enter input code.

D275AX-5E0

If the input codes are normal, the


mo nito ring s cree n sh own a t
appears.

49

SEN01416-00
a

3)

50

30 Testing and adjusting

If the input codes are abnormal,


the code input screen appears
again after the screen shown at
right.

4)

When operating machine in monitoring


mode
If the parking brake lever is set in the
FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
a To select another screen, return the
parking brake lever to the FREE position and perform the necessary procedure.

Contents of display on monitoring screen


(Right figure shows examples)
[1] Code 1
[2] Information 1
[3] Code 2
[4] Information 2
a For the details, see the "Monitoring
mode table".

D275AX-5E0

SEN01416-00

30 Testing and adjusting

D275AX-5E0 Bulldozer
Form No. SEN01416-00

52

D275AX-5E0

SEN01417-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

30 Testing and adjusting

Testing and adjusting, Part 4


Adjustment method when controller has been replaced ................................................................................. 2
Method of starting use of KOMTRAX terminal ................................................................................................ 4
Indication by KOMTRAX terminal lamps......................................................................................................... 7
Preparation work for troubleshooting for electric system .............................................................................. 10
Handling of optional devices ......................................................................................................................... 13
Pm Clinic....................................................................................................................................................... 14

D275AX-5E0

SEN01417-00

Adjustment method when


controller has been replaced
a

1.

2.

3.

30 Testing and adjusting

After the machine is assembled or transmission controller or steering controller is


replaced, adjust the system according to the
following procedure.
If the system is not adjusted, the machine
may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. Accordingly, take a record of the next replacement
periods of the oils and filters.
Precautions for replacing a controller:
Stop the machine on a save place, turn the
starting switch OFF, check that the battery relay
is turned OFF, wait for about 1 minute, and then
replace the controller.
The control is still operating for a while after
the starting switch is turned OFF and the battery relay is turned OFF. Accordingly, do not
remove the controller just after the battery
relay is turned OFF.
Controller initial setting
After replacing controller, turn the switch ON
temporarily (ACC position) and after approx.
10 seconds, turn the switch OFF.
q
After turning the switch OFF, the controller
is initialized. Therefore leave it for approx.
1 minute after turning the switch OFF
even if the battery relay shuts down.
a When the starting switch is turned ON for
the first time, an error (CALL E04) may be
displayed. You may continue the work,
however.
Setting system in service mode
After step 1, turn the starting switch ON again
and set the monitor panel in the "Adjustment
mode" of the service mode.
a For details of the operation in the service
mode, see the special functions section of
machine monitor (EMMS).

4.

Adjusting transmission controller


Select Transmission controller specification set
(0003) and adjust the transmission controller.
a Execute this code only when the steering
controller is also replaced.

5.

Turning power on again


Turn the starting switch off (battery relay off)
and leave it for 1 minute. Then turn the starting
switch on, then reset the monitor panel in the
"Adjustment Mode" of the service mode.

6.

Adjusting machine specification


Select Machine specification set (0004) and
adjust the machine specification.

Adjusting steering controller


Select Steering controller specification set
(0002) and adjust the steering controller.
a Execute this code only when the transmission controller is also replaced.

D275AX-5E0

30 Testing and adjusting

7.

Adjusting brake potentiometer


Select Brake potentiometer initial set (0005)
and adjust the brake potentiometer.

8.

Adjusting pitch angle sensor


Select the initial setting (0009) of the pitch
angle sensor and adjust the pitch angle sensor.

9.

KOMTRAX system set


Set KOMTRAX system using Adjustment
mode (0021).
(If not, take care that default is not-equipped
set.)

D275AX-5E0

SEN01417-00

10. Turning power on again


Turn the starting switch OFF (battery relay off)
and after leaving it for 1 minute, turn it ON
again.
11. Checking failure codes
1) Set the monitor panel in the Electrical
system failure code display mode of the
service mode.
2) Check if any active failure codes exist. If
not, delete all the failure codes recorded.
a If any active failure codes exist, eliminate the cause of the incident by troubleshooting, then carry out steps 10
and 11 again.
a Precautions after replacing controller:
If any controller is replaced, the service meter in the oil and filter maintenance mode is reset to 0.
As a result, the replacement period
displayed on the monitor panel may
be different from the actual operating
hours. To solve this problem, determine the first replacement periods of
the oils and filters after the replacement of the controller according to the
replacement periods recorded before
the replacement of the controller.

SEN01417-00

Method of starting use of


KOMTRAX terminal

30 Testing and adjusting

4)

If KOMTRAX terminal is installed when machine


is delivered:
a If the KOMTRAX terminal is installed (as standard) when the machine is delivered, carry out
the following procedure.
1.

Notification of machine name, machine


model, and serial No.
Notify the responsible person for use of
KOMTRAX of the name, model, and serial No.
of the machine.

2.

Registration of machine
Using the KOMTRAX client personal computer, the responsible person for use of
KOMTRAX must register the machine.
a For the procedure, see "Manual for responsible person for use of KOMTRAX".
a The above is all of the necessary work.

5)
6)
7)
8)

Turn the starting switch ON and wait for 5


seconds.
Disconnect inspection connector 2 and
wait for 5 seconds.
Reconnect inspection connector 1 and
wait for 5 seconds.
Reconnect inspection connector 2 and
wait for 5 seconds.
Check that the 7-segment lamp of the
KOMTRAX terminal indicates normally.
a If the inspection result is normal, the
7-segment lamp indicates for 30 seconds after step 7). (It indicates "d",
"0" and "" repeatedly.)

If KOMTRAX terminal is installed after machine


is delivered:
a If the KOMTRAX terminal is installed (retrofitted) after the machine is delivered, carry out
the following procedure.
1.

Inspection of machine for starting use of


KOMTRAX
a Perform steps 4) to 7) in 30 seconds.
1) Turn the starting switch OFF and wait for
at least 5 seconds, and then go to the next
step.
2) Visually check that inspection connectors
1 and 2 are connected.
q
Inspection connector 1:
T0F (female) and T0M (male)
q
Inspection connector 2:
T1F (female) and T1M (male)
a
a

3)

If the 7-segment lamp indicates "Normal", go to the next step.


If the 7-segment lamp indicates
"Abnormal", repeat the above procedure from step 1).

Disconnect inspection connector 1 and


wait for 5 seconds.

D275AX-5E0

30 Testing and adjusting

SEN01417-00
a

If the 7-segment lamp indicates "Network trouble", check for "LED-C4",


referring to "Display of KOMTRAX
terminal lamp" (If CAN is not recognized, check the CAN wiring harness
of the KOMTRAX terminal. If there is
any defect, repair and repeat the
above procedure from step 1).

9)

Turn the starting switch to the START


position and hold it for at least 5 seconds
and check that the engine does not start.
a If the engine starts, repeat the above
procedure from step 1).
10) Return the starting switch to the ON position and hold it for at least 5 seconds.
a Do not return the starting switch to
the OFF position.
11) Turn the starting switch to the START
position again and check that the engine
starts.
12) Check that the 7-segment lamp of the
KOMTRAX terminal indicates normally.
a If the 7-segment lamp of the
KOMTRAX terminal indicates "Normal", go to the next step (It takes 90
seconds 15 minutes for the system
to indicate "Normal").
a If the 7-segment lamp indicates "GPS
data detection trouble", check the
GPS antenna and cable for a defect.
If there is any defect, repair and
repeat the above procedure from step
1).
a If the 7-segment lamp indicates
"Communication receiving trouble",
check the communication antenna
and cable for a defect. If there is any
defect, repair and repeat the above
procedure from step 1).
a If the 7-segment lamp indicates "GPS
data detection trouble and Communication receiving trouble", check the
GPS antenna and cable and the communication antenna and cable for a
defect. If there is any defect, repair
and repeat the above procedure from
step 1).

D275AX-5E0

SEN01417-00

13) Turn the starting switch to the OFF position.


14) After 5 seconds, check that the 7-segment
lamp indicates "Normal".
a If "Normal" is indicated, the inspection
for starting use is finished.
a If "Abnormal" is indicated, the inspection for starting use is not finished
normally. In this case, repeat the
above procedure from step 1).

30 Testing and adjusting

2.

Application for start of use


a Before applying for start of use, be sure to
finish the inspection of the machine for
starting use.
1) Notify the following data of the machine
inspected for start of use to the responsible person for use of KOMTRAX.
(1) Data of machine inspected for start of
use (Machine name, machine monitor, and serial No.)
(2) Part No. and serial No. of KOMTRAX
terminal
(3) Service meter reading when KOMTRAX
terminal is installed (Unit: 0.1 h)

The condition of the indicator lamp can also be


checked in the monitoring mode (ID: 20300) of
the machine monitor.

2)

Using the KOMTRAX client personal computer, the responsible person for use of
KOMTRAX must register the machine.
a For the procedure, see "Manual for
responsible person for use of
KOMTRAX".
a The above is all of the necessary
work.

D275AX-5E0

30 Testing and adjusting

SEN01417-00

Indication by KOMTRAX terminal lamps

LEDs for CPU


1. LED-C1 (R signal and ACC signal)
2. LED-C2 (Condition of starting output)
3. LED-C3 (Condition of S-NET and C signal)
4. LED-C4 (Condition of CAN)
5. LED-C5 (Download writing condition)
6. LED-C6 (Download writing condition)

D275AX-5E0

7-segment lamp and dot for CPU


7. 7-segment lamp (Number of males which are
not sent yet)
8. Dot (Measuring condition of GPS)

SEN01417-00

30 Testing and adjusting

The KOMTRAX system indicates the information in the system and contents of processing with the LED display unit at the top of the KOMTRAX terminal. Accordingly, if the system seems to have a trouble, carry out
the following checks.
q
Check of antennas
q
Check of terminal LEDs
Before using the KOMTRAX system, you must complete application for start of use and inspection of the
machine for starting use.
Check of antennas
a Before checking the indication of the LED unit, check that the communication antenna and GPS
antenna are free from abnormality.
q
The communication antenna must not be off the position and must not be broken.
q
The communication antenna cable must not be disconnected and must be connected to the KOMTRAX
terminal normally.
q
The GPS antenna must not be off the position and must not be broken.
q
The GPS antenna cable must not be disconnected and must be connected to the KOMTRAX terminal
normally.
Check of terminal LEDs
1. Contents of indication of LEDs for CPU
a When checking the indication of the LEDs, turn the starting switch to the ON or START position or run
the engine.
No.

