D375A 5 Workshop Manual

GENERAL

01 GENERAL SPECIFICATION DRAWING ..................................................................................................................... SPECIFICATIONS ..................................................................................................................................... WEIGHT TABLE ........................................................................................................................................ TABLE OF FUEL, COOLANT AND LUBRICANT ......................................................................................

01- 2 01- 4 01-10 01-12

D375A-5

01-1

GENERAL

SPECIFICATION DRAWING

SPECIFICATION DRAWING

Item

Unit

Semi U-tilt dozer + Giant ripper

U-tilt dozer + Giant ripper

Semi U-tilt dozer + Multi-shank ripper

U-tilt dozer + Multi-shank ripper

A

Overall length

mm

10,330

10,695

10,040

10,405

B

Overall height (with ROPS)

mm

4,035 (4,230)

4,035 (4,230)

4,035 (4,230)

4,035 (4,230)

C

Overall width

mm

4,695

5,140

4,695

5,140

01-2

D375A-5

GENERAL

SPECIFICATIONS

SPECIFICATIONS

Machine model

D375A-5

Serial number

18001 and up

Machine weight Bare tractor with semi u-dozer Ditto with variable multi-shank ripper

49,800 kg

60,340

Ditto with ROPS cab + Air conditioner +

67,060

Seat belt + Perforated side cover + SSC

68,500

Minimum turning radius

m

4.2

Gradeability

deg.

30

Stability (front, rear, left, right)

deg.

35

1st speed 2nd speed

0 3.8 km/h

0 6.8

3rd speed

0 11.8

1st speed

0 5.1

2nd speed

km/h

3rd speed

0 9.2 0 15.8

Bare tractor

103.16 {1.06}

With semi U-dozer

125.53 {1.28} 140.37 {1.43}

With semi U-dozer + Variable multishank ripper

kPa {kg/cm2} 143.38 {1.46}

Ditto with ROPS cab + air conditioner + Seat belt + Perforated side cover + SSC Bare tractor

5,770

With semi U-dozer

7,635

With semi U-dozer + Variable multishank ripper

mm

With U dozer + Variable multi-shank

10,040 10,405

ripper Bare tractor With semi U-dozer

3,220 mm

With U-dozer To top of exhaust pipe To top of air intake duct

01-4

4,695 5,140

mm

4,035 3,429

D375A-5

GENERAL

SPECIFICATIONS

Machine model

D375A-5

Serial number

18001 and up

Track gauge Length of track on ground Track shoe width Minimum ground clearance

mm

Name

SA6D170E-3

Type of engine Number of cylinders Bore × Stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption ratio

Starting motor Alternator Battery Radiator core type Torque converter

Transmission

2,500 3,840 610 610

4-cycle, water-cooled, in-line vertical type, direct injection type with turbocharger and aftercooler mm ¬ {cc}

6 170 × 170 23.15 {23,150}

kw {HP}/rpm Nm {kgm}/rpm rpm rpm

391 {525}/1,800 2,648 {270}/1,300 1,900 720

g/kw.h {g/HP.h}

209 {156}

24 V, 7.5 kW × 2 24 V, 60 A 12 V, 170 Ah × 2 Type D 3-element, 1-stage, 1-phase (with lockup clutch) Planetary gear type, multiple disc clutch type, hydraulic actuation type, lubricating oil pump force-feeding type, forward 3-speed, reverse 3-speed

Bevel gear shaft

Spiral bevel gear type, lubricating oil splashing type

Steering clutch

Wet type, multiple disc clutch type, spring-boosted type, hydraulic actuation type (manual type), brake linkage type

Steering brake

Wet type, multiple disc clutch type, spring-boosted type, hydraulic actuation type (foot operation, manual type), clutch linkage type

Final drive

Spur gear 1-stage, planetary gear 1-stage deceleration type, lubricating oil splashing type

D375A-5

01-5

GENERAL

SPECIFICATIONS

Machine model

D375A-5

Serial number

18001 and up

Suspension

Rigid, balancing beam type

Carrier roller

2 each side

Track roller

7 each side

Track shoe

Assembly type, single grouser, 40 each side, pitch: 280.0 mm, width: 610 mm

Power train + lubricating oil pump (tandem)

Gear type (BAL 180 + 112)

Scavenging pump (tandem)

Gear type (BAR 63 + 277)

PPC charge pump

Gear type (SAR(1) 022)

(work equipment pump and tandem) Maximum pressure

MPa {kg/cm2}

Type

20.6 {210} Gear type, double type (SAR(4) 140 + (3) 071)

Delivery

¬/min

405

(at engine speed of 1,800 rpm) Type For blade lift

Single pilot spool type, with demand spool

For blade tilt, ripper LO

Triple pilot spool type

For ripper HI

Double pilot spool type

Type

Double acting piston type Cylinder bore

150

Piston rod outside diameter Piston stroke

90 mm

Max. distance between pins

2,650

Min. distance between pins

1,145 225

Cylinder bore Piston rod outside diameter Piston stroke

01-6

1,505

110 mm

240


1,668


1,428

D375A-5

GENERAL

SPECIFICATIONS

Machine model

D375A-5

Serial number

18001 and up

Cylinder bore

Left cylinder: 225, Right cylinder: 250

Piston rod outside diameter

110

(both right and left) Piston stroke (both right and left)

185 mm


1,665

(both right and left) Min. distance between pins

1,480

(both right and left) Cylinder bore

225 110


mm

495


1,855


1,360 200

Cylinder bore

110


mm

550


1,800


1,250 Control valve assembly type

Hydraulic tank

(external installation type) Hydraulic semi U-tilt dozer,

Type

Hydraulic U-tilt dozer

Blade support method Max. lifting height

Brace type mm

1,660

mm

715

Max. tilt

mm

1,065

Blade cutting angle variation

deg.

±5

(from ground level) Max. lowering depth (from ground level)

D375A-5

3

Blade capacity

m

24.0

Blade width

mm

4,695

Blade height

mm

2,265

Blade cutting angle

deg.

55

01-7

GENERAL

SPECIFICATIONS

Machine model

D375A-5

Serial number

18001 and up

Max. lifting height

mm

1,660

mm

715

Max. tilt

mm

1,165

Blade cutting angle variation

(from ground level) Max. lowering depth (from ground level) deg.

±5

Blade capacity

m3

26.3

Blade width

mm

5,140

Blade height

mm

2,265

Blade cutting angle

deg.

55

Max. tilt

mm

1,150

Max. pitch angle

deg.

5

Blade cutting angle

deg.

5

Max. tilt

mm

1,260

Max. pitch angle

deg.

5

Blade cutting angle

deg.

5

Max. digging depth

mm

1,075

Max. lifting height

mm

1,050

Point digging angle

deg.

45 (Stepless adjustment is possible between 32.5 and 55.5 deg.)

Max. beam width Shank position

mm

2,854

Number of

2

holes Max. digging depth

mm

1,435

Max. lifting height

mm

1,060

Point digging angle

deg.

45 (Stepless adjustment is possible between 32.5 and 55.5 deg.)

Max. beam width Shank position

mm

1,367

Number of

3

holes

01-8

D375A-5

GENERAL

WEIGHT TABLE

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

Unit: kg

Machine model

D375A-5

Serial number

18001 and up

Engine and damper assemblies

3,080

Engine assembly

2,850

Damper assembly Engine mounting parts Radiator assembly Oil cooler assembly Fuel tank assembly (when full)

160 70 390 100 478 (1,368)

Power train unit Torque converter, PTO assembly Transmission assembly Transmission valve assembly Steering clutch and brake assembly Steering valve assembly

795 1,000 13 1,712 13

Final drive assembly

2,200 × 2

Main frame assembly

5,541

Track group assembly (each side)

7,259

Track frame

2,038

Idler assembly

478

Track roller assembly (single flange × 1)

150 × 4

Track roller assembly (double flange × 1)

160 × 3

Carrier roller assembly (each) First bogie and track roller assembly Second fourth bogies and track roller assembly Track shoe assembly Pivot shaft

71 × 2 258 717 × 3 4,200 × 2 210 × 2

Equalizer assembly

490

Hydraulic tank assembly

370

Work equipment valve (blade lift)

57

Work equipment valve (blade tilt, ripper LO)

36

01-10

D375A-5

GENERAL

WEIGHT TABLE

Unit: kg Machine model

D375A-5

Serial number

18001 and up

Semi U-dozer assembly

10,540

Blade

4,870

Straight frame (left)

1,130

Straight frame (right)

1,130

Tilt cylinder assembly Variable multi-shank ripper assembly

295 6,720

Shank assembly

470 × 3

Ripper lift cylinder assembly

345 × 2

Ripper tilt cylinder assembly

265 × 2

Variable giant ripper assembly

5,470

Shank assembly

650 × 1

Ripper lift cylinder assembly

345 × 2

Ripper tilt cylinder assembly

265 × 2

Radiator guard assembly (including cylinder yoke)

2,100

Radiator guard

1,332

Blade lift cylinder assembly Mask

268 × 2 50

Engine underguard

285

Power train underguard (front)

275

Power train underguard (rear)

250

Hood

145

Fender (left)

315

Fender (right)

355

ROPS assembly

766

Floor frame assembly

591

Cab assembly

415

Operator seat assembly

D375A-5

64

01-11

GENERAL

TABLE OF FUEL, COOLANT AND LUBRICANT

TABLE OF FUEL, COOLANT AND LUBRICANT

Ambient temperature Refilling position

Kind of oil –30

–20

–10

0

10

20

30

Specified Refilled oil amount oil amount 40°C (¬) (¬)

SAE 30CD

SAE 10WCD

Engine oil pan

68

55.5

275

150

2.1

2.1

61

61

18

18

280

120

0.95 – 1.05

0.95 – 1.05

1.40 – 1.50

1.40 – 1.50

0.70 – 0.80

0.70 – 0.80

0.095 – 0.115

0.095 – 0.115

1,050

—

165

—

SAE 10W-30CD

SAE 15W-40CD

Power train oil pan including torque converter, transmission and bevel gear case

SAE 30CD

Engine oil

SAE 10WCD

Damper case Final drive case (each side)

SAE 30CD

Pivot shaft case (each side)

SAE 10WCD

SAE 10W-30CD

Hydraulic oil

SAE 15W-40CD

Idler (each) Track roller (each) Gear oil

GO 140

Carrier roller (each) Bogie cartridge pin (each)

ASTM D975 No. 2

Fuel tank

Diesel fuel ASTM D975 No. 1

Cooling system

01-12 4

Coolant

Komatsu genuine super coolant (AF-NAC added)

D375A-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN ........................................................................................................................................ OVERALL DRAWING OF POWER TRAIN UNIT .................................................................................... POWER TRAIN HYDRAULIC PIPING DRAWING .................................................................................. DAMPER, UNIVERSAL JOINT ................................................................................................................ TORQUE CONVERTER, PTO ................................................................................................................. TORQUE CONVERTER VALVE .............................................................................................................. SCAVENGING PUMP ............................................................................................................................. TRANSMISSION CONTROL ................................................................................................................... TRANSMISSION ...................................................................................................................................... TRANSMISSION ECMV .......................................................................................................................... TRANSMISSION LUBRICATION RELIEF VALVE .................................................................................. POWER TRAIN PUMP + LUBRICATION PUMP .................................................................................... STEERING, BRAKE CONTROL ............................................................................................................. TRANSFER, BEVEL GEAR SHAFT, STEERING .................................................................................... STEERING ECMV ................................................................................................................................... STEERING CLUTCH, STEERING BRAKE ECMV .................................................................................. PARKING BRAKE VALVE ....................................................................................................................... SUDDEN STOPS PREVENTION VALVE ................................................................................................ FINAL DRIVE .......................................................................................................................................... TRACK FRAME ....................................................................................................................................... RECOIL SPRING .................................................................................................................................... IDLER ...................................................................................................................................................... TRACK ROLLER ...................................................................................................................................... CARRIER ROLLER ................................................................................................................................. TRACK ROLLER BOGIE ......................................................................................................................... TRACK SHOE .......................................................................................................................................... MAIN FRAME .......................................................................................................................................... SUSPENSION ......................................................................................................................................... WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM ........................................................................... PPC CONTROL PIPING DIAGRAM ........................................................................................................ WORK EQUIPMENT CONTROL ............................................................................................................ HYDRAULIC TANK ................................................................................................................................. PPC CHARGE VALVE ............................................................................................................................ ACCUMULATOR ..................................................................................................................................... PPC LOCK VALVE .................................................................................................................................. PPC VALVE ............................................................................................................................................. WORK EQUIPMENT CYLINDER ............................................................................................................ PISTON VALVE ....................................................................................................................................... QUICK DROP VALVE ............................................................................................................................. PIN PULLER SWITCH ............................................................................................................................. PIN PULLER SOLENOID VALVE ............................................................................................................ BLADE CONTROL KNOB ....................................................................................................................... PITCH, DUAL TILT SOLENOID VALVE ..................................................................................................

D375A-5

10- 4 10- 6 10- 8 10- 10 10- 12 10- 20 10- 31 10- 32 10- 34 10- 46 10- 52 10- 53 10- 54 10- 57 10- 64 10- 68 10- 75 10- 76 10- 77 10- 82 10- 84 10- 86 10- 88 10- 89 10- 90 10- 92 10- 94 10- 96 10- 99 10-103 10-104 10-106 10-108 10-111 10-112 10-114 10-124 10-127 10-128 10-130 10-131 10-133 10-134

10-1


WORK EQUIPMENT + PPC CHARGE PUMP ........................................................................................ 10-136 MAIN CONTROL VALVE ......................................................................................................................... 10-138 CYLINDER STAY .................................................................................................................................... 10-168 BLADE ..................................................................................................................................................... 10-170 RIPPER EQUIPMENT ............................................................................................................................. 10-176 CAB MOUNT ........................................................................................................................................... 10-178 CAB .......................................................................................................................................................... 10-179 AIR CONDITIONER ................................................................................................................................. 10-181 ENGINE CONTROL ................................................................................................................................. 10-182 ENGINE CONTROL SYSTEM ................................................................................................................. 10-183 DECELERATOR POTENTIOMETER ...................................................................................................... 10-184 HPI ENGINE CONTROL SYSTEM .......................................................................................................... 10-186 MONITOR SYSTEM ................................................................................................................................ 10-188 MONITOR PANEL ................................................................................................................................... 10-190 SENSORS ............................................................................................................................................... 10-194 MODE SELECTION SYSTEM ................................................................................................................. 10-197 SENSORS ............................................................................................................................................... 10-200 ELECTRICAL DEVICE ............................................................................................................................ 10-203 STEERING ELECTRONIC CONTROL .................................................................................................... 10-206

10-2

D375A-5


POWER TRAIN

POWER TRAIN

Outline

The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3), and it transmitted to torque converter (7). The power from the engine is transmitted through oil by torque converter (7) to the input shaft (turbine shaft) of transmission (8) in accordance with the change in the load. There is a lock-up clutch assembled to the torque converter, and when the rotating speed beyond the torque converter becomes higher, the lock-up clutch is engaged. When this happens, the drive case and turbine form one unit, so the power from the engine is transmitted directly to the transmission input shaft. Transmission (8) uses a combination of a planetary gear system and hydraulic equipment to reduce the speed and shift the gears (forward: 3 gears, reverse: 3 gears). It connects two sets of clutches selected with the gear shift lever according to the change in the load, and transmits the power from the transmission to transfer (14) from the output shaft. The power entering transfer (14) has its speed reduced. Its speed is further reduced by the bev-

10-4

el pinion and bevel gear of the bevel gear shaft, and it is then divided at right angles to the left and right and transmitted to the respective steering clutches (9). The power transmitted from the bevel gear shaft to the final drive is used to steer the machine by engaging on disengaging steering clutch (9). The steering lever is operated to disengage the steering clutch on the side to which the machine is to be steered in order to change the direction of travel. The size of the turning radius is controlled by steering brake (10) installed to the outside of the steering clutch. Steering brake (10) uses the same disc system that is used for the steering clutch. The power output from the steering clutch enters final drive (11), where it is reduced, and rotates sprocket (12). Final drive (15) is a double reduction type consisting of a single stage spur gear and single stage planetary gear system. It rotates the sprocket to drive track shoe (13) and move the machine.

D375A-5


1. 2. 3. 4.

Engine (SA6D170E-3) Damper Universal joint Power train pump (BAL 180 + 112) 5. PTO

D375A-5

POWER TRAIN

6. Hydraulic pump (SAR(4)140 + (3)071 + (1)022) 7. Torque converter 8. Transmission 9. Steering clutch 10. Steering brake

11. 12. 13. 14. 15.

Final drive Sprocket Track shoe Transfer Scavenging pump (BAR 63 + 277)

10-5


OVERALL DRAWING OF POWER TRAIN UNIT


10-6

D375A-5


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

PTO Torque converter Torque converter valve Transmission control valve Transmission Steering clutch, brake Steering control valve Power train pump (BAL 180 + 112) Transmission lubrication oil filter Power train oil filter Power train oil strainer Scavenging pump (BAR 63 + 277) Power train oil tank

D375A-5


Function

The power train unit can be broadly divided into the torque converter and transmission unit and the steering unit. Therefore, after the power train is removed as a unit, it can be divided into the torque converter and transmission unit and the steering unit. The steering unit consists of the transfer, bevel gear shaft, steering clutches, and steering brakes.

10-7


POWER TRAIN HYDRAULIC PIPING DRAWING

POWER TRAIN HYDRAULIC PIPING DRAWING

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

Oil cooler Power train oil filter Transmission lubrication oil filter Centralized pressure detection port Torque converter valve Transmission control valve (ECMV) Steering control valve (ECMV) Power train oil tank Power train oil strainer Power train pump (BAL 180 + 112) Scavenging pump (BAR 63 + 277)

A. B. C. D. E. F. G. H. J. K. L. M. N. P.

10-8

Torque converter lock-up pressure pick-up port Torque converter stator clutch pressure pick-up port Left-steering clutch operating pressure pick-up port Left-steering brake operation pressure pick-up port Transmission 2nd clutch operating pressure pick-up port Transmission R clutch operating pressure pick-up port Transmission 3rd clutch operating pressure pick-up port Transmission F clutch operating pressure pick-up port Right-steering brake operating pressure pick-up port Right-steering clutch operating pressure pick-up port Transmission 1st clutch operating pressure pick-up port Transmission main relief pressure pick-up port Torque converter regulator pressure pick-up port Torque converter relief pressure pick-up port

D375A-5


DAMPER, UNIVERSAL JOINT


10-10

D375A-5


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


Outline

Outer body Engine flywheel Output shaft Coupling Universal joint Flange Rubber coupling Cover Breather Oil level gauge tube

The damper protects the power train (such as the torque converter and transmission) by buffering torsional vibrations resulting from fluctuations in engine torque or impact torque resulting from sudden acceleration or heavy-duty operation. The rubber coupling on the damper efficiently absorbs vibrations by rubber materials internal damping effects and deformation as well as frictional damping effects of the rubber material. This arrangement also helps reducing number of components used.

Operation

No.

Check item

Clearance between the flywheel 11 housing and cover

12

Clearance between the flywheel and damper

Outside diameter of the couplings 13 oil seal contact surface 14

Outside diameter of the output shafts oil seal contact surface

15

Dimension between the bearing and holder

D375A-5

Motive power of engine is transmitted to the flywheel (2) and outer body (1) through the rubber coupling (8). After absorption of torsional vibrations of the engine by the rubber coupling, power is then transmitted to the coupling (4) via the output shaft (3). Then, power is further transmitted from the coupling to the universal joint (5) up to the torque converter input shaft. Unit: mm Criteria

Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

647.7

+0.024 +0.105

+0.080 0

0.024 0.185

0.2

546.0

0.022 0.092

+0.110 0

0.022 0.202

0.25

Standard size

Repair limit

0 110 0.035

109.9

0 110 0.035

109.9

48 ± 0.1

47.7

Replace

10-11


TORQUE CONVERTER, PTO


1. Coupling 2. Seal cage 3. Input shaft [PTO drive gear (61 teeth)] 4. Front housing 5. Idler gear (77 teeth) 6. Idler gear shaft 7. Clutch housing 8. Drive case 9. Turbine 10. Rear housing 11. Stator 12. Pump 13. Stator shaft

10-12

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Bearing cage Retainer Shaft Transmission input shaft Stator shaft boss Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lock-up clutch disc Lock-up clutch plate Lock-up clutch piston

28. Scavenging pump gear (63 teeth) 29. Seal seat 30. Spacer 31. Cover 32. Hydraulic pump gear (57 teeth) 33. Power train pump gear (57 teeth) 34. Cover 35. Cover A. Hydraulic pump mount B. Power train pump mount C. Scavenging pump mount

D375A-5


D375A-5


10-13


10-14


D375A-5



Unit: mm No. 1

Check item Outside diameter of coupling oil seal contact surface

Criteria

Remedy

Standard size

Tolerance

Repair limit

125

0 0.063

124.8

2

Inside diameter of retainer seal ring contact surface

190

+0.046 0

190.5

3

Inside diameter of sleeve seal ring contact surface

110

+0.035 0

110.2

4

Backlash between PTO drive gear and scavenging pump drive gear

5

Backlash between PTO drive gear and driven gear

6

Wear of stator shaft seal ring

7

8

Standard clearance

Clearance limit

0.250 0.420

0.204 0.516

Standard size

Repair limit

Width: 5.95 Height: 6.50

Width: 5.35 Height: 5.85

Thickness of disk

5.4

5.0

Thickness of plate

5.0

4.5

Thickness of overall assembly

15.8

14.5

Thickness of disk

5.4

5.1

Thickness of plate

5.0

4.5

15.8

14.7

Thickness of overall assembly

Standard size 9

Stator clutch spring

D375A-5

Repair hard chrome plating or replace

Replace

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

54.1

37.0

125.5 N {12.8 kg}

52.5

106.9 N {10.9 kg}

10-15



Outline

Structure

The torque converter design employs 3-element, 1-stage and 3-phase arrangement. It is, structurally, united with the transmission. In order to reduce consumption of fuel and engine horsepower as well as increase operating performance, the torque converter incorporates the wet type/double plate clutch type torque converter lock-up device plus the stator clutch device. In continuous light load dozing operations or leveling operation, motive power of the engine can be more effectively utilized when it is transmitted directly to the transmissions input shaft. It is why the hydraulically operated lock-up clutch is incorporated into the converter. When the torque converter is locked up (when the pump and turbine are united), oil supply from the converter relief valve is not stopped. Thus, the oil conducted out of the pump - turbine used to be provided with unnecessary directivity by the stator, resulting in resisting against the pump and turbine rotation (stirring of oil). In order to return the oil discharged from the pump - turbine to the pump with smaller resistance, the stator clutch has been installed to enable drag turning of the stator accompanying the rotation of the pump and turbine as the torque converter is locked up. ★ Following describes the lock-up mode of the torque converter and the conditions to be met by the torque converter mode. Lock-up range Torque converter output shaft rotation speed: 1,260 rpm minimum Torque converter range Torque converter output shaft rotation speed: 1,230 rpm maximum ★ The torque converter mode is maintained as long as gear speed change from the transmission is taking place.

10-16

The pump (12) is united with the coupling (1), shaft (3), clutch housing (7) and drive case (8). It is rotated by motive power from the engine. The turbine (9) is united with the turbine boss (24) and transmission input shaft (turbine shaft) (17). It is rotated by oil from the pump. The stator (l1) is united with the stator shaft (13) and stator boss (18). It is fixed to the rear housing (10) via the stator clutch device. The lock-up clutch device is consisted of the clutch plate (26) engaged with the drive case (8), the clutch disk (25) engaged with the turbine boss (24), and the clutch piston (27) that slides in the housing (7) united with the drive case. The stator clutch device is consisted of the clutch disk (22) engaged with the boss (18) (the boss is connected to the stator shaft (13) via the spline), the clutch plate (21) being secured to the clutch housing (19) and rear housing (10) with the pin, and the clutch piston (23) that slides in the rear housing. PTO device is consisted of the input shaft (3), idler gear (5), scavenging pump drive gear (28), work equipment pump drive gear (32) and power train pump drive gear (33).

D375A-5



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

2. Lock-up clutch ON, stator clutch OFF When the lock-up clutch is ON, drive case (8) and turbine (9) are connected to form one unit; and when the stator clutch is OFF, the connection between rear housing (10) and stator shaft (13) is cut, so stator (11) follows the rotation of pump (12) and turbine (9). The power generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. In addition, the drive case and turbine (9) are connected by the clutch, so the oil is not used. The motive force is transmitted directly to the turbine and transmission input shaft (17).

D375A-5

10-17



Flow of oil

Oil set to within 0.90 MPa {9 kg/cm2} by the torque converter relief valve flows from port A, passes through the oil hole inside rear housing (10), and enters pump (12). The pump is always being rotated by the power from the engine, so the oil entering the pump is given centrifugal force, and enters turbine (9). The turbine is rotated by the centrifugal force of the oil. The turbine forms one unit with transmission input shaft (17), so the motive force received by the turbine is transmitted to the transmission. The oil leaving the turbine is sent to stator (11) and enters the pump again, but some of the oil passes from the stator through port B and is sent to the oil cooler.

10-18

D375A-5


TORQUE CONVERTER VALVE


1. Valve body 2. Torque converter relief valve 3. Valve spring 4. Valve spring 5. Main relieve valve 6. Cover 7. Piston 8. Piston ring 9. Piston 10. Stator clutch modulating valve 11. Piston 12. Piston ring (small) 13. Piston

10-20

14. Lock application clutch modulating valve 15. Cover 16. Piston 17. Piston ring (small) 18. Piston 19. Valve spring (outside) 20. Valve spring (inside) 21. Stopper 22. Load piston 23. Cover 24. Valve spring (outside) 25. Cover 26. Valve spring 27. Valve body

28. Lock-up selector valve 29. Piston 30. Cover Lock-up solenoid valve assembly 31. Cap 32. Coil 33. Valve 34. Ball 35. Valve 36. Base 37. Shaft 38. Case 39. Plunger

P.

Status clutch pressure pick-up port P1. Torque converter relief pressure pick-up port P3. Lock-up clutch pressure pick-up port P8. Main relief pressure pick-up port P10. Torque converter regulator pressure pickup port

D375A-5



Outline

The torque converter valves are provided at the top of the torque converter housing. They are consisted of the following six types of the valves.

1. Main relief valve The main relief valve (5) regulates pressure on the hydraulic circuits of the transmission, steering clutch, lock-up clutch of the brake and torque converter, and stator clutch to 2.55 to 2.75 MPa {26.0 28.0 kg/cm2}. 2. Torque converter relief valve The torque converter relief valve (2) regulates the pressure at the entrance of the torque converter to 0.88 MPa {9.0 kg/cm2} in order to protect it from abnormally high pressure. 3. Converter lock-up valve The lock-up selector valve (24) are used to turn on or off the lock-up clutch and the stator clutch.

D375A-5

4. Torque converter lock-up solenoid valve As the electric signal from the controller is received, the solenoid valve switches the pilot pressure to the lock-up selector valve (28) in order to turn on or off the two clutches via the selector valve (28). 5. Stator clutch modulating valve The modulating valve (10) regulates the clutch pressure to 2.65 MPa {27.0 kg/cm2} in order to protect the stator clutch from abnormally high temperature. It is also used to increase pressure of the oil from the lock-up selector valve (28) to the specified level. 6. Lock-up clutch modulating valve Function of the modulating valve (14) is similar to that of the stator clutch modulating valve (10). This valve is used to regulate the clutch pressure to 1.3 MPa {13 kg/cm2}.

10-21


10-22


D375A-5



Unit: mm No.

1

Check item

Clearance between main relief valve and valve body

Criteria Standard size

Tolerance

Remedy Standard clearance

Clearance limit

+0.016 0

0.035 0.061

0.08

Shaft

Hole

40

0.035 0.045

2

Clearance between torque converter relief valve and valve

40

0.035 0.045

+0.016 0

0.035 0.061

0.08

3

Clearance between stator clutch modulating valve and valve body

25

0.035 0.045

+0.013 0

0.035 0.058

0.08

4

Clearance between lock-up clutch modulating valve and valve body

25

0.035 0.045

+0.013 0

0.035 0.058

0.08

5

Clearance between lock-up valve and valve body

25

0.020 0.030

+0.013 0

0.020 0.043

0.06

Standard size 6

Main relief valve spring

Repair limit

Replace

Free length

Installed length

Installed load

Free length

Installed load

120.3

103

1,339.4 N {136.7 kg}

116.7

1,272.4 N {129.9 kg}

7

Torque converter relief valve spring

116.92

90.8

550.4 N {56.16 kg}

113.41

523.2 N {53.35 kg}

8

Stator clutch modulating valve spring

103.5

95.2

151.9 N {15.5 kg}

100.4

144.4 N {14.7 kg}

9

Lock-up clutch modulating valve spring (Outside)

141.4

88.7

158.6 N {16.18 kg}

137.16

150.7 N {15.37 kg}

10

Lock-up clutch modulating valve spring (Inside)

80.5

80.5

78.09

66

54.0

55.9 N {5.7 kg}

64.0

53.1 N {5.42 kg}

11 Lock-up valve spring

D375A-5

10-23



Operation of main relief valve

The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to rise. When the pressure in the circuit rises, the oil entering port B pushes piston (9). The reaction force compresses spring (4), moves main relief valve (5) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure in the circuit at this point is 2.55 2.75 MPa {26.0 28.0 kg/cm2}.

Operation of torque converter relief valve

The oil relieved from the main relief valve flows into the torque converter from port C, and at the same time passes through orifice b and enters port D. When the oil fills the torque converter, the pressure starts to rise. If the pressure in the torque converter rises, the oil entering port D pushes piston (9). The reaction force compresses spring (3), moves relief valve (2) to the right in the direction of the arrow, and opens ports C and E. When this happens, the oil at port C is relieved to port E, and is drained to the oil tank. The pressure in the circuit at this point is 0.88 MPa {9 kg/cm2}.

10-24

D375A-5



Torque Converter Lock-up Control System System diagram

Operation

The torque converter lock-up control system automatically locks up the torque converter depending on the load of a machine by one sensor signal and controller. When the torque converter is locked up, the indicator lamp on the monitor panel lights up. The transmission output shaft rotation sensor signal is input to the transmission controller. Set the lock-up mode on the mode selection panel.

D375A-5

The machine body controller receives the transmission controller gear speed information, and the transmission output shaft rotation sensor signal which is sent from the SSC controlle to connect or disconnect the lock-up solenoid and indicator lamp, performing the ON/OFF of the lock-up.

10-25



The lock-up ON/OFF operation is carried out when the sensor signal conforms to the conditions below. (It is not turned ON during gear shifting.) 1. Conditions for ON (AND circuit) 1) Not during gear shifting (The status that the clutch is completely engaged): The transmission controller recognizes the status. 2) When the right-sided conditions for the ON rpm are conformed to: When the both above conditions 1) and 2) are conformed to. 2. Conditions for OFF (OR circuit) 1) During gear shifting (The status that the clutch is not completely engaged.) 2) When the right-sided conditions for the OFF rpm are conformed to.

The status quo is maintained when the conditions of either 1 or 2 are not conformed to.

10-26

Gear speed

F1

F2, F3, R1, R2, R3

ON

1,230 rpm or less

1,260 rpm or more

OFF

1,200 rpm or less

1,230 rpm or more

ON

2,140 rpm or less

OFF

2,200 rpm or more

rpm

D375A-5



1. When the machine is in torque converter travel mode

When the machine enters torque converter travel mode, the solenoid valve is demagnetized to bring back the plunger (34) upward by oil pressure, opening the seats of valve (27) and ball (28), and the ports P and N. Since the drain circuit of the port N is open, the oil at the port M is drained as well. The lock-up selector valve (24) is pushed rightward by the spring (22), closing the ports Q, L, S, and T and opening the ports Q, S, L, and R.

D375A-5

Then, the oil from the pump goes through the port Q to the port S to function as the back pressure of the piston of the stator clutch. It turns ON the stator clutch after the oil pressure of the circuit goes up. At the same time, the oil which has been functioning as the back pressure of the piston of the lock-up clutch is drained through the port L to the port R, turning OFF the lock-up clutch. The oil from the pump also enters the port P. Since the solenoid valve is demagnetized, however, it is drained through the orifice A. The oil pressure at the port Q is kept by the orifice A and regulated by the modulating valve (10).

10-27



2. When the machine is in direct travel mode

When the machine enters direct travel mode, the solenoid valve is magnetized to push the plunger (34) downward, closing the seats of ball (28) and valve (27) to open the ports P and M and close the drain circuit of the port N. Then, the oil from M moves the piston (25) and lockup selector valve (24) leftward to close the ports Q, S, L, and R, and open the ports Q, L, S, and T.

10-28

The oil from the pump goes through the port Q to the port L to function as the back pressure of the piston of the lock-up clutch. It turns ON the lock-up clutch after the oil pressure of the circuit goes up. At the same time, the oil which has been functioning as the back pressure of the piston of the lock-up clutch is drained through the port S to the port T, turning OFF the stator clutch. The oil pressure at the port L is regulated by the lock-up clutch modulating valve (11).

D375A-5



Operation of the stator clutch and lock-up clutch modulating valves

The modulating valve is mounted at the circuit between the lock-up selector valve and the inlet of two pairs of clutches. To smoothly turn on the clutch, it gradually increases the oil pressure applied to the piston up to the specified level. This operation reduces a shock to the torque converter or transmission. ★ In the following operation explanation, the modulating valve for the stator clutch is taken as an example, and that for the lock-up clutch is alike. The oil flow to the clutch is reverse, however, depending on the direct travel mode or torque converter travel mode. 1. When the machine is in direct travel mode When the machine enters direct travel mode, the solenoid valve is magnetized to cause the oil at the port M of lock-up selector valve (24) to push the piston (25) and valve (24) leftward. Then, the lock-up selector valve (24) is pushed leftward by an oil pressure larger than the tension of the spring (22) to close the ports Q and S and open the ports S and T, draining the oil at the port S through the port T. When the oil pressure at the port S vanishes, the modulating valve (10) is pushed back by the tension of spring (16) rightward to open the part B of the port S completely. At that time, the operating pressure of the stator clutch is drained through the port S to the port T to turn OFF the clutch. The oil from the pump flows through the port Q to the port L to turn ON the lock-up clutch.

D375A-5

10-29



2. When the machine is in torque converter travel mode When the machine enters torque converter travel mode, the solenoid valve is demagnetized to drain the oil from the pump and at the port M. The valve (24) moves the valve rightward by the tension of the spring (22) to close the ports Q, L, S, and T, and open the ports Q and S. By this operation, the circuit from the port Q, the modulating valve (10), and up to the stator clutch is created. The oil from the pump flows to the stator clutch through the port Q to start increasing the oil pressure of the circuit. When the oil pressure at the circuit is increased, the oil which flowed through the orifice d of the modulating valve (10) pushes the piston (13), and its reaction force moves the modulating valve leftward to throttle back the part B of the port S. The port S, which is connected to the port U which applies a back pressure to the load piston (19), moves the load piston rightward to shrink the spring (16) to open the part B of the port S by the tension of the spring. The above operation is intermittently repeated to increase the load of the spring (16), gradually increasing the oil pressure until the oil pressure increase stops at a position where the part B of the port S closes. The oil pressure of the stator clutch at that time is 2.65 ± 0.1 MPa {27.0 ± 1 kg/cm2}. The oil pressure of the lock-up clutch is 2 +1 1.3 +0.1 0 MPa {13 0 kg/cm }.

10-30

D375A-5


SCAVENGING PUMP

SCAVENGING PUMP BAR 63 + 277

A. Discharge port B. Small pump suction port C. Large pump suction port No. 1

Check item

Criteria

Spline shaft rotation torque Delivery

Unit: mm

Oil: E010-CD Oil temperature: 45 55°C

Type BAR 63 BAR 277

D375A-5

Remedy

Rotating speed (rpm) 1,743

Discharge pressure

Standard discharge amount

Permissible discharge amount

0.15 {1.5}

63.3

276.8

MPa {kg/cm }

(¬/min)

(¬/min)

10-31


TRANSMISSION CONTROL

TRANSMISSION CONTROL ★ Regarding the steering-related description of the Palm Command Control System lever (PCCS lever), refer to the Steering/Brake Control. ★ PCCS: Palm Command Control System

1. Brake pedal 2. Safety lever 3. PCCS lever (Forward-reverse, gear shift) 3A, UP switch (Shift up by every one pressing) 3B, DOWN switch (Shift down by every one pressing) 4. Transmission neutral safety switch 5. Cable 6. Transmission control valve

10-32

Lever position 1: 2: 3: 4: 5: 6: 7: 8:

Neutral Forward Reverse OFF Shift UP Shift DOWN Free Lock

Outline

Control the transmission by the PCCS lever (3). The PCCS lever operates forward/reverse shifting and gear shift operation. The adopted safety mechanism does not cause the transmission neutral safety switch (4) to function except when the safety lever (2) is at the Lock position, not allowing the engine to start.

D375A-5


TRANSMISSION CONTROL

Gear shift of the machine Since gear shift during travel is possible, there is no need to stop the machine to shift gears. Gear shift operation Operate the gear shift lever by pressing the switches (1) and (2) when the steering, forward/reverse, and gear shift lever is at the forward or reverse position. (1) One pressing the up shifts the gear speed one up. (2) One pressing the down shifts the gear speed one down. ★ If you carry out the gear shift, the gear speed in use is indicated on the display of the panel. Neutral: Indicates N on the display. Forward 2nd speed gear: Indicates F2 on the display. Reverse 3rd speed gear: Indicates R3 on the display. P is indicated when the safety lever is placed at the Lock position.

D375A-5

10-33


TRANSMISSION

TRANSMISSION

1. 2. 3. 4.

Input shaft Transmission valve Front case Rear case

10-34

A. B. C. D. E.

2nd clutch operating pressure pick-up port R clutch operating pressure pick-up port 3rd clutch operating pressure pick-up port F clutch operating pressure pick-up port 1st clutch operating pressure pick-up port

D375A-5


10-36

TRANSMISSION

D375A-5


5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

TRANSMISSION

Front cover Sun gear for reverse (34 teeth) Ring gear for reverse (91 teeth) Pinion shaft Planetary pinion for reverse (25 teeth) Ring gear for reverse (84 teeth) Sun gear for forward (41 teeth) Planetary pinion for forward (25 teeth) Ring gear for forward (91 teeth) Pinion shaft Ring gear for 3rd speed gear (91 teeth) Planetary pinion for 3rd speed gear (25 teeth) Sun gear for 3rd speed gear (41 teeth) Ring gear for 2nd speed gear (93 teeth) Planetary pinion for 2nd speed gear (23 teeth) Pinion shaft Sun gear for 2nd speed gear (47 teeth) 1st clutch inner drum 1st clutch piston 1st clutch piston housing Output shaft Collar Block 1st clutch spring Seal ring Carrier for 2nd speed gear Plate Carrier for forward, 3rd speed gear Piston housing for forward, 3rd speed gear Carrier for reverse Piston housing for reverse Clutch piston for reverse Clutch spring Clutch plate Clutch disc Tie bolt Carrier gear for reverse (91 teeth)

D375A-5

10-37


10-38

TRANSMISSION

D375A-5


TRANSMISSION

Unit: mm No.

Check item

Criteria

Remedy

Standard size 1

2 3 4

No. 1 clutch spring

No. 2 clutch spring No. 3, 4 clutch spring No. 5 clutch spring

(× 12)

(× 12) (× 12) (× 3)

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

66.0

57.0

125.5 N {12.8 kg}

64.0

107.9 N {11.0 kg}

70.0

60.3

218.7 N {22.3 kg}

68.0

196.1 N {20.0 kg}

97.0

82.4

149.1 N {15.2 kg}

95.0

127.5 N {13.0 kg}

7.75

6.75

3,422.5 N {349 kg}

3,079.3 N {314 kg}

Standard size

Tolerance

Repair limit

54.6

±0.33

49.0

Overall assembled thickness of No. 2 clutch

50.3

±0.33

45.0

7


36.4

±0.26

32.0

8


27.3

±0.22

24.0

9


50.0

±0.33

45.2

10

Thickness of clutch disc (No. 1 4 clutch)

4.8

±0.1

4.0

11

Thickness of clutch disc (No. 5 clutch)

5.0

±0.1

4.2

12

Thickness of clutch plate (No. 1 4 clutch)

4.3

±0.1

4.0

13

Thickness of clutch plate (No. 5 clutch)

4.0

±0.1

3.8

14

Wear of seal ring on transmission input shaft

Width: 3.0 Thickness: 3.5

Width:

0.01 0.03 Thickness: ±0.15


15

Wear of seal ring on transmission output shaft


Width:

0.01 0.03 Thickness: ±0.1


16 Wear of seal ring on No. 5 clutch


Width:

0.01 0.03 Thickness: ±0.15


5


6

17

Backlash between No. 1, 2 sun gear and planet pinion

18

Backlash between No. 1 planet pinion and ring gear inner teeth

Backlash between No. 2, 3, 4 19 planet pinion and ring gear inner teeth

Standard clearance

Clearance limit

0.13 0.40

0.13 0.40

0.14 0.40

20

Backlash between No. 3, 4 sun gear and planet pinion

0.13 0.37

21

Clearance between bearing and thrust washer

0.16 1.59

D375A-5

Replace

10-39


TRANSMISSION

Outline

The transmission is a forward 3 gear, reverse 3 gear transmission that consists of a combination of a planetary gear system and disc clutches. The transmission actuates the control valve to use hydraulic pressure to fix two of the clutches in the five sets pf planetary gears and disc clutches to select one rotating direction and one gear speed. The clutches are locked as follows: No. 1 clutch for REVERSE, No. 2 clutch for FORWARD, No. 3 clutch for 3rd, No. 4 clutch for 2nd and No. 5 clutch for 1st.

No. of plates and discs used Clutch No.

No. of plates

No. of discs

No. 1 clutch

6

6

No. 2 clutch

5

6

No. 3 clutch

4

4

No. 4 clutch

3

3

No. 5 clutch

5

6

Gear speed, clutch combination. Gear speed FORWARD 1st FORWARD 2nd FORWARD 3rd NEUTRAL REVERSE 1st REVERSE 2nd REVERSE 3rd

Clutch combination (engaged) No. 2 . No. 5 No. 2 . No. 4 No. 2 . No. 3 1 . No. 5

No. 1 . No. 5 No. 1 . No. 4 No. 1 . No. 3

1: Only low pressure oil fills the 1st clutch.

10-40

D375A-5


TRANSMISSION

Operation of disc clutch

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

Clutch engaged (Locked)

Oil from the control valve flows under pressure through the port in housing (35) to the back of piston (36). The piston presses plates (38) and discs (39) together, and the resulting frictional force stops the rotation of discs (39), so ring gear (7) meshing with the internal teeth of the disc is locked.

Clutch disengaged (free)

When the supply of pressure oil from the control valve is shut off, piston (36) is returned to its original position by the force of piston return spring (37). This relieves the frictional force between plates (38) and discs (39), making the ring gear (7) free. Washer spring (43) installed between the plates at the pin acts to speed up the return of the piston when the clutch is disengaged, and also to separate the plate and disc cleanly to prevent continued rotation.

D375A-5

10-41


TRANSMISSION

1st clutch oil circuit The 1st clutch is farthest from the control valve, and the piping to the cylinder is longer, so it takes a longer time for the oil to fill the piping. For this reason, even when the gear shift lever is in neutral, oil still flows to the 1st clutch. Therefore, when moving the gear shift lever from neutral to F1, it is only necessary for the oil from the pump to fill the FORWARD clutch. When the gear shift lever is moved from F1 to F2, the FORWARD clutch is already filled with oil, so the oil from the pump only needs to fill the 2nd clutch. By using the oil in this way, the time lag when shifting gear is reduced.

10-42

D375A-5


TRANSMISSION

OPERATION OF TRANSMISSION FIRST FORWARD SPEED

For FORWARD 1st, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 2 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks ring gear (13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engaged No. 5 gear (22) and No. 4 ring gear (18). The motive force from the torque converter is transmitted to input shaft (1). The rotation of the input shaft is transmitted through sun gear (11) to planet pinion (12).

D375A-5

Ring gear (13) is locked in position by No. 2 clutch, so planet gear (12) rotates carrier (32), which is on the inside of ring gear (13). No. 5 clutch is also engaged, so the No. 5 gear (22), sun gears (17) and (21), planet pinions, ring gear (15) and (18), and No. 4 carrier (30) form one unit. In addition, carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25). Output shaft (25) rotates at the same speed as carrier (32).

10-43


TRANSMISSION

FIRST REVERSE SPEED

For REVERSE 1st, No. 1 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 1 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks carrier (34) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engaged No. 5 gear (22) and No. 4 ring gear (18). The motive force from the torque converter is transmitted to input shaft (1). The rotation of the input shaft is transmitted through sun gear (6) to planet pinion (9).

10-44

Carrier (34) is locked in position by No. 1 clutch, so the rotation of planet pinion (9) rotates ring gear (10). Ring gear (10) rotates in the opposite direction from the input shaft, and it rotates carrier (32). No. 5 clutch is also engaged, so the No. 5 gear (22), sun gears (17) and (21), planet pinions, ring gear (15) and (18), and No. 4 carrier (30) form one unit. In addition, carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).

D375A-5


TRANSMISSION ECMV

TRANSMISSION ECMV (Electronic Control Modulation Valve)

10-46

D375A-5


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

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

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

1st operating pressure pick-up port 3rd operating pressure pick-up port R operating pressure pick-up port 2nd operating pressure pick-up port F operating pressure pick-up port To clutch From pump Drain

D375A-5

TRANSMISSION ECMV

10-47


10-48

TRANSMISSION ECMV

D375A-5


TRANSMISSION ECMV

Outline of ECMV

ECMV and proportional solenoid

•

•

The ECMV consists of a pressure regulator valve and a fill switch. • Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve, to an oil pressure. • Fill switch Detects that the clutch is filled with oil. It has the functions below. 1) When the clutch is filled with oil, a signal (the fill signal) is sent to the controller to notify that filling is finished. 2) While oil pressure is being applied to the clutch, a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied. A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point: Start of filling F point: Finish of filling

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

Current-Propulsion force characteristics of proportional solenoid

Propulsion force-Hydraulic pressure characteristics of proportional solenoid

ECMV and fill switch ★ The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

D375A-5

•

One fill switch is installed for one ECMV. If the clutch finishes filling,the fill switch is turned "ON" by the pressure of the clutch. By this signal, the oil pressure starts build-up.

10-49 (7)


ECMV operation •

The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. The relationship between the proportional command current for the ECMV, clutch input pressure, and output signal of the fill switch is shown in the graph below.

TRANSMISSION ECMV

1. Before shifting gear (when drained) (A range in chart) When a current is not carried to the proportional solenoid (1), the pressure control valve (2) is draining the oil at the clutch port A through the drain port Dr. Since oil pressure is not applied to oil pressure detector valve (3) at this time,fill switch (4) is turned "OFF".

A range:Before shifting gear (when drained) B range:Filling C range:Pressure regulation D range:Filling (triggering) E point:Start of filling F point:Finish of filling

★ The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

10-50 (7)

D375A-5


2. Filling (B range in chart) If you supply current to the proportional solenoid (1) with no oil in the clutch, an oil pressure proportional to the solenoid force acts on the chamber B, pushing the pressure control valve (2) rightward. As a result, pump port P and clutch port A are opened and oil starts filling the clutch. If the clutch is filled with oil,fill switch (4) is turned "ON".

D375A-5

TRANSMISSION ECMV

3. Pressure regulation (C range in chart) If you supply current to the proportional solenoid (1), the solenoid produces thrust proportional to the current. Pressure is regulated by balancing the thrust of the solenoid, the thrust of clutch port A, and reaction force of the pressure control spring (5).

10-51 (7)


TRANSMISSION LUBRICATION RELIEF VALVE

TRANSMISSION LUBRICATION RELIEF VALVE

1. Lubrication oil pressure measurement plug 2. Lubrication relief spool 3. Valve body

Function

The lubrication relief valve is installed to the right side face of the transmission, and acts to prevent any abnormal pressure in the transmission lubricating oil. Cracking pressure: 0.26 MPa {2.7 kg/cm2}

10-52

D375A-5


POWER TRAIN PUMP + LUBRICATION PUMP

POWER TRAIN PUMP + LUBRICATION PUMP BAL 180 + 112

Unit: mm No.

1

2

Check item

Side clearance

Clearance between plain bearing inside diameter and gear shaft outside diameter

Criteria Type

Standard clearance

Clearance limit

BAL 180

0.07 0.12

0.15

BAL 112

0.04 0.10

0.13

0.060 0.145

0.20

BAL 180 BAL 112 Type

3

Driving depth of pin

BAL 180 BAL 112

4

Spline shaft rotation torque Delivery

Oil: E010-CD Oil temperature: 45 50°C (Engine speed: 1,900 rpm)

D375A-5

Remedy

Standard size

Tolerance

Repair limit

14

0 0.5

Replace

5.9 Nm {0.6 kgm} or less Type

Rotating speed (rpm)

Discharge pressure



MPa {kg/cm }

(¬/min)

(¬/min)

BAL 180

2,033

2.5 2.7 {26 28}

334

308

BAL 112

2,033

0.26 {2.7}

210

200

10-53


10 Structure, function and maintenance standard STEERING, BRAKE CONTROL

STEERING, BRAKE CONTROL ★ Regarding the transmission-related description of the operation of the PCCS lever, refer to the Transmission Control. ★ PCCS: Palm Command Control System

10-54

D375A-5


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

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

STEERING, BRAKE CONTROL

Positions of lever and pedal 1: 2: 3: 4: 5: 6: 7: 8: 9: :: A:

Neutral Forward straight-travel Reverse straight-travel Left clutch OFF Left clutch OFF Left brake ON Right clutch OFF Right clutch OFF Right brake ON Brake RELEASE Brake ON Free Lock

Outline

The PCCS lever (3) sends an electric signal to the steering controller (10). After receiving it, the steering controller (10) sends a proportional current to the steering ECMV (6) to operate the steering clutch and brake. The brake pedal (1) sends an electric signal to the steering controller (10) via the potentiometer (11). After receiving it, the steering controller (10) sends a proportional current to the steering ECMV (6) to operate the brake. In this case, the right and left brakes operate at the same time to activate braking. The rod (5) operates the brake via the brake valve (9) for redundant use. (Only at the time of complete braking) If you slightly tilt the PCCS lever (3) leftward, the left steering clutch is partially disengaged, causing the machine to make a slow left swing.

D375A-5

If you completely tilt the PCCS lever (3) leftward, the left steering clutch is turned OFF completely and the left steering brake is turned ON, causing the machine to make a sudden left swing. The safety bar (2) is connected to the parking brake lever (8) and it also serves as a parking brake.

10-55


TRANSFER, BEVEL GEAR SHAFT, STEERING


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

Transmission unit Input shaft Steering unit Breather Parking brake valve Left brake ECMV Right brake ECMV Transmission output rotation sensor Filter Left clutch ECMV Right clutch ECMV Sudden braking prevention valve

D375A-5

10-57



Transfer Bevel Gear Pinion

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

Input shaft Drive gear (35 teeth) Transmission output rotation sensor Rear cover Bearing gauge Driven gear (33 teeth) Bevel pinion (23 teeth) Bevel gear (40 teeth)

10-58

Outline

The transfer bevel pinion is mounted at the rear part inside the steering case, which receives the power from the transmission output shaft by its input shaft (1). The transfer consists of the drive gear (2) and the driven gear (6) to reduce the power speed from the input shaft (1), transferring it to the bevel pinion (7). It is also provided with the transmission output rotation sensor (3) to send the pulse signal of the drive gear (2) to the torque converter lock-up controller using an electric signal.

D375A-5



Unit: mm No.

Check item

1

Backlash of transfer gear

2

Thickness of collar between transfer gear and bearing

3

Standard shim thickness for bearing cage mount

D375A-5

Criteria

Remedy

Standard clearance

Clearance limit

0.24 0.63

0.75

Standard size

Repair limit

24

23.6 2.0

Adjust or replace

Replace Adjust

10-59



BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE

10-60

D375A-5


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

Clutch cage Clutch housing Clutch spring Clutch piston Torque pin Clutch disc (One side: 9 sheets) Clutch plate (One side: 9 sheets) Spacer Clutch stopper Clutch hub Bearing cage Bevel gear (Number of teeth: 40) Bevel gear shaft Bevel gear shaft Bearing cage Pipe Brake stopper Brake hub Brake disc (One side: 9 sheets) Spacer Brake plate (One side: 9 sheets) Torque pin Brake piston Brake case Brake spring Brake cage Sleeve Output shaft

D375A-5


Outline

As steering clutches, wet-type, multiple disc type, and spring-boosted types are adopted. If you operate the PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering ECMV while interlocking with the brake. As a lubrication method, forced lubrication is adopted, which makes oil from the power train oil cooler flow through the passage in the steering case to the housing and cage, and up to the disc plate.

As steering brakes, wet-type, multiple disc type, and spring-boosted types brakes are adopted. If you operate the brake pedal and PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering valve ECMV while interlocking with the brake. As a lubrication method, forced lubrication is adopted, which makes oil from the power train oil cooler flow through the passage in the steering case to the housing and cage, and up to the disc plate. When the engine is stopping, the steering brake is ON since the back pressure of the brake piston lowers unless you press the brake pedal. Since the brake is released as the oil pressure in the circuit goes up when the engine restarts, the parking lock lever must be locked.

10-61


10-62


D375A-5



Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

2.9

2.5

Tolerance

Repair limit

Less than 0.3

0.4

Standard size

Repair limit

4.7

4.2

Tolerance

Repair limit

Less than 0.3

0.4

Standard size

Repair limit

68.4

64.7

68.4

65.4

Standard clearance

Repair limit

0.17 0.52

1.0

Thickness of brake, clutch plate 1 Distortion of brake, clutch plate Thickness of brake, clutch disc 2 Distortion of brake, clutch 3

Overall assembled thickness of brake plates and discs

4

Overall assembled thickness of clutch plates and discs

5

Backlash between brake, clutch disc and brake hub

6

Backlash between bevel gear and pinion

0.3 0.4

0.75

7

Clearance between piston seal ring groove and seal ring

0.5 0.8

0.8

8

Clearance between cage seal ring groove and seal ring

0.5 0.8

0.8

9

10

Inside diameter of cage seal ring contact surface Inside diameter of piston seal ring contact surface

Tolerance Shaft

Hole

Standard clearance

290

0.5 0.7

+0.081 0

0.5 0.781

245

0.050 0.122

+0.046 0

0.050 0.168

Standard size

Standard size 11 Brake belleville spring

12 Clutch belleville spring

13

Interference between bevel gear and reamer bolt

14 Runout of back face of bevel gear

Replace Repair or replace Replace Repair or replace

Replace

Adjust or replace

Clearance limit

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

17.1

11.2

38.7 kN {3,950 kg}

16.5

33.9 kN {3,460 kg}

17.6

11.35

37.9 kN {3,860 kg}

17.0

36.0 kN {3,670 kg}

Standard size 16

Tolerance Shaft

Hole

Standard interference

Interference limit

+0.019 +0.001

+0.027 0

0.026 0.019

0.02

Repair limit: 0.05 (measure after installing to bevel gear)

Replace

Repair or replace

15

Standard rotating torque: 4.9 5.9 Nm {0.5 0.6 kgm} Preload of bevel gear shaft taper (At tip of bevel gear teeth with bevel pinion and gear not meshed: Adjust roller bearing 23.5 28.4 N {2.4 2.9 kg})

16

Standard shim thickness for bearing cage

D375A-5

2.0

Adjust shim

10-63


STEERING ECMV

STEERING ECMV (Electronic Control Modulation Valve)

10-64

D375A-5


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

ECMV (For left clutch) ECMV (For right clutch) Sudden braking prevention valve Parking brake valve ECMV (For left brake) ECMV (For right brake) Filter Valve seat

D375A-5

STEERING ECMV

A. B. C. D. E. F. G. H. J. K. L. M. N. P.

Left clutch operating pressure pick-up port Right clutch operating pressure pick-up port Left brake operating pressure pick-up port Right brake operating pressure pick-up port To left clutch To left lubrication To left brake To right clutch To right lubrication To right brake Bevel gear shaft lubrication inlet To pin puller solenoid valve From pin puller solenoid valve From pump

10-65


10-66

STEERING ECMV

D375A-5


STEERING ECMV

Outline

This machine employs four ECMV (electroniccontrolled modulation valve) on the steering control valve. The steering control valve is provided on respective valve sheets as the assembly. The steering control valve is situated in the circuit between the power train pump via the main relief valve and the piston of the steering clutch and the brake. It is configured with two pairs of the steering ECMV (right and left) and the brake ECMV (right and left). Shifting the PCCS lever (steering and forward/ reverse) right or left disconnects the steering clutch. Shifting it further turns ON the brake. The controller sends the instruction to respective ECMV to cause the gradual or sudden turn whichever is designated by the operating position of the PCCS lever (steering lever). Depending on depth of the pedal depression, the controller instructs ECMV to apply the right and left brakes to stop the machine. The controller that is electrically connected to the PCCS lever and pedal performs above operations by switching the steering control valves (each ECMV). The steering control valves feed the oil from the power train pump to the steering clutch and brake to operate their disk clutches. The sudden stop prevention valve disables sudden braking that can result when a failure is detected in the electric systems. Shifting the parking brake lever to the Lock position switches the port of the parking brake valve, thereby draining the oil between the ECMV for left-and-right brakes and the brake. As the result, the machine brake is turned on. The parking brake is also connected to the brake pedal via the linkage.

D375A-5

10-67


STEERING CLUTCH, STEERING BRAKE ECMV

STEERING CLUTCH, STEERING BRAKE ECMV (Electronic control modulating valve)

A: To clutch or brake P: From pump T: Drain Dr: Drain P1: Clutch or brake pressure pick-up port P2: Pilot pressure pick-up port

10-68

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

Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve

D375A-5



Outline of ECMV

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

ECMV and Proportional Solenoid

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

Operation of ECMV

The ECMV is controlled using the command current from the controller to the proportional solenoid and a fill switch output signal.

ECMV for Steering Clutch and Steering Brake Outline

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

D375A-5

10-69



Operation 1. In case of PCCS lever Neutral, brake pedal Released: Straight travel (Left and right clutch ON, left and right brake Released, parking brake OFF)

In the position of PCCS lever Neutral and brake pedal Released, because the solenoid valve (1) of the steering ECMV is deenergized, the sealing portion of the ball (2) is opened. The oil from the power train pump enters the port 2? of the steering ECMV via the main relief valve. The oil that entered the port 2? passes through the orifice = and passes through the sealing portion of the ball (2), then is drained. The valve (3) is moved right by the tension of the spring (4) and closes the 2? and + ports, then opens the + and ,H ports. At this time, the oil from the back pressure port of a clutch piston is drained from the port + and the clutch is set to ON by the tension of the clutch spring. The oil pressure of the brake circuit is ensured by the orifice =.

10-70

Further, the proportional solenoid valve (5) of the brake ECMV is energized and pushes the ball (6) to the left direction, then closes the sealing portion. The oil that entered the pump port 2> enters the port, pushes the valve (7) left, opens the 2> and * ports, and closes the * and ,H ports. The oil that entered the 2> port passes through the * port and flows into the back pressure port of the brake piston. Subsequently, the piston moves to the left direction waiting for the rise of the circuit oil pressure and compresses the brake spring, then sets the brake Released. In the parking brake OFF, the parking brake is closed and the oil of the brake circuit is not drained.

D375A-5



2. When the PCCS lever is actuated halfway to the left: Slow swing (Left clutch OFF, left brake Semi-released, right clutch ON, right brake Released, parking brake OFF)

When the PCCS lever is actuated halfway to the left, the solenoid valve (1) of the left steering ECMV is energized and pushes the ball (2) to the left direction, then closes the sealing portion. The oil from the power train pump passes through the orifice = from the port 2? and enters .. Subsequently, the oil pushes the valve (3) to the left and opens the 2? and + ports, then closes the + and ,H ports. The oil of the + port flows into the clutch piston port and becomes the back pressure, then sets the left clutch to OFF. Further, the proportional solenoid valve (5) of the left ECMV is energized and pushes the ball (6) to the left direction, then closes the sealing portion. The oil that entered the pump port 2> enters the port and pushes the valve (7) to the left. Besides, the oil pressure of the port * and later outputs a command current from the controller to the

D375A-5

proportional solenoid valve (5) in accordance with the stroke of the PCCS lever. When the current flows into the proportional solenoid (5), the solenoid generates a thrust in proportion to the current. The sum of the thrust of this solenoid, the thrust caused by the brake port oil pressure, and the restitution of the pressure control valve spring (8) is balanced and pressure-adjusted. Accordingly, if the stroke of the PCCS lever is small, the oil pressure of the port * and later is also specified high and the brake changes from Released to Semi-released. If the stroke is large, the oil pressure is specified low and the brake changes from Semi-released to ON. In the parking brake OFF, the parking brake valve is closed and the oil of the brake circuit is not drained.

10-71



3. When the PCCS lever is actuated fully to the left: Sudden swing (Left clutch OFF, left brake ON, right clutch ON, right brake Released, parking brake OFF)

When the PCCS lever is actuated fully to the left from the state of Section 2, the proportional solenoid valve (5) of the left brake ECMV is deenergized and sets the ball (6) free, then opens the sealing portion. Because the oil of the port E passes through the sealing portion and is drained, the valve (7) is moved right by the tension of the spring (8). At this time, the port Pb closes and the port B and drain port Dr open. The oil from the power train pump passes through the orifice b from the port Pb and passes through the sealing portion, then is drained. The oil pressure of the clutch circuit is ensured by the orifice b. On the other hand, the oil that flows into the brake piston port and reached the back pressure is drained from the port B to Dr.

10-72

The left brake is set to ON by the tension of the brake spring. In the parking brake OFF, the parking brake valve is closed and the oil of the brake circuit is not drained.

D375A-5



4. In case of brake pedal Stepped on (Clutch ON, brake ON, parking brake OFF)

When the brake pedal is stepped on, the proportional solenoid valve (5) of the left and right brake ECMVs is deenergized from energization by the pedal full actuation. A command current is output from the controller to the proportional solenoid valve (5) in accordance with the actuation stroke of the brake pedal. When the current flows into the proportional solenoid valve (5), the solenoid generates a thrust that is proportional to the current. The sum of the thrust of this solenoid, the thrust caused by the oil pressure of the brake port, and the restitution of the pressure control valve spring (8) is balanced and oil pressure is specified, thereby enabling adjustment of the effect of the brake. Besides, because the PCCS lever is not actuated, the solenoid valve (1) of the left and right

D375A-5

steering ECMVs is deenergized and the left and right clutches are set to ON. Further, when the brake pedal is stepped on, the parking brake valve linked using a linkage is actuated and drains the oil of the brake circuit.

10-73



5. In case of parking brake ON (Clutch ON, brake ON, PCCS lever Neutral, braking pedal Released)

When the safety lever for the PCCS lever is set to the position of Locked, the parking brake valve (1) moves to the left direction and the ports A, B, and C open. Accordingly, the oil that flows into the brake piston port and reached the back pressure passes through the port C from the ports A and B and is drained. The back pressure of the brake piston port continues decreasing and the brake is fully set to ON, then is held in the state. Further, because the ports A and B continue being opened together with the drain port C even if the engine is restarted, the state of the brake ON is held. In the parking brake OFF, the parking brake valve (1) moves right and is closed between the

10-74

port A, port B, and drain port C, then the brake is set Released by oil pressure.

D375A-5


PARKING BRAKE VALVE

PARKING BRAKE VALVE

Unit: mm No.

1

Check item

Clearance between parking brake valve spool and valve body

Criteria Standard size 14

2

Sliding portion outside diameter (spool) with dust sealing and Vpacking

Tolerance Shaft

Hole

Standard clearance

0.020 0.030

+0.011 0

0.020 0.041

Parking brake valve spool spring

D375A-5

Clearance limit 0.05

Tolerance

Repair limit

0.020 0.030

13.9

14

Standard size 3

Remedy

Replace

Hard chrome plating correction and replace

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

65

47.7

38.2 N {3.9 kg}

63.1

36.3 N {3.71 kg}

Replace

10-75


SUDDEN STOPS PREVENTION VALVE

SUDDEN STOPS PREVENTION VALVE

Outline

This sudden stops valve is installed to prevent a vehicle from being braked suddenly when an error occurs in an electrical system. When the sudden stops prevention valve (1) is installed in the drain circuit of the brake ECMV and the solenoid valve (2) of the brake ECMV is deenergized, the oil of the brake circuit D is drained and sudden braking is prevented from being applied. Accordingly, when the solenoid valve (3) of the sudden stops prevention valve (1) is deenergized, the brake is set to Semi-released by throttling the brake drain circuit D that works as the orifice a circuit.

10-76

D375A-5


FINAL DRIVE

FINAL DRIVE

Outline

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

D375A-5

10-77


10-78

FINAL DRIVE

D375A-5


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

Floating seal Sun gear Carrier Hub Cover Sprocket boss Sprocket teeth

FINAL DRIVE

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

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

Floating seal guard Cover Planetary pinion Ring gear Cover First gear First gear hub

First pinion Final drive case Bearing cage Boss Shaft Wear guard Pivot shaft Unit: mm

No.

Check item

22

Backlash between first pinion and first gear

23

Criteria

Remedy

Standard clearance

Clearance limit

0.25 0.99

1.5

Backlash between sun gear and planetary pinion

0.22 0.81

1.5

24

Backlash between planetary pinion and ring gear

0.25 0.81

1.5

25

Outside diameter of oil seal contact surface of first pinion

Standard size

Repair limit

115.0

114.9

26

Thickness of thrust collar in roller bearing of inner body

25.14

24.9

27

Thickness of thrust collar in roller bearing of first gear boss

10.0

9.5

28

Dimensions from cover mounting face to button head

24.0

22.5

Clearance between pinion shaft 29 and carrier

Standard size 85

30

Standard shim thickness of first pinion bearing cage

31

Dimensions of final cover end surface and bearing end surface

32 Clearance of floating seal guard

D375A-5

Tolerance

Replace

Shaft

Hole

Standard clearance

Clearance limit

0.036 0.058

0.024 0.059

0.023 0.034

0.1

2 7

0 0.2

Adjust

4.1 5.3

10-79


FINAL DRIVE

PATH OF POWER TRANSMISSION

10-80

D375A-5


FINAL DRIVE

The power from the bevel gear and steering clutch is transmitted to No. 1 pinion (15). It then passes through No. 1 gear (13), which is meshed with the No. 1 pinion, and is transmitted to sun gear (2) to rotate it. The rotation of sun gear (2) is transmitted to planet pinion (10), but ring gear (11), which is meshed with the planet pinion, is fixed to cover (9), so the planet pinion rotates on its own axis and moves around the sun gear along the ring gear. Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports the planet pinion, and is transmitted to sprocket hub (4). The direction of rotation of carrier (3) is the same as that of sun gear (2). The rotating force transmitted to sprocket hub (4) is transmitted to sprocket teeth (7).

D375A-5

10-81


TRACK FRAME

TRACK FRAME

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

Idler Recoil spring assembly Carrier roller Track frame Sprocket Sprocket cover Track roller bogie Track roller Gap Idler yoke Cylinder Guide

10-82

Outline

The track roller adopts a K type bogie mount, thereby increasing the actual ground contact area between a road surface and a track shoe in an uneven ground and increasing drawbar pull. Because a rubber pad is mounted on a K type bogie, the shock from a road surface is absorbed.

Track roller bogie Track roller flange type and bogie arrangement No. 1

No. 2

No. 3

No. 4

No. 5

No. 6

No. 7

S

D

S

D

S

D

S

D375A-5


TRACK FRAME

Unit: mm No.

Check item

Criteria Item

4

Clearance between inner sleeve 13 and adjustment cylinder protruding portion

14

Clearance between idler bogie and guide

15 Press fit force of cartridge pin

D375A-5

Repair limit

Bend

Deformation of track frame outer sleeve

Remedy

7 (Per length 3,000)

Torsion

3 (Per level length 300)

Concave (Pipe portion)

12

Standard size 60

Tolerance Shaft

Hole

Standard clearance

0.15 0.35

+0.3 0

0.15 0.65

Clearance limit 2.0

Standard clearance

Clearance limit

0 0.5

3.0

245 441 kN {25 45 ton}

Correct or replace

Replace

Adjust

10-83


RECOIL SPRING

RECOIL SPRING

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

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

10-84

Outline

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

D375A-5


RECOIL SPRING

Unit: mm No.

Check item


4

Recoil spring

Clearance between outer and 12 inner sleeve sides of outer sleeve bushing

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

1,416

1,230.5

499.7 kN {50,994 kg}

1,440

458.5 kN {46,790 kg}

Standard size

Tolerance Shaft

Hole

Standard clearance

380

0.058 0.228

+0.317 +0.060

0.118 0.545

135

0.600 1.000

13

Clearance between adjustment cylinder and bushing

14

Press fit force of outer sleeve bushing (outer sleeve side)

49.0 109.8 kN {5.0 11.2 ton}

15

Press fit force of outer sleeve bushing (inner sleeve side)

91.2 322.6 kN {9.3 32.9 ton}

16

Clearance between recoil spring mounting nut and lockplate

D375A-5

Clearance Replace limit 0.8

Adjust

0 1.0

10-85


IDLER

IDLER

10-86

D375A-5


IDLER

Unit: mm No. 1

Check item

Criteria

Outside diameter of protruding portion

Remedy

Standard size

Repair limit

927

—

2

Outside diameter of tread

880

855

3

Depth of tread

23.5

—

4

Thickness of tread

32.5

20

5

Total width

294.4

—

6

Width of tread

79.0

87.5

7

Clearance between shaft and busing

Standard size 155

8

9

Tolerance Shaft

Hole

Standard clearance

–0.350 –0.413

+0.198 –0.053

0.297 – 0.611

Rebuild or replace

Clearance limit Replace bushing

Standard size

Repair limit

252

—

— Rebuild or replace

Collar width of shaft

Interference between shaft and ring

Standard size 95

Tolerance Shaft

Hole

+0.046 0

–0.15 –0.20

Standard Interference interference limit Replace ring 0.15 – 0.246

Standard clearance

Clearance limit

0.49 – 0.86

—

10 End play

D375A-5

0.8

Adjust or replace

10-87 4


TRACK ROLLER

TRACK ROLLER

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

310

300

270

200

270

210

Single flange

60

25

Double flange

60

30

1

Outside diameter of flange (outside)

2

Outside diameter of flange (inside)

3

Outside diame- Single flange ter of tread Double flange

4

Thickness of tread

5

Total width

358

6

Width of tread (Single flange)

82

7

Width of tread (Double flange)

82

8

Width of flange (Outside double flange)

29

14

9

Width of flange (Inside double flange)

27

12

306

10 Collar width of shaft

11

12

Clearance between shaft and bushing


13 End play

10-88

Standard size 140 Standard size 75

Tolerance Shaft

Hole

Standard clearance

0.350 0.413

+0.260 +0.010

0.360 0.673

Tolerance Shaft

Hole

+0.046 0

0.13 0.18

Rebuild or replace

Clearance limit

Standard Interference interference limit 0.130 0.226

Standard clearance

Clearance limit

0.44 0.91

Replace bushing

Replace

Adjust or replace

D375A-5


CARRIER ROLLER

CARRIER ROLLER

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

242

Outside diameter of tread

210

185

3

Width of tread

79

4

Thickness of tread

40

27.5

5

Width of flange

23

12

1

Outside diameter of flange

2

6


Standard size 90

7

Clearance between shaft and support

Standard size 86

8

Axial play of roller

D375A-5

Tolerance Shaft

Hole

+0.245 +0.185

+0.035 0

Tolerance Shaft

Hole

0 0.2

+0.350 0

Rebuild or replace

Standard Interference interference limit 0.150 245 Standard clearance

Clearance Replace limit

0 0.550

Standard clearance

Clearance limit

0.01 0.22

10-89


TRACK ROLLER BOGIE

TRACK ROLLER BOGIE

1. 2. 3. 4. 5.

Guide Gap Track roller assembly (Double) Large bogie Rubber mount

6. 7. 8. 9.

Small bogie Track roller assembly Cover Cartridge pin

Outline

10-90

The track roller is mounted on the small bogie (6) respectively so that the track roller and track shoe can be touched constantly. The vehicle body vibration from a road surface is absorbed by the rubber mount (5).

D375A-5


TRACK SHOE

TRACK SHOE

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

10-92

D375A-5


TRACK SHOE

Unit: mm No.

Check item Link pitch

2

Height of grouser

3

Total height of shoe

Outside diameter of bushing

5

Thickness of bushing

6

Height of link

7

Thickness of link

8

Clearance between links (Busing press fir force)

9

10

Interference between bushing and link

Interference between regular pin and link

11 Shoe bolt

a. Regular link b. Master link

D375A-5

Remedy

Standard size

1

4

Criteria Repair limit

280.3

283.3

93

30

116

53

Lug welding, rebuild or replace

Reverse

Standard size

Light load

Heavy load

98.5

90

92.5

18.8

10.3

12.8

Standard size

Repair limit

181

163

56

38

One side

Both side

1.4

2.8

Standard size

Reverse or replace

Reverse or replace

Rebuild or replace

Tolerance

Standard interference

Shaft

Hole

98

+0.622 +0.522

+0.087 0

0.435 0.622

60

+0.426 +0.366

+0.127 +0.053

0.239 0.373

Tightening torque (Nm {kgm})

Retightening angle (Angle)

1,372 ± 137 {140 ± 14}

120 ± 10

686.4 ± 68.6 {70 ± 7}

180 ± 10

Adjust or replace

Retightening

10-93


10 Structure, function and maintenance standard MAIN FRAME

MAIN FRAME

10-94

D375A-5


1. 2. 3. 4. 5.

Main frame Bracket Gap Cushion Plate

MAIN FRAME

6. 7. 8. 9. 10.

11. 12. 13. 14. 15.

Cage Clamp Seal Cover Coupling

Gap Cushion Bushing Flange Cushion spacer Unit: mm

No.

Check item

Interference between steering 16 case and bushing


Tolerance

Remedy Standard Interference interference limit

Shaft

Hole

275

+0.108 +0.056

+0.052 0

0.004 0.108

Min. 0

17

Clearance between steering frame and final cage

332

0.018 0.075

+0.057 0

0.018 0.132

0.2

18

Clearance between bracket and cushion

70

+0.018 0.012

+0.046 0

0.018 0.058

0.1

19

Clearance between ripper beam mounting pin and bushing

120

0.036 0.090

+0.166 +0.028

0.064 0.256

1.5

100

0.036 0.090

+0.287 +0.200

0.236 0.377

1.5

Clearance between ripper 20 cylinder mounting pin and bushing 21

Clearance between radiator guard mounting pin and bushing

80

0.030 0.076

+0.371 +0.269

0.299 0.477

1.5

22

Clearance between radiator guard mounting pin and bushing

90

0.036 0.090

+0.369 +0.267

0.303 0.459

1.0

23

Clearance between equalizer bar shaft and bushing

120

0.036 0.090

+0.243 +0.101

0.137 0.333

1.0

24

Amount of rubber protrusion on seal end surface

Standard size

Repair limit

1

0.5

25 Free height of front mount rubber

105

103

26 Free height of rear mount rubber

58

56

27

Press fit force of ripper beam mounting bushing

44.1-117.6 kN {4.5 12 ton}

28

Press fit force of ripper cylinder mounting bushing

58.8-171.6 kN {6 17.5 ton}

29

Press fit force of radiator guard mounting bushing

98.0-181.4 kN {10 18.5 ton}

30

Press fit force of radiator guard mounting bushing

58.8-137.3 kN {6 14 ton}

31

Press fit force of equalizer bar shaft mounting bushing

31.4-105.9 kN {3.2 10.8 ton}

D375A-5

Replace

Adjust

10-95


SUSPENSION

SUSPENSION

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

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

10-96

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

Cover Seal Bushing Side pin Center pin Busing

Outline

For the track frame, the front is set upside down centering around the pivot shaft (6) at the tail. Further, the equalizer (1) is swung centering around the center pin (12) and linked with the left and right track frames using the side pin (11).

D375A-5


SUSPENSION

Unit: mm No.

14

15

Check item

Clearance between center pin and bushing

Clearance between side pin and bushing

Interference between side pin 16 boss and bushing


Shaft

Hole

Standard clearance

120

0.036 0.090

+0.243 +0.101

0.137 0.333

1.0

95

0.048 0.078

+0.015 0.015

0.033 0.093

1.0

Standard size 160

17

Press fit force of center pin bushing

18 Press fit force of side pin bushing

D375A-5

Tolerance

Remedy

Tolerance Shaft

Hole

+0.045 +0.027

0.028 0.068

Clearance limit

Replace bushing

Standard Interference interference limit 0.055 0.113

49.0-186.3 kN {5 9 ton}

34.3-73.5 kN {3.5 7.5 ton}

10-97


SUSPENSION

1. Indicates the left of the blade single tilt specifications. 2. Indicates the right of the blade single tilt specifications.

Unit: mm No.

19

Check item Interference between thrust washer and seal

Interference between thrust 20 washer and seal 21

Interference between pivot shaft and seal

Clearance between pivot shaft 22 and busing

23

Clearance between pivot shaft and bushing

10-98


Tolerance

Remedy Standard Interference interference limit

Shaft

Hole

230

+0.213 +0.098

0.180 0.226

0.278 0.439

165

+0.140 +0.100

0.061 0.124

0.161 0.264

213

+0.096 +0.050

0.115 0.187

0.165 0.283

Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

175

0.145 0.208

+0.097 +0.029

0.174 0.305

1.0

210

0.170 0.242

+0.072 0

0.170 0.314

1.0

Replace

Replace bushing

D375A-5


WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM BLADE SYSTEM

SEMI U + TILT

1. 2. 3. 4. 5.

Blade tilt cylinder R.H. blade lift cylinder Blade lift valve Blade tilt, ripper Lo valve Hydraulic filter

D375A-5

6. Hydraulic tank 7. Ripper Hi valve 8. Work equipment + PPC charge pump (SAR(4)140 + (3)071 + (1)022) 9. L.H. blade lift cylinder

10-99


U-DOZER + DUAL TILT

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

Blade tilt cylinder R.H blade lift cylinder Pitch solenoid valve Dual tilt solenoid valve Blade lift valve Blade tilt, ripper Lo valve Hydraulic filter

10-100


8. Hydraulic tank 9. Ripper Hi valve 10. Work equipment + PPC charge pump (SAR(4)140 + (3)071 + (1)022) 11. L.H. blade lift cylinder 12. Blade pitch cylinder

D375A-5



RIPPER SYSTEM

MULTIPLE SHANK RIPPER

1. Ripper Hi valve 2. Ripper tilt cylinder 3. Ripper lift cylinder

D375A-5

10-101



GIANT RIPPER

1. 2. 3. 4. 5.

Steering control valve Ripper Hi valve Ripper tilt cylinder Ripper lift cylinder Pin puller cylinder (from power train hydraulic circuit) 6. Solenoid valve (for pin-puller)

10-102

D375A-5


PPC CONTROL PIPING DIAGRAM

PPC CONTROL PIPING DIAGRAM BLADE, RIPPER CONTROL

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

Blade lift valve Blade tilt, ripper Lo valve PPC charge valve Accumulator Ripper control PPC valve Blade control PPC valve PPC lock valve

D375A-5

8. PPC charge pump (SAR(1)022) 9. Hydraulic pump (SAR(4)140 + (3)071) 10. Oil cooler (for PPC)

10-103


WORK EQUIPMENT CONTROL


The drawing shows a pitch dozer and pin puller installed vehicle.

10-104

D375A-5


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


Work equipment safety lever Blade control lever Tilt/pitch selector switch Ripper control lever Pin puller switch PPC lock valve

Lever positions : : !: ": #: $: %: &: ': (: ): *: +: ,: -: .: /: 0: 1:

Blade HOLD Blade LOWER Blade FLOAT Blade RAISE Blade (left tilt/pitch) Blade (right tilt/pitch) Ripper HOLD Ripper RAISE Ripper LOWER Ripper TILT IN Ripper TILT BACK FREE LOCK Pitch selector switch OFF Pitch selector switch ON Dual tilt selector switch OFF Dual tilt selector switch ON Pin puller switch PUSH IN Pin puller switch PULL OUT

Outline

The work equipment control employs a PPC system which uses a PPC valve to move the spools of the control valve. Work equipment safety lever (1) is interconnected with PPC lock valve (6), and when it is at the LOCK position, the flow of oil in the PPC circuit is stopped.

D375A-5

10-105


HYDRAULIC TANK

HYDRAULIC TANK

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

Sight gauge Oil filler Valve Hydraulic filter Baffle tube Blade tilt, ripper Lo valve Blade lift valve

Outline

The hydraulic tank has an assembled type (externally installed) main control valve and a builtin hydraulic filter. The tank capacity is 230 ¬ and the amount of oil inside the tank is set at 120 ¬.

P1. From large pump A. To blade lift cylinder head B. To blade lift cylinder bottom P. From small pump A1. To blade tilt cylinder bottom B1. To blade tilt cylinder head A2. To ripper tilt cylinder bottom B2. To ripper lift cylinder head A3. To ripper lift cylinder head B3. To ripper lift cylinder bottom T. From ripper Hi valve

10-106

D375A-5


PPC CHARGE VALVE

PPC CHARGE VALVE

10-108

D375A-5


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

PPC CHARGE VALVE

Strainer Body Piston Valve Spring Relief valve Sleeve Screw Accumulator Accumulator check valve Oil cooler bypass valve

Item Cracking pressure

MPa {kg/cm2}

3.78 {38.5}

Set pressure

MPa {kg/cm2}

4.46 {45.5}

Oil cooler bypass Cracking pressure valve

KPa {kg/cm2}

490 ± 49 {5 ± 0.5}

Accumulator check valve

Cracking pressure

KPa {kg/cm2}

24.5 ± 4.9 {0.25 ± 0.05}

Filter mesh size

µm

24 × 110

Filtering area

cm2

62.2

Relief valve

C. Oil cooler P. From PPC pump P2. To valve T. To hydraulic tank

Specified value

Strainer

Unit: mm No.

11

12

Check item

Clearance between relief valve and spool

Clearance between check valve and body


Tolerance

Remedy

Shaft

Hole

Standard clearance

13

0.040 0.061

+0.018 0

0.040 0.079

0.10

14

0.032 0.059

+0.027 0

0.032 0.086

0.11

Standard size

Clearance limit

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

39.3

33.1

215.7 N {22.0 kg}

38.1

204.9 N {20.9 kg}

14 Oil cooler bypass valve spring

26.3

19.1

37.3 N {3.8 kg}

25.4

35.3 N {3.6 kg}

15 Accumulator check valve spring

20.6

19.1

1.96 N {0.2 kg}

20.0

1.77 N {0.18 kg}

13 Relief valve spring

D375A-5

Replace

10-109


PPC CHARGE VALVE

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

Adjustment screw Lock nut Sleeve Main valve spring Pilot piston Main valve Set pressure: 4.46 MPa {45.5 kg/cm2} (At 44.5 ¬/min)

Outline

The PPC charge valve acts to relieve the oil sent from the pump when the PPC valve is at NEUTRAL. It also acts to set the pressure sent to the PPC valve to the set pressure.

Operation

Chamber A is connected to the pump circuit and chamber C is connected to the tank drain circuit. The oil passes through the orifice in the main valve and fills chamber B.

When the pressure in chamber A rises, and the π differential pressure [ 4 (D2d2) × pressure of chamber A] caused by the difference in the area of diameter D and d reaches the pressure set by the main valve spring, the main valve opens. The pressurized oil in chamber A then escapes to chamber C, so the pressure in chamber A drops.

10-110

D375A-5


ACCUMULATOR

ACCUMULATOR FOR PPC VALVE 1. 2. 3. 4. 5. 6.

Gas plug Shell Poppet Holder Bladder Oil port

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

Function

The accumulator is installed between the PPC charge pump and the PPC valve. Even if the engine is started with the work equipment still raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot pressure to the main control valve to actuate it and enable the work equipment to move down under its own weight.

Operation

After the engine is stopped, when the PPC valve is at neutral, chamber A inside the bladder is compressed by the oil pressure in chamber B. When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa {30 kg/ cm 2}, and the pressure of the nitrogen gas in chamber A expands the bladder, so the oil in chamber B acts the pilot pressure and actuates the main control valve.

D375A-5

10-111


PPC LOCK VALVE

PPC LOCK VALVE

1. 2. 3. 4. 5.

Lever End cap Ball Seat Body

Outline

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

10-112

D375A-5


PPC VALVE

PPC VALVE FOR BLADE LIFT, TILT

1. 2. 3. 4. 5.

Spool Metering spring Centering spring Piston Disc

10-114 4

6. Nut (for lever joint) 7. Joint 8. Plate 9. Retainer 10. Body

P. From PPC charge valve port P2 (through PPC lock valve) T. To hydraulic tank P1. To blade lift valve (LOWER) port PA P2. To blade lift valve (RAISE) port PB P3. To blade tilt valve (left tilt) port PA1 P4. To blade tilt valve (Right tilt) port PB1

D375A-5

TESTI TESTING AND ADJUSTING

MEASURING FUEL PUMP OUTLET PORT PRESSURE

5. Run the engine at each speed and check that the signal voltage of the fuel pump pressure sensor is within the range in the table. ★ Sensor signal voltage (between C and B): Engine speed

Signal voltage

Fuel pump outlet port pressure (Reference)

700 rpm

1.38 ± 0.21 V

0.55 ± 0.14 MPa {5.62 ± 1.41 kg/cm2}

800 rpm

1.38 ± 0.21 V

0.55 ± 0.14 MPa {5.62 ± 1.41 kg/cm2}

1,000 rpm

2.48 ± 0.21 V

1.25 ± 0.14 MPa {12.70 ± 1.41 kg/cm2}

1,300 rpm

3.00 ± 0.21 V

1.57 ± 0.14 MPa {16.00 ± 1.41 kg/cm2}

6. After completing the measurement, remove the measuring equipment and set to the original condition.

4. Run the engine at low idling and check that the power source voltage of the fuel pump pressure sensor is within the following range. ★ Sensor signal voltage (between A and B): 4.75 – 5.25 V

D375A-5

20-114-1 4

MEASURING FUEL PUMP INLET PORT PRESSURE (NEGATIVE PRESSURE)

TESTING AND ADJUSTING

MEASURING FUEL PUMP INLET PORT PRESSURE (NEGATIVE PRESSURE) ★ Tools for measuring fuel pump inlet port pressure (negative pressure) Symbol

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

3

795-799-5550

Adapter

4

795-799-5560

Negative pressure gauge (0 – –0.1 MPa) {0 – –1 kg/cm2}

1 H

Part No.

1. Fit adapter H3 to pump inlet port pressure measuring nipple (3). 2. Fit nipple [1] of hydraulic tester H1 to adapter H3, install them to coupler (3) of the fuel pump, and connect negative pressure gauge H4.

★ If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. ★ If there is oil inside the hose, the gauge will not work, so always bleed the oil. 4. Run the engine at each engine speed and measure the pump inlet port pressure. ★ Fuel pump inlet port pressure Fuel filter

Fuel pump inlet port pressure

New

Max. –13.60 kPa {Max. –102 mmHg}

Used


3. Run the engine at a medium speed to bleed the oil from the hose. ★ Insert the connection of the hose and negative pressure gauge about halfway, repeat the action to open the self-seal portion at the hose end, and bleed the oil.

20-114-2 4

D375A-5


PPC VALVE

Unit: mm No.

Check item


Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

34.0 × 15.5

31.9

94 N {9.6 kg}

75.2 N {7.67 kg}

12 Metering spring (for P1, P2)

27.23 × 8.14

24.9

16.7 N {1.7 kg}

13.7 N {1.4 kg}

13 Centering spring (for P2)

43.2 × 15.5

31.9

96.1 N {9.8 kg}

76.5 N {7.8 kg}

14 Centering spring (for P3, P4)

48.57 × 15.5

31.9

111.8 N {11.4 kg}

89.4 N {9.1 kg}

15 Metering spring (for P3, P4)

26.53 × 8.15

24.9

16.7 N {1.7 kg}

13.7 N {1.4 kg}

16 Detent spring (for P1)

20.39 × 19.5

13.1

159.36 N {16.25 kg}

127.5 N {13 kg}

17 Detent spring (for P2)

45.36 × 7.5

26

38.44 N {3.92 kg}

30.79 N {3.14 kg}

11 Centering spring (for P1)

D375A-5

Replace spring if damaged or deformed

10-115


PPC VALVE

Operation 1) At neutral (i) PPC valve for blade lift Ports PA and PB of the blade lift control valve, and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool(1).

(ii) PPC valve for blade tilt Ports PA1 and PB1 of the blade tilt control valve, and ports P3 and P4 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1).

10-116

D375A-5


PPC VALVE

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

D375A-5

10-117


PPC VALVE

3) During fine control (When control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up to the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D, and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f' in the valve on the side that is not working. The oil passes through port P2 and enters chamber PA to fill the chamber with oil.

4) At full stroke When disc (5) pushed down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber PB from port P1, and pushes the control valve spool. The oil returning from chamber PA from port P2 through fine control hole f' and flows to drain chamber D.

10-118

D375A-5


PPC VALVE

5) Blade operated to FLOAT When piston (4) at port P1 (LOWER side) is pushed by disc (5) and moves down, protrusion a of the piston contacts ball (11) during the downward stroke. (The detent starts to be actuated.) If piston (4) is pushed further, ball (11) pushes up collar (12), which is being held by detent spring (13), and moves to the outside, so the ball passes over protrusion a of the piston. At this point, piston (4') at the opposite side is pushed up by the spring (14). As a result, the oil inside chamber F flows through b and c and enters chamber E, and piston (4') follows disc (5). Passage d is interconnected with port P1, so it is under more or less the same pressure as port P1. Chamber E is normally interconnected with drain chamber D, but when ball (11) passes over protrusion a of the poston, passage d and chamber E (which were shut off) are interconnected and pressurized oil flowa. At the same time, the control valve also moves to the FLOAT position, so the blade circuit is set to the FLOAT condition. The pressurized oil inside chamber E pushes up piston (4'), so even of the lever is released, it is held at the FLOAT position. 6) Blade released from FLOAT When disc (5) is retuned from the FLOAT position, it is pushed down by a force greater than the pressure of the oil in chamber E. For this reason, chamber E is shut off from passage d and is connected to the drain chamber. Therefore, the oil pressure inside chamber E is lost, and the FLOAT, position is released.

D375A-5

10-119


PPC VALVE

FOR RIPPER

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

Spool Metering spring Centering spring Piston Disc Nut (for lever joint)

10-120

7. Joint 8. Plate 9. Retainer 10. Body 11. Filter

P. From PPC charge valve port P2 (through PPC lock valve) T. To hydraulic tank P1. To ripper tilt valve (TILT BACK) port PB2 P2. To ripper tilt valve (TILT IN) port PA2 P3. To ripper tilt valve (LOWER) port PA3 P4. To ripper tilt valve (RAISE) port PB3

D375A-5


PPC VALVE

Unit: mm No.

Check item


Remedy Repair limit

Free length × O.D.

Installed length

Installed load

Free length

Installed load

50.4 × 15.5

34

55.9 N {5.7 kg}

45.1 N {4.6 kg}

13 Metering spring

26.6 × 7.5

24.9

16.7 N {1.7 kg}

13.7 N {1.4 kg}


50.1 × 15.5

34

71.6 N {7.3 kg}

56.9 N {5.8 kg}


D375A-5

Replace spring if damaged or deformed

10-121


PPC VALVE

Operation 1) At neutral Ports PA2, PA3, PB2 and PB3 of the ripper control valve and ports P1, P2, P3, and P4 of the PPC valve are connected to drain chamber D Through fine control hole f of spool (1).

2) During fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the charging pump passes through fine control hole f and goes from port P2 to port PA2. When the pressure at port P2 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P2. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port P2. The relationship in the position of the spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P2 also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber PA2 (the same as the pressure at port P2) and the force of the control valve spool return spring are balanced.

10-122

D375A-5


PPC VALVE

3) During fine control (When control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P2. When this happens, fine control hole f is connected to drain chamber D, and the pressure oil at port P2 is released. If the pressure at port P2 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P2 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f' in the valve on the side that is not working. The oil passes through port P1 and enters chamber PB1 to fill the chamber with oil.

4) At full stroke When disc (5) pushed down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber PA1 from port P2, and pushes the control valve spool. The oil returning from chamber PB1 passes from port P1 through fine control hole f' and flows to drain chamber D.

D375A-5

10-123


10 Structure, function and maintenance standard WORK EQUIPMENT CYLINDER

WORK EQUIPMENT CYLINDER

BLADE LIFT CYLINDER

BLADE TILT CYLINDER

PIN PULLER CYLINDER

10-124

D375A-5



Unit: mm No.

Check item


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Blade LIFT

90

0.036 0.090

+0.270 +0.061

0.097 0.360

0.693

Blade TILT

110

0.036 0.090

+0.274 +0.060

0.096 0.364

Pin puller

30

0.065 0.117

+0.133 +0.007

0.072 0.250

0.55

2

Clearance between piston rod spherical surface and blade ball portion

Blade LIFT

100 (Ball)

+0.300 0.300

1.0

3

Clearance between cylinder support shaft bushing and yoke

Blade LIFT

105

0.120 0.207

+0.035 0

0.120 0.242

0.5

4

Thickness of standard shim between tip of piston rod and cap

Blade LIFT

1

5

Clearance between piston rod and bushing

Clearance between piston rod support shaft and bushing Blade TILT

4.0 Standard size

Tolerance

Adjust

Shaft

Hole

Standard clearance

Clearance limit

75

0.200 0.300

+0.200 0

0.200 0.500

1.0

6

Clearance between Blade cylinder bottom support TILT shaft and bushing

75

0.200 0.300

+0.174 +0.100

0.300 0.474

1.0

7

Clearance between piston rod spherical surface and cap

Pin puller

29

0.100 0.200

+1.300 +1.200

1.3 1.5

8

Clearance between Pin cylinder bottom support puller shaft and boss

26

1.1 1.2

±0.1

1.0 1.3

D375A-5

Replace

Replace

10-125


RIPPER LIFT CYLINDER

RIPPER TILT CYLINDER


Unit: mm No.

Check item


1

2

3

Clearance between piston rod and bushing

Shaft

Hole

Standard clearance

Clearance limit

Ripper LIFT

110

0.036 0.123

+0.274 +0.060

0.096 0.397

0.697

Ripper TILT

110

0.036 0.123

+0.274 +0.060

0.096 0.397

0.697

100

0.036 0.090

+0.207 +0.120

0.156 0.297

1.0

100

0.036 0.090

+0.207 +0.120

0.156 0.297

1.0

100

0.036 0.090

+0.207 +0.120

0.156 0.297

1.0

100

0.036 0.090

+0.207 +0.120

0.156 0.297

1.0

Ripper Clearance between LIFT piston rod support shaft Ripper and bushing TILT Ripper Clearance between LIFT cylinder bottom support Ripper shaft and bushing TILT

10-126

Tolerance

Remedy

Replace

D375A-5


PISTON VALVE

PISTON VALVE (BLADE LIFT CYLINDER) Outline

The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. In addition the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.

Operation 1. Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (2) and piston valve (3). The piston valve (3) is pushed in the direction of the arrow until piston valve seat (4) comes into snug contact with the tapered section, thereby, this causing the pressure in the cylinder to rise and moving piston (2) in the direction of the arrow.

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

D375A-5

10-127


QUICK DROP VALVE

QUICK DROP VALVE (BLADE LIFT CYLINDER) Structure

The quick drop valve consists of valve body (1), spool (2), check valve (3), and spring (4). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started. The blade lowering speed, which is generally determined by the pump discharge, can be made faster with the quick drop valve. 1. Valve body 2. Spool

3. Check valve 4. Spring

Operation 1. Start of lowering When the blade lever is operated to LOWER, the oil from the control valve enters the cylinder bottom through port A and pushes the piston. In the meantime, the oil in the cylinder head is pushed out into the piston, enters valve port B, and flows into the tank from port C.

2. While lowering Pressurized oil from the cylinder head flows into port C through port B. At this time, the oil flow is restricted by an orifice a provided along the way, causing a differential pressure between front and back of orifice. When the pressure of port B becomes greater than the force of spring (4), it compresses the spring and moves spool (2) and check valve (3) to the right. When the spool and the check valve have moved, the circuit of port B and A is opend, part of the oil flowing from the cylinder head to port C enters the passage port A, and merged with the oil from the control valve, and flows to the cylinder bottom. Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylinder.

10-128

D375A-5


QUICK DROP VALVE

Unit: mm No.

1

Check item

Clearance between spool and valve body

Criteria Standard size 38.0

Tolerance Shaft

Hole

Standard clearance

0.011 0.016

+0.010 0

0.011 0.026

Standard size 2

Valve spring

D375A-5

Remedy Clearance limit 0.03

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

75.2

55.9

136.3 N {13.9 kg}

67.7

122.6 N {12.5 kg}

Replace

10-129


PIN PULLER SWITCH

PIN PULLER SWITCH

Function

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

10-130

1. 2. 3. 4.

Connector Wire Switch Knob

D375A-5


PIN PULLER SOLENOID VALVE


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

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

D375A-5

A. B. P. T.

To pin puller cylinder bottom To pin puller cylinder head From power train pump To steering case

10-131



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

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

10-132

D375A-5


BLADE CONTROL KNOB

BLADE CONTROL KNOB

1. 2. 3. 4. 5.

Switch (Dual, single tilt switching) Switch (Pitch) Cover Connector (Male) Connector (Female)

Outline

By setting the blade control knob to the front and the rear or the left and the tight, the blade is raised or lowered and tilted left or right. Further, by setting the switch (1) to the DUAL side and setting the lever to the left and right, the dual tilt actuation is performed. Also by setting the lever to the left and right pressing (2), the pitch actuation is performed.

D375A-5

When the switch (2) is pressed and the lever is actuated, the blade is pitched. When the lever is set to the left, the blade is pitched back. When the lever is set to the right, the blade is pitchdamped. When the switch (1) is set to the DUAL side and the lever is actuated, the blade is dually tilted. When the lever is set to the left, the blade is dually tilted left. When the lever is set to the right, the blade is dually tilted right. Even if the switch (1) is switched to either DUAL or SINGLE, the blade is pitched when the lever is set left and right pressing the switch (2).

10-133


PITCH, DUAL TILT SOLENOID VALVE

PITCH, DUAL TILT SOLENOID VALVE MACHINES EQUIPPED WITH DUAL TILT

1. Main spool assembly 2. Pilot solenoid assembly 3. Connector A. B. T1. T2. P1, P2. P. T.

To R.H. blade pitch (dual tilt) cylinder bottom To R.H. blade pitch (dual tilt) cylinder head To L.H. blade pitch (dual tilt) cylinder bottom To L.H. blade pitch (dual tilt) cylinder head From blade tilt control valve From PPC charge valve To hydraulic tank

10-134

Function

This valve is installed between the blade tilt, pitch cylinder and the blade tilt, ripper Lo valve. It acts to open or close the hydraulic circuit to the blade tilt or pitch cylinder according to the pitch or dual tilt switch signal.

D375A-5


PITCH, DUAL TILT SOLENOID VALVE

Operation Pitch switch ON

When pitch switch (1) is operated, electricity flows to pitch solenoid valve (2) and it is excited. When this happens, main spool (4) opens the circuit between port T1 and B and between A and P1, and the hydraulic circuit is connected to the bottom end of left pitch cylinder (5) and to the head end of right pitch cylinder (6). As a result, both the right pitch cylinder and left pitch cylinder are retracted and the blade is pitched to the rear.

Dual tilt switch ON

When dual pitch switch (2) is operated, electricity flows to dual tilt solenoid valve (3) and it is excited. When this happens, main spool (4) opens the circuit between port T2 and B and between A and P2, and the hydraulic circuit is connected to the head end of left tilt cylinder (5) and to the bottom end of right tilt cylinder (6). As a result, the left dual tilt cylinder is extended and the right dual tilt cylinder is retracted to tilt the blade.

D375A-5

10-135


WORK EQUIPMENT + PPC CHARGE PUMP

WORK EQUIPMENT + PPC CHARGE PUMP SAR(4)140 + (3)071 + (1)022

10-136

D375A-5


WORK EQUIPMENT + PPC CHARGE PUMP

Unit: mm No.

1

2

3

4

Check item

Side clearance

Clearance between plain bearing inside diameter and gear shaft outside diameter

Driving depth of pin

Criteria Type

Standard clearance

Clearance limit

SAR(4)-140

0.11 0.16

0.19

SAR(3)-071

0.10 0.15

0.19

SAR(1)-022

0.10 0.15

0.19

SAR(4)-140

0.060 0.140

0.20

SAR(3)-071

0.060 0.149

0.20

SAR(1)-022

0.060 0.144

0.20

Type

Standard size

Tolerance

Repair limit

SAR(4)-140

21

0 0.5

SAR(3)-071

14

0 0.5

SAR(1)-022

10

0 0.5

Spline shaft rotation torque

Oil: EO10-CD Oil temperature: 45 50°C

D375A-5

Replace

16.7 26.5 Nm {1.7 2.7 kgm} Type

Delivery

Remedy

Rotating speed (rpm)

Discharge pressure



MPa {kg/cm }

(¬/min)

(¬/min)

SAR(4)-140

2,200

20.6 {210}

287

266

SAR(3)-071

2,200

20.6 {210}

137

125

SAR(1)-022

2,200

4.9 {50}

43

39

10-137


MAIN CONTROL VALVE

MAIN CONTROL VALVE BLADE LIFT VALVE

Outline

Demand valve (14) is assembled to the blade lift valve, and the oil from the two hydraulic pumps is merged by check valve (4). With the demand valve, the oil from the large pump becomes the pilot pressure, and at the same time, the oil from the ripper circuit or the blade lift circuit through shuttle valve (18B) also becomes the pilot pressure, so the oil from the two hydraulic pumps is used efficiently.

10-138

P1. P2. A. B. T. PA. PB. PL.

From large pump From small pump To blade lift cylinder head To blade lift cylinder bottom To hydraulic tank From blade lift PPC valve port P2 From blade lift PPC valve port P1 From ripper Lo valve

D375A-5


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

Check valve spring Small pump circuit check valve Check valve Check valve spring Valve body Return spring Blade lift valve Shuttle valve seat (plug)

D375A-5

MAIN CONTROL VALVE

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

Shuttle valve ball Shuttle valve seat (plug) Retainer Return spring (for FLOAT) Case Demand valve spring Demand valve RAISE suction valve

17. Suction valve spring 18. LOWER suction valve 19. Main relief, shuttle valve assembly 19A. Main relief valve 19B. Shuttle valve

10-139


MAIN CONTROL VALVE

Unit: mm No.

Check item


1

Spool return spring

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

69.9

63

431.5 N {44 kg}

345.2 N {35.2 kg}

2

Spool return spring

80.69

76.5

400.1 N {40.8 kg}

319.7 N {32.6 kg}

3

Spool return spring (for floating)

43.82

32.5

588.4 N {60 kg}

470.7 N {48 kg}

4

Check valve spring

75.7

43.5

9.8 N {1.0 kg}

69.3

7.9 N {0.8 kg}

5

Check valve spring

32.7

24.5

44.1 N {4.5 kg}

31.0

35.3 N {3.6 kg}

6

Suction valve spring

75.9

38.5

11.38 N {1.16 kg}

68.4

9.12 N {0.93 kg}

7

Demand spool spring

74.5

55

235 N {24 kg}

10-140

Replace

D375A-5


MAIN CONTROL VALVE

MAIN RELIEF, SHUTTLE VALVE

10-142

D375A-5


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

MAIN CONTROL VALVE

Overview

Valve body Piston Shuttle valve Shuttle valve spring Plug Valve seat Main relief valve poppet Main relief valve spring Sleeve Main relief pressure adjustment screw

PL. PB. PD. T.

From shuttle valve inside ripper valve From shuttle valve inside blade lift valve Inside demand valve pilot port To hydraulic tank

The main relief valve exists in the blade lift circuit via the shuttle valve (3) and the circuit between the ripper circuit and the hydraulic tank, and the oil pressure of the blade lift circuit, that is, a large pump circuit is set to 20.6 MPa {210 kg/cm2}. The shuttle valve exists in the blade lift circuit and the circuit between the ripper circuit and the demand valve via the main relief valve, and two circuits that applies the pilot pressure to the demand valve are selected. That is, either the blade lift circuit or the ripper circuit is selected. Besides, the shuttle valve connects the blade lift circuit and the pilot port of the demand valve by the tension of the spring (4) when work equipment is not used (control lever Neutral). Unit: mm

No.

Check item


4

Shaft valve spring

8


10

Height of main relief pressure adjustment screw

D375A-5

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

42.7

22.0

8.14 N {0.83 kg}

38.6

6.47 N {0.66 kg}

41.1

32.6

258.9 N {26.4 kg}

39.4

206.9 N {21.1 kg}

8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2})

Replace

Adjust

10-143


MAIN CONTROL VALVE

BLADE TILT, RIPPER LO VALVE

P. A1. B1. A2.

From small pump To blade tilt cylinder bottom To blade tilt cylinder head To ripper tilt cylinder bottom (through ripper Hi valve PA1) B2. To ripper tilt cylinder head (through ripper Hi valve PB1) A3. To ripper lift cylinder head (through ripper Hi valve PB2) B3. To ripper lift cylinder bottom (through ripper Hi valve PA2)

10-144

CO. PL. PA1. PA2. PA3. PB1. PB2. PB3.

To demand valve To shuttle valve inside blade lift valve To blade tilt PPC valve P3 (left tilt) To ripper tilt PPC valve P2 (tilt in) To ripper lift PPC valve P3 (lower) To blade tilt PPC valve P4 (right tilt) To ripper tilt PPC valve P1 (tilt back) To ripper lift PPC valve P4 (raise)

D375A-5


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

Blade tilt valve Ripper tilt valve Ripper lift valve Valve body Return spring O-ring Case Main relief pressure adjustment screw

D375A-5

MAIN CONTROL VALVE

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

Sleeve Main relief valve body Poppet spring Main relief valve poppet Valve seat Main relief valve spring Main relief valve Valve seat

17. 18. 19. 20. 21. 22.

Check valve Check valve spring Valve seat Shuttle valve seat (plug) Shuttle valve ball Shuttle valve seat

10-145


MAIN CONTROL VALVE

Unit: mm No.

Check item


1

Spool return spring

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

52.18

50.0

117.7 N {12.0 kg}

94.1 N {9.6 kg}

2

Check valve spring

28.0

18.0

6.9 N {0.7 kg}

26.0

5.5 N {0.56 kg}

3


24.2

18.3

31.4 N {3.2 kg}

23.0

25.1 {2.56 kg}

4

Main relief valve poppet spring

41.1

32.6

258.9 N {26.4 kg}

39.4

206.9 N {21.1 kg}

5

Height of main relief pressure adjustment screw

10-146

8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2})

Replace

Adjust

D375A-5


MAIN CONTROL VALVE

RIPPER HI VALVE

P. PA1. PB1. PA2. PB2. A1-1. B1-1. A1-2. B1-2. A2-1. B2-1. A2-2. B2-2.

D375A-5

From small pump From Lo valve tilt in From Lo valve tilt back From Lo valve ripper raise From Lo valve ripper lower To L.H. tilt cylinder bottom To L.H. tilt cylinder head To R.H. tilt cylinder bottom To R.H. tilt cylinder head To L.H. lift cylinder bottom To L.H. lift cylinder head To R.H. lift cylinder bottom To R.H. lift cylinder head

10-147


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

Valve body Shuttle valve seat Shuttle valve ball Valve body Plug Fixed differential pressure valve spring Fixed differential pressure valve Fixed differential pressure valve Fixed differential pressure valve Fixed differential pressure valve

10-148

MAIN CONTROL VALVE

11. 12. 13. 14. 15. 16. 17. 18. 19.

Plug Check valve spring Check valve Valve return spring Plug Ripper lift Hi valve Suction valve spring Suction valve Ripper tilt Hi valve

D375A-5


MAIN CONTROL VALVE

Unit: mm No.

Check item


1

Hi valve return spring

Remedy Repair limit

Free length

Installed length

Installed load

Free length

Installed load

79.5

42.0

152.0 N {15.5 kg}

72.0

121.6 N {12.4 kg}

2

Check valve spring

32.6

27.0

30.2 N {3.08 kg}

31.5

24.1 {2.46 kg}

3

Suction valve spring

75.7

43.5

9.8 N {1.0 kg}

69.3

7.9 N {0.8 kg}

4

Constant differential pressure valve spring

57.4

33.5

169.7 N {17.3 kg}

52.6

135.3 N {13.8 kg}

D375A-5

Replace

10-149


MAIN CONTROL VALVE

Operation 1. Blade lever at HOLD, ripper lever at HOLD

10-150

D375A-5


When the blade is at the HOLD position, the spool of the PPC valve directly connected to the control lever is not actuated; blade lift spool (5) closes the circuit from port B to ports C and D, and opens the circuits of ports H and E and ports J and F; blade tilt spool (16) close the circuit from port B3 to ports C3 and D3. Therefore, the circuits for blade lift cylinder (9) and blade tilt cylinder (17) become closed circuits, and the cylinders are held in the same position. If the ripper lever is placed at the HOLD position, the spool of the PPC valve directly connected to the control lever does not move; ripper tilt spool (19) closes the circuit from port B4 to ports C4 and D4, and ripper lift spool (21) closes the circuit from port B5 to ports C5 and D5. Therefore, the circuits for ripper tilt cylinder (45) and ripper lift cylinder (33) become closed circuits through the two ripper valves, and the cylinders are kept in the same position. If the engine is started in this condition, the oil from the large pump enters port A of the blade lift valve. Some of the oil pushes open check valve (3) and enters port B where it stops. The rest of the oil passes through orifice a of demand valve (1), and enters ports L and M. (The demand valve is pushed to the right by the tension of spring (2).) The oil from the large pump flows to the blade lift valve, but it also enters port A1 of the ripper Hi valve, pushes open the two check valve (23) and (35), then enters ports B1 and B2 and stops. The oil from the small pump flows from port A2 of the ripper Lo valve and blade tilt valve to ports A3, A4, and A5. Some of the oil pushes open check valves (15), (18) and (20), then enters ports B3, B4 and B5, and stops. The rest of the oil flows from port A5, enters port R of the blade lift valve, pushes open check valve (4), and flows to port A where it merges with the oil from the large pump.

D375A-5

MAIN CONTROL VALVE

When oil is drained

In the condition already explained, if the hydraulic pressure in the circuit rises, the surface pressure (force pushing the demand valve to the left) on port L of demand valve (1) becomes greater than the combined force (force pushing the demand valve to the right) of the surface pressure bearing on port M and tension of spring (2), it moves the demand valve to the left, opens the circuit between ports A and E, and ports R and F. The oil from the large and small pumps is then relieved to ports E and F and is drained from port G to the hydraulic tank. Therefore, both the large and small pumps are put in an unload condition.

10-151


MAIN CONTROL VALVE

2. Blade lever at RAISE (blade operating at high speed)

10-152

D375A-5


MAIN CONTROL VALVE

When the blade lever is moved fully to the RAISE position, the spool of the PPC valve directly connected to the control lever is actuated. When this happens, the pilot pressure entering the PPC valve from the PPC pump is sent to port PB of the blade lift valve. This pilot pressure moves spool (5) to the left to the end of its stroke, and fully opens the circuits between ports B and C, ports C and H, and ports D and F. When this happens, the oil from the two pumps passes from ports A and B and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from ports H and H', pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, O, and P of shuttle valve (10). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (1), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G to the hydraulic tank. When the hydraulic pressure in the circuit rises in this way, spool (5) opens the circuit between ports B and C fully, so the resistance of the oil flowing from port B to port C is small, and there is little pressure difference generated between port B and port C. Therefore, no pressure difference is generated between port L and ports M and Q of the demand valve. The surface pressure acting on the left and right of the demand valve is equal, so the demand valve is moved to the right by the tension of spring (2). When this happens, the circuits between ports A and E', and ports R and F' are closed, and all the oil from both the large and small pumps flows to the head end of the cylinder to increase the speed of movement of the cylinder.

D375A-5

10-153


MAIN CONTROL VALVE

3. Blade lever at RAISE (blade operating at low speed)

10-154

D375A-5


When the blade lever is operated slightly to the RAISE position the spool of the PPC valve directly connected to the control lever is actuated. When this happens, the pilot pressure entering the PPC valve from the PPC pump is sent to port PB of the blade lift valve. This pilot pressure moves spool (5) slightly to the left to a point where the pilot pressure and the force of the spring are in balance, and partially opens the circuit between ports B and C, ports C and H, and Ports D and F. When this happens, the oil from the two pumps passes from ports A and B, is throttled by spool (5) and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from ports H and H', pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, O, and P of shuttle valve (10). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (1), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G to the hydraulic tank. When the hydraulic pressure in the circuit rises in this way the situation is different from in item 2: spool (5) is throttling the circuit between ports B and C, so the flow of oil from port B to port C is restricted, and a pressure difference is generated between port B and port C. The hydraulic pressure in the circuit up to port B becomes higher. Therefore, when the surface pressure acting on port L of the demand valve becomes greater than the combined force of the surface pressure acting on port M, the surface pressure (low pressure) acting on port Q, and the tension of spring (2), the demand valve is moved to the left. When this happens, the circuits between ports A and E', and ports R and F' are opened, and the oil from both the large and small pumps is relieved to the hydraulic tank. This suppresses the rise in the hydraulic pressure at ports A and B, and the cylinder moves slowly. As explained in the items above, the speed of movement of the cylinder is determined by the amount of opening of ports B and C, which corresponds to the movement of the lever. If it is wide open, the flow of oil beyond port C increases, the hydraulic pressure rises, and the speed of movement becomes faster.

D375A-5

MAIN CONTROL VALVE

If it is opened only slightly, the flow of oil beyond port C is throttled, so the oil flow is reduced, the hydraulic pressure becomes low, and the speed of movement is slow. In other words, the hydraulic pressure and oil flow beyond port C is proportional, so this provides operation of the blade that follows the fine movement of the blade lever. When cylinder is at stroke end

If cylinder (9) moves to the end of its stroke from the condition in items 2 and 3, the hydraulic pressure in the whole circuit rises. Therefore, the hydraulic pressure beyond port C rises, and the oil entering the main relief valve through shuttle valves (8) and (10) (that is, the oil at port P) pushes open poppet (13) and is relieved to port T. At this point, the circuit from port O to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure of pilot port Q of demand valve (1) drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E' and ports R and F' are opened, and the oil from the two pumps is relieved to prevent the hydraulic pressure from rising any further. The hydraulic pressure at this point is 20.6 MPa {210 kg/cm2}.

10-155

ADJUSTMENT OF PCCS LEVER POTENTIOMETERS


ADJUSTMENT OF PCCS LEVER POTENTIOMETERS When adjusting the lever assembly independently

X

kΩ

Y

kΩ

1. Position lever in “NEUTRAL (both forward & reverse, steering)” 2. Using tester (2), measure resistance between 5 V pin and signal pin. (See table 1). (ex. For ST1, measure resistance between pins A (5 V) and H (SIG)) 3. Using tester (2), measure resistance between signal pin and GND pin. (See table 1). (ex. For ST1, measure between pins H (SIG) and G (GND)) 4. Adjust resistance to be X = Y (tolerance: X – Y ≤ 0.04 kΩ) by slightly turning the potentiometer body. (Loosen screws (1) before adjusting) 5. Secure the potentiometer in place by tightening screw (1). Table 1 POTENTIOMETER No. 1 2 3 4

ST1 ST2 FR3 FR4

20-155-1 4

5V A M L O

PIN No. SIG GND H G E F K J P Q

D375A-5



Related electrical circuit diagram

D375A-5

20-155-2 4


CHECKING THE ADJUSTMENT OF PCCS LEVER

CHECKING THE ADJUSTMENT OF PCCS LEVER 1. Install the pre-adjusted PCCS lever to the machine. (For details, see DISASSEMBLY OF PCCS LEVER.) 2. Position PCCS lever in “NEUTRAL (both forward & reverse, steering)” 3. Turn key switch “ON”. 4. Check the voltage of each potentiometer (ST1, 2 & FR3, 4) by using the monitoring mode of the monitor panel. (For details, see SPECIAL FUNCTION OF MONITOR PANEL EMMS.) 5. Voltage should be 2,500 ± 50 mV for each potentiometer. ADJUSTING IN ATTACHED CONDITION 1. Position PCCS lever in “NEUTRAL (both forward & reverse, steering)” 2. Using tester (4), adjust voltage by turning potentiometer slightly, so that the voltage becomes 2.5 V. 3. Tighten screw (2) at the position of voltage 2.5 V, and fix the potentiometer (1).

1. Potentiometer

5. T-adapter

2. Screw

6. Controller

3. PCCS lever

7. Machine power source

4. Tester

8. External power source (5 V)

20-155-3 4

A. Wiring connection of adjustment for machine power source. B. Wiring connection of adjustment for external power source.

D375A-5


DISASSEMBLY AND ASSEMBLY OF PCCS LEVER

DISASSEMBLY AND ASSEMBLY OF PCCS LEVER DISASSEMBLY 1. Open armrest and remove screws (1) (4 places/ hexagon socket head).

2. Remove armrest & box assembly.

3. Remove screws (3).

4. Remove cover (4).

D375A-5

20-155-4 4



5. Remove screws (5) (6 places).

6. Sling cover (6) and disconnect wiring for fuel dial.

7. Peel boot, remove bolts (7) (4 places/hexagon socket head) and remove lever assembly (8).

8. Remove lever assembly (8) from console case (11). 9. Loosen screw (9), then adjust voltage by turning potentiometer (10) slightly.

ASSEMBLY •

For assembly, procedure in reverse order.

20-155-5 4

D375A-5


MAIN CONTROL VALVE

4. Blade lever at LEFT TILT

10-156

D375A-5


MAIN CONTROL VALVE

When the blade lever is moved to the LEFT TILT position the spool of the PPC valve directly connected to the control lever is actuated. When this happens, the pilot pressure entering the PPC valve from the PPC pump is sent to port PA1 of the ripper Lo valve. This pilot pressure moves spool (16) down, opens the circuits of ports B3 and C3 and ports D3 and F3, and closes the circuit of ports A2 and A3. When this happens, the oil from the small pump flows from ports A2, pushes open check valve (15), flows from port B3, and enters port C3. It flows to the bottom end of cylinder (17), and when the hydraulic pressure in the circuit rises, it extends the cylinder. At this point, the oil at the head end of the cylinder returns from port D3 to port F3, and is drained from port E3 to the hydraulic tank. The oil from the large pump enters port A of the blade lift valve, and actuates demand valve (1), is relieved from port A to E, and is drained to the hydraulic tank. When the blade is operated, the circuit between ports A2 and A3 is closed, so the oil does not enter the ripper circuit, and it is impossible to operate the ripper. In other words, the blade tilt circuit is given priority over the ripper circuit.

When cylinder is at stroke end

From the above condition, if cylinder (17) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, the oil from the small pump flows from port A2, and pushes open main relief valve poppet (14). It is then relieved to port E2, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 20.6 MPa {210 kg/cm2}.

D375A-5

10-157


MAIN CONTROL VALVE

5. Ripper lever at TILT IN (ripper Lo valve, shuttle valve actuated)

10-158

D375A-5


MAIN CONTROL VALVE

When the ripper lever is moved to the TILT IN position, the spool of the PPC valve directly connected to the control lever is actuated. When this happens, the pilot pressure entering the PPC valve from the PPC pump is sent to port PA2 of the ripper Lo valve. This pilot pressure moves spool (19) down, opens the circuits between ports B4 and C4, and ports D4 and F4, and ports A3 and G4, and closes the circuit between ports A3 and A4. When this happens, the oil from the small pump enters ports A2 and A3. Some of the oil pushes open check valve (18), flows from port B4 into port C4, and the flows to port H2 of the ripper Hi valve. The rest of the oil passes through the groove in spool (19), enters port G4, pushes shuttle valve (22) down fully, then flows from port H5 to port S of shuttle valve (10). The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (10) to the left, closes the circuit between ports N and O, and opens the circuit between ports S and O. The oil entering port O from port S then passes through orifice c, and enters ports P and Q. It becomes the pilot pressure of demand valve (1), and moves the demand valve to the right. When this happens, the circuit between ports A and E' is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A1 of the ripper Hi valve.

D375A-5

10-159


MAIN CONTROL VALVE

6. Ripper lever at TILT IN (ripper Hi valve actuated)

10-160

D375A-5


MAIN CONTROL VALVE

As explained in item 5, the oil from the large pump enters A1 of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B1 and B2, and stops. The oil from the small pump flows from port C4 of the ripper Lo valve and enters port H2. Some of the oil entering port H2 passes through the passage inside valve (42), flows to port L2, and pushes shuttle valve (44) fully to the right. It then enters port O2, pushes spool (36) up, and becomes the pilot pressure. The rest of the oil is throttled by orifice g and enters port D2. Some of the oil entering port D2 passes through the passage inside valve (42), flows to port J2, and pushes shuttle valve (41) fully to the left. It then enters port N2, pushes spool (36) down, and becomes the pilot pressure. The rest of the oil flows from port D2 to the bottom end of ripper tilt cylinder (45). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise. From the condition previously explained, if the hydraulic pressure continues to rise, the oil at port H2 is throttled by orifice g and enters port D2. Because of the resistance, the hydraulic pressure at port H2 becomes higher than the pressure beyond port D2. Therefore, the hydraulic pressure at pilot port O2 of spool (36) becomes higher than the hydraulic pressure at port N2, so when this pressure difference becomes greater than the tension of spring (38), it pushes spool (36) up. When this happens, the circuits between ports B2 and D2, and ports C2 and F1 open, the oil from the large pump flows from port B2 to port D2, enters the bottom end of ripper tilt cylinder (45), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port C2 to port F1, and is drained to the hydraulic tank. The rest of the oil flows from port C2, is throttled by orifice f of valve (39), and returns to port G2. It then flows from port D4 of the ripper Lo valve, returns to port F4, and is drained to the hydraulic tank.

D375A-5

10-161


MAIN CONTROL VALVE

7. Ripper level at LOWER (ripper Lo valve, shuttle valve actuated)

10-162

D375A-5


MAIN CONTROL VALVE

When the ripper lever is moved to the LOWER position, the spool of the PPC valve directly connected to the control lever is actuated. When this happens, the pilot pressure entering the PPC valve from the PPC pump is sent to port PA3 of the ripper Lo valve. This pilot pressure moves spool (21) moves down, opens the circuits of ports B5 and C5, and ports D5 and F5, and ports A4 and G5 and closes the circuit of ports A4 and A5. When this happens, the oil from the small pump enters ports A2, A3, and A4. Some of the oil pushes open check valve (20), flows from port B5 into port C5, and the flows to port H1 of the ripper Hi valve. The rest of the oil passes through the groove in the spool, enters port G5, pushes shuttle valve (22) up fully, then flows from port H5 to port S of shuttle valve (10). The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (10) to the left, closes the circuit between ports N and O, and opens the circuit between ports S and O. The oil entering port O from port S then passes through orifice c, and enters ports P and Q. It becomes the pilot pressure of demand valve (1), and moves the demand valve to the right. When this happens, the circuit between ports A and E is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A1 of the ripper Hi valve.

D375A-5

10-163


MAIN CONTROL VALVE

8. Blade lever at HOLD, ripper lever at LOWER (ripper Hi valve actuated)

10-164

D375A-5


MAIN CONTROL VALVE

As explained in item 7, the oil from the large pump enters A1 of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B1 and B2, and stops. The oil from the small pump flows from port C5 of the ripper Lo valve and enters port H1. Some of the oil entering port H1 passes through the passage inside valve (30), flows to port M1, and pushes shuttle valve (32) fully to the left. It then enters port O1, pushes spool (24) up, and becomes the pilot pressure. The rest of the oil is throttled by orifice e and enters port D1. Some of the oil entering port D1 passes through the passage inside valve (30), flows to port K1, and pushes shuttle valve (29) fully to the right. It then enters port N1, pushes spool (24) down, and becomes the pilot pressure. The rest of the oil flows from port D1 to the bottom end of ripper tilt cylinder (33). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise. From the condition previously explained, if the hydraulic pressure continues to rise, the oil at port H1 is throttled by orifice e and enters port D1. Because of the resistance, the hydraulic pressure at port H1 becomes higher than the pressure beyond port D1. Therefore, the hydraulic pressure at pilot port O1 of spool (24) becomes higher than the hydraulic pressure at port N1, so when this pressure difference becomes greater than the tension of spring (25), it pushes spool (24) up. When this happens, the circuits between ports B1 and D1, and ports C1 and E1 open, the oil from the large pump flows from port B1 to port D1, enters the bottom end of ripper lift cylinder (33), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port C1 to port E1, and is drained to the hydraulic tank. The rest of the oil flows from port C1, is throttled by orifice d of valve (27), and returns to port G1. It then flows from port D5 of the ripper Lo valve, returns to port E5, and is drained to the hydraulic tank.

D375A-5

10-165


MAIN CONTROL VALVE

9. Ripper lever at LOWER (cylinder at stroke end)

10-166

D375A-5


MAIN CONTROL VALVE

From the condition in items 7 and 8. if cylinder (33) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, in the same way as in item 4, the oil from the small pump flows from port A2 and pushes open main relief valve poppet (14). It is then relieved to port E2, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 20.6 MPa {210 kg/cm2}. The oil passing through shuttle valves (22) and (10), and flowing from ports S and O to port P also pushes open main relief valve poppet (13), and is relieved to port T. The circuit from port O to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure at pilot port Q of demand valve (1) also drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E' opens, and the oil from the large pump is relieved, so the hydraulic pressure in the circuit of the large pump does not rise any further. The hydraulic pressure at this point is 20.6 MPa {210 kg/cm2}. When the hydraulic pressure in the whole circuit is set at 20.6 MPa {210 kg/cm2}, the pressure difference on both sides of orifice e of valve (30) (that is, the difference in pressure between ports H1 and D1) disappears. The pilot pressure at port O1 that is pushing spool (24) up becomes the same pressure as the pressure at port N1. When this happens, spool (24) is pushed down by the tension of spring (25) to a position where it is in balance with the tension of spring (26). At this point, the circuits between ports B1 and D1 and ports C1 and E1 are closed. The oil from the large pump goes as far as port B1, and stops. The oil at the head end of cylinder (33) flows from port C1, passes through orifice d of valve (27), and returns only to port G1.

D375A-5

10-167


CYLINDER STAY

CYLINDER STAY

1. 2. 3. 4.

Yoke Oil seal Bushing Bushing Unit: mm

No.

Check item

Criteria Tolerance Shaft

Hole

Standard clearance

Clearance limit

150

0.085 0.148

+0.063 0

0.085 0.211

0.5

6

Clearance between cylinder yoke and bushing

115

0.072 0.126

+0.054 0

0.072 0.180

0.5

7

Clearance between lift cylinder support shaft and bushing

105

0.120 0.207

+0.035 0

0.120 0.242

0.5

5

Clearance between cylinder yoke and bushing

10-168

Standard size

Remedy

Replace

D375A-5


BLADE

BLADE SEM-U DOZER

10-170

D375A-5


BLADE

Unit: mm No.

1

Check item

Clearance between brace pin and brace


Tolerance


Clearance limit

Shaft

Hole

75

0.2 0.3

+0.3 +0.1

0.3 0.6

2

2

Clearance between brace pin and bracket

75

0.2 0.3

+0.3 +0.1

0.3 0.6

2

3


75

0.2 0.3

+0.3 0

0.2 0.6

1

4

Clearance between brace pin and bushing

75

0.2 0.3

+0.2 0

0.2 0.5

1

5

Clearance between center brace and cap spherical surface

170

0.2 0.3

+0.3 0

0.2 0.6

1

6

Clearance between joint and bracket

200

0.2 0.7

+0.3 +0.1

0.3 1.0

3

7

Clearance between frame pin and joint

100

0.3 0.5

+0.3 0

0.3 0.8

3

8


100

0.3 0.5

+0.5 +0.2

0.5 1.0

2

9

Clearance between straight frame joint bushings

160

0.3 0.4

1

10

Clearance between trunnion and cap spherical surface

200

0.5 1.0

+0.5 0

0.5 1.5

8

11


200

0.2 0.7

+0.3 +0.1

0.3 1.0

3

12

Clearance between blade pin and joint

100

0.3 0.5

+0.3 0

0.3 0.8

3

13

Clearance between blade pin and bracket

100

0.3 0.5

+0.5 +0.2

0.5 1.0

2

14

Clearance between center link pin and blade bracket

125

0.3 0.5

+0.5 +0.2

0.5 1.0

2

15

Clearance between center link pin and center link

125

0.3 0.5

+0.5 +0.2

0.5 1.0

2

16

Clearance between center link and blade bracket

280

0.2 0.4

+0.3 +0.1

0.3 0.7

2

17

Clearance between center brace spherical surface and cap

170

0.2 0.3

+0.3 0

0.2 0.6

1

D375A-5

Replace

Adjust shim or replace

Replace


10-171


BLADE

U-DOZER

10-172

D375A-5


BLADE

Unit: mm No.

1

Check item

Clearance between brace pin and brace


Tolerance


Clearance limit

Shaft

Hole

75

0.2 0.3

+0.3 +0.1

0.3 0.6

2

2


75

0.2 0.3

+0.3 +0.1

0.3 0.6

2

3


75

0.2 0.3

+0.3 0

0.2 0.6

1

4

Clearance between brace pin and bushing

75

0.2 0.3

+0.2 0

0.2 0.5

1

5

Clearance between center brace and cap spherical surface

170

0.2 0.3

+0.3 0

0.2 0.6

1

6


200

0.2 0.7

+0.3 +0.1

0.3 1.0

3

7


100

0.3 0.5

+0.3 0

0.3 0.8

3

8

Clearance between frame pin and bracket

100

0.3 0.5

+0.5 +0.2

0.5 1.0

2

9

Clearance between straight frame joint bushings

160

0.3 0.4

1

10

Clearance between trunnion and cap spherical surface

200

0.5 1.0

+0.5 0

0.5 1.5

8

11


200

0.2 0.7

+0.3 +0.1

0.3 1.0

3

12

Clearance between blade pin and joint

100

0.3 0.5

+0.3 0

0.3 0.8

3

13

Clearance between blade pin and bracket

100

0.3 0.5

+0.5 +0.2

0.5 1.0

2

14

Clearance between center link pin and blade bracket

125

0.3 0.5

+0.5 +0.2

0.5 1.0

2

15

Clearance between center link pin and center link

125

0.3 0.5

+0.5 +0.2

0.5 1.0

2

16

Clearance between center link and blade bracket

280

0.2 0.4

+0.3 +0.1

0.3 0.7

2

17

Clearance between center brace spherical surface and cap

170

0.2 0.3

+0.3 0

0.2 0.6

1

D375A-5

Replace


Replace


10-173


BLADE

CUTTING EDGE, END BIT

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Repair limit

478

380

Width of end bit

734

600

3

Height of end bit inside

393

300

4

Height of cutting edge

406

335 (264 after turned)

1

Height of end bit outside

2

10-174

Replace

Replace or turn

D375A-5


RIPPER EQUIPMENT

RIPPER EQUIPMENT VARIABLE MULTIPLE SHANK RIPPER

10-176

D375A-5


RIPPER EQUIPMENT

GIANT RIPPER

Unit: mm No.

1

Check item

Clearance between bushing and bracket and arm mount pin


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearence limit

120

0.036 0.090

+0.208 +0.125

0.161 0.298

1.5

2

Clearance between bushing and beam and arm mount pin

120

0.036 0.090

+0.208 +0.125

0.161 0.298

1.5

3

Clearance between cylinder mount pin and bushing

100

0.036 0.090

+0.207 +0.120

0.156 0.207

1.5

4

Clearance between shank and mount pin

5

Wear of point

6

Wear of protector

D375A-5

Standard size

Tolerance

Repair limit

82

±0.3

Standard size

Repair limit

420

255

155

115

Replace

10-177


CAB MOUNT

CAB MOUNT

1. Support 2. Damper mount (Front) 3. Damper mount (Rear)

Outline

10-178

The cab mount is installed at two places in the front and at two places in the rear, and the floor frame and the cab are secured. The cab mount adopts an oil seal type damper mount and absorbs vibration.

D375A-5


CAB

CAB CAB ASEMBLY

1. 2. 3. 4.

Front wiper Front glass Rear wiper Door

D375A-5

10-179


CAB

ROPS GUARD

1. ROPS guard

10-180

D375A-5

10 Structure, function and maintenance standard STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AIR CONDITIONER

AIR CONDITIONER AIR CONDITIONER PIPING

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

Air conditioner compressor Window defroster Side defroster Air conditioner unit Blower port Blower motor Hot water pick-up piping Condenser Receiver tank

D375A-5

10. 11. 12. 13.

Valve (hot water outlet) Hot water return piping Valve (hot water inlet) Refrigerant piping

A. Fresh air B. Recirculated air C. Hot air/cold air

10-181


ENGINE CONTROL

ENGINE CONTROL

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

Decelerator pedal Starter switch Decelerator potentiometer Steering controller Transmission controller Fuel throttle dial Battery Battery relay Starter Engine controller Fuel pump

10-182

Outline

The throttle signal of the throttle dial enters the steering controller and the transmission controller and is processed together with another information, then sent to the engine controller as a throttle command. The engine controller controls the control valve unit and the fuel pump in accordance with the command.

D375A-5


ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM

Outline

The engine controller receives the manual signal of the second throttle and the third throttle signal that is the control signal from a vehicle body and selects a low engine speed, then controls the control valve unit. The third throttle control signal includes the following items: 1 First throttle signal 2 SSC (Shoe Slip Control) control 3 Auto decelerators (F3, R3, R2)

The engine control system shares the information about the engine controller with another controller through networks and contributes to the optimum control between the engine and the vehicle body. As the auto decelerator function, the engine speed is temporarily set to 1,000 rpm when forward and reverse from F3, R3, and R2 are switched. (For transmission clutch protection)

The steering controller selects the lowest engine speed from the information 1, 2, and 3 and sends it to the engine controller as the third throttle.

D375A-5

10-183


DECELERATOR POTENTIOMETER

DECELERATOR POTENTIOMETER

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

Connector Lever Body Potentiometer Coupling Shaft Stopper

10-184

Outline

The decelerator potentiometer is mounted on the lower front of the operator cab and connected with the decelerator pedal using a linkage.

When the decelerator pedal is actuated, the shaft of the throttle potentiometer rotates via the linkage and a resistance value is changed. Fixed voltage is applied between the pins A to C of the potentiometer and a voltage signal that matches the actuation position of the decelerator pedal is sent from the B pin to the engine controller.

D375A-5


HPI ENGINE CONTROL SYSTEM

HPI ENGINE CONTROL SYSTEM ★ HPI is an abbreviation of High Pressure Injection. System drawing

Outline

The signals detected by various sensors are input to the engine controller. The input signals are operated arithmetically by the controller. A signal is issued to each actuator and controls a fuel injection level and fuel injection timing.

10-186

D375A-5


1. Fuel tank 2. Fuel filter 3. Fuel pump assembly 3A. Gear pump 3B. Pump regulator 3C. Check valve 3D. Fuel pump actuator 3E. Fuel pump pressure sensor 4. Control valve assembly 4A. Timing rail actuator valve 4B. Fuel leak throttle (220 cc/min) 4C. Timing rail pressure sensor 4D. Shut-off valve 4E. Fuel rail actuator valve 4F. Fuel leak throttle (110 cc/min) 4G. Fuel rail pressure sensor 5. Injector assembly 5A. Timing orifice 5B. Fuel orifice 5C. Gravity check valve 5D. Bypass orifice 5E. Injector 5F. Plunger 5G. Gravity check valve 6. Fuel cooler 7. ECM controller 8. Engine speed sensor 9. Atmospheric pressure sensor 10. Boost pressure sensor 11. Boost temperature sensor

D375A-5

HPI ENGINE CONTROL SYSTEM

OUTLINE OF HPI SYSTEM

The HPI system consists of injector assembly (5), control valve assembly (4), and fuel pump assembly (3). Injector assembly (5) controls the amount of fuel injection and the injection timing by controlling the amount of fuel passing through fuel orifice (5B). In order to control the fuel flow, it is necessary to control the fuel rail pressure and timig rail pressure. To control these pressures, control valve assembly (4) has 2 pressure sensors and 2 actuator valves built in. These carry out control so that the fuel rail rail pressure and timing rail pressure become the target value. Shut-off valve (4D), used to stop the engine, is installed in the fuel rail line. Fuel pump assembly controls the basic pressure of the fuel. The fuel supplied from fuel tank (1) passes through fuel filter (2), is then sucked up by gear pump (3A), and is supplied to control valve assembly (4). The discharge pressure of the fuel pump is controlled to a suitable level by adjusting the opening angle of fuel pump actuator (3D).

10-187


MONITOR SYSTEM

MONITOR SYSTEM

The monitor system monitors the state of the vehicle by the sensor mounted on each portion of the vehicle and quickly processes the information, then displays it on the panel, thereby reporting the state of the vehicle to the operator. The contents displayed on the panel are roughly divided as follows: 1. Monitor portion that issues an alarm when an error occurred in the vehicle. 2. Gauge portion (coolant temperature, torque converter oil temperature, fuel level) that always displays the state. 3. Function that displays error codes. 4. Function that monitors current and voltage values of each sensor and solenoid.

10-188

Further, the monitor panel incorporates the various mode selection switches of the SSC (shoe slip control) and has the function of the control portion of the vehicle control system. The monitor panel has the monitor display function and the switch function for the SSC mode selection. A CPU (central processing unit) is installed inside. The CPU processes information and displays and outputs it. The CPU uses an LCD as the monitor display portion. Further, the switch is a flat sheet switch.

D375A-5


MONITOR SYSTEM

Monitor Panel Processing (All Specifications) Monitor panel display 1 Processing contents and condition

2 System

3 Flow of signal

1) Display of forward-reverse, number of gear S-NET communication Transmission controller → Steering controller → Monitor panel ratios F1 and R3 are reported by S-NET based on the information about the transmission controller. S-NET communication Engine speed sensor → Engine 2) Gauge display of engine speed controller → Steering controller → The pulse of the engine speed sensor is Monitor panel substituted for the number of gauges and the number of gauges is reported to the monitor panel by S-NET. S-NET communication Each sensor, solenoid → Controller 3) Troubleshooting display → Monitor panel At fault, the relevant failure code is reported to the monitor panel by S-NET. The information as to whether the buzzer sounds or the caution lamp comes on according to the failure contents is also reported. 1 At normal time User codes 2 In failure history display mode Service codes The monitor panel alternatively displays codes and hour meter values on the hour meter display portion. Monitoring display 1 Processing contents and condition

2 System

3 Flow of signal

1) The communication states of each sensor, S-NET communication Each sensor → Controller → Monitor panel each solenoid, and S-NET are displayed. An item number and an equipment state are reported to the monitor panel by S-NET. The monitor panel displays an item on the speed display portion and the relevant value on the hour meter portion. 2) An item advances by the reverse slow button of the monitor panel. The item returns by the buzzer cancel switch.

D375A-5

Monitor panel → Controller → Monitor panel

10-189


MONITOR PANEL

MONITOR PANEL Monitor portion

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

Display plate (Speed range display) Power train oil temperature gauge Engine water temperature gauge Charge lamp Fuel thermometer gauge Engine oil pressure caution lamp Engine water temperature caution lamp

Outline

The monitor portion consists of a monitor that issues an alarm when an error occurred in a vehicle, a gauge that always displays the state of the vehicle, and the service meter. The monitor portion installs a microcomputer and processes and displays signals from each sensor. Besides, the items displayed on the monitor portion and gauge portion are listed in the table on the next page.

Operation 1. When the power turns on (When the starter switch is ON) 1) All items of the gauge and monitor portions come on for three seconds. 2) The alarm lamp comes on for two seconds.

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

Power train oil temperature caution lamp Hydraulic oil temperature caution lamp Preheat pilot lamp Dual tilt display lamp Radiator water level check lamp Fuel gauge Service meter 2) Start-up inspection items comes off when the engine starts. (Whether the engine is operating or not is decided depending on whether the engine oil pressure is raised or the voltage from the alternator exceeds 10 V.)

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

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

10-190

D375A-5


MONITOR PANEL

Monitor Panel Display Category

Symbol

Display item

Display range

Display method The monitor panel is displayed when the engine is stopped and the starter switch is ON. For the display, the monitor panel comes off at normal time and flashes at abnormal time.

Radiator water level

Below low level

Engine oil pressure

For the display, the monitor panel comes At sensor error or haroff at normal time and flashes at abnorness disconnection mal time.

Charge level

At faulty charge

Engine oil pressure

49.0 kPa {0.5 kg/cm2} or less


Below low level

SAP00522

When the start switch is ON and the engine is rotating, the monitor panel is displayed. For the display, the monitor panel comes off at normal time and flashes at abnormal time. At the same time, the alarm lamp flashes.

When the start switch is ON and the engine is rotating, the monitor panel is disWhen the engine coolplayed. ant temperature Engine coolant temperFor the display, the monitor panel comes gauge is in the maxiature off at normal time and flashes at abnormum level (108°C or mal time. more) At the same time, the alarm lamp flashWhen the torque con- es and the alarm buzzer sounds. Torque converter oil verter oil temperature temperature is in the maximum level (130°C or more) Hydraulic oil temperature

Preheat

D375A-5

103 ± 3°C or higher

Preheat time

When the atmospheric temperature is below about 5°C, the switch panel comes on for 36 seconds with the sheet switch (ENGINE HEAT) ON. Subsequently, it flashes for 16 seconds and displays the completion of preheat.

10-191


Category

Symbol

MONITOR PANEL

Display item

Display range

Display method

Engine coolant temperature

The relevant one place comes on.

Torque converter oil temperature

All places come on below the relevant level.

Fuel level

Time meter

10-192

0 to 99,999 hours

Actuated when the alternator is charged.

D375A-5


MONITOR PANEL

Switch Portion 1. Switch functions a) ON-OFF switching in lock-up mode b) Economy mode setting - OFF, mode 1, mode 2 c) ON-OFF switching in reverse slow mode d) ON-OFF switching in SSC mode e) SSC mode level setting - Mode 1 to 5 a, b, and c are mounted for all specifications and d and e are mounted for the SSC specifications.

SSC specifications

Without SSC specifications

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

D375A-5

2. Initial Setup at key ON The function the operator desires according to the situation of an operating place is selected and all functions shall be set to the OFF state.

10-193


SENSORS

SENSORS

Sensor and type

Sensor system

Normal time

Abnormal time

Engine oil pressure

Contact

OFF

ON

Engine water temperature

Resistor


Resistor

Hydraulic oil temperature

Contact

ON

OFF


Contact

ON

OFF

Fuel level

Resistor

Engine oil pressure sensor

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

Plug Contact ring Contact Diaphragm Spring Terminal

10-194

D375A-5


SENSORS

Engine Water Temperature Sensor Torque converter oil temperature sensor

1. Thermistor 2. Body 3. Tube

4. Tube 5. Wire 6. Connector

Hydraulic oil temperature sensor

1. Switch 2. Plug 3. Tube

4. Wire 5. Connector

Radiator water level sensor

1. Float 2. Sensor 3. Tube

D375A-5

4. Wire 5. Connector

10-195


SENSORS

Fuel level sensor

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

Connector Float Arm Body Spring Contact Spacer

10-196

Function

The fuel level sensor is installed to the bottom right of the front face of the fuel tank. Float (2) moves up and down according to the fuel level. This movement of the float is transmitted by arm (3) and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display on the monitor panel reaches a certain level, a warning lamp flashes.

D375A-5


MODE SELECTION SYSTEM

MODE SELECTION SYSTEM (SSC (Shoe slip control) system) System drawing

Outline

The mode selection system automatically performs the engine control that matches the work condition selected by the operator. It reduces a fuel cost, makes the life of the track longer, and reduces the frequency of decelerator operation. The engine control mode includes the economy mode control used at dozing time, the SSC used at ripping time, and the reverse slow mode control that can be used in both.

D375A-5

The lock-up control mode is the same mode as the conventional lock-up function and cannot perform simultaneous selection with the above mode.

10-197


Mode selection function

This system comprises the mode selection panel (with a built-in microcomputer) for the operation mode selection, steering controller (with a builtin microcomputer) for the engine control and the engine controller that, responding to the instruction from the steering controller, implements the actual control by use of the control valve. The system also comprises the transmission controller that turns on or off the torque converter lockup responding to the signal from the transmission output speed sensor plus various types of sensors. Following describes the functions of respective controllers.


4. The transmission controller sends the lock-up signal to the lock-up solenoid valve. The applicable lock-up signal is decided based the entered gear speed information of the transmission controller. ★ Refer to the Operation of Torque Converter Lock-up Control System.

Functions of the engine controller 1. The engine controller controls the control valve unit responding to the manual instruction entered from the deceleration potentiometer or the SSC instruction whichever designates a slower engine speed (a higher voltage).

Functions of the steering controller and transmission controller 1. The steering controller computes the machine bodys ground speed based on the input signal from the acceleration sensor and then computes the shoe speed by adding the signal from the transmission output speed sensor to the ground speed. The steering controller then calculates the shoe slip rate based on above information. 2. Then the steering controller computes the drawbar pull using the input signals from the engine speed sensor and the transmission output speed sensor. 3. This controller calculates an optimum engine speed using above 1 and 2 plus the set mode signal and the speed information from the transmission controller. This optimum value is then sent from the speed controller to the engine controller as the SSC instruction.

10-198

D375A-5



Operation of mode selection system

Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in accordance with the contents of work.

Work

Mode Single Simultaneous switch selection selection

Mode work condition ON/OFF switching is automatically performed in accordance with a load. Speed number of gear ratios ON

1,230 rpm or more

F2, F3 R1, R2, R3 1,260 rpm or more

OFF

1,200 rpm or more

1,230 rpm or more

ON

2,140 rpm or more

OFF

F1

Mode operation, characteristic 1. When the torque converter approaches to the stall area or performs gear shaft operation, lock-up is set to OFF. When the torque converter reaches a light lode, lock-up is set to ON. 2. Can be used in all number of gear ratios. 3. Simultaneous selection disabled with another mode 4. Suitable for dozing work of comparatively a few load fluctuations

2,200 rpm or more

1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC mode switch 1 or 2 ON are set simultaneously, the F1 shift economy control is performed. When the ripper lever is actuated and the switch is turned on, the slip control is performed. 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 performing the decelerator operation of the engine. 2. Target travel speed at reverse time R1 R2 70% at full operation R3

The following conditions are satisfied: 1. At start, to prevent rashing out, the modulating valve is actuated. At this time, the steering con1 When F1 is shifted. troller performs index characteristic down of 2 After the ripper down, ripper tilt levers are about 40% and performs the engine outpuut actuated and the switch is set to ON control if a ripper down signal is input. 2. The seering controller performs the engine output control in accordance with the index force characteristic (refer to the rock-bed selection shown below) selected by the operator among the index force characteristics set in five stages and suppresses the generation of a slip. 3. The steering controller regards the index force immediately before the slip (exceeding the shoe ripping ratio of 30% is generated, as the maximum, and performs the engine output control. At this time, the steering controller performs index characteristic down of about 30 to 80% and performs the engine outpuut control if a ripper tilt or ripper up signal is input. 4. At neutral time, the engine speed is suppressed partially. Set to ON in connection with SSC

1. When the SSC is set to ON, the selection mode 3 comes on. 2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the state and load of the rock-bed.

★ When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the engine output control is performed in accordance with the command having the smallest value among the control command, throttle command, and decelerator command. D375A-5

10-199


SENSORS

SENSORS Engine speed sensor Transmission output shaft speed sensor

1. 2. 3. 4. 5.

Magnet Terminal Case Boots Connector

10-200

D375A-5


SENSORS

Acceleration sensor

1. Sensor portion 2. Wire 3. Connector

Outline

The acceleration sensor is mounted at the lower front of the operator cab. The acceleration sensor changes the position of a ball inside the sensor in accordance with acceleration. The coil that detects the position of this ball is provided inside the sensor. This is amplified by an amplifier to change voltage and the result is sent to the SSC controller. Refer to the drawing at the right for the sensor input/output chatacteristics.

D375A-5

10-201


SENSORS

Pitch angle sensor

1. 2. 3. 4.

Body Tube Wire Connector

10-202

D375A-5


ELECTRICAL DEVICE

ELECTRICAL DEVICE Relay box

D375A-5

10-203


ELECTRICAL DEVICE

OPERATION OF LAMP SYSTEM

ELECTRICAL CIRCUIT OF LAMP SYSTEM

10-204

D375A-5


ELECTRICAL DEVICE

OPERATION OF ELECTRICAL INTAKE AIR HEATER

ELECTRCAL CIRCUIT OF PREHEATING

D375A-5

10-205


STEERING ELECTRONIC CONTROL


1. 2. 3. 4. 5.

Monitor panel (Speed range display) Auto shift down switch Engine controller Transmission controller Steering controller

10-206

6. 7. 8. 9.

Steering control valve Transmission output shaft speed sensor Transmission control valve Engine speed sensor

D375A-5



Shift Mode Function

1. Function If you shift the lever to the forward or reverse, the gear speed selected from the shift mode is turned on. A: Shift mode 1 B: Shift mode 2 2. Type of Modes 1 F1-R2 2 F2-R2A 3 F1-R1 (Manual mode) Shift the steering or forward-reverse lever to N. 3. Selecting method Shift up switch ON

Manual mode

Shit up switch ON

Shift mode 1 Shift down switch ON

Shift mode 2 Shift down switch ON

4. Displaying method Monitor panel

Auto Shift-down Function

1. Operating condition This function automatically shifts the gear speed down if load is increased while the machine is travelling at 2nd or 3rd speed or while the machine is in operation. 2. Selecting method Turn the auto shift-down switch (1) ON. 3. Operation and features of the mode 1) This function turns on the shift-down automatically by calculating the drawbar pull (load to the machine body) based the engine speed, transmission speed and throttle information from the steering controller. 2) Once the machine is automatically shifted down, shit-up wont be turned on automatically (shift up from the manual switch is available, though). 3) This function is available for both the forward and reverse travel.

D375A-5

10-207


20 TESTING AND ADJUSTING STANDARD VALUE TABLES Standard value table for engine related parts .......................................................................................... Standard value table for machine related parts ....................................................................................... TESTING AND ADJUSTING .................................................................................................................... TROUBLESHOOTING..............................................................................................................................

20- 2 20- 3 20-101 20-301

★ Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims

D375A-5

20-1 1


STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Engine unit Machine model

D375A-5

Engine Engine

Item

Engine speed

High idling Low idling Rated speed

Air supply (boost pressure)

At rated output

Exhaust temperature

Whole speed range (ambient temperature: 20°C)

Exhaust gas color

At sudden acceleration At high idling

Valve clearance Intake valve (normal temperature) Exhaust valve

SA6D170E-3 Unit

Standard value for new machine

Service limit value

rpm

1,900 ± 30 720 ± 30 1,800

1,900 ± 30 720 ± 30 1,800

kPa {mmHg}

Min. 107 {Min. 800}

93{700}

°C

Max. 680

700

Bosch index

Max. 4.0 Max. 1.0

6.0 2.0

mm

Max. 0.32 Max. 0.62

Max. 0.32 Max. 0.62

MPa {kg/cm2} (rpm)

Min. 2.9 {Min. 30} (210 - 250)

2.1{21} (210 - 250)

Max. 4.9 {Min. 500}

7.9{800}

0.38 - 0.59{4.0 - 6.0} 0.34 - 0.54{3.5 - 5.5}

0.21{2.1} 0.18{1.8}

Min. 0.12 {Min. 1.2} Min. 0.10{Min. 1.0}

0.07{0.7} 0.05{0.5}

Compression pressure

Oil temperature: 40 - 60°C (engine speed)

Blow-by pressure

Water temperature: Within operating range At rated output

kPa {mmH2O}

Oil pressure

Water temperature: Within operating range At high idling SAE30 or SAE15W-40 oil SAE10W oil At low idling SAE30 or SAE15W-40 oil SAE10W oil

MPa {kg/cm2}

Oil temperature

Whole speed range (inside oil pan)

°C

90 - 110

120

Fan belt tension

Deflection when pressed with finger force of approx. 58.8 N {6 kg}

mm

Auto tension

Auto tension

Alternator, air conditioner compressor belt tension

Deflection when pressed with finger force of approx. 98 N {10 kg}

mm

New part: 19 - 21

When adjusting tension: 24 - 26

★ When measuring the low idling speed after reducing speed suddenly from high speed, wait for several seconds for the speed to stabilize before measuring.

20-2 (5) 1

D375A-5

20-2 TESTING AND ADJUSTING TESTING AND ADJUSTING


STANDARD VALUE TABLE FOR ENGINE RELATED PARTS HPI control devices Name of component

Atmospheric pressure sensor

Boost pressure sensor

Intake air temperature sensor

Oil pressure sensor

D375A-5

Connector Inspection No. method

Judgment table

Measurement conditions

AAPR

If the condition is as shown in the table below, it is normal 1) Connect T-adapter to connector. Atmospheric 2) Turn starting Pin Altitude Voltage pressure switch ON. Between (A) — — 4.75 – 5.25 V and (B) 101.0 kPa 0m 4.42 ± 0.12 V {760 mmHg} 89.9 kPa 1,000 m 3.97 ± 0.12 V {674 mmHg} Between (C) 79.5 kPa 2,000 m 3.57 ± 0.12 V and (B) {596 mmHg} 70.1 kPa 3,000 m 3.21 ± 0.12 V {526 mmHg} 61.6 kPa 4,000 m 2.88 ± 0.12 V {462 mmHg}

IMPR

If the condition is as shown in the table below, it is normal 1) Connect T-adapter to connector. Pin Boost pressure Voltage 2) Turn starting Between (A) and (B) — 4.75 – 5.25 V switch ON. 0 kPa 0.5 ± 0.03 V {0 mmHg} Between (C) and (B) 345 kPa 4.5 ± 0.08 V {2,590 mmHg}

IMTP

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. Intake air 2) Disconnect conPin Resistance temperature nector. 0ºC 30 k – 36 kz 25ºC 9 k – 11 kz Between (A) and (B) 50ºC 3 k – 4 kz 75ºC 1,350 – 1,500 z 100ºC 600 – 675 z Between (A), (B) — Min. 1 Mz and ground

OPS

If the condition is as shown in the table below, it is normal 1) Connect T-adapter to connector. Pin Oil pressure Voltage 2) Turn starting Between (A) and (B) — 4.75 – 5.25 V switch ON. 0 kPa 0.5 ± 0.08 V {0 kg/cm2} Between (C) and (B) 689 kPa 4.5 ± 0.08 V {7.03 kg/cm2}

20-2-1 (5)


Name of component

Fuel temperature sensor

Water temperature sensor

Engine speed sensor

Fuel pump pressure sensor

Fuel rail pressure sensor

20-2-2 (5)



Judgment table


FLTP

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. Fuel 2) Disconnect conPin Resistance temperature nector. 0ºC 30 k – 36 kz 25ºC 9 k – 11 kz Between (A) and (B) 50ºC 3 k – 4 kz 75ºC 1,350 – 1,500 z 100ºC 600 – 675 z Between (A), (B) — Min. 1 Mz and ground

CLTP

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. Water 2) Disconnect conPin Resistance temperature nector. 0ºC 30 k – 36 kz 25ºC 9 k – 11 kz Between (A) and (B) 50ºC 3 k – 4 kz 75ºC 1,350 – 1,500 z 100ºC 600 – 675 z Between (A), (B) — Min. 1 Mz and ground

SP1 · SP2

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. Pin Resistance 2) Disconnect conBetween (A) and (B) 1,000 – 2,000 z nector. Between (A) (B) and ground Min. 1 Mz

PMPR

If the condition is as shown in the table below, it is normal 1) Connect T-adapter to connector. Pin Fuel pressure Voltage 2) Turn starting Between (A) and (B) — 4.75 – 5.25 V switch ON. 0 kPa 0.5 ± 0.04 V {0 kg/cm2} Between (C) and (B) 2,582 kPa 4.5 ± 0.06 V {26.33 kg/cm2}

RPR

If the condition is as shown in the table below, it is normal 1) Connect T-adapter to connector. Pin Fuel pressure Voltage 2) Turn starting Between (A) and (B) — 4.75 – 5.25 V switch ON. 103 kPa 0.5 ± 0.04 V {10.5 kg/cm2} Between (C) and (B) 1,722 kPa 4.5 ± 0.06 V {17.56 kg/cm2}

D375A-5


Name of component

Timing rail pressure sensor

Fuel pump actuator

Fuel shut-off valve

Fuel rail actuator

Timing rail actuator

D375A-5


TPR


Judgment table


If the condition is as shown in the table below, it is normal 1) Connect T-adapter to connector. Pin Fuel pressure Voltage 2) Turn starting Between (A) and (B) — 4.75 – 5.25 V switch ON. 0 kPa 0.5 ± 0.04 V {0 kg/cm2} Between (C) and (B) 2,582 kPa 4.5 ± 0.06 V {26.33 kg/cm2}

PUMP

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. Pin Resistance 2) Disconnect conBetween (A) and (C) 7–9z nector. Between (A) (C) and ground Min. 1 Mz

FSO+ · FSO–

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. Pin Resistance 2) Disconnect conBetween FSO+ and FSO– 23 – 40 z nector. Between FSO+, FSO– and ground Min. 1 Mz

RAIL


TIMG


20-2-3 (5)


STANDARD VALUE TABLE FOR MACHINE RELATED PARTS

STANDARD VALUE TABLE FOR MACHINE RELATED PARTS Machine model Engine

Item

D375A-5


Unit

900 ± 50

900 ± 50 1,430

1,300 ± 60

1,160

Neutral → FORWARD

30 ± 5

Max. 8.0

Neutral → REVERSE

30 ± 5

30 ± 5

40 ± 5 (Play: Max. 3)

40 ± 5 (Play: Max. 3)

9±5

9±5

45 ± 15

45 ± 15

75 ± 10

75 ± 10

75 ± 10

75 ± 10

72 ± 10

72 ± 10

53 ± 10

53 ± 10

78 ± 10

78 ± 10

81 ± 10

81 ± 10

Neutral ! FORWARD

53.9 ± 9.8 {5.5 ± 1.0}

53.9 ± 9.8 {5.5 ± 1.0}

Neutral ! REVERSE

53.9 ± 9.8 {5.5 ± 1.0}

53.9 ± 9.8 {5.5 ± 1.0}

Until clutch is completely disengaged

14.7 ± 4.9 {1.5 ± 0.5}

14.7 ± 4.9 {1.5 ± 0.5}

26.5 ± 4.9 {1.5 ± 0.5}

26.5 ± 4.9 {1.5 ± 0.5}


16.7 ± 4.9 {1.7 ± 0.5}

16.7 ± 4.9 {1.7 ± 0.5}

Until brake takes effect and machine turns

29.4 ± 4.9 {3.0 ± 0.5}

29.4 ± 4.9 {3.0 ± 0.5}

49.0 ± 9.8 {5.0 ± 1.0}

49.0 ± 9.8 {5.0 ± 1.0}

• Engine water temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 - 55°C Torque converter stall + work equipment re- • Deceleration speed: Pedal depressed • Torque converter stall speed: F3 lief speed • Torque converter stall + work equipment speed: F3 + ripper RAISE

Torque converter stall

Direction

Full stroke (Neutral - Left, right) Steering

Deceleration pedal

• Engine stopped • Center of lever knob

Brake pedal

Blade lever

Ripper lever

Direction

D375A-5

mm

mm Full stroke Stroke until oil pressure becomes 0

mm

• Engine at low idling HOLD - RAISE, • Hydraulic oil temperature: FLOAT 45 - 55°C HOLD - Left, • Center of lever knob right tilt

mm

• Engine at low idling HOLD - RAISE, • Hydraulic oil temperature: LOWER 45 - 55°C HOLD - Tilt in, • Center of lever knob tilt out

mm


Until brake takes effect and machine turns

Steering

Deceleration pedal

rpm


• Engine at low idling • Center of lever knob

• Engine stopped • Center of pedal

Service limit value

1,520 ± 50

Deceleration speed



N {kg}

N {kg}

20-3 4 1



Machine model Engine

Item

Control lever, pedal operating effort

Brake pedal

Blade lever

D375A-5 Unit


Service limit value

N {kg}

460.6 ± 49.0 {47.0 ± 5.0}

460.6 ± 49.0 {47.0 ± 5.0}

39.2 ± 4.9 {4.0 ± 0.5}

39.2 ± 4.9 {4.0 ± 0.5}

83.3 ± 9.8 {8.5 ± 1.0}

83.3 ± 9.8 {8.5 ± 1.0}

28.4 ± 4.9 {2.9 ± 0.5}

28.4 ± 4.9 {2.9 ± 0.5}

21.6 ± 4.9 {2.2 ± 0.5}

21.6 ± 4.9 {2.2 ± 0.5}

20.6 ± 4.9 {2.1 ± 0.5}

20.6 ± 4.9 {2.1 ± 0.5}

Low idling

0.03 – 0.15 {0.3 – 1.5}

0.03 – 0.15 {0.3 – 1.5}

High idling

0.9 ± 0.10 {9.0 ± 1.0}

0.9 ± 0.10 {9.0 ± 1.0}

Low idling

0.01 – 0.15 {0.1 – 1.5}

0.01 – 0.15 {0.1 – 1.5}

0.39 – 0.64 {4.0 – 6.5}

0.39 – 0.64 {4.0 – 6.5}

Low idling

—

—

High idling

1.27 – 1.47 {13.0 – 15.0}

1.27 – 1.47 {13.0 – 15.0}

Low idling

2.45 ± 0.20 {25.0 ± 2.0}

2.45 ± 0.20 {25.0 ± 2.0}

High idling

2.65 ± 0.20 {27.0 ± 2.0}

2.65 ± 0.20 {27.0 ± 2.0}

Low idling

2.55 ± 0.15 {26.0 ± 1.5}

2.35 – 2.94 {24.0 – 30.0}

High idling

2.70 ± 0.15 {27.5 ± 1.5}

2.45 – 2.94 {25.0 – 30.0}

2.55 ± 0.15 {26.0 ± 1.5}

2.35 – 2.94 {24.0 – 30.0}

High idling

2.70 ± 0.15 {27.5 ± 1.5}

2.45 – 2.94 {25.0 – 30.0}

Low idling

2.55 ± 0.15 {26.0 ± 1.5}

2.35 – 2.94 {24.0 – 30.0}

High idling

2.70 ± 0.15 {27.5 ± 1.5}

2.45 – 2.94 {25.0 – 30.0}

Measurement conditions • Engine at low idling • Center of pedal • Engine at low idling • Hydraulic oil temperature: 45 55°C • Center of lever knob

HOLD→ RAISE HOLD→ FLOAT

N {kg}

HOLD – Left, right tilt

Ripper lever

Torque converter inlet pressure

• Engine at low idling • Hydraulic oil temperature: 45 55°C • Center of lever knob

• Torque converter oil temperature: Within operating range

Torque converter outlet pressure

HOLD – RAISE, LOWER HOLD – Tilt in, tilt out

N {kg}

High idling

Power train oil pressure

MPa {kg/cm2} Torque converter lockup clutch pressure

Torque converter stator clutch pressure

Transmission main relief pressure


Low idling MPa {kg/cm2}

Transmission F clutch pressure

Transmission R clutch pressure

20-4

1

D375A-5




Item

Transmission 1st clutch pressure

D375A-5


Power train oil pressure

Transmission lubrication pressure • Torque converter oil temperature: Within operating range

Steering left brake pressure

Steering right brake pressure • Torque converter oil temperature: Within operating range • Flat ground • Engine water temperature: Within operating range • Torque converter oil temperature: Within operating range • Engine at high idling • Run-up distance: 10 - 30 m • Measuring distance: 20 m

When lock-up switch is OFF

Power train performance

D375A-5

2.25 ± 0.2 {23.0 ± 2.0}

1.96 – 2.55 {20.0 – 26.0}

High idling

2.25 ± 0.2 {23.0 ± 2.0}

1.96 – 2.55 {20.0 – 26.0}

Low idling

2.55 ± 0.15 {26.0 ± 1.5}

2.35 – 2.94 {24.0 – 30.0}

2.70 ± 0.15 {27.5 ± 1.5}

2.45 – 2.94 {25.0 – 30.0}

Low idling

2.55 ± 0.15 {26.0 ± 1.5}

2.35 – 2.94 {24.0 – 30.0}

High idling

2.70 ± 0.15 {27.5 ± 1.5}

2.45 – 2.94 {25.0 – 30.0}

High idling

0.20 ± 0.05 {2.0 ± 0.5}

0.20 ± 0.05 {2.0 ± 0.5}

Low idling

2.55 ± 0.15 {26.0 ± 1.5}

High idling

27.0 ± 0.15 {27.5 ± 1.5}

Min. 2.4 {Min. 24} Min. 2.4 {Min. 24}

Low idling

2.50 ± 0.15 {25.5 ± 1.5}

Min. 2.4 {Min. 24}

High idling

2.65 ± 0.15 {27.0 ± 1.5}

MPa {kg/cm 2}

High idling

27.0 ± 0.15 {27.5 ± 1.5}

Min. 2.4 {Min. 24} Min. 2.4 {Min. 24} Min. 2.4 {Min. 24}

Low idling

2.50 ± 0.15 {25.5 ± 1.5}

Min. 2.4 {Min. 24}

High idling

2.65 ± 1.5 {27.0 ± 1.5}

Low idling

Steering right clutch pressure

Travel speed

Low idling

Unit

High idling

Transmission 3rd clutch pressure

Pin puller actuation pressure

Service limit value


Transmission 2nd clutch pressure

Steering left clutch pressure


MPa {kg/cm 2}

2.55 ± 0.15 {26.0 ± 1.5}

F1

18.9 ± 1.0 (3.8 ± 0.2)

Min. 2.4 {Min. 24} Min. 2.2 {Min. 22} 18.9 ± 1.0 (3.8 ± 0.2)

F2

10.6 ± 0.6 (6.8 ± 0.3)

10.6 ± 0.6 (6.8 ± 0.3)

F3

6.1 ± 0.3 (11.8 ± 0.6)

6.1 ± 0.3 (11.8 ± 0.6)

15.0 ± 0.8 (4.8 ± 0.2)

15.0 ± 0.8 (4.8 ± 0.2)

R2

8.3 ± 0.4 (8.7 ± 0.4)

8.3 ± 0.4 (8.7 ± 0.4)

R3

4.9 ± 0.3 (14.7 ± 0.7)

4.9 ± 0.3 (14.7 ± 0.7)

High idling

R1

MPa {kg/cm 2}

Sec. (km/h)

2.55 ± 0.10 {26.0 ± 2.0}

20-5

1



Machine model Item

Travel speed

Blade lift relief pressure

D375A-5 Standard value for new machine

Service limit value

F1

18.9 ± 1.0 {3.8 ± 0.2}

18.9 ± 1.0 {3.8 ± 0.2}

F2

10.6 ± 0.6 {6.8 ± 0.3}

10.6 ± 0.6 {6.8 ± 0.3}

F3

6.1 ± 0.3 {11.8 ± 0.6}

6.1 ± 0.3 {11.8 ± 0.6}

R1

14.1 ± 0.7 {5.1 ± 0.3}

14.1 ± 0.7 {5.1 ± 0.3}

R2

7.8 ± 0.4 {9.2 ± 0.5}

7.8 ± 0.4 {9.2 ± 0.5}

R3

4.6 ± 0.3 {15.8 ± 0.8}

4.6 ± 0.3 {15.8 ± 0.8}

Measurement conditions • Flat ground • Engine water temperature: Within operating range • Torque converter oil temperature: Within operating range • Engine at high idling • Run-up distance: 10 - 30 m • Measuring distance: 20 m

When lock-up switch is ON

Power train performance

Engine

Unit

Sec. (km/h)

• Hydraulic oil temperature: Low idling 45 - 55°C • Cylinder at stroke end • Standard value measured with High idling oil pressure gauge

Work equipment oil pressure

+0.98

Min. 19.6 {Min. 200} Min. 18.6 {Min. 190}

+0.98

High idling

20.6 0 {210 +100 }

Min. 19.6 {Min. 200}

MPa {kg/cm2}

+0.98

Low idling

19.6 0 {200 +100 }

Min. 18.6 {Min. 190}

+0.98

High idling

20.6 0 {210 +100 }

Min. 19.6 {Min. 200}

+0.98

Low idling

19.6 0 {200 +100 }

Min. 18.6 {Min. 190}

+0.98

High idling

20.6 0 {210 +100 }

Min. 19.6 {Min. 200}

18.6 – 20.6 {190 – 210}

Min. 17.6 {Min. 180}

19.6 – 21.6 {200 – 220}

Min. 18.6 {Min. 190}

18.6 – 20.6 {190 – 210}

Min. 17.6 {Min. 180}

19.6 – 21.6 {200 – 220}

Min. 18.6 {Min. 190}

Low idling

18.6 – 20.6 {190 – 210}

Min. 17.6 {Min. 180}

High idling

19.6 – 21.6 {200 – 220}

Min. 18.6 {Min. 190}

Low idling

18.6 – 20.6 {190 – 210}

Min. 17.6 {Min. 180}

High idling

19.6 – 21.6 {200 – 220}

Min. 18.6 {Min. 190}

Ripper tilt relief pressure • Hydraulic oil temperature: Low idling 45 - 55°C • Cylinder at stroke end • Standard value measured with High idling monitor panel

Blade tilt relief pressure High idling

Ripper lift relief pressure

Ripper tilt relief pressure

20.6 0 {210 +100 } +0.98

Low idling

1 3

Min. 18.6 {Min. 190}

19.6 0 {200 +100 }

Ripper lift relief pressure

20-6

+0.98

Low idling Blade tilt relief pressure

Blade lift relief pressure

19.6 0 {200 +100 }

MPa {kg/cm2}

D375A-5



Machine model Item


Service limit value

4.51 ± 0.29 {46.0 ± 3.0}

Min. 3.9 {Min. 40.0}

High idling

9 – 15

26

Low idling

3.5 – 4.5

6

High idling

1.1 – 1.6

1.1 – 1.6

Low idling

1.1 – 1.6

1.1 – 1.6

Low idling

10 – 15

17

High idling

4–5

6

Low idling

8 – 12

16

High idling

3–4

5


Control circuit oil pres- • Hydraulic oil temperature: 45 - 55°C • Engine at high idling sure • Circuit oil pressure: Lever at HOLD • Output pressure: Lever at full stroke PPC valve output pressure

RAISE

Work equipment oil pressure

Engine

LOWER Left tilt

Blade tilt • Hydraulic oil temperature: 45 - 55°C • Blade: No load • Full left tilt - Full right tilt

Right tilt

Sec.

Left tilt

Work equipment speed

• Hydraulic oil temperature: 45 - 55°C • Blade: No load • Ground level - Max. height

Work equipment

MPa {kg/cm 2}

Sec.

Blade lift

Low idling

High idling

Blade dual tilt Right tilt

Sec. • Hydraulic oil temperature: 45 - 55°C • Blade: No load • Full left tilt - Full right tilt

D375A-5

Unit

Low idling

High idling

20-7 3 1




Item


Service limit value

Low idling

7 – 11

15

High idling

2.5 – 3.5

5

Low idling

2–3

2–3

High idling

2–3

2–3

Low idling

12 – 18

24

High idling

4.5 – 5.5

7

Low idling

8 – 12

16

High idling

3–4

6

Max. 8

12

Max. 1.8

2.0

—

—

Max. 1.0

1.5


Unit

Dump

Low idling

High idling Blade pitch

Sec. Back RAISE LOWER

Sec. • Hydraulic oil temperature: 45 - 55°C • Blade: No load • Ground level - Max. height

Sec.

Time lag Ripper

Tilt back

Ripper tilt

Blade

1 3

High idling

Ripper lift

• Hydraulic oil temperature: 45 - 55°C • Blade: No load • Full tilt in - Full tilt out

20-8

Low idling

Tilt in

Work equipment

Work equipment speed

• Hydraulic oil temperature: 45 - 55°C • Blade: No load • Full dump - Full back

Low idling • Hydraulic oil temperature: 45 - 55°C • Lever at full stroke • Raise blade to maximum height, then lower blade and measure time taken from point High idling where blade contacts ground to point where idler comes off ground Low idling • Hydraulic oil temperature: 45 - 55°C • Lever at full stroke • Raise ripper to maximum height, then lower ripper and measure time taken from point High idling where ripper contacts ground to point where sprocket comes off ground

Sec.

D375A-5




Item


Blade lift

D375A-5 Unit


Service limit value

mm

Max. 200/15 min

400/15 min

mm

Max. 50/5 min

100/5 min

mm

Max. 50/5 min

80/5 min

mm

Max. 80/15 min

160/15 min

• Hydraulic oil temperature: 45 - 55°C • Engine stopped • Hydraulic drift for 15 minutes at bottom edge of blade (change in height h)

• Hydraulic oil temperature: 45 - 55°C • Engine stopped • Hydraulic drift for 5 minutes at center of idler (change in height h)

Hydraulic drift

Work equipment

Hydraulic drift of chassis (blade lift)

Blade tilt

• Hydraulic oil temperature: 45 - 55°C • Engine stopped • Retraction h of tilt cylinder

Ripper lift

• Hydraulic oil temperature: 45 - 55°C • Engine stopped • Hydraulic drift for 15 minutes at tip of shank (change in height h)

D375A-5

20-9 3 1



Machine model

Hydraulic drift

Item

20-10

1 3


Hydraulic drift of chassis (ripper lift)

Unit


Service limit value

mm

Max. 30/5 min

60/5 min

Max. 3.0

12

Max. 3.6

12

Max. 3.2

12

• Hydraulic oil temperature: 45 - 55°C • Engine stopped • Hydraulic drift for 5 minutes at center of sprocket (change in height h) Oil leakage from cylinder

Work equipment

Engine

D375A-5

• Engine at high idling Blade tilt cylinder • Hydraulic oil temperature: 45 - 55°C • Measure oil leakage during 1 minute at cylinder relief Ripper lift cc/min cylinder Ripper tilt cylinder

D375A-5


MEASURING ENGINE SPEED

MEASURING ENGINE SPEED ★ Measure the engine speed under the following condition. • Engine water temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 - 55°C 1. Preparation work Turn the starting switch ON and set the monitor panel in the "Monitoring mode" to prepare for measurement of the engine speed. ★ For the operating method, see "Special functions of monitor panel (EMMS)". • Monitoring code: 99 (Engine speed) ★ The engine speed is displayed on the service meter display section in 1 rpm.

3. Measuring high idling speed 1) Start the engine and set the fuel control dial in the high idling position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. 4. Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idling position. 2) Set the PCCS lever and work equipment control lever in neutral and press the decelerator pedal and measure the engine speed. 5. Measuring torque converter stall speed 1) Start the engine and set the fuel control dial in the low idling position. 2) Press the brake pedal securely and set the parking brake lever in the FREE position and set the PCCS lever in the FORWARD and 3rd gear speed position. ★ Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. ★ Keep the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idling position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idling. ¤ Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 5) Just after the torque converter oil temperature gauge reads the top line of the green range, return the direction of the PCCS lever into neutral.

2. Measuring low idling speed 1) Start the engine and set the fuel control dial in the low idling position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. ★ When measuring the low idling speed after lowering the engine speed sharply from the high speed range, wait for several seconds until the engine speed is stabilized.

20-102 (5) 1

D375A-5


6) Repeat above steps 2) - 5) 3 times. 7) Perform steps 2) - 4) again and measure the engine speed about 5 seconds after the torque conver ter oil temperature gauge reads the top line of the green range. ★ After finishing measurement, return the direction of the PCCS lever into neutral and lower the torque converter oil temperature with the engine at high idling.

6. Torque converter stall + Work equipment relief speed (Full stall speed) 1) Start the engine and set the fuel control dial in the low idling position and raise the ripper to the stroke end. 2) Keep pressing the brake pedal securely and set the parking brake lever in the FREE position and set the PCCS lever in the FORWARD and 3rd gear speed position. ★ Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. ★ Set the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idling position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idling. ¤ Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.

D375A-5

MEASURING ENGINE SPEED

5) Just after the torque converter oil temperature gauge reads the top line of the green range, return the direction of the PCCS lever into neutral.

6) Repeat above steps 2) - 5) 3 times. 7) Perform steps 2) - 4) again and relieve the ripper in the raising direction and measure the engine speed about 5 seconds after the torque conver ter oil temperature gauge reads the top line of the green range. ★ After finishing measurement, return the direction of the PCCS lever into neutral and lower the torque converter oil temperature with the engine at high idling.

20-103 1


MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ★ Tools for measuring intake air pressure (boost pressure) Symbol

Part No.

A

799-201-2202

Part Name Boost gauge kit

★ A nipple (quick coupler) is installed to the intake air pressure (boost pressure) pickup port of the Pm clinic specification machine. ¤ Be careful not to touch any hot parts when removing or installing the measuring tools. ★ Measure the intake air pressure (boost pressure) under the following conditions. • Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 - 55°C 1. Open the engine left side cover. 2. Remove intake air pressure measurement plug (1).

3. Fit nipple 1 of boost gauge kit A, then connect gauge 2.

20-104 (5) 1

4. Run the engine at a mid-range speed or above to bleed the oil from the hose. ★ Insert the connection of the hose and pressure gauge about half way, repeat the action to open the self-seal portion at the hose end, and bleed the oil. ★ If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. ★ If there is oil inside the hose, the gauge will not work, so always bleed the oil. 5. Run the engine at high idling to stall the torque converter, and measure the intake air pressure (boost pressure). ★ For details of the procedure for stalling the t o r q u e c o n ve r t e r, s e e M E A S U R I N G TORQUE CONVERTER STALL SPEED. ★ The intake air pressure (boost pressure) should be measured with the engine running at rated output. However, when measuring in the field, a similar value can be obtained at torque converter stall speed.


D375A-5


MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST TEMPERATURE ★ Tools for measuring exhaust temperature Symbol

Part No.

B

799-101-1502

Part Name Digital temperature gauge

★ Measuring instruments for exhaust temperature (Pm clinic specification) Since the exhaust temperature sensor is installed to the Pm clinic specification machine, prepare an adapter connector to connect the exhaust temperature sensor and digital temperature gauge. Symbol

Part No.

Part Name

B

799-101-1502

Digital temperature gauge

—

799-201-1150

Adapter connector

¤ Wait for the manifold temperature to go down before removing or installing the measuring equipment. ★ Measure the exhaust temperature under the following conditions. • Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 - 55°C

4. Procedure when measuring the maximum value during troubleshooting Carry out actual work and measure the maximum value during operation. ★ Use the PEAK mode of the digital temperature gauge. ★ The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation using the following formula. • Compensation value [°C] = Measured value + 2 x (20 - ambient temperature)

1. Open the engine right side cover, then remove the adiabatic cover. 2. Remove exhaust temperature measurement plug (1).

3. Fit sensor 1 of digital temperature gauge B, then connect to meter 2. ★ Clamp the wiring harness of the digital temperature gauge to prevent it from touching any hot part during measurement.

D375A-5

5. Procedure when measuring periodically or during preventive maintenance ★ If only torque converter stall is used, the power train oil temperature will overheat before the exhaust temperature stabilizes, so always use the following procedure when measuring. 1) Use the following procedure to carry out full stall and raise the exhaust temperature to approx. 650°C. (Condition a in the diagram). i) Start the engine, set the fuel control dial to the low idling position, then operate the ripper lever to move the ripper lift cylinder to the end of the RAISE stroke. ii) Keep the brake pedal firmly depressed, operate the PCCS lever to the F position and set the speed to 3.

20-105 (5) 1


MEASURING EXHAUST TEMPERATURE

iii) Depress the decelerator pedal and set the fuel control dial to high idling. iv) Let the decelerator pedal back slowly, run the engine at high idling, stall the torque converter, and at the same time, operate the ripper lever to RAISE relief. ¤ Keep the brake pedal depressed firmly during operation. For safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation. 2) From the above condition, cancel the hydraulic pump relief and carry out only torque converter relief to lower the exhaust temperature. (Condition b in the diagram). ★ If the exhaust temperature does not go down but rises, use the procedure in Step 1) to make the set temperature higher. 3) When the exhaust temperature goes down and becomes stable, record the temperature. (Condition c in the diagram). ¤ If the torque converter oil temperature gauge enters the red range, return the directional lever immediately to the neutral position and lower the torque converter oil temperature.


20-106 (5) 1

D375A-5


MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR 6) Start the engine. 7) Accelerate the engine suddenly or run at high idling, and depress the accelerator pedal of Smoke Meter C2 at the same time to collect the exhaust gas color on the filter. 8) Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of unused filter paper inside the filter paper holder, and read the value shown. 9) After completing the measurement, remove the measuring equipment and set to the original condition.

20-107-1 (5)

D375A-5


TROUBLESHOOTING FOR INJECTOR

TROUBLESHOOTING FOR INJECTOR ★ Tools for adjusting Symbol

Part No.

D

795-799-5510

Part Name Heat gun

★ If the engine power down and bad combustion seems to be caused by defective fuel injection, perform troubleshooting for the injector according to the following procedure. 1. Stop the engine and wait for it to cool down. ★ A guideline for judging if the engine has cooled down is that the temperature of the exhaust manifold is less than 20°C above the ambient temperature. 2. Make measurement marks a to the exhaust manifold outlets of the all cylinders. ★ Make the marks at the same points of the tops or bottoms of the exhaust manifolds of the all cylinders.

6. Compensate the measured value for each cylinder 12 minutes after starting the engine and judge if there is any cylinder with a problem. ★ Compensation value Unit: °C

Cylinder Compensation value

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 +20

+5

0

0

+5

+20

★ Method of judgement After compensating, add up the values for the exhaust gas temperature and calculate the average value. Any cylinder that is more than 20°C lower than the average value can be considered abnormal. ★ Measurement and judgement example 1 No. 2 cylinder is more than 20°C lower than the average value, so judge it as abnormal. Unit: °C Cylinder

3. Using heat gun D, measure the temperature at the exhaust manifold outlet port of each cylinder before starting the engine. ★ Apply the measurement light (center) of the heat gun to mark a of each cylinder to prevent dispersion of the measurement results caused by difference of the measuring points. 4. Run the engine at low idling speed. 5. Using heat gun D, measure the temperature at the exhaust manifold outlet port of each cylinder 3 minutes, 6 minutes, 9 minutes, and 12 minutes after starting the engine. ★ Apply the measurement light (center) of the heat gun to mark a of each cylinder to prevent dispersion of the measurement results caused by difference of the measuring points.

85

62

79

112

89

82

Compensated value

105

67

79

112

94

102

Average value

4 1

93

★ Measurement and judgement example 2 No. 3 cylinder is more than 20°C lower than the average value, so judge it as abnormal. Unit: °C Cylinder

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

Measured value

86

96

73

91

94

103

Compensated value

106

101

73

91

99

123

Average value

99

★ Measurement and judgement example 3 No cylinder is more than 20°C lower than the average value, so judge all cylinders as normal. Unit: °C

Cylinder

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

Measured value

70

88

88

93

86

72

Compensated value

90

93

88

93

91

92

Average value

20-108

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

Measured value

91

D375A-5


ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE ★ Tools for adjusting valve clearance Symbol

Part No.

E

Commercially available

Part Name Thickness gauge

1. Open the engine left side cover and right side cover. 2. Remove all cylinder head covers (1).

4. Insert thickness gauge E2 into clearance b between rocker arm (3) and crosshead (4), and adjust the valve clearance with adjustment screw (5). ★ Insert the thickness gauge and turn the adjustment screw until the clearance is a sliding fit.

3. Rotate the crankshaft in the normal direction, to set the No. 1 cylinder at compression top dead center, and align [1.6TOP] line a on the damper with pointer (2). ★ Crank the engine with barring device 1 of the flywheel housing.

★ At compression top dead center, the rocker arm of the No. 1 cylinder can be moved by hand an amount equal to the valve clearance. If the rocker arm does not move, it is not at compression top dead center, so rotate the crankshaft one more turn.

5. Hold adjustment screw (5) in position, then tighten locknut (6). 3 Locknut:

57.8 - 77.4 Nm {5.9 - 7.9 kgm} ★ After tightening the locknut, check the valve clearance again.

6. Rotate the crankshaft 120 ° each time in the normal direction and repeat the procedure in Steps 3 - 5 to adjust the valve clearance of each cylinder according to the firing order. • Firing order: 1-5-3-6-2-4 7. After completing the adjustment, set to the original condition. 3 Cylinder head cover mounting bolt:

9.8 ± 1.0Nm{1.0 ± 0.1kgm}

D375A-5

20-109 (5) 1


ADJUSTING INJECTOR SET LOAD

ADJUSTING INJECTOR SET LOAD 1. Open the engine left side cover and right side cover. 2. Remove all cylinder head covers (1).

3. Rotate the crankshaft in the normal direction, align [1.6TOP] line a on the damper with pointer (2), and set the No. 1 cylinder at compression top dead center. ★ Crank the engine with barring device 1 of the flywheel housing.

★ Cylinder at compression top dead center and cylinder where injector is adjusted Compression top dead center

1

5

3

6

2

4

Injector to be adjusted

2

4

1

5

3

6

4. Loosen locknut (4) of the injector to be adjusted. Completely loosen adjustment screw (3), then tighten it with your fingers. ★ Check that the bearing at the tip of the rocker arm and the ball at the push rod end are fitted securely in the injector and push rod respectively. 5. Tighten and loosen adjustment screw (3) repeatedly in the following order, then tighten it finally. 3 Adjustment screw:

★ At compression top dead center, the rocker arm of the No. 1 cylinder can be moved by hand and amount equal to the valve clearance. If the rocker arm does not move, it is not at compression top dead center, so rotate the crankshaft one more turn. ★ The cylinder where the injector is adjusted is different from the cylinder at compression top dead center, so check the chart below when carrying out the operation.

20-110 (5) 1

1st pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm} 2nd pass: Loosen completely 3rd pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm} 4th pass: Loosen completely 5th pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}

D375A-5


ADJUSTING INJECTOR SET LOAD

6. Hold adjustment screw (3) in position, then tighten locknut (4).

3 Locknut: 205.8 - 245 Nm {21 - 25 kgm}

7. After completing the adjusting, set to the original condition. 3 Cylinder head cover mounting bolt:

9.8 ± 1.0Nm{1.0 ± 0.1kgm}

D375A-5

20-111 (5) 1


MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE a Measuring instruments for compression pressure Symbol 1

F

2

3

Part No.

3. Remove rocker arm assemblies (1) of all the cylinders.

Part Name

795-502-1590

Compression gauge

795-611-1210

Adapter

6560-11-8410

O-ring (TOP)

6560-11-8310

O-ring (2ND)

6560-11-8210

O-ring (3RD)

6560-11-8510

O-ring (4TH)

6560-11-7310

Gasket

795-799-5410

Adapter

795-799-5420

Remover

k

When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. a Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60ºC) a Since the compression pressure of all the cylinders should be measured at the same time for efficiency, preapre 6 adapter assemblies F2.

4. Remove injector push rods (2) and injectors (3) of all the cylinders. a Using remover F3, pull out each injector.

1. Open the right side cover and left side cover of the engine. 2. Remove all cylinder head covers (5).

5. Install adapter assemblies F2 to the all cylinders and secure them with the holders. a Install the adapter assemblies with the forcing screw holes directed in the diagonal direction of the holders. a Secure the adapter assemblies with the injector holders.

3 Holder mounting bolt:

24.5 – 34.3 Nm {2.5 – 3.5 kgm}

20-111-1 (5)

D375A-5


MEASURING COMPRESSION PRESSURE

6. Install rocker arm assemblies (1) and adjust the valve clearance.

2 Threads and seat of mounting bolt: 3 Mounting bolt:

8. Connect compression gauge F1 to adapter assembly F2 of the cylinder to be measured.

Engine oil (EO30CD)

235.2 – 254.8 Nm {24 – 26 kgm} a See ADJUSTING VALVE CLEARANCE.

9. Crank the engine with the starting motor and measure the compression pressure. a Read the gauge when its pointer is stabilized.

7. Disconnect the EG1 (POW) connector and EG2 (SIG) connector (4) of the engine. a After this step, the fuel pump does not supply fuel to the injectors.

10. After finishing measurement, remove the measuring instruments and return the removed parts. a Measure the stem length of the injector holder mounting bolt. If it is longer than 80 mm, replace the bolt.

2 Threads and seat of

holder mounting bolt: Engine oil (EO30CD)

3 Holder mounting bolt:

1st time: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 2nd time: Tighten by 90 – 120º

2 Threads and seat of rocker arm

assembly mounting bolt: Engine oil (EO30CD)

3 Rocker arm assembly mounting bolt:

235.2 – 254.8 Nm {24 – 26 kgm} a Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. a Adjust the set load of the injector. For details, see ADJUSTING SET LOAD OF INJECTOR.

3 Cylinder head cover mounting bolt:

9.8 ± 1.0 Nm {1 ± 0.1 kgm}

D375A-5

20-111-2 (5)


MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE ★ Tools for measuring blow-by pressure Symbol

Part No.

G

799-201-1504

Part Name Blow-by kit

★ Measure the blow-by pressure under the following conditions. • Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 - 55°C

★ Blow-by varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.

1. Open the engine left side cover and pull out blow-by hose (1). 2. Install nozzle 1 of blow-by checker G to blow-by hose (1), then connect to gauge 2.


3. Run the engine at high idling and measure the blow-by pressure when the torque converter stalls. ★ For details of the procedure for stalling the t o r q u e c o nv e r t e r, s e e M E A S U R I N G TORQUE CONVERTER STALL SPEED. ★ The blow-by should be measured with the engine running at rated output. However, when measuring in the field, a similar value can be obtained at torque converter stall. ★ If it is impossible to check at rated output or torque conver ter stall, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output.

20-112 1

D375A-5


HANDLING EQUIPMENT IN FUEL SYSTEM

HANDLING EQUIPMENT IN FUEL SYSTEM ★ Precautions for inspection and maintenance of fuel system The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so problems may occur if dirt or dust get in. When carrying out inspection and maintenance of the fuel system, pay more attention than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part, use clean fuel to wash it off completely. ★ Precautions when replacing fuel filter cartridge Always use a genuine Komatsu part for the fuel filter cartridge. The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. For this reason, if any filter is used as a substitute for the genuine filter, there is danger that problems will occur with the fuel system. To prevent this, never use such filters.

20-114 (5) 1

D375A-5


MEASURING FUEL CIRCUIT PRESSURE

4) Measure the fuel pump outlet pressure at each engine speed. a Check that the fuel pump outlet pressure is in the following range. a Fuel pump outlet pressure: Engine speed

3) Start the engine, set the monitor panel in the MONITORING MODE, and prepare for measuring the engine speed. a For the operating method, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: 99 (Engine speed) a The engine speed is displayed on the service meter display section in 1 rpm.

Fuel pump outlet pressure

Sensor voltage (Reference)

600 rpm

0.83 ± 0.14 MPa 1.78 ± 0.21 V {8.45 ± 1.41 kg/cm2}

700 rpm

0.93 ± 0.14 MPa 1.94 ± 0.21 V {9.50 ± 1.41 kg/cm2}

800 rpm

1.03 ± 0.14 MPa 2.10 ± 0.21 V {10.53 ± 1.41 kg/cm2}

900 rpm

1.14 ± 0.14 MPa 2.26 ± 0.21 V {11.60 ± 1.41 kg/cm2}

1,000 rpm

1.25 ± 0.14 MPa 2.42 ± 0.21 V {12.70 ± 1.41 kg/cm2}

1,100 rpm

1.34 ± 0.14 MPa 2.59 ± 0.21 V {13.70 ± 1.41 kg/cm2}

1,200 rpm

1.46 ± 0.14 MPa 2.76 ± 0.21 V {14.90 ± 1.41 kg/cm2}

a The sensor voltage shown in the above table is the voltage measured at the PMPR connector of the fuel pump pressure sensor. It is shown for reference.

5) After finishing measurement, remove the measuring instruments and return the removed parts.

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VISUAL INSPECTION OF RETURN FUEL

VISUAL INSPECTION OF RETURN FUEL ★ The fuel used for control of the timing rail in the fuel circuit and the excessive fuel that is not used injected in the fuel rail are returned from the injector through the fuel cooler to the fuel tank. ★ If the engine does not revolve normally or fuel consumption is abnormally high, inspect the spill fuel according to the following procedure. 1. Disconnect fuel return hose before the fuel tank. ★ Plug the hole of the fuel tank. ★ Keep the spill hose open and receive the fuel with an oil pan, etc. 2. Start the engine and check that the fuel flows out of the spill hose smoothly. ★ Spillage (Referene) At low idling: 4 – 6 ¬/min. At high idling: 10 – 12 ¬/min. ★ If the spillage is extremely low, check the return piping and fuel cooler for clogging.

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ARRANGEMENT OF CONTROL DEVICES FOR HPI

ARRANGEMENT OF CONTROL DEVICES FOR HPI Arrangement of control devices (for troubleshooting)

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ARRANGEMENT OF CONTROL DEVICES FOR HPI

Controller pump valve 1. Engine controller 2. Fuel pump assembly 3. Control valve assembly Sensors 4. Atmospheric pressure sensor (AAPR) 5. Boost pressure sensor (IMPR) 6. Intake air temperature sensor (IMTP) 7. Oil pressure sensor (OPS) 8. Fuel temperature sensor (FLTP) 9. Water temperature sensor (CLTP) 10. Speed sensor (SP1, SP2) 11. Fuel pump pressure sensor (PMPR) 12. Fuel rail pressure sensor (RPR) 13. Timing rail pressure sensor (TRP) Actuator 14. Fuel pump actuator (PUMP) 15. Fuel shut-off valve (FSO+, FSO–) 16. Fuel rail actuator (RAIL) 17. Timing rail actuator (TIMG)

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BLEEDING AIR FROM FUEL CIRCUIT


★ If the engine does not start or is difficult to start after the following operations or conditions, bleed the air from the fuel circuit as follows. • When starting the engine for the first time • After cleaning the fuel tank • After adding fuel when the engine has stalled • After replacing the fuel filter (only when the air is not bled easily)

★ Add fuel from the inlet port a (8 places). Portion b is the outlet port after filtering (clean side), so never add fuel from portion b.

1. Open the stop valve at the fuel tank supply side, then open the engine right side cover. ★ Check that there is ample fuel in the fuel tank. 2. Remove fuel filter (1), fill it with fuel, then install it again. ★ Carry out this operation only if the fuel filter has been replaced. ★ If the fuel filter is not to be replaced, there is danger of dirt getting in, so do not remove the fuel filter.

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3. Crank the engine with the starting motor, push air bleed the valve (1), and bleed the air from the vent circuit. ★ There is no problem with starting even if some air is in the circuit, so if the fuel flows out the bleeding operation is completed. 4. Start the engine and run at low idling. ★ The injector is an open circuit, so while the engine is running the air remaining in the circuit is released from the injector to the inside of the engine or the fuel tank. ★ After the engine is started, the engine rotation will be slightly unstable until the air remaining in the circuit is completely bled, so continue to run the engine at low idling until it stabilizes. ★ If the engine will still not start after the above operation, fill the fuel pump with fuel as follows. 1) Remove air bleed valve (1). 2) Fill with clean fuel through the hole in the valve until it overflows. ★ Amount of fuel to add: Approx. 30 cc (reference) 3) Install air bleed plug (1).

Air bleed plug: 12.7 Nm {1.3 kgm}

4) Crank the engine with the starting motor.

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ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED SENSOR ★ If the engine speed sensor has been removed and installed or the flywheel has been removed or installed, adjust as follows. 1. Remove the floor inspection cover, then remove engine speed sensor (1). ★ Before adjusting, remove the engine speed sensor, check that the tip of the sensor is not scratched and that there are no iron particles sticking to it, then install it again.

5. After completing the adjustment, switch the monitor panel to the monitoring mode display, and check that the engine speed is displayed normally. ★ For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: 99 (Engine speed) 2. Screw in engine speed sensor (1) until its tip lightly touches the tooth tip of flywheel ring gear (2). ★ Before installing the sensor, check that its tip is free from steel chips and flaws. 2 Threads: Hydraulic sealant (No. 21028) manufactured by LOCTITE

3. Return engine speed sensor (1) by 1/2 – 3/4 turns. ★ Adjust clearance a between the engine speed sensor tip and gear tooth tip to 0.75 – 1.25 mm. 4. Hold engine speed sensor (1) and tighten locknut (3). 3 Locknut: 33.9 - 47.5 Nm {3.5 - 4.8 kgm}

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REPLACING AND ADJUSTING FAN BELT

REPLACING AND ADJUSTING FAN BELT Replacing 1. Open the engine right side cover. 2. Loosen locknut (1), then turn adjustment screw (2) back fully. 3. Use one of the following methods to loosen the belt tension. 1) Insert bar (approx. 50 cm) into hole a (M12 x 1.75) in tension pulley lever (3), pull strongly and keep the tension of the fan belt loosened. 2) Remove adjustment screw (2), then screw it into hole b (M16 x 1.0) of bracket (4) and loosen the tension. ★ After replacing the belts, set the adjustment screw back to its original condition.

Adjusting ★ If the fan belt whines during operation, or a gap forms between the tension pulley lever and the adjustment screw, adjust as follows. 1. Screw in adjustment screw (2) until the tip contacts tension pulley lever (3).

2. From this position, tighten adjustment screw (2) a further 2 turns, then secure in position with locknut (1). Locknut: 245.0 - 308.7 Nm {25.0 - 31.5 kgm}

4. Remove the old fan belts and replace them with new belts.

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TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER COMPRESSOR BELT TENSION

TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER COMPRESSOR BELT TENSION Testing • Measure deflection a when a point midway between the alternator pulley and the air conditioner compressor pulley (or idler pulley) is pressed with a finger. ★ Pushing force: Approx. 98 N {approx. 10 kg}

Adjusting ★ If the deflection is not correct, adjust as follows. 1. Loosen the 2 alternator mounting bolts and 1 lock bolt for the adjustment rod. 2. Loosen locknut (1), then turn adjustment nut (2) to move alternator (3) and adjust the belt tension.

3. Tighten the 2 alternator mounting bolts and 1 lock bolt for the adjustment rod.

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Alternator mounting bolt (4): 65 - 85 Nm {6.7 - 8.7 kgm} Alternator locknut (1): 147 - 247 Nm {15 - 25 kgm}

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ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL


1. Outline of fuel control system • The speed signals from the fuel control dial and decelerator pedal (decelerator potentiometer) are both input to the engine controller (the signal from the fuel control dial passes through the steering controller). The controller gives priority to the lower of these two speed signals and sends a command to the fuel control system (HPI system) of the engine. • Adjustment of the engine speed is all carried out by the linkage of the deceleration pedal.

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2. Preparatory work 1) Start the engine, switch the monitor panel to the monitoring mode display, and prepare to measure the engine speed. ★ For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: 99 (Engine speed) ★ The engine speed is displayed on the service meter display section in 1 rpm.

3. Adjusting deceleration pedal speed With the fuel control dial in the high idling position, press decelerator pedal (2) until it touches the stopper. Check that the decelerator pedal speed is normal under this condition. • Deceleration speed: 900 ± 50 rpm ★ If the deceleration speed is not correct, adjust installed dimension a of rod (1). • Standard installed dimension a of rod: 124 mm (reference) 4. High idling speed Set the fuel control dial to the high idling position and check that the high idling speed is correct. • High idling speed: 1900 ± 25 rpm ★ If the high idling speed is abnormal, adjust it according to the following procedure. If the engine speed is more than 1850 rpm: To remove the play of the decelerator pedal, use stopper bolt (3) to adjust the engine speed to less than 1800 rpm, then adjust to the high idling speed. If the engine speed is less than 1850 rpm: Use stopper bolt (3) to adjust to the high idling speed.

2) Set the fuel control dial to the high idling position and check that the engine speed is at least 1000 rpm. ★ If the engine speed is less than 1000 rpm, extend installation dimension a of rod (1) to raise the speed to above 1000 rpm.

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1. Measuring torque converter inlet pressure (IN) 1) Connect oil pressure gauge (1) of hydraulic tester H1 to oil pressure measurement nipple (1). ★ Use a 2.5 MPa {25 kg/cm2} oil pressure gauge.

2) Start the engine and set all the functions of the PCCS lever to neutral. 3) Measure the oil pressure with the engine at low idling and high idling.

4) After completing the measurement, remove the measuring equipment and set to the original condition.

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MEASURING POWER TRAIN OIL PRESSURE

2. Measuring torque converter outlet pressure (OUT) 1) Connect hydraulic tester H2 to oil pressure measurement nipple (2). ★ Use a 0.98 MPa {10 kg/cm2} oil pressure gauge.



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3. Measuring torque converter lock-up clutch pressure (LU) 1) Connect oil pressure gauge 1 of hydraulic tester H1 to oil pressure measurement nipple (3). ★ Use a 2.5 MPa {25 kg/cm2} oil pressure gauge.

3) Set the parking brake lever in the FREE position and turn the lock-up mode switch ON. 4) Set the PCCS lever direction to F and the speed to the 1st, and rotate the transmission under no load. 5) Gradually raise the engine speed, and measure the oil pressure when the lock-up pilot lamp lights up.

2) Start the engine and set the monitor panel in the "Adjustment mode" and disengage both steering clutches. ★ For the operating method, see "Special functions of monitor panel (EMMS)". ★ Adjustment code: Co (Disengagement of both steering clutches) ★ The transmission speed is displayed on the service meter display section (Unit: 1 rpm).

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4. Measuring torque converter stator clutch pressure (SC) 1) Connect oil pressure gauge 1 of hydraulic tester H1 to oil pressure measurement nipple (4). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

5. Measuring transmission main relief pressure (TM) 1) Connect oil pressure gauge 1 of hydraulic tester H1 to oil pressure measurement nipple (5). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.





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6. Measuring transmission F clutch pressure (FWD) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (6). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

7. Measuring transmission R clutch pressure (R) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (7). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

2) Start the engine and set the monitor panel in the "Adjustment mode" and disengage both steering clutches. ★ For the display on the panel, see "5. Measuring torque converter lock-up clutch pressure (LU)". ★ Adjustment code: Co (Disengagement of both steering clutches) 3) Set the parking brake lever in the FREE position. 4) Keep pressing the brake pedal, set the PCCS lever direction to F and the speed to the 3rd, and rotate the transmission under no load. 5) Measure the oil pressure at low idling.

2) Start the engine and set the monitor panel in the "Adjustment mode" and disengage both steering clutches. ★ For the display on the panel, see "5. Measuring torque converter lock-up clutch pressure (LU)". ★ Adjustment code: Co (Disengagement of both steering clutches) 3) Set the parking brake lever in the FREE position. 4) Keep pressing the brake pedal, set the PCCS lever direction to R and the speed to the 3rd, and rotate the transmission under no load. 5) Measure the oil pressure at low idling.



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8. Measuring transmission 1st clutch pressure (1ST) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (8). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

9. Measuring transmission 2nd clutch pressure (2ND) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (9). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

2) Start the engine and set the monitor panel in the "Adjustment mode" and disengage both steering clutches. ★ For the display on the panel, see "5. Measuring torque converter lock-up clutch pressure (LU)". ★ Adjustment code: Co (Disengagement of both steering clutches) 3) Set the parking brake lever in the FREE position. 4) Keep pressing the brake pedal, set the PCCS lever direction to F and the speed to the 1st, and rotate the transmission under no load. 5) Measure the oil pressure at low idling.

2) Start the engine and set the monitor panel in the "Adjustment mode" and disengage both steering clutches. ★ For the display on the panel, see "5. Measuring torque converter lock-up clutch pressure (LU)". ★ Adjustment code: Co (Disengagement of both steering clutches) 3) Set the parking brake lever in the FREE position. 4) Keep pressing the brake pedal, set the PCCS lever direction to F and the speed to the 2nd, and rotate the transmission under no load. 5) Measure the oil pressure at low idling.



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10. Measuring transmission 3rd clutch pressure (3RD) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (10). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

2) Start the engine and set the monitor panel in the "Adjustment mode" and disengage both steering clutches. ★ For the display on the panel, see "5. Measuring torque converter lock-up clutch pressure (LU)". ★ Adjustment code: Co (Disengagement of both steering clutches) 3) Set the parking brake lever in the FREE position. 4) Keep pressing the brake pedal, set the PCCS lever direction to F and the speed to the 3rd, and rotate the transmission under no load. 5) Measure the oil pressure at low idling.

11. Measuring left steering clutch pressure (LC) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (11). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

2) Start the engine and set the parking lever to the FREE position. 3) Operate the PCCS lever steering fully to the left. ★ Set the direction to the neutral position. 4) Measure the oil pressure with the engine at low idling and high idling. ★ Check that the oil pressure becomes 0 when the PCCS lever steering is returned to neutral.



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12. Measuring left steering brake pressure (LB) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (12). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

13. Measuring right steering clutch pressure (RC) 1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nipple (13). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

2) Start the engine and set the parking lever to the FREE position. 3) Measure the oil pressure with the engine at low idling and high idling. ★ Check that the oil pressure becomes 0 when the PCCS lever steering is operated fully to the left. ★ Check that the oil pressure becomes 0 when the brake pedal is depressed or the parking lever is operated to the LOCK position.

2) Start the engine and set the parking lever to the FREE position. 3) Operate the PCCS lever steering fully to the right. ★ Set the direction to the neutral position. 4) Measure the oil pressure with the engine at low idling and high idling. ★ Check that the oil pressure becomes 0 when the PCCS lever steering is returned to neutral.


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14. Measuring right steering brake pressure (RB) 1) Connect oil pressure gauge 1 of hydraulic tester H1 to oil pressure measurement nipple (14). ★ Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.

2) Start the engine and set the parking lever to the FREE position. 3) Measure the oil pressure with the engine at low idling and high idling. ★ Check that the oil pressure becomes 0 when the PCCS lever steering is operated fully to the right. ★ Check that the oil pressure becomes 0 when the brake pedal is depressed or the parking lever is operated to the LOCK position.


15. Measuring transmission lubrication pressure 1) Connect hydraulic tester H2 to oil pressure measurement nipple (15). ★ Use a 0.98 MPa {10 kg/cm2} oil pressure gauge.

2) Start the engine and measure the oil pressure with the engine at high idling.



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MEASURING POWER TRAIN OIL PRESSURE 16. Measuring output pressure of sudden stop prevention valve 1) Connect oil pressure gauge 1 of hydraulic tester H1 to oil pressure pickup nipples (12) and (14). a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. • (12): For steering left brake

•

(14): For steering right brake

2) Start the engine, set the monitor panel in the ADJUSTMENT MODE, and set the sudden stop prevention valve in the operation mode. a For the operating method, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). a Adjustment code: b5 (Operation mode of sudden stop prevention valve) a The voltage of the brake pedal potentiometer is displayed on the service meter display section (in 1 mV).

3) Set the parking brake lever in the FREE position and set the PCCS lever in the ALL NEUTRAL position. 4) Run the engine at low idling and measure the oil pressure. a If the output pressure of the sudden stop prevention valve is as follows, it is normal. • 1.13 – 1.57 MPa {11.5 – 16.0 kg/cm2}


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ADJUSTING TRANSMISSION SPEED SENSOR SIMPLE PROCEDURE FOR TESTING BRAKE SPEED PERFORMANCE ADJUSTING TRANSMISSION SENSOR

ADJUSTING TRANSMISSION SPEED SENSOR 1. Remove the cover at the bottom of the fuel tank, then remove transmission speed sensor (1). ★ Before adjusting, remove the transmission speed sensor, and check that the tip of the sensor is not scratched and that there are no iron particles sticking to it.

SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE ★ Carry out the simple test of the brake performance under the following conditions. • Torque converter oil temperature: Within operating range 1. Stop the machine on a level surface and set the blade and ripper to the travel posture.

2. Screw in transmission speed sensor (1) until its tip lightly touches the tooth tip of gear (2). 2 Threads of sensor: Gasket sealant (LG-5)

3. Return transmission speed sensor (1) by 1/2 – 1 turn. ★ Adjust clearance a between the engine speed sensor tip and gear tooth tip to 0.75 – 1.25 mm. 4. Hold transmission speed sensor (1) and tighten locknut (3). 3 Nut: 49.0 - 68.6 Nm {5 - 7 kgm}

2. Start the engine and set the parking lever to the FREE position. 3. With the engine at low idling, depress the brake pedal firmly, and set the PCCS lever direction to F and the speed to 2. ¤ If it is set to 1, there will be excess load on the brakes, so always carry out this test in position 2. ★ Set the steering to the neutral position. 4. Depress the decelerator pedal and set the fuel control lever to the high idling position. 5. Release the decelerator pedal gradually and raise the engine speed to high idling. Check that the machine does not start to move. ¤ The torque converter is stalled, so keep the brake pedal depressed firmly during the operation. For safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.

5. After completing the adjustment, switch the monitor panel to the monitoring mode display, and check that the transmission speed is displayed normally. ★ For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). ★ Monitoring code: 70 (Transmission speed)

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ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER Adjusting brake pedal

Adjusting parking lever

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Adjusting brake pedal 1. Adjusting travel of brake pedal Adjust installation dimension b of stopper bolt (2) so that the travel of brake pedal (1) is dimension a. ★ When adjusting the travel of the brake pedal, disconnect the brake rod from the pedal. • Pedal travel a: 74 mm • Stopper bolt installation dimension b: 42 mm 2. Adjusting installed length of brake rod 1) Install brake rod (3) and release brake pedal (1) (do not depress it). 2) Adjust installed dimensions c and d of brake rod (3) with turnbuckle (5) so that the spool of brake valve (4) is at the OFF position. ★ The locknut of the turnbuckle has a lefthanded thread (reverse thread) at the brake pedal end. • Installed dimension c: 32 mm • Installed dimension d: 14 mm 3 Locknut: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}

3. Checking travel of brake pedal 1) Depress brake pedal (1) and check that the travel is as given in Step 1 above. 2) Depress brake pedal (1) and check that the pedal is stopped by stopper (6). 3) Check that spool travel e of brake valve (4) is within the correct range when brake pedal (1) is depressed. • Spool travel e: 19 – 23 mm

5. Initial setting of brake potentiometer Turn the starting switch ON, set the monitor panel in the ADJUSTMENT MODE, and set the brake potentiometer to the initial value. ★ For the operating method, see SPECIAL F U N C T I O N S O F M O N I TO R PA N E L (EMMS). ★ Adjustment code: bP (Setting brake pedal standard position) Adjusting parking lever 6. Assembly and installation of lever assembly 1) Assemble lever assembly (7) and adjust the actuation of limit switch (8). ★ When assembling the lever assembly, disconnect the parking cable from the lever. • Lever raised: OFF, lever lowered: ON • Limit switch actuation travel: 3 mm 2) Install lever assembly (7). 7. Adjusting installed length of parking cable 1) Connect parking cable (9) to the lever and valve, then adjust installed dimensions f and g. • Installed dimension f of cable: 112.8 mm • Installed dimension g of cable: 114.0 mm 2) Operate parking lever (10) between the FREE position and LOCK position, and adjust the position of rod end (11) so that spool travel h of brake valve (4) is correct. • Spool travel h: 23.0 mm

4. Checking brake oil pressure 1) Start the engine and set the monitor panel in the ADJUSTMENT MODE. ★ For the operating method, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). ★ Adjustment code: bL (Brake release mode) 2) With the parking brake lever in the FREE position, press the brake pedal and check that the brake oil pressures on both sides become 0. ★ For the measuring points of the brake oil pressure, see MEASURING POWER TRAIN OIL PRESSURE.

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ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER 8. Checking brake oil pressure Start the engine, set the parking brake lever in the FREE position and LOCK position, and check that the brake oil pressure becomes as follows at the respective positions. a For details of the method of measuring the brake oil pressure, see MEASURING POWER TRAIN OIL PRESSURE. • LOCK position: 0, FREE position: Specified pressure 9. Checking limit switch 1) Turn the starting switch ON and set the monitor panel in the MONITORING MODE. a For the operating method, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: L9 (Steering controller switch input 1) 2) Set the parking brake lever in the FREE position and LOCK position and check that the limit switch signals are input normally at the respective positions.

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ADJUSTING POSITION OF PCCS LEVER CONSOLE

ADJUSTING POSITION OF PCCS LEVER CONSOLE

1. Set operator’s seat (1) facing the front (dozing position). 2. In this condition, check that console (2) is parallel to operator’s seat (1). ★ If it is not parallel, adjust installed dimension a of rod (3). • Standard installed dimension a: 179 mm ★ The locknut at the rear of the turnbuckle has a left-handed thread (reverse thread)

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EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER TRAIN



★ Insert switch assembly inside the cab through the cab window.

★ Tools for emergency escape Symbol

K

1

2

Part No.

Part Name

19M-06-32820

Switch assembly

7824-66-6430

Resistor

195-06-71220

Wiring harness

790-190-1600

Pump assembly

1. Emergency escape method using switch box (using K1) ★ If a problem occurs in the electrical system of the power train control (direction, speed, steering) and the machine does not move, carry out the emergency escape as follows. ★ With this procedure, it is necessary to be able to start the engine. If the engine will not start, see EMERGENCY ESCAPE METHOD USING BRAKE RELEASE DEVICE. 1) Connect switch assembly and resistor to wiring harness of emergency escape device K1. Resistor controls the drive voltage of the solenoid, so connect it before connecting the wiring harness to the machine. In order to prevent mistaken actuation, set all the speed range switches of switch assembly to the OFF position and the directional switch to the P position.

¤ ¤

2) Open the inspection cover on the left fender and connect wiring harness to PL1 connector (1) and PL2 connector (2). • PL1 connector (1): Connect to male and female ends • PL2 connector (2): Connect to male end ★ The female end of connector PL2 remains disconnected, so cover it with vinyl.

3) Disconnect the neutral safety relay (NSF) inside the fuse room, then connect pin and pin of the connector at the wiring harness end directly. ★ With this operation, the neutral safety relay or transmission controller will not work, so carry out this operation only if the engine will not start electrically. With this method, if the engine starts, the neutral safety relay function will not work, so before starting the engine, set the parking lever to the LOCK position and all the PCCS lever functions to the neutral position. With this method, start the engine only when carrying out the emergency escape. In all other cases when the engine does not start, always carry out troubleshooting and repair the cause.

¤ ¤

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4) Start the engine and set the parking lever to the FREE position. 5) Operate switch assembly and move the machine to a safe place. ★ The speed switch has an electric circuit that gives priority to operation of the low speed switch.

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2. Emergency escape method using brake release device (using K2) ★ If the engine cannot be started, and the parking brake cannot be released, carry out the emergency escape as follows. 1) Assemble pump assembly K2.

2) Set volume pump 1 of pump assembly K2 on the outside of the operator’s cab.

4) Connect the hose at the tip of pump assembly K2 to the supply hose. ★ Block the solenoid valve end with a plug. 5) Turn the starting switch ON and set the parking lever to the FREE position. 6) Operate the volume pump to raise the brake release oil pressure to the initial pressure. • Initial pressure: approx. 2.74 MPa {approx. 28 kg/cm2} ★ An accumulator is installed in the circuit, so it is necessary to operate the handle 30 - 50 times to raise the oil pressure. ★ If the pressure does not go above the set pressure, the set pressure of the relief valve may be too low, so adjust it. 7) Tow the machine to a safe place. ★ The brake release oil pressure will go down gradually because of internal leakage, and the brake will be actuated after approx. one minute, so carry out the operation quickly. ★ When the brake release pressure goes down to approx. 1.57 MPa {16 kg/cm2}, the brake is actuated. If this happens, operate the volume pump again to raise the brake release pressure to the initial pressure.

3) Remove the cover at the bottom of the fuel tank, then disconnect supply hose (3) of the pin-puller solenoid valve.

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ADJUSTING IDLER CLEARANCE CHECKING WEAR OF SPROCKET

ADJUSTING IDLER CLEARANCE

CHECKING WEAR OF SPROCKET

★ If there is wear of the idler side guide, top and bottom guide, or guide plate, and the idler sways to the side or is at an angle, adjust as follows.

★ Copy the SPROCKET TOOTH BASIC DIMENSION DRAWING on a clear paper or sheet, and place it directly on the sprocket to judge pass/fail for the sprocket wear.

1. Travel for 1 - 2 m on flat ground, then measure clearance a (outside, inside). 2. If clearance a is more than 3 mm, remove bolt (1) and reduce shim (2) to adjust. • Standard clearance a on one side: 0 - 0.5 mm • Types of shim thickness: 0.5 mm, 1.0 mm ★ When the machine is new, 10 mm thickness of shim is installed on each side. ★ When adjusting, reduce the shim thickness uniformly on the inside and outside.

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1

Mounting bolt: 824 - 1030 Nm {84 - 105 kgm}

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TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Drive the machine forward and stop on a horizontal surface. ★ Stop the machine without using the brake.

3. If tension is too low: Pump in grease through grease fitting (4). ★ If the the track tension is poor, move the machine backwards or forwards slowly.

2. Put straight steel rod (1) on top of the track between the idler and front carrier roller, and measure clearance a from the bottom of the steel rod to the track shoe grouser. • Standard clearance a: 20 - 30 mm

Adjusting ★ If the track shoe tension is not correct, adjust as follows. 1. Remove cover (2).

2. If tension is too high: Loosen plug (3) and release some of the grease. ¤ There is danger that the plug may fly out under the high internal pressure of the grease, so never loosen the plug more than 1 turn. 3 Plug: 59 - 88 Nm {6 - 9 kgm}

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TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE

2. Measuring center pump relief pressure 1) Remove work equipment small pump pressure sensor (10).

2) Install adapter Q2, nipple 1 of hydraulic tester Q1, and pressure sensor (10), and connect them to oil pressure gauge 2. ★ Use the oil pressure gauge of 39.2 MPa {400 kg/cm2}.

4) Run the engine at low idling and high idling and operate the blade lever or ripper lever to relieve each cylinder circuit. Measure the oil pressure at this time.


3) Start the engine and reset the safety lock lever.

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20-141 (5) 1



TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE Measuring (Measuring with monitor panel) a Meaure the work equipment oil pressure under the following condition. • Hydraulic oil temperature: 45 – 55ºC 1. Measuring front pump relief pressure 1) Disconnect the blade lift cylinder hoses from the cylinder and block the control valve side. • Flange for blocking: 07379-01260 (4 pieces) a Stop the cylinder side, too, with cork stoppers, etc. 2) Start the engine, set the monitor panel in the MONITORING MODE, and prepare for measuring the oil pressure. a For the operating method, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: HL (Work equipment large pump oil pressure) a The oil pressure is displayed on the service meter display section in 1 kg/cm2.

20-141-1 (5)

3) Start the engine and reset the safety lock lever. 4) Run the engine at low idling and high idling and operate the blade lever to relieve the blade lift cylinder circuit. Measure the oil pressure at this time.

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2. Measuring center pump relief oil pressure 1) Start the engine, switch the monitor panel to the monitoring mode display, and prepare to measure the oil pressure. a For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: H5 (Center pump oil pressure) a The oil pressure is displayed on the service meter display section in 1 kg/cm2.

Adjusting 1. Adjusting front pump relief pressure a If the front pump relief pressure is not correct, adjust main relief valve (1) of the blade lift valve as follows.

1) Remove the right side cover. 2) Remove cover (2). 3) Loosen locknut (3), then turn adjustment screw (4) to adjust. a Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE a Amount of adjustment for one turn of adjustment screw: Approx. 2.43 MPa (approx. 24.8 kg/cm2)

3 Locknut :

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3 Cover:

4) Install cover (2).

29.4 – 39.2 Nm {3 – 4 kgm} 2) Start the engine and reset the safety lock lever. 3) Run the engine at low idling and high idling and operate the blade lever or ripper lever to relieve each cylinder circuit. Measure the oil pressure at this time.

5) After completion of the adjustment, repeat the above procedure to check the oil pressure again.

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20-141-2 (5)



2. Adjusting center pump relief pressure ★ If the center pump relief pressure are not correct, adjust main relief valve (5) of the blade tilt and ripper Lo valve as follows.


1) Remove the right side cover. 2) Remove cover (6). 3) Loosen locknut (7), then turn adjustment screw (8) to adjust. ★ Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE ★ Amount of adjustment for one turn of adjustment screw: Approx. 2.43 MPa (approx. 24.8 kg/cm2) 4) Install cover (6). 3 Cover: 29.4 - 39.2 Nm {3 - 4 kgm}

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TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE

Adjusting ★ If the control circuit main pressure is not correct, adjust charge relief valve (2) as follows.

1) Loosen locknut (3), then turn adjustment screw (4) to adjust. ★ Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE ★ Amount of adjustment for one turn of adjustment screw: 0.77 MPa (7.8 kg/cm2) 3 Locknut: 54 - 74 Nm (5.5 - 7.5 kgm}


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20-146 1

MEASURING PPC VALVE OUTPUT PRESSURE

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ADJUSTING PLAY OF PPC VALVE

ADJUSTING PLAY OF PPC VALVE ★ If there is excessive play at the tip of the ripper lever and blade lever, adjust the PPC valve as follows. ★ The diagram shows the PPC valve for the ripper. • Standard play dimension a: 0.5 - 3.0 mm at a point 200 mm from rotation center of lever (both to front and rear, and to left and right) 1. Remove boot (1). 2. Loosen locknut (2) and rotate disc (3) to adjust the amount of play. ★ When doing this, do not make the piston move. 3. Secure disc (3) in position and tighten locknut (2). 3 Locknut: 98 - 127 Nm {10 - 13 kgm}

4. Install boot (1).

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CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER

CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER ★ If hydraulic drift occurs in the blade or ripper, check as follows to see if the cause is in the cylinder packing or in the control valve. 1. Set the cylinder to be inspected to the following posture, then stop the engine. 1) Blade lift cylinder Push the blade against the ground to raise the front of the chassis. ★ The blade lift cylinder has a built-in piston valve, so do not operate the cylinder to the end of the stroke.

2. Operate the control lever in the direction to extend the cylinder rod, and check the movement of the cylinder. • If the downward movement becomes faster, the packing is defective. • If there is no change, the control valve is defective. ★ If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to charge the accumulator. 2) Blade tilt cylinder Extend the tilt cylinder rod fully, then push the blade against the ground to raise the right side of the chassis.

3) Ripper lift cylinder Push the ripper against the ground to raise the rear of the chassis.

D375A-5

[Reference:] If the cause of the hydraulic drift is in the packing, the speed of downward movement in the above operation will become faster for the following reasons. 1) When the work equipment is set to the posture given above, (holding pressure applied to the bottom end), oil will leak from the bottom end to the head end. However, the volume at the head end is smaller than at the bottom end (by an amount proportional to the volume of the rod), so if the oil flows in from the bottom end, the internal pressure at the head end will rise. 2) If the internal pressure at the head end rises, a balance will be made in proportion to this at a certain pressure (this differs according to the amount of leakage). When the pressure becomes balanced, the speed of downward movement becomes slower. 3) In this condition, if the lever is operated as shown above, the circuit at the head end is connected to the drain circuit (the bottom end is closed by a check valve), and the oil at the head end flows to the drain circuit. As a result, the balance is lost and the speed of downward movement increases.)

20-149 1


MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER ★ Tools for measuring leakage from work equipment cylinder Symbol

Part No.

P

Commercially available

Part Name Measuring cylinder

★ Measure the oil leakage inside the hydraulic cylinder under the following conditions. • Hydraulic oil temperature: 45 - 55°C ★ The blade lift cylinder has a built-in piston valve, so the internal leakage cannot be measured.

3. Run the engine at high idling and apply the relief pressure to the bottom end of the cylinder. • Blade tilt cylinder: Extract the cylinder to be measured • Ripper lift cylinder: Lower ripper • Ripper tilt cylinder: Tilt ripper to front 4. Wait for 30 seconds, then measure the amount of leakage over the next 1 minute. 5. After completing the measurement, set to the original condition.

1. Fully extend the cylinder to be measured, and set to the measurement posture. 1) Blade tilt cylinder: Extract the cylinder to be measured to the stroke end. 2) Ripper lift cylinder: Remove the shank pin and lower the ripper fully. 3) Ripper tilt cylinder: Tilt the ripper fully to the front. 2. Disconnect the piping at the head end of the cylinder and block the hose with an oil stopper plug. ★ Remove the cover when disconnecting the blade tilt cylinder hose. ¤ Be careful not to disconnect the hose at the bottom end.

20-150 (5) 1

D375A-5


RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS

RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS ★ When disconnecting the piping between the control valve and work equipment cylinder, first release the remaining pressure inside the circuit as follows. 1. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 2. Set the safety lock lever to the FREE position, then operate the work equipment control levers to the front, rear, left, and right. ★ When the levers are operated 2 - 3 times, the pressure inside the accumulator is fully released. 3. Start the engine, run at low idling for approx. 5 seconds, then stop the engine.

BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS ★ After removing or installing work equipment cylinders or disconnecting and connecting hydraulic piping, bleed the air from the circuit as follows. 1. Start the engine and run at idling for about 5 minutes. 2. Run the engine at low idling, and extend and retract the cylinders 4 - 5 times. ★ Stop the piston rod about 100 mm before the end of the stroke. Never operate it to the relief position. 3. Run the engine at high idling and repeat the procedure in Step 2. 4. Run the engine at low idling and operate the cylinder to the end of the stroke to relieve the circuit.

4. Repeat the operation in Steps 2 and 3 above 2 3 times.

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ADJUSTING RIPPER LEVER POSITION

ADJUSTING RIPPER LEVER POSITION

★ Use the following procedure to adjust the ripper lever to the optimum position. ★ It is possible to adjust the position of the ripper lever within a range of ± 40 mm to the front and rear of the center of the lever shaft.

5) Loosen nut (3). 6) Turn knob (4) 180°. 7) Tighten nut (3) to hold knob (4) in position.

1. Adjusting within range of 40 mm from center to rear 1) Loosen lock bolt (1). 2) Set lever (2) to the optimum position. 3) Tighten lock bolt (1) to hold lever (2) in position. 2. Adjusting within range of 40 mm from center to front 1) Loosen lock bolt (1). 2) Remove lever (2) and turn it 180°. 3) Install lever (2) to lever (5), then set it to the optimum position. 4) Tighten lock bolt (1) to hold lever (2) in position.

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1

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ADJUSTING BLADE

ADJUSTING BLADE

★ If the blade has been removed or disassembled, adjust as follows. 1. Procedure for adjusting with shims when assembling 1) Use shims to adjust the clearance at center portion (1). Adjustment loca- Clearance tion 1

a

2) Use shims to adjust the clearance at lift portion (2). Adjustment loca- Clearance tion 2

b

Standard clearance

Standard shim thickness

Max. 1 mm

4.0mm

Standard Standard shim thickclearance ness See Note

4.5mm

Note: Adjust so that the play of the ball at the spherical portion in the axial direction is within 1 mm. Check that the ball rotates smoothly.

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1

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ADJUSTING BLADE

3) Use shims to adjust the clearance at trunnion portion (3) (shim adjustment type). Adjustment loca- Clearance tion 3

c

Standard clearance

Standard shim thickness

1.56±0.65mm Total clearance

12mm

2. Adjusting blade tilt 1) Adjust installation dimension d of brace (4) with the handle. • Installation dimension d of brace (3): 1554 mm 2) Measure left and right tilt e1 and e2. • Right tilt e1: Approx. 700 mm • Left tilt e2: Approx. 700 mm 3) If the tilt is not the same on the left and right sides, adjust installation dimension d of brace (4) as follows to give the same tilt on both sides. • e1 > e2: Carry out fine adjustment to make installation dimension d longer • e1 < e2: Carry out fine adjustment to make installation dimension d shorter

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ADJUSTMENT OF PCCS LEVER POTENTIOMETERS When adjusting the lever assembly independently

X

kΩ

Y

kΩ

1. Position lever in “NEUTRAL (both forward & reverse, steering)” 2. Using tester (2), measure resistance between 5 V pin and signal pin. (See table 1). (ex. For ST1, measure resistance between pins A (5 V) and H (SIG)) 3. Using tester (2), measure resistance between signal pin and GND pin. (See table 1). (ex. For ST1, measure between pins H (SIG) and G (GND)) 4. Adjust resistance to be X = Y (tolerance: X – Y ≤ 0.04 kΩ) by slightly turning the potentiometer body. (Loosen screws (1) before adjusting) 5. Secure the potentiometer in place by tightening screw (1). Table 1 POTENTIOMETER No. 1 2 3 4

ST1 ST2 FR3 FR4

20-155-1 4

5V A M L O

PIN No. SIG GND H G E F K J P Q

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20-155-2 4


CHECKING THE ADJUSTMENT OF PCCS LEVER

CHECKING THE ADJUSTMENT OF PCCS LEVER 1. Install the pre-adjusted PCCS lever to the machine. (For details, see DISASSEMBLY OF PCCS LEVER.) 2. Position PCCS lever in “NEUTRAL (both forward & reverse, steering)” 3. Turn key switch “ON”. 4. Check the voltage of each potentiometer (ST1, 2 & FR3, 4) by using the monitoring mode of the monitor panel. (For details, see SPECIAL FUNCTION OF MONITOR PANEL EMMS.) 5. Voltage should be 2,500 ± 50 mV for each potentiometer. ADJUSTING IN ATTACHED CONDITION 1. Position PCCS lever in “NEUTRAL (both forward & reverse, steering)” 2. Using tester (4), adjust voltage by turning potentiometer slightly, so that the voltage becomes 2.5 V. 3. Tighten screw (2) at the position of voltage 2.5 V, and fix the potentiometer (1).

1. Potentiometer

5. T-adapter

2. Screw

6. Controller

3. PCCS lever

7. Machine power source

4. Tester

8. External power source (5 V)

20-155-3 4

A. Wiring connection of adjustment for machine power source. B. Wiring connection of adjustment for external power source.

D375A-5



DISASSEMBLY AND ASSEMBLY OF PCCS LEVER DISASSEMBLY 1. Open armrest and remove screws (1) (4 places/ hexagon socket head).

2. Remove armrest & box assembly.

3. Remove screws (3).


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5. Remove screws (5) (6 places).

6. Sling cover (6) and disconnect wiring for fuel dial.

7. Peel boot, remove bolts (7) (4 places/hexagon socket head) and remove lever assembly (8).

8. Remove lever assembly (8) from console case (11). 9. Loosen screw (9), then adjust voltage by turning potentiometer (10) slightly.

ASSEMBLY •

For assembly, procedure in reverse order.

20-155-5 4

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SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)


Special functions are displayed portion 1. Speed range display portion 2. Service meter display portion

Special functions control portion 1 (basic control) 3. Service switch 4. Buzzer cancel switch 5. Economy mode switch

★ EMMS: Equipment Management Monitoring System

20-156 (5) 1

Special functions control portion 2 (switch control) 6. Slow reverse mode switch 7. SSC (Shoe Slip Control) switch 8. Bedrock selection switch 9. Auto shift down switch 10. Shift up switch 11. Shift down switch

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OPERATION AND DISPLAY OF OPERATOR MODE (OUTLINE) ★ This section gives only an outline of the operator mode. For details of each function and mode and the method of operation, see the Operation and Maintenance Manual. 1. Normal display (default) When the condition of the machine is normal, the monitor panel displays the following information. Speed range display (1): • Left side: Direction (P, N, F, R) • Right side: Speed range (1, 2, 3) • Bottom: Shift mode (!lamp) • Graphics: Engine speed Service meter display (2): • Service meter (in units of 0.1h)

2. User code display function If an abnormality occurs during operation and it is necessary to inform the operator, the user code and service meter are displayed in turn in service meter display (2). If the user code indicates a serious problem, the warning lamp flashes and the alarm buzzer sounds at the same time. The user code is displayed only when a serious problem occurs. There are cases when an abnormality occurs and the user code is not displayed, so if you feel there is in the problem, always check for a service code display on the service code display function of the service mode.

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Table of user codes User code

Method of displaying abnormality

Nature of abnormality

• Only user code is displayed • Torque converter does not lock up • Blade dual tilt does not work

• Automatic functions stop or some functions stop, but operation is possible • Please contact your Komatsu distributor for repairs

• User code is displayed • Warning lamp flashes • Alarm buzzer sounds

• Does not shift up or down • Blade pitch does not work

• Engine stops but it is possible to start it again and carry out operations without limit. However, care must be taken by user • Please contact your Komatsu distributor for repairs


• Abnormality in engine water temper- • Move to a safe place ature sensor • Please contact your Komatsu distrib• Available speed ranges are limited utor for repairs • Engine does not rise to full speed • Excessive transmission shock • Difficult to turn (steer) • Excessive shock when braking


• Engine control impossible • Travel impossible • Machine stops

E01

E02

CALL 03

CALL

D375A-5

Action recommended to operator

• Stop machine immediately • Please contact your Komatsu distributor for repairs

20-159 1



OPERATION AND DISPLAY OF SERVICE MODE Method of switching to service mode ★ When using the service mode, carry out the following special operation to switch the screen display. 1) Special operation of switches Set service switch (3) to the ON position, then hold buzzer cancel switch (4) at the ON position for at least 7 seconds. ★ The mode displayed on the panel differs according to the selection position of the economy mode switch (see next section). 2) Selecting mode to use After switching to the service mode, operate the following switches to switch to the mode to be used. • Economy mode switch (5) Economy mode

Mode

F1-R2 F2-R2 lamp lamp

OFF

Monitoring mode

!

1

Adjustment mode

!

2

Service code display mode

!

★ When switching to each mode, the shift mode display lamp lights up or goes out to indicate which mode is now being used. ★ The economy mode switch can be set to the position to be used before switching to the service mode. ★ The diagram on the right shows the initial screen when the economy mode switch is OFF and the monitoring mode has been selected. 3) Finishing mode, function When the service switch is turned OFF, the mode or function can be finished regardless of the mode or level being operated.

20-160 (5) 1

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3. Monitoring mode In the monitoring mode, it is possible to check the condition of various parts of the machine on the monitor panel according to the signals from the sensors installed to various parts of the machine. 1) Selecting mode Switch to the service mode and select the monitoring mode with the economy mode switch. • Economy mode switch (5): OFF 2) Content of display In the monitoring mode, the following information is displayed on the monitor panel. • Speed range display (1): Monitoring code • Service meter display (2): Monitoring data ★ For details of the code and data, see TABLE OF MONITORING MODES. 3) Method of selecting monitoring code ★ There are the following three methods of selecting the monitoring code, so operate the mode that is easiest to use. i) Method of scrolling code forward or in reverse The monitoring codes are in the internally set order. If the following switches are operated, the codes are scrolled forward or in reverse in the internally set order, so scroll to the code to be selected. • Slow reverse mode switch (6): Scroll forward • Buzzer cancel switch (4): Scroll in reverse ★ When the system is switched to the monitoring mode, the 1st code is displayed. ★ For details of the order of the codes, see TABLE OF MONITORING MODES.

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ii) Method of block jump + scrolling forward and in reverse The monitoring codes are divided into 5 blocks internally according to the type of data. If the following switches are operated, the screen will jump to the 1st code of each block, so scroll forward or in reverse to select the code from the lock. • SSC switch (7): Go to next block ★ When the system is switched to the monitoring mode, block 1 is displayed. ★ The blocks jump in the following order (for details, see TABLE OF MONITORING CODES). 1

Steering system

38 items

2

Transmission system

27 items

3

Work equipment system

13 items

4

Engine system

5

Monitor panel system

9 items 15 items

iii) Method of inputting code The monitoring codes are set internally as 2digit alphanumerical codes. If the following switches are operated, the codes in the speed range display (left, right) change, so input the code to be used. • Bedrock selection switch (8) Left switch: Left code changes Right switch: Right code changes ★ The left and right codes change in the following order according to the operation of the switches (letters which are not used for any code are jumped). 9→A→b→C→d→E→F→H→J→L→N→ o→P→R→U→0→1→2→3→4→5→6→ 7→8→9

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4) Hold function for monitoring data For data such as the engine speed, which is not stable during monitoring, if it is difficult to read the screen display, operate the following switch to hold the data or cancel the hold. The switch for holding or canceling the hold acts as a toggle switch to switch ON or OFF. • Auto shift down switch (9): Switches between HOLD and CANCEL HOLD

5) When operating machine with monitoring mode still displayed If it is necessary to move the work equipment or travel with the monitoring mode still displayed, do as follows. i) Method of operating work equipment: Use auto shift down switch (9) to switch the existing condition. ★ The auto shift down switch acts as both the holder function and work equipment operation function, so be careful when operating it. ★ Service meter display (2) continues to display the monitoring data, and speed range display (1) returns to the normal display. ★ While the machine is being operated, the monitoring code cannot be changed, so if it is necessary to change the code, return first to the monitoring mode. ii) Method of returning to monitoring mode: Operate the parking lever to the LOCK position and hold buzzer cancel switch (4) at the ON position for at least 1 sec.

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Table of monitoring modes Order

Code

Content of display

Unit

Controller

1 Steering system 1

99

Engine speed

rpm

Steering controller

2

91

Value of voltage for engine speed sensor

mV

Steering controller

3

7o

Transmission speed

rpm

Steering controller

4

93

Value of voltage for transmission speed sensor

mV

Steering controller

5

7R

Torque converter speed

rpm

Steering controller

6

95

Value of voltage for torque converter speed sensor

mV

Steering controller

7

bA

Battery voltage value

mV

Steering controller

8

L1

Value of voltage for steering potentiometer 1

mV

Steering controller

9

L2

Value of voltage for steering potentiometer 2

mV

Steering controller

10

L7

Value of voltage for brake potentiometer

mV

Steering controller

11

A6

Tilt angle

0.001°

Steering controller

12

A8

Value of voltage for tilt angle sensor

mV

Steering controller

13

F5

Fuel control dial command speed

rpm

Steering controller

14

F6

Value of voltage for fuel control dial

mV

Steering controller

15

d5

Deceleration potentiometer command speed

rpm

Steering controller

16

d6

Value of voltage for deceleration potentiometer

mV

Steering controller

17

A5

Value of voltage for acceleration sensor

mV

Steering controller

18

5U

SSC command speed

rpm

Steering controller

19

5d

Value of voltage for engine command

mV

Steering controller

20

L9

Steering controller switch input 1

(bit)

Steering controller

21

LE


(bit)

Steering controller

22

LL

Steering controller oil pressure switch input 3

(bit)

Steering controller

23

CE

Steering controller HPI input 4

(bit)

Steering controller

24

LF


(bit)

Steering controller

25

LJ


(bit)

Steering controller

26

7b

Steering fill switch input

(bit)

Steering controller

27

P1

Value of voltage for left brake ECMV output command

mA

Steering controller

28

c1

Value of voltage for left brake ECMV output FB

mA

Steering controller

29

P2

Value of voltage for right brake ECMV output command

mA

Steering controller

30

c2

Value of voltage for right brake ECMV output FB

mA

Steering controller

31

P3

Value of voltage for left clutch ECMV output command

mA

Steering controller

32

c3

Value of voltage for left clutch ECMV output FB

mA

Steering controller

33

P4

Value of voltage for right clutch ECMV output command

mA

Steering controller

34

c4

Value of voltage for right clutch ECMV output FB

mA

Steering controller

35

58

Steering controller output

(bit)

Steering controller

36

d5

Value of voltage for sudden stop prevention solenoid drive

mV

Steering controller

37

d8

Value of voltage for engine controller relay drive

mV

Steering controller

38

dA

Value of voltage for battery relay drive

mV

Steering controller

: Code for PCCS lever potentiometers.

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Order

Code


Content of display

Unit

Controller

2 Transmission system 39

3E

Engine speed

rpm

Transmission controller

40

92

Value of voltage for engine speed sensor

mV


41

7P

Transmission speed

rpm


42

94

Value of voltage for transmission speed sensor

mV


43

A7

Tilt angle

0.001°


44

A9

Value of voltage for tilt angle sensor

mV


45

L3

Value of voltage for directional potentiometer 1

mV


46

L4

Value of voltage for directional potentiometer 2

mV


47

L5

Transmission controller switch input 1

(bit)


48

L8

Transmission controller switch input 2

(bit)


49

7H

Transmission fill switch input

(bit)


50

P5

Value of voltage for FORWARD clutch ECMV (E-POCV) output command

mA


51

c5

Value of voltage for FORWARD clutch ECMV (E-POCV) output FB

mA


52

P6

Value of voltage for REVERSE clutch ECMV (E-POCV) output command

mA


53

c6

Value of voltage for REVERSE clutch ECMV output FB

mA


54

P7

Value of voltage for 1st clutch ECMV output command

mA


55

c7

Value of voltage for 1st clutch ECMV output FB

mA


56

P8

Value of voltage for 2nd clutch ECMV output command

mA


57

c8

Value of voltage for 2nd clutch ECMV output FB

mA


58

P9

Value of voltage for 3rd clutch ECMV output command

mA


59

c9

Value of voltage for 3rd clutch ECMV output FB

mA


60

Ld

Transmission controller output

(bit)


61

dL

Value of voltage for lock-up solenoid drive

mV


62

db

Value of voltage for back-up alarm relay drive

mV


63

dN

Value of voltage for neutral safety relay drive

mV


64

d1

(Not used)

—

—

65

d2

(Not used)

—

—

3 Work equipment system 66

bd

Blade lever knob switch input

(bit)


67

bH

Blade lever oil pressure switch input

(bit)


68

57

Transmission controller toggle switch input

(bit)

69

HL

Front pump oil pressure

70

4L

Value of voltage for front pump oil pressure sensor

kg/cm

Transmission controller 2

mV kg/cm

Transmission controller Transmission controller

2

71

H5

Center pump oil pressure

72

45

Value of voltage for center pump oil pressure sensor

mV


73

56

Transmission controller solenoid drive status

(bit)


74

d3

Value of voltage for blade pitch solenoid drive

mV


75

d4

Value of voltage for blade dual solenoid drive

mV



: Code for PCCS lever potentiometers.

D375A-5

20-165 (7) 1



Order

Code

Content of display

Unit

Controller

76

Fc

(Not used)

—

—

77

FF

(Not used)

—

—

78

R7

Ripper lever oil pressure switch input

(bit)


4 Engine system 79

60

Deceleration pedal speed

rpm

Engine controller

80

61

Engine No. 2 throttle speed

rpm

Engine controller

81

62

Engine speed

rpm

Engine controller

82

63

Engine water temperature

°C

Engine controller

83

64

(Not used)

—

84

65

Engine oil pressure

85

66

Fuel consumption ratio

86

67

Fuel temperature

87

68

Fuel consumption amount

—

kPa

Engine controller

0.1¬/h

Engine controller

°C

Engine controller

¬

Engine controller

5 Monitor panel system 88

U2

Monitor panel (tachometer) program No.

Numeral Monitor panel (tachometer)

89

U3

Transmission controller program No.

Numeral Transmission controller

90

U4

Monitor panel (caution) program No.

Numeral Monitor panel (caution)

91

U5

Steering controller program No.

Numeral Steering controller

92

5N

S-NET communication connection status

93

78

94

(bit)

Steering controller

(Not used)

—

Steering controller

77


°C

Steering controller

95

FL

Value of voltage for fuel level sensor

mV

Steering controller

96

Bu

Travel speed (theoretical value)

m/h

Steering controller

97

FR

Drawbar pull (theoretical value)

m(F/W)

Steering controller

98

C5

Steering status code

HEX

Steering controller

99

CF

Fill condition setting variable

HEX

Steering controller

100

Cb

Modulation condition setting variable

HEX

Steering controller

101

Cc

Gearshift point setting variable

HEX

Steering controller

102

5F

Slip flag

(bit)

Steering controller

★ Order for scrolling forward and in reverse when selecting code: The monitoring code is scrolled forward and in reverse in the order shown in the table. ★ Jump function when selecting code: If the jump function is used when selecting the code, the 1st code for eachblock ((1), 2, 3, 4, 5) is displayed. ★ Bit for units: The ON-OFF input signal or output signal are items displayed on the special screen display. (For details, see Details of bit display codes.)

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Details of bit display codes Example of bit data display: • The bit data is displayed on service meter display (2) as [-] for OFF and [o] for ON. • 135 show the bit OFF • 246 show the bit ON ★ The item status given in this section shows the conditions when the bit is ON.

L9: Steering controller switch input 1 1: (Not used) 2: (Not used) 3: (Not used) 4: (Not used) 5: Parking lever switch FREE 6: Parking lever switch LOCK

LE: Steering controller switch input 2 1: Buzzer cancel switch ON (operated) 2: (Not used) 3: (Not used) 4: (Not used) 5: Service switch ON 6: (Not used)

LL: Steering controller oil pressure switch input 3 1: (Not used) 2: (Not used) 3: (Not used) 4: Ripper RAISE oil pressure switch ON (operated) 5: Ripper LOWER oil pressure switch ON (operated) 6: Ripper TILT IN oil pressure switch ON (operated)

D375A-5

20-167 (5) 1



CE: Steering controller switch HPI input 4 1: Red lamp signal ON 2: Yellow lamp signal ON 3: Orange lamp signal ON 4: (Not used) 5: Engine oil pressure signal ON 6: Fuel temperature signal ON

LF: Steering controller switch input 5 1: Starting switch ACC signal ON 2: Turbo timer signal ON 3: Engine Li command signal ON 4: Motoring switch signal ON 5: N signal 1 ON 6: N signal 2 ON

LJ: Steering controller switch input 6 1: Preheating signal ON 2: Starting switch C signal ON 3: (Not used) 4: Night lighting signal ON 5: (Not used) 6: (Not used)

7b: Steering fill switch input 1: Left brake fill switch ON 2: Left clutch fill switch ON 3: (Not used) 4: (Not used) 5: Right clutch fill switch ON 6: Right brake fill switch ON

20-168 1

D375A-5



58: Steering controller output : (Not used) : (Not used) : (Not used) : Engine controller drive relay output: Output : Battery relay drive output: Output : Emergency stop prevention solenoid relay drive output: Output

L5: Transmission controller switch input 1 : Shift up switch OFF : Shift up switch ON : Shift down switch OFF : Shift down switch ON : Parking lever switch FREE : Parking lever switch LOCK

L8: Transmission controller switch input 2 : Auto shift down switch ON : (Not used) : (Not used) : (Not used) : Service switch ON : (Not used)

7H: Transmission fill switch input : F clutch fill switch ON : R clutch fill switch ON : 1st clutch fill switch ON : 2nd clutch fill switch ON : 3rd clutch fill switch ON : (Not used)

D375A-5

20-169

1



Ld: Transmission controller output : (Not used) : (Not used) : (Not used) : Backup alarm relay drive output: Output : Neutral safety relay drive output: Output : Lock-up solenoid drive output: Output

bd: Blade lever knob switch input : Blade lever tilt switch: Dual : Blade lever tilt switch: Single : Blade lever pitch switch OFF : Blade lever pitch switch ON : (Not used) : (Not used)

bH: Blade lever oil pressure switch input : (Not used) : (Not used) : (Not used) : (Not used) : Blade tilt left oil pressure switch ON (operated) : Blade tilt right oil pressure switch ON (operated)

57: Transmission controller toggle switch input : Auto shift down switch ON : (Not used) : (Not used) : (Not used) : (Not used) : (Not used)

20-170

1

D375A-5



56: Transmission controller solenoid drive status 1: Dual selection solenoid drive output: Output 2: Pitch selection solenoid drive output: Output 3: (Not used) 4: (Not used) 5: (Not used) 6: (Not used)

R7: Ripper lever oil pressure switch input 1: (Not used) 2: Ripper RAISE oil pressure switch ON (operated) 3: Ripper LOWER oil pressure switch ON (operated) 4: Ripper TILT IN oil pressure switch ON (operated) 5: Ripper TILT BACK oil pressure switch ON (operated) 6: (Not used)

5N: S-NET communication connection 1: (Not used) 2: Monitor panel (tachometer) connected 3: Transmission controller connected 4: Monitor panel (caution) connected 5: Steering controller connected 6: (Not used)

5F: Slip flag 1: (Not used) 2: (Not used) 3: (Not used) 4: (Not used) 5: (Not used) 6: (Not used)

D375A-5

20-171 1



4. Adjustment mode In the adjustment mode, it is possible to check the status and carry out adjustment of the machine controller and various equipment. 1) Selecting mode Switch to the service mode, then use the economy mode switch to select the adjustment mode. • Economy mode switch (5): 1 2) content of display In the adjustment mode, the following information is displayed on the monitor panel. • Speed range display (1): Adjustment mode • Service meter display (2): Related data ★ For details of the code and related data, see TABLE OF ADJUSTMENT MODES AND ADJUSTMENT PROCEDURE. 3) Selecting adjustment mode In the adjustment mode, there is a fixed order for the internal settings. When the following switch is pressed, the code will scroll forward in the order set internally, so the code to use is displayed. • Slow reverse mode switch (6): Scroll forward ★ for details of the order for the adjustment mode, see TAB LE O F ADJUSTMENT MODES AND ADJUSTMENT PROCEDURE. ★ The code cannot be scrolled in reverse, so if you go past the code to be used, it is necessary to continue scrolling forward for one cycle, or to switch to another mode and then enter the adjustment mode again. 4) Switches and buzzers used in adjustment mode • Buzzer cancel switch (4): Confirmation function • Auto shift down switch (9): Selection function • Shift up switch (10): Increase value (oil pressure only) • Shift down switch (11): Decrease value (oil pressure only) ★ When the confirmation operation of the buzzer cancel switch is recognized, the alarm buzzer will sound once.

20-172 (5) 1

D375A-5



1 AF: Transmission manual mode • This code is the function to set the transmission to the manual mode and to make it possible to travel in 2nd or 3rd. • The service meter display shows the travel speed (unit: 0.01 km/h). • Method of use When this code is displayed, set the parking lever to the FREE position and operate the shift up switch or shift down switch. When this is done, the speed range display will switch as follows to make it possible to travel in 2nd or 3rd. Screen display: N1 ↔ N2 ↔ N3 ★ When this code is finished, the function becomes ineffective.

2 CH: (Not used)

20-174 (5) 1

D375A-5



3 Co: Both steering clutches released • This code is the function to engage the transmission clutch without allowing the machine to move when carrying out inspection, maintenance, troubleshooting, or Pm clinic. • The service meter display shows the transmission speed (unit: rpm). • