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Prepared by : N.

NAMIKI
D475A-5
Pm-clinic Training Kit
ITEMS
1. How to check Hot bushing of link.
2. How to measure Engine RPM.
Deceleration pedal adjustment.
3. How to measure Exhaust gas temperature.
4. How to measure Blow-by pressure.
5. How to measure Boost pressure.
6. How to measure Engine oil pressure.
7. How to measure Steering lubricating oil pressure.
8. How to measure Torque converter Inlet/Outlet pressure.
9. How to measure Stator clutch pressure.
10. How to measure T/M Main pressure.
11. How to measure L/U clutch and T/M clutch pressure.
12. How to measure Clutch & Brake oil pressure.
13. How to check Brake performance.
14. How to measure PPC oil pressure.
15. How to measure Work equipment relief pressure.
16. How to measure Fan pump pressure & Fan speed.
17. How to measure Work equipment speed.
18. How to measure Hydraulic cylinder drift.
19. Data sheet.
1.How to check Hot bushing of link pin.
HOT BUSHING CHECKING RIGHT AFTER WORKING !
L.H. SIDE Clockwise ( Reverse )------
35 36 37 38 39 40 1 2 3 4 5 6 7 H : HOT
Can not keep to be
34 MASTER LINK 8 touched.
33 9 ( Over 50 )
32 20 SETS 20 SETS 10 W : WARM
31 PORTION PORTION 11 Warmer than cool
30 12 ones.
29 13 ( 3550 )
28 14 C : COOL
Cool
27 26 25 24 23 22 21 20 19 18 17 16 15

Digital emission thermometer


2. How to measure Engine RPM.
1. Parking lever "ON". Key switch "ON". Engine start. 5 - E X C H G . I N T V A L .
S E T M O D E
2. Turn buzzer cancel SW to [] and service SW "ON" for 3 seconds.
Display B shows . 8 - S E R V I C E A D J U S T

3. Turn information SW () for three times. M O D E
Display B shows . Information SW
0 0 0 0 - S E L E C T N O .
4. Set buzzer cancel SW in the [] position.
Display A shows "Cb". Display B shows . Buzzer cancel SW

5. Turn information SW () three times. 0 0 0 7 - S E L E C T N O .


Press the shift-up button seven times.
Display B shows .

6. Set buzzer cancel SW in the [] position. 0 0 0 7 - E N G . F U L L C H


Display B shows . 2 1 5 0 r p m
Service SW
After measuring Engine RPM.
ON
7. Turn buzzer cancel SW in the [] position.
until display B show normal condition.
OFF

Measuring items.
1. Engine low idling RPM : Fuel dial is MIN position.
2. Engine high idling RPM : Fuel dial is MAX position. MIN
MAX
3. Decelerator pedal RPM : Fuel dial is MAX position, Deceleration pedal slow.
then press decelerator pedal. Fuel dial 90050rpm
DECELERATION PEDAL ADJUSTMENT

Full idling stopper


Potentiometer

Deceleration slow RPM :


90050 rpm

Adjust turn buckle for


deceleration slow RPM.
4. Engine stall RPM : T/M range shift to F3 at high idling speed.
Never put the gear shift to the F1.
Refer to below.
1. Parking lever "OFF". Display A shows "".
2. Fuel dial is MIN position.
3. Brake pedal "ON".
4. PCCS lever shift to forward. Display A shows "F1"
5. Press the shift up button twice. Display A shows "F3"
6. Fuel dial is MAX position.
7. When the lamp A at before the top of the green range of T/C oil temp' gauge light up,
depress the decelerator pedal, return the PCCS lever to Position.
then Set the Fuel dial to MIN position to lower the T/C oil temp' gauge to the 5th
or 6th position of the white range. (from bottom.)

Repeat the operation in steps No2 to No7 three to five times.


T/C Oil temp' gauge
8. Measure the engine speed after continuing the torque converter stall A
after lamp A at before the top of green range of T/C oil temp' gauge light up.
9. Engine stall RPM shows display B.

Be careful not let the power train oil temperature gauge


go into the red range.
If it goes into the red range, return the PCCS lever immediately N position
and lower the oil temperature.
5. Engine stallRipper lift relief RPM:T/M range shift to F3 and Ripper lift relief.
A
A
Never put the gear shift to the F1.
1.Measure the engine speed of the torque converter stall and ripper lift relief
after measured the engine speed of the torque converter stall.
2.Measure the engine speed after continuing the torque converter stall & ripper lift relief
after lamp A at before the top of green range of T/C oil temp' gauge light up.
3.Engine stallRipper lift relief RPM shows display B.
4.Service switch "OFF". Key "OFF". T/C Oil temp' gauge

Be careful not let the power train oil temperature gauge go into the red range.
If it goes into the red range, return the PCCS lever immediately N position
and lower the oil temperature.

Special Notes
In particular, in the D475A-5, if the warm-up run is not enough, the engine speed varies greatly.
As a rule, measurement should be made immediately after operation, e,g.. During a lunch break.
Execute measurement after a warm-up run as shown below.
1.Measurement immediately after operation.
Perform torque converter stall in three times before low idling/high idling measurement.

2.Measurement when the temperature is low early in the morning, perform torque converter stall
about 4 to 5 times to warm the whole power train fully.
3. How to measure Exhaust Gas Temperature A

For details of the measurement conditions,


See T/C Stall in Engine RPM measurement. T/C Oil temp' gauge
1.Measure the ambient temperature
by monitoring mode

2.Firstly, carry out torque converter stall and Assumed temperature


and hydraulic relief at same time to made the reading at T/C stall
higher than the assumed gas temperature at T/C stall.
Temp When measured
About : 10--15 seconds. with only
3.Then stop hydraulic relief only and continue to carry out T/C stalled.
T/C stall until reading will be saturated.

If T/C stall only is used, T/C outlet temperature T/C stall T/C stall
Time
& Hyd,relief
will be overheated before the reading is saturated.

Display A 1 1 - D U A L D I S P L A Y
M O N I T O R I N G M O D E

3 7 5 0 1 - A T M T E M P .

4 2 6 0 0 - E X H T E M P L
4 2 6 0 1 - E X H T E M P R
Exhaust gas temperature sensor.(RH)

Digital Thermometer
DT Connector must be install

Exhaust gas temperature sensor.(LH)

Atmosphere temp sensor


4. How to measure Blow-by Pressure.
Measure the ambient temperature Blow-by pressure 1 0 - R E A L T I M E
by monitoring mode.
M O N I T O R I N G M O D E
Start the engine and measure the blow-by pressure
with the T/C Stalled.
Use the manometer gauge. 4 2 8 0 0 - B L O W B Y P R S

For details of the measurement conditions,


0 k p a
See T/C Stall in Engine RPM measurement.
Blow-by adapter

5. How to measure Boost Pressure.


Measure the boost pressure with the stalled.
For details of the measurement conditions,
See T/C Stall in Engine RPM measurement.

Boost pressure test port (RH) Boost pressure test port (LH)

Nipple
Use a 1500mmHg gauge.

Use a female plug for boost


pressure measurement and
drain all the oil from
the inside the hose.
6. How to measure Engine oil pressure. Engine oil pressure sensor
Measure the Engine oil pressure and oil temperature
by monitoring mode.

With the PCCS lever at N, Measure the engine oil pressure with
the engine at low idling, high idling.
Pressure gauge : 10 Kg/cm2

Display B
1 1 - D U A L D I S P L A Y
M O N I T O R I N G M O D E

4 2 7 0 0 - E N G O I L T M P
3 7 2 0 0 - E N G O I L P R S Forward

T/M lubricating oil pressure test port


7. How to measure T/M lubricating
oil pressure.
With the PCCS lever at N, Measure Forward
the steering lubricating oil pressure
the engine at low idling, high idling.
Pressure gauge : 10 Kg/cm2
8. How to measure Torque converter inlet/outlet pressure
Measure the Torque converter Inlet/Outlet pressure after measuring
Engine stall RPM.
With the PCCS lever at N, Measure the Torque converter Inlet/Outlet
pressure with the engine at low idling, high idling.
Pressure gauge : 10 -- 25 Kg/cm2

9. How to measure Stator clutch pressure


With the PCCS lever at N, Measure the Stator clutch pressure
with the engine at low idling, high idling.
Pressure gauge : 60 Kg/cm2

10. How to measure T/M Main pressure


Measure the T/M Main pressure by monitoring mode.
With the PCCS lever at N, Measure the T/M Main oil pressure
with the engine at low idling, high idling.
Pressure gauge : 60 Kg/cm2

4 3 0 0 0 - T / M P R E S S
2 . 5 0 M p a Nipple
11. How to measure L/U clutch and T/M clutch pressure
With the PCCS lever at N, Measure the T/M 1st clutch pressure.
with the engine at low idling, high idling. Note : Brake pedal ON
Measure the 1ST, 2ND, 3RD, FWD, R, clutch pressure
with the engine at low idling.
Input the adjustment code 5535. (Both steering clutch released)
With the PCCS lever at F1, F2, F3, R1
L/U Switch ON, With the PCCS lever at F1, then the engine rpm
increase to high rpm.
L/U pilot lamp ON, Then measure the L/U pressure.

Pressure gauge : 60 Kg/cm2

5 5 3 5 - C L U T C H O P E N
2 5 r p m

12. How to measure Clutch & Brake oil pressure.


With the PCCS lever at , measure the clutch & brake oil pressure
with engine at low idling and high idling when the steering lever and
brake pedal are not operated. (Clutch and Brake)
Make sure that the clutch oil pressure is when the PCCS to limit
to steering.
Make sure that the brake oil pressure is when the Brake pedal
is locked.
Pressure gauge : 60Kg/cm2
Make sure that the brake oil pressure is
when Parking lever is ON position.
Nipple
TEST PORT
Forward 3RD
2ND
1ST
OUT

SC

RC
T/M
RB R
FWD
IN
T/M Press sensor
LU

LC
LB
13. How to check Brake performance.
1. Stop the machine on flat level ground and set the blade
in the travel position.
2. Run the engine at low idling, the brake pedal firmly,
and set shift change F2.
Don't carry out this test F1 under any circumstance.
3. Depress the decelerator pedal and move the engine dial to MAX Position.
4. Release the decelerator pedal slowly to raise the engine speed to high idling.
at this time, check that the machine does not move.
If the machine should start moving, depress the decelerator pedal
and return the PCCS lever to N position.

14. How to measure PPC oil pressure.


With the Safety lock lever at FREE, measure the PPC oil pressure
with engine with at low idling and high idling.
Pressure gauge : 60Kg/cm2

PPC Pressure test port


15. How to measure Work equipment oil pump pressure.
Temp' in hydraulic tank : 50--80 Information SW
The work equipment oil pressure can be measured
in the Service mode" of the monitor panel.
Buzzer cancel SW

Single dozer
Measure relief pressure by ripper lift relief 1 0 - R E A L T I M E
at low and high idling. ( 280 Kg/cm2 ) M O N I T O R I N G M O D E
Measure relief pressure by LH single tilt at low
and high idling. ( 215 Kg/cm2 )
0 4 4 0 1 - H Y D . T E M P
Dual tilt dozer and Super dozer
Measure relief pressure by pitch dump at low and
4 2 . 5
high idling. ( 215 Kg/cm2 )
Measure relief pressure by pitch back at low and
high idling. ( 280 Kg/cm2 )

1 1 - D U A L D I S P L A Y
M O N I T O R I N G M O D E

7 0 7 0 0 - H Y D . P U M P 1
7 0 7 0 2 - H Y D . P U M P 2
Main control valve

Unload valve

Merge-Divide valve

RH Tilt LH Tilt
Blade lift Ripper
Ripper
lift F R tilt
Ripper Blade lift LH Tilt Ripper
lift RH Tilt tilt
F R

258Kg/cm21 Turn
Adjust cap Unload valve
Lock nut

Suction valve

RH tilt port
Blade lift
safety valve
From PR port port relief
LH tilt port (390K)
Blade lift port relief valve (245K) safety valve F R
(390K) (245K)
Self reducing valve

RH tilt cyl bottom port relief


(215K)

LH tilt cyl bottom port relief


(215K)

Ls by-pass valve

Main relief (280K)


To Blade tilt LH cyl head To Blade tilt RH cyl head

To Ripper tilt cyl head Ls by-pass valve


To Ripper lift cyl head
To Blade tilt LH cyl bottom
To Front pump control
To Ripper tilt cyl bottom
To Ripper lift cyl bottom

Front To Rear pump control

[R ]Main relief (280K) [F ]Main relief (280K)


Main relief valve (280K) Tilt cyl bottom port relief valve (215K)

RH tilt cyl bottom port LH tilt cyl bottom port


[R]Main relief [F ]Main relief
relief valve relief valve
valve valve
Lock nut Adjust
Lock nut Adjust screw cap

128Kg/cm21 Turn 258Kg/cm21 Turn


16. How to measure Fan pump pressure & Fan speed.
Temp' in hydraulic tank : 50--80 1 - O I L . F I L T E R

1. Parking lever "ON". Key switch "ON". Engine start.
M A I N T E N A N C E M O D E

2. Turn buzzer cancel SW to [] for 3 seconds. 4 - U S E R A D J U S T


Display B shows . M O D E

3. Turn information SW () three times. 0 1 : L C D . B R I G H T N E S


Display B shows .
S E L E C T M O D E
4. Set buzzer cancel SW in the [] position.
Display B shows . 0 5 : F A N . 1 0 0 % M O D E
S E L E C T M O D E
5. Turn information SW () four times.
Display B shows . 0 5 : F A N . 1 0 0 % M O D E
6. Set buzzer cancel SW in the [] position. 9 0 2 r p m
Display B shows .
( FAN 100% MODE )

Measure the fan pump pressure and


fan speed the engine at high idling.

7. Turn buzzer cancel SW to [] until display B


show normal condition.

Fan motor Test port


Measuring fan speed Reflex tape

Digital tachometer

Fan pump

Reflex tape
17. How to measure Work equipment speed. Blade lift
1. Blade lift speed
Stop the machine on flat level ground and
the blade completely lowering it to the ground
horizontally, then apply the brake.
With the engine speed at low idling and high idling.
Measure the time required for the blade to reach the maximum
height above the ground by using a stop watch.

2. Single tilt speed. (Single tilt dozer)
Stop the machine on flat level ground, raise the blade LH Single tilt
about 400mm height above the ground,
then apply the brake.
With the engine speed at low idling and high idling.
Measure the time required for the blade single LH-tilt.

3. Pitch dump speed. (Dual tilt dozer) Pitch dump


Stop the machine on flat level ground, raise the blade
about 400mm height above the ground,
then apply the brake.
With the engine speed at low idling and high idling.
Measure the time required for the blade pitch dump.

4. Ripper tilt out speed.


Stop the machine on flat level ground, raise the ripper Ripper tilt out
about 500mm height above the ground,
then apply the brake.
With the engine speed at low idling and high idling.
Measure the time required for the ripper tilt out.
18. How to measure Hydraulic cylinder drift
Hydraulic tank oil temperature.
Stop the machine on the flat level ground
Measure the surface of Hydraulic tank by Digital emission thermometer.
Temperature of hydraulic oil must be more than

1. Blade lift cylinder drift


Raise the cutting edge of the blade to a position of
about 600mm above ground.
At measurement position, stop the engine and wait for one minute.
After that, measure the hydraulic drift of the blade lift cylinder
for 5 minutes.
600mm

2. Ripper lift cylinder drift


Raise the cutting edge of the ripper to a position of
about 600mm above ground.
At measurement position, stop the engine and wait for one minute.
After that, measure the hydraulic drift of the ripper lift cylinder
for 5 minutes.

600mm

Note: For the first 1 minute, the drift speed becomes high,
because of an effect of bubbles in the oil.