LED

Name/Function

Starting switch ACC


LED-C1 signal and alternator
R signal
Condition of engine
control signal

LED-C2

Condition of S-NET
LED-C3 connection and starting switch C signal

LED-C4

Condition of CAN
connection

Indication (*1)
ON

Starting switch ACC signal: ON, Alternator R signal: ON

Quick blink

Starting switch ACC signal: OFF, Alternator R signal: ON

Slow blink

Starting switch ACC signal: ON, Alternator R signal: OFF

OFF

Starting switch ACC signal: OFF, Alternator R signal: OFF

ON

Engine control signal: ON

OFF

Engine control signal: OFF

ON

S-NET: Connected, Starting switch C signal: OFF

Quick blink

Starting switch C signal: ON

Slow blink

(Unused)

OFF

S-NET: Disconnected, Starting switch C signal: OFF

ON

CAN: Installed, (Fuel sensor: Not installed)

Quick blink

CAN: Installed, (Fuel sensor: Installed)

Slow blink

CAN: Not installed, (Fuel sensor: Installed)

OFF
5
6

LED-C5 Condition of
download writing
LED-C6

Contents of indication

Either is ON

CAN: Not installed, (Fuel sensor: Not installed)


Download writing mode (Special function of system
administrator)

Both are OFF Normal operation mode

*1: Types of blink and blinking interval


Quick blink: Blinking at intervals of about 1 second
Slow blink: Blinking at intervals of about 4 seconds
a

The contents of the LED display can also be checked in the monitoring mode (ID: 20300) of the machine
monitor.

D275AX-5E0

30 Testing and adjusting

2.
a

Contents of indication of 7-segment lamp and dot for CPU


When checking the indication of the LEDs, turn the starting switch to the ON position.

No. Indicator

SEN01417-00

7-segment
lamp

Dot

Name/Function

Indication (*2)

Lighting of 0 9
Number of mails
which are not sent yet
and satellite capturQuick blink of
ing condition
09

Measuring condition
of GPS

Contents of indication
Figure indicates number of mails which are not sent yet (When
10 or more mails are not sent yet, 9 is indicated).
Lighting indicates that satellite is captured.
Figure indicates number of mails which are not sent yet (When
10 or more mails are not sent yet, 9 is indicated).
Quick blink indicates that satellite is not captured.

ON

GPS has completed measuring (Position is recognized. See


*3.)

OFF

GPS has not completed measuring (Position is not recognized.


See *3.)

*2: Types of blink and blinking interval


Quick blink: Blinking at intervals of about 0.5 seconds
Slow blink: Blinking at intervals of about 2.0 seconds
*3: Remarks on measuring condition of GPS
Even in an outdoor place where the radio waves are strong enough, it may take more than 1 minute to
complete measurement after the starting switch is turned ON. If the radio waves are very weak or no
radio waves are received, the GPS cannot measure the position.
a

The contents of the 7-segment and dot display can also be checked in the monitoring mode (ID: 20300)
of the machine monitor.

D275AX-5E0

SEN01417-00

Preparation work for


troubleshooting for electric
system

30 Testing and adjusting

2.

When carrying out troubleshooting for an electric circuit related to the machine monitor,
engine controller, transmission controller, or
steering controller, expose the related connectors according to the following procedure.

1.

Machine monitor
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
machine monitor (2) toward the operators
seat.

Engine controller
1) Open left engine side cover (3) and
remove cover (4).

2)

3)

10

Insert or connect T-adapters in or to conne ctors S01, S02, S 0 3 , a n d S 0 4 o f


machine monitor (2).

Remove the cover (5).

3)

Insert or connect troubleshooting T-adapters in or to connectors EGC1, EGC2 and


EGC3 of engine controller (6).
a Since connectors EGC1 and EGC2 are
fixed with screws, loosen those screws
before disconnecting.
a When connecting connectors EGC1 and
EGC2, tighten the screws to the specified
torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}

D275AX-5E0

30 Testing and adjusting

3.

Transmission controller
1) Slide the operator's seat to the front end
and fold the seat back forward.
2) Remove cover (7).

3)

Insert or connect T-adapters in or to connectors TMCN1, TMCN2, and TMCN3 of


transmission controller (8).
a If the connectors cannot be disconnected and connected easily, remove
the controller from the floor frame.
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
a When connecting the connectors,
tighten the screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}

D275AX-5E0

SEN01417-00

4.

Steering controller
1) Slide the operator's seat to the front end
and fold the seat back forward.
2) Remove cover (7).

3)

Insert or connect T-adapters in or to connectors STCN1, STCN2, and STCN3 of


transmission controller (9).
a If the connectors cannot be disconnected and connected easily, remove
the controller from the floor frame.
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
a When connecting the connectors,
tighten the screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}

11

SEN01417-00

5.

KOMTRAX terminal
1) Slide the operator's seat to the front end
and fold the seat back forward.
2) Remove cover (10) from the right rear of
the operator's seat.

3)

12

30 Testing and adjusting

Insert or connect a troubleshooting Tadapter in or to connector KOM1 of


KOMTRAX terminal (11).
a If it is difficult to disconnect and connect the connector, remove the terminal from the floor frame.
a Since the connector is fixed with
screws, loosen those screws before
disconnecting.
a When connecting the connector,
tighten the screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}

D275AX-5E0

30 Testing and adjusting

Handling of optional devices

SEN01417-00

This machine has connectors to install optional


devices in its fuse box. When installing any
optional device, receive the necessary signals
and power through those connectors without
modifying the wiring harness.

1.

Taking out ACC signal of starting switch


If the ACC signal (ON signal) of the starting
switch is necessary to an optional device such
as the turbocharger timer, take it out through
the following connector pin.
q
Pin (B) of CN-ESD (3-pole heavy duty wire
connector)
a A 20-A fuse is installed on the upstream
side of this connector pin.

2.

Inputting engine stop signal


When it is required to stop the engine with an
optional engine emergency stop function etc.
while the starting switch is in the ON position,
utilize the circuit of the following connectors
and pins.
q
Pin (A) of CN-ESD (3-pole heavy duty wire
connector)
a Before using, be sure to notify the Service
Section.

3.

Inputting engine low-idle command


When it is required to keep the engine speed
at low idle with an optional engine protection
function etc., utilize the circuit of the following
connectors and pins.
q
Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a Before using, be sure to notify the Service
Section.

D275AX-5E0

4.

Taking out C signal of starting switch


If the C signal (starting signal) of the starting
switch is necessary to an optional device such
as the pre-lubricator, take it out through the following connector pin.
q
CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine is shipped and connect pin (1) to
the starting signal to be output finally by
the optional device and connect pin (2) to
the starting switch signal to be input to the
optional device.

5.

Taking out external power source


If an external power source is necessary, take
it through the following connectors.
q
CN-800, CN-810 (Plug connectors)
q
CN-801, CN-811 (Plug connectors)
a A 20-A fuse is installed on the upstream
side of each of these connectors.
a CN-800 and CN-801 are prepared in the
fuse box and CN-810 and CN-811 are prepared on the outside of the floor.

13

Pm Clinic

1
Model

Serial No.

Service meter

D275AX-5E0

User name

Date of clinic

Blade

Specifications
Rear attachment

Semi-U blade
U-blade
Dual tilt blade

Multi-shank ripper
Variable giant ripper
Counterweight (

Serviceman

kg)

Shoe width
610 mm
710 mm
760 mm

Operating conditions
Quarry, mine
Coal
Gold
Limestone

Construction
Construction,
civil engineering
Roads
Tunnels

Type of soil (specific gravity )


Rock
Gravel
Sand
Clay

Type of work
Dozing
Side cutting
Ripping
Travel

%
%
%
%

Existence of abnormalities
Oil, water level check
Engine coolant level
Engine oil level
Hydraulic oil level
Engine coolant temperature Max. range

When necessary
Damper case
(

Power train
Final drive

Ambient temperature

Power train oil temperature Max. range

Max.
Min.

Height above sea level


m
Operator's opinion

Visual check results

Service code history


h
Content:

h
Content:

h
Content:

14

h
Content:

D275AX-5E0

Check positions/Method 1

D275AX-5E0

15

Check positions/Method 2

16

D275AX-5E0

Check positions/Method 3

D275AX-5E0

17

Pm Clinic check sheet

D275AX-5E0
Date

Work order No.

Serial No

Serviceman

Service meter
h

Item

Engine speed

Measurement conditions
Low idle
Deceleration pedal depressed
High idle

Unit

High idle (Deceleration cut-off mode)

rpm

Torque converter stall


Torque converter stall + work equipment relief

Engine

Blow-by pressure

Torque converter stall


High idle

Engine oil
pressure
Low idle
Boost pressure

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH Oil
Oil temperature:
Min. 80

Torque converter stall

kPa
{mmH2O}

Standard value for new machine Service limit value

650 - 750
850 - 950
2,125 - 2,175
1,570 - 1,670

Test results

Pass Fail

650 - 750
850 - 950
2,125 - 2,175

1,530 - 1,630
Max. 2.94
{Max. 300}

Min. 1,510
Min. 1,450
3.92
{400}

Min. 0.34
{Min. 3.5}

0.21
{2.1}

Min. 0.10
{Min. 1.0}

0.08
{0.8}

Min. 169
{Min. 1,270}

144
{1,080}

Max. 620

670

MPa
{kg/cm2}

kPa
{mmHg}

Exhaust temperature Torque converter stall

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.

Item

Measurement conditions

Unit

Standard value for new machine

Service limit value

MPa
{kg/cm2}

Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
0.49 - 1.0
{5 - 10}
0.39 - 0.59
{4 - 6}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
1.07 - 1.47
{11.0 - 15.0}
0-0
{0 - 0}

Max. 0.2
{Max. 2}
Max. 0.2
{Max. 2}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
0.49 - 1.0
{5 - 10}
0.39 - 0.59
{4 - 6}
1.08 - 1.47
{11 - 15}
2.45 - 2.85
{25 - 29}
1.07 - 1.47
{11.0 - 15.0}
0-0
{0 - 0}

Unit

Standard value for new machine

Service limit value

2.74 - 3.06
{28 - 31.2}
3.04 - 3.30
{31 - 33.7}

Min. 2.65
{Min. 27}
Min. 2.94
{Min. 30}

0.05 - 0.29
{0.5 - 3.0}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}
2.84 - 3.14
{29 - 32}

0.05 - 0.29
{0.5 - 3.0}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}
Min. 2.65
{Min. 27}

Inlet oil pressure


Outlet oil pressure
Low idle
Torque converter

Lock-up clutch pressure


Stator clutch pressure
Inlet oil pressure

Transmission:
Neutral
Oil temperature:
70-90

Outlet oil pressure


High idle
Lock-up clutch pressure
Stator clutch pressure
Lock-up clutch pressure

Raise engine speed,


Transmission: F1 when lock-up lamp
lights up
Stator clutch pressure
Item

Measurement conditions
Low idle

Transmission

Main relief pressure

Lubricating oil
pressure (Reference)

Steering brake

High idle

High idle
Transmission: F3

R clutch pressure

Transmission: R3 Low idle

1st clutch pressure

Transmission: F1

Low idle

2nd clutch pressure

Transmission: F2

Low idle

3rd clutch pressure

Transmission: F3

Low idle

Left brake pressure

Pass Fail

Test results

Pass Fail

Low idle

F clutch pressure

Item

18

Transmission:
Neutral

Test results

Low idle

Measurement conditions
Transmission: Low idle
Neutral High idle
Low idle

Right brake pressure

Transmission:
Neutral High idle

Brake performance

High idle, F2, brake actuated

MPa
{kg/cm2}

Unit

MPa
{kg/cm2}

Standard value for new machine Service limit value

2.84 - 3.14
{29 - 32}
3.14 - 3.43
{32 - 35}
2.84 - 3.14
{29 - 32}
3.14 - 3.43
{32 - 35}

Test results Pass Fail

Min. 2.26
{Min. 23}
Min. 2.45
{Min. 25}
Min. 2.26
{Min. 23}
Min. 2.45
{Min. 25}

Machine must not move

D275AX-5E0

Pm Clinic check sheet

D275AX-5E0
Date

Work order No.

