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Shop
Manual
D475A-5E0
D475ASD-5E0
BULLDOZER
SERIAL NUMBERS D475A-5E0 30001 and up
D475ASD-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.
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00205-01 00 Index and foreword
01 Specification SEN00207-00
Specification and technical data SEN00208-00
40 Troubleshooting SEN00222-00
Failure code table and fuse locations SEN01821-00 Q
General information on troubleshooting SEN01822-00 Q
Troubleshooting by failure code (Display of code), Part 1 SEN01823-00 Q
Troubleshooting by failure code (Display of code), Part 2 SEN01824-00 Q
Troubleshooting by failure code (Display of code), Part 3 SEN01825-00 Q
2 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 3
SEN00205-01 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN00205-01
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
01 Specification
Specification and technical data SEN00208-00
Specification and technical data .................................................................................................. 2
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 12
Fuel, coolant and lubricants..................................................................................................... 16
4 D475A, D475ASD-5E0
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Sprocket................................................................................................................................... 18
Steering unit............................................................................................................................. 21
Steering control valve .............................................................................................................. 32
Steering clutch ECMV, Steering brake ECMV ......................................................................... 34
Parking brake valve ................................................................................................................. 40
Sudden stop prevention valve ................................................................................................. 42
Undercarriage and frame SEN00213-00
Undercarriage and frame ............................................................................................................ 2
Track frame.............................................................................................................................. 2
Recoil spring............................................................................................................................ 4
Idler.......................................................................................................................................... 6
Track roller............................................................................................................................... 8
Carrier roller............................................................................................................................. 12
Track roller bogie ..................................................................................................................... 13
Track shoe ............................................................................................................................... 14
Main frame............................................................................................................................... 18
Suspension.............................................................................................................................. 20
Hydraulic system, Part 1 SEN00214-00
Hydraulic system, Part 1 ............................................................................................................. 2
Work equipment hydraulic equipment arrangement diagram .................................................. 2
PPC control piping diagram..................................................................................................... 6
Work equipment control........................................................................................................... 8
Work equipment pump ............................................................................................................ 10
PPC valve................................................................................................................................ 27
PCCS lever.............................................................................................................................. 38
Hydraulic system, Part 2 SEN00215-00
Hydraulic system, Part 2 ............................................................................................................. 2
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 17
Unload valve............................................................................................................................ 20
Introduction of LS pressure ..................................................................................................... 21
LS bypass plug ........................................................................................................................ 22
Pressure compensation valve ................................................................................................. 23
Blade lift valve ......................................................................................................................... 26
Merge-divider valve ................................................................................................................. 34
Self pressure reducing valve ................................................................................................... 36
Pilot solenoid valve.................................................................................................................. 40
Hydraulic system, Part 3 SEN00216-00
Hydraulic system, Part 3 ............................................................................................................. 2
Hydraulic tank, hydraulic filter.................................................................................................. 2
Accumulator............................................................................................................................. 4
Work equipment cylinder ......................................................................................................... 6
Piston valve ............................................................................................................................. 8
Quick drop valve...................................................................................................................... 10
Blade control knob (Dual tilt specification)............................................................................... 12
Blade control knob (Superdozer specification) ........................................................................ 13
Pitch and dual solenoid valve .................................................................................................. 14
Pin puller hydraulic circuit diagram.......................................................................................... 15
Pin puller solenoid valve.......................................................................................................... 16
Work equipment SEN00217-00
Work equipment .......................................................................................................................... 2
Cylinder stay ............................................................................................................................ 2
Blade ....................................................................................................................................... 4
Ripper equipment .................................................................................................................... 8
D475A, D475ASD-5E0 5
SEN00205-01 00 Index and foreword
6 D475A, D475ASD-5E0
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40 Troubleshooting
Failure code table and fuse locations SEN01821-00
Failure code table and fuse locations.......................................................................................... 2
Failure code table .................................................................................................................... 2
Fuse locations ......................................................................................................................... 12
General information on troubleshooting SEN01822-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Checks before troubleshooting................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
Contents of troubleshooting table ............................................................................................ 8
Wiring table for connector pin numbers ................................................................................... 10
T-adapter box and T-adapter table .......................................................................................... 39
Troubleshooting by failure code (Display of code), Part 1 SEN01823-00
Troubleshooting by failure code (Display of code), Part 1........................................................... 3
Failure code [1500L0] Transmission clutch: Dual engagement............................................... 3
Failure code [15SAL1] Forward clutch oil pressure:
Command current OFF and fill signal ON............................................................................ 4
Failure code [15SALH] Forward clutch oil pressure:
Command current ON and fill signal OFF............................................................................ 5
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ................. 6
D475A, D475ASD-5E0 7
SEN00205-01 00 Index and foreword
8 D475A, D475ASD-5E0
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Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Low voltage detection .......................................................................................................... 29
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
High voltage detection ......................................................................................................... 30
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Low voltage detection .......................................................................................................... 31
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Excessively high voltage detected ....................................................................................... 32
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Excessively low voltage detected ........................................................................................ 34
Failure code [CA227] Sensor power source (2) too high (At left bank):
Excessively high voltage detected ....................................................................................... 36
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
High voltage detection ......................................................................................................... 38
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ........... 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Excessively low voltage detected ........................................................................................ 42
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Excessively low voltage detected ........................................................................................ 44
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Excessively high voltage detected ....................................................................................... 46
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Excessively high voltage detected ....................................................................................... 48
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 49
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Low voltage detection .......................................................................................................... 49
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit .......................................... 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ....................................... 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection................................... 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ................................ 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit .......................................... 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ....................................... 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection................................... 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ................................ 57
Troubleshooting by failure code (Display of code), Part 3 SEN01825-00
Troubleshooting by failure code (Display of code), Part 3........................................................... 4
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 4
Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 6
Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 8
Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 10
Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 12
Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 14
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ....................... 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch..................... 17
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit.............. 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ....... 20
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 22
D475A, D475ASD-5E0 9
SEN00205-01 00 Index and foreword
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank):
Low voltage detection .......................................................................................................... 23
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
High voltage detection.......................................................................................................... 24
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank):
High voltage detection.......................................................................................................... 26
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 28
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Low voltage detection .......................................................................................................... 28
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
High voltage detection.......................................................................................................... 29
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
High voltage detection.......................................................................................................... 29
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence.................................................................................. 30
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence.................................................................................. 30
Failure code [CA451] Common rail pressure sensor too high (At left bank):
Excessively high voltage detected ....................................................................................... 32
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
High voltage detection.......................................................................................................... 34
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection......................................................................................... 36
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection......................................................................................... 36
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected..................................................................................... 37
Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected..................................................................................... 38
Failure code [CA554] In-range error in common rail pressure sensor (At left bank):
In-range error ....................................................................................................................... 39
Failure code [CB554] In-range error in common rail pressure sensor (At right bank):
In-range error ....................................................................................................................... 39
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank):
Loss of pressure feed detected............................................................................................ 40
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank):
Loss of pressure feed detected............................................................................................ 44
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ..... 48
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ... 50
Failure code [CA691] Intake air temperature sensor abnormally high level
(Only left bank): High voltage detection ............................................................................... 52
Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection ................................................................................ 54
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank):
Abnormal phase ................................................................................................................... 55
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank):
Abnormal phase ................................................................................................................... 55
Troubleshooting by failure code (Display of code), Part 4 SEN01826-00
Troubleshooting by failure code (Display of code), Part 4........................................................... 3
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data........... 3
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data......... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank):
Abnormal Bkup signal .......................................................................................................... 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank):
Bkup signal error .................................................................................................................. 6
Failure code [CA781] Inter-multicontroller communication error (Left bank):
Communication error............................................................................................................ 8
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D475A, D475ASD-5E0 11
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D475A, D475ASD-5E0 13
SEN00205-01 00 Index and foreword
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range ... 5
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit.......... 6
Failure code [DK55L8] Forward-reverse potentiometer: See table ......................................... 7
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection............................ 8
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit .............................. 10
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................ 12
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit .............................. 14
Failure code [DK60KA] Acceleration sensor: Disconnection ................................................... 16
Failure code [DK60KB] Acceleration sensor: Short circuit....................................................... 18
Failure code [DKH1KA] Pitch angle sensor: disconnection ..................................................... 19
Failure code [DKH1KB] Pitch angle sensor: Short circuit ........................................................ 20
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range.................................... 21
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection ...................... 22
Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 23
Failure code [dLT3KA] Transmission output speed sensor: Disconnection............................. 24
Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 26
Failure code [DV00KB] Caution buzzer: Short circuit .............................................................. 27
Failure code [DW55KA] Blade pitch back solenoid: Disconnection......................................... 28
Failure code [DW55KB] Blade pitch back solenoid: Short circuit ............................................ 29
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection ....................................... 30
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit ........................................... 31
Failure code [DW56KY] Blade pitch dump solenoid: Hot short ............................................... 32
Failure code [DW57KA] Left tilt limit solenoid: Disconnection ................................................. 33
Failure code [DW57KB] Left tilt limit solenoid: Short circuit..................................................... 34
Failure code [DW57KY] Left tilt limit solenoid: Hot short ......................................................... 35
Failure code [DW58KA] Right tilt limit solenoid: Disconnection............................................... 36
Failure code [DW58KB] Right tilt limit solenoid: Short circuit .................................................. 37
Failure code [DW58KY] Right tilt limit solenoid: Hot short....................................................... 38
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection.......................................... 39
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit ............................................. 40
Failure code [DW59KY] Dual tilt selector solenoid: Hot short.................................................. 41
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection ................................... 42
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit ....................................... 43
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ........................................... 44
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification):
Disconnection....................................................................................................................... 45
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification):
Short circuit .......................................................................................................................... 46
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification):
Hot short............................................................................................................................... 47
Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 48
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 49
Failure code [DW7BKY] Fan reverse solenoid: Hot short........................................................ 50
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection ................................... 51
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit....................................... 52
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short ........................................... 53
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection............................. 54
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit ................................ 55
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short..................................... 56
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ............................................... 57
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ................................................... 58
Failure code [DWN5KY] Fan pump solenoid 1: Hot short ....................................................... 59
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection............................................... 60
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .................................................. 61
Failure code [DWNCKY] Fan pump solenoid 2: Hot short....................................................... 62
Troubleshooting by failure code (Display of code), Part 8 SEN01830-00
Troubleshooting by failure code (Display of code), Part 8........................................................... 3
Failure code [DXE0KA] LS set solenoid: Disconnection.......................................................... 3
14 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 15
SEN00205-01 00 Index and foreword
16 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 17
SEN00206-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00206-00 00 Index and foreword
Safety notice 1
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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 D475A, D475ASD-5E0
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3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
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 cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot 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
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
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 wir-
ing. Damaged wiring may cause electrical
fires.
D475A, D475ASD-5E0 3
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4 D475A, D475ASD-5E0
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
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 immedi-
ately in an emergency.
D475A, D475ASD-5E0 5
SEN00206-00 00 Index and foreword
q 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.
q Materials and specifications are subject to change without notice.
q 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.
01. Specification
This section explains the specifications of the machine.
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.
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.
6 D475A, D475ASD-5E0
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain 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, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
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SEN00206-00 00 Index and foreword
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 9
SEN00206-00 00 Index and foreword
10 D475A, D475ASD-5E0
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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 sol-
dering may be damaged, or the wiring
may be broken.
D475A, D475ASD-5E0 11
SEN00206-00 00 Index and foreword
12 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
2) 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 dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected 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.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
D475A, D475ASD-5E0 13
SEN00206-00 00 Index and foreword
14 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol 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 control-
ler.
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 con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
D475A, D475ASD-5E0 15
SEN00206-00 00 Index and foreword
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.
16 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D475A, D475ASD-5E0 17
SEN00206-00 00 Index and foreword
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. 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 nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 D475A, D475ASD-5E0
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
D475A, D475ASD-5E0 19
SEN00206-00 00 Index and foreword
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW 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.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 D475A, D475ASD-5E0
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D475A, D475ASD-5E0 21
SEN00206-00 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 hexag-
onal 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 discon-
nect 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 hexag-
onal portion at the male end. (Fig. 9)
22 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
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 hexag-
onal 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 por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect 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 hexag-
onal portion at the male end. (Fig. 13)
D475A, D475ASD-5E0 23
SEN00206-00 00 Index and foreword
a Fig. A a Fig. B
24 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 25
SEN00206-00 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. 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.
26 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
8. 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.
D475A, D475ASD-5E0 27
SEN00206-00 00 Index and foreword
Conversion table 1
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
28 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D475A, D475ASD-5E0 29
SEN00206-00 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D475A, D475ASD-5E0 31
SEN00206-00 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade 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.
If it is desired to 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.
If it is desired to 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
32 D475A, D475ASD-5E0
00 Index and foreword SEN00206-00
D475A, D475ASD-5E0 33
SEN00206-00
34
SEN00208-00
D475A-5E0
D475ASD-5E0
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification drawings.......................................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ....................................................................................................................................... 12
Fuel, coolant and lubricants ............................................................................................................... 16
D475A, D475ASD-5E0 1
SEN00208-00 01 Specification
2 D475A, D475ASD-5E0
01 Specification SEN00208-00
Specifications 1
Semi-U tiltdozer and full-U tiltdozer specifications
Machine weight
• Tractor 83,510
Weight
3rd 0 – 10.9
Gear
Performance
1st 0 – 4.7
Reverse
mm
Semi-U dozer + Variable giant ripper 11,565
Full-U dozer + Variable giant ripper 12,065
Tractor 3,620
Overall
width
D475A, D475ASD-5E0 3
SEN00208-00 01 Specification
Power train + Lubricating oil pump (Tandem) Gear type (BAL 160 + 160 + 112)
4 D475A, D475ASD-5E0
01 Specification SEN00208-00
MPa {kg/cm } 2
Max. using pressure: 17.5 {178}
Type
Work equipment
D475A, D475ASD-5E0 5
SEN00208-00 01 Specification
6 D475A, D475ASD-5E0
01 Specification SEN00208-00
Performance
D475A, D475ASD-5E0 7
SEN00208-00 01 Specification
Superdozer specification
Machine weight
Weight
• Tractor 84,430
kg
• Superdozer + ROPS cab + Air conditioner 113,120
+ Counterweight
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Front, Rear, Left, Right) deg. 35
1st 0 – 3.5
Forward
Gear speeds
3rd 0 – 10.9
1st 0 – 4.7
Reverse
Tractor 6,680
length
mm
Superdozer + Counterweight 10,525
Overall
Tractor 3,620
width
mm
Superdozer 6,465
Dimensions
8 D475A, D475ASD-5E0
01 Specification SEN00208-00
D475A, D475ASD-5E0 9
SEN00208-00 01 Specification
Type
Work equipment
10 D475A, D475ASD-5E0
01 Specification SEN00208-00
D475A, D475ASD-5E0 11
SEN00208-00 01 Specification
Weight table 1
k This weight table is a reference for handling and transportation of components.
Unit: kg
12 D475A, D475ASD-5E0
01 Specification SEN00208-00
Unit: kg
D475A, D475ASD-5E0 13
SEN00208-00 01 Specification
Superdozer specification
Unit: kg
14 D475A, D475ASD-5E0
01 Specification SEN00208-00
Unit: kg
D475A, D475ASD-5E0 15
SEN00208-00 01 Specification
16 D475A, D475ASD-5E0
01 Specification SEN00208-00
Unit: l
D475A, D475ASD-5E0
Refilling points
Specified capacity Refill capacity
Engine oil pan 126 121
Damper case 2.2 2.2
Power train case 410 210
Final drive case (each) 75 75
Hydraulic system
420 170
(with blade, without ripper)
Cooling system
210 —
(including reservoir tank)
Fuel tank 1670 —
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SEN00208-00
18
SEN00210-00
D475A-5E0
D475ASD-5E0
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SEN00210-00 10 Structure, function and maintenance standard
1. Main radiator
2. Sub radiator
3. Turbocharger
4. Engine
5. Power train oil cooler
6. Water pump
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Engine mount 1
Unit: mm
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Function Structure
q The rotation and torque of the engine are q Cylinder block (7) is supported on shaft (1)
transmitted to the shaft of this pump. Then, through spline (C). Shaft (1) is supported on
this pump converts the rotation and torque into the front and rear bearings.
hydraulic energy and discharges hydraulic oil q The end of piston (6) has a spherical hollow
according to the load. which is combined with shoe (5). Piston (6)
q The discharge of this pump can be changed by and shoe (5) form a spherical bearing.
changing the swash plate angle in it. q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly. Rocker cam
(4) receives high-pressure oil and forms a
static pressure bearing and slides on cylindri-
cal surface B of cradle (2).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
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2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (1).
q Servo piston (1) reciprocates straight accord-
ing to the signal pressure of the PC valve. This
straight motion is transmitted to rocker cam
(4). Then, rocker cam (4) supported on the
cylindrical surface of cradle (2) slides in the
rotating direction.
q The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
(PA) is kept led in the pressure chamber on the
small-diameter piston side (upper side).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
according to the difference between pressure
(PA) on the small-diameter piston side and
pressure (PEN) on the large-diameter piston
side and the ratio of the pressure receiving
area of the small-diameter piston to that of the
large-diameter piston.
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Function
q The PC valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
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(1) When EPC output pressure is high [When EPC current (i) is large]
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Operation
q The relationship between the EPC valve input
current (i) and EPC valve output pressure (F)
is as shown in the figure below.
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(2) When EPC output pressure is low [When EPC current (i) is small]
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Operation
q If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the
right by the force of spring (6).
q Accordingly, port (g) is disconnected from port
(f) and port (f) is connected to the drain circuit.
q At this time, the oil in chamber (X) on the large
diameter side of servo piston (1) flows through
port (f) of the PC valve to the drain circuit.
q As a result, servo piston (1) is moved toward
the maximum swash plate angle side (lower
side) by the pressure of chamber (Y) on the
small diameter side.
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1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
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Function
q The rotation and torque of the engine are
transmitted to the shaft of this pump. Then,
this pump converts the rotation and torque into
hydraulic energy and discharges hydraulic oil
according to the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q Cylinder block (7) is supported on shaft (1)
through spline (B). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6)
and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slid circularly. Rocker cam
(4) slides around ball (11).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
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2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight motion is transmitted to rocker
cam (4). Then, rocker cam (4) supported on
ball (11) rocks around ball (11).
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3) Servo valve
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
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Function
q The servo valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
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10 Structure, function and maintenance standard SEN00210-00
Operation
q The output oil of the EPC valve flows in the pis-
ton chamber (C) to push piston (6). Piston (6)
pushes spool (5) until it is balanced with the
spring.
q Then, land (PE) of the servo piston pressure
passage is connected to the pump discharge
passage by the cut of spool (5) and the dis-
charge 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 dis-
charge circuit and the servo piston circuit are
shut off. The pressure in the servo piston
chamber lowers and the rocker cam returns
toward the maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put 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.
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Specifications
Type : LMF180
Capacity : 180 cc/rev
Rated speed : 982 rpm
Rated flow : 178 l/min
Check valve cracking pressure:
0.07 MPa {0.7 kg/cm2}
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1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Safety-suction valve
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1. Hydraulic motor
Function
q This hydraulic motor is a swash plate type axial
piston motor, which converts the pressure of
the hydraulic oil sent from the hydraulic pump
into revolution.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y – Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (4 or 5 pieces) and gener-
ates force (F1) (F1 kg = P kg/cm2 x x/4D2 cm2).
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft (1), the force is
divided into components (F2) and (F3).
q Radial component (F3) generates torque
against the (Y – Y) line connecting the top
dead center and bottom dead center (T = F3 x
ri).
q The resultant of this torque [T = s (F3 x ri)]
rotates cylinder block (5) through the piston.
q Since cylinder block (5) is coupled with the out-
put shaft by means of spline, the output shaft
revolves to transmit the torque.
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2. Safety-suction valve
1. Piston
2. Main valve
3. Piston spring
4. Valve seat
5. Poppet
6. Poppet spring
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
q When the pressure in port (P) of the motor
rises at the starting time of the engine, this
valve protects the fan system circuit. (Safety
valve)
q When the fan pump stops, the hydraulic oil
does not flow into the motor. Since the motor
continues revolution because of the force of
inertia, however, the pressure on the outlet
side of the motor rises.
q When the oil stops flowing in from inlet port (P),
the safety-suction valve sucks in the oil on the
outlet side and supplies it to port (MA) where
there is not sufficient oil to prevent cavitation.
(Suction valve)
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34
SEN00211-00
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D475ASD-5E0
D475A, D475ASD-5E0 1
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Outline
q The power generated by engine (1) has its tor- shaft, and it is then divided at right angles to
sional vibration dampened by damper (2), and the left and right and transmitted to the respec-
then passes through universal joint (3), and is tive steering clutches (9). The power transmit-
transmitted to torque converter (7). ted from the bevel gear shaft to the final drive
The power from the engine is transmitted is used to steer the machine by engaging or
through oil by torque converter (7) to the input disengaging steering clutch (9).
shaft (turbine shaft) of transmission (8) in The steering lever is operated to disengage
accordance with the change in the load. the steering clutch on the side to which the
There is a lockup clutch assembled to the machine is to be steered in order to change the
torque converter, and when the rotating speed direction of travel. The size of the turning
beyond the torque converter becomes higher, radius is controlled by steering brake (10)
the lockup clutch is engaged. When this hap- installed to the outside of the steering clutch.
pens, the drive case and turbine form one unit, Steering brake (10) uses the same disc system
so the power from the engine is transmitted that is used for the steering clutch.
directly to the transmission input shaft. The power output from the steering clutch
Transmission (8) uses a combination of a plan- enters final drive (11), where it is reduced, and
etary gear system and hydraulic equipment to rotates sprocket (12).
reduce the speed and shift the gears (forward: Final drive is a double reduction type consist-
3 gears, reverse: 3 gears). It connects two sets ing of a single stage spur gear and single stage
of clutches selected with the gear shift lever planetary gear system.
according to the change in the load, and trans- It rotates the sprocket to drive track shoe (13)
mits the power from the transmission to trans- and moves the machine.
fer (14) from output shaft.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the
bevel pinion and bevel gear of the bevel gear
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D475A, D475ASD-5E0 3
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1. Torque converter oil filter A. Transmission main relief pressure pickup port (TM)
2. Transmission lubricating oil filter B. Transmission R clutch pressure pickup port (REV)
3. Transmission oil filter C. Transmission F clutch pressure pickup port (FWD)
4. Torque converter valve D. Torque converter inlet pressure pickup port (IN)
5. Transmission control valve E. Lockup clutch pressure pickup port (LU)
6. Steering control valve F. Left clutch pressure pickup port (LC)
7. Power train oil strainer G. Left brake pressure pickup port (LB)
8. Oil tank H. Right brake pressure pickup port (RB)
9. Power train, lubrication pump J. Right clutch pressure pickup port (RC)
(BAL160+160+112) K. Stator clutch pressure pickup port (SC)
10. Scavenging pump L. Torque converter outlet pressure pickup port (OUT)
11. Power train oil cooler M. Transmission 1st clutch pressure pickup port (1ST)
N. Transmission 2nd clutch pressure pickup port (2ND)
P. Transmission 3rd clutch pressure pickup port (3RD)
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Operation
q The power from the engine is transmitted
through flywheel (2) to outer body (3). The
tensional vibration of the engine is absorbed in
rubber coupling (10) and the power is transmit-
ted to output shaft (1), and then transmitted
through universal joint (9) to the torque con-
verter and transmission.
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Unit: mm
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Outline
q The power train unit broadly consists of torque
converter and PTO (4), transmission (7), and
steering unit (9). Therefore, after the power
train unit is removed, it can be divided into
torque converter and PTO (4), transmission
(7), and steering unit (9).
q Steering unit (9) consists of the transfer, bevel
gear shaft, steering clutch, and the steering
brake.
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Outline Structure
q The torque converter is a 3-element, 1-stage, q Pump (17) is integral with coupling (6), input
and 1-phase type, which is integral with the shaft (8), lockup clutch housing (12), and drive
transmission. case (13), and rotated by the engine power.
q The torque converter is equipped with a wet q Turbine (14) is integral with turbine boss (29)
multiple disc clutch type torque converter and transmission input shaft (22), and rotated
lockup device and a wet double disc clutch by the oil from pump (17).
type stator clutch in order to reduce fuel con- q Stator (16) is integral with stator shaft (18) and
sumption, to increase the operability, and to stator clutch hub gear (23), and fixed to rear
reduce the horsepower consumption by the housing (15) through the stator clutch unit.
engine. q The lockup clutch unit consists of clutch plate
q For higher efficiency of continuous light dozing (30) meshed with drive case (13), clutch disc
and leveling operation, the torque converter is (31) meshed with turbine boss (29), and clutch
locked up and the engine power is transferred piston (32) which slides inside clutch housing
directly to the transmissions input shaft. (12) integral with drive case (13).
q When the torque converter is locked up (the q The stator clutch unit consists of clutch hub
pump and turbine is integrated into 1 unit), the gear (23) attached to stator shaft (18) with
oil is still supplied to the torque converter. spline, clutch disc (27) meshed with clutch hub
Accordingly, the oil flowing from the pump gear (23), clutch plate (26) supported by the
through the turbine to the stator is obstructed pins on clutch housing (24) and rear housing
by the stator blades and cannot flow in any (15), and clutch piston (28) which slides inside
direction. As a result, this oil resists the rotation rear housing (15).
of the pump and turbine (it is agitated). q The PTO unit consists of input shaft (8), PTO
q To reduce the rotating resistance of the pump idler gear (10), and pump drive gears (33), (36)
and turbine, the stator clutch is disengaged and (40).
simultaneously with lockup of the torque con-
verter so that the stator can rotate freely.
As the stator is dragged and turned by the
pump and turbine, the oil returns from the tur-
bine to the pump smoothly against less resis-
tance.
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Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of oil seal contact
surface of input coupling 125 0 124.8
–0.063
Inside diameter of seal ring con- +0.035 Repair by hard
2 tact surface of sleeve 115 0 115.1 chrome plating
or replace
3 Inside diameter of seal ring contact 190 +0.046 190.5
surface of retainer 0
16 Stator clutch return spring Free length Installed length Installed load Free length Installed load
125.4 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}
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SEN00211-00 10 Structure, function and maintenance standard
When lockup clutch is “disengaged” and stator When lockup clutch is “engaged” and stator
clutch is “engaged” clutch is “disengaged”
q If lockup clutch (3) is “disengaged”, drive case q If lockup clutch (3) is “engaged”, drive case (5)
(5) and turbine (7) are disconnected from each and turbine (7) are connected to each other.
other. If stator clutch (9) is “disengaged” at this time,
If stator clutch (9) is “engaged” at this time, rear housing (10) and stator shaft (11) are dis-
rear housing (10) and stator shaft (11) are con- connected from each other, and stator (8) is
nected to each other to fix stator (8). dragged and turned by pump (6) and turbine
Therefore, the torque converter works as an (7).
ordinary torque converter. Therefore, the torque converter works as a
q The power from the engine is transmitted to lockup torque converter.
coupling (1) through the damper and the uni- q The power from the engine is transmitted to
versal joint. coupling (1) through the damper and the uni-
q The power transmitted to coupling (1) rotates versal joint.
input shaft (2), clutch housing (4), drive case q The power transmitted to coupling (1) rotates
(5) and pump (6) integrally. input shaft (2), clutch housing (4), drive case
q The power transmitted to pump (6) rotates tur- (5) and pump (6) integrally.
bine (7) through the medium of oil and is trans- q The power transmitted to drive case (5) rotates
ferred to transmission input shaft (12) attached turbine (7) directly since lockup clutch (3) is
to turbine (7) with spline. fixed, and is transferred to transmission input
shaft (12) attached to turbine (7) with spline.
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Oil flow
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Unit: mm
No. Check item Criteria Remedy
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Outline
q The torque converter valve is installed at the
top of the rear housing of the toque converter,
and consists of the following 6 types of valves.
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q The oil from the hydraulic pump flows through q The oil from the main relief valve flows through
the filter, port (A) of the torque converter valve, port (C) to the torque converter, and at the
and orifice (a) of torque converter relief valve same time, also flows through orifice (b) of
(1) to chamber (B). torque converter relief valve (3) to chamber
(D).
q When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber
(D) pushes piston (4), the reaction force of
which moves torque converter relief valve (3)
to the right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E)
to the oil tank.
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q While the machine is in the “torque converter q The oil from the pump flows through port (D)
range”, the lockup solenoid valve is “de-ener- into port (E) and applies back pressure to sta-
gized” and therefore plunger (1) is pushed tor clutch piston (7). It turns “engaged” the sta-
back upward by the oil pressure from the tor clutch as the oil pressure in the circuit is
pump. raised.
q As the seats of valve (2) and ball (3) are At the same time, the oil which applied back
opened, the drain circuit of port (B) is opened pressure to lockup clutch piston (8) is drained
and the oil in port (A) and port (C) is drained. through port (F) into port (H) to turn the lockup
q Lockup selector valve (5) is pushed back to the clutch “disengaged”.
right by the tension of spring (6). As a result, q The oil from the pump flows into port (A) and
the passages between port (D) and port (F) port (D). The oil in port (A) is drained as the
and between port (E) and port (G) are closed, lockup solenoid valve is “de-energized”, while
while the passages between port (D) and port the oil pressure in port (D) is secured by orifice
(E) and between port (F) and port (H) are (a) and adjusted by modulating valve (9).
opened.
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q While the machine is in the “direct range”, the q The oil from the pump flows through port (D)
lockup solenoid valve is “energized” and there- into port (F) and applies back pressure to sta-
fore plunger (1) moves downward. tor clutch piston (8). It turns the lockup clutch
q As the seats of valve (2) and ball (3) are “engaged” as the oil pressure in the circuit is
closed, the drain circuit of port (B) is closed raised.
and the oil in port (A) flows to port (C) At the same time, the oil which had applied
q The oil from port (C) pushes piston (4) to move back pressure to stator clutch piston (7) is
lockup selector valve (5) to the left. As a drained through port (E) into port (G) to turn
result, the passages between port (D) and port the stator clutch “disengaged”.
(E) and between port (F) and port (H) are q The pressure of the oil which flows from the
closed, while the passages between port (D) pump into port (D) is adjusted by modulating
and port (F) and between port (E) and port (G) valve (10).
are opened.
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Modulating valve
Outline
q The modulating valve is located between the
lockup selector valve and the inlet of each
clutch.
q When each clutch is turned “engaged”, it
raises the oil pressure applied to the piston
gradually to the set pressure to engage the
clutch smoothly and to reduce the shock given
to the torque converter and transmission.
a Though the following explanation on operation
takes the modulating valve for the stator clutch
as an example, the modulating valve for the
lockup clutch also operates in a similar way.
However, please note that the oil flow into the
clutches in the torque converter range and in
the direct range is opposite in direction.
Operation
When traveling in torque converter range
q While the machine is in the “torque converter
range”, lockup solenoid valve (1) is “de-ener-
gized” and the oil from the pump and the oil in
port (B) are drained.
q Lockup selector valve (2) is pushed back to the
right by the tension of spring (3). Then the pas-
sages between port (A) and port (E) and
between port (D) and port (G) are closed, while
the passage between port (A) and port (D) is
opened. As a result, the circuit is connected
through modulating valve (5) to stator clutch
(9).
q The oil from the pump flows through port (A)
into stator clutch (9), and the oil pressure in the
circuit starts rising.
q If the oil pressure in the circuit rises, the oil
flowing through orifice (a) of modulating valve
(5) pushes piston (6), the reaction force of
which moves modulating valve (5) to the left to
throttle part (C).
q Port (D) is connected to port (F) which applies
back pressure to load piston (7). Load piston
(7) is pushed to the right to retract spring (8),
the tension of which opens part (C).
q By repeating the above operation intermit-
tently, load on spring (8) increases and the oil
pressure rises gradually.
Ultimately, modulating valve (5) stops at the
position where it closed part (C). Rise in the oil
pressure is completed and stator clutch (9) is
completely turned “engaged”.
26 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 27
SEN00211-00 10 Structure, function and maintenance standard
Operation
q The torque converter lockup control system
controls the lockup operation of the torque
converter automatically with a sensor signal
and the controller in it according to the load on
the machine. When the torque converter is
locked up, the pilot lamp on the monitor panel
lights up.
q The signal of the transmission outlet speed
sensor is input to the transmission controller.
q The lockup mode is set with the mode selec-
tion panel.
q The machine controller receives the gear
speed information from the transmission con-
troller and the transmission outlet speed sen-
sor signal from the shoe slip controller and
turns ON and OFF the lockup system by con-
necting and disconnecting the lockup solenoid
and pilot lamp to and from the chassis ground.
a As for the details of the valve, refer to section
“Torque converter valve”.
28 D475A, D475ASD-5E0
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Scavenging pump 1
Type: BAR(3)63+320
Specifications
D475A, D475ASD-5E0 29
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30 D475A, D475ASD-5E0
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Transmission control 1
a PCCS: Abbreviation for Palm Command Control System
a For steering operation concerned to operation of the Palm Command Control System lever (PCCS
lever), see “Steering and brake control”.
D475A, D475ASD-5E0 31
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Transmission 1
32 D475A, D475ASD-5E0
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34 D475A, D475ASD-5E0
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36 D475A, D475ASD-5E0
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Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 R clutch spring (12 pcs.) length load load
140.5 N 119.6 N
100.0 90.0 94.0
{14.3 kg} {12.2 kg}
84.3 N 70.6 N
2 F clutch spring (12 pcs.) 100.0 94.0 94.0
{8.5 kg} {7.2 kg}
150.5 N 128.5 N
3 3rd clutch spring (12 pcs.) 84.0 72.0 79.0
{15.4 kg} {13.1 kg}
119.1 N 102.0 N
4 2nd clutch spring (12 pcs.) 81.7 63.0 76.8
{12.2 kg} {10.4 kg}
238.7 N 203.0 N
5 1st clutch spring (12 pcs.) 103.5 76.0 97.3
{24.4 kg} {20.7 kg}
D475A, D475ASD-5E0 37
SEN00211-00 10 Structure, function and maintenance standard
Disc clutch
Structure Operation
When clutch is “engaged” (fixed)
q The disc clutch consists of piston (2), plates q The oil from ECMV is sent with pressure to the
(3), discs (4), pin (5), return spring (6) etc. to fix rear side of piston (2) through the oil passage
ring gear (1). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-00
q When the transmission is set to the forward 1st q The rotation of F and 3rd carrier (10) is trans-
s p e e d , th e F c l u t c h a n d 1 s t c l u t c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the F clutch piston, and fixes F ring transmitted through 2nd carrier (13) to 1st
gear (4). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to F planetary pinion (3) through input clutch inner drum (16) to output shaft (20).
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
D475A, D475ASD-5E0 39
SEN00211-00 10 Structure, function and maintenance standard
q When the transmission is set to the forward q The rotation of F and 3rd carrier (10) is trans-
2nd speed, the F clutch and 2nd clutch are mitted through 3rd planetary pinion (11) to 3rd
engaged.The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 2nd carrier (13) is
applied to the F clutch piston, and fixes F ring transmitted to 2nd planetary pinion (15).
gear (4). The 2nd clutch is actuated by the oil q As 2nd ring gear (17) is fixed by the 2nd clutch,
pressure applied to the 2nd clutch piston, and the power transmitted to 2nd planetary pinion
fixes 2nd ring gear (17). (15) is transmitted through 2nd sun gear (18)
q The power from the torque converter is trans- to output shaft (20).
mitted to F planetary pinion (3) through input
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-00
q When the transmission is set to the forward 3rd q As 3rd ring gear (12) is fixed by the 3rd clutch,
s p e ed , th e F c l u t c h an d 3 r d c l ut c h a r e the power transmitted to F and 3rd carrier (10)
engaged. The power transmitted from the is transmitted through 3rd planetary pinion (11)
torque converter to input shaft (1) is then trans- and 3rd sun gear (19) to output shaft (20).
mitted to output shaft (20).
q The F clutch is actuated by the oil pressure
applied to the F clutch piston, and fixes F ring
gear (4). The 3rd clutch is actuated by the oil
pressure applied to the 3rd clutch piston, and
fixes 3rd ring gear (12).
q The power from the torque converter is trans-
mitted to F planetary pinion (3) through input
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
D475A, D475ASD-5E0 41
SEN00211-00 10 Structure, function and maintenance standard
q When the transmission is set to the reverse 1st q The rotation of F and 3rd carrier (10) is trans-
s p e ed , th e R c l ut c h a nd 1 s t c l ut c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The R clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the R clutch piston, and fixes ring transmitted through 2nd carrier (13) to 1st
gear (7). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to R planetary pinion (6) through input clutch inner drum (16) to output shaft (20).
shaft (1) and R sun gear (5).
q Ring gear (7) and R carrier (8) are meshed
with each other and fixed by the R clutch.
Accordingly, the rotation of R planetary pinion
(6) rotates R ring gear (9). The rotation of R
ring gear (9), the direction of which is opposite
to that of input shaft (1), rotates F and 3rd car-
rier (10).
42 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 43
SEN00211-00
44
SEN00212-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
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2 D475A, D475ASD-5E0
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PF: F clutch oil pressure pickup port (FWD) Operation table of ECMV
PR: R clutch oil pressure pickup port (REV)
P1: 1st clutch pressure pickup port (1ST) ECMV
P2: 2nd clutch pressure pickup port (2ND) F R 1st 2nd 3rd
Gear speed
P3: 3rd clutch pressure pickup port (3RD)
Forward 1st Q Q
PV: To priority valve
LV: To lubricating oil relief valve Forward 2nd Q Q
LD: Drain (from lubricating oil relief valve) Forward 3rd Q Q
CF: To F clutch Reverse 1st Q Q
CR: To R clutch
Reverse 2nd Q Q
C1: To 1st clutch
C2: To 2nd clutch Reverse 3rd Q Q
C3: To 3rd clutch * Neutral Q
dr: Drain *: Filled with oil at low pressure.
(Except for low temperature and abnormal conditions.)
1. Filter
2. Priority valve
3. Lubricating oil relief valve
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. F clutch ECMV
8. R clutch ECMV
9. Valve seat
D475A, D475ASD-5E0 3
SEN00212-00 10 Structure, function and maintenance standard
A: To clutch
P: From pump *1:
T: Drain
Stamp of the
Dr: Drain Clutch used
nameplate
P1: Clutch oil pressure pickup port
F, R, 1st, 2nd, 3rd A*******
1. Fill switch connector
2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
4 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 5
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6 D475A, D475ASD-5E0
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q If current is applied to proportional solenoid (1) q If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control with the sum of the thrust generated by the oil
valve (3) to the left. This opens pump port (P) pressure in clutch port and the tension of pres-
and clutch port (A) to feed oil in the clutch. sure control valve spring (2), and then the
When the clutch is filled with oil, pressure pressure is settled.
detection valve (4) actuates to turn “ON” fill
switch (5).
D475A, D475ASD-5E0 7
SEN00212-00 10 Structure, function and maintenance standard
Priority valve 1
Unit: mm
No. Check item Criteria Remedy
8 D475A, D475ASD-5E0
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Operation from start to finish of gear shifting Operation right after finishing of gear shifting
q The oil from the pump flows through port (A) q If the gear shift lever is operated, the oil pres-
and orifice (a) to chamber (C). sure in port (B) decreases sharply nearing 0
q If the oil flow from the pump increases and the MPa { 0 kg/cm2} as a result of the ECMV oper-
oil pressure rises, the oil in chamber (C) ation.
pushes piston (1). Then, the reaction force of q Then, the oil pressure in port (A) also
piston (1) compresses spring (2) and moves decreases, but valve (3) is pushed back to the
valve (3) to the left. right by the tension of spring (2).
q If valve (3) moves, port (A) and port (B) are q As a result, the oil pressure in port (A) (pilot
connected and the oil from the pump flows pressure) is kept to the set pressure.
through port (B) to the ECMV. The oil pressure
at this time is the set pressure of the priority
valve.
q Then, the oil pressure transmitted from port (B)
to the ECMV rises to the set pressure of the
clutch.
D475A, D475ASD-5E0 9
SEN00212-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
10 D475A, D475ASD-5E0
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Unit: mm
No. Check item Criteria Remedy
Type Standard clearance Clearance limit
1 Side clearance BAL(4)160
0.04 – 0.10 0.13
BAL(4)112
D475A, D475ASD-5E0 11
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12 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 13
SEN00212-00 10 Structure, function and maintenance standard
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle 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 slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
14 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 15
SEN00212-00 10 Structure, function and maintenance standard
Unit: mm
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-00
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to No. 1 pinion (15). It the rotating force of carrier (3), which supports
then passes through No. 1 gear (13), which is the planetary pinion, and is transmitted to
meshed with the No. 1 pinion, and is transmit- sprocket hub (6).
ted to sun gear (2) to rotate it. The rotation direction of carrier (3) is the same
The rotation of sun gear (2) is transmitted to as sun gear (2).
planetary pinion (10), but ring gear (11), which The rotating force transmitted to sprocket hub
is meshed with the planetary pinion, is fixed to (6) is transmitted to sprocket teeth (7).
cover (9), so the planetary pinion rotates on its
own axis and moves around the sun gear
along the ring gear.
D475A, D475ASD-5E0 17
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Sprocket 1
Unit: mm
18 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 19
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20 D475A, D475ASD-5E0
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Steering unit 1
D475A, D475ASD-5E0 21
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22 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 23
SEN00212-00 10 Structure, function and maintenance standard
Outline
24 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 25
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26 D475A, D475ASD-5E0
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Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Replace
1 Brake plate Thickness 4.2 ±0.1 3.8
Strain — Max. 0.3 0.4 Repair or replace
Thickness 5.4 ±0.1 4.3 Replace
2 Brake disc
Strain — Max. 0.3 0.4 Repair or replace
Total assembled thickness of
3 82.2 ±0.41 72.6
8 brake plates and 9 discs Replace
Thickness 4.2 ±0.1 3.8
4 Clutch plate
Strain — Max. 0.3 0.4 Repair or replace
Thickness 5.4 ±0.1 4.5 Replace
5 Clutch disc
Strain — Max. 0.4 0.5 Repair or replace
Total assembled thickness of
6 76.8 ±0.40 69.3
8 clutch plates and 8 discs
Inside diameter of seal ring +0.046
7 190 190.5
contact surface of sleeve 0
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
8 of seal ring contact
surface of brake piston Small
+0.052
diameter 300 300.1
0
parts
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
9 of seal ring contact
face of clutch piston Small
+0.052
diameter 300 300.1
0
parts
Standard size Repair limit Replace
D475A, D475ASD-5E0 27
SEN00212-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
18 Backlash between transfer gears Adjust or replace
0.26 – 0.67 0.75
28 D475A, D475ASD-5E0
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When steering clutch is turned “engaged” When steering clutch is turned “disengaged”
q When the PCCS lever is in the “neutral” posi- q If the PCCS lever is operated to the left or
tion, the oil in the back side of clutch piston (1) right, the oil pressure is applied to the back of
is drained by the steering control valve. clutch piston (1) by the steering control valve.
q At this time, clutch piston (1) is pushed back to q As the oil pressure rises, clutch piston (1) com-
the right by the tension of clutch spring (2) to press clutch spring (2) and moves to the left to
press discs (3) and plates (4) against stopper eliminate the pressing force between discs (3)
(5). and plates (4).
q The power from steering shaft (6) is transmit- q The power from steering shaft (6) is not trans-
ted through clutch hub (7), pressed discs (3) mitted after housing (8) and accordingly is not
and plates (4) to housing (8). transmitted to the final drive.
q Since housing (8) is connected to brake hub q If the PCCS lever is released, the oil in the
(9) and output shaft (10), the power is transmit- back side of clutch piston (1) is drained by the
ted through output shaft (10 ) to the final drive. steering control valve, thus the steering clutch
is turned “engaged”.
q If the L.H. steering clutch is turned “disen-
gaged”, the power is transmitted only to the
R.H. steering clutch, and consequently the
machine turns to the left.
D475A, D475ASD-5E0 29
SEN00212-00 10 Structure, function and maintenance standard
q When the PCCS lever is in the “neutral” posi- q If the PCCS lever is operated to the left or
tion and the brake pedal is released, the steer- right, the steering control valve turns the steer-
ing control valve only sets the brake pressure ing clutch “disengaged” and the oil in the back
to the maximum. Accordingly, the steering side of piston (1) starts to be drained.
clutch is turned “engaged” and the oil pressure q At this time, brake piston (1) is pushed back to
is applied to the back of brake piston (1). the right by the tension of brake spring (2) to
q As the oil pressure rises, brake piston (1) com- press discs (3) and plates (4) against stopper
presses brake spring (2) and moves to the left (5).
to eliminate the pressing force between discs q Brake piston (1) and stopper (5) are fixed to
(3) and plates (4). the steering case by the pin.
q The power transmitted from the steering shaft q Brake hub (7) and output shaft (8), which tend
(6) through the steering clutch to brake hub (7) to rotate by the inertia force even after the
is further transmitted through output shaft (8) steering clutch is turned “disengaged”, can be
to the final drive. stopped by pressing discs (3) and plates (4) to
each other.
q The turning radius and speed can be adjusted
by the brake force controlled by the oil pres-
sure in the back side of piston (1) according to
the stroke of the PCCS lever to the left and
right.
30 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 31
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32 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 33
SEN00212-00 10 Structure, function and maintenance standard
A: To clutch or brake
P: From pump *1:
T: Drain
Clutch used Stamp of the nameplate
Dr: Drain
P1: To clutch or brake pressure pickup port Steering clutch,
R*******
Steering brake
1. Fill switch connector
2. Proportional solenoid connector Outline
3. Pressure detection valve q Each ECMV keeps the steering clutch oil pres-
4. Fill switch sure and steering brake oil pressure to the set
5. Proportional solenoid pressure and furthermore changes the circuit
6. Pressure control valve to the piston chamber of the steering clutch
7. Nameplate (*1) and steering brake.
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-00
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the steering controller and
this valve converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the sig-
nal (fill signal) to the controller to notify the
finishing of filling.
2. While the oil pressure is applied to the
clutch or brake, the fill switch outputs the
signal (fill signal) to the controller to notify
the presence of the oil pressure.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D475A, D475ASD-5E0 35
SEN00212-00 10 Structure, function and maintenance standard
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in
“free” position: Straight travel
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “released”, and parking brake is
“released”.)
q When the PCCS lever is in “neutral” position q Proportional solenoid (5) of the brake ECMV is
and the brake pedal is “released”, proportional energized and pushes ball (6) to the left and
solenoid (1) of the clutch ECMV is de-ener- closes the sealing part.
gized and the sealing part of ball (2) is opened. q The oil in port (Pb) of the brake ECMV flows in
q The oil from the power train pump flows port (E) and pushes valve (7) to the left to con-
through port (Pc) of the clutch ECMV to orifice nect port (Pb) with port (B) and disconnect port
(a), then it is drained through the sealing part (B) from port (Dr). At this time, the oil flows in
of ball (2). the back pressure port of the brake piston. As
q Valve (3) is moved to the right by the tension of the oil pressure rises, the brake piston is
spring (4) to disconnect port (Pc) from port (C), pushed to the left to compress the brake
and connect port (C) with port (Dr). At this spring, then the brake is “released”.
time, the oil from the back pressure port of the q When the parking brake lever is in “free” posi-
clutch piston is drained through port (C) and tion, as the parking brake valve is closed, the
the clutch is turned “engaged” by the tension of oil in the brake circuit is not drained.
the clutch spring.
q The oil pressure in the brake circuit, etc. is
secured by orifice (a).
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-00
When PCCS lever is “operated to the left halfway”, brake pedal is “released”, and parking brake lever
is in “free” position: Gradual left turn
(L.H. clutch is turned “disengaged”, L.H. brake is “semi-released”, R.H. clutch is turned “engaged”, R.H.
brake is “released”, and parking brake is “released”.)
q When the PCCS lever is “operated to left half- q Proportional solenoid (5) generates the propul-
way” and the brake pedal is “released”, propor- sion force in proportion to the command cur-
tional solenoid (1) of the L.H. clutch ECMV is rent. This propulsion force is balanced with the
energized and the sealing part of ball (2) is sum of the propulsion force generated by the
closed. oil pressure in the back pressure port of the
q The oil from the power train pump flows brake piston and the tension of spring (8), then
through port (Pc) of the clutch EMCV and ori- the brake pressure is set up to adjust the brake
fice (a) to port (F) and pushes valve (3) to the force.
left to connect port (Pc) with port (C) and dis- q Accordingly, if the stroke of the PCCS lever is
connect port (C) from port (Dr). At this time, the short, the oil pressure after port (B) is set high
oil flows in the back pressure port of the clutch and the brake is turned from “released” to
piston. As the oil pressure rises, the clutch pis- “semi-released”. If the stroke of the PCCS
ton is pushed to the left to compress the clutch lever is long, the oil pressure after port (B) is
spring, then the clutch is turned “disengaged”. set low and the brake is turned from “semi-
q Proportional solenoid (5) of the brake ECMV is released” to “applied”.
energized and pushes ball (6) to the left and q When the parking brake lever is in “free” posi-
closes the sealing part. tion, as the parking brake valve is closed, the
q The oil in port (Pb) of the brake ECMV flows in oil in the brake circuit is not drained.
port (E) and pushes valve (7) to the left. As for
the oil pressure after port (B), the controller
outputs the command current to proportional
solenoid (5) according to the stroke of the
PCCS lever.
D475A, D475ASD-5E0 37
SEN00212-00 10 Structure, function and maintenance standard
When PCCS lever is “operated fully to the left”, brake pedal is “released”, and parking brake lever is
in “free” position: Sharp left turn
(L.H. clutch is turned “disengaged”, L.H. brake is “applied”, R.H. clutch is turned “engaged”, R.H. brake is
“released”, and parking brake is “released”.)
q When the PCCS lever is shifted from “operated q When the parking brake lever is in “free” posi-
to left halfway” to “operated to left fully”, pro- tion, as the parking brake valve is closed, the
portional solenoid (5) of the L.H. brake ECMV oil in the brake circuit is not drained.
is de-energized and the sealing part of ball (6)
is fully opened.
q Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr). At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned “applied” by the tension
of the brake spring.
q The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
fice (b), then it is drained through sealing part
of ball (6).
q The oil pressure in the clutch circuit, etc. is
secured by orifice (b).
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-00
When PCCS lever is in “neutral”, brake pedal is “depressed”, and parking brake lever is in “free”
position: Stop
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is
“released”.)
q When the brake pedal is depressed fully, pro- q If the brake pedal is depressed, the parking
portional solenoids (5) of L.H. and R.H. brake brake valve connected by the linkage operates
ECMV are de-energized to open the sealing to open the brake circuit and drain the oil.
part of ball (6).
q The controller outputs the command current to
proportional solenoid (5) according to the
brake pedal stroke.
q Proportional solenoid (5) generates the propul-
sion force in proportion to the command cur-
rent. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (8), then
the brake pressure is set up to adjust the brake
force.
q Since the PCCS lever is in “neutral” position,
proportional solenoids (1) of L.H. and R.H.
clutch ECMV are de-energized and L.H. and
R.H. clutch are turned “engaged”.
D475A, D475ASD-5E0 39
SEN00212-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
4. Spool Outline
5. Valve body q The parking brake valve is installed to the
steering control valve, and spool (4) operates
with the parking brake lever.
q When the parking brake lever is in “lock” posi-
tion, the brake operates by draining the operat-
ing pressure of the L.H. and R.H. steering
brake.
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-00
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in
“lock” position : Parking
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is
“applied”.)
D475A, D475ASD-5E0 41
SEN00212-00 10 Structure, function and maintenance standard
Outline
q The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electri-
cal system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) when
brake ECMV coil (2) is de-energized, and con-
sequently the sudden brake can be avoided.
q If an abnormality takes place in the electrical
system, also solenoid (3) of sudden stop pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
42 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-00
D475A, D475ASD-5E0 43
SEN00212-00
44
SEN00213-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00213-00 10 Structure, function and maintenance standard
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
Outline
q The track roller uses K-shape bogie mount to
increase the ground contact area between the
track shoe and ground surface on rough sur-
faces, thereby increasing the drawbar pull.
q The K-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
Unit: mm
D475A, D475ASD-5E0 3
SEN00213-00 10 Structure, function and maintenance standard
Recoil spring 1
1. Yoke Outline
2. Nut q Recoil spring (10) damps sudden shocks
3. Retainer applied to the idler.
4. Rod q The recoil spring is also used to adjust the
5. Spring cylinder track shoe tension by supplying or discharging
6. Retainer grease through lubricator (8) and moving rod
7. Piston (4) forward or in reverse.
8. Lubricator
(for supplying and discharging grease)
9. Grease chamber cylinder
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
Unit: mm
D475A, D475ASD-5E0 5
SEN00213-00 10 Structure, function and maintenance standard
Idler 1
Unit: mm
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
D475A, D475ASD-5E0 7
SEN00213-00 10 Structure, function and maintenance standard
Track roller 1
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
D475A, D475ASD-5E0 9
SEN00213-00 10 Structure, function and maintenance standard
6 Width of tread — —
7 Width of flange 34.5 19.5
9 Width of shaft flange 377 —
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
D475A, D475ASD-5E0 11
SEN00213-00 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
Outline 1. Guide
q The track rollers are installed to small bogie 2. Cap
(6). The track rollers and track shoes are 3. Track roller assembly (double)
always in contact. 4. Large bogie
q The vibration of the machine from the ground 5. Rubber mount
surface is absorbed by rubber mount (5). 6. Small bogie
7. Track roller assembly (single)
8. Cover
9. Cartridge pin
D475A, D475ASD-5E0 13
SEN00213-00 10 Structure, function and maintenance standard
Track shoe 1
a Portion P shows the link on the side where the bushing is pressed fitted.
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
Unit: mm
*1: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit
is 183 mm.
*2: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit
is 37.5 mm.
D475A, D475ASD-5E0 15
SEN00213-00 10 Structure, function and maintenance standard
Unit: mm
2 Thickness 18
3 33 Repair by
Length of base build-up
4 27 welding or
replace
5 25.5
7 23.5
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
D475A, D475ASD-5E0 17
SEN00213-00 10 Structure, function and maintenance standard
Main frame 1
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
Unit: mm
D475A, D475ASD-5E0 19
SEN00213-00 10 Structure, function and maintenance standard
Suspension 1
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
D475A, D475ASD-5E0 21
SEN00213-00 10 Structure, function and maintenance standard
Unit: mm
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-00
D475A, D475ASD-5E0 23
SEN00213-00
24
SEN00214-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00214-00 10 Structure, function and maintenance standard
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 3
SEN00214-00 10 Structure, function and maintenance standard
Multi-shank ripper
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Giant ripper
q The diagram shows a machine equipped with a pin puller cylinder
D475A, D475ASD-5E0 5
SEN00214-00 10 Structure, function and maintenance standard
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 7
SEN00214-00 10 Structure, function and maintenance standard
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
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 intercon-
nected with PPC lock valve (7), and at the
LOCK position (N), the oil in the PPC circuit is
stopped.
D475A, D475ASD-5E0 9
SEN00214-00 10 Structure, function and maintenance standard
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
A PBF : Front pump pressure input port L PLSR : Load pressure input port
B PAF : Front pump discharge port M PLSRC: Load pressure pickup port
C PLSC : LS set selector pressure pickup port N PLSFC : Load pressure pickup port
D PBR : Rear pump pressure input port P PLSF : Load pressure input port
E PENR : Control pressure pickup port Q PEPC : EPC basic pressure port
F PAR : Rear pump discharge port R PFC : Front pump discharge pressure pickup
G PENF : Control pressure pickup port port
H PD1F : Case drain port S PD2F : Drain plug
J PEPB : EPC basic pressure pickup port T ISIG : LS set selector current
K PRC : Rear pump discharge pressure pickup U PS : Pump suction port
port V PD2R : Air breather mounting port
D475A, D475ASD-5E0 11
SEN00214-00 10 Structure, function and maintenance standard
Function Structure
q The rotation and torque transmitted to the q Cylinder block (7) is supported to shaft (1) by a
pump shaft are converted into hydraulic pres- spline, and shaft (1) is supported by the front
sure, and pressurized oil is discharged accord- and rear bearings.
ing to the load. q The tip of piston (6) is a concave ball, and shoe
q It is possible to change the discharge amount (5) is caulked to it to form one unit. Piston (6)
by changing the swash plate angle. and shoe (5) form a spherical bearing.
q Shoe (5) is always pressed against flat surface
(A) of rocker cam (4) while sliding in a circular
movement.
q Rocker cam (4) brings high pressure oil at cyl-
inder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q The cylinder block (7) seals the pressure oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylin-
der block (7) is sucked in and discharged
through valve plate (8).
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 13
SEN00214-00 10 Structure, function and maintenance standard
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
3. LS valve
4. CO valve
D475A, D475ASD-5E0 15
SEN00214-00 10 Structure, function and maintenance standard
Function 2) CO valve
1) LS valve q When the pump pressure in the hydraulic cir-
q The LS (Load Sensing) valve detects the load cuit becomes maximum, the CO (Cut-OFF)
and controls the discharge amount. valve minimizes the pump swash plate angle
q This valve controls main pump delivery amount to limit the pressure and protect the circuit.
(Q) according to differential pressure (dPLS) q Since the pump swash plate angle is mini-
between main pump pressure (PP) and con- mized, the pump absorption torque is reduced
trol valve outlet port pressure (PLS) (= PP – and the fuel consumption is reduced.
PLS) [called the LS differential pressure].
q Main pump pressure (PP), pressure (PLS)
[called the LS pressure] from the control valve
output, and pressure (PSIG) from the propor-
tional solenoid valve [called the LS selector
pressure] enter this valve.
q The relationship between differential pressure
(dPLS) between main pump pressure (PP) and
LS pressure (PLS) (= PP – PLS) and delivery
amount (Q) changes according to LS selector
current (ISIG) of the LS-EPC valve as shown in
the figure below.
q As (ISIG) changes from 0 to 0.9 A, the set
force of the spring changes. As a result, the
median of the standard changing point of the
pump delivery amount changes from 2.5 to
0.98 MPa {from 25 to 10 kg/cm2}.
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Operation
1) LS valve
(1) When control valve is at neutral position
q The LS valve is a three-way selector valve, q At this point, spool (6) is pushed to the right,
with pressure (PLS) (LS pressure) from the and port (C) and port (D) are connected. Pump
inlet port of the control valve brought to spring pressure (PP) enters the large diameter end of
chamber (B), and main pump discharge pres- the piston from port (K) and the same pump
sure (PP) brought to port (H) of sleeve (8). The pressure (PP) also enters port (J) at the small
size of this LS pressure (PLS) + force of spring diameter end of the piston, so the swash plate
(4) and the main pump pressure (self pres- is moved to the minimum angle by the differ-
sure) (PP) determines the position of spool (6). ence in the area of piston (12).
q However, the size of the output pressure
(PSIG) (the LS selection pressure) of the EPC
valve for the LS valve entering port (G) also
changes the position of spool (6). (The set
pressure of the spring changes).
q Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on the
right)
q When the engine is started and the control
lever is at the neutral position, LS pressure
(PLS) is 0 MPa {0 kg/cm2}. (It is interconnected
with the drain circuit through the control valve
spool.)
D475A, D475ASD-5E0 17
SEN00214-00 10 Structure, function and maintenance standard
q When the difference between main pump pres- q If the output pressure of the EPC valve for the
sure (PP) and LS pressure (PLS), or LS differ- LS valve is applied to port (G) at this time, it
ential pressure (dPLS), becomes smaller (for pushes piston (7) to the left.
example, when the area of opening of the con- q If piston (7) is pushed to the left, the set force
trol valve becomes larger and LS pressure of spring (4) is reduced and LS differential
(PLS) increases), the combined force of LS pressure (dPLS) [the difference between oil
pressure (PLS) and force of spring (4) pushes pressures (PLS) and (PP)] changes when
spool (6) to the right. ports (D) and (E) of spool (6) are connected.
q As spool (6) moves, ports (D) and (E) are con-
nected to each other and to the CO valve.
q At this time, the CO valve is connected to the
drain port and the pressure in circuit (D) – (K)
becomes drain pressure (PT). (Operation of
the CO valve will be explained later.)
q Accordingly, the pressure on the large diame-
ter end of servo piston (12) becomes drain
pressure (PT). Since pump pressure (PP) is
constantly applied to port (J) on the small
diameter end, servo piston (12) is pushed to
the left and the swash plate is moved in the
direction for increasing the delivery amount.
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 19
SEN00214-00 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q At this time, the relationship between the areas
the large diameter end of the piston as (A1), receiving the pressure at both ends of servo
the area receiving the pressure at the small piston (12) is (A0) : (A1) = 1 : 2. Accordingly,
diameter end as (A0), and the pressure flowing the relationship between the pressures applied
into the large diameter end of the piston as to both ends of the piston when the piston is
(PEN). balanced becomes (PP) : (PEN) C 2 : 1.
q When main pump pressure (PP) of the LS q The position where spool (6) is balanced and
valve is balanced with the combined force of stopped is the standard center. The force of
LS pressure (PLS) and the force of spring (4) spring (4) is so adjusted that the standard cen-
and their relationship is (A0) × (PP) = (A1) × ter will be decided when (PP) – (PLS) = 2.5
(PEN), servo piston (12) stops in the current MPa {25 kg/cm2}.
position. q When the input current to the LS-EPC valve
q Then, swash plate is kept at an intermediate changes from 0 to 0.9A and (PSIG) (the output
position. [It stops at a position where the pressure of the LS-EPC valve varying from 0 to
opening between ports (D) and (E) of spool (6) 2.9 MPa {0 to 30 kg/cm2}) is applied to port (G),
and that between ports (C) and (D) are approx- however, the balancing and stopping position
imately the same.] changes in proportion to the (PSIG) pressure
in the range from (PP) – (PLS) = 2.5 to 0.98
MPa {25 to 10 kg/cm2}.
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Left tilt q q q
Left tilt limit q
Single tilt
Right tilt q q q
Right tilt limit q
Blade
Left tilt q
Left tilt limit q
Dual tilt
Right tilt q
Right tilt limit q
Rear pitch q
Pitch
Forward pitch q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A, D475ASD-5E0 21
SEN00214-00 10 Structure, function and maintenance standard
2) CO valve
(1) When actuator load is small and pump pressure (PP) is low
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
(2) When actuator load is large and pump discharge pressure reaches maximum
D475A, D475ASD-5E0 23
SEN00214-00 10 Structure, function and maintenance standard
5. LS-EPC valve
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Function Operation
q The EPC valve consists of the solenoid portion 1) When signal current is 0
and the hydraulic valve portion. (coil de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (1), coil (1) is de-energized.
pressure in proportion to the size of the signal, q For this reason, spool (4) is pushed to the right
and outputs it to the LS valve. in the direction of the arrow by spring (3).
q As a result, port (C) (PEPC) closes and the
pressurized oil from the main pump does not
flow to the LS valve.
q At the same time, the pressurized oil from the
LS valve passes from port (A) (PSIG) through
port (B) (PT) and is drained to the tank.
D475A, D475ASD-5E0 25
SEN00214-00 10 Structure, function and maintenance standard
2) When signal current is small (Coil is ener- 3) When signal current is maximum (Coil is
gized) energized)
q If a small signal current flows in coil (1), coil (1) q If the signal current flows in coil (1), coil (1) is
is “energized” and a thrust to the right is gener- “energized”.
ated in plunger (6). q Since the signal current is at the maximum, the
q Rod (5) pushes spool (2) to the right and the oil thrust in plunger (6) becomes maximum.
from port (C) (PEPC) flows in port (A) (PSIG). q Accordingly, rod (5) presses spool (2) to the
q The pressure in port (A) (PSIG) rises. If the right.
total of the force applied to spool (2) and the q As a result, the maximum oil flows from port
load of spring (3) exceeds the thrust of plunger (C) (PEPC) to port (A) (PSIG) and the pressure
(6), spool (2) is pushed to the left. Then, port in the circuit between the EPC valve and LS
(C) (PEPC) and port (A) (PSIG) are discon- valve becomes highest.
nected and port (A) (PSIG) and port (B) (PT) q At this time, port (C) (PT) is closed and the oil
are connected simultaneously. does not flow in the tank.
q As a result, spool (2) moves up and down until
the thrust of plunger (6) is balanced with the
total of the pressure in port (A) (PSIG) and the
load of spring (3).
q Accordingly, the pressure in the circuit
between the EPC valve and LS valve is con-
trolled in proportion to the signal current.
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
PPC valve 1
1. Blade PPC valve
P : From self pressure reducing valve P3 : To blade tilt valve (LEFT TILT) PPC port
P1 : To blade lift valve (LOWER) PPC port P4 : To blade tilt valve (RIGHT TILT) PPC port
P2 : To blade lift valve (RAISE) PPC port T : To hydraulic tank
D475A, D475ASD-5E0 27
SEN00214-00 10 Structure, function and maintenance standard
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connecting lever)
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Unit: mm
D475A, D475ASD-5E0 29
SEN00214-00 10 Structure, function and maintenance standard
Operation
1) When in neutral
(1) For lifting blade (2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 31
SEN00214-00 10 Structure, function and maintenance standard
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 33
SEN00214-00 10 Structure, function and maintenance standard
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Unit: mm
D475A, D475ASD-5E0 35
SEN00214-00 10 Structure, function and maintenance standard
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 37
SEN00214-00 10 Structure, function and maintenance standard
PCCS lever 1
Travel and steering PCCS lever
a Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operat-
ing effort characteristics will need to be adjusted.
1. Bellows 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Function
1. Operating effort characteristics
1) Operation for forward and reverse travel 2) Operation for steering
q The control lever is held at 3 positions of For- q Free return.
ward, Neutral, and Reverse.
D475A, D475ASD-5E0 39
SEN00214-00 10 Structure, function and maintenance standard
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 41
SEN00214-00
42
SEN00215-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00215-00 10 Structure, function and maintenance standard
A1 : To ripper lift cylinder head P10 : From blade tilt PPC valve
A2 : To blade tilt right cylinder head P11 : From ripper tilt PPC valve
A3 : To blade lift cylinder head P12 : From ripper tilt PPC valve
A4 : To blade lift cylinder head PLS1 : To rear pump control
A5 : To blade tilt left cylinder head PLS2 : To front pump control
A6 : To ripper tilt cylinder head PP1 : From rear main pump
B1 : To ripper lift cylinder bottom PP2 : From front main pump
B2 : To blade tilt right cylinder bottom PPS1: To rear pump control
B3 : To blade lift cylinder bottom PPS2: To front pump control
B4 : To blade lift cylinder bottom PR : To solenoid valve, PPC valve, and EPC valve
B5 : To blade tilt left cylinder bottom PS : From merge-divider solenoid valve
B6 : To ripper tilt cylinder bottom PST : From port PR
P1 : From ripper lift PPC valve SA : Pressure sensor mounting port
P2 : From ripper lift PPC valve SB : Pressure sensor mounting port
P3 : From blade tilt PPC valve T : To tank
P4 : From blade tilt PPC valve TS : To tank
P7 : From blade lift PPC valve
P8 : From blade lift PPC valve
P9 : From blade tilt PPC valve
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Merge-divider valve
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
6-spool valve
(1/8)
D475A, D475ASD-5E0 3
SEN00215-00 10 Structure, function and maintenance standard
(2/8)
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
(3/8)
D475A, D475ASD-5E0 5
SEN00215-00 10 Structure, function and maintenance standard
(4/8)
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
D475A, D475ASD-5E0 7
SEN00215-00 10 Structure, function and maintenance standard
(5/8)
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
D475A, D475ASD-5E0 9
SEN00215-00 10 Structure, function and maintenance standard
(6/8)
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
1. Unload valve
2. Main relief valve
D475A, D475ASD-5E0 11
SEN00215-00 10 Structure, function and maintenance standard
(7/8)
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
D475A, D475ASD-5E0 13
SEN00215-00 10 Structure, function and maintenance standard
(8/8)
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
1. Unload valve
2. Main relief valve
3. Merge-divider valve (For main)
4. Spool return spring
5. Merge-divider valve (For LS)
6. Spool return spring
7. Valve (Sequence valve)
8. Spring (Sequence valve)
9. LS bypass plug
10. Spring (Safety valve)
11. Ball
12. Valve (Pressure reducing valve)
13. Spring (Main pressure reducing valve)
14. Spring (Pilot pressure reducing valve)
15. Poppet
16. Screw
17. Spring (Safety valve)
18. Ball
Unit: mm
D475A, D475ASD-5E0 15
SEN00215-00 10 Structure, function and maintenance standard
1. Spring
2. Poppet
Function
q The main relief valve sets the maximum pump
pressure of the main valve.
Operation
q The set pressure of the relief valve depends on
the installed load of spring (1).
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
CLSS 1
1. Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a main pump (2 pumps),
tem, and has the following features. control valve, and actuators for the work equip-
q Fine control not influenced by load ment.
q Control enabling digging even with fine control q The work equipment pump body consists of
q Ease of compound operation ensured by flow the pump itself, CO valve and LS valve.
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
D475A, D475ASD-5E0 17
SEN00215-00 10 Structure, function and maintenance standard
2. Basic principle
1) Control of pump swash plate
q The pump swash plate angle (pump delivery q If LS differential pressure (dPLS) becomes
amount) is controlled so that LS differential lower than the set pressure of the LS valve
pressure (dPLS) [the difference between pump (when the actuator load pressure is high), the
pressure (PP) and control valve outlet port LS pump swash plate moves towards the maxi-
pressure (PLS)] (load pressure of actuator) is mum position; if it becomes higher than the set
constant. pressure of the LS valve (when the actuator
[LS pressure (dPLS) = Pump discharge pres- load pressure is low), the pump swash plate
sure (PP) – LS pressure (PLS)] moves towards the minimum position.
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
2) Pressure compensation
q A pressure compensation valve is installed to
the outlet port side of the control valve to bal-
ance the load.
q When two actuators are operated together, this
valve acts to make pressure difference (dP)
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
q In this way, the flow of oil from the pump is
divided (compensated) in proportion to the
area of openings (S1) and (S2) of each valve.
D475A, D475ASD-5E0 19
SEN00215-00 10 Structure, function and maintenance standard
Unload valve 1
Function
q When the pump flow is merged and the control
valve group on one side is actuated (with the
remaining control valve group at neutral), the
sub-unload valve drains the pump flow to the
group that is at neutral.
Operation
q The pressure in pump passages (A) is
received at the end portion of valve (1). The
control valve is at neutral, so the pressure in
LS circuit (B) is 0 MPa {0 kg/cm2}.
q The pressurized oil in pump passage (A) is
stopped by valve (1) and cannot escape, so
the pr essur e r ises . When this pr essur e
becomes larger than the force of spring (2),
valve (1) moves to the left, ports (C) and (D)
are interconnected, and the pump pressure
flows to tank passsage (E). In addition, the
pressurized oil in LS circuit (B) passes from
orifice (f) through port (D) and is drained to
tank passage (E). Therefore, in this operation,
LS pressure C tank pressure.
q In this unload operation, pump discharge pres-
sure – LS circuit pressure is greater than the
pump LS control pressure, so a signal is sent
to set the pump swash plate to the minimum
angle.
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Introduction of LS pressure 1
(LS shuttle valve)
Function Operation
q LS pressure (PLS) is the actuator load pres- q When main spool (2) is operated, pump dis-
sure at the output side of the control valve. charge pressure (PP) starts to flow to actuator
q The upstream pressure (= spool meter-in circuit (A).
downstream pressure) of pressure compensa- q First, this pump discharge pressure (PP)
tion valve (3) is taken inside main spool (2) and passes through introduction hole (a) of main
goes to LS shuttle valve (5). spool (2), and is taken to LS circuit (PLS).
q When this happens, it connects actuator circuit q When actuator circuit pressure (A) rises to the
(A) and LS circcuit (PLS) through check valve necessary pressure, pump pressure (PP) rises
(4), and sets so that LS pressure (PLS) C actu- and check valve (4) inside main spool (2)
ator load pressure. opens. The high pressure of LS circuit (PLS)
q Introduction hole (a) inside main spool (2) has then flows to actuator circuit (A).
a small diameter, so it also acts as a throttle. q In this way, LS pressure (PLS) becomes
almost the same as actuator circuit pressure
(A).
D475A, D475ASD-5E0 21
SEN00215-00 10 Structure, function and maintenance standard
LS bypass plug 1
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q If pump pressure (PP) and LS pressure (PLS)
are lower than actuator circuit (B), shuttle valve
(3) inside the pressure compensation valve
moves to the left in the direction of the arrow to
interconnect spring chamber (C).
q When this happens, piston (4) is pushed to the
right by spring (5), so pump outlet circuit (A)
closes. This prevents the oil from flowing back
from actuator circuit (B) to pump outlet circuit
(A).
D475A, D475ASD-5E0 23
SEN00215-00 10 Structure, function and maintenance standard
Function Operation
q During compound operations, if the load pres- q During compound operations, if the load pres-
sure is lower than the other actuators and the sure for the other actuators rises, the oil flow in
flow of oil starts to increase, the pressure com- actuator circuit (B) tries to increase.
pensation valve carries out compensation. In q When this happens, LS pressure (PLS) for the
this case, it tries to make the load pressure for other actuator also increases, so this LS pres-
the other actuators greater and reduce the flow sure (PLS) pushes shuttle valve (3) of the
of oil. pressure compensation valve to the right in the
direction of the arrow, passes through the pas-
sage inside piston (4), and flows to spring
chamber (C).
q As a results, piston (4) is pushed to the right in
the direction of the arrow, and the outlet side of
pump circuit (PP) is closed, so outlet port pres-
sure (A) (spool meter-in downstream pressure)
becomes the same as the outlet port pressure
of the other actuators.
q Pump pressure (PP) (spool meter-in upstream
pressure) is the same between all actuators,
so pump pressure (PP) and outlet port pres-
sure (A) become the same between all spools
that are being operated. Therefore, the pump
flow is divided in proportion to the area of the
opening of each valve.
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
D475A, D475ASD-5E0 25
SEN00215-00 10 Structure, function and maintenance standard
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q When the blade lift lever is in NEUTRAL, spool
(3) is held in the neutral position by springs (1)
and (6) through retainers (2) and (4).
q At this time, the oil does not flow in either of the
head and bottom of the blade lift cylinder.
D475A, D475ASD-5E0 27
SEN00215-00 10 Structure, function and maintenance standard
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q If the blade lift lever is set in the RAISE posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (E) and spool (3)
moves to the left.
q The oil from the main pump flows through
notch (11) of spool (3) and cylinder port (A) to
the cylinder head.
q The oil returning from the cylinder bottom flows
through cylinder port (B) and notch (9) of spool
(3) to drain port (D).
D475A, D475ASD-5E0 29
SEN00215-00 10 Structure, function and maintenance standard
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q If the blade lift lever is set in the LOWER posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (F) and spool (3)
moves to the right.
q If the blade lift lever is set to the LOWER
stroke end, retainer (4) moves to retainer (5)
and the load of spring (7) is added to the load
of spring (6) and spool (3) stops moving.
q At this time, the oil from the main pump flows
through notch (10) of spool (3) and cylinder
port (B) to the cylinder bottom.
q The oil returning from the cylinder head flows
through cylinder port (A) and notch (12) of
spool (3) to drain port (C).
D475A, D475ASD-5E0 31
SEN00215-00 10 Structure, function and maintenance standard
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q If the blade lift lever is moved from the LOWER
position to the FLOAT position, the pilot pres-
sure is applied through the blade PPC valve to
chamber (F) and spool (3) moves further to the
right.
q At this time, retainer (5) moves against the
total load of springs (6) and (7) until its right
end touches plug (8).
q Since cylinder ports (A) and (B) are connected
to drain ports (C) and (D) respectively, both
head and bottom of the blade lift cylinder are
connected to the drain port and the blade is
“FLOATED”.
D475A, D475ASD-5E0 33
SEN00215-00 10 Structure, function and maintenance standard
Merge-divider valve 1
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
D475A, D475ASD-5E0 35
SEN00215-00 10 Structure, function and maintenance standard
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q Valve (7) is pressed by spring (8) and (PR) q Accordingly, differential pressure is generated
pressure (which is 0 MPa {0 kg/cm2} while the over orifice (a) in spool (14), and spool (14)
engine is stopped) to close the passage moves in the direction to close the passage
between ports (P2) and (A2). If hydraulic oil between ports (P2) and (PR). The P2 pressure
flows in through port (P2), however, (ød area x is lowered and controlled to a constant pres-
pressure P2) = force of spring (8) + (ød area x sure (set pressure) by the opening ratio of the
PR pressure), and they are balanced. Then, passage at this time and supplied as the PR
the passage between ports (P2) and (A2) is so pressure.
adjusted that the P2 pressure will be kept at a
certain value higher than the PR pressure.
q If the PR pressure rises higher than the set
level, poppet (11) opens and the hydraulic oil
flows from port (PR) through orifice (a) in spool
(14) and opening of poppet (11) into seal drain
port (TS).
D475A, D475ASD-5E0 37
SEN00215-00 10 Structure, function and maintenance standard
Operation
q If load pressure (A2) is heightened and the q Accordingly, differential pressure is generated
pump delivery amount is increased because of over orifice (a) in spool (14) and spool (14)
digging operation, etc., the P2 pressure rises moves in the direction to close the passage
{(ød area × P2 pressure) > force of spring (8) + between ports (P2) and (PR). The P2 pressure
(ød area × PR pressure)}, then valve (7) is lowered and controlled to a constant pres-
moves to the right stroke end. sure (set pressure) by the opening ratio of the
q As a result, the opening ratio of the passage passage at this time and supplied as the PR
between ports (P2) and (A2) is increased and pressure.
the passage resistance is reduced. Conse-
quently, the loss of the engine horsepower is
reduced.
q If the PR pressure rises higher than the set
level, poppet (11) opens and the hydraulic oil
flows from port (PR) through orifice (a) in spool
(14) and opening of poppet (11) into seal drain
port (TS).
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
Operation
q If the PR pressure of the self pressure reduc-
ing valve is raised abnormally, ball (16) sepa-
rates from the seat against the force of spring
(15). As a result, the hydraulic oil flows from
output port (PR) to (TS) and the PR pressure
lowers. Accordingly, the devices receiving the
oil pressure (PPC valves, solenoid valves, etc.)
are protected from abnormally high pressure.
D475A, D475ASD-5E0 39
SEN00215-00 10 Structure, function and maintenance standard
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-00
q The operation of the pilot solenoid valve is shown in the following table.
D475A, D475ASD-5E0 41
SEN00215-00
42
SEN00216-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00216-00 10 Structure, function and maintenance standard
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
Specified value
Tank capacity (l) 310
Specified value
Cracking pressure 150 ± 30
(kPa {kg/cm2}) {1.53 ± 0.3}
Hydraulic Mesh size (µm) 30/8
filter
Filtering area (cm )
2
17,600
Filtering oil flow (l/min) 703
Mesh size (µm) 105
Strainer 2
Filtering area (cm ) 3,600
D475A, D475ASD-5E0 3
SEN00216-00 10 Structure, function and maintenance standard
Accumulator 1
For PPC valve Operation
q After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the PPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas:Nitrogen
Gas volume:300 cc
Max. actuation pressure:3.1 MPa {32 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
Function
q The accumulator is installed between the pres-
sure reducing valve and the PPC valve. Even if
the engine is stopped with the work equipment
still raised, the pressure of the nitrogen gas
compressed inside the accumulator sends the
pilot pressure to the main control valve to actu-
ate it and enable the work equipment to move
down under its own weight.
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
D475A, D475ASD-5E0 5
SEN00216-00 10 Structure, function and maintenance standard
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
Unit: mm
D475A, D475ASD-5E0 7
SEN00216-00 10 Structure, function and maintenance standard
Piston valve 1
For blade lift cylinder
Operation
1. When piston valve is “closed”
The oil from the work equipment pump acts on
piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right to
seal the tapered part of piston valve seat (4).
As a result, the oil pressure in the cylinder
rises to move piston (2) to the right.
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
D475A, D475ASD-5E0 9
SEN00216-00 10 Structure, function and maintenance standard
Operation
1. Start of lowering blade
If the blade control lever is set in the LOWER
position, the oil from the control valve flows
through port (A) to the cylinder bottom side and
pushes the piston.
The oil on the cylinder head side is pushed out
by the piston into port (B), and then flows
through port (C) and control valve to the
hydraulic tank.
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
Unit: mm
D475A, D475ASD-5E0 11
SEN00216-00 10 Structure, function and maintenance standard
1. Switch (dual-single selector switch) q If switch (2) is pressed and the lever is oper-
2. Switch (pitch) ated, the blade is pitched. If the lever is tilted to
3. Cover the left, the blade is pitched back. If the former
4. Connector (male) is tilted to the right, the latter is pitched for-
5. Connector (female) ward.
q If switch (1) is set to the “DUAL” position and
Outline the lever is operated, blade carries out dual tilt
q If the blade control knob is tilted forward, back- operation. If the lever is tilted to the left, the
ward, to the right, or to the left, the blade is blade carries out left dual tilt operation. If the
raised, lowered, tilted to the right, or tilted to the lever is tilted to the right, the blade carries out
left. If switch (1) is set to the “DUAL” position right dual tilt operation.
and the lever is tilted to the right or left, dual tilt q If switch (1) is set in either “DUAL” or
operation is carried out. If the lever is tilted to “SINGLE” position and the lever is tilted to the
the right or left while switch (2) is pressed and right or left while switch (2) is pressed and
held, pitching operation is carried out. held, the blade is pitched.
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
D475A, D475ASD-5E0 13
SEN00216-00 10 Structure, function and maintenance standard
1. Connector Outline
2. Solenoid (a) q The pitch and dual solenoid valve is installed
3. Valve between the PPC valve and main control valve
4. Solenoid (b) and used to select the PPC pilot pressure.
5. Manual push pin q Operation of the pitch switch of the blade con-
trol lever (or the rear pitch switch or forward
A: Port A pitch switch of the superdozer specification),
B: Port B pilot pressure can be applied so the right and
P: Port P left pitch cylinders will move similarly and the
T: Port T tilt operation can be changed to the pitch oper-
ation.
q If the dual tilt specification is installed and the
toggle switch of the blade control lever is set in
the "dual" position, the pilot pressure is applied
to both right and left tilt cylinder spools to
change the single tilt operation to the dual tilt
operation.
q The pitch and dual tilt solenoid valve is oper-
ated by the controller.
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
D475A, D475ASD-5E0 15
SEN00216-00 10 Structure, function and maintenance standard
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-00
Operation
1. Pin puller switch at PUSH IN position 2. Pin-puller switch at PULL OUT position
When the pin-puller switch is turned to the When the pin puller switch is turned to the
PUSH IN position, no current flows to solenoid PULL OUT position, current flows to solenoid
(9) and it is deactivated. (9) and it is excited.
When this happens, spool (5) opens ports (A) When this happens, the solenoid pushes out
and (B) and ports (C) and (D), and the oil from push pin (8), and spool (5) moves to the left in
the power train pump flows from port (A) to the direction of the arrow.
port (B) and enters the bottom of pin puller cyl- Ports (A) and (B) and ports (C) and (D) close,
inder (10). and ports (A) and (C) and ports (B) and (D)
The oil entering the bottom end of the cylinder open. The oil from the power train pump flows
increases the hydraulic pressure in the circuit from port (A) to port (C) and enters the head of
and extends the cylinder. Shank mounting pin pin puller cylinder (10).
(11) is pushed into shank (12). The oil entering the head end of the cylinder
increases the hydraulic pressure in the circuit
and retracts the cylinder. Shank mounting pin
(11) is pulled out of shank (12).
D475A, D475ASD-5E0 17
SEN00216-00
18
SEN00217-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00217-00 10 Structure, function and maintenance standard
Work equipment 1
Cylinder stay 1
Unit: mm
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00217-00
D475A, D475ASD-5E0 3
SEN00217-00 10 Structure, function and maintenance standard
Blade 1
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
4 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 5
SEN00217-00 10 Structure, function and maintenance standard
Unit: mm
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00217-00
D475A, D475ASD-5E0 7
SEN00217-00 10 Structure, function and maintenance standard
Ripper equipment 1
Variable giant ripper
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00217-00
Unit: mm
D475A, D475ASD-5E0 9
SEN00217-00
10
SEN00218-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00218-00 10 Structure, function and maintenance standard
1. Support Outline
2. Damper mount (front) q Mounts are installed at two places at the front
3. Damper mount (rear) 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.
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00218-00
Cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D475A, D475ASD-5E0 3
SEN00218-00 10 Structure, function and maintenance standard
ROPS guard
1. ROPS guard
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00218-00
D475A, D475ASD-5E0 5
SEN00218-00 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00218-00
1. Condenser
2. Air conditioner compressor
3. Refrigerant piping
4. Window defroster
5. Side defroster
6. Vent
7. Hot water pickup piping
8. Valve (hot water outlet)
9. Receiver tank
10. Hot water return piping
11. Valve (hot water inlet)
12. Air conditioner unit
13. Additional blower motor
A. Fresh air
B. Recirculated air
C. Hot air/cold air
D475A, D475ASD-5E0 7
SEN00218-00
8
SEN00219-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00219-00 10 Structure, function and maintenance standard
Electrical system 1
Engine control 1
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
Outline
q The engine throttle controller receives the q The steering controller sends the most suitable
manual signals of the 1st throttle, 2nd throttle for engine speed from informations 1) and 2)
and the 3rd throttle signals which is the control and transmits it as the 3rd throttle to the engine
signals from the machine body, then selects throttle controller.
the lower engine speed and controls the fuel q Information of the engine throttle controller is
supply pump. commonly used by all the controllers through-
The 3rd throttle control signals contain the fol- out the network, for optimum control of the
lowing. engine and machine body.
1) High idle speed control q The automatic deceleration function sets the
2) SSC (Shoe Slip Control) engine speed to 1,000 rpm temporarily when
3) Automatic deceleration (F3, R3, R2) the travel direction is changed from F3, R3, or
R2 (to protect the transmission clutch).
D475A, D475ASD-5E0 3
SEN00219-00 10 Structure, function and maintenance standard
Deceleration potentiometer 1
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the front lower part of the operator’s cab and
4. Potentiometer connected to the decelerator pedal by linkage.
5. Coupling q If the decelerator pedal is pressed, the throttle
6. Shaft potentiometer shaft rotates by the linkage and
7. Stopper the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
throttle controller according to the position of
the decelerator pedal.
4 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 5
SEN00219-00 10 Structure, function and maintenance standard
Outline
q The signals detected by various sensors are
input to the engine throttle controller.
q The input signals are processed by the control-
ler and output to each actuator to control the
fuel injection rate and fuel injection timing.
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
D475A, D475ASD-5E0 7
SEN00219-00 10 Structure, function and maintenance standard
Monitor system 1
q The monitor system monitors the machine con- q In the monitor panel, there are various mode
dition with sensors installed to various parts of selector switches of the SSC (Shoe Slip Con-
the machine, and quickly processes and dis- trol), which are used to operate the machine
plays obtained information on the monitor control system (with SSC).
panel, to notify the operator of machine condi- q The monitor panel has the functions of display-
tion. ing data and selecting the SSC mode (with
The function of the monitor system is as fol- SSC).
lows. q The CPU (Central Processing Unit) in it pro-
1) Function which turns on the alarm when cesses, displays, and outputs the information.
the machine has a trouble on the monitor. The display unit is LCD (Liquid Crystal Display)
2) Function which constantly displays the and the switches are seat switches.
machine condition (coolant temperature,
torque converter oil temperature, fuel
level, hydraulic oil level, etc.) on the
gauge.
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids.
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
3) Display of failure
When the machine has a failure, the corresponding CAN Engine sensor/solenoid o Steering
failure code is notified to the monitor panel by CAN. controller or transmission controller
Which one should be turned on, the buzzer or the o Monitor panel
caution lamp, is notified, too.
i) In normal state
User code
ii) In fault history display mode Sensors and solenoids o Engine
The service code (6-digit code) and the throttle controller o Steering
following items are displayed controller o Monitor panel
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrence
The monitor panel displays code on the hour meter
section.
Other items
1. Contents and conditions of processing 2. Method 3. Flow of signals
1) Function selection mode (Displayed each time CAN Steeging controller o Monitor panel
cancel switch is turned to left)
i) Replacement periods of oil filter and oil are
displayed.
ii) Engine speed, oil pressure in work equipment
circuit, etc. are displayed.
iii) Failure codes related to electronic control are
displayed.
iv) Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of
maintenance mode
3) Mode to display failure codes related to the
machine such as overheating, abnormal coolant
temperature, etc.
4) Mode to display service meter and information
related to load on machine
D475A, D475ASD-5E0 9
SEN00219-00 10 Structure, function and maintenance standard
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
Monitor panel 1
Monitor portion
D475A, D475ASD-5E0 11
SEN00219-00 10 Structure, function and maintenance standard
Hydraulic oil
105±3°C or above
temperature
12 D475A, D475ASD-5E0
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Display
Symbol Display item Display range Display method
category
Lights according to required time
determined by engine controller
based.
Preheating When preheating It also lights at the time of manual
preheat by setting starting switch
at preheat position (turning it
Pilot
counterclockwise).
Engine coolant
temperature
Hydraulic oil
temperature
From 0 to 99999
(Hours meter) rotating
D475A, D475ASD-5E0 13
SEN00219-00 10 Structure, function and maintenance standard
Switch portion
1. Switch functions
1) ON-OFF switching in lockup mode
2) Economy mode setting – OFF, mode 1, mode 2
3) ON-OFF switching in reverse slow mode
4) ON-OFF switching in SSC mode
5) 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.
q SSC specifications
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
Sensors 1
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance — —
Torque converter oil temperature Resistance — —
Hydraulic oil temperature Resistance — —
Radiator coolant level Contact ON OFF
Fuel level Resistance — —
Engine oil level Contact ON OFF
All cleaner clogging Contact ON OFF
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
D475A, D475ASD-5E0 15
SEN00219-00 10 Structure, function and maintenance standard
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
1. Connector Function
2. Float q The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down according to the fuel level. This move-
5. Spring ment of the float is transmitted by the arm and
6. Contact actuates a variable resistance. This sends a
7. Spacer signal to the monitor panel to indicate the
remaining fuel level. When the display on the
monitor panel reaches a certain level, a warn-
ing lamp flashes.
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit
D475A, D475ASD-5E0 17
SEN00219-00 10 Structure, function and maintenance standard
Outline
q The mode selection system automatically car- q The lockup control mode is the same as the
ries out engine control to match the operating conventional lockup function. It cannot be
mode selected by the operator, and acts to selected in combination with the above modes.
reduce fuel consumption, extend the life of the
track shoes, and reduce the frequency of oper-
ation of the deceleration.
q The engine control modes consist of the econ-
omy mode control used when dozing, the SSC
(shoe slip control) used when ripping, and the
reverse slow mode control, which can be used
for either operation.
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
D475A, D475ASD-5E0 19
SEN00219-00 10 Structure, function and maintenance standard
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC are
mode switch 1) or 2) ON set simultaneously, the F1 shift economy control
is performed. When the ripper lever is actuated
and the switch is turned on, the slip control is
Economy
performed.
2. 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)
3. At neutral time, the engine speed can be
suppressed partially.
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
Reverse slow
The following conditions are satisfied: 1. At start, to prevent rashing out, the modulating
1) When F1 is shifted. valve is actuated. At this time, the steering
2) After the ripper down, ripper tilt levers controller performs index characteristic down
are actuated and the switch is set to of about 40% and performs the engine output
ON control if a ripper down signal is input.
SSC (Shoe Slip Control)
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection mode
3 comes on.
2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the
state and load of the rock-bed.
a 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.
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
Sensors
Transmission output shaft speed sensor
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
1. Connector
2. Flange
3. Sensor
D475A, D475ASD-5E0 21
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Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
1. Body
2. Tube
3. Wire
4. Connector
D475A, D475ASD-5E0 23
SEN00219-00 10 Structure, function and maintenance standard
Electrical equipment 1
Relay box
24 D475A, D475ASD-5E0
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Preheating circuit
26 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 27
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Manual mode
Shift mode 1
Shift mode 2
28 D475A, D475ASD-5E0
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VHMS controller 1
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30 D475A, D475ASD-5E0
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Sensors
Engine oil temperature sensor Exhaust temperature sensor/amplifier
Specifications Specifications
Type of sensor: Thermistor Rated voltage: DC 24 V
Measurement range: 40 – 130°C Sensed temperature range: 100 – 1,000°C
80 – 130°C 300 – 800°C
(Assured accuracy: ±2°C) (Assured accuracy: ±10°C)
Max. power consumption: 0.5 mW Output voltage characteristics
Pressure resistance: 4.9 MPa {50 kg/cm2} (Ambient temperature: 20°C)
– Reference values
Using temperature: –30°C to +140°C
Sensed
Performance table
temperature 50 100 400 700 800
Temper- Resis- Temper- Resis- Temper- Resis- (°C)
ature tance ature tance ature tance
Output voltage
(°C) (kz) (°C) (kz) (°C) (kz) 1.191 1.397 2.626 3.899 4.316
(V)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544 Operating temperature range: –40 to +110°C
Current consumption: Max. 30 mA
50 17.05 90 4.931 120 2.248
a: Heat sensing part of sensor – Outside diame-
60 12.20 95 4.293 125 1.992
ter of mounting part: R1/8
70 8.884 100 3.750 130 1.769 b: Amplifier
a: Heat sensing part of sensor – Outside diame- c: Connector (Power supply side)
ter of mounting part: R1/4 d: Connector (Sensor side)
Function Function
The exhaust temperature sensor/amplifier is a ther-
The engine oil temperature sensor is installed to
mocouple-type temperature sensor, which is
the engine oil filter. It inputs the change of the tem-
installed to the turbocharger inlet. It outputs the
perature as the change of the thermistor resistance
exhaust temperature data to the VHMS controller.
to the VHMS controller.
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-00
Function
The atmospheric temperature sensor inputs the
change of the atmospheric temperature as the
change of the thermistor resistance to the VHMS
controller.
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34 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 35
SEN00219-00
36
SEN01816-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN01816-00 20 Standard value table
(*1): Refer to the item 3. of “Measuring engine speed” in Testing and adjusting, Part 1.
2 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
Deceleration low idle • Engine coolant temperature: Within operating
range 900 ± 50 900 ± 50
speed
• Power train oil temperature: Within operating
Deceleration high idle range
• Hydraulic oil temperature: Within operating 2,000 ± 50 2,000 ± 50
speed
Engine speed
range
• Deceleration low idle: Press decelerator pedal
Torque converter stall • Deceleration high idle: Set forward-reverse rpm
lever in neutral + Set work equipment control 1,690 ± 50 Min. 1,590
speed lever in neutral
• Torque converter stall: Stall at F3
Torque converter stall + • Torque converter stall + Work equipment relief
Work equipment relief speed: Stall at F3 + Raise ripper or relieve 1,615 ± 75 Min. 1,450
speed pitch back circuit
• Stop engine
Decelerator pedal mm 45 ± 15 45 ± 15
• Press pedal to center
40 ± 5 40 ± 5
Neutral o Right
(Play: Max. 3) (Play: Max. 3)
Full stroke 78 ± 10 78 ± 10
• Run engine at low idle
Brake pedal Stroke to oil pres- mm
• Press pedal to center 58 ± 10 58 ± 10
sure of 0
Neutral o Float 90 ± 10 90 ± 10
• Run engine at low idle
• Hydraulic oil tempera- Neutral o
60 ± 10 60 ± 10
Blade control lever ture: Raise/Lower mm
Within operating range
• Set lever to center Neutral o
60 ± 10 60 ± 10
Left/Right tilt
• Run engine at low idle Neutral o
• Hydraulic oil tempera- 78 ± 10 78 ± 10
Raise/Lower
Ripper control lever ture: mm
Within operating range Neutral o
• Set lever to center 81 ± 10 81 ± 10
Tilt in/out
59 ± 9.8 59 ± 9.8
Control lever and pedal operating effort
• Stop engine
Decelerator pedal N{kg}
• Press pedal to center {6.0 ± 1.0} {6.0 ± 1.0}
Neutral o 56.9 ± 6.9 56.9 ± 6.9
Forward, Forward, Reverse {5.8 ± 0.7} {5.8 ± 0.7}
reverse Forward, Reverse 51 ± 6.9 51 ± 6.9
o Neutral {5.2 ± 0.7} {5.2 ± 0.7}
PCCS • Stop engine N{kg}
lever • Set lever to center 25.5 ± 4.9 25.5 ± 4.9
Neutral o Left
{2.6 ± 0.5} {2.6 ± 0.5}
Steering
28.4 ± 4.9 28.4 ± 4.9
Neutral o Right
{2.9 ± 0.5} {2.9 ± 0.5}
D475A, D475ASD-5E0 3
SEN01816-00 20 Standard value table
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
4 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
Transmission 3rd clutch 2.35 – 2.74 2.25 – 2.74
Low idle
pressure {24.0 – 28.0} {23.0 – 28.0}
Transmission lubricating 0.15 – 0.29 0.15 – 0.29
High idle
pressure {1.5 – 3.0} {1.5 – 3.0}
2.65 – 2.98 Min. 2.45
High idle
{27.0 – 30.4} Min. {25}
Steering left clutch pressure
2.35 – 2.89 2.26 – 2.89
Low idle
{24.0 – 29.5} {23.0 – 29.5}
Power train oil pressure
• Reverse slow
mode: OFF Forward 2nd 6.3 ± 0.3 6.3 ± 0.3
• Run-up distance: Forward 3rd 11.6 ± 0.6 11.6 ± 0.6
is ON
10 – 30 m
• Measuring dis- Reverse 1st 4.4 ± 0.3 4.4 ± 0.3
tance: 20 m
Reverse 2nd 8.4 ± 0.4 8.4 ± 0.4
Reverse 3rd 14.3 ± 0.7 14.3 ± 0.7
D475A, D475ASD-5E0 5
SEN01816-00 20 Standard value table
merge
Measurement
/divide Unit
Measurement
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
tilt oil temper- 21.1 ± 1.4 21.1 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
ature: Low
Dual tilt
45 – 55°C MPa {215 ± 14} {215 ± 14} {280 ± 14} {280 ± 14}
• Relieve {kg/cm2} 27.4 ± 1.4 27.4 ± 1.4 24.0 ± 1.4 24.0 ± 1.4
only circuit High
Right dual to be mea- {280 ± 14} {280 ± 14} {245 ± 14} {245 ± 14}
Divide
tilt sured 27.4 ± 1.4 27.4 ± 1.4 21.1 ± 1.4 21.1 ± 1.4
Low
Blade {280 ± 14} {280 ± 14} {215 ± 14} {215 ± 14}
dual tilt 24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4
High
Pitch {250 ± 14} {250 ± 14} {250 ± 14} {250 ± 14}
Divide
dump 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4
Low
{215 ± 14} {215 ± 14} {215 ± 14} {215 ± 14}
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
High
Pitch {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Divide
back 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Low
{280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
High
Raise {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Merge
relief 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Low
{280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Ripper
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
High
Lower {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Merge
relief 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Low
{280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
6 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
merge
Measurement
/divide Unit
Measurement
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
Ripper
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
High
{280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Tilt back Merge
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Low
{280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
26.5 ± 1.4 26.5 ± 1.4 26.5 ± 1.4 26.5 ± 1.4
High
Raise {270 ± 14} {270 ± 14} {270 ± 14} {270 ± 14}
Merge
relief 22.1 ± 1.4 22.1 ± 1.4 22.1 ± 1.4 22.1 ± 1.4
Low
{225 ± 14} {225 ± 14} {225 ± 14} {225 ± 14}
Blade
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
High
Lower {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Merge
relief 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Low
{280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Work equipment oil pressure
oil temper-
tilt ature: 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4
Blade Low
45 – 55°C MPa {235 ± 14} {235 ± 14} {235 ± 14} {235 ± 14}
single • Relieve {kg/cm2}
tilt only circuit High 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Right to be mea- {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
steering Merge sured
tilt 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Low
Single tilt
D475A, D475ASD-5E0 7
SEN01816-00 20 Standard value table
merge
Measurement
/divide Unit
Measurement
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
dump oil temper- 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4
ature: Low
{215 ± 14} {215 ± 14} {215 ± 14} {215 ± 14}
Super
8 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
Specification
Work Standard value for
Relieving Measurement conditions Unit Service limit value
equip- new machine
method
ment
{25 ± 2} {25 ± 2}
Lower 2.45 ± 0.2 2.45 ± 0.2
relief • Hydraulic oil temperature: MPa {25 ± 2} {25 ± 2}
Ripper Within operating range
• Run engine at high idle {kg/cm2} 2.45 ± 0.2 2.45 ± 0.2
Tilt in
{25 ± 2} {25 ± 2}
2.45 ± 0.2 2.45 ± 0.2
Tilt back
{25 ± 2} {25 ± 2}
2.45 ± 0.2 2.45 ± 0.2
Raise relief
{25 ± 2} {25 ± 2}
Blade
Lower 2.45 ± 0.2 2.45 ± 0.2
relief {25 ± 2} {25 ± 2}
Left steer- 1.76 ± 0.2 1.76 ± 0.2
Blade ing tilt {18 ± 2} {18 ± 2}
single tilt Right 1.76 ± 0.2 1.76 ± 0.2
Single tilt
D475A, D475ASD-5E0 9
SEN01816-00 20 Standard value table
Specification
Blade
Within operating range
dual tilt • Run engine at high idle 1.76 ± 0.2 1.76 ± 0.2
Pitch back
Work equipment oil pressure
{18 ± 2} {18 ± 2}
2.45 ± 0.2 2.45 ± 0.2
Raise relief
{25 ± 2} {25 ± 2}
Lower MPa 2.45 ± 0.2 2.45 ± 0.2
relief {kg/cm2} {25 ± 2} {25 ± 2}
Ripper
2.45 ± 0.2 2.45 ± 0.2
Tilt in
{25 ± 2} {25 ± 2}
2.45 ± 0.2 2.45 ± 0.2
Tilt back
{25 ± 2} {25 ± 2}
• Hydraulic oil temperature:
45 – 55 °C 2.94 – 4.9 2.94 – 4.9
Unload pressure • Set all work equipment {30 – 50} {30 – 50}
control levers in neutral
• Hydraulic oil temperature:
Work equipment control oil Within operating range 3.92 – 4.51 Min. 3.72
• Set all work equipment
pressure control levers in neutral {40 – 46} {Min. 38}
• Engine at high idle
• Hydraulic oil temperature:
Within operating range 3.92 – 4.51 Min. 3.72
PPC valve output pressure • Set lever at stroke end {40 – 46} {Min. 38}
• Engine at high idle
Work equipment
10 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Low
14 ± 3.5 Max. 20.0
idle
Raise
Blade lift High
5.0 ± 0.5 Max. 6.0
(Single tiltdozer idle
specification) sec
(Dual tiltdozer Low
specification) 1.8 ± 0.3 Max. 2.5
idle
• Hydraulic oil temperature:
Within operating range Lower
• Apply no load on blade. High
• Between blade on ground and rais- 1.8 ± 0.3 Max. 2.5
idle
ing stroke end
Measuring posture
Low
15.8 ± 3.5 Max. 22.0
idle
Raise
High
5.1 ± 0.5 Max. 7.0
Blade lift idle
(Superdozer sec
specification) Low
1.7 ± 0.3 Max. 3.0
idle
• Hydraulic oil temperature:
Within operating range Lower
Work equipment
D475A, D475ASD-5E0 11
SEN01816-00 20 Standard value table
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Low
4.0 ± 1.5 Max. 6.0
idle
Left tilt
High +0.5
3.3 Max. 6.0
Blade tilt idle -0.8
(Superdozer sec
specification) Low
4.4 ± 1.5 Max. 6.5
idle
• Hydraulic oil temperature:
Within operating range Right tilt
• Apply no load on blade. High +0.5
• Between left tilt end and right tilt 3.6 Max. 6.0
idle -0.8
end
12 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Blade — —
range idle
(Superdozer • Lower blade from max. rising position and
specification) measure time after blade comes in contact High
with ground until idler is lifted. Max. 2.7 3.5
idle
• Hydraulic oil temperature: Within operating
Work equipment
range High
Ripper • Lower ripper from max. rising position and sec Max. 1.0 1.5
measure time after ripper comes in contact idle
with ground until sprocket is lifted.
Measuring posture
Hydraulic drift of
mm/
machine tilted by Max. 50/5 Max. 100/5
min
blade
• Hydraulic oil temperature: Within operating range
• Stop engine.
• Tilt blade to maximum to push up shoe on either side
and then measure reduction of shoe height (h) in 5
minutes.
D475A, D475ASD-5E0 13
SEN01816-00 20 Standard value table
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Hydraulic drift of
mm/
machine lifted by Max. 50/5 Max. 100/5
min
blade
• Hydraulic oil temperature: Within operating range
• Stop engine.
• Push up front part of machine with blade and then
measure reduction of idler center height (h) in 5 min-
utes.
Measuring posture
Work equipment
Hydraulic drift
Hydraulic drift of
mm/
machine lifted by Max. 30/5 Max. 60/5
min
ripper
• Hydraulic oil temperature: Within operating range
• Stop engine.
• Push up rear part of machine with ripper and then
measure reduction of sprocket center height (h) in 5
minutes.
14 D475A, D475ASD-5E0
20 Standard value table SEN01816-00
D475A, D475ASD-5E0 15
SEN01817-00
D475A-5E0
D475ASD-5E0
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SEN01817-00 30 Testing and adjusting
2 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-00
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
Air boost pressure 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
(boost pressure) 790-401-2220 Hose 1
Coolant temperature,
oil temperature and B 799-101-1502 Digital temperature gauge 1 –99.9 – 1,299°C
exhaust temperature
1 799-201-9001 Handy smoke checker 1
Exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
Commercial
Valve clearance D Thickness gauge 1
item
0 – 6.9 MPa {0 – 70 kg/cm2}
1 795-502-1590 Compression gauge 1
KIT Part No.: 795-502-1205
Compression pressure E
2 795-471-1310 Adapter 1
3 6217-71-6150 Gasket 1
Blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Engine oil pressure G
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure H 2 799-401-2320 Hydraulic tester 1 *As common as G2
3 795-471-1450 Adapter 1
4 07005-00812 Gasket 1
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercial
3 Hose 1
item
Commercial
Testing fuel return and 4 Hose 1
J item
leak amount
Commercial
5 Measuring cylinder 1
item
Commercial
6 Stopwatch 1
item
7 07376-70315 Plug 1
799-101-5002 Hydraulic tester 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
Power train oil pressure K 2 799-401-2320 Hydraulic tester 1 *As common as G2
799-101-5220 Nipple (10 x 1.25 mm) 1
3
07002-11023 O-ring 1
D475A, D475ASD-5E0 3
SEN01817-00 30 Testing and adjusting
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
4 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-00
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
D475A, D475ASD-5E0 5
SEN01817-00 30 Testing and adjusting
6 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-00
5. Measuring torque converter stall speed 7) Perform steps 2) – 4) again and measure
a Use Adjustment mode to measure. the engine speed when the power train oil
q Adjustment mode: temperature gauge reaches position (a) of
0530 (Stall speed check mode) the green range.
k This machine is equipped with the a After finishing measurement, return
cooling fan speed control function to the direction of the PCCS lever into
protect the radiator when the engine is neutral and lower the power train oil
not fully warmed up. Since that func- temperature with the engine at high
tion does not work while this mode is idle.
used, warm up the engine fully before a After finishing measurement, finish
using this mode. the Adjustment mode.
1) Start the engine and set the fuel control
dial in the low idle position. 6. Measuring torque converter stall + work
2) With the brake pedal depressed securely equipment relief speed (full stall speed)
and the parking brake lever in the “free” a Use Adjustment mode to measure.
position, set the PCCS lever in the “for- q Adjustment mode:
ward” and 3rd gear speed position. 0530 (Stall speed check mode)
a Before going to the next step, check 1) Start the engine and set the fuel control
that the upper display unit of the mon- dial in the low idle position.
itor panel is set in the normal display 2) With the brake pedal depressed securely
state and it displays [F3]. and the parking brake lever in the “free”
a Keep the steering unit in neutral. position, set the PCCS lever in the “for-
3) Press the decelerator pedal and set the ward” and 3rd gear speed position.
fuel control dial in the high idle position. a Before going to the next step, check
4) Return the decelerator pedal slowly to stall that the upper display unit of the mon-
the torque converter with the engine at itor panel is set in the normal display
high idle. state and it displays [F3].
k Keep pressing the brake pedal a Keep the steering unit in neutral.
securely and keep your right foot 3) Press the decelerator pedal and set the
on the decelerator pedal for safety fuel control dial in the high idle position.
until the work is finished. 4) Return the decelerator pedal slowly to stall
5) Just after the power train oil temperature the torque converter with the engine at
gauge reaches position (a) of the green high idle.
range, return the direction of the PCCS k Keep pressing the brake pedal
lever into neutral. 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.
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Measuring intake air pressure 2. Remove air intake connector boost pressure
(boost pressure) 1 pickup plugs (2) and (3) (R1/8).
a If nipple [1] is installed as standard to the
a Measuring instruments for intake air pressure intake air pressure (boost pressure) mea-
(boost pressure) suring port, install gauge [2] without
installing anything to the port.
Symbol Part No. Part name
q Plug (2): For left bank
799-201-2202 Boost gauge kit q Plug (3): For right bank
A
790-401-2220 Hose
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q Right bank
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4. Procedure for measuring maximum exhaust 2) Stop relieving the ripper or pitch back, and
temperature for troubleshooting. lower the exhaust temperature by only
Operate the machine and measure the maxi- stalling the torque converter (Condition (b)
mum exhaust temperature. in the figure).
a Use the PEAK mode of the digital ther- a If the temperature does not lower but
mometer. rises, set the temperature to high in
a The exhaust temperature largely depends step 1).
on the outside air temperature (intake air 3) After the temperature lowers and is stabi-
temperature of the engine). Accordingly, if lized, measure it (Condition (c) in the fig-
any abnormal value is obtained, correct it ure).
by the following calculation. k Just after the power train oil tempera-
q Corrected value [°C] = Measured ture gauge reads the red range, return
value + 2 x (20 – Outside air tempera- the direction of the PCCS lever into
ture) neutral and lower the power train oil
temperature.
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1. Check the engine oil pressure with the monitor 5) After finishing measurement, remove the
panel since the machine is equipped with measuring instruments and return the
engine oil pressure sensors for the VHMS. removed parts.
q Monitoring code: 37200 (Engine oil pres-
sure)
q Unit: MPa
a For the operating method, see “Special
functions of monitor panel (EMMS)”.
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Testing fuel pressure 1 4. Start the engine and inspect the fuel pressure
with the engine running at high idle or at the
a Measuring tools for fuel pressure equivalent of rated output speed (stall load).
a If the fuel pressure is in the following
Symbol Part No. Part name
range, it is normal.
799-101-5002 Hydraulic tester
1 Engine speed Fuel pressure
790-261-1204 Digital hydraulic tester
At high idle or
H 2 799-401-2320 Hydraulic tester 0.15 – 0.3 MPa
at the equivalent of rated
{1.5 – 3 kg/cm2}
3 795-471-1450 Adapter output speed
4 07005-00812 Gasket
D475A, D475ASD-5E0 23
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a Testing tools for fuel return and leak amount 1. Preparation work (example for left bank)
1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and supply pump (2).
1 6151-51-8490 Spacer 2) Insert spacer J1 to supply pump (2) side
2 6206-71-1770 Joint and retighten it with the currently removed
joint bolt.
Commercially
3 Hose a Be sure to fit the gaskets to both ends
available
of the spacer.
Commercially 3) Connect the return piping to the fuel tank
4 Hose
J available
side again.
5
Commercially
Measuring cylinder a Be sure to fit the gaskets to both ends
available of the spacer.
Commercially
6 Stopwatch
available
7 07376-70315 Plug
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a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (2).
circuit according to the following procedure.
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Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
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Testing
q Measure deflection (a) of the belt when it is
pus hed with a fing er at a point midwa y
between the compressor pulley and the engine
drive pulley.
q Pushing force: Approx. 59 N {approx. 6 kg}
q Deflection (a) of belt: 20 ± 2 mm
Adjusting
a If the belt deflection is outside the standard
value, adjust as follows.
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1. Outline of fuel control system [1] Fuel control dial (2nd throttle signal)
q The following signals are inputted as rota- [2] Engine controller
tion command signals to the engine con- [3] Steering controller
troller. [4] Decelerator pedal (1st throttle signal)
q Decelerator pedal potentiometer signal [5] Decelerator potentiometer
q 3rd throttle signal [6] Engine (CRI system)
The engine controller controls the fuel [7] Machine control signal
control system of the engine (CRI system) (3rd throttle signal)
according to the lowest engine speed sig- [8] Rod
nal among those input signals.
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
D475A, D475ASD-5E0 33
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SEN01818-00
D475A-5E0
D475ASD-5E0
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Gauge
No. Stamp Measured oil pressure
(MPa {kg/cm2})
1 IN T/C inlet pressure 2.5 {25}
2 OUT T/C outlet pressure 0.98 {10}
3 SC T/C stator clutch pressure 5.9 {60}
4 LU T/C lockup clutch pressure 2.5 {25}
5 TM T/M main relief pressure 5.9 {60}
6 FWD T/M F clutch pressure 5.9 {60}
7 REV T/M R clutch pressure 5.9 {60}
8 1ST T/M 1st clutch pressure 5.9 {60}
9 2ND T/M 2nd clutch pressure 5.9 {60}
10 3RD T/M 3rd clutch pressure 5.9 {60}
11 LB S/T left brake pressure 5.9 {60}
12 RB S/T right brake pressure 5.9 {60}
13 LC Left clutch pressure 5.9 {60}
14 RC Right clutch pressure 5.9 {60}
15 — T/M lubricating pressure 0.98 {10}
D475A, D475ASD-5E0 3
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1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect hydraulic tester K2 to oil pres-
lic tester K1 to oil pressure pick-up nipple sure pick-up nipple (2).
(1). a Use an oil pressure gauge of 0.98
a Use an oil pressure gauge of 2.5 MPa MPa {10 kg/cm2}.
{25 kg/cm2}.
4) After finishing measurement, remove the 4) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
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3. Measuring torque converter stator clutch 4. Measuring torque converter lock-up clutch
pressure (SC) pressure (LU)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pick-up nipple lic tester K1 to oil pressure pick-up nipple
(3). (4).
a Use an oil pressure gauge of 5.9 MPa a Use an oil pressure gauge of 2.5 MPa
{60 kg/cm2}. {25 kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Start the engine and set the monitor panel
the full neutral position. in the “Adjustment mode” and disengage
3) Measure the oil pressure while the engine both steering clutches.
is running at low idle and high idle. a For the operating method, see “Spe-
cial functions of monitor panel
(EMMS)”.
a Adjustment code: 5535 (Disengage-
ment of both steering clutches)
a The transmission speed is displayed
on the lower display section (Unit: 1
rpm).
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2) Run the engine, set the monitor panel in 2) Run the engine, set the monitor panel in
the “Adjustment mode”, and disengage the “Adjustment mode”, and disengage
both steering clutches. both steering clutches.
a For the operating method, see “Spe- a For the operating method, see “Spe-
cial functions of monitor panel cial functions of monitor panel
(EMMS)”. (EMMS)”.
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The lower message display displays a The lower message display displays
the transmission speed (in rpm). the transmission speed (Unit: 1 rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Set the PCCS lever in the REVERSE 3rd 4) Set the PCCS lever in the FORWARD 1st
gear speed position, and run the transmis- gear speed position, and run the transmis-
sion idle. sion idle.
k Keep ready to press the brake k Keep ready to press the brake
pedal at any time for safety. pedal at any time for safety.
5) Measure the oil pressure while the engine 5) Measure the oil pressure while the engine
is running at low idle. is running at low idle.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
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9. Measuring transmission 2nd clutch pres- 10. Measuring transmission 3rd clutch pres-
sure (2ND) sure (3RD)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pickup nipple lic tester K1 to oil pressure pickup nipple
(9). (10).
a Use an oil pressure gauge of 5.9 MPa a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine, set the monitor panel in 2) Run the engine, set the monitor panel in
the “Adjustment mode”, and disengage the “Adjustment mode”, and disengage
both steering clutches. both steering clutches.
a For the operating method, see “Spe- a For the operating method, see “Spe-
cial functions of monitor panel cial functions of monitor panel
(EMMS)”. (EMMS)”.
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The lower message display displays a The message display displays the
the transmission speed (in rpm). transmission speed (in rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Set the PCCS lever in the FORWARD 2nd 4) Set the PCCS lever in the FORWARD 3rd
gear speed position, and run the transmis- gear speed position, and run the transmis-
sion idle. sion idle.
k Keep ready to press the brake k Keep ready to press the brake
pedal at any time for safety. pedal at any time for safety.
5) Measure the oil pressure while the engine 5) Measure the oil pressure while the engine
is running at low idle. is running at low idle.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
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30 Testing and adjusting SEN01818-00
11. Measuring steering left brake pressure (LB) 12. Measuring steering right brake pressure
1) Connect oil pressure gauge [1] of hydrau- (RB)
lic tester K1 to oil pressure pickup nipple 1) Connect oil pressure gauge [1] of hydrau-
(11). lic tester K1 to oil pressure pickup nipple
a Use an oil pressure gauge of 5.9 MPa (12).
{60 kg/cm2}. a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
D475A, D475ASD-5E0 9
SEN01818-00 30 Testing and adjusting
13. Measuring steering left clutch pressure 14. Measuring steering right clutch pressure
(LC) (RC)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pickup nipple lic tester K1 to oil pressure pickup nipple
(13). (14).
a Use an oil pressure gauge of 5.9 MPa a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Set the PCCS lever to the steering left 3) Set the PCCS lever to the steering right
stroke end. stroke end.
a Set the direction of the PCCS lever in a Set the direction of the PCCS lever in
neutral. neutral.
4) Measure the oil pressure while the engine 4) Measure the oil pressure while the engine
is running at low idle and high idle. is running at low idle and high idle.
a Check that the oil pressure becomes a Check that the oil pressure becomes
0 when the steering of the PCCS 0 when the steering of the PCCS
lever is returned to the neutral posi- lever is returned to the neutral posi-
tion. tion.
5) After finishing measurement, remove the 5) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
10 D475A, D475ASD-5E0
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Adjusting transmission speed 6. Remove sensor (1) and flange (2) together and
sensor 1 secure them with nut (3).
a Take care that the adjustment angle of the
sensor will not change.
a The torque converter output speed sensor for 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
the VHMS is not adjustable.
7. Install flange (2) and the sensor together to the
1. Remove the fuel tank undercover, and then steering case.
remove transmission output speed sensor (1) 2 Flange and mounting bolt:
and the flange together. Gasket sealant (LG-6)
a Before adjusting transmission speed sen- 3 Mounting bolt:
sor (1), remove it temporarily and check 59 – 74 Nm {6 – 7.5 kgm}
that its tip is free from a steel chip and a
flaw.
a Before installing the transmission speed
sensor, separate sensor (1), flange (2),
and nut (3).
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30 Testing and adjusting SEN01818-00
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14 D475A, D475ASD-5E0
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Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
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22 D475A, D475ASD-5E0
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24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
D475A, D475ASD-5E0 25
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26 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
D475A, D475ASD-5E0 27
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28 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
a When using oil pressure gauge: 8. Measuring LS valve output pressure (servo
Use the oil pressure gauge of 39.2 MPa piston inlet pressure)
{400 kg/cm2}. 1) Open the inspection cover of the cross bar
Since the differential pressure is about 3.9 front undercover.
MPa {40 kg/cm2} at maximum, measure it 2) Remove oil pressure pickup plugs (5) and
by installing the same gauge to the pickup (6) from the work equipment pump.
plugs alternately. q (5):For front pump LS valve output
pressure
q (6):For rear pump LS valve output
pressure
D475A, D475ASD-5E0 29
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30 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
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32 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
Testing and adjusting control 3. Run the engine at high idle, set the blade lever
circuit basic pressure 1 and ripper lever in neutral, and measure the oil
pressure.
Measuring
k Stop the machine on a level place, lower 4. After finishing measurement, remove the mea-
the work equipment to the ground, and set suring instrument and return the removed
the parking brake lever and work equip- parts.
ment lock lever in the LOCK position.
a Measure the control circuit basic pressure Adjusting
under the following condition. a The self-pressure reducing valve cannot be
q Hydraulic oil temperature: Within operat- adjusted.
ing range
D475A, D475ASD-5E0 33
SEN01818-00 30 Testing and adjusting
Measuring PPC valve output a The PPC valve output pressure of the
pressure and solenoid valve following circuits is the basic pressure
of the solenoid valve (Dual tilt specifi-
output pressure 1 cation and superdozer specification).
q Blade right tilt/left tilt:
a Measuring instruments for PPC valve output Pitch/Tilt solenoid valve basic pres-
pressure and solenoid valve output pressure sure
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30 Testing and adjusting SEN01818-00
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40 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 41
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42 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
Measuring internal leakage of 3. Run the engine at high idle and apply the relief
work equipment cylinder 1 pressure to the cylinder bottom side.
q Blade tilt cylinder:
Operate to extend the cylinder to
a Measuring instruments for internal leakage of be measured.
work equipment cylinder q Ripper lift cylinder:
Operate to lower ripper.
Symbol Part No. Name
q Ripper Tilt cylinder:
L Purchased Measuring cylinder Operate to tilt ripper forward.
a Measure the internal leakage of work equip- 4. After 30 seconds, measure leakage for 1
ment cylinder under the following condition. minute.
q Hydraulic oil temperature: 45 – 55ºC
a Since the blade lift cylinder is equipped with a 5. After finishing measurement, return the
piston valve, its internal leakage cannot be removed parts.
measured.
D475A, D475ASD-5E0 43
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46 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
Measuring fan motor speed 1 4. Insert probe [2] of tachometer kit S through the
radiator mask and set it out of the fan net with
stand [3] and connect it to multi-tachometer [4].
a Measuring instruments for fan motor speed a The probe tip cannot be inserted in an
opening of the fan net, but it can measure
Symbol Part No. Name
the fan motor speed. Remove all obsta-
S 799-205-1100 Tachometer kit
cles between the lighting part of the probe
and the reflecting tape.
1. Open the radiator mask and remove the
mounting bolts of fan net (1) under the fan
motor.
a Fan net (1) cannot be removed since the
fan motor piping is installed.
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Measurement procedure for blade 2. Run the engine at low idle, set the toggle
tilt control angle switch of the blade lever to the dual tilt posi-
tion, and set the blade in the following standard
(Dual tiltdozer specification) 1 posture.
1) Set the blade horizontally (Set it to 0°).
a Measuring instrument for blade tilt control 2) Pitch back the blade to the maximum.
angle 3) Raise the blade at 100 mm above the
ground.
Symbol Part No. Name
U 799-402-3800 Angle gauge
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30 Testing and adjusting SEN01818-00
6. Operate information switches [<] and [>] to 10. Operate the blade lever to tilt the blade to the
select the tilt limit setting screen. left and set the left tilting angle to 12°.
a Since the tilt limiting function does not
work at this time, operate the lever slowly
and take care not to increase the tilting
angle too much.
a Adjust the tilting angle accurately with
angle gauge U.
D475A, D475ASD-5E0 51
SEN01818-00 30 Testing and adjusting
19. Start the engine again, tilt the blade to the right
and left, and check that the blade does not
interfere with the track shoe at any height.
52 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
2. Run the engine at low idle and set the blade in 6. Operate information switches [<] and [>] to
the following standard posture. select the tilt limit setting screen.
1) Set the blade horizontally (Set it to 0°).
2) Pitch back the blade to the maximum.
3) Raise the blade at 100 mm above the
ground.
D475A, D475ASD-5E0 53
SEN01818-00 30 Testing and adjusting
7. Set the buzzer cancel switch in the select posi- 13. Press the pitch dump button (upper button),
tion [U] to select the tilt limit adjustment mode. and the buzzer sounds and the left limit posi-
tion is saved.
8. Press the pitch back button (lower button) of a Since the tilt limiting function does not
the work equipment lever, and the buzzer work at this time, operate the lever slowly
sounds and the work equipment position in the and take care not to increase the tilting
standard posture is saved. angle too much.
a Adjust the tilting angle accurately with
9. Set the buzzer cancel switch in the cancel angle gauge U.
position [t] once to cancel the tilt limit adjust-
ment mode temporarily. 14. Tilt the work equipment to the right by 7°.
18. Start the engine again, tilt the blade to the right
and left, and check that the blade stops auto-
matically in the following range at any height.
q Automatic tilt stopping angle: 7 ± 1°
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30 Testing and adjusting SEN01818-00
D475A, D475ASD-5E0 55
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56 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
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4. Testing open lock ii) Check the installed height of the stop-
Lock the door open and check the relationship per rubbers.
between the operator's cab and door. If there is (Check both sides, 4 pieces on each.)
any fault, repair it. q Lock the door open and shake it in
1) Check of condition the forward and reverse directions to
1] Check the relationship between open see if it has any play.
lock latch (9) and striker (10) from the q Check that the operating effort of the
direction of B. unlock lever is not heavy.
2) Adjusting
1] Adjusting latch and striker
q Loosen the adjustment nut of striker
(10) and adjust striker (10) so that it
will not interfere with or ride over
open latch (9), then tighten the nut.
q If interference cannot be eliminated
by adjusting striker (10), loosen the
mounting bolt of open latch (9) and
adjust open latch (9).
q Push the door. If it moves until clear-
ance (b) between striker (7) and open
latch (9) is reduced to “0”, loosen
mounting nut (12) of stopper rubber
a Open the door and check the engag- (11) and extend stopper rubber (11) in
ing condition of the open latch and the pushing direction to adjust.
striker.
q Check that the claw of open latch (9)
does not ride over the bent part of
striker (10).
q Check that the body of open latch (9)
does not interfere with striker (10).
58 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
Adjusting blade 1
D475A, D475ASD-5E0 59
SEN01818-00 30 Testing and adjusting
Blade U Semi-U
Right tilt distance Approx. 900 Approx. 750
(e1) mm mm
Left tilt distance Approx. 900 Approx. 750
(e2) mm mm
60 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-00
D475A, D475ASD-5E0 61
SEN01819-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
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2 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
D475A, D475ASD-5E0 3
SEN01819-00 30 Testing and adjusting
4 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 5
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6 D475A, D475ASD-5E0
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3) Contrast of display
This mode is to adjust contrast of the liquid
crystal at the multi-information section.
(See “Operation and maintenance man-
ual”.)
D475A, D475ASD-5E0 7
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8 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
Action
Indication method of fault Contents of fault Remedy
code
• Automatic function stops or normal
• Only action code is dis- • Torque converter is not locked up. function stops partially but machine
E01 played. • Blade dual tilt mechanism does not can work.
work. • Call your Komatsu distributor for
repair.
• Stop engine and start it again, and
• Action code is displayed. • Gear is not shifted up or down. you can operate machine without lim-
E02 • Caution lamp flashes. • Blade tilt is not limited. iting function. You must take care,
• Caution buzzer sounds. • Blade pitch mechanism does not however.
work. • Call your Komatsu distributor for
repair.
• Engine coolant temperature sensor
is defective.
• Action code is displayed. • Usable gear speeds are limited. • Move machine to safe place.
CALL E03 • Caution lamp flashes. • Engine speed does not rise fully. • Call your Komatsu distributor for
• Caution buzzer sounds. • Gear shifting shocks become large. repair.
• Steering performance lowers.
• Brake shocks become large.
• Action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
CALL E04 • Caution lamp flashes. • Machine cannot travel. • Call your Komatsu distributor for
• Caution buzzer sounds. • Machine stops. repair.
D475A, D475ASD-5E0 9
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10 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 11
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4) Changing replacement interval time 2] If the input time is correct, enter the
1] Change the set time by operating change of setting by operating buzzer
information switch (5), shift-up switch cancel switch (4).
(6), and shift-down switch (7). q [U]: Enter change.
q [ > ]: Move cursor to right. a If the change is finished normally,
q [ < ]: Move cursor to left. the information display screen
q [UP]: Increase number. appears after the screen shown
q [DOWN]: Decrease number. below.
a If you do not use the mainte- a If the change does not finish nor-
nance function, set the all times mally, above message “SET-
to 0. TING NOW!!” is not displayed
but the replacement interval
change screen is kept displayed.
(The screen does not return to
the information display screen.)
12 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that
the first maintenance has been finished in the maintenance mode of the operator mode, then change
the 2nd and after interval times.
D475A, D475ASD-5E0 13
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14 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
a Condition for detecting and keeping 7. Mechanical system failure code display
failure code mode
If a failure code of any item other than (7-MACHINE CHECK CODE MODE)
communication and engine is output, In this mode, you can check the past mechani-
it keeps flashing until the starting cal system error codes.
switch is turned off. After the starting a Refer to the item “Failure code list” in
switch is turn on or the engine is Troubleshooting, General.
started again, the failure code keeps
lighting until the same fault is 1) Selecting and executing mode
detected. 1] Select “Mechanical system failure
A failure codes of communication and code display mode” on the mode
engine start lighting when the fault is selection screen.
solved, even if the starting switch is a If the mode is selected, code
not turned off. (bE) is displayed on gear speed
display section (1) and the title is
4) Operation to take when multiple codes are displayed on multi-information
recorded. section (2).
When multiple codes are recorded, they 2] Display the failure code display
can be displayed one by one by operating screen by operating buzzer cancel
information switch (5). switch (4).
q [ > ]: Next code q [U]: Execute mode.
q [ < ]: Previous code
a The failure codes are displayed from
the oldest one in order of length of
time after they were output.
D475A, D475ASD-5E0 15
SEN01819-00 30 Testing and adjusting
2) Display in the case where no codes are a Flashing and lighting of failure code
recorded Flashing: Code is being output cur-
If no failure codes have been output up to rently.
now, the information section displays as Lighting: Code is not being output
shown below. currently.
a Condition for detecting and keeping
failure code
A failure code of mechanical system
starts lighting when the fault is solved,
even if the starting switch is not
turned off.
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D475A, D475ASD-5E0 17
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18 D475A, D475ASD-5E0
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Disassembly Sending
No. Code Adjustment item Related information
and assembly in order
[1] 0001 INP TEL NO. Phone No. input mode Numerals and symbols
[2] 0002 S/T S. CODE Steering controller specification set Code q 1
Transmission controller specification
[3] 0003 T/M S. CODE Code q 2
set
[4] 0004 BODY TYPE Machine specification set Code q 3
Brake potentiometer zero point adjust-
[5] 0005 BRAKE BASE Voltage q 4
ment
[6] 0007 ENG. FULL CH Engine deceleration cut mode Engine speed 5
Speed/Fuel injection
[7] 0008 INT-> 123456 Common rail reduced cylinder mode
rate
[8] 0009 PITCH SENS. Pitch angle sensor initialization set Voltage q 6
[9] 0010 FAN 70%MODE Fan speed 70% speed mode (Adjustment amount) 8
[10] 0022 VHMS INST VHMS specification set Set state 7
[11] 0530 STALL CHECK Stall speed check mode Engine speed
(Date of adjustment in
[12] 1005 FAN 100%MODE Fan speed 100% mode 9
factory)
[13] 1012 S/T N-SET Steering lever neutral set Voltage
[14] 1013 S/T M. L-SET Steering lever left set Voltage
[15] 1014 S/T M. R-SET Steering lever right set Voltage
[16] 1015 BRKLH. OFST Left brake oil pressure offset (set) Oil pressure
[17] 1016 BRKRH. OFST Right brake oil pressure offset (set) Oil pressure
[18] 1112 PRE LUB SEL Pre-lubrication set Set state
[19] 2223 R SLOW CUT Reverse slow stop set Set state
[20] 5535 CLUTCH OPEN Clutch disengagement mode Transmission speed
[21] 5537 CLT LH. OFST Left clutch oil pressure offset (set) Oil pressure
[22] 5538 CLT RH. OFST Right clutch oil pressure offset (set) Oil pressure
Engine oil level display mode
[23] 9801 ENG. LEVEL Set state
(if equipped)
Hydraulic oil level display mode
[24] 9993 HYD. LEVEL Set state
(if equipped)
[25] 9995 LOCK BRAKE Electrical brake constantly ON mode Voltage
[26] 9996 MECHA BRAKE Electrical brake release mode Voltage
[27] 9997 HI IDLE SET High idle limit mode Revolving speed
[28] 9998 SFT INHIBIT 3rd speed cut set Permit
a After assembling the machine or replacing each controller, be sure to adjust the items marked with q in
the “Disassembly and assembly” column of the above table. (For the adjustment procedure, see
“Adjustment procedure after replacement of controller”.)
a The numbers in “Sending in order” column can be displayed in order by setting the information switch in
[>] or [<] position.
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[1] 0001: Phone number input mode [2] 0002: Steering controller specification set
q This code inputs or changes a phone number q This code is used to initialize the specification
to be displayed simultaneously when the user codes recognized by the steering controller
code is displayed. and the set values of the memory in the con-
q The lower part displays a phone number and troller.
symbols. q The specification code is displayed on the
q Available characters: lower line.
0123456789:;<=>? q Adjustment method
q Instructions for use: 1) Set buzzer cancel switch (4) in the [U]
1) By operating the information switch (5), position and check that the caution buzzer
shift up switch (6), and shift down switch sounds.
(7), input a phone number and symbols. 2) Check that the displayed specification
q [ > ]: Moves the cursor rightward. code has changed from [2*2] to [222].
q [ < ]: Moves the cursor leftward. a If specification code [222] is not displayed,
q [UP]: Advance the numeric character or the controller wiring harness or the con-
character (in the order of available charac- troller unit may be defective.
ters). a Even if this code is turned off, the setting
q [DOMN]: Reverse the numeric character is effective.
or character (in the reverse order of avail-
able characters).
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds.
a Sixteen digits of numeric characters are
provided. To avoid confusion, input sym-
bols other than numeric characters at dig-
its you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory. (No
phone number is displayed under this con-
dition.)
a The setting is enabled even after ending
this code.
20 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
[3] 0003: Transmission controller specification set [4] 0004: Machine specification set
q This code is used to initialize the specifi- q This code is used to have the machine specifi-
cation codes recognized by the transmis- cation recognized by the controllers which
sion controller and the set values of the compose the system.
memory in the controller. q The machine specification code is displayed
q The specification code is displayed on the on the lower line.
lower line. q Adjustment method:
q Adjustment method: a Since this code is reset when “Transmis-
1) Set buzzer cancel switch (4) in the [U] sion controller specification set” is exe-
position and check that the alarm buzzer cuted, adjust it after that.
sounds. 1) Select the code of the machine specifica-
2) Check that the displayed specification tion by setting shift up switch (6), and shift
code has changed from [1*1] to [111]. down switch (7).
a If specification code [111] is not dis- a Be sure to select “SSC power setting
played, the controller wiring harness 1” as the SSC type.
or the controller unit may be defec- 2) Set buzzer cancel switch (4) in the [U]
tive. position and check that the caution buzzer
a Even if this code is turned off, the set- sounds.
ting is effective. k If the machine specification is different
from the setting in the controller, the
machine may move abnormally or an
error may be made. Accordingly, be
sure to match the setting to the
machine specification.
a Even if this code is turned off, the setting
is effective.
D475A, D475ASD-5E0 21
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22 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
a When the cursor is at cylinder “6”, if infor- [10] 0022: Setting of VHMS specification
mation switch (5) is operated to the right q This code is used to set the installation of
[>], the r ight ba nk c yli nders can be VHMS terminal. If the installation is not set, the
reduced. VHMS operation data is not set normally and
(L 1,2,3,4,5,6 o R 1,2,3,4,5,6) the data related to the VHMS cannot be moni-
tored.
[8] 0009: Pitch angle sensor initial set q The installation condition of the terminal is dis-
q This code is used to adjust the zero point and played on the lower line.
installation error of the pitch angle sensor. q ACTIVE: Setting of installation of VHMS
q The deviation from the standard neutral posi- q DEACTIVE: Setting of non-installation of
tion is displayed by voltage on the lower line VHMS
(Display range: -2500 to 2500 mV). q Setting method
q Adjustment method: 1) Select an installation condition of the
Set buzzer cancel switch (4) in the [U] position VHMS terminal with shift-up switch (6) and
and check that the caution buzzer sounds. shift-down switch (7).
a Even if this code is turned off, the setting 2) After selecting the condition of the termi-
is effective. nal, set buzzer cancel switch (4) in the [?]
position.
3) The buzzer sounds and the set condition
is saved.
a The setting is effective even after this
code is finished.
a After the control is replaced, be sure to set
(check) the condition.
D475A, D475ASD-5E0 23
SEN01819-00 30 Testing and adjusting
[11] 0530: Stall speed check mode [12] 1005: Fan 100% mode
q This code is the function to make the cooling q This code forcedly sets the speed of cooling
fan speed maximum to check the torque con- fan at approximately 100% of the maximum
verter stall speed. speed.
k In this machine the cooling fan speed con- Also by this code, the adjustment value for the
trol function is installed in order to protect maximum speed can be set.
the radiator when the engine is not yet q The adjustment data is displayed on the lower
warmed up enough. However, in case that line.
this mode is in use, the protecting function q How to use:
does not work. So use the machine after a The function is effective with this code dis-
carrying out enough warming up. played to control the speed of cooling fan
q The engine speed is displayed on the lower line. to approximately 100% of the maximum
(Display range: 0 – 3000) speed.
q How to use i) When changing the adjustment value,
While this code is displayed, its function is operate shift up switch (6) and shift down
enabled and the cooling fan speed becomes switch (7) to set the adjustment value for
maximum. the maximum speed.
a If this code is turned off, its function is disabled. q [UP]: Adjustment value increases.
q [DOWN]: Adjustment value decreases.
ii) For confirming the adjustment value, set
buzzer cancel switch (4) in the [U] posi-
tion and check that the alarm buzzer
sounds.
a If this code is turned off, its function is dis-
abled. However, the adjustment value
once set is still effective.
24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
D475A, D475ASD-5E0 25
SEN01819-00 30 Testing and adjusting
[16] 1015: Left brake oil pressure offset 2) Operate the buzzer cancel switch to [U]
q This code is used to adjust the left brake oil side and check that the caution buzzer
pressure manually. sounds.
q The offset oil pressure (Unit: MPa) is displayed a Even if this code is turned off, the setting
on the lower line (If it has been adjusted, its is effective.
value is displayed. It can be adjusted further
within the allowable range).
q Adjustment method:
a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil
pressure.
q Shiftup switch (6): Increase oil pres-
sure
q Shiftdown switch (7): Decrease oil
pressure
a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05).
2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer [18] 1112: Pre-lubrication set (if equipped)
sounds. q This code is used to set the machine equipped
a Even if this code is turned off, the setting with the pre-lubrication system.
is effective. q Installation or non-installation of the pre-lubri-
cation system is displayed on the lower line by
letters.
q Adjustment method:
Operate information switch (5) to change the
setting.
q [ < ] [ > ]: Change display
q [Pre-Lub ON]: Machine is equipped with
pre-lubrication system
q [Pre-Lub OFF]: Machine is not equipped
with pre-lubrication system
a If setting of installation and non-installation
of the pre-lubrication system is wrong, an
error may be detected.
a Even if this code is turned off, the setting
is effective.
[17] 1016: Right brake oil pressure offset
q This code is used to adjust the right brake oil
pressure manually.
q The offset oil pressure (Unit: MPa) is displayed
on the lower line (If it has been adjusted, its
value is displayed. It can be adjusted further
within the allowable range).
q Adjustment method:
a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil
pressure.
q Shiftup switch (6): Increase oil pres-
sure
q Shiftdown switch (7): Decrease oil
pressure
a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05).
26 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
[19] 2223: Reverse slow stop set [20] 5535: Both steering clutches disengagement
q This code is used to turn off the reverse slow q This code is used to engage the transmission
function forcibly, regardless of the operation of clutch without driving the machine for testing,
the switches on the monitor panel. adjusting, troubleshooting, Pm Clinic, etc.
q The state of the reverse slow function is dis- q The transmission speed (Unit: rpm) is dis-
played on the lower line by letters. played on the lower line.
q Adjustment method: q Using method:
Operate information switch (5) to change the While this code is displayed, the function is
setting. effective and steering clutches on both sides
q [ < ] [ > ]: Change display are disengaged. Accordingly, the machine
q [DEACTIVE]: Turn reverse slow function does not travel even if the PCCS lever is oper-
OFF ated.
q [ACTIVE]: Turn reverse slow function ON a If this code is turned off, the function
a Once the reverse slow function is turned becomes ineffective.
OFF, the reverse speed is not lowered,
even if the reverse slow mode switch on
the monitor panel is turned ON.
a Even if this code is turned off, the setting
is effective.
D475A, D475ASD-5E0 27
SEN01819-00 30 Testing and adjusting
[21] 5537: Left steering clutch oil pressure offset [22] 5538: Right steering clutch oil pressure offset
q This code is used to adjust the left clutch oil q This code is used to adjust the right clutch oil
pressure manually. pressure manually.
q The offset oil pressure (Unit: MPa) is displayed q The offset oil pressure (Unit: MPa) is displayed
on the lower line (If it has been adjusted, its on the lower line (If it has been adjusted, its
value is displayed. It can be adjusted further value is displayed. It can be adjusted further
within the allowable range). within the allowable range).
q Adjustment method: q Adjustment method:
a The allowable adjustment range is ± 0.3 a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3) MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil 1) Operate the shift switch to set the offset oil
pressure. pressure.
q Shiftup switch (6): Increase oil pres- q Shiftup switch (6): Increase oil pres-
sure sure
q Shiftdown switch (7): Decrease oil q Shiftdown switch (7): Decrease oil
pressure pressure
a The offset pressure is increased or a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2} decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05). (Displayed value: 0.05).
2) Set buzzer cancel switch (4) in the [U] 2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer position and check that the caution buzzer
sounds. sounds.
a Even if this code is turned off, the setting a Even if this code is turned off, the setting
is effective. is effective.
28 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
[23] 9801: Engine oil level set (if equipped) [24] 9993: Hydraulic oil level set (if equipped)
q This code is used to set the machine equipped q This code is used to set the hydraulic oil level
with the engine oil level switch. caution.
q Installation or non-installation of the engine oil q The setting of the hydraulic oil level caution is
level switch is displayed on the lower line by displayed on the lower line by letters.
letters. q Adjustment method:
q Adjustment method: Operate information switch (5) to change the
Operate information switch (5) to change the setting.
setting. q [ < ] [ > ]: Change display
q [ < ] [ > ]: Change display q [ACTIVE]: Turn hydraulic oil level caution
q [ACTIVE]: Machine is equipped with function ON
engine oil level switch q [DEACTIVE]: Turn hydraulic oil level cau-
q [DEACTIVE]: Machine is not equipped tion function OFF
with engine oil level switch a To use this function, the hydraulic oil level
a To use this function, the engine oil level switch switch must be installed.
must be installed. a If [ACTIVE] is selected while the hydraulic oil
a If [ACTIVE] is selected while the engine oil level switch is not installed, the caution buzzer
level switch is not installed, the caution buzzer sounds. Take care.
sounds. Take care. a Even if this code is turned off, the setting is
effective.
D475A, D475ASD-5E0 29
SEN01819-00 30 Testing and adjusting
[25] 9995: Electric brake constantly ON mode [27] 9997: High idle limit mode
q This code is used to see if the sudden stop q This code is used to limit the high idle speed.
prevent valve operates normally. q The engine speed (set value) is displayed on
q The voltage of the brake potentiometer is dis- the lower line.
played on the lower line. q Possible limiting range: High idle speed –400
q Using method: rpm
While this code is displayed, the function is q Using method:
effective and the electric brake is constantly 1) Set information switch (5) in the [ > ] or [ < ]
turned on. position to select the limit speed.
a If this code is turned off, the function 2) Set buzzer cancel switch (4) in the [U]
becomes ineffective. position and check that the caution buzzer
sounds.
a Once the high idle speed is limited, the
engine speed does not reach the original
high idle speed, even if the fuel control dial
is operated.
a Even if this code is turned off, the setting
is effective.
30 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
D475A, D475ASD-5E0 31
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32 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 33
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10) Display of R2 odometer (08) 12) Moving machine with saved load dis-
On this screen, the integrated R2 played
(Reverse 2nd gear) travel distance is dis- If the parking brake lever is set in the
played. FREE position, gear speed display unit (1)
a The data cannot be reset. is set in the normal display mode again
and the machine can operate normally.
a At this time, even if the shift up or shift
down switch is pressed with the
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
load saving display mode.)
To change the shift, shift the PCCS
lever to the “forward” or “reverse”
position and press the shift up or shift
down switch while the machine is
traveling.
a To select another screen, return the
parking brake lever to the LOCK posi-
tion temporarily, and then start the
11) Display of R3 odometer (09) operation.
On this screen, the integrated R3
(Reverse 3rd gear) travel distance is dis-
played.
a The data cannot be reset.
34 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
D475A, D475ASD-5E0 35
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36 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
D475A, D475ASD-5E0 37
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Auto-
No. Code Monitoring item Unit Remarks matic
selection
1 00201 ENG M ID L Engine controller model selection name, left bank Letter — —
2 00203 ENG M ID R Engine controller model selection name, right bank Letter — —
3 01002 ENG REV L Engine speed, left bank rpm — 1
4 01004 ENG REV R Engine speed, right bank rpm — 2
5 01603 Remote Th 2nd throttle position % — —
6 03000 FUEL DIAL Fuel control dial voltage mV — 25
7 03200 BATTERY Battery voltage mV — 39
8 03201 S/T ACC Steering controller ACC input voltage mV — —
9 03202 S/T PWR2 Steering controller load power supply voltage mV — —
10 03203 E-ECM PW L Engine controller power supply voltage, left bank mV — —
11 03206 E-ECM PW R Engine controller power supply voltage, right bank mV — —
12 03207 S/T PWR1 Steering controller unswitched power supply voltage mV — —
Transmission controller unswitched power supply volt-
13 03208 T/M PWR1 mV — —
age
14 03212 T/M ACC Transmission controller ACC input voltage mV — —
15 03216 T/M PWR2 Transmission controller load power supply voltage mV — —
16 04104 COOLANT TP Engine coolant temperature °C — 6
17 04105 COOLANT TP Engine coolant temperature sensor voltage mV — —
18 04200 FUEL SENS Fuel level sensor voltage mV — 37
19 04401 HYD.TEMP Hydraulic oil temperature °C — 7
20 08100 HSI BREAK HSI line break point rpm — —
21 08200 TQ Sel Torque curve selection Letter — —
22 08300 Droop Type Droop type selection Letter — —
23 08400 Droop SW Droop switch selection Letter — —
24 08500 Droop Trim Droop trim selection Letter — —
25 10500 S/T 5V PW1 Steering controller sensor 5V power supply voltage 1 mV — —
Transmission controller sensor 5V power supply voltage
26 10501 T/M 5V PW1 mV — —
1
27 10505 S/T 5V PW2 Steering controller sensor 5V power supply voltage 2 mV — —
Transmission controller sensor 5V power supply voltage
28 10506 T/M 5V PW2 mV — —
2
29 10700 S/T 24V PW Steering controller sensor 24V power supply voltage mV — —
Transmission controller sensor 24V power supply volt-
30 10701 T/M 24V PW mV — —
age
31 14200 FUEL TMP L Fuel temperature, left bank °C — —
32 14201 FUEL TMP L Fuel temperature sensor voltage, left bank mV — —
33 14202 FUEL TMP R Fuel temperature, right bank °C — —
34 14203 FUEL TMP R Fuel temperature sensor voltage, right bank mV — —
35 17201 PCV TMG L PCV closing timing, left bank CA — —
36 17202 PCV TMG R PCV closing timing, right bank CA — —
37 17500 ENG MODE Engine controller mode selection Letter — —
(See detailed
38 18300 ENG IVSW 1 Engine controller idle validation switch 1 bit —
information)
(See detailed
39 18301 ENG IVSW 1 Engine controller idle validation switch 2 bit —
information)
38 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
Auto-
No. Code Monitoring item Unit Remarks matic
selection
40 18400 INTAKE TEMP Intake air temperature °C — —
41 18401 INTAKE TEMP Intake air temperature sensor voltage mV — —
42 18500 BOOST TEMP Boost temperature °C — —
43 18501 BOOST TEMP Boost temperature sensor voltage mV — —
44 18600 INJECT CMD Final injection rate command mg/st — —
45 18700 ENG TRUQUE Engine output torque Nm — —
46 18900 E-ECM TP L Engine controller ECM inside temperature, left bank °C — —
47 18902 E-ECM TP R Engine controller ECM inside temperature, right bank °C — —
48 20201 T/M. PROGRM Transmission controller program version Letter — —
49 20202 S/T. PROGRM Steering controller program version Letter — —
50 20216 ENG BLD L Engine controller build version, left bank Letter — —
51 20217 ENG CAL L Engine controller calibration data version, left bank Letter — —
52 20218 ENG CAL R Engine controller calibration data version, right bank Letter — —
53 20219 ENG BLD R Engine controller build version, right bank Letter — —
54 20301 VHMS VHMS LED monitor LED — 40
55 20400 E-ECM SN L Engine controller ECM serial No., left bank Letter — —
56 20401 E-ECM SN R Engine controller ECM serial No., right bank Letter —
57 30100 T/C TEMP. Torque converter oil temperature °C — 8
58 31200 T/M IN Transmission input speed rpm —
59 31400 T/M OUT Transmission output speed rpm — 3
(See detailed
60 31520 T/M-FILL Transmission-related fill switch input state bit —
information)
(See detailed
61 31521 S/T FILL Steering-related fill switch input state bit —
information)
62 31602 1st CLUTCH 1st clutch ECMV current command value mA — —
63 31603 2nd CLUTCH 2nd clutch ECMV current command value mA — —
64 31604 3rd CLUTCH 3rd clutch ECMV current command value mA — —
65 31606 Rev CLUTCH Reverse clutch ECMV current command value mA — —
66 31608 Frd CLUTCH Forward clutch ECMV current command value mA — —
67 31612 1 CLUTCH F 1st clutch ECMV output feedback current mA — 33
68 31613 2 CLUTCH F 2nd clutch ECMV output feedback current mA — 34
69 31614 3 CLUTCH F 3rd clutch ECMV output feedback current mA — 35
70 31616 R CLUTCH F Reverse clutch ECMV output feedback current mA — 32
71 31618 BRAKE R.H. Right brake ECMV output feedback current mA — 27
72 31619 BRAKE L.H. Left brake ECMV output feedback current mA — 26
73 31620 BRAKE R.H. Right brake ECMV current command value mA — —
74 31621 BRAKE L.H. Left brake ECMV current command value mA — —
75 31622 F CLUTCH F Forward clutch ECMV output feedback current mA 31
76 31623 FAN PUMP. O Cooling fan pump solenoid output command current mA — —
77 31624 FAN PUMP. F Cooling fan pump solenoid output feedback current mA — —
78 31625 PITCH SOL. Blade pitch solenoid output feedback current mA — —
Torque converter lockup solenoid output feedback cur-
79 31627 L/U SOL mA — 36
rent
Sudden stop prevention solenoid output feedback cur-
80 31628 E. BRAKE SL mA — 28
rent
81 31633 FAN PMP2. O Cooling fan pump 2 solenoid output command current mA — —
D475A, D475ASD-5E0 39
SEN01819-00 30 Testing and adjusting
Auto-
No. Code Monitoring item Unit Remarks matic
selection
82 31634 FAN PMP2. F Cooling fan pump 2 solenoid output feedback current mA — —
83 31701 DECEL Decelerator position % — 9
84 31703 DECEL Decelerator pedal potentiometer voltage mV — 24
85 31706 F THROTTLE Final accelerator position % — 10
86 32900 BODY ANGLE Machine pitch angle ° — 18
87 36001 Accel Adj Throttle correction value data % — —
88 36200 PRESS CMD Final common rail pressure command MPa — —
89 36300 INJECT CMD Final injection timing command CA — —
90 36400 RAIL PR L Common rail pressure, left bank MPa — 12
91 36401 RAIL PR L Common rail pressure sensor voltage, left bank mV — —
92 36403 RAIL PR R Common rail pressure, right bank MPa — 13
93 36404 RAIL PR R Common rail pressure sensor voltage, right bank mV — —
94 36500 BOOST PRS Boost pressure KPa — 14
95 36501 BOOST PRS Boost pressure sensor voltage mV — —
96 36700 ENG TORQUE Engine converted torque % — 15
97 37200 ENG OIL PRS Engine oil pressure KPa — 11
98 37201 ENG OIL PRS Engine oil pressure sensor voltage mV — —
99 37301 FUEL RATE Fuel injection rate L/h — —
100 37400 ABM PRESS Ambient pressure KPa — —
101 37401 ABM PRESS Ambient pressure sensor voltage mV — —
102 37500 ATM TEMP Ambient temperature °C — —
103 40001 VEHICLE SP Travel speed (Theoretical value) km/h — 4
(See detailed
104 40905 T/M-SW1 Transmission-related controller input signal 1 bit —
information)
(See detailed
105 40906 T/M-SW2 Transmission-related controller input signal 2 bit —
information)
(See detailed
106 40907 T/M OP SIG Transmission-related controller operation input signal bit —
information)
(See detailed
107 40908 T/M HYD SW Blade lever oil pressure switch input signal bit —
information)
(See detailed
108 40909 T/M SOL. 2 Transmission-related controller ON/OFF output 2 bit —
information)
(See detailed
109 40910 S/T-SW1 Steering-related controller switch input signal 1 bit —
information)
(See detailed
110 40911 S/T-SW2 Steering-related controller switch input signal 2 bit —
information)
(See detailed
111 40913 S/T-SW5 Steering-related controller switch input signal 5 bit —
information)
(See detailed
112 40914 S/T SOL. 1 Transmission-related controller ON/OFF output 1 bit —
information)
(See detailed
113 40915 S/T SOL. 2 Steering-related controller output signal 2 bit —
information)
114 42600 EXH TEMP LF Exhaust temperature, left front °C — —
115 42601 EXH TEMP RR Exhaust temperature, right rear °C — —
116 42602 EXH TEMP RF Exhaust temperature, right front °C — —
117 42603 EXH TEMP RF Exhaust temperature sensor voltage, right front mV — —
118 42604 EXH TEMP LF Exhaust temperature sensor voltage, left front mV — —
119 42605 EXH TEMP RR Exhaust temperature sensor voltage, right rear mV — —
40 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
Auto-
No. Code Monitoring item Unit Remarks matic
selection
120 42606 EXH TEMP LR Exhaust temperature, left rear °C — —
121 42607 EXH TEMP LR Exhaust temperature sensor voltage, left rear mV — —
122 42700 ENG OIL TMP Engine oil temperature °C — —
123 42701 ENG OIL TMP Engine oil pressure sensor voltage mV — —
124 42800 BLOWBY PRS Blow-by pressure KPa — —
125 43000 T/M PRESS Transmission main relief pressure MPa — —
(See detailed
126 43502 IdleCancel Warm-up operation cancel flag bit —
information)
127 44202 Accel Up Throttle upper limit value data % —
128 44203 Accel low Throttle lower limit value data % —
129 50200 T/M LEVR 1 Directional lever potentiometer 1 voltage mV 19
130 50201 T/M LEVR 2 Directional lever potentiometer 2 voltage mV 20
131 50300 S/T LEVR 1 Steering potentiometer 1 voltage mV 21
132 50301 S/T LEVR 2 Steering potentiometer 2 voltage mV 22
133 50400 BRAKE PEDL Brake pedal potentiometer voltage mV 23
134 50900 N-SAFTY Neutral safety relay drive voltage mV 38
135 51000 ENG REG Regulation command speed rpm —
136 51100 FUEL DIAL Fuel control dial command speed rpm
137 60000 TRACTION Traction force (Theoretical value) W 5
138 60100 BODY ANGLE Machine pitch angle sensor voltage mV —
139 60200 ACCELERATN Acceleration sensor voltage mV —
140 60300 SSC ORDER SSC command speed rpm —
(See detailed
141 60400 S/T-SW6 Steering-related controller input signal 6 bit —
information)
142 60500 ENG.CON. PW Engine controller drive voltage mV — —
143 60600 BR HOLD Battery relay drive voltage mV — —
144 60700 S/T MODE Steering state code Letter — —
145 60800 FILL MODE Fill condition setting variable Letter — —
146 60909 MOD MODE Modulation condition setting variable Letter — —
147 70000 CHG.P. MODE Gearshift point condition setting variable Letter — —
148 70200 T/M OUT Transmission speed sensor voltage mV — —
(See detailed
149 70300 B. KNOB SW Blade lever knob switch input signal bit —
information)
(See detailed
150 70305 T/M RIPER2 Ripper lever oil pressure switch input signal bit —
information)
151 70400 BACK ALARM Backup alarm relay drive voltage mV — —
152 70600 DUAL SOL. Dual tilt solenoid drive current mA — —
153 70700 HYD. PUMP 1 Work equipment pump oil pressure 1 MPa — 16
154 70701 HYD. PUMP 1 Work equipment oil pressure sensor 1 voltage mV — —
155 70702 HYD. PUMP 2 Work equipment pump oil pressure 2 MPa — 17
156 70703 HYD. PUMP 2 Work equipment oil pressure sensor 2 voltage mV — —
(See detailed
157 90000 T/M SOL. 3 Tilt and pitch solenoid output 3 bit output signal bit —
information)
(See detailed
158 90001 T/M SOL. 4 Dual tilt and pitch solenoid output 4 bit output signal bit —
information)
159 90002 BL YOKE L Left yoke angle sensor voltage mV — —
160 90003 BL YOKE R Right yoke angle sensor voltage mV — —
D475A, D475ASD-5E0 41
SEN01819-00 30 Testing and adjusting
Auto-
No. Code Monitoring item Unit Remarks matic
selection
161 90600 S/T CLT LH Left clutch ECMV output feedback current mA — 29
162 90601 S/T CLT RH Right clutch ECMV output feedback current mA — 30
163 90602 S/T CLT LH Left clutch ECMV output current mA — —
164 90603 S/T CLT RH Right clutch ECMV output current mA — —
165 92100 F1 SMR F1 integrated travel hours h — —
166 92101 F2 SMR F2 integrated travel hours h — —
167 92102 F3 SMR F3 integrated travel hours h — —
168 92200 R1 SMR R1 integrated travel hours h — —
169 92201 R2 SMR R2 integrated travel hours h — —
170 92202 R3 SMR R3 integrated travel hours h — —
171 99901 TRIG T F Trigger time F msec — —
172 99902 TRIG T R Trigger time R msec — —
173 99903 TRIG T 1 Trigger time 1 msec — —
174 99904 TRIG T 2 Trigger time 2 msec — —
175 99905 TRIG T 3 Trigger time 3 msec — —
176 99906 TM SFT Transmission shift Letter — —
(See detailed
177 99907 LU Lockup state bit —
information)
178 99908 TM IN TRQ Transmission input torque Nm — —
179 99909 DOZING h Dozing hours h — —
180 99910 RIPPING h Ripping hours h — —
181 99911 PATH NUM Number of path path — —
182 99913 TC IN TRQ Torque converter input torque Nm — —
183 99914 H. P 1 TRQ Work equipment pump 1 input torque Nm — —
184 99915 H. P 2 TRQ Work equipment pump 2 input torque Nm — —
185 99917 BR L PRESS Left brake oil pressure MPa — —
186 99918 BR R PRESS Right brake oil pressure MPa — —
187 99919 CL L PRESS Left clutch oil pressure MPa — —
188 99920 CL R PRESS Right clutch oil pressure MPa — —
a The numbers in the Automatic selection column can be displayed in numeric order by setting the infor-
mation switch in the “>” or “<” position.
42 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
Detailed information on bit display 18301: Engine controller idle validation switch 2
codes 1: Idle validation switch 2: ON
2: (Unused)
Examples of display of bit information 3: (Unused)
a The display position of the bit information in the 4: (Unused)
“Real-time monitoring mode (Display of only 1 5: (Unused)
item)” is different from that in the “Dual display 6: (Unused)
monitoring mode (Simultaneous display of 2 7: (Unused)
items)”. 8: (Unused)
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 con-
dition for turning on the bit.
D475A, D475ASD-5E0 43
SEN01819-00 30 Testing and adjusting
31521: Input state of steering related fill switch 40906: Transmission related controller input signal 2
1: Left brake fill switch: ON 1: Automatic gear shift-down switch: ON
2: Left clutch fill switch: ON 2: Neutral switch (OPT-type travel lever): OFF
3: (Unused) 3: Neutral switch (OPT-type travel lever): ON
4: (Unused) 4: Neutral switch (OPT-type travel lever): OFF
5: Right clutch fill switch: ON 5: Neutral switch (OPT-type travel lever): ON
6: Right brake fill switch: ON 6: Automatic pitch back switch: ON
7: (Unused) 7: (Unused)
8: (Unused) 8: (Unused)
40905: Transmission related controller input signal 1 40907: Transmission related controller function
1: Shift-up switch: OFF input signal
2: Shift-up switch: ON 1: ACC signal switch: ON
3: Shift-down switch: OFF 2: (Unused)
4: Shift-down switch: ON 3: R signal: ON
5: Parking brake switch: FREE 4: (Unused)
6: Parking brake switch: LOCK 5: (Unused)
7: (Unused) 6: (Unused)
8: (Unused) 7: (Unused)
8: (Unused)
44 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
40908: Blade lever oil pressure switch input signal 40910: Steering related controller input signal 1
1: Blade lift raise oil pressure switch: ON 1: (Unused)
2: Blade lift lower oil pressure switch: ON 2: (Unused)
3: (Unused) 3: (Unused)
4: (Unused) 4: (Unused)
5: Blade left tilt oil pressure switch: ON 5: Parking brake lever switch: FREE
6: Blade right tilt oil pressure switch: ON 6: Parking brake lever switch: LOCK
7: (Unused) 7: (Unused)
8: (Unused) 8: (Unused)
40909: Transmission related controller output 40911: Steering related controller input signal 2
signal 2 1: Buzzer cancel switch: t position
1: (Unused) 2: Buzzer cancel switch: U position
2: (Unused) 3: Information switch: > position
3: (Unused) 4: Information switch: < position
4: Backup alarm relay: ON 5: Service switch: ON
5: Neutral safety relay: ON 6: (Unused)
6: Lockup: ON 7: (Unused)
7: (Unused) 8: (Unused)
8: (Unused)
D475A, D475ASD-5E0 45
SEN01819-00 30 Testing and adjusting
40913: Steering related controller input signal 5 40915: Steering related controller ON-OFF output
1: ACC signal: ON signal 2
2: Pre-lubrication oil pressure switch: ON 1: Pre-lubrication motor relay: ON
3: R signal: ON 2: Engine stop relay: ON
4: (Unused) 3: (Unused)
5: Fan reverse switch: ON 4: (Unused)
6: Fan cleaning switch: ON 5: (Unused)
7: (Unused) 6: (Unused)
8: (Unused) 7: (Unused)
8: (Unused)
46 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
60400: Steering related controller input signal 6 70305: Ripper lever oil pressure switch input signal
1: (Unused) 1: (Unused)
2: C signal: ON 2: Ripper lift raise oil pressure switch:
3: Engine low idle signal: ON ON (Operated)
4: Engine stop command signal: ON 3: Ripper lift lower oil pressure switch:
5: Hydraulic oil level switch signal: ON ON (Operated)
6: Pre-lubrication motor drive signal: ON 4: Ripper tilt in oil pressure switch: ON (Operated)
7: (Unused) 5: Ripper tilt out oil pressure switch: ON (Oper-
8: (Unused) ated)
6: (Unused)
7: (Unused)
8: (Unused)
D475A, D475ASD-5E0 47
SEN01819-00 30 Testing and adjusting
90000: Dual/Pitch dump solenoid output 4 bit out- 99907: Lockup state
put signal (Other than superdozer specification) 1: Forward clutch output: ON
1: Left tilt limit solenoid: ON 2: Reverse clutch output: ON
2: Right tilt limit solenoid: ON 3: 1st clutch output: ON
3: (Unused) 4: 2nd clutch output: ON
4: (Unused) 5: 3rd clutch output: ON
5: (Unused) 6: Clutch modulation: Modulating
6: (Unused) 7: Lockup clutch output: ON
7: (Unused) 8: Clutch state: Neutral
8: (Unused)
48 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
11. Dual display monitoring mode 2) Selecting and entering monitored items
(11-DUAL DISPLAY MONITORING MODE) 1] On the code input screen, input the 5-
In this mode, 2 monitored items can be dis- digit codes of the items to be moni-
played simultaneously. tored to the upper and lower lines by
a Note that only codes and monitoring infor- operating information switch (5), shift-
mation are displayed in this mode since up switch (6), and shift-down switch
the usable display columns are limited. (7).
(Item names and units cannot be dis- q [ > ]: Move cursor to right.
played.) q [ < ]: Move cursor to left.
q [UP]: Increase number.
1) Selecting and executing mode q [DOWN]: Decrease number.
1] Select “Dual display monitoring 2] After inputting the codes, display the
mode” on the mode selection screen. m on i to r in g s c r e en b y op er a ti n g
a If the mode is selected, code buzzer cancel switch (4).
(dR) is displayed on gear speed q [U]: Enter input code.
display section (1) and the title is
displayed on multi-information
section (2).
2] Display the monitoring code input
screen by operating buzzer cancel
switch (4).
q [U]: Execute mode.
D475A, D475ASD-5E0 49
SEN01819-00 30 Testing and adjusting
50 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-00
D475A, D475ASD-5E0 51
SEN01820-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN01820-00 30 Testing and adjusting
2 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 3
SEN01820-00 30 Testing and adjusting
1. Monitor panel
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
monitor panel (2) toward the operator’s
seat.
4 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
3. Transmission controller
1) Remove dashboard cover (1).
D475A, D475ASD-5E0 5
SEN01820-00 30 Testing and adjusting
6 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
6. ORBCOMM terminal
1) Open the floor left side cover and remove
cover (1).
D475A, D475ASD-5E0 7
SEN01820-00 30 Testing and adjusting
8 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 9
SEN01820-00 30 Testing and adjusting
10 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 11
SEN01820-00 30 Testing and adjusting
Right decimal
Display
point
• Power is not supplied to ORB-
COMM controller.
OFF
• Communication line to VHMS
controller is abnormal.
• Satellite is not captured.
• Power is supplied to ORB-
ON COMM controller.
• Communication line to VHMS
controller is normal.
• Power is supplied to ORB-
4. Startup of VHMS initialization tool
COMM controller.
a This step is a work performed in the oper-
Blinking • Communication line to VHMS
controller is normal. ator's cab (on the personal computer).
• Satellite is captured. 1) Turn on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
8) Check the controller for normal operation on the personal computer screen to start
referencing 7-segment LED of VHMS con- the VHMS initialization tool.
troller. a The setting screen varies with the
a VHMS controller is fed with switch version No. of the VHMS setting tool.
power supply. Thus, its operation is a When using a tool before Ver. 3.5.2.1
judged normal if its 7-segment LED (CD-ROM), set the VHMS in step 5.
starts flashing while rotating as the a When using an updated tool (Ver.
starting switch is turned on and then if 3.5.2.1 or after), set the VHMS in step
the controller starts counting in the 6.
ascending order. a It is recommended to download the
latest VHMS setting tool from the
WebCARE and update your tool.
(Related material: Servicemate SMP-
623)
3) Input the 10-digit service ID in [Service
ID].
a Service ID: 7286146000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen.
12 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 13
SEN01820-00 30 Testing and adjusting
14 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
9) To change setting in [SHORT TREND 11) After checking/changing all the data in
ANALYSIS], follow the procedures below: [Communication Setting], press [Apply]
1] Select [SHORT TREND ANALYSIS] button to settle the setting.
on the screen and press [Edit] button a If the [Apply] button is pressed, the
on the left lower part of the [File s c r e e n f o r c h e c k in g t h e s e t t i n g
Transfer Setting] block to display the appears. Check the setting again and
setting screen. press the [OK] button if the setting is
2] Change the setting and then press correct.
the [OK] button.
a At initialization, input [20h] to
[SMR] and set the function to
[ON].
D475A, D475ASD-5E0 15
SEN01820-00 30 Testing and adjusting
6. Initialization of VHMS controller (Ver. 3.5.2.1 3) Check the machine information. If it does
or after) not need to be corrected, press the “Next”
a This step is a work performed in the oper- button.
ator's cab (on the personal computer).
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
“Next” button.
16 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
4) Select the time zone. 8) The contents of the setting are displayed
5) Input the local time. finally. If there is not a problem, press the
6) If the DST (Daylight Saving Time) is used “Apply” button.
now, select it and press the “Next” button.
a If the DST is selected, the clock is
advanced 1 hour automatically, thus
the time must be corrected again.
D475A, D475ASD-5E0 17
SEN01820-00 30 Testing and adjusting
7. Procedures for executing Quick Pm 2] Set the buzzer cancel switch in the
a The Quick Pm means the Pm Clinic exe- [U] position.
cuted with the manual snap shot function 3] “READY” is displayed and the system
of the monitor panel. is ready to start.
a Data in 7 minutes 30 seconds are saved in a On the lower line, 15 pieces of “-”
the VHMS controller. are displayed.
k Stop the machine on a flat place.
18 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 19
SEN01820-00 30 Testing and adjusting
Fuel
No.
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine
speed to high idle.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to
overheat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
20 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 21
SEN01820-00 30 Testing and adjusting
22 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 23
SEN01820-00 30 Testing and adjusting
Measurement items
24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 25
SEN01820-00 30 Testing and adjusting
26 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
E-mail: webcare@komatsu.co.jp
D475A, D475ASD-5E0 27
SEN01820-00 30 Testing and adjusting
28 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 29
SEN01820-00 30 Testing and adjusting
30 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
Precautions for replacing VHMS 2) Select “Save/Load” and press the “OK”
controller 1 button.
D475A, D475ASD-5E0 31
SEN01820-00 30 Testing and adjusting
5) Check the information again and press the 3) Select [Load] from [File] in the menu.
“OK” button to save it.
32 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
7) After setting the time, press the “OK” but- 9) The system asks you if you will save the
ton. previous data. Press the “NO” button.
a Usually, you do not need to save the
previous data.
D475A, D475ASD-5E0 33
SEN01820-00 30 Testing and adjusting
3) Select [Save Current Setting before 3-2. Writing of set information in new VHMS con-
replacement of VHMS controller] and troller
press the “Next” button. 1) Connect the personal computer again and
start the VHMS technical analysis tool.
a See “Initialization procedures for
VHMS controller”.
2) Select [When VHMS needs to be
replaced] and press the “Next” button.
34 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
4) The saved information is displayed. Press 7) The above completes modification of the
the “Next” button. setting. Press [OK] button to end the
VHMS initial setting tool.
D475A, D475ASD-5E0 35
SEN01820-00 30 Testing and adjusting
Pm Clinic service 1
Model Serial No. Service meter
T D475A-5E0
h
T D475ASD-5E0
Specifications
Blade Attachment Shoe width
T Semi U blade T Variable Multi-shank ripper T 710 mm %
T U blade T Variable giant ripper T 810 mm %
T Super blade T Counterweight ( kg) T 910 mm %
T T T %
Operating conditions
Quarry, mine Construction Type of soil (specific gravity) Type of work
T Construction, civil engi-
T Coal T Rock T Dozing
neering
T Gold T Roads T Gravel T Side cutting
T Limestone T Tunnels T Sand T Ripping
T T T Clay T Travel
Existence of abnormalities
Oil, coolant level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Operator's opinion
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
36 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 37
SEN01820-00 30 Testing and adjusting
38 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 39
SEN01820-00 30 Testing and adjusting
40 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
D475A, D475ASD-5E0 41
SEN01820-00 30 Testing and adjusting
42 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-00
Pm clinic T D475A-5E0 #
Serial number
Undercarriage check sheet T D475ASD-5E0 #
a Measurement results
Pass Fail
Left side of
machine
Right side of
machine
D475A, D475ASD-5E0 43
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
44 D475A, D475ASD-5E0
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
IMPACT
D475A, D475ASD-5E0 45
SEN01821-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table and fuse locations ............................................................................................................. 2
Failure code table................................................................................................................................. 2
Fuse locations .................................................................................................................................... 12
D475A, D475ASD-5E0 1
SEN01821-00 40 Troubleshooting
B@CHZG HSS charge oil pressure Oil pressure reduction MON — Mechanical system
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
CA111 Engine controller (Left bank) Internal abnormality ENG CALL E04 Electrical system
CB111 Engine controller (Right bank) Internal abnormality ENG CALL E04 Electrical system
Engine NE/Bkup speed sensor
CA115 Speed sensor signal error ENG CALL E04 Electrical system
abnormality (Left bank)
Engine NE/Bkup speed sensor
CB115 Speed sensor signal error ENG CALL E04 Electrical system
abnormality (Right bank)
Charge pressure sensor abnormally
CA122 High voltage detection ENG CALL E03 Electrical system
high level (Only left bank)
Charge pressure sensor abnormally
CA123 Low voltage detection ENG CALL E03 Electrical system
low level (Only left bank)
Decelerator pedal sensor abnormally
CA131 High voltage detection ENG CALL E03 Electrical system
high level (Only left bank)
Decelerator pedal sensor abnormally
CA132 Low voltage detection ENG CALL E03 Electrical system
low level (Only left bank)
Oil pressure sensor abnormally high
CA135 High voltage detection ENG CALL E02 Electrical system
level (Only left bank)
Oil pressure sensor abnormally low
CA141 Low voltage detection ENG CALL E02 Electrical system
level (Only left bank)
Coolant temperature sensor abnor-
CA144 High voltage detection ENG CALL E02 Electrical system
mally high level (Only left bank)
Coolant temperature sensor abnor-
CA145 Low voltage detection ENG CALL E02 Electrical system
mally low level (Only left bank)
Charge temperature sensor abnor-
CA153 High voltage detection ENG CALL E01 Electrical system
mally high level (Only left bank)
Charge temperature sensor abnor-
CA154 Low voltage detection ENG CALL E01 Electrical system
mally low level (Only left bank)
Sensor power supply (2) abnormally
CA187 Low voltage detection ENG CALL E03 Electrical system
low level (Left bank) Troubleshoot-
Sensor power supply (2) abnormally ing by failure
CB187 Low voltage detection ENG CALL E03 Electrical system
low level (Right bank) code (Display
Engine oil temperature sensor of code)
CA212 High voltage detection ENG CALL E01 Electrical system
abnormally high level (Only left bank) (Part 2)
Engine oil temperature sensor
CA213 Low voltage detection ENG CALL E01 Electrical system
abnormally low level (Only left bank) SEN01824-00
Ambient temperature sensor abnor-
CA221 High voltage detection ENG CALL E03 Electrical system
mally high level (Only left bank)
Ambient temperature sensor abnor-
CA222 Low voltage detection ENG CALL E03 Electrical system
mally low level (Only left bank)
Sensor power supply (2) abnormally
CA227 High voltage detection ENG CALL E03 Electrical system
high level (Left bank)
Sensor power supply (2) abnormally
CB227 High voltage detection ENG CALL E03 Electrical system
high level (Right bank)
CA234 Engine overspeed (Only left bank) Abnormally high speed ENG — Mechanical system
Ne speed sensor power supply
CA238 Low voltage detection ENG CALL E03 Electrical system
abnormality (Left bank)
Ne speed sensor power supply
CB238 Low voltage detection ENG CALL E03 Electrical system
abnormality (Right bank)
Fuel temperature sensor abnormally
CA263 Abnormally high speed ENG CALL E01 Electrical system
high level (Left bank)
Fuel temperature sensor abnormally
CB263 Abnormally high speed ENG CALL E01 Electrical system
high level (Right bank)
Fuel temperature sensor abnormally
CA265 Low voltage detection ENG CALL E01 Electrical system
low level (Left bank)
Fuel temperature sensor abnormally
CB265 Low voltage detection ENG CALL E01 Electrical system
low level (Right bank)
CA271 PCV1 short circuit (Left bank) Short circuit ENG CALL E03 Electrical system
CB271 PCV1 short circuit (Right bank) Short circuit ENG CALL E03 Electrical system
CA272 PCV1 disconnection (Left bank) Disconnection ENG CALL E03 Electrical system
CB272 PCV1 disconnection (Right bank) Disconnection ENG CALL E03 Electrical system
D475A, D475ASD-5E0 3
SEN01821-00 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
CA273 PCV2 short circuit (Left bank) Short circuit ENG CALL E03 Electrical system Troubleshoot-
ing by failure
CB273 PCV2 short circuit (Right bank) Short circuit ENG CALL E03 Electrical system code (Display
of code)
CA274 PCV2 disconnection (Left bank) Disconnection ENG CALL E03 Electrical system (Part 2)
CB274 PCV2 disconnection (Right bank) Disconnection ENG CALL E03 Electrical system
SEN01824-00
Injector #1 (L/B#1) system discon-
CA322 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #5 (L/B#5) system discon-
CA323 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #3 (L/B#3) system discon-
CA324 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #6 (L/B#6) system discon-
CA325 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #2 (L/B#2) system discon-
CA331 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #4 (L/B#4) system discon-
CA332 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Engine controller data mismatch
CA342 Mismatch ENG CALL E03 Electrical system
(Left bank)
Engine controller data mismatch
CB342 Mismatch ENG CALL E03 Electrical system
(Right bank)
Injector drive circuit abnormality
CA351 Circuit abnormality ENG CALL E03 Electrical system
(Left bank)
Injector drive circuit abnormality
CB351 Circuit abnormality ENG CALL E03 Electrical system
(Right bank)
Sensor power supply (1) abnormally
CA352 Low voltage detection ENG CALL E03 Electrical system
low level (Left bank)
Sensor power supply (1) abnormally
CB352 Low voltage detection ENG CALL E03 Electrical system
low level (Right bank)
Sensor power supply (1) abnormally
CA386 High voltage detection ENG CALL E03 Electrical system
high level (Left bank)
Troubleshoot-
Sensor power supply (1) abnormally
CB386 High voltage detection ENG CALL E03 Electrical system ing by failure
high level (Right bank)
code (Display
Power supply voltage abnormally low
CA441 Low voltage detection ENG CALL E04 Electrical system of code)
level (Left bank)
(Part 3)
Power supply voltage abnormally low
CB441 Low voltage detection ENG CALL E04 Electrical system
level (Right bank)
SEN01825-00
Power supply voltage abnormally
CA442 High voltage detection ENG CALL E04 Electrical system
high level (Left bank)
Power supply voltage abnormally
CB442 High voltage detection ENG CALL E04 Electrical system
high level (Right bank)
Common rail abnormally high pres- Abnormally high pressure
CA449 ENG CALL E03 Electrical system
sure (2) (Left bank) occurrence
Common rail abnormally high pres- Abnormally high pressure
CB449 ENG CALL E03 Electrical system
sure (2) (Right bank) occurrence
Common rail pressure sensor abnor-
CA451 High voltage detection ENG CALL E03 Electrical system
mally high level (Left bank)
Common rail pressure sensor abnor-
CB451 High voltage detection ENG CALL E03 Electrical system
mally high level (Right bank)
Common rail pressure sensor abnor-
CA452 Low voltage detection ENG CALL E03 Electrical system
mally low level (Left bank)
Common rail pressure sensor abnor-
CB452 Low voltage detection ENG CALL E03 Electrical system
mally low level (Right bank)
Common rail abnormally high pres- Abnormally high pressure
CA553 ENG E02 Electrical system
sure (1) (Left bank) occurrence
Common rail abnormally high pres- Abnormally high pressure
CB553 ENG E02 Electrical system
sure (1) (Right bank) occurrence
Common rail pressure sensor in-
CA554 In-range error occurrence ENG CALL E03 Electrical system
range error (Left bank)
Common rail pressure sensor in-
CB554 In-range error occurrence ENG CALL E03 Electrical system
range error (Right bank)
Supply pump low pressure (1)
CA559 Low pressure occurrence ENG E02 Electrical system
(Left bank)
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
Supply pump low pressure (1)
CB559 Low pressure occurrence ENG E02 Electrical system
(Right bank)
Engine Ne speed sensor abnormality
CA689 Signal error ENG CALL E03 Electrical system
(Left bank)
Troubleshoot-
Engine Ne speed sensor abnormality
CB689 Signal error ENG CALL E03 Electrical system ing by failure
(Right bank)
code (Display
Intake air temperature sensor abnor-
CA691 High voltage detection ENG E01 Electrical system of code)
mally high level (Only left bank)
(Part 3)
Intake air temperature sensor abnor-
CA692 Low voltage detection ENG E01 Electrical system
mally low level (Only left bank)
SEN01825-00
Engine Bkup speed sensor abnormal
CA731 Phase error ENG CALL E03 Electrical system
phase (Left bank)
Engine Bkup speed sensor abnormal
CB731 Phase error ENG CALL E03 Electrical system
phase (Right bank)
Engine controller all data loss
CA757 All data loss ENG CALL E04 Electrical system
(Left bank)
Engine controller all data loss
CB757 All data loss ENG CALL E04 Electrical system
(Right bank)
Engine Bkup speed sensor abnor-
CA778 Bkup signal error ENG CALL E03 Electrical system
mality (Left bank)
Engine Bkup speed sensor abnor-
CB778 Bkup signal error ENG CALL E03 Electrical system
mality (Right bank)
Inter-multicontroller communication
CA781 Communication error ENG CALL E03 Electrical system
error (Left bank)
Inter-multicontroller communication
CB781 Communication error ENG CALL E03 Electrical system
error (Right bank)
Multicontroller distinction wiring har-
CA1257 Distinction error ENG CALL E03 Electrical system
ness key error (Left bank)
Multicontroller distinction wiring har-
CB1257 Distinction error ENG CALL E03 Electrical system
ness key error (Right bank)
Injector #7 (R/B#1) system discon-
CB1548 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #8 (R/B#2) system discon-
CB1549 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #10 (R/B#4) system discon-
CB1551 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #11 (R/B#5) system discon- Troubleshoot-
CB1552 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank) ing by failure
Injector #12 (R/B#6) system discon- code (Display
CB1553 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank) of code)
Injector #19 (R/B#3) system discon- (Part 4)
CB1622 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
CA1633 KOMNET abnormality (Left bank) Communication error ENG CALL E03 Electrical system SEN01826-00
Decelerator pedal sensor power sup-
CA2185 ply abnormally high level (Only left High voltage detection ENG CALL E03 Electrical system
bank)
Decelerator pedal sensor power sup-
CA2186 ply abnormally low level (Only left Low voltage detection ENG CALL E03 Electrical system
bank)
Supply pump low pressure (2)
CA2249 Low pressure occurrence ENG CALL E03 Electrical system
(Left bank)
Supply pump low pressure (2)
CB2249 Low pressure occurrence ENG CALL E03 Electrical system
(Right bank)
D110KA Battery relay Disconnection S/T — Electrical system
D130KB Neutral safety relay Short circuit T/M E02 Electrical system
D161KB Backup alarm relay Short circuit T/M E01 Electrical system
D475A, D475ASD-5E0 5
SEN01821-00 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
Engine controller ACC signal cut
D190KA Disconnection S/T — Electrical system
relay
Engine controller ACC signal cut
D190KB Short circuit S/T — Electrical system
relay
D5ZRKA Snap shot switch Disconnection S/T — Electrical system
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DBBQKR
VHMS KOM-NET Communication error VHMS — —
[n8 o 02]
VHMS controller CAN communica-
dbBRKR Communication error S/T — Electrical system
tion
DD12KA Shift-up switch Disconnection T/M E02 Electrical system
DD14KA Parking brake lever switch Disconnection T/M CALL E03 Electrical system
DD14KB Parking brake lever switch Short circuit T/M CALL E03 Electrical system
DDN7KB Blade pitch switch Short circuit T/M E02 Electrical system
DDN9KB Blade tilt switch Short circuit T/M E01 Electrical system
DDNALD Blade lift raise full oil pressure switch Switch ON for long time T/M — Electrical system
DDNBLD Ripper lift raise oil pressure switch Switch ON for long time T/M — Electrical system
DDNCLD Ripper lift lower oil pressure switch Switch ON for long time T/M — Electrical system
DDNDLD Ripper tilt in oil pressure switch Switch ON for long time T/M — Electrical system
DDNELD Ripper tilt back oil pressure switch Switch ON for long time T/M — Electrical system
Ripper lift lower full oil pressure
DDNFLD Switch ON for long time T/M — Electrical system
switch
DDQ2KA Parking brake lever switch Disconnection S/T CALL E03 Electrical system
DDQ2KB Parking brake lever switch Short circuit S/T CALL E03 Electrical system
DDQ2L4 Parking brake lever switch (S/T) Signal disagreement S/T CALL E03 Electrical system
dDQ2L4 Parking brake lever switch (T/M) Signal disagreement T/M CALL E03 Electrical system
DGT1KA Power train oil temperature sensor Disconnection MON E01 Electrical system SEN01828-00
DGT1KX Power train oil temperature sensor Out of input signal range MON E01 Electrical system
DGT5KA Left bank exhaust temperature sen-
Disconnection VHMS — —
[n3 o 12] sor system (Front)
dGT5KA Left bank exhaust temperature sen-
Disconnection VHMS — —
[n3 o 22] sor system (Rear)
DGT5KB Left bank exhaust temperature sen-
Short circuit VHMS — —
[n3 o 11] sor system (Front)
D475A, D475ASD-5E0 7
SEN01821-00 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
dGT5KB Left bank exhaust temperature sen-
Short circuit VHMS — —
[n3 o 21] sor system (Rear)
DGT6KA Right bank exhaust temperature sen-
Disconnection VHMS — —
[n3 o 24] sor system (Front)
dGT6KA Right bank exhaust temperature sen-
Disconnection VHMS — —
[n3 o 26] sor system (Rear)
DGT6KB Right bank exhaust temperature sen-
Short circuit VHMS — —
[n3 o 23] sor system (Front)
dGT6KB Right bank exhaust temperature sen-
Short circuit VHMS — —
[n3 o 25] sor system (Rear)
Work equipment pump oil pressure
DH22KA Disconnection T/M — Electrical system
sensor (F)
Work equipment pump oil pressure
DH22KB Short circuit T/M — Electrical system
sensor (F)
Work equipment pump oil pressure
DH23KA Disconnection T/M — Electrical system
sensor (R)
Work equipment pump oil pressure
DH23KB Short circuit T/M — Electrical system
sensor (R)
DHE5KB
Blow-by pressure sensor system Disconnection VHMS — —
[n3 o 32]
Troubleshoot-
DHE5KY ing by failure
Blow-by pressure sensor system Hot short VHMS — —
[n3 o 31] code (Display
DHT3KX of code)
Transmission oil pressure sensor Out of input signal range VHMS — —
[n6 o 14] (Part 6)
DK01KA Left yoke angle sensor Disconnection T/M E02 Electrical system
SEN01828-00
DK01KB Left yoke angle sensor Short circuit T/M E02 Electrical system
DK03KA Right yoke angle sensor Disconnection T/M E02 Electrical system
DK03KB Right yoke angle sensor Short circuit T/M E02 Electrical system
DK10KA Fuel control dial Disconnection S/T CALL E03 Electrical system
DK10KB Fuel control dial Short circuit S/T CALL E03 Electrical system
DK30KA Steering potentiometer (1) Disconnection S/T CALL E03 Electrical system
DK30KB Steering potentiometer (1) Short circuit S/T CALL E03 Electrical system
DK30KX Steering potentiometer (1) Out of input signal range S/T CALL E04 Electrical system
DK30KZ Steering potentiometer (1) Disconnection or short circuit S/T CALL E04 Electrical system
DK30L8 Steering potentiometer (1) Analog signal disagreement S/T CALL E03 Electrical system
DK31KA Steering potentiometer (2) Disconnection S/T CALL E03 Electrical system
DK31KB Steering potentiometer (2) Short circuit S/T CALL E03 Electrical system
DK40KB Brake potentiometer Short circuit S/T CALL E03 Electrical system
DK55KX Forward-reverse potentiometer Out of input signal range T/M CALL E04 Electrical system
DK55KZ Forward-reverse potentiometer Disconnection or short circuit T/M CALL E04 Electrical system
Troubleshoot-
DK55L8 Forward-reverse potentiometer Analog signal disagreement T/M CALL E03 Electrical system ing by failure
code (Display
DK56KA Forward-reverse potentiometer (1) Disconnection T/M CALL E03 Electrical system of code)
(Part 7)
DK56KB Forward-reverse potentiometer (1) Short circuit T/M CALL E03 Electrical system
DK57KA Forward-reverse potentiometer (2) Disconnection T/M CALL E03 Electrical system SEN01829-00
DK57KB Forward-reverse potentiometer (2) Short circuit T/M CALL E03 Electrical system
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DKH1KA Pitch angle sensor Disconnection S/T CALL E03 Electrical system
DKH1KB Pitch angle sensor Short circuit S/T CALL E03 Electrical system
DKH1KX Pitch angle sensor Out of input signal range S/T E01 Electrical system
Torque converter output speed sen-
DLF1KA Disconnection T/M — Electrical system
sor
DLT3KA Transmission output speed sensor Disconnection T/M E01 Electrical system
dLT3KA Transmission output speed sensor Disconnection T/M E01 Electrical system
DLT3KB Transmission output speed sensor Short circuit T/M E01 Electrical system
DW55KA Blade pitch back solenoid Disconnection T/M CALL E03 Electrical system
DW55KB Blade pitch back solenoid Short circuit T/M CALL E03 Electrical system
DW56KA Blade pitch dump solenoid Disconnection T/M CALL E03 Electrical system
DW56KB Blade pitch dump solenoid Short circuit T/M CALL E03 Electrical system
DW56KY Blade pitch dump solenoid Hot short T/M CALL E03 Electrical system
DW57KA Left tilt limit solenoid Disconnection T/M E02 Electrical system
DW57KB Left tilt limit solenoid Short circuit T/M E02 Electrical system
DW57KY Left tilt limit solenoid Hot short T/M E02 Electrical system
DW58KA Right tilt limit solenoid Disconnection T/M E02 Electrical system
DW58KB Right tilt limit solenoid Short circuit T/M E02 Electrical system Troubleshoot-
ing by failure
DW58KY Right tilt limit solenoid Hot short T/M E02 Electrical system code (Display
of code)
DW59KA Dual tilt selector solenoid Disconnection T/M E01 Electrical system
(Part 7)
DW59KB Dual tilt selector solenoid Short circuit T/M E01 Electrical system
SEN01829-00
DW59KY Dual tilt selector solenoid Hot short T/M E01 Electrical system
DW5AKA Blade pitch selector solenoid Disconnection T/M E02 Electrical system
DW5AKB Blade pitch selector solenoid Short circuit T/M E02 Electrical system
DW5AKY Blade pitch selector solenoid Hot short T/M E02 Electrical system
Blade pitch dump solenoid
DW5DKA Disconnection T/M CALL E03 Electrical system
(Superdozer specification)
Blade pitch dump solenoid
DW5DKB Short circuit T/M CALL E03 Electrical system
(Superdozer specification)
Blade pitch dump solenoid
DW5DKY Hot short T/M CALL E03 Electrical system
(Superdozer specification)
DW7BKA Fan reverse solenoid Disconnection T/M E01 Electrical system
DW7BKB Fan reverse solenoid Short circuit T/M E01 Electrical system
DW7BKY Fan reverse solenoid Hot short T/M E01 Electrical system
DWJ0KB Pump merge-divider solenoid Short circuit S/T E02 Electrical system
DWJ0KY Pump merge-divider solenoid Hot short S/T E02 Electrical system
DWN3KA Sudden stop prevention solenoid Disconnection S/T CALL E04 Electrical system
DWN3KB Sudden stop prevention solenoid Short circuit S/T CALL E04 Electrical system
DWN3KY Sudden stop prevention solenoid Hot short S/T CALL E04 Electrical system
DWN5KA Fan pump solenoid (1) Disconnection T/M E01 Electrical system
D475A, D475ASD-5E0 9
SEN01821-00 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DWN5KB Fan pump solenoid (1) Short circuit T/M E01 Electrical system
Troubleshoot-
DWN5KY Fan pump solenoid (1) Hot short T/M E02 Electrical system ing by failure
code (Display
DWNCKA Fan pump solenoid (2) Disconnection T/M E01 Electrical system of code)
(Part 7)
DWNCKB Fan pump solenoid (2) Short circuit T/M E01 Electrical system
SEN01829-00
DWNCKY Fan pump solenoid (2) Hot short T/M E02 Electrical system
DXH1KY Lockup solenoid Hot short T/M CALL E03 Electrical system
DXH4KA 1st clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH4KB 1st clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH4KY 1st clutch ECMV Hot short T/M CALL E03 Electrical system
DXH5KA 2nd clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH5KB 2nd clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH5KY 2nd clutch ECMV Hot short T/M CALL E03 Electrical system
DXH6KA 3rd clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH6KB 3rd clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH6KY 3rd clutch ECMV Hot short T/M CALL E03 Electrical system
DXH7KA Reverse clutch ECMV Disconnection T/M CALL E03 Electrical system Troubleshoot-
ing by failure
DXH7KB Reverse clutch ECMV Short circuit T/M CALL E03 Electrical system code (Display
of code)
DXH7KY Reverse clutch ECMV Hot short T/M CALL E03 Electrical system (Part 8)
DXH8KA Forward clutch ECMV Disconnection T/M CALL E03 Electrical system
SEN01830-00
DXH8KB Forward clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH8KY Forward clutch ECMV Hot short T/M CALL E03 Electrical system
DXH9KA Right steering clutch ECMV Disconnection S/T CALL E03 Electrical system
DXH9KB Right steering clutch ECMV Short circuit S/T CALL E03 Electrical system
DXH9KY Right steering clutch ECMV Hot short S/T CALL E04 Electrical system
DXHAKA Left steering clutch ECMV Disconnection S/T CALL E03 Electrical system
DXHAKB Left steering clutch ECMV Short circuit S/T CALL E03 Electrical system
DXHAKY Left steering clutch ECMV Hot short S/T CALL E04 Electrical system
DXHBKA Right brake ECMV Disconnection S/T CALL E04 Electrical system
DXHBKB Right brake ECMV Short circuit S/T CALL E04 Electrical system
DXHBKY Right brake ECMV Hot short S/T CALL E04 Electrical system
DXHCKA Left brake ECMV Disconnection S/T CALL E04 Electrical system
DXHCKB Left brake ECMV Short circuit S/T CALL E04 Electrical system
DXHCKY Left brake ECMV Hot short S/T CALL E04 Electrical system
F@BBZL Abnormality high pressure
Engine blow-by pressure sensor VHMS — —
[n3 o 38] occurrence
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
F@BYNS Left front exhaust temperature sen- Exhaust temperature abnormal
VHMS — —
[n3 o 61] sor (1) rise
f@BYNS Left rear exhaust temperature sensor Exhaust temperature abnormal
VHMS — —
[n3 o 71] (1) rise
F@BZNS Right front exhaust temperature sen- Exhaust temperature abnormal
VHMS — — Troubleshoot-
[n3 o 81] sor (1) rise
ing by failure
f@BZNS Right rear exhaust temperature sen- Exhaust temperature abnormal
VHMS — — code (Display
[n3 o 91] sor (1) rise
of code)
F@BYNR Left front exhaust temperature sen- Exhaust temperature abnormal
VHMS — — (Part 8)
[n3 o 62] sor (2) rise
f@BYNR Left rear exhaust temperature sensor Exhaust temperature abnormal SEN01830-00
VHMS — —
[n3 o 72] (2) rise
F@BZNR Right front exhaust temperature sen- Exhaust temperature abnormal
VHMS — —
[n3 o 82] sor (2) rise
f@BZNR Right rear exhaust temperature sen- Exhaust temperature abnormal
VHMS — —
[n3 o 92] sor (2) rise
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the monitor panel in charge of the system check.
MON : Monitor panel
ENG : Engine controller
T/M : Transmission controller
S/T : Steering controller
VHMS : VHMS controller
a 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).
a The history classification column shows in which system each failure is classified, the electrical equip-
ment system or mechanical equipment system, when it is recorded in the failure history.
Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS
controller, however, they are not recorded in the fault history. The 4-letter codes in [ ] among the VHMS
codes are the failure codes displayed on the 7-segment LED of the VHMS controller (They are divided
into 2 2-letter codes).
a Blinking and lighting of failure code
q Blinking : The trouble has not been repaired.
q Lighting : The trouble has been repaired.
D475A, D475ASD-5E0 11
SEN01821-00 40 Troubleshooting
Fuse locations 1
Connection table of fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
D475A, D475ASD-5E0 13
SEN01821-00 40 Troubleshooting
Circuit breaker
No Connector No. Capacity (A) Circuit Remarks
1 F30 30 Cab unswitched power supply
2 F96 105 Main power supply
Electrical intake air heater main power supply
3 B105H2L 105 Installed in battery box at
(Right bank)
left of operator's seat
4 B105H1L 105 Electrical intake air heater main power supply
6 B7L 30 Engine controller unswitched power supply
7 B8L 30 Engine controller unswitched power supply
8 CB1 20 Steering controller
9 CB2 20 Monitor panel
10 CB3 20 Transmission controller Installed in console box at
11 CB4 20 Air conditioner left of operator's seat
12 CB5 20 Headlamp
13 CB6 20 Starting switch unswitched power supply
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-00
D475A, D475ASD-5E0 15
SEN01822-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Checks before troubleshooting ............................................................................................................ 4
Classification and procedures of troubleshooting ................................................................................ 5
Contents of troubleshooting table......................................................................................................... 8
Wiring table for connector pin numbers ............................................................................................. 10
T-adapter box and T-adapter table ..................................................................................................... 39
D475A, D475ASD-5E0 1
SEN01822-00 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent 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 symp-
toms.
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-00
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Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check fuel filter — Replace
Checks before starting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-00
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
D475A, D475ASD-5E0 5
SEN01822-00 40 Troubleshooting
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action code or error code
1 Action codes are displayed on the monitor panel Check the error code
2 Error codes are displayed in the error code display mode q
Phenomena related to engine
3 The engine does not start easily (It always takes time to start) S-1
4 The engine does not crank E-1 S-2a)
The engine cranks but exhaust smoke does
5 The engine does not S-2b)
not come out
start
Exhaust smoke comes out but the engine does
6 S-2c)
not start
The engine speed does not rise sharply (Follow-up performance is
7 S-3
low)
8 The engine stops during operation S-4
9 Engine rotation is abnormal (The engine hunts) S-5
10 Output is insufficient or power is low S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much or exhaust gas color is bad S-8
13 Oil becomes dirty quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (or it blows back or reduces) S-11
16 The engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
17 Oil level rises S-13
18 Coolant temperature rises too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 The preheater does not operate E-2
Phenomena related to power train
22 Power is low (Drawbar pull is low) H-1 S-6
23 The machine does not travel (in the 2nd or 3rd gear speed) H-2
24 The machine does not travel start in any gear speed H-3
25 The machine can travel in only forward or reverse direction H-4
Time lag is large in shifting the gear speed or changing the travel
26 H-5
direction
27 The machine cannot be steered H-6
28 The machine can be steered in only 1 direction H-7
29 The machine overruns when steered H-8
30 The brake does not operate H-9
31 The torque converter is not locked up H-10
32 The torque converter oil is overheated H-11
Phenomena related to work equipment
33 Speed of the whole work equipment is low H-12
34 Any part of the equipment does not move H-13
35 Blade lifting speed or power is low H-14
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-00
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
36 Blade tilting speed or power is low H-15
37 Ripper lifting speed or power is low H-16
38 Ripper tilting speed or power is low H-17
39 Hydraulic drift of blade lifting is large H-18
40 Hydraulic drift of blade tilting is large H-19
41 Hydraulic drift of ripper lifting is large H-20
The ripper pin puller cylinder does not operate (if the giant ripper is
42 H-21
installed)
43 The blade does not pitch (if the dual tilt system installed) H-22
44 Abnormal sound comes out from around hydraulic pump H-23
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8 D475A, D475ASD-5E0
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40 Troubleshooting SEN01822-00
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
D475A, D475ASD-5E0 39
SEN01822-00 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
D475A, D475ASD-5E0 41
SEN01823-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
Failure code [1500L0] Transmission clutch: Dual engagement ........................................................... 3
Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON .......... 4
Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF.......... 5
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON.............................. 6
Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF ......... 7
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON................... 8
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF .................. 9
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON................ 10
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF ................11
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON................ 12
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF ............... 13
Failure code [1800MW] Power train clutch: Slip ................................................................................ 14
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON.............. 15
D475A, D475ASD-5E0 1
SEN01823-00 40 Troubleshooting
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF ............. 16
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON ................ 17
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF ................ 18
Failure code [2300NR] Brake thermal load: Abnormal heating .......................................................... 19
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON .............. 20
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF.............. 21
Failure code [2301NR] Right steering brake thermal load: Abnormal heating ................................... 22
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON................. 23
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF ................ 24
Failure code [2302NR] Left steering brake thermal load: Abnormal heating...................................... 25
Failure code [AA10NX] Air cleaner: Clogging .................................................................................... 26
Failure code [AB00MA] Battery charge abnormality: Malfunction ...................................................... 27
Failure code [B@BAZG] Engine oil: Oil pressure too low .................................................................. 28
Failure code [B@BAZK] Engine oil: Oil level reduction...................................................................... 29
Failure code [B@BCNS] Radiator coolant: Overheat......................................................................... 30
Failure code [B@BCZK] Radiator coolant: Level too low................................................................... 31
Failure code [B@CENS] Power train oil: Overheat ............................................................................ 32
Failure code [B@CHZG] Power train oil: Low oil pressure ................................................................ 33
Failure code [B@HANS] Hydraulic oil: Overheat ............................................................................... 34
Failure code [B@HAZK] Hydraulic oil: Level reduction ...................................................................... 35
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40 Troubleshooting SEN01823-00
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4 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
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Failure code [15SBL1] Reverse clutch: Command current OFF and fill
signal ON 1
Action code Failure code Symptom of Reverse clutch: Command current OFF and fill signal ON
CALL E03 15SBL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
Controller's
• Becomes neutral (N) at forward operation.
action
• Limits operation of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing failure code: Engine start + Neutral running
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
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Failure code [15SEL1] 1st clutch oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of 1st clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SEL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, running is limited to F1 and R1.
machine
• The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing failure code: Engine start + F1 or R1 o Neutral running
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
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SEN01823-00 40 Troubleshooting
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of 2nd clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SFL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, running is limited to F2 and R2.
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing failure code: Engine start + F2 or R2 running o Neutral running
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
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Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of 3rd clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SGL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, running is limited to F3 and R3.
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing failure code: Engine start + F3 or R3 running o Neutral running
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
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14 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
Failure code [2201L1] Right clutch oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of Right clutch oil pressure: Command current OFF and fill signal OFF
CALL E04 2201L1 failure (Steering controller system)
Failure content • The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine, transmission, and brake.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, it never runs.
machine
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring
General mode.
information (Code 31521: Steering fill switch input state)
• Method of reproducing failure code: Engine start
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16 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
Failure code [2202L1] Left clutch oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of Left clutch oil pressure: Command current OFF and fill signal ON
CALL E04 2202L1 failure (Steering controller system)
Failure content • The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine, transmission, and brake.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, it never runs.
machine
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring
General
mode. (Code 31521: Steering fill switch input state)
information
• Method of reproducing failure code: Engine start
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18 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed)
standard values Defective steering control-
when normal 2 When the operation in cause 1 is not performed
ler
D475A, D475ASD-5E0 19
SEN01823-00 40 Troubleshooting
Failure code [2301L1] Right brake oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of Right brake oil pressure: Command current OFF and fill signal ON
CALL E04 2301L1 failure (Steering controller system)
Failure content • The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine, transmission, and brake.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, it never runs.
machine
• The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring
General mode.
information (Code 31521: Steering fill switch input state)
• Method of reproducing failure code: Engine start
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
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22 D475A, D475ASD-5E0
40 Troubleshooting SEN01823-00
Failure code [2302L1] Left brake oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of Left brake oil pressure: Command current OFF and fill signal ON
CALL E04 2302L1 failure (Steering controller system)
Failure content • The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
action • Limits operation of engine, transmission, and brake.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, it never runs.
machine
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring
General
mode. (Code 31521: Steering fill switch input state)
information
• Method of reproducing failure code: Engine start
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SEN01824-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 2
Troubleshooting by failure code (Display of code), Part 2 .............................................................................. 4
Failure code [CA111] Engine controller (Left bank): Internal abnormality ............................................ 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality.......................................... 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal................................................................................................... 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal................................................................................................... 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ........................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 12
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank):
High voltage detection ............................................................................................................. 13
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Failure code [CA132] Decelerator pedal sensor too low (At left bank only):
Excessively low voltage detected............................................................................................. 15
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Excessively high voltage detected ........................................................................................... 16
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Excessively low voltage detected............................................................................................. 18
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ...... 20
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Excessively low voltage detected............................................................................................. 22
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Excessively high voltage detected ........................................................................................... 24
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Excessively low voltage detected............................................................................................. 26
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 29
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
High voltage detection.............................................................................................................. 30
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Low voltage detection .............................................................................................................. 31
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Excessively high voltage detected ........................................................................................... 32
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Excessively low voltage detected............................................................................................. 34
Failure code [CA227] Sensor power source 2 too high (At left bank):
Excessively high voltage detected ........................................................................................... 36
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
High voltage detection.............................................................................................................. 38
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ...................... 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Excessively low voltage detected............................................................................................. 42
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Excessively low voltage detected............................................................................................. 44
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Excessively high voltage detected ........................................................................................... 46
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Excessively high voltage detected ........................................................................................... 48
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 49
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 49
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit..................................................... 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit .................................................. 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ............................................. 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ........................................... 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit..................................................... 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit .................................................. 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ............................................. 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ........................................... 57
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 3
SEN01824-00 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 5
SEN01824-00 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 7
SEN01824-00 40 Troubleshooting
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At
left bank): Abnormal speed sensor signal 1
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At left bank): Abnor-
CALL E04 CA115 failure mal speed sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At
right bank): Abnormal speed sensor signal 1
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At right bank): Abnor-
CALL E04 CB115 failure mal speed sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information
D475A, D475ASD-5E0 9
SEN01824-00 40 Troubleshooting
Failure code [CA122] Charge pressure sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Symptom of Charge pressure sensor too high (At left bank only): Excessively high
CALL E03 CA122 failure voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 11
SEN01824-00 40 Troubleshooting
Failure code [CA123] Charge pressure sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom of Charge pressure sensor too low (At left bank only): Excessively low
CALL E03 CA123 failure voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
when normal
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 13
SEN01824-00 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Failure code [CA132] Decelerator pedal sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom of Decelerator pedal sensor too low: excessively low voltage detected
CALL E03 CA132 failure (At left bank only) (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of decelerator pedal.
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller oper-
action
ates with 100% value.
• Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Engine speed cannot be controlled by decelerator pedal.
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
General
(Code: 31703 Decelerator voltage)
information
• Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the Defective decelerator
If failure code [CA2186] is displayed at the same time, carry out trou-
standard values 1 pedal sensor power sup-
when normal bleshooting for it first.
ply circuit
D475A, D475ASD-5E0 15
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Failure code [CA135] Oil pressure sensor too high (At left bank only):
Excessively high voltage detected 1
Action code Failure code Symptom of Oil pressure sensor too high (At left bank only): Excessively high volt-
CALL E02 CA135 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 17
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Failure code [CA141] Oil pressure sensor too low (At left bank only):
Excessively low voltage detected 1
Action code Failure code Symptom of Oil pressure sensor too low (At left bank only): Excessively low volt-
CALL E03 CA132 failure age detected (At left bank only) (Engine controller system)
Failure content • Excessively low voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
when normal
18 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 19
SEN01824-00 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 21
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Failure code [CA145] Coolant temperature sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom of Coolant temperature sensor too low (At left bank only): Excessively
E01 CA145 failure low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Exhaust gas color becomes white.
machine
General • The signal voltage of coolant temperature sensor can be checked in monitoring function.
information (Code: 04105 Coolant temperature sensor voltage)
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 23
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Failure code [CA153] Charge temperature sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Symptom of Charge temperature sensor too high (At left bank only): Excessively
E01 CA153 failure high voltage detected. (Engine controller system)
• Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
appear on • Exhaust gas color becomes white.
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 25
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Failure code [CA154] Charge temperature sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom of Charge temperature sensor too low (At left bank only): Excessively
E01 CA154 failure low voltage detected (Engine controller system)
• Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
appear on • Exhaust gas color becomes white.
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 27
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Failure code [CA187] Sensor power supply (2) abnormally low level
(Left bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Left bank): Low voltage
CALL E03 CA187 failure detection (Engine controller system)
Failure content • Low voltage was detected in sensor power supply (2) (5 V) circuit.
• Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and
continues operation.
• Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues opera-
Controller's
tion.
action
• Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation.
• Bkup sensor operates with Ne speed sensor signal.
• Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA227].
when normal
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Failure code [CB187] Sensor power supply (2) abnormally low level
(Right bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low volt-
CALL E03 CA187 failure age detection (Engine controller system)
Failure content • Low voltage was detected in sensor power supply (2) (5 V) circuit.