Serial No

Serviceman

Service meter
h

Measurement conditions

HSS oil pressure

Item
HSS main relief pressure
HSS charge relief pressure
HSS servo charge pressure

PCCS lever (for travel)


right FULL
PCCS lever (for travel)
High idle
left FULL
PCCS lever (for travel)
NEUTRAL

Unit
MPa
{kg/cm2}

Measurement conditions

Unit

Hydraulic components

Ripper lift
relief

Standard value for new machine Service limit value

26.1 - 28.8
{266 - 294}

Pass Fail

Test results

Pass Fail

26.1 - 28.8
{266 - 294}

26.1 - 28.8
{266 - 294}

26.1 - 28.8
{266 - 294}

26.1 - 28.8
{266 - 294}

Blade tilt relief


High idle
(single tilt only)

26.1 - 28.8
{266 - 294}

26.1 - 28.8
{266 - 294}

Lever: Neutral

3.43 - 3.92
{35 - 40}

3.23 - 3.92
{33 - 40}
Test results

Pass Fail

Test results

Pass Fail

Test results

Pass Fail

Test results

Pass Fail

Low idle

Work equipment pump


MPa
{kg/cm2}

Ripper lift
relief

Measurement conditions

Item
Work equipment speed

Test results

38.2 - 41.7
{390 - 425}
38.2 - 41.7
{390 - 425}
2.6 - 3.4
{27 - 35}

26.1 - 28.8
{266 - 294}

Blade tilt relief


(single tilt only)

Control circuit basic


pressure

Blade RAISE
Single tilt (left

Dual tilt (left

Ripper tilt (in

right)

right)

out)

Unit

Standard value for new machine Service limit value

Low idle

8 - 15

20

High idle

3-5

Low idle

3-5

2.3 - 3.3

3.5

Low idle

5-8

10

High idle

2.3 - 3.3

3.5

Low idle

8 - 14

17

High idle

3-4

4.5

High idle

Item
Hydraulic drift

38.2 - 41.7
{390 - 425}
38.2 - 41.7
{390 - 425}
2.6 - 3.4
{27 - 35}

Common use with work equipment PPC and fan pump control
at control initial pressure

Item

Measurement conditions

Sec.

Unit

Standard value for new machine Service limit value

Hydraulic oil temperature


Blade lift drift level

Engine stopped

Max. 100

Max. 150

Max. 15

Max. 30

mm/5 min.
Ripper lift drift level
Item

Fan

Standard value for new machine Service limit value

Fan speed
Fan oil pressure

Measurement conditions
Max rotation speed
Fan 100%
Min rotation speed
speed mode
High idle

Item
Visual inspection of final drive drain plug

Measurement conditions

Unit

Standard value for new machine Service limit value

420 - 480
rpm
MPa
{kg/cm2}
Unit

Engine stopped

400

1,400 - 1,500

1,350

16.17 - 19.11
{165 - 195}

16.17 - 19.11
{165 - 195}

Standard value for new machine Service limit value


There must be no excessive metal particles

Always fill in the record when repairing, adjusting, or replacing main parts.
Date

D275AX-5E0

Service meter

Repair record

Date

Service meter

Repair record

19

Pm Clinic undercarriage check sheet

Work order No.

Date

D275AX-5E0

Serial No

Serviceman

Service meter
h

Measure the bushing temperature immediately after operations


Left side of machine
Measurement
results

Pass Fail

Measurement
results

Pass Fail

Right side of machine

Opening of track link

20

Left track

A: Clearance between links

Pin No.

1.4

Right track

A: Clearance between links

Pin No.

1.4

D275AX-5E0

Undercarriage troubleshooting report (Normal)


(Program form No.: SELA195001)

Komatsu
Undercarriage Inspection

Customer name:
Address:

D275AX-5E0

Model
Location
Soil condition

Dealer

Shoe width (mm)


Shoe type
(yyyy/m/d)

Wear
%

New

SMR
Hours on
Rebuilt Parts:

Wet
SINGLE

Wear type
NORMAL
Comments/Observation

L=l/4

RH 1042.4 1054.4
LH

master pin

Work Order No
Wet,AR,HD or Dry

Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
LH 1042.4 1054.4

LINK PITCH

Equip#

SMR
Inspector

Working condition

Serial#

260.60 263.60

1.3

RH 260.60 263.60

LINK HEIGHT1.3
BUSHING

d1

d
D is the smallest
of d1,d2 and,d3

LH

166.0

148.0

RH

166.0

148.0

LH

90.5

82.0

RH

90.5

82.0

LH

88.0

30.0

RH

88.0
200.0

30.0
175.0

200.0
200.0

175.0
175.0

200.0
21.0

175.0
33.5

21.0
21.0

33.5
33.5

LH

21.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
0.0

33.5
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
8.0

RH

0.0

8.0

New

Turned

New

Turned

GROUSER HIGHT
H

LH

CARRIER
CARRIER
Front

RH
LH

D
Rear

1.3

RH
LH

IDLER
IDLER
Front

RH

LH
Rear

1.3

TRACK ROLLER

D
h2

h1

D=2(h1-h2)

1.3
SPROCKET

h1

H is the smallest of
h1,h2,h3
h3

h2

1.3

RH
1

LH

LH

LH

LH

LH

LH

LH

LH

LH

10

LH

RH

RH

RH

RH

RH

RH

RH

RH

RH

10

RH

Remarks:

D275AX-5E0

21

Undercarriage troubleshooting report (Impact)


(Program form No.: SELA195001)

Komatsu
Undercarriage Inspection

Customer name:
Address:

D275AX-5E0

Model
Location
Soil condition

Dealer

Shoe width (mm)


Shoe type
(yyyy/m/d)

Wear
%

New

SMR
Hours on
Rebuilt Parts:

Wet
SINGLE

Wear type
IMPACT
Comments/Observation

L=l/4

RH 1042.4 1054.4
LH

master pin

Work Order No
Wet,AR,HD or Dry

Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
LH 1042.4 1054.4

LINK PITCH

Equip#

SMR
Inspector

Working condition

Serial#

260.60 263.60

1.3

RH 260.60 263.60

LINK HEIGHT1.3
BUSHING

d1

d
D is the smallest
of d1,d2 and,d3

LH

166.0

148.0

RH

166.0

148.0

LH

90.5

84.5

RH

90.5

84.5

LH

88.0

30.0

RH

88.0
200.0

30.0
175.0

200.0
200.0

175.0
175.0

200.0
21.0

175.0
33.5

21.0
21.0

33.5
33.5

LH

21.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
255.0
0.0

33.5
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
195.0
8.0

RH

0.0

8.0

New

Turned

New

Turned

GROUSER HIGHT
H

LH

CARRIER
CARRIER
Front

RH
LH

D
Rear

1.3

RH
LH

IDLER
IDLER
Front

RH

LH
Rear

1.3

TRACK ROLLER

D
h2

h1

D=2(h1-h2)

1.3
SPROCKET
H is the smallest of
h1,h2,h3
h3

h1

h2

1.3

RH
1

LH

LH

LH

LH

LH

LH

LH

LH

LH

10

LH

RH

RH

RH

RH

RH

RH

RH

RH

RH

10

RH

Remarks:

22

D275AX-5E0

SEN01417-00

30 Testing and adjusting

D275AX-5E0 Bulldozer
Form No. SEN01417-00

24

D275AX-5E0

SEN01767-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

40 Troubleshooting

Failure code table and fuse locations


Failure codes table.......................................................................................................................................... 2
Fuse locations............................................................................................................................................... 10

D275AX-5E0

SEN01767-00

40 Troubleshooting

Failure codes table


Failure
code

1
Applicable
equipment

Action
code

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 clutch oil pressure 1

TM

CALL E03

15SELH 1st clutch oil pressure 2

TM

CALL E03

15SFL1

2nd clutch oil pressure 1

TM

CALL E03

15SFLH 2nd clutch oil pressure 2

TM

CALL E03

15SGL1 3rd clutch oil pressure 1

TM

CALL E03

15SGLH 3rd clutch oil pressure 2

TM

CALL E03

1800MW Power train clutch slip

TM

E02

2300NR Brake thermal load

ST

2301L1

Right steering brake oil pressure 1

ST

CALL E04

2301LH

Right steering brake oil pressure 2

ST

CALL E04

2301NR Right steering brake thermal load

ST

2302L1

Left steering brake oil pressure 1

ST

CALL E04

2302LH

Left steering brake oil pressure 2

ST

CALL E04

2302NR Left steering brake thermal load

ST

A000NS Engine overheat

AA10NX Air cleaner clogging

MON

AB00MA Battery charge abnormal

MON

B@BAZG Eng oil press low

ENG

B@BAZK Eng oil level low

B@BCNS Eng coolant overheat

ENG

B@BCZK Radiator coolant level low

MON

B@BEBF Water gets mixed with fuel

B@BFZK Fuel level abnormal reduction

MON

B@CENS Torque converter oil overheat

MON

B@CHZG HSS charge oil pressure reduction

MON

1500L0

Trouble
Transmission clutch dual engagement

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system

Reference
manual

Troubleshooting
by failure code,
Part 1
SEN01655-00

D275AX-5E0

40 Troubleshooting

Failure
code

SEN01767-00

Applicable
equipment

Action
code

B@CHZK Power train oil level reduction

B@GAZK Battery electrolyte level reduction

MON

Trouble

B@HANS Hyd oil overheat


B@HAZK Hydraulic oil level reduction
CA111

EMC critical internal failure

ENG

CALL E04

CA115

Eng Ne and Bkup speed sens error

ENG

CALL E04

CA122

Chg air press sensor high error

ENG

CALL E03

CA123

Chg air press sensor low error

ENG

CALL E03

CA131

Throttle sensor high error

ENG

CALL E03

CA132

Throttle sensor low error

ENG

CALL E03

CA135

Eng oil press sensor high error

ENG

E02

CA141

Eng oil press sensor low error

ENG

E02

CA144

Coolant temp sens high error

ENG

E02

CA145

Coolant temp sens low error

ENG

E02

CA153

Chg air temp sensor high error

ENG

E01

CA154

Chg air temp sensor low error

ENG

E01

CA187

Sens supply 2 volt low error

ENG

CALL E03

CA221

Ambient press sens high error

ENG

CALL E03

CA222

Ambient press sens low error

ENG

CALL E03

CA227

Sens supply 2 volt high error

ENG

CALL E03

CA234

Eng overspeed

ENG

CA238

Ne speed sens supply volt error

ENG

CALL E03

CA263

Fuel temp sensor high error

ENG

E01

CA265

Fuel temp sensor low error

ENG

E01

CA271

PCV1 short error

ENG

CALL E03

CA272

PCV1 open error

ENG

CALL E03

CA273

PCV2 short error

ENG

CALL E03

CA274

PCV2 open error

ENG

CALL E03

CA322

Inj #1 (L#1) open/short error

ENG

CALL E03

CA323

Inj #5 (L#5) open/short error

ENG

CALL E03

CA324

Inj #3 (L#3) open/short error

ENG

CALL E03

D275AX-5E0

History
classification
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 1
SEN01655-00

Troubleshooting
by failure code,
Part 2
SEN01656-00

SEN01767-00

Failure
code

40 Troubleshooting

Trouble

Applicable
equipment

Action
code

CA325

Inj #6 (L#6) open/short error

ENG

CALL E03

CA331

Inj #2 (L#2) open/short error

ENG

CALL E03

CA332

Inj #4 (L#4) open/short error

ENG

CALL E03

CA342

Calibration code incompatibility

ENG

CALL E04

CA351

Injectors drive circuit error

ENG

CALL E03

CA352

Sens supply 1 volt low error

ENG

CALL E03

CA386

Sens supply 1 volt high error

ENG

CALL E03

CA441

Battery voltage low error

ENG

CALL E04

CA442

Battery voltage high error

ENG

CALL E04

CA449

Rail press very high error

ENG

CALL E03

CA451

Rail press sensor high error

ENG

CALL E03

CA452

Rail press sensor low error

ENG

CALL E03

CA553

Rail press high error

ENG

E02

CA554

Rail press sensor in range error

ENG

CALL E03

CA559

Rail press low error

ENG

E02

CA689

Eng Ne speed sensor error

ENG

CALL E03

CA731

Eng Bkup speed sens phase error

ENG

CALL E03

CA757

All continuous data lost error

ENG

CALL E04

CA778

Eng Bkup speed sensor error

ENG

CALL E03

CA1228 EGR valve servo error 1

ENG

E02

CA1625 EGR valve servo error 2

ENG

CALL E03

CA1626 BP valve sol current high error

ENG

CALL E03

CA1627 BP valve sol current low error

ENG

CALL E03

CA1628 Bypass valve servo error 1

ENG

E02

CA1629 Bypass valve servo error 2

ENG

CALL E03

CA1631 BP valve pos sens high error

ENG

CALL E03

CA1632 BP valve pos sens low error

ENG

CALL E03

CA1633 KOMNET datalink timeout error

ENG

CALL E03

CA1642 EGR inlet press sens low error

ENG

E01

CA1653 EGR inlet press sens high error

ENG

E01

CA2185 Throt sens sup volt high error

ENG

CALL E03

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 2
SEN01656-00

Troubleshooting
by failure code,
Part 3
SEN01657-00

D275AX-5E0

40 Troubleshooting

Failure
code

SEN01767-00

Applicable
equipment

Action
code

CA2186 Throt sens sup volt low error

ENG

CALL E03

CA2249 Rail press very low error

ENG

CALL E03

CA2271 EGR valve pos sens high error

ENG

CALL E03

CA2272 EGR valve pos sens low error

ENG

CALL E03

CA2351 EGR valve sol current high error

ENG

CALL E03

CA2352 EGR valve sol current low error

ENG

CALL E03

CA2555 Grid htr relay volt low error

ENG

E01

CA2556 Grid htr relay volt high error

ENG

E01

D110KA Battery relay holding disconnection

ST

D110KB Battery relay drive short circuit

ST

D130KA Neutral safety relay disconnection

TM

E02

D130KB Neutral safety relay short circuit

TM

E02

D161KA Back-up alarm relay disconnection

TM

E01

D161KB Back-up alarm relay short circuit

TM

E01

D190KA Engine controller ACC signal cut relay

ST

D190KB Engine controller ACC signal cut relay short

ST

D811KR KOMTRAX controller CAN defective communication

ST

MON

CALL E03

DAQ0KT Transmission controller internal abnormality

TM

E01

controller main source voltage reducDAQ1KK Transmission


tion

TM

CALL E04

DAQ2KK Transmission controller load voltage reduction

TM

CALL E04

controller sensor 5 V power source


DAQ5KK Transmission
(1) power supply source voltage reduction
controller sensor 24 V power supply
DAQ6KK Transmission
source voltage reduction
controller sensor 5 V power supply
DAQ7KK Transmission
source (2) power source voltage reduction
Transmission controller type collation (Type select
DAQ9KQ signal
inconsistency)
controller CAN defective communicaDAQRKR Transmission
tion (Abnormality in objective component system)
controller S-NET defective communiDAQSKR Transmission
cation (Abnormality in objective component system)

TM

CALL E03

TM

E01

TM

CALL E03

TM

CALL E04

ST

CALL E03

TM

E01

DB2RKR Engine controller CAN defective communication

ST

CALL E03

DB30KT Steering controller abnormality in controller

ST

E01

controller main power supply source voltDB31KK Steering


age reduction
power source of steering controller power
DB32KK Load
source voltage drop

ST

CALL E04

ST

CALL E04

Trouble

monitor CAN communication defective


DAFRKR Machine
communication

D275AX-5E0

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 3
SEN01657-00

Troubleshooting
by failure code,
Part 4
SEN01658-00

SEN01767-00

Failure
code

40 Troubleshooting

Applicable
equipment

Action
code

ST

CALL E03

ST

CALL E03

ST

CALL E03

ST

CALL E04

TM

CALL E03

ST

E01

DD12KA Shift up switch disconnection

TM

E02

DD12KB Shift up switch short circuit

TM

E02

DD13KA Shift down switch disconnection

TM

E02

DD13KB Shift down switch short circuit

TM

E02

DD14KA Parking brake lever switch disconnection

TM

CALL E03

DD14KB Parking brake lever switch short circuit

TM

E03

DDB9L4 Reverse switch disagreement

TM

CALL E03

DDK3L4 Forward switch disagreement

TM

CALL E03

DDK5KA Gearshift switch disconnection

TM

CALL E03

DDK5KB Gearshift switch short circuit

TM

CALL E03

DDN7KA Blade pitch switch disconnection

TM

E02

DDN7KB Blade pitch switch short circuit

TM

E02

DDN9KA Blade tilt switch disconnection

TM

E01

DDN9KB Blade tilt switch short circuit

TM

E01

lift raise oil pressure switch is kept ON for


DDNBLD Ripper
long time
lift lower oil pressure switch is kept ON for
DDNCLD Ripper
long time
lift tilt-in oil pressure switch is kept ON for
DDNDLD Ripper
long time

TM

TM

TM

DDQ2KA Parking brake lever switch disconnection

TM

CALL E03

DDQ2KB Parking brake lever switch short circuit

ST

CALL E03

DDQ2L4 Parking brake lever switch disagreement

ST

CALL E03

DDT5KA Neutral switch disconnection

TM

CALL E04

DDT5KB Neutral switch short circuit

TM

CALL E04

specification selection (Model selection signal


DDT5KQ Lever
disagreement)
oil temperature sensor input signal is out
DGS1KX Hydraulic
of normal range

TM

CALL E04

TM

Trouble

controller sensor 5 V power source (1)


DB35KK Steering
power source voltage drop
controller sensor 24 V power supply
DB36KK Steering
source voltage reduction
controller sensor 5 V power source (2)
DB37KK Steering
power source voltage drop
controller type collation (Type select signal
DB39KQ Steering
inconsistency)
controller CAN defective communication
DB3RKR Steering
(Abnormality in objective component system)
Steering controller S-NET defective communication
DB3SKR (Abnormality
in objective component system)

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 4
SEN01658-00

D275AX-5E0

40 Troubleshooting

Failure
code

SEN01767-00

Trouble

DGT1KA Power train oil temp sensor disconnection


DGT1KX Power train oil temp sensor out of signal range

Applicable
equipment

Action
code

TM

E01

MON

E01

equipment pump oil pressure sensor short cirDH21KB Work


cuit
equipment pump oil pressure sensor disconDH22KA Work
nection
equipment pump oil pressure sensor short cirDH22KB Work
cuit

ST

E01

TM

TM

DHH3KA HSS pump oil pressure sensor A disconnection

ST

CALL E03

DHH3KB HSS pump oil pressure sensor A short circuit

ST

CALL E03

DHH4KA HSS pump oil pressure sensor B disconnection

ST

CALL E03

DHH4KB HSS pump oil pressure sensor B short circuit

ST

CALL E03

DK10KA Fuel control dial disconnection

ST

CALL E03

DK10KB Fuel control dial short circuit

ST

CALL E03

DK30KA Steering potentiometer (1) disconnection

ST

CALL E03

DK30KB Steering potentiometer (1) short circuit

ST

CALL E03

DK30KX Steering potentiometer (1) out of input signal range

ST

CALL E04

potentiometer (1) disconnection or short


DK30KZ Steering
circuit
potentiometer (1) analog signals do not
DK30L8 Steering
agree

ST

CALL E04

ST

CALL E03

DK31KA Steering potentiometer (2) disconnection

ST

CALL E03

DK31KB Steering potentiometer (2) short circuit

ST

CALL E03

DK40KA Brake potentiometer disconnection

ST

CALL E03

DK40KB Brake potentiometer short circuit

ST

CALL E03

DK55KX Directional potentiometer out of input signal range

TM

CALL E04

Directional potentiometer disconnection or short cirDK55KZ cuit


potentiometer analog signals do not
DK55L8 Directional
agree

TM

CALL E04

TM

CALL E03

DK56KA F-R potentiometer (1) disconnection

TM

CALL E03

DK56KB F-R potentiometer (1) short circuit

TM

CALL E03

DK57KA F-R potentiometer (2) disconnection

TM

CALL E03

DK57KB F-R potentiometer (2) short circuit

TM

CALL E03

DK60KA Acceleration sensor disconnection

ST

E01

DK60KB Acceleration sensor short circuit

ST

E01

DKH1KA Pitch angle sensor disconnection

ST

CALL E03

DKH1KB Pitch angle sensor short circuit

ST

CALL E03

D275AX-5E0

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 5
SEN01659-00

SEN01767-00

Failure
code

40 Troubleshooting

Applicable
equipment

Action
code

DKH1KX Pitch angle sensor out of input signal range

TM

E01

DLT3KA Transmission out-speed sensor disconnection

TM

E01

DLT3KB Transmission out-speed sensor abnormal

TM

E01

MON

DW59KA Blade dual selector solenoid disconnection

TM

E01

DW59KB Blade dual selector solenoid short circuit

TM

E01

DW59KY Blade dual selector solenoid hot short

TM

E01

DW5AKA Blade pitch selector solenoid disconnection

TM

E02

DW5AKB Blade pitch selector solenoid short circuit

TM

E02

DW5AKY Blade pitch selection solenoid hot short circuit

TM

E02

DW7BKA Fan rev EPC disconnection

ST

E01

DW7BKB Fan rev EPC short circuit

ST

E01

DW7BKY Fan reverse solenoid hot short circuit

ST

E02

DWN1KA HSS pump solenoid right disconnection

ST

CALL E03

DWN1KB HSS pump solenoid right short circuit

ST

CALL E03

DWN1KY HSS pump solenoid right hot short

ST

CALL E04

DWN2KA HSS pump solenoid left disconnection

ST

CALL E03

DWN2KB HSS pump solenoid left short circuit

ST

CALL E03

DWN2KY HSS pump solenoid left short circuit

ST

CALL E03

DWN3KA Sudden stop prevention solenoid disconnection

ST

CALL E04

DWN3KB Sudden stop prevention solenoid short circuit

ST

CALL E04

DWN3KY Sudden stop prevention solenoid hot short circuit

ST

CALL E04

DWN4KA HSS motor free solenoid disconnection

ST

E01

DWN4KB HSS motor free solenoid short circuit

ST

E01

DWN5KA Fan pump solenoid disconnection

TM

E01

DWN5KB Fan pump solenoid short circuit

TM

E01

DWN5KY Fan pump solenoid hot short circuit

TM

E02

DXH1KA Lock-up solenoid disconnection

TM

E01

DXH1KB Lock-up solenoid short circuit

TM

E01

DXH1KY Lock-up solenoid hot short

TM

E03

DXH4KA 1st clutch ECMV disconnection

TM

CALL E03

Trouble

DV00KB Caution buzzer short circuit

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 5
SEN01659-00

Troubleshooting
by failure code,
Part 6
SEN01878-00

D275AX-5E0

40 Troubleshooting

Failure
code

SEN01767-00

Applicable
equipment

Action
code

DXH4KB 1st clutch ECMV short circuit

TM

CALL E03

DXH4KY 1st clutch ECMV hot short circuit

TM

CALL E03

DXH5KA 2nd clutch ECMV disconnection

TM

CALL E03

DXH5KB 2nd clutch ECMV short circuit

TM

CALL E03

DXH5KY 2nd clutch ECMV hot short circuit

TM

CALL E03

DXH6KA 3rd clutch ECMV disconnection

TM

CALL E03

DXH6KB 3rd clutch ECMV short circuit

TM

CALL E03

DXH6KY 3rd clutch ECMV hot short circuit

TM

E03

DXH7KA Reverse clutch ECMV disconnection

TM

CALL E03

DXH7KB Reverse clutch ECMV short circuit

TM

CALL E03

DXH7KY R clutch ECMV hot short circuit

TM

CALL E03

DXH8KA Forward clutch ECMV disconnection

TM

CALL E03

DXH8KB Forward clutch ECMV short circuit

TM

CALL E03

DXH8KY F clutch ECMV hot short circuit

TM

CALL E03

DXHBKA Right brake ECMV disconnection

ST

CALL E04

DXHBKB Right brake ECMV short circuit

ST

CALL E04

DXHBKY Right brake ECMV hot short circuit

ST

CALL E04

DXHCKA Left brake ECMV disconnection

ST

CALL E04

DXHCKB Left brake ECMV short circuit

ST

CALL E04

DXHCKY Left brake ECMV hot short circuit

ST

CALL E04

a
a

a
a
a

Trouble

History
classification
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system

Reference
manual

Troubleshooting
by failure code,
Part 6
SEN01878-00

The items in this table are arranged in the order of the failure codes.
A component in charge is a controller or the machine monitor in charge of the system check.
MON : Machine monitor
ENG : Engine controller
TM
: Transmission controller
ST
: Steering controller
The failure codes having no numbers in the action code column are not displayed on the ordinary
screen when abnormality related to them occurs. They are simply recorded in the fault history of the
service menu (Electrical equipment system or mechanical equipment system).
The history classification column shows in which system each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history.
Blinking and lighting of failure code
q
Blinking : The trouble has not been repaired.
q
Lighting : The trouble has been repaired.

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SEN01767-00

40 Troubleshooting

Fuse locations

Connection table of circuit breakers and fuse boxes


a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breakers
Breaker No.

Conector No.

Breaker capacity
(A)

CB105H

105

Electrical intake air heater relay

B7L

30

Engine controller

F96

105

Main power supply

F32

30

Unswitched power supply

CB1

20

Steering controller

CB2

20

Machine monitor

CB3

20

Transmission controller

CB4

20

Air conditioner

CB5

20

Head lamp

10

CB6

20

Unswitched power supply of starting switch

Destination of power

Fuse box FS11, FS12


Fuse No.

Power source

Fuse capacity
(A)

Accessory power supply

20
20

Unswitched power supply of controller

Unswitched power supply

20

Unswitched power supply of cab

10

Unswitched power supply of 12 volt converter

20

Power supply of 12 volt converter

2
3
4
5

Accessory power supply

Destination of power

Fuse box FS21, FS22


Fuse No.

Power source

Destination of power

Backup alarm

20

Pin puller, Pre-heat, Air suspension seat

20

Additional heater

20

Working lamp

20

Rear lamp

2
3

10

Fuse capacity
(A)

Accessory power supply

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40 Troubleshooting

SEN01767-00

Fuse box FS31, FS32


Fuse No.

Power source

Fuse capacity
(A)

Destination of power

Engine controller ACC

20

Horn

Accessory power supply

20

Spare power supply 1

20

Spare power supply 2

20

Spare ACC signal

D275AX-5E0

11

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40 Troubleshooting

Locations of circuit breakers (Breaker No. 1 4) (In battery room)

Locations of circuit breakers (Breaker No. 5 10) and fuse boxes FS11, FS12, FS21, FS22, FS31, and
FS32 (Operator's seat on left side forward front under)

12

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40 Troubleshooting

SEN01767-00

Fuse box
Fuse No.

Power source

Fuse capacity
(A)

Destination of power

10

Radio, Cigarette lighter, Room lamp

10

Rear wiper

10

Right wiper

10

Front wiper

10

Left wiper

20

Additional rear lamp

20

Additional head lamp, Revolving warning lamp

Spare

Spare

10

Radio memory

Accessory power supply

10

Unswitched power supply

Location of fuse box

D275AX-5E0

(In operator's cab)

13

SEN01767-00

Reset method for main power supply circuit


breaker
Turn the starting switch to the OFF position to turn
the electric circuit OFF, wait for 5 10 minutes, and
press reset buttons (1) (4).
a Check by the operating effort of each reset button that the circuit is reset.
a If the electric circuit is turned OFF, the operating effort of the reset button is heavier than
when the electric circuit is turned ON.
a Do not hold down the reset button.
a If the starting motor still does not run after the
reset operation, carry out troubleshooting and
repair the faulty part.

14

40 Troubleshooting

Reset method for circuit breaker


Turn the starting switch to the OFF position and
push in reset button (5) which was pushed out
when the electric circuit was turned OFF.
a If the reset button is pushed out again soon
after it is pushed in, carry out troubleshooting
and repair the faulty part.

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40 Troubleshooting

D275AX-5E0 Bulldozer
Form No. SEN01767-00

16

D275AX-5E0

SEN01768-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

40 Troubleshooting

General information on troubleshooting


Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Contents of troubleshooting table ................................................................................................................... 8
Connection table for connector pin numbers ................................................................................................ 10
T-adapter box and T-adapter table................................................................................................................ 39

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40 Troubleshooting

Points to remember when troubleshooting


k
k
k
k
k
k

Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing testing 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.

2.

3.

When carrying out troubleshooting, do not


hurry to disassemble the components.
If components are disassembled immediately
any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator. For
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior
investigation and to carry out troubleshooting
in accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure? When were these repairs carried out?
6) Has the same kind of failure occurred
before?

4)

Other maintenance items can be checked


externally, so check any item that is considered to be necessary.

4.

Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.

5.

Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
of the the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or
information.

6.

Measures to remove root cause of failure


Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again.To prevent this, always investigate why the problem occurred. Then, remove
the root cause.

Check before troubleshooting


1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
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40 Troubleshooting

SEN01768-00

Sequence of events in troubleshooting

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40 Troubleshooting

Check before troubleshooting


Item

Criterion

Remedy

1. Check of level and type of fuel

Add fuel

2. Check of fuel for foreign matter

Clean and drain

Between H L

Add oil

3. Check of hydraulic oil level


Lubricating
oil/Coolant

Hydraulic/
Mechanical
equipment

4. Check of damper case oil level

Between H L

Add oil

5. Check of power train oil level

Between H L

Add oil

6. Check of level and type of engine oil (in oil pan)

Between H L

Add oil

7. Check of coolant level (in sub tank)

Between FULL - LOW

Add coolant

8. Check of dust indicator for clogging

Out of red range

Clean or replace

9. Check of brake pedal stroke

Adjust

1. Check for abnormal noise/smell

Repair

2. Check for oil leakage

Repair

3. Bleeding air

Bleed air

1. Check of battery terminals and wiring for looseness and corrosion

Retighten or replace

2. Check of alternator terminals and wiring for


looseness and corrosion

Retighten or replace

3. Check of starting motor terminals and wiring for


looseness and corrosion

Retighten or replace

4. Check of battery voltage (with engine stopped)

20 30 V

Charge or replace

5. Check of electrolyte level


Electrical
equipment

Between H L

Add or replace

6. Check of wires for discoloration, burn, and


removal of cover

Repair or replace

7. Check for released wire clamp and drooping wire

Repair

8. Check of wires for wetness (Check connectors


and terminals for wetness, in particular)

Dry

9. Check circuit breaker for turning OFF and fuse


for disconnection and corrosion

Replace

10. Check of alternator voltage


(while engine speed is at middle or higher)

After operating for several


minutes: 27.5 29.5 V

Replace

11. Check of battery relay for operating sound


(when starting switch is turned ON or OFF)

Replace

D275AX-5E0

40 Troubleshooting

SEN01768-00

Classification and procedures for troubleshooting

Classification for troubleshooting


Type
Display of code

Contents
Troubleshooting by failure code

E mode

Troubleshooting for electrical system

H mode

Troubleshooting for hydraulic and mechanical system

S mode

Troubleshooting for engine

Procedure for troubleshooting


If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1.

Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.

2.

When electrical system failure code or mechanical system failure code is recorded in fault history:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" according to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".

3.

When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".

D275AX-5E0

SEN01768-00

40 Troubleshooting

Phenomena looking like troubles and troubleshooting Nos.


Troubleshooting
No.

Phenomena looking like troubles

Display
of code

E mode

H mode

S mode

Phenomena related to action code/failure code


1 Action code and failure code are displayed on machine monitor
2

When fault history is checked, failure code is displayed in mechanical


system fault history

When fault history is checked, failure code is displayed in electrical


system fault history

When fault history is checked, failure code is displayed in air conditioner


or heater fault history

According to displayed
code
E-28

Phenomena related to engine


5 Starting performance of engine is poor
6 Engine does not start

S-1
E-1

S-2

7 Engine does not pick up smoothly

S-3

8 Engine stops during operation

S-4

9 Engine does not rotate smoothly

S-5

10 Engine lack output (or lacks power)

S-6

11 Exhaust gas is black (incomplete combustion)

S-7

12 Oil consumption is excessive (or exhaust gas is blue)

S-8

13 Oil becomes dirty quickly

S-9

14 Fuel consumption is excessive

S-10

15 Oil is in coolant (or coolant spurts back or coolant level goes down)

S-11

16 Oil pressure drops

S-12

17 Oil level rises (Entry of coolant or fuel)

S-13

18 Coolant temperature becomes too high (Overheating)

S-14

19 Abnormal noise is made

S-15

20 Vibration is excessive

S-16

21 The preheater does not operate (Manual preheating function)

E-2

Phenomena related to power train


22 No travel power (No drawbar pull)

H-1

23 Machine does not move (At 2nd or 3rd speed)

H-2

24 Machine does not move in any speed range

H-3

25 Machine travels only in one direction forward or in reverse

H-4

26

When gear is shifted or travel direction is changed, large time lag is


made

H-5

27 Machine does not turn (Not turned rightward or leftward)

H-6

28 Steering speed or power is low

H-7

29 Brake does not work

H-8

30 Torque converter does not lock-up

H-9

31 Overheat of power train oil temperature

H-10

32 Abnormal sound around HSS pump or HSS motor

H-11

Phenomena related to work equipment


33 All work equipment speeds are slow

H-12

34 Work equipment does not move

H-13

35 Blade lift speed is slow or lacks power

H-14

36 Blade tilt speed is slow or lacks power

H-15

37 Ripper lift speed is slow or lacks power

H-16

38 Ripper tilt speed is slow or lacks power

H-17

D275AX-5E0

40 Troubleshooting

SEN01768-00

Troubleshooting
No.

Phenomena looking like troubles

Display
of code

E mode

39 Excessive hydraulic drift of blade lift

H mode
H-18

40 Excessive hydraulic drift of blade tilt

H-19

41 Excessive hydraulic drift of ripper lift

H-20

42

S mode

Ripper pin puller cylinder does not work (Giant ripper attachment
machine)

H-21

43 Blade pitch does not work (Dual tilt attachment machine)

H-22

44 Abnormal sound comes out from around work equipment pump

H-23

Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally


45
large or engine overheats)

H-24

Phenomena related to machine monitor


46 The ripper pin puller cylinder does not operate

E-3

The machine monitor does not come on at all when the starting switch is
47
turned ON

E-4

When the starting switch is turned ON, the machine monitor completely
remains lighted and does not go out

E-5

48

49 When the starting switch is turned ON, the basic check items flash

E-6

50 While the engine is operating, any caution item flashes

E-7

51 While the engine is operating, the emergency warning item flashes

E-8

While the preheater is operating, the preheating pilot lamp does not
52
come on

E-9

53

At the selecting time of dual tilt, the dual/single tilt selector lamp does
not come on (Dual tilt-mounted machine)

E-10

54

At the locking-up of the torque converter, the torque converter lock-up


display lamp does not come on

E-11

55 The engine coolant temperature gauge does not indicate normally

E-12

56 Indication of the torque converter temperature gauge is abnormal

E-13

57 The hydraulic oil temperature gauge does not indicate normally

E-14

58 Indication of the fuel gauge is abnormal

E-15

59 Indications of gear speed and engine speed are abnormal

E-16

60 Indication of the shift mode service meter is abnormal

E-17

61 The switch module cannot be operated

E-18

62 The warning lamp does not flash or does not go out

E-19

63 The alarm buzzer does not sound or does not stop

E-20

64 Auto shift down is not possible or is not released

E-21

65 Pivot turn is not possible or is not released

E-22

66 The alarm buzzer cannot be cancelled

E-23

67 The operator mode cannot be operated

E-24

68 The service mode cannot be operated

E-25

69 The back-up alarm does not sound

E-26

70

The night light, the headlamp, the working lamp and the rear lamp on
the panel do not come on

71 The air conditioner does not operate

E-27
E-28

Other phenomena
72 KOMTRAX system does not operate normally

D275AX-5E0

E-29

SEN01768-00

40 Troubleshooting

Contents of troubleshooting table


a

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

Failure code

Machine
monitor
display

Machine monitor
display

Contents of
trouble

Trouble

Names of the failure symptoms displayed in the failure history


on the machine monitor

State where the machine monitor or controller detects the trouble

Action of
Action to be taken to protect the system and equipment when the machine monitor or controlmachine moniler detects a trouble
tor or controller
Problem that
appears on
machine
Related
information

Problem that appears as an abnormality in the machine by the action (above) taken by monitor
or controller
Information related to troubles occurred or troubleshooting

Cause

2
Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


<Described contents>
Standard value when normal required to judge the possible cause
Remarks required to judge whether any cause is right or
not
<Symptoms of defective harness>
Disconnection in wiring
The connector connection is defective or the wiring harness is disconnected.
Defective grounding
A harness not connected to GND (ground) circuit comes
into contact with the GND (ground) circuit.
Hot short defect
A harness not connected to the electric power supply
(24V) circuit comes into contact with the electric power
supply (24V) circuit.
Short circuit
A harness abnormally comes into contact with a harness
of separate circuit.

Cause by which a trouble is


assumed to be detected
(The order number indicates
a serial number, not a priority <Points to remember when troubleshooting>
sequence.)
(1) Method of indicating connector numbers and handling Tadapter
For troubleshooting, insert or connect the T- adapter as
described below unless especially specified.
3
When maleor female is not indicated for a connector number, disconnect the connector, and insert the Tadapter in both the male and female.
When maleor female is indicated for a connector
number, disconnect the connector, and insert the Tadapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-)
leads of the tester as described below unless especially
4
specified.
Connect the plus (+) lead to a pin number or harness
indicated in the front.
Connect the minus (-) lead to a pin number or harness
indicated in the rear.

D275AX-5E0

40 Troubleshooting

SEN01768-00

Circuit diagram related

This drawing is a part of the electric circuit diagram related to troubleshooting.


Connector No.: Indicates (Model - Number of pins) and (Color).
Connector No. and pin No. from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
Arrow ( ): Roughly shows the location on the machine.

D275AX-5E0

SEN01768-00

Connection table for connector pin numbers


a

10

40 Troubleshooting

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.

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40 Troubleshooting

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D275AX-5E0

40 Troubleshooting

D275AX-5E0

SEN01768-00

35

SEN01768-00

36

40 Troubleshooting

D275AX-5E0

40 Troubleshooting

D275AX-5E0

SEN01768-00

37

SEN01768-00

38

40 Troubleshooting

D275AX-5E0

40 Troubleshooting

SEN01768-00

T-adapter box and T-adapter table

The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.

Out of kit

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7000

799-601-7100

799-601-2800

Identification
symbol

799-601-2700

Part name

T-adapter kit
799-601-2500

Part No.

Number of pins

799-601-2600

T-box (for ECONO)

21

799-601-3100

T-box (for MS)

37

799-601-3200

T-box (for MS)

37

799-601-3380

Plate for MS (14-pin)

799-601-3410

Adapter for BENDIX (MS)

24

MS-24P

799-601-3420

Adapter for BENDIX (MS)

24

MS-24P

799-601-3430

Adapter for BENDIX (MS)

17

MS-17P

799-601-3440

Adapter for BENDIX (MS)

17

MS-17P

799-601-3450

Adapter for BENDIX (MS)

MS-5P

799-601-3460

Adapter for BENDIX (MS)

10

MS-10P

799-601-3510

Adapter for BENDIX (MS)

MS-5S

799-601-3520

Adapter for BENDIX (MS)

17

MS-17P

799-601-3530

Adapter for BENDIX (MS)

19

MS-19P

799-601-2910

Adapter for BENDIX (MS)

14

MS-14P

799-601-3470

Case

799-601-2710

Adapter for MIC

MIC-5P

799-601-2720

Adapter for MIC

13

MIC-13P

799-601-2730

Adapter for MIC

17

MIC-17P

799-601-2740

Adapter for MIC

21

MIC-21P

799-601-2950

Adapter for MIC

MIC-9P

799-601-2750

Adapter for ECONO

ECONO2P

799-601-2760

Adapter for ECONO

ECONO3P

799-601-2770

Adapter for ECONO

ECONO4P

799-601-2780

Adapter for ECONO

ECONO8P

799-601-2790

Adapter for ECONO

12

ECONO12P

799-601-2810

Adapter for DLI

DLI-8P

799-601-2820

Adapter for DLI

12

DLI-12P

799-601-2830

Adapter for DLI

16

DLI-16P

799-601-2840

Extension cable (ECONO type)

12

ECONO12P

799-601-2850

Case

799-601-4210

Adapter for DRC

50

799-601-7010

Adapter for X (T-adapter)

799-601-7020

Adapter for X

X2P

799-601-7030

Adapter for X

X3P

799-601-7040

Adapter for X

X4P

799-601-7050

Adapter for SWP

SW6P

799-601-7060

Adapter for SWP

SW8P

799-601-7310

Adapter for SWP

12

SW12P

799-601-7070

Adapter for SWP

14

SW14P

799-601-7320

Adapter for SWP

16

SW16P

799-601-7080

Adapter for M (T-adapter)

D275AX-5E0

q
q

q
q

DRC50
q

q
q
q

q
q

39

SEN01768-00

40 Troubleshooting

799-601-7120

Adapter for M

M4P

799-601-7130

Adapter for M

M6P

Out of kit

799-601-9300

799-601-9200

799-601-9100

M3P

799-601-9000

799-601-7400

M2P

799-601-8000

799-601-7100

Adapter for M

799-601-7500

799-601-7000

Adapter for M

799-601-7110

799-601-2800

799-601-7090

Part name

799-601-2700

Identification
symbol

Part No.

799-601-2500

Number of pins

T-adapter kit

799-601-7340

Adapter for M

M8P

799-601-7140

Adapter for S

S8P

799-601-7150

Adapter for S (White)

10

S10P

799-601-7160

Adapter for S (Blue)

12

S12P

799-601-7170

Adapter for S (Blue)

16

S16P

799-601-7330

Adapter for S (White)

16

S16PW

799-601-7350

Adapter for S (White)

12

S12PW

799-601-7180

Adapter for AMP040

A8P

799-601-7190

Adapter for AMP040

12

A12P

799-601-7210

Adapter for AMP040

16

A16P

799-601-7220

Adapter for AMP040

20

A20P

799-601-7230

Short connector for X

799-601-7240

Case

799-601-7270

Case

799-601-7510

Adapter for 070

10

07-10

799-601-7520

Adapter for 070

12

07-12

799-601-7530

Adapter for 070

14

07-14

799-601-7540

Adapter for 070

18

07-18

799-601-7550

Adapter for 070

20

07-20

799-601-7360

Adapter for relay

REL-5P

799-601-7370

Adapter for relay

REL-6P

799-601-7380

Adapter for JFC

q
q
q

799-601-9010

Adapter for DTM

DTM2

799-601-9020

Adapter for DT

DT2

799-601-9030

Adapter for DT

DT3

799-601-9040

Adapter for DT

DT4

799-601-9050

Adapter for DT

DT6

799-601-9060

Adapter for DT (Gray)

DT8GR

799-601-9070

Adapter for DT (Black)

DT8B

799-601-9080

Adapter for DT (Green)

DT8G

799-601-9090

Adapter for DT (Brown)

DT8BR

799-601-9110

Adapter for DT (Gray)

12

DT12GR

799-601-9120

Adapter for DT (Black)

12

DT12B

799-601-9130

Adapter for DT (Green)

12

DT12G

799-601-9140

Adapter for DT

12

DT12BR

799-601-9210

Adapter for HD30-18

D18-8

799-601-9220

Adapter for HD30-18

14

D18-14

799-601-9230

Adapter for HD30-18

20

D18-20

799-601-9240

Adapter for HD30-18

21

D18-21

799-601-9250

Adapter for HD30-24

D24-9

799-601-9260

Adapter for HD30-24

16

D24-16

40

D275AX-5E0

40 Troubleshooting

SEN01768-00

31

D24-31

Plate for HD30 (24-pin)

799-601-9320

T-box (for DT/HD)

799-601-9330

Case

12

Out of kit

Adapter for HD30-24

799-601-9310

799-601-9300

799-601-9100

799-601-9290

799-601-9200

799-601-9000

799-601-8000

799-601-7500

D24-23

799-601-7400

D24-21

23

799-601-7100

21

Adapter for HD30-24

799-601-7000

Adapter for HD30-24

799-601-9280

799-601-2800

799-601-9270

Part name

799-601-2700

Identification
symbol

Part No.

799-601-2500

Number of pins

T-adapter kit

q
q

799-601-9340

Case

799-601-9350

Adapter for DRC

40

DRC-40

799-601-9360

Adapter for DRC

24

DRC-24

799-601-9410

Adapter for engine (CRI-T2)

799-601-9420

Adapter for engine (CRI-T2)


Adapter for engine (CRI-T3)

A3

799-601-9430

Adapter for engine (CRI-T2)


Adapter for engine (CRI-T3)

799-601-9440

Adapter for engine (CRI-T2)

1,2,3

795-799-5520

Adapter for engine (HPI-T2)

795-799-5530

Adapter for engine (HPI-T2)


Adapter for engine (CRI-T3)

795-799-5540

Adapter for engine (HPI-T2)


Adapter for engine (CRI-T3)

795-799-5460

Cable for engine (HPI-T2)

795-799-5470

Cable for engine (HPI-T2)

795-799-5480

Cable for engine (HPI-T2)

799-601-4160

Adapter for engine (CRI-T3)

q
OIL

799-601-4340

Adapter for engine (CRI-T3)

1,2,3

799-601-4130

Adapter for engine (CRI-T3)

FCIN

799-601-4140

Adapter for engine (CRI-T3)

FCIG

799-601-4150

Adapter for engine (CRI-T3)

FCIB

799-601-4180

Adapter for engine (CRI-T3)

FCIP3

799-601-4190

Adapter for engine (CRI-T3)

1,2,3

799-601-4240

Adapter for engine (CRI-T3)

1,2,3

799-601-4250

Adapter for engine (CRI-T3)

1,2,3

799-601-4330

Adapter for engine (CRI-T3)

1,2,3

799-601-4230

Adapter for engine (CRI-T3)

1,2,3,4

799-601-4260

Adapter for controller (ENG)

DTP4

799-601-4210

Adapter for controller (ENG)

50

DRC50

799-601-4220

Adapter for controller (ENG)

60

DRC60

799-601-4280

Box for controller (PUMP)

121

799-601-9720

Adapter for controller (HST)

16

HST16A

799-601-9710

Adapter for controller (HST)

16

HST16B

799-601-9370

Adapter for controller (HST)

26

HST26A

D275AX-5E0

41

SEN01768-00

40 Troubleshooting

D275AX-5E0 Bulldozer
Form No. SEN01768-00

42

D275AX-5E0

SEN01655-00

BULLDOZER
1SHOP MANUAL

D275AX-5E0

Machine model

Serial number

D275AX-5E0

30001 and up

40 Troubleshooting

Troubleshooting by failure and error


codes, Part 1
Failure code [1500L0] Transmission clutch dual engagement........................................................................ 3
Failure code [15SAL1] Forward clutch oil pressure 1 ..................................................................................... 4
Failure code [15SALH] Forward clutch oil pressure 2..................................................................................... 6
Failure code [15SBL1] Reverse clutch oil pressure 1 ..................................................................................... 8
Failure code [15SBLH] Reverse clutch oil pressure 2 .................................................................................. 10
Failure code [15SEL1] 1st clutch oil pressure 1............................................................................................ 12
Failure code [15SELH] 1st clutch oil pressure 2 ........................................................................................... 13
Failure code [15SFL1] 2nd clutch oil pressure 1........................................................................................... 14
Failure code [15SFLH] 2nd clutch oil pressure 2 .......................................................................................... 15
Failure code [15SGL1] 3rd clutch oil pressure 1........................................................................................... 16
Failure code [15SGLH] 3rd clutch oil pressure 2 .......................................................................................... 17
Failure code [1800MW] Power train clutch slip............................................................................................. 18
Failure code [2300NR] Brake thermal load................................................................................................... 19
Failure code [2301L1] Right steering brake oil pressure 1 ........................................................................... 20

D275AX-5E0

SEN01655-00

40 Troubleshooting

Failure code [2301LH] Right steering brake oil pressure 2 ........................................................................... 22


Failure code [2301NR] Right steering brake thermal load ............................................................................ 24
Failure code [2302L1] Left steering brake oil pressure 1 .............................................................................. 26
Failure code [2302LH] Left steering brake oil pressure 2 ............................................................................. 28
Failure code [2302NR] Left steering brake thermal load............................................................................... 30
Failure code [A000NS] Engine overheat....................................................................................................... 30
Failure code [AA10NX] Air cleaner clogging ................................................................................................. 32
Failure code [AB00MA] Battery charge abnormal......................................................................................... 34
Failure code [B@BAZG] Eng oil press low ................................................................................................... 36
Failure code [B@BAZK] Eng oil level low ..................................................................................................... 37
Failure code [B@BCNS] Eng coolant overheat ............................................................................................ 38
Failure code [B@BCZK] Radiator coolant level low...................................................................................... 38
Failure code [B@BEBF] Water gets mixed with fuel ..................................................................................... 39
Failure code [B@BFZK] Fuel level abnormal reduction ................................................................................ 39
Failure code [B@CENS] Torque converter oil overheat................................................................................ 40
Failure code [B@CHZG] HSS charge oil pressure reduction ....................................................................... 41
Failure code [B@CHZK] Power train oil oil level reduction ........................................................................... 41
Failure code [B@GAZK] Battery electrolyte level reduction.......................................................................... 42
Failure code [B@HANS] Hyd oil overheat .................................................................................................... 42
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................................... 43

D275AX-5E0

40 Troubleshooting

SEN01655-00

Failure code [1500L0] Transmission clutch dual engagement


Action code

Failure code

CALL E03

Contents of
trouble

Action of
controller
Problem that
appears on
machine
Related
information

1500L0

D275AX-5E0

Transmission clutch dual engagement


(Transmission controller system)

Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Gear speed is limited.)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Machine can not travel.)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Flashes warning lamp and turns on alarm buzzer.
Limits operation of engine and transmission.

The auto shift down function does not start.


Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, traveling is limited to specific gear speeds.
Machine cannot travel.

Duplication of failure code: Engine start + travel

Cause
Possible causes
and standard
value in normal
state

Trouble

Standard value in normal state/Remarks on troubleshooting

Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
[15SAL1], [15SALH ], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
[15SGLH]
[DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA], [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA], [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]

SEN01655-00

40 Troubleshooting

Failure code [15SAL1] Forward clutch oil pressure 1


Action code

Failure code

CALL E03

15SAL1

Trouble

Forward clutch oil pressure 1 (Command current is OFF but fill signal is ON)
(Transmission controller system)

Contents of
trouble

The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.

Action of
controller

Flashes caution lamp and turns on caution buzzer.


Decides that engine speed is neutral (N) at reverse operation. (Prevention of double engagement)
Limits operation of engine and transmission.

Problem that
appears on
machine
Related
information

Once machine is stopped, engine speed is limited to medium (half).


Once machine is stopped, running is limited to F1.
The input state (ON/OFF) from the forward clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Neutral running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective forward clutch fill


switch (Internal short)

FFT (male)

PCCS lever

Resistance

Between (1)
chassis ground

Min. 1 Mz

F (Forward)

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring harness between TMCN1 (female)
Resiscuit)
Max. 1 Mz
(5) FFT (female) (1) with chassis ground
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (5)
chassis ground

5 11 V

F (Forward)

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trou4
system
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

SEN01655-00

40 Troubleshooting

Failure code [15SALH] Forward clutch oil pressure 2


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SALH

Trouble

Forward clutch oil pressure 2 (Command current is ON but fill signal is OFF)
(Transmission controller system)

The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Decides that engine speed is neutral (N) at forward operation. (Prevention of double engagement)
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to R1.
The input state (ON/OFF) from the forward clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Forward running
Cause
Defective forward clutch fill
1 switch (Internal disconnection in wiring)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.
FFT (male)

PCCS lever

Resistance

Between (1)
chassis ground

Min. 1 Mz

F (Forward)

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between TMCN1 (female)
ResisMax. 1 z
nector)
(5) FFT (female) (1)
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (5)
chassis ground

5 11 V

F (Forward)

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trou4
system
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

SEN01655-00

40 Troubleshooting

Failure code [15SBL1] Reverse clutch oil pressure 1


Action code

Failure code

CALL E03

15SBL1

Trouble

Reverse clutch oil pressure 1 (Command current is OFF but fill signal is ON)
(Transmission controller system)

Contents of
trouble

The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.

Action of
controller

Flashes caution lamp and turns on caution buzzer.


Decides that engine speed is neutral (N) at forward operation. (Prevention of double engagement)
Limits operation of engine and transmission.

Problem that
appears on
machine
Related
information

Once machine is stopped, engine speed is limited to medium (half).


Once machine is stopped, running is limited to R1.
The input state (ON/OFF) from the reverse clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Neutral running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective reverse clutch fill


switch (Internal short)

FRT (male)

PCCS lever

Resistance

Between (1)
chassis ground

Min. 1 Mz

R (Reverse)

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring harness between TMCN1 (female)
Resiscuit)
Min. 1 Mz
(24) FFT (female) (1) with chassis ground
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (24)
chassis ground

5 11 V

R (Reverse)

Max. 1V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trou4
system
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

SEN01655-00

40 Troubleshooting

Failure code [15SBLH] Reverse clutch oil pressure 2


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SBLH

Trouble

Reverse clutch oil pressure 2 (Command current is ON but fill signal is OFF)
(Transmission controller system)

The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Decides that engine speed is neutral (N) at reverse operation. (Prevention of double engagement)
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F1.
The input state (ON/OFF) from the reverse clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Reverse running
Cause
Defective reverse clutch fill
1 switch (Internal disconnection in wiring)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.
FRT (male)

PCCS lever

Resistance

Between (1)
chassis ground

Min. 1 Mz

R (Reverse)

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between TMCN1 (female)
ResisMax. 1 z
nector)
(24) FRT (female) (1)
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (24)
chassis ground

5 11 V

R (Reverse)

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trou4
system
bleshooting (H mode).

10

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

11

SEN01655-00

40 Troubleshooting

Failure code [15SEL1] 1st clutch oil pressure 1


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SEL1

Trouble

1st clutch oil pressure 1 (Command current is OFF but fill signal is
ON)
(Transmission controller system)

The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F1 and R1.
The input state (ON/OFF) from the level 1 clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + F2 or R2 running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective 1st clutch fill switch


(Internal short)

F1T (male)

PCCS lever

Resistance

Between (1)
chassis ground

Other than F1/R1

Min. 1 Mz

F1 R1

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring
harness between TMCN1 (female)
Resiscuit)
Min. 1 Mz
(23) F1T (female) (1) with chassis ground
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (23)
chassis ground

Other than F1/R1

5 11 V

F1 R1

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

Circuit diagram related

12

D275AX-5E0

40 Troubleshooting

SEN01655-00

Failure code [15SELH] 1st clutch oil pressure 2


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SELH

Trouble

1st clutch oil pressure 2 (Command current is ON but fill signal is


OFF)
(Transmission controller system)

The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine and transmission.
The auto shift down function does not start.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F2 and R2.
The input state (ON/OFF) from the 1st clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + F1 or R1 running
Cause
Defective 1st clutch fill switch
1 (Internal disconnection in
wiring)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.
F1T (male)

PCCS lever

Resistance

Between (1)
chassis ground

Other than F1/R1

Min. 1 Mz

F1 R1

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between TMCN1 (female)
ResisMin. 1 Mz
nector)
(23) F1T (female) (1)
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (23)
chassis ground

Other than F1/R1

5 11 V

F1 R1

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

Circuit diagram related

D275AX-5E0

13

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40 Troubleshooting

Failure code [15SFL1] 2nd clutch oil pressure 1


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SFL1

Trouble

2nd clutch oil pressure 1 (Command current is OFF but fill signal is
ON)
(Transmission controller system)

The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine and transmission.
The auto shift down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F2 and R2.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Neutral running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective 2nd clutch fill


switch (Internal short)

F2T (male)

PCCS lever

Resistance

Between (1)
chassis ground

Other than F2/R2

Min. 1 Mz

F2 R2

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring
harness between TMCN1 (female)
Resiscuit)
Min. 1 Mz
(17) F2T (female) (1) with chassis ground
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (17)
chassis ground

Other than F2/R2

5 11 V

F2 R2

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

Circuit diagram related

14

D275AX-5E0

40 Troubleshooting

SEN01655-00

Failure code [15SFLH] 2nd clutch oil pressure 2


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SFLH

Trouble

2nd clutch oil pressure 2 (Command current is ON but fill signal is


OFF)
(Transmission controller system)

The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F1 and R1.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + F2 or R2 running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective 2nd clutch fill


switch (Internal short)

F2T (male)

PCCS lever

Resistance

Between (1)
chassis ground

Other than F2/R2

Min. 1 Mz

F2 R2

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between TMCN1 (female)
ResisMax. 1 Mz
nector)
(17) F2T (female) (1)
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (17)
chassis ground

Other than F2/R2

5 11 V

F2 R2

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

Circuit diagram related

D275AX-5E0

15

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40 Troubleshooting

Failure code [15SGL1] 3rd clutch oil pressure 1


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SGL1

Trouble

3rd clutch oil pressure 1 (Command current is OFF but fill signal is
ON)
(Transmission controller system)

The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine and transmission.
The auto shift down function does not operate.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F3 and R3.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + Neutral running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective 3rd clutch fill


switch (Internal short)

F3T (male)

PCCS lever

Resistance

Between (1)
chassis ground

Other than F3/R3

Min. 1 Mz

F3 R3

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring
harness between TMCN1 (female)
Resiscuit)
Max. 1 Mz
(11) F3T (female) (1) with chassis ground
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (11)
chassis ground

Other than F3/R3

5 11 V

F3 R3

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

Circuit diagram related

16

D275AX-5E0

40 Troubleshooting

SEN01655-00

Failure code [15SGLH] 3rd clutch oil pressure 2


Action code

Failure code

CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

15SGLH

Trouble

3rd clutch oil pressure 2 (Command current is ON but fill signal is


OFF)
(Transmission controller system)

The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, running is limited to F1 and R1.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in real-time monitoring
mode. (Code 31520: Transmission fill switch input state)
Method of reproducing failure code: Engine start + F3 or R3 running
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then start the engine for troubleshooting.

Possible causes
and standard
value in normal
state

Defective 3rd clutch fill


switch (Internal short)

F3T (male)

PCCS lever

Resistance

Between (1)
chassis ground

Other than F3/R3

Min. 1 Mz

F3 R3

Max. 1 z

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between TMCN1 (female)
ResisMax. 1 z
nector)
(11) F3T (female) (1)
tance
a Prepare with starting switch OFF, then start the engine for troubleshooting.
3

Defective transmission controller

TMCN1

PCCS lever

Voltage

Between (11)
chassis ground

Other than F3/R3

5 11 V

F3 R3

Max. 1 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

Circuit diagram related

D275AX-5E0

17

SEN01655-00

40 Troubleshooting

Failure code [1800MW] Power train clutch slip


Action code

Failure code

E02

1800MW

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

18

Power train clutch slip


(Transmission controller system)

When torque converter is locked up, engine speed does not match transmission speed data.
Flashes caution lamp and turns on caution buzzer.
The auto shift down function does not operate.
The number of engine rotations and the number of transmission rotations can be checked in realtime monitoring mode.
(Code 01000: Number of engine rotations, code 31400: Transmission output speed)
Method of reproducing failure code: Engine start + Lock-up switch ON + Actual running
Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

Power train clutch slip


a Clutch slip was detected; check the cause and machine dam(When the system is normal)
age state, then repair the machine.

Defective engine rotation


sensor

Defective transmission rota- Check whether failure codes [DLT3KA] and [DLT3KB] are distion sensor system
played. If it is displayed, carry out the troubleshooting.

Defective transmission controller

Check whether failure codes [CA115] and [CA238] are displayed.


If they are displayed, carry out the troubleshooting.

Internally trouble; troubleshooting is impossible.

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40 Troubleshooting

SEN01655-00

Failure code [2300NR] Brake thermal load


Action code

Failure code

Contents of
trouble
Action of
controller

2300NR

Trouble

Brake thermal load


(Steering controller system)

Steering controller judged from pitch angle, travel speed, continuous pedal brake operation time,
etc. that brake was heating abnormally.
None in particular.

Problem that
appears on
machine
Related
information

Possible causes
and standard
value in normal
state

D275AX-5E0

Cause
1

Standard value in normal state/Remarks on troubleshooting

Improper braking during downslope travel (e.g. Continous downhill travel with brake pedal
pressed)

2 Defective steering controller When the operation in cause 1 is not performed

19

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40 Troubleshooting

Failure code [2301L1] Right steering brake oil pressure 1


Action code

Failure code

CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2301L1

Trouble

Right steering brake oil pressure 1 (Command current is OFF but


fill signal is ON)
(Steering controller system)

The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it never runs.
The input state (ON/OFF) from the right steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.

Defective right steering


1 brake fill switch
(Internal short)

Possible causes
and standard
value in normal
state

FRB (male)
Between (1)
chassis ground

Resistance

N (Neutral)

Max. 1 z

Right steering stroke


end

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring harness between STCN2 (female)
Resiscuit)
Max. 1 Mz
(25) FRB (female) (1) with chassis ground
tance
a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.
3 Defective steering controller

STCN2
Between (25)
chassis ground

20

PCCS lever

PCCS lever

Voltage

N (Neutral)

Max. 1 V

Right steering stroke


end

5 11 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

21

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40 Troubleshooting

Failure code [2301LH] Right steering brake oil pressure 2


Action code

Failure code

CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2301LH

Trouble

Right steering brake oil pressure 2 (Command current is ON but fill


signal is OFF)
(Steering controller system)

The fill switch signal is not set off at output to the right steering brake solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it never runs.
The input state (ON/OFF) from the right steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start + Parking brake release
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.

Defective right steering


1 clutch fill switch
(Internal short)

Possible causes
and standard
value in normal
state

FRB (male)
Between (1)
chassis ground

Resistance

N (Neutral)

Max. 1 z

Right steering stroke


end

Min. 1 Mz

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STCN2 (female)
ResisMax. 1 Mz
nector)
(25) FRB (female) (1)
tance
a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.
3 Defective steering controller

STCN2
Between (25)
chassis ground

22

PCCS lever

PCCS lever

Voltage

N (Neutral)

Max. 1 V

Right steering stroke


end

5 11 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

23

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40 Troubleshooting

Failure code [2301NR] Right steering brake thermal load


Action code

Contents of
trouble
Action of
controller

Failure code
2301NR

Trouble

Right steering brake thermal load (Abnormal heating)


(Steering controller system)

Steering controller judged from pitch angle, travel speed and continuous right steering operation
time that right steering brake was heating abnormally.
None in particular.

Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state

24

Cause

Standard value in normal state/Remarks on troubleshooting

1 Improper steering during downslope travel (e.g. Continuous downhill travel with right steering ON)
2 Defective steering controller When the operation in cause 1 is not performed

D275AX-5E0

SEN01655-00

40 Troubleshooting

Failure code [2302L1] Left steering brake oil pressure 1


Action code

Failure code

CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2302L1

Trouble

Left steering brake oil pressure 1 (Command current is OFF but fill
signal is ON)
(Steering controller system)

The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it never runs.
The input state (ON/OFF) from the left steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.

Defective left steering clutch


1 fill switch
(Internal short)

Possible causes
and standard
value in normal
state

FRB (male)
Between (1)
chassis ground

Resistance

N (Neutral)

Max. 1 z

Left steering stroke


end

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshootDefective harness grounding without turning starting switch ON.
2 ing (Contact with ground cirWiring harness between STCN2 (female)
Resiscuit)
Max. 1 Mz
(35) FLB (female) (1) with chassis ground
tance
a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.
3 Defective steering controller

STCN2
Between (35)
chassis ground

26

PCCS lever

PCCS lever

Voltage

N (Neutral)

Max. 1 V

Left steering stroke


end

5 11 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

27

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40 Troubleshooting

Failure code [2302LH] Left steering brake oil pressure 2


Action code

Failure code

CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2302LH

Trouble

Left steering brake oil pressure 2 (Command current is ON but fill


signal is OFF)
(Steering controller system)

The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it never runs.
The input state (ON/OFF) from the left steering brake fill switch can be checked in real-time monitoring mode. (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start + Parking brake release
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.

Defective left steering brake


1 fill switch
(Internal short)

Possible causes
and standard
value in normal
state

FLB (male)
Between (1)
chassis ground

Resistance

N (Neutral)

Max. 1 z

Left steering stroke


end

Min. 1 Mz

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between STCN2 (female)
ResisMax. 1 Mz
nector)
(35) FLB (female) (1)
tance
a Prepare with starting switch OFF. Engine start + Pivot turn
switch ON + Forward for troubleshooting.
3 Defective steering controller

STCN2
Between (35)
chassis ground

28

PCCS lever

PCCS lever

Voltage

N (Neutral)

Max. 1 V

Left steering stroke


end

5 11 V

When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure
sure system is assumed to be abnormal. Carry out the related trousystem
bleshooting (H mode).

D275AX-5E0

40 Troubleshooting

SEN01655-00

Circuit diagram related

D275AX-5E0

29

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40 Troubleshooting

F