Controller's • Bkup sensor operates with Ne speed sensor signal.
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB227].
when normal
D475A, D475ASD-5E0 29
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30 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA212].
when normal
D475A, D475ASD-5E0 31
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Failure code [CA221] Atmospheric pressure sensor too high (At left
bank only): Excessively high voltage detected 1
Action code Failure code Symptom of Atmospheric pressure sensor too high (At left bank only): Excessively
CALL E03 CA213 failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
32 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 33
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Failure code [CA222] Atmospheric pressure sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively
CALL E03 CA222 failure low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of failure code [CA221].
when normal
34 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 35
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Failure code [CA227] Sensor power source (2) too high (At left bank):
Excessively high voltage detected 1
Action code Failure code Symptom of Sensor power source (2) too high (At left bank): Excessively high volt-
CALL E03 CA227 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected in sensor power source (2) (5V) circuit.
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
Controller's
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
action
• Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
• Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
General
information
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 37
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Failure code [CB227] Sensor power supply (2) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally high level (Right bank): High volt-
CALL E03 CB227 failure age detection (Engine controller system)
Failure content • High voltage was detected in sensor power supply (2) (5 V) circuit.
Controller's
• Bkup speed sensor operates with Ne speed sensor signal.
action
Symptoms that
appear on • Output lowers.
machine
General
information
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Circuit diagram related to sensor power source (2) (At right bank)
D475A, D475ASD-5E0 39
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Failure code [CA234] Engine over speed (At left bank only): Excessively
high speed 1
Action code Failure code Symptom of Engine over speed (At left bank only): Excessively high speed
— CA234 failure (Engine controller system)
• The engine speed exceeds upper control limit speed.
Failure content
• Flashes warning lamp and turns on alarm buzzer.
Controller's
• Stops operation of injector until the engine speed drops to the normal speed.
action
Symptoms that
appear on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
General
(Code: 01000 Engine speed)
information
• Duplication of failure code: Start engine and operate at high idle.
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 41
SEN01824-00 40 Troubleshooting
Failure code [CA238] Abnormal power source for Ne speed sensor (At
left bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At left bank only):
CALL E03 CA238 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 43
SEN01824-00 40 Troubleshooting
Failure code [CB238] Abnormal power source for Ne speed sensor (At
right bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At right bank only):
CALL E03 CB238 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 45
SEN01824-00 40 Troubleshooting
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Excessively high voltage detected 1
Action code Failure code Symptom of Fuel temperature sensor too high (At left bank): Excessively high volt-
E01 CA263 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
• Operates with a fixed fuel temperature (95°C).
action
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 47
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Failure code [CB263] Fuel temperature sensor too high (At right bank):
Excessively high voltage detected 1
Action code Failure code Symptom of Fuel temperature sensor too high (At right bank): Excessively high
E01 CB263 failure voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
• Operates with a fixed fuel temperature (95°C).
action
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA263].
when normal
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB263].
when normal
D475A, D475ASD-5E0 49
SEN01824-00 40 Troubleshooting
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 1
Action code Failure code Symptom of PCV1 short circuit (Left bank): Short circuit
CALL E03 CA271 failure (Engine controller system)
Failure content • Short circuit occurred in supply pump PCV1 circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General
information
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 1
Action code Failure code Symptom of PCV1 short circuit (Right bank): Short circuit
CALL E03 CB271 failure (Engine controller system)
Failure content • Short circuit occurred in supply pump PCV1 circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General
information
D475A, D475ASD-5E0 51
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52 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 53
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Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 1
Action code Failure code Symptom of PCV2 short circuit (Left bank): Short circuit
CALL E03 CA273 failure (Engine controller system)
Failure content • Short circuit occurred in supply pump PCV2 circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General
information
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 1
Action code Failure code Symptom of PCV2 short circuit (Right bank): Short circuit
CALL E03 CB273 failure (Engine controller system)
Failure content • Short circuit occurred in supply pump PCV2 circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General
information
D475A, D475ASD-5E0 55
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56 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-00
D475A, D475ASD-5E0 57
SEN01825-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
Troubleshooting by failure code (Display of code), Part 3 .............................................................................. 4
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank):
Disconnection, short circuit ........................................................................................................ 4
Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (At left bank):
Disconnection, short circuit ........................................................................................................ 6
Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (At left bank):
Disconnection, short circuit ........................................................................................................ 8
Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (At left bank):
Disconnection, short circuit ...................................................................................................... 10
Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (At left bank):
Disconnection, short circuit ...................................................................................................... 12
Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (At left bank):
Disconnection, short circuit ...................................................................................................... 14
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch.................................. 16
D475A, D475ASD-5E0 1
SEN01825-00 40 Troubleshooting
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch ............................... 17
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit ........................ 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality.................. 20
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 22
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 23
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
High voltage detection.............................................................................................................. 24
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank):
High voltage detection.............................................................................................................. 26
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 28
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Low voltage detection .............................................................................................................. 28
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
High voltage detection.............................................................................................................. 29
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
High voltage detection.............................................................................................................. 29
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence...................................................................................... 30
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence...................................................................................... 30
Failure code [CA451] Common rail pressure sensor too high (At left bank):
Excessively high voltage detected ........................................................................................... 32
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
High voltage detection.............................................................................................................. 34
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection............................................................................................. 36
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection............................................................................................. 36
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected......................................................................................... 37
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure
detected ................................................................................................................................... 38
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error.....39
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error ..39
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank):
Loss of pressure feed detected................................................................................................ 40
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank):
Loss of pressure feed detected................................................................................................ 44
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ................ 48
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal.............. 50
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank):
High voltage detection.............................................................................................................. 52
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank):
Low voltage detection .............................................................................................................. 54
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase....55
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase .55
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D475A, D475ASD-5E0 3
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4 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 5
SEN01825-00 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 7
SEN01825-00 40 Troubleshooting
8 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 9
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10 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 11
SEN01825-00 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 13
SEN01825-00 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 15
SEN01825-00 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA111].
when normal
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB111].
when normal
D475A, D475ASD-5E0 17
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Failure code [CA351] Abnormal injector drive circuit (At left bank):
Abnormal circuit 1
Action code Failure code Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit
CALL E03 CA351 failure (Engine controller system)
Failure content • Abnormality has occurred in injector drive circuit.
Controller's • Operates with limited output. (Limits common rail pressure.)
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
General
information
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 19
SEN01825-00 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 21
SEN01825-00 40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level
(Left bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (1) abnormally low level (Left bank): Low volt-
CALL E03 CA352 failure age detection (Engine controller system)
Failure content • Low voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA386].
when normal
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Failure code [CB352] Sensor power supply (1) abnormally low level
(Right bank): Low voltage detection 1
Action code Failure code Sensor power supply (1) abnormally low level (Right bank): Low volt-
Symptom of
age detection
CALL E03 CB352 failure
(Engine controller system)
Failure content • Low voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB386].
when normal
D475A, D475ASD-5E0 23
SEN01825-00 40 Troubleshooting
Failure code [CA386] Sensor power supply (1) abnormally high level
(Left bank): High voltage detection 1
Action code Failure code Symptom of Sensor power supply (1) abnormally high level (Left bank): High volt-
CALL E03 CA386 failure age detection (Engine controller system)
Failure content • High voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 25
SEN01825-00 40 Troubleshooting
Failure code [CB386] Sensor power supply (1) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Sensor power supply (1) abnormally high level (Right bank): High
Symptom of
voltage detection
CALL E03 CB386 failure
(Engine controller system)
Failure content • High voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 27
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Failure code [CA441] Power supply voltage abnormally low level (Left
bank): Low voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally low level (Left bank): Low voltage
CALL E04 CA441 failure detection (Engine controller system)
Failure content • Low voltage was detected in power supply voltage circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA111].
when normal
Failure code [CB441] Power supply voltage abnormally low level (Right
bank): Low voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally low level (Right bank): Low voltage
CALL E04 CB441 failure detection (Engine controller system)
Failure content • Low voltage was detected in power supply voltage circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB111].
when normal
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Failure code [CA442] Power supply voltage abnormally high level (Left
bank): High voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally high level (Left bank): High voltage
CALL E04 CA442 failure detection (Engine controller system)
Failure content • High voltage was detected in power supply voltage circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA111].
when normal
Failure code [CB442] Power supply voltage abnormally high level (Right
bank): High voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally high level (Right bank): High volt-
CALL E04 CB442 failure age detection (Engine controller system)
Failure content • High voltage was detected in power supply voltage circuit.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB111].
when normal
D475A, D475ASD-5E0 29
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Failure code [CA449] Common rail abnormally high pressure (2) (Left
bank): Abnormally high pressure occurrence 1
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Left bank): Abnormally
CALL E03 CA449 failure high pressure occurrence (Engine controller system)
Failure content • Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Controller's • Limits output and continues operation (Limits common rail pressure).
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA2249].
when normal
Failure code [CB449] Common rail abnormally high pressure (2) (Right
bank): Abnormally high pressure occurrence 1
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Right bank): Abnormally
CALL E03 CB449 failure high pressure occurrence (Engine controller system)
Failure content • Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Controller's • Limits output and continues operation (Limits common rail pressure).
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on • Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA2249].
when normal
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 31
SEN01825-00 40 Troubleshooting
Failure code [CA451] Common rail pressure sensor too high (At left
bank): Excessively high voltage detected 1
Action code Failure code Symptom of Common rail pressure sensor too high (At left bank): Excessively
CALL E03 CA451 failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage has occurred in the common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
General • The signal voltage of the common rail pressure sensor can be checked with the monitoring func-
information tion. (Code: 36401 Common rail pressure sensor voltage)
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 33
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34 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 35
SEN01825-00 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA451].
when normal
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB451].
when normal
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected 1
Action code Failure code Symptom of Common rail pressure high trouble (1) (At left bank): Excessively
CALL E03 CA553 failure high pressure trouble occurred (Engine controller system)
Failure content • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on • Output decreases.
machine
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
D475A, D475ASD-5E0 37
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Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected 1
Action code Failure code Symptom of Common rail pressure high trouble (1) (At right bank): Excessively
CALL E03 CB553 failure high pressure trouble occurred (Engine controller system)
Failure content • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on • Output decreases.
machine
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Failure code [CA554] In-range error in common rail pressure sensor (At
left bank): In-range error 1
Action code Failure code Symptom of In-range error in common rail pressure sensor (At left bank): In-
CALL E03 CA554 failure range error occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CA451].
when normal
Failure code [CB554] In-range error in common rail pressure sensor (At
right bank): In-range error 1
Action code Failure code Symptom of In-range error in common rail pressure sensor (At right bank): In-
CALL E03 CB554 failure range error occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Output decreases.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CB451].
when normal
D475A, D475ASD-5E0 39
SEN01825-00 40 Troubleshooting
Failure code [CA559] Loss of pressure feed from supply pump (1) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of
E02 CA559 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
• Output decreases.
appear on
• Flashes warning lamp and turns on alarm buzzer.
machine
General
information
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0 41
SEN01825-00 40 Troubleshooting
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 660 – 700
*1 Engine speed High idle rpm 2,100 – 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
*9 Low idle °C — — —
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 43
SEN01825-00 40 Troubleshooting
Failure code [CB559] Loss of pressure feed from supply pump (1) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of
E02 CB559 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
• Output decreases.
appear on
• Flashes warning lamp and turns on alarm buzzer.
machine
General
information
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0 45
SEN01825-00 40 Troubleshooting
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 660 – 700
*1 Engine speed High idle rpm 2,100 – 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
*9 Low idle °C — — —
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 47
SEN01825-00 40 Troubleshooting
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank):
Abnormal signal 1
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At left bank): Abnormal signal
CALL E03 CA689 failure (Engine controller system)
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 49
SEN01825-00 40 Troubleshooting
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank):
Abnormal signal 1
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At right bank): Abnormal signal
CALL E03 CB689 failure (Engine controller system)
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 51
SEN01825-00 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
D475A, D475ASD-5E0 53
SEN01825-00 40 Troubleshooting
Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection 1
Action code Failure code Symptom of Intake air temperature sensor abnormally low level (Only left bank):
E01 CA692 failure Low voltage detection (Engine controller system)
Failure content • Intake air temperature sensor circuit detected low voltage.
Controller's
• Fixes intake air temperature (25°C) and continues operation.
action
Symptoms that
appear on
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA691].
when normal
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-00
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At
left bank): Abnormal phase 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At left bank): Abnormal
CALL E03 CA731 failure phase (Engine controller system)
Failure content • Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's • Operates using engine Ne speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At
right bank): Abnormal phase 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At right bank): Abnor-
CALL E03 CB731 failure mal phase (Engine controller system)
Failure content • Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's • Operates using engine Ne speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information
D475A, D475ASD-5E0 55
SEN01826-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 4
Troubleshooting by failure code (Display of code), Part 4 .............................................................................. 3
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data ....................... 3
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data..................... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal ..... 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error .......... 6
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error .... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error .. 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error ........................................................................................................................ 11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error ........................................................................................................................ 12
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 14
D475A, D475ASD-5E0 1
SEN01826-00 40 Troubleshooting
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank):
Disconnection/Short circuit....................................................................................................... 16
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank):
Disconnection/Short circuit....................................................................................................... 18
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank):
Disconnection/Short circuit....................................................................................................... 20
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank):
Disconnection/Short circuit....................................................................................................... 22
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank):
Disconnection/Short circuit....................................................................................................... 24
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error.............................. 26
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level
(Only left bank): High voltage detection ................................................................................... 28
Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only):
Excessively low voltage detected............................................................................................. 30
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank):
Loss of pressure feed detected................................................................................................ 31
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank):
Loss of pressure feed detected................................................................................................ 31
Failure code [D110KA] Battery relay: Disconnection ......................................................................... 32
Failure code [D110KB] Battery relay: Short circuit ............................................................................. 34
Failure code [D130KA] Neutral safety relay: Disconnection............................................................... 36
Failure code [D130KB] Neutral safety relay: Short circuit .................................................................. 38
Failure code [D161KA] Back-up alarm relay: Disconnection.............................................................. 40
Failure code [D161KB] Back-up alarm relay: Short circuit ................................................................. 42
Failure code [D182KZ] Preheater relay: Disconnection or short circuit.............................................. 44
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ............................ 46
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit................................ 48
Failure code [D5ZRKA] Snap shot switch: Disconnection.................................................................. 50
Failure code [D5ZRKB] Snap shot switch: Short circuit ..................................................................... 51
Failure code [DAFRKR] Monitor panel CAN communication: Communication error.......................... 52
Failure code [dAFRKR] Monitor panel CAN communication: Communication error .......................... 54
Failure code [daFRKR] Monitor panel CAN communication: Communication error........................... 56
Failure code [DAQ0KT] Transmission controller: Abnormality in controller ....................................... 58
Failure code [DAQ1KK] Transmission controller main power supply:
Power supply voltage reduction (Input).................................................................................... 60
Failure code [DAQ2KK] Transmission controller load power supply:
Power supply voltage reduction (Input).................................................................................... 62
Failure code [DAQ5KK] Transmission controller potentiometer power supply:
Source voltage reduction (input) .............................................................................................. 64
Failure code [DAQ6KK] Transmission controller sensor power supply:
Source voltage reduction (input) .............................................................................................. 65
Failure code [DAQ7KK] Transmission controller sensor power supply:
Power supply voltage reduction (Input).................................................................................... 66
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency .... 67
Failure code [DAQRKR] Transmission controller sensor CAN communication:
Communication error (Objective component system abnormality) .......................................... 68
Failure code [DAQSKR] Transmission controller S-NET communication:
Defective communication (Abnormality in objective component system) ................................ 70
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CA111].
when normal
Failure code [CB757] Loss of all engine controller data (At right bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At right bank): Loss of all data
CALL E04 CB757 failure (Engine controller system)
Failure content • Loss of all data in engine controller has been detected.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on • The engine cannot be started, or cannot be operated.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CB111].
when normal
D475A, D475ASD-5E0 3
SEN01826-00 40 Troubleshooting
Failure code [CA778] Abnormal engine Bkup speed sensor (At left
bank): Abnormal Bkup signal 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup
CALL E03 CA778 failure signal (Engine controller system)
Failure content • Abnormal engine Bkup speed sensor signal has been detected.
Controller's • Operates using Ne speed sensor signal.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 5
SEN01826-00 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 7
SEN01826-00 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 9
SEN01826-00 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA781].
when normal
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 11
SEN01826-00 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 13
SEN01826-00 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 15
SEN01826-00 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 17
SEN01826-00 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 19
SEN01826-00 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 21
SEN01826-00 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 23
SEN01826-00 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 25
SEN01826-00 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 27
SEN01826-00 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 29
SEN01826-00 40 Troubleshooting
Failure code [CA2186] Decelerator pedal sensor power source too low
(At left bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Decelerator pedal sensor power source too low (At left bank only):
CALL E03 CA2186 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller oper-
action
ates with 100% value.
• Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Engine speed cannot be controlled by decelerator pedal.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1 Carry out troubleshooting for failure code [CA2185].
when normal
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of
CALL E03 CA2249 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's • Operates with limited output.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1 Carry out troubleshooting of [CA559].
when normal
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At right bank): Loss of
CALL E03 CB2249 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's • Operates with limited output.
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1 Carry out troubleshooting of [CB559].
when normal
D475A, D475ASD-5E0 31
SEN01826-00 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 33
SEN01826-00 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 35
SEN01826-00 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 37
SEN01826-00 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 39
SEN01826-00 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 41
SEN01826-00 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 43
SEN01826-00 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 45
SEN01826-00 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 47
SEN01826-00 40 Troubleshooting
Failure code [D190KB] Engine controller ACC signal cutout relay: Short
circuit 1
Action code Failure code Symptom of Engine controller ACC signal cutout relay: Short circuit
— D190KB failure (Steering controller system)
• Abnormal current flowed in the engine controller ACC signal cutout relay circuit at the time of
Failure content
ground output.
Controller's
• Stops the ground output of the engine controller ACC signal cutout relay circuit.
action
Symptoms that
appear on • Engine cannot be stopped by steering controller.
machine
General a This failure code identifies a detected abnormality in primary side (coil side) of engine controller
information ACC signal cutout relay, but an abnormality in secondary side (contact side) can not be detected.
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 49
SEN01826-00 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 51
SEN01826-00 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 53
SEN01826-00 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 55
SEN01826-00 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 57
SEN01826-00 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the Troubleshooting cannot be carried out since it is internal defect.
Defective transmission
standard values 1 (It is no problem even if you use controller unless no visible problem
when normal controller
appears on machine.)
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 59
SEN01826-00 40 Troubleshooting
60 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 61
SEN01826-00 40 Troubleshooting
62 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 63
SEN01826-00 40 Troubleshooting
64 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 65
SEN01826-00 40 Troubleshooting
66 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 67
SEN01826-00 40 Troubleshooting
68 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 69
SEN01826-00 40 Troubleshooting
70 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-00
D475A, D475ASD-5E0 71
SEN01827-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 5
Troubleshooting by failure code (Display of code), Part 5 .............................................................................. 4
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error .... 4
Failure code [DB30KT] Steering controller: Abnormality in controller .................................................. 6
Failure code [DB31KK] Steering controller main power supply:
Power supply voltage reduction (Input)...................................................................................... 8
Failure code [DB32KK] Steering controller load power supply:
Power supply voltage reduction (Input).................................................................................... 10
Failure code [DB35KK] Steering controller potentiometer power supply:
Power supply voltage reduction (Input).................................................................................... 12
Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input).. 14
Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input).. 15
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency ............ 16
Failure code [dB3RKR] Steering controller CAN communication: Communication error ................... 18
D475A, D475ASD-5E0 1
SEN01827-00 40 Troubleshooting
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 3
SEN01827-00 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 5
SEN01827-00 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the Troubleshooting cannot be carried out since it is internal defect.
standard values Defective steering
1 (It is no problem even if you use controller unless no visible problem
controller
when normal appears on machine.)
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 7
SEN01827-00 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 9
SEN01827-00 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 11
SEN01827-00 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 13
SEN01827-00 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 15
SEN01827-00 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 17
SEN01827-00 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 19
SEN01827-00 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 21
SEN01827-00 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 23
SEN01827-00 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 25
SEN01827-00 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 27
SEN01827-00 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 29
SEN01827-00 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 31
SEN01827-00 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 33
SEN01827-00 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 35
SEN01827-00 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 37
SEN01827-00 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 39
SEN01827-00 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 41
SEN01827-00 40 Troubleshooting
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking brake lever switch Parking brake lever
1 NSW (male)
(Internal disconnection) Free position Lock position
Between (A) – (B) Max. 1 z Min. 1 Mz
Possible
Between (A) – (B) Min. 1 Mz Max. 1 z
causes and the
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
Disconnection in wiring Wiring harness between NSW (female) (B) – Resis-
Max. 1 z
harness (Disconnection in TMC1 (female) (18), – STCN2 (female) (5) tance
2
wiring or defective contact Wiring harness between NSW (female) (C) – Resis-
Max. 1 z
in connector) TMC1 (female) (12), – STCN2 (female) (15) tance
Wiring harness between NSW (female) (A) – Resis-
Max. 1 z
chassis ground tance
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
Possible
causes and the Short circuit of wiring harness between NSW
Hot short in wiring harness (female) (B) – TMC1 (female) (18), – STCN2 Voltage Max. 1 V
standard values 3
(Contact with 24 V circuit) (female) (5) with chassis ground
when normal
Short circuit of wiring harness between NSW
(female) (C) – TMC1 (female) (12), – STCN2 Voltage Max. 1 V
(female) (15) with chassis ground
D475A, D475ASD-5E0 43
SEN01827-00 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 45
SEN01827-00 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 47
SEN01827-00 40 Troubleshooting
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 49
SEN01827-00 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 51
SEN01827-00 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 53
SEN01827-00 40 Troubleshooting
Failure code [DDN2LD] (Blade tilt right oil pressure switch system:
Switch is ON for long time 1
Action code Failure code Symptom of Blade tilt right oil pressure switch system: Switch is ON for long time
E02 DDN2LD failure (Transmission controller system)
Failure content • The signal of the blade tilt right oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's • Flashes the caution lamp and turns on the caution buzzer.
action • Recognizes that the oil pressure switch is turned OFF.
Symptoms that • During right dual tilt operation, tilting is not limited.
appear on • Blade tilt right operation becomes slow.
machine • VHMS data is not always correct.
• The input state (ON/OFF) from the blade tilt right oil pressure switch can be checked in the moni-
General toring mode. (Code 40908: Blade lever oil pressure switch input state)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch
is ON for long time 1
Action code Failure code Symptom of Blade tilt left oil pressure switch system: Switch is ON for long time
E02 DDN3LD failure (Transmission controller system)
Failure content • The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's • Flashes the caution lamp and turns on the caution buzzer.
action • Recognizes that the oil pressure switch is turned OFF.
Symptoms that • During left dual tilt operation, tilting is not limited.
appear on • Blade tilt left operation becomes slow.
machine • VHMS data is not always correct.
• The input state (ON/OFF) from the blade tilt left oil pressure switch can be checked in the monitor-
General ing mode. (Code 40908: Blade lever oil pressure switch input state)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
D475A, D475ASD-5E0 55
SEN01827-00 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Circuit diagram related to blade pitch switch and blade tilt switch
D475A, D475ASD-5E0 57
SEN01827-00 40 Troubleshooting
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 59
SEN01827-00 40 Troubleshooting
60 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 61
SEN01827-00 40 Troubleshooting
62 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 63
SEN01827-00 40 Troubleshooting
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch
is ON for long time 1
Action code Failure code Symptom of Blade lift raise full oil pressure switch: Switch is ON for long time
— DDNALD failure (Transmission controller system)
Failure content • The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
• Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that
• The data of the VHMS may become abnormal.
appear on
• Blade lift raise operation becomes slow.
machine
• The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the
General monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
Circuit diagram related to blade lift raise full oil pressure switch
64 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper lift raise oil pressure switch: Switch is ON for long time
— DDNBLD failure (Transmission controller system)
Failure content • The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
• Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that • The shoe slip control (SSC) function does not operate normally.
appear on • Ripper lift raise operation becomes slow.
machine • The data of the VHMS may become abnormal.
• The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Steering controller input signal 3)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
D475A, D475ASD-5E0 65
SEN01827-00 40 Troubleshooting
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper lift lower oil pressure switch: Switch is ON for long time
— DDNCLD failure (Transmission controller system)
Failure content • The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
• Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that • The shoe slip control (SSC) function does not operate normally.
appear on • The data of the VHMS may become abnormal.
machine • Ripper lift lower operation becomes slow.
• The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Steering controller input signal 3)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
66 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
D475A, D475ASD-5E0 67
SEN01827-00 40 Troubleshooting
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper tilt back oil pressure switch: Switch is ON for long time
— DDNELD failure (Transmission controller system)
Failure content • The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
• Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that • The shoe slip control (SSC) function does not operate normally.
appear on • The tilt back speed of the ripper lowers.
machine • The data of the VHMS may become abnormal.
• The input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Ripper lever oil pressure switch input signal)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
68 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-00
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch
is ON for long time 1
Action code Failure code Symptom of Blade lift lower full pressure switch: Switch is ON for long time
— DDNFLD failure (Transmission controller system)
Failure content • The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
• Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that
• The lift lower speed of the blade lowers.
appear on
• The data of the VHMS may become abnormal.
machine
• The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the mon-
General itoring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 180 sec-
onds).
Circuit diagram related to blade lift lower full oil pressure switch
D475A, D475ASD-5E0 69
SEN01828-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 6
Troubleshooting by failure code (Display of code), Part 6 .............................................................................. 4
Failure code [DDQ2KA] Parking brake lever switch: Disconnection .................................................... 4
Failure code [DDQ2KB] Parking brake lever switch: Short circuit........................................................ 6
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals ..................................... 8
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals ..................................... 9
Failure code [DDT5KA] Neutral switch: Disconnection ...................................................................... 10
Failure code [DDT5KB] Neutral switch: Short circuit.......................................................................... 12
Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement............ 14
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range......... 15
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection...................................... 16
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ...... 18
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front):
Disconnection (or LED of VHMS controller indicates "n3" o "12") .......................................... 20
D475A, D475ASD-5E0 1
SEN01828-00 40 Troubleshooting
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear):
Disconnection (or LED of VHMS controller indicates "n3" o "22") .......................................... 22
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front):
Short circuit (or LED of VHMS controller indicates "n3" o "11") .............................................. 24
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21")
Left bank exhaust temperature sensor system (Rear): Short circuit ........................................ 26
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24")
Right bank exhaust temperature sensor system (Front): Disconnection ................................. 28
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26")
Right bank exhaust temperature sensor system (Rear): Disconnection .................................. 30
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23")
Right bank exhaust temperature sensor system (Front): Short circuit ..................................... 32
Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25")
Right bank exhaust temperature sensor system (Rear): Short circuit...................................... 34
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection .................... 36
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit ....................... 37
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection ................... 38
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit ....................... 39
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32")
Blow-by pressure sensor system: Disconnection..................................................................... 40
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31")
Blow-by pressure sensor system: Hot short............................................................................. 41
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14")
Transmission oil pressure sensor: Out of input signal range ................................................... 42
Failure code [DK01KA] Left yoke angle sensor: Disconnection ......................................................... 43
Failure code [DK01KB] Left yoke angle sensor: Short circuit............................................................. 44
Failure code [DK03KA] Right yoke angle sensor: Disconnection....................................................... 45
Failure code [DK03KB] Right yoke angle sensor: Short circuit .......................................................... 46
Failure code [DK10KA] Fuel dial: Disconnection................................................................................ 47
Failure code [DK10KB] Fuel dial: Short circuit ................................................................................... 48
Failure code [DK30KA] Steering potentiometer (1): Disconnection.................................................... 49
Failure code [DK30KB] Steering potentiometer (1): Short circuit ....................................................... 50
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range .................... 51
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit ............................ 52
Failure code [DK30L8] Steering potentiometer (1): See table............................................................ 53
Failure code [DK31KA] Steering potentiometer (2): Disconnection.................................................... 54
Failure code [DK31KB] Steering potentiometer (2): Short circuit ....................................................... 55
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 3
SEN01828-00 40 Troubleshooting
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking brake lever Parking brake lever
1 switch NSW
Free position Lock position
(Internal disconnection)
Between (A) – (B) Max. 1 z Min. 1 Mz
Possible
Between (A) – (B) Min. 1 Mz Max. 1 z
causes and the
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
Disconnection in wiring Wiring harness between NSW (female) (B) – Resis-
Max. 1 z
harness (Disconnection TMC1 (female) (18), – STCN2 (female) (5) tance
2
in wiring or defective con- Wiring harness between NSW (female) (C) – Resis-
Max. 1 z
tact in connector) TMC1 (female) (12), – STCN2 (female) (15) tance
Wiring harness between NSW (female) (A) – Resis-
Max. 1 z
chassis ground tance
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Possible
causes and the Short circuit of wiring harness between NSW
Hot short in wiring har-
(female) (B) – TMC1 (female) (18) – STCN2 Voltage Max. 1 V
standard values 3 ness (Contact with 24 V
(female) (5) with chassis ground
when normal circuit)
Short circuit of wiring harness between NSW
(female) (C) – TMC1 (female) (12) – STCN2 Voltage Max. 1 V
(female) (15) with chassis ground
D475A, D475ASD-5E0 5
SEN01828-00 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 7
SEN01828-00 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 9
SEN01828-00 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 11
SEN01828-00 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 13
SEN01828-00 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 15
SEN01828-00 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 17
SEN01828-00 40 Troubleshooting
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range 1
Action code Failure code Symptom of Power train oil temperature sensor: Input signal out of range
E01 DGT1KX failure (Machine monitor system)
Failure content • Power train temperature sensor signal is out of normal range.
Controller's
• Nothing particular.
action
Symptoms that • Power train oil temperature on machine monitor is not displayed properly.
appear on • Fan speed is limited to half.
machine • Gear shift shock of transmission is large.
• Power train temperature state (temperature) can be checked in monitoring mode.
General
(Code 30100: Power train oil temperature)
information
• Duplication of failure code: Turn starting switch ON or start engine.
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 19
SEN01828-00 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 21
SEN01828-00 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 23
SEN01828-00 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 25
SEN01828-00 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 27
SEN01828-00 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 29
SEN01828-00 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 31
SEN01828-00 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 33
SEN01828-00 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 35
SEN01828-00 40 Troubleshooting
Failure code [DH22KA] Work equipment pump oil pressure sensor (F):
Disconnection 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (F): Disconnection
— DH22KA failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.2 V.
Controller's
• Does not take any particular action.
action
Symptoms that
appear on • Work equipment pump (F) oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring
General
mode. (Code 70701: Voltage of work equipment pump oil sensor (F))
information
• Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (F)
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
Failure code [DH22KB] Work equipment pump oil pressure sensor (F):
Short circuit 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (F): Short circuit
— DH22KB failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 4.8 V
Controller's
• Does not take any particular action.
action
Symptoms that
appear on • Work equipment pump (F) oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring
General mode.
information (Code 70701: Voltage of work equipment pump oil pressure sensor (F))
• Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (F)
D475A, D475ASD-5E0 37
SEN01828-00 40 Troubleshooting
Failure code [DH23KA] Work equipment pump oil pressure sensor (R):
Disconnection 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (R): Disconnection
— DH23KA failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.2 V.
Controller's
• Does not take any particular action.
action
Symptoms that
appear on • Work equipment pump (R) oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring
General
mode. (Code 70703: Voltage of work equipment pump oil sensor (R))
information
• Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (R)
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
Failure code [DH23KB] Work equipment pump oil pressure sensor (R):
Short circuit 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (R): Short circuit
— DH23KB failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 4.8 V
Controller's
• Does not take any particular action.
action
Symptoms that
appear on • Work equipment pump (R) oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring
General mode.
information (Code 70703: Voltage of work equipment pump oil pressure sensor (R))
• Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A, D475ASD-5E0 39
SEN01828-00 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 41
SEN01828-00 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 43
SEN01828-00 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 45
SEN01828-00 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 47
SEN01828-00 40 Troubleshooting
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 49
SEN01828-00 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
D475A, D475ASD-5E0 51
SEN01828-00 40 Troubleshooting
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
D475A, D475ASD-5E0 53
SEN01828-00 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-00
D475A, D475ASD-5E0 55
SEN01829-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 7
Troubleshooting by failure code (Display of code), Part 7 .............................................................................. 3
Failure code [DK40KA] Brake potentiometer: Disconnection............................................................... 3
Failure code [DK40KB] Brake potentiometer: Short circuit .................................................................. 4
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range .............. 5
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit ...................... 6
Failure code [DK55L8] Forward-reverse potentiometer: See table...................................................... 7
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection ........................................ 8
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit ........................................ 10
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ...................................... 12
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit ........................................ 14
Failure code [DK60KA] Acceleration sensor: Disconnection ............................................................. 16
Failure code [DK60KB] Acceleration sensor: Short circuit ................................................................. 18
Failure code [DKH1KA] Pitch angle sensor: disconnection ............................................................... 19
Failure code [DKH1KB] Pitch angle sensor: Short circuit .................................................................. 20
D475A, D475ASD-5E0 1
SEN01829-00 40 Troubleshooting
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range .............................................. 21
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection ................................ 22
Failure code [DLT3KA] Transmission output speed sensor: Disconnection ...................................... 23
Failure code [dLT3KA] Transmission output speed sensor: Disconnection ....................................... 24
Failure code [DLT3KB] Transmission output speed sensor: Short circuit .......................................... 26
Failure code [DV00KB] Caution buzzer: Short circuit......................................................................... 27
Failure code [DW55KA] Blade pitch back solenoid: Disconnection ................................................... 28
Failure code [DW55KB] Blade pitch back solenoid: Short circuit ....................................................... 29
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection .................................................. 30
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit...................................................... 31
Failure code [DW56KY] Blade pitch dump solenoid: Hot short .......................................................... 32
Failure code [DW57KA] Left tilt limit solenoid: Disconnection............................................................ 33
Failure code [DW57KB] Left tilt limit solenoid: Short circuit ............................................................... 34
Failure code [DW57KY] Left tilt limit solenoid: Hot short.................................................................... 35
Failure code [DW58KA] Right tilt limit solenoid: Disconnection ......................................................... 36
Failure code [DW58KB] Right tilt limit solenoid: Short circuit ............................................................. 37
Failure code [DW58KY] Right tilt limit solenoid: Hot short ................................................................. 38
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection .................................................... 39
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit........................................................ 40
Failure code [DW59KY] Dual tilt selector solenoid: Hot short ............................................................ 41
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection .............................................. 42
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit.................................................. 43
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ...................................................... 44
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection.... 45
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit....... 46
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short ........... 47
Failure code [DW7BKA] Fan reverse solenoid: Disconnection .......................................................... 48
Failure code [DW7BKB] Fan reverse solenoid: Short circuit.............................................................. 49
Failure code [DW7BKY] Fan reverse solenoid: Hot short .................................................................. 50
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection.............................................. 51
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit ................................................. 52
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short...................................................... 53
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection ....................................... 54
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit........................................... 55
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short ............................................... 56
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection .......................................................... 57
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit.............................................................. 58
Failure code [DWN5KY] Fan pump solenoid 1: Hot short .................................................................. 59
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ......................................................... 60
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit ............................................................. 61
Failure code [DWNCKY] Fan pump solenoid 2: Hot short ................................................................. 62
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 3
SEN01829-00 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
when normal
D475A, D475ASD-5E0 5
SEN01829-00 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
when normal
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
when normal
D475A, D475ASD-5E0 7
SEN01829-00 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 9
SEN01829-00 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 11
SEN01829-00 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 13
SEN01829-00 40 Troubleshooting
Action code Failure code Symptom of Forward-Reverse potentiometer (2): Short circuit
CALL E03 DK57KB failure (Transmission controller system)
• Signal voltage of forward-reverse potentiometer (2) system (F) circuit is higher than specified
Failure content
value.
• Blinks warning lamp and sounds alarm buzzer.
Controller's
• Continues control with signal of forward-reverse potentiometer (1) system (R).
action
• Limits operations of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, gear speed is limited to F1 and R1.
machine
• Input state (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring
General mode (Code 50201: Forward-Reverse potentiometer (2) voltage).
information • Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and
reverse)).
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 15
SEN01829-00 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 17
SEN01829-00 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 19
SEN01829-00 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range 1
Action code Failure code Symptom of Pitch angle sensor: Out of input signal range
E01 DKH1KX failure (Steering controller system)
• Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN
Failure content
communication error [DB3RKR] occurred.
Controller's
• Cannot recognize pitch angle.
action
Symptoms that
appear on • Gear speed is not changed automatically.
machine
• Input state (Voltage) from pitch angle sensor can be checked in monitoring mode
General
(Code 60100: Pitch angle sensor voltage).
information
• Method of reproducing failure code: Turn starting switch ON.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for disconnection [DKH1KA] and short circuit [DKH1KB] in pitch angle
sensor and steering controller CAN communication [DB3RKR].
when normal
D475A, D475ASD-5E0 21
SEN01829-00 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
Carry out troubleshooting for disconnection [dLT3KA] and transmission CAN communication error
standard values
when normal [DAQRKR].
D475A, D475ASD-5E0 23
SEN01829-00 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 25
SEN01829-00 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 27
SEN01829-00 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 29
SEN01829-00 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 31
SEN01829-00 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 33
SEN01829-00 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 35
SEN01829-00 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 37
SEN01829-00 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 39
SEN01829-00 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 41
SEN01829-00 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 43
SEN01829-00 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 45
SEN01829-00 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 47
SEN01829-00 40 Troubleshooting
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 49
SEN01829-00 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 51
SEN01829-00 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 53
SEN01829-00 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 55
SEN01829-00 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 57
SEN01829-00 40 Troubleshooting
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 59
SEN01829-00 40 Troubleshooting
60 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 61
SEN01829-00 40 Troubleshooting
62 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-00
D475A, D475ASD-5E0 63
SEN01830-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 8
Troubleshooting by failure code (Display of code), Part 8 .............................................................................. 3
Failure code [DXE0KA] LS set solenoid: Disconnection ...................................................................... 3
Failure code [DXE0KB] LS set solenoid: Short circuit.......................................................................... 4
Failure code [DXE0KY] LS set solenoid: Hot short .............................................................................. 5
Failure code [DXH1KA] Lock-up solenoid: Disconnection ................................................................... 6
Failure code [DXH1KB] Lock-up solenoid: Short circuit....................................................................... 7
Failure code [DXH1KY] Lockup solenoid: Hot short ............................................................................ 8
Failure code [DXH4KA] 1st clutch ECMV: Disconnection.................................................................... 9
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ..................................................................... 10
Failure code [DXH4KY] 1st clutch ECMV: Hot short.......................................................................... 11
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................................. 12
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .................................................................... 13
Failure code [DXH5KY] 2nd clutch ECMV: Hot short......................................................................... 14
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ................................................................. 15
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2 D475A, D475ASD-5E0
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36 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 37
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Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Left front exhaust temperature sensor (1): Exhaust temperature
Symptom of
abnormal rise
— F@BYNS failure
(VHMS controller system)
• Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C
in range above rated output speed and 750°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "61".
38 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 39
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Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Left rear exhaust temperature sensor (1): Exhaust temperature
— f@BYNS failure abnormal rise (VHMS controller system)
• Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C
in range above rated output speed and 750°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "71".
40 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 41
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Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Right front exhaust temperature sensor (1): Exhaust temperature
— F@BZNS failure abnormal rise (VHMS controller system)
• Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between
700°C in range above rated output speed and 750°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on machine monitor (It can be checked, however, by downloading
General
data saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "38".
42 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 43
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Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Right rear exhaust temperature sensor (1): Exhaust temperature
Symptom of
abnormal rise
— f@BZNS failure
(VHMS controller system)
• Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between
700°C in range above rated output speed and 750°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "39".
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D475A, D475ASD-5E0 45
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Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Left front exhaust temperature sensor (2): Exhaust temperature
— F@BYNR failure abnormal rise (VHMS controller system)
• Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C
in range above rated output speed and 800°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "62".
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D475A, D475ASD-5E0 47
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Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Left rear exhaust temperature sensor (2): Exhaust temperature
— f@BYNR failure abnormal rise (VHMS controller system)
• Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C
in range above rated output speed and 800°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "72".
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D475A, D475ASD-5E0 49
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Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Right front exhaust temperature sensor (2): Exhaust temperature
— F@BZNR failure abnormal rise (VHMS controller system)
• Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between
750°C in range above rated output speed and 800°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "82".
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D475A, D475ASD-5E0 51
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Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Right rear exhaust temperature sensor (2): Exhaust temperature
— f@BZNR failure abnormal rise (VHMS controller system)
• Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between
750°C in range above rated output speed and 800°C in range below maximum torque speed)
Controller's
• None in particular.
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "92".
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D475A, D475ASD-5E0 53
SEN01831-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 2
Contents of troubleshooting table......................................................................................................... 2
E-1 The engine does not start. ............................................................................................................. 3
E-2 The preheater does not operate. ................................................................................................... 7
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Symptom of • Trouble (1) is not detected but the engine does not start (When the machine is equipped with pre-
failure (2) lubricator).
• "PE" is displayed on the gear speed display unit and "E" on the right side flashes.
• After the engine is started, if "Po" is displayed on the gear speed display unit and "o" on the right
General
side flashes, the engine oil pressure is not heightened. (In this case, the pre-lubrication motor and
information
the engine oil pressure switch for pre-lubrication may be defective. Accordingly, carry out the fol-
lowing troubleshooting.)
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D475A, D475ASD-5E0 9
SEN01832-00
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Information in troubleshooting table ..................................................................................................... 3
H-1 No force (no drawbar pull)............................................................................................................. 4
H-2 No travel (at 2nd or 3rd speed) ..................................................................................................... 6
H-3 No travel at all gear speeds........................................................................................................... 7
H-4 Machine travels only in one direction forward or in reverse .......................................................... 8
H-5 Large time lag at gear speed shifting or forward-reverse shifting ................................................. 9
H-6 Steering is not possible ............................................................................................................... 10
H-7 Steering is possible only on one side .......................................................................................... 11
H-8 Steering overrun occurs .............................................................................................................. 12
H-9 Brake does not work.................................................................................................................... 13
H-10 Torque converter is not lock-up................................................................................................. 14
H-11 Power train oil is overheated ..................................................................................................... 15
H-12 All work equipment speeds are slow ......................................................................................... 16
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Possible causes 2
Possible causes of trouble
and standard <Contents of description>
(Given numbers are refer-
value in normal • Standard value in normal state to judge possible causes
state ence numbers, which do not
• Remarks on judgment
indicate priority)
3
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H-21 Ripper pin puller cylinder does not work (giant ripper attachment
machine) 1
Symptom of
• The ripper pin puller cylinder does not work.
failure
General
• Confirm that the main relief pressure for transmission is normal before troubleshooting.
information
24 D475A, D475ASD-5E0
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H-22 Blade pitch does not work (dual tilt attachment machine) 1
Symptom of
• The blade pitch does not work.
failure
General
information
H-23 Abnormal sound comes out from around work equipment pump 1
Symptom of
• Abnormal noise from around work equipment pump.
failure
General
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information
D475A, D475ASD-5E0 25
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D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
S-1 Starting performance is poor ......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 7
S-3 Engine does not pick up smoothly............................................................................................... 10
S-4 Engine stops during operations ....................................................................................................11
S-5 Engine does not rotate smoothly ................................................................................................. 12
S-6 Engine lacks output (or lacks power)........................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 16
S-9 Oil becomes contaminated quickly .............................................................................................. 17
S-10 Fuel consumption is excessive.................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 19
S-12 Oil pressure drops ..................................................................................................................... 20
S-13 Oil level rises (Entry of coolant or fuel)...................................................................................... 21
S-14 Coolant temperature becomes too high (overheating) .............................................................. 22
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Questions:
Information to be obtained by questioning the user
or operator, and which corresponds to the sections
A and B in the right chart.
Section A includes basic information, and section B
contains items which can be obtained depending
on the level of the user or operator.
Check items:
Items checked by the serviceman in order to nar-
row down the causes, section C of the right chart is
corresponding to them.
Causes:
Items to be narrowed down by the questions and
check items.
The serviceman narrows down the causes to highly
probable causes according to the information from
A, B and C.
Troubleshooting:
Items to be verified at the end in order to check if
the narrowed down causes are the true factors
causing the failure. The verification is carried out
by applying diagnostic tools or implementing direct
inspection in the order of probability.
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If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
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Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Carry out troubleshooting of the failure code for "No-pressure feed by supply pump
(*1)"
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm
q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
in E-mode
When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
D475A, D475ASD-5E0 7
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Defective injector
Confirm recent repair history
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
Replacement of filters not carried out according to Operation and Maintenance
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA271], [CB271] and failure code [CA272], [CB272]
*3: Failure code [CA273], [CB273] and failure code [CA274], [CB274]
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40 Troubleshooting SEN01833-00
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
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gas is Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
D475A, D475ASD-5E0 11
SEN01833-00 40 Troubleshooting
Correct
Correct
Correct
Clean
Remedy
Add
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Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
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*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA122] and failure code[CA123]
*3: Failure code [CA263], [CB263] and failure code [CA265], [CB265]
14 D475A, D475ASD-5E0
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Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA144] and failure code[CA145]
D475A, D475ASD-5E0 15
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Turbocharger
ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
D475A, D475ASD-5E0 17
SEN01833-00 40 Troubleshooting
Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor (*2)" q
Confirm with monitoring function of machine monitor q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA144] and failure code[CA145]
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
operation
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Remedy
D475A, D475ASD-5E0 19
SEN01833-00 40 Troubleshooting
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-
Degree of
machine operation
Operated for long period E E E E
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
D475A, D475ASD-5E0 21
SEN01833-00 40 Troubleshooting
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged with
Check items
dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge enters red range faster than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed) on the installed machine side
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
D475A, D475ASD-5E0 23
SEN01833-00 40 Troubleshooting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-00
D475A, D475ASD-5E0 25
SEN00225-00
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Hydraulic circuit diagram (1/3) Hydraulic circuit diagram (1/3)
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Hydraulic circuit diagram (2/3) Hydraulic circuit diagram (2/3)
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Hydraulic circuit diagram (3/3) Hydraulic circuit diagram (3/3)
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Electrical circuit diagram (2/13) Electrical circuit diagram (2/13)
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Electrical circuit diagram (3/13) Electrical circuit diagram (3/13)
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Electrical circuit diagram (4/13) Electrical circuit diagram (4/13)
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Electrical circuit diagram (5/13) Electrical circuit diagram (5/13)
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Electrical circuit diagram (6/13) Electrical circuit diagram (6/13)
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Electrical circuit diagram (7/13) Electrical circuit diagram (7/13)
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Electrical circuit diagram (8/13) Electrical circuit diagram (8/13)
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Electrical circuit diagram (9/13) Electrical circuit diagram (9/13)
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Electrical circuit diagram (10/13) Electrical circuit diagram (10/13)
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Electrical circuit diagram (11/13) Electrical circuit diagram (11/13)
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Electrical circuit diagram (12/13) Electrical circuit diagram (12/13)
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Electrical circuit diagram (13/13) Electrical circuit diagram (13/13)
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90 Diagrams and drawings SEN00226-01
Electrical circuit diagram of inside cab Electrical circuit diagram of inside cab
D475A, D475ASD-5E0
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Connector arrangement diagram
D475A, D475ASD-5E0
Connector arrangement diagram D475A, D475ASD-5E0
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1 Giboshi 1 Lamp outlet connector (Cab) J-9 BRE Terninal 1 Battery relay (Right) (Terminal E) E-8 GND4 Terninal 1 Ground (Engine) AT-3 SFTU — 3 PCCS lever shift-up switch V-9
2 Terninal 1 Rear left speaker (Cab) J-9 BRE Terninal 1 Battery relay (Left) (Terminal E) I-2 H01 Giboshi 1 Additional heater switch (If equipped) Y-2 SL81 DT 2 Left brake ECMV (Solenoid) BB-6
3 Terninal 1 Rear left speaker (Cab) J-9 BRK DT 3 Brake potentiometer U-2 H02 Giboshi 1 Additional heater switch (If equipped) Y-2 SLC5 DT 2 Left clutch ECMV (Solenoid) BA-6
4 — 4 Rear wiper motor (Cab) I-9 BSW HD-18 14 Intermediate connector (BULGA specification) X-2 HLS DT 2 Hydraulic oil level switch (If equipped) H-9 SLS — 2 Daylight sensor AF-8
5 Terninal 1 Rear right speaker (Cab) I-9 BUA DT 2 Backup alarm I-9 HP1 DT 3 Work equipment pump oil pressure (F) F-9 SR83 DT 2 Right brake ECMV (Solenoid) BB-6
6 Terninal 1 Rear right speaker (Cab) I-9 BUZ KES-1 3 Buzzer switch AH-7 HP2 DT 3 Work equipment pump oil pressure (R) F-9 SRC7 DT 2 Right clutch ECMV (Solenoid) BA-7
9 — 6 Front wiper motor (Cab) G-9 CB1 Terninal 1 Circuit breaker (20 A) (Steering controller) AK-4 HR1 DT-B 12 Intermediate connector (Hood) P-4 SRT1 DT 2 Reverse clutch ECMV (Solenoid) AX-5
10 — 9 Radio (Cab) K-9 CB2 Terninal 1 Circuit breaker (20 A) (Monitor panel) AK-4 HR2 DT-A 12 Intermediate connector (Hood) P-4 SRV DT-A 12 Service connector AH-2
11 KES1 6 Left wiper switch (Cab) J-1 CB3 Terninal 1 Circuit breaker (20 A) (Transmission controller) AK-4 HRN1 Terninal 1 Horn (415 Hz) D-1 SSA DT 4 Acceleration sensor (SSC model) R-1
12 KES1 6 Front wiper switch (Cab) J-2 CB4 Terninal 1 Circuit breaker (20 A) (Air conditioner) AK-3 HRN2 Terninal 1 Horn (350 Hz) C-7 ST/B2 Terninal 1 Safety relay (Terminal B) AV-4
13 KES1 6 Right wiper switch (Cab) K-2 CB5 Terninal 1 Circuit breaker (20 A) (Headlamp) AK-3 HT1 Terninal 1 Electrical intake air heater (Left bank) AV-6 ST1 DT 3 Intermediate connector (Starting motor A) AV-5
14 KES1 6 Rear wiper switch (Cab) K-2 CB6 Terninal 1 Circuit breaker (20 A) (Starting switch terminal B) AK-3 HT2 Terninal 1 Electrical intake air heater (Right bank) AR-8 ST2 DT 2 Intermediate connector (Starting motor B) AV-5
15 M 2 Lamp switch (Cab) K-2 CM29 AMP070 10 ORBCOMM terminal AK-9 HTR1A Terninal 1 Preheater relay (Left) AR-1 ST8 DT 2 Emergency stop valve BB-6
17 YAZAKI 4 Right door wiper motor (Cab) G-9 CM30 AMP070 14 ORBCOMM terminal AJ-8 HTR1C Terninal 1 Preheater relay (Left) AR-1 STB Terninal 1 Safety relay (Terminal B) AV-5
18 YAZAKI 4 Left door wiper motor (Cab) L-4 CN1 DT 2 Injector #1 (Left bank) AS-9 HTR2A Terninal 1 Preheater relay (Right) AQ-1 STCN1 DRC26 24 Steering controller AD-2
19 DT 4 Intermediate connector (Window washer) K-3 CN1 DT 2 Injector #1 (Right bank) AQ-7 HTR2C Terninal 1 Preheater relay (Right) AQ-2 STCN2 DRC26 40 Steering controller AE-2
20 DTHD#8 1 Cab power supply Z-4 CN2 DT 2 Injector #2 (Left bank) AV-4 J1939 DT-A 8 Intermediate connector AU-2 STCN3 DRC26 40 Steering controller AE-1
21 DTHD#12 1 Cab unswitched power supply Z-3 CN2 DT 2 Injector #2 (Right bank) AR-8 KEY DT 6 Starting switch AH-8 STF X 4 Steering controller write connector AD-4
22 Terninal 1 Cigarette lighter (Cab) L-9 CN3 DT 2 Injector #3 (Left bank) AV-5 L.P. HD-18 14 Intermediate connector (Injector left bank) AS-2 SW Terninal 1 Battery relay (Right) (Terminal BR) F-9
25 Giboshi 1 Rotary lamp outlet connector (Cab) K-9 CN3 DT 2 Injector #3 (Right bank) AR-8 L.S. HD-18 14 Intermediate connector (Injector left bank) AS-2 SW Terninal 1 Battery relay (Left) (Terminal BR) I-1
26 M 2 Rotary lamp switch (Cab) K-2 CN4 DT 2 Injector #4 (Left bank) AV-5 LMFL Relay 5 Front lamp relay (Left) AK-1 SX8 Terninal 1 Ground L-4
81 — 2 Room lamp (Cab) H-9 CN4 DT 2 Injector #4 (Right bank) AS-8 LMFR Relay 5 Front lamp relay (Right) AL-1 TAM1 PACKARD 2 Intake air temperature sensor AV-8
101 DT-B 12 Intermediate connector (Bulkhead wiring harness) P-3 CN5 DT 2 Injector #5 (Left bank) AV-6 LMRP Relay 5 Ripper point lamp relay AL-1 TC1 DT 2 Torque converter outlet speed sensor BB-5
102 DT-A 12 Intermediate connector (Bulkhead wiring harness) P-3 CN5 DT 2 Injector #5 (Right bank) AS-9 LMW Relay 5 Working lamp relay AL-1 TFUEL PACKARD 2 Fuel temperature sensor (Left bank) AU-4
201 DT-B 12 Intermediate connector (Yoke angle sensor) D-7 CN6 DT 2 Injector #6 (Left bank) AV-6 LSV DT 2 Pump LS selector solenoid AW-5 TFUEL PACKARD 2 Fuel temperature sensor (Right bank) AQ-6
203 DT 2 Right headlamp C-7 CN6 DT 2 Injector #6 (Right bank) AU-9 MFD DT 2 Merge-divider solenoid valve R-7 TIM PACKARD 2 Intake air temperature sensor AQ-4
204 DT 2 Left headlamp C-7 CONV DT 6 Converter X-8 MMS DT-C 12 Intermediate connector AO-6 TL1 HD-24 23 Intermediate connector (PCCS lever) Y-2
207 DT 2 Left headlamp D-7 CSL DT 3 Left yoke angle sensor E-1 NE SUMITOMO 3 Ne sensor AV-8 TL2 DT-B 8 PCCS lever potentiometer W-8
208 DT 2 Right headlamp C-7 CSR DT 3 Right yoke angle sensor B-3 NSF Relay 5 Neutral safety relay AM-1 TL3 DT 6 Intermediate connector (Console) W-9
209 DT-A 12 Intermediate connector (Small hood) E-1 CT1 DT 3 CAN terminal resistor AF-8 NSW DT 3 Parking brake switch AM-4 TLL DT 2 Left tilt limit solenoid valve Q-7
217 DT 2 Caution buzzer AE-6 CTV DT 3 CAN terminal resistor AN-6 OEM HD-24 21 Intermediate connector AR-3 TLR DT 2 Right tilt limit solenoid valve Q-7
221 DT 2 Left working lamp H-1 CUR KES-1 3 Cursor switch AI-7 OEM L DRC-50 50 Engine controller (Left bank) AV-1 TLS DT 2 Blade tilt left oil pressure switch Q-8
223 DT 2 Ripper point lamp (If equipped) L-6 DEC DT 3 Decelerator pedal T-2 OEM R DRC-50 50 Engine controller (Right bank) AU-2 TM1 DT 2 Transmission outlet speed sensor BB-5
226 DT 2 Left rear working lamp L-7 DIAL M 3 Fuel control dial W-9 OLLV DT 2 Engine oil level switch AR-3 TMC1 DRC26 24 Transmission controller AI-5
241 DT-A 12 Intermediate connector (Right fender) G-9, P-6 DL1 BENDIX 5 Download connector (ORBCOM specification) M-3 OLV1 DT 2 Intermediate connector (Engine oil level) AU-9 TMC2 DRC26 40 Transmission controller AI-5
242 DT 2 Right working lamp D-8 DLT DT 2 Download right (ORBCOM specification) L-2 OLV2 — 2 Intermediate connector (Engine oil level) AS-8 TMC3 DRC26 40 Transmission controller AI-4
243 DT 2 Right rear working lamp H-9 DPNL DT 2 Diode AX-8 P03 DT 6 Intermediate connector (Work equipment knob switch) Q-9 TMF X 4 Transmission write connector AD-4
244 DT 2 Pin puller solenoid L-5 DUL DT 2 Dual tilt selector solenoid valve R-8 PAMB AMP 3 Ambient pressure sensor AV-6 TMMD DT 3 Transmission main oil pressure AW-5
250 Terninal 1 Starting switch (Terminal B) AI-9 EG1 DTP 4 Intermediate connector (Engine) AQ-1 PCV1 SUMITOMO 2 Supply pump #1 (Left bank) AU-3 TOIL PACKARD 2 Engine oil temperature sensor AV-4
255 Terninal 1 Starting switch (Terminal R1) AI-8 EG2 HD-24 23 Intermediate connector (Engine) AV-7 PCV1 SUMITOMO 2 Supply pump #1 (Right bank) AQ-5 TRS DT 2 Blade tilt right oil pressure switch P-8
256 Terninal 1 Starting switch (Terminal R2) AI-8 EHL Relay 5 Engine hold relay AK-1 PCV2 SUMITOMO 2 Supply pump #2 (Left bank) AU-4 TS1 DT-C 12 Intermediate connector (Monitor panel) AI-3
260 Terninal 1 Starting switch (Terminal BR) AH-8 ENBP DT 3 Blow-by pressure AQ-3 PCV2 SUMITOMO 2 Supply pump #2 (Right bank) AQ-5 TS1F DT-C 12 Intermediate connector (Steering controller) AI-3
262 X 2 Intermediate connector (Horn switch) S-9 ENG DRC-60 60 Engine controller (Left bank) AV-1 PFUEL AMP 3 Common rail pressure sensor (Left bank) AU-4 TS2 DT-D 12 Intermediate connector (Monitor panel) AD-3
263 X 2 Pin puller switch U-9 ENG DRC-60 60 Engine controller (Right bank) AU-2 PFUEL AMP 3 Common rail pressure sensor (Right bank) AU-9 TS2F DT-D 12 Intermediate connector (Steering controller) AD-3
265 Terninal 1 Horn switch T-9 ENGL HD-18 21 Intermediate connector (Engine sensor) AS-2 PHR Relay 5 Preheater relay AM-1 TTM DT-B 12 Intermediate connector (Monitor panel) AD-5
266 Terninal 1 Horn switch T-9 ESD DT 3 Intermediate connector (Fuse box) AN-1 PIM SUMITOMO 3 Boost pressure sensor AR-3 TTMF DT-B 12 Intermediate connector (Transmission controller) AD-5
270 Terninal 1 Starting switch (Terminal ACC) AH-9 EXA1 DT 3 Exhaust temperature sensor amplifier (Left 1) AN-6 PL1 HD-24 23 Intermediate connector (Power train) BB-4 TWTR PACKARD 2 Coolant temperature sensor AR-3
280 Terninal 1 Starting switch (Terminal C) AI-9 EXA2 DT 3 Exhaust temperature sensor amplifier (Left 2) AL-5 PL1F HD-24 23 Intermediate connector (Emergency escape device) (If equipped) AY-8 USB DTHD#8 1 Intermediate connector (Fuse) Z-4
360 DT 6 Washing tank motor K-3 EXA3 DT 3 Exhaust temperature sensor amplifier (Right 1) AN-8 PL1M HD-24 23 Intermediate connector (Emergency escape device) (If equipped) AY-8 V1 AMP070 20 VHMS controller AK-6
369 DT 6 Washing tank motor L-3 EXA4 DT 3 Exhaust temperature sensor amplifier (Right 2) AJ-7 PL2 HD-24 31 Intermediate connector (Power train) AY-8, BB-4 V2A AMP070 18 VHMS controller AL-9
422 DT 2 Fuel level gauge L-5 EXTLF DT 2 Exhaust temperature sensor (Left front) AU-9 PL3 HD-18 14 Intermediate connector (Power train) BB-4 V2B AMP070 12 VHMS controller AM-9
453 DT 2 Torque converter oil temperature sensor AZ-2 EXTLR DT 2 Exhaust temperature sensor (Left rear) AT-9 PLUB Relay 5 Pre-lubricator relay AK-3 V3A AMP070 18 VHMS controller AM-5
599 DT-A 12 Intermediate connector (Left fender) Z-4 EXTRF DT 2 Exhaust temperature sensor (Right front) AT-9 PM1 Terninal 1 Pre-lubricator motor (If equipped) F-1 V3B AMP070 12 VHMS controller AL-5
653 DT 2 Lockup solenoid AX-5 EXTRR DT 2 Exhaust temperature sensor (Right rear) AT-9 PNL HD-24 31 Intermediate connector (Emergency escape device) (If equipped) AW-9 V4A AMP070 14 VHMS controller AO-8
800 Giboshi 1 Intermediate connector (Spare power supply 1) AN-2 EXT1 DT 2 Exhaust temperature sensor amplifier (Left 1) AM-5 POIL FRAMATOME 3 Engine oil pressure sensor AV-4 V4B AMP070 10 VHMS controller AO-7
801 Giboshi 1 Intermediate connector (Spare power supply 2) AN-2 EXT2 DT 2 Exhaust temperature sensor amplifier (Left 2) AN-9 POP Terninal 1 Pre-lubricator pressure switch (If equipped) AV-5 VDA HD-18 14 Intermediate connector (Download) M-3
810 Giboshi 1 Spare power supply 1 Z-5 EXT3 DT 2 Exhaust temperature sensor amplifier (Right 1) AJ-7 PPB DT 2 Pitch back solenoid valve R-8 VDB DT-A 8 Intermediate connector (Left fender) Z-4
811 Giboshi 1 Spare power supply 2 Z-5 EXT4 DT 2 Exhaust temperature sensor amplifier (Right 2) AN-9 PPD DT 2 Pitch dump solenoid valve R-8 VDW BENDIX 5 VHMS download (ORBCOM specification) Y-8
12S1 YAZAKI 2 Accessory socket X-8 F1T8 DT 2 1st clutch ECMV (Fill switch) AY-6 PPV DT 2 Pitch priority solenoid valve S-8 VEG HD-24 21 Intermediate connector (Engine) AV-7
12S2 YAZAKI 2 Accessory socket X-8 F2T6 DT 2 2nd clutch ECMV (Fill switch) AY-6 PR1 Terninal 1 Pre-lubricator relay (If equipped) E-8 VF1 HD-24 21 Intermediate connector (Floor) AJ-6
12V DT 3 Intermediate connector (Cab) Z-3 F3T4 DT 2 3rd clutch ECMV (Fill switch) AZ-6 PR2 Terninal 1 Pre-lubricator relay (If equipped) E-8 VF2 HD-24 23 Intermediate connector (Floor) AK-5
AC DT 2 Air conditioner compressor AQ-7 F30 — 1 Circuit breaker (30 A) B-9 PR3 Terninal 1 Pre-lubricator relay (If equipped) F-1 WLD DT 2 Coolant level sensor C-2
AC1 DT-A 12 Intermediate connector (Air conditioner) W-8 F96 — 1 Circuit breaker (105 A) B-9 PR4 Terninal 1 Pre-lubricator relay (If equipped) G-1 a The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows.
AC2 HD-24 31 Intermediate connector (Air conditioner) Z-6 FA1 DT 2 Fun pump solenoid AZ-2 PRE DT 2 Pre-lubricator AN-3 DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
ACT DT 2 Air conditioner external air sensor E-8 FA2 DT 2 Fun pump solenoid BA-3 PRS DT 2 Pre-lubricator AN-4
ACT Relay 5 ACC cut relay AK-2 FAN1 KES1 3 Fan clean mode switch AI-7 PT1 DT 3 Pitch angle sensor R-1
ACU S 12 Air conditioner unit Z-7 FAN2 KES1 4 Fan reverse mode switch AI-6 PTH DT 2 Pitch selector solenoid valve R-8
ADH KES1 4 Additional heater switch AI-6 FAR DT 2 Fan reverse solenoid D-2 PW L DTP 4 Engine controller (Left bank) AV-1
AF1 DT 2 Air cleaner clogging sensor G-1 FD5 DT-B 12 Fuse wiring harness W-1 PW R DTP 4 Engine controller (Right bank) AT-2
AF2 DT 2 Air cleaner clogging sensor H-1 FFT2 DT 2 Forward clutch ECMV (Fill switch) AZ-6 PWR1 DTHD#4 1 Intermediate connector (fuse) Z-5
ANB Terninal 1 Alternator (Terminal B) AQ-7 FL82 DT 2 Left brake ECMV (Fill switch) BB-6 PWR2 DTHD#4 1 Intermediate connector (fuse) Z-5
ANR Terninal 1 Alternator (Terminal R) AQ-7 FLC6 DT 2 Left clutch ECMV (Fill switch) BA-7 R.P. HD-18 14 Intermediate connector AQ-5
AP1 AMP040 16 Air conditioner control panel U-2 FR84 DT 2 Right brake ECMV (Fill switch) BA-6 R.S. HD-18 14 Intermediate connector (Injector right bank) AQ-5
AP2 AMP040 20 Air conditioner control panel U-2 FRC8 DT 2 Right clutch ECMV (Fill switch) BA-7 REL1 Terninal 1 Preheater relay (Left) AR-2
AP3 SWP 12 Air conditioner unit Y-7 FRT2 DT 2 Reverse clutch ECMV (Fill switch) AY-6 REL2 Terninal 1 Preheater relay (Right) AQ-2
AP4 SWP 16 Air conditioner unit Z-7 FS11 — — Fuse box AL-4 RES DT 2 Left bank resistor (Pull-up) AT-3
AP5 SWP 8 Air conditioner unit Y-7 FS12 — — Fuse box AL-4 RES DT 2 Right bank resistor (Pull-up) AQ-4
ASD KES1 4 Auto shift-down switch AH-8 FS21 — — Fuse box AL-4 RES L DT 3 CAN terminal resistor (Left bank) AU-1
ASUS DT 2 Intermediate connector (Air suspension seat) U-9 FS22 — — Fuse box AL-4 RES R DT 3 CAN terminal resistor (Right bank) AQ-3
B7L — 1 Circuit breaker (30 A) C-9 FS31 — — Fuse box AM-4 RPD DT 2 Ripper lower oil pressure switch P-9
B7S — 1 Circuit breaker (30 A) C-8 FS32 — — Fuse box AM-4 RPNL X 2 Resistor AY-9
B8L — 1 Circuit breaker (30 A) C-8 FSB HD-24 31 Intermediate connector (Fuse box) W-1 RPU DT 2 Ripper raise oil pressure switch Q-9
B8S — 1 Circuit breaker (30 A) C-8 FTU KES-1 4 Auto pitch back switch AH-8 RSD DT 2 Diode P-6
B30S — 1 Circuit breaker (30 A) B-9 FWL KES-1 4 Front working lamp switch AI-6 RTB DT 2 Ripper tilt back oil pressure switch Q-8
B105H1L — 1 Circuit breaker (105 A) C-9 G SUMITOMO 3 G sensor (Left bank) AU-3 RTI DT 2 Ripper tilt in oil pressure switch P-9
B105H1S — 1 Circuit breaker (105 A) C-9 G SUMITOMO 3 G sensor (Right bank) AQ-5 RWL KES-1 4 Rear working lamp switch AI-7
B105H2L — 1 Circuit breaker (105 A) B-9 GND Terninal 1 Ground (Engine) AT-3 S01 AMP040 12 Monitor panel AG-8
B105H2S — 1 Circuit breaker (105 A) B-9 GND01 Terninal 1 Ground (Floor) X-1 S02 M 2 Monitor panel AF-8
B105S — 1 Circuit breaker (105 A) B-9 GND02 Terninal 1 Ground (Floor) X-1 S03 AMP070 20 Monitor panel AG-8
BKA Relay 5 Backup alarm relay AK-2 GND03 Terninal 1 Ground (Left fender) J-2 S04 AMP070 12 Monitor panel AG-8
BLD DT 2 Blade lower oil pressure switch Q-8 GND04 Terninal 1 Ground (Right fender) E-8 S1T7 DT 2 1st clutch ECMV (Solenoid) AY-6
BLMT YAZAKI 2 Air conditioner additional blower X-8 GND05 Terninal 1 Ground (Bulkhead) P-3 S21 DT 3 Intermediate connector (Monitor) AG-8
BLSW KES1 4 Additional blower motor switch AI-6 GND06 Terninal 1 Ground (Heater relay) AQ-2 S24 — — Service switch AD-6
BLU DT 2 Blade raise oil pressure switch Q-8 GND07 Terninal 1 Ground (Floor) AG-1 S2T5 DT 2 2nd clutch ECMV (Solenoid) AY-6
BRB Terninal 1 Battery relay (Right) (Terminal B) F-9 GND09 Terninal 1 Ground (Left fender) J-2 S3T3 DT 2 3rd clutch ECMV (Solenoid) AZ-6
BRB Terninal 1 Battery relay (Left) (Terminal B) J-2 GND1 Terninal 1 Ground (Engine) AS-2 SDS DT 2 Hydraulic oil temperature sensor AZ-2
BRC Terninal 1 Battery relay (Right) (Terminal M) F-8 GND2 Terninal 1 Ground (Engine) AS-2 SFT1 DT 2 Forward clutch ECMV (Solenoid) AZ-6
BRC Terninal 1 Battery relay (Left) (Terminal M) H-1 GND3 Terninal 1 Ground (Engine) AT-3 SFTD — 3 PCCS lever shift-down switch V-9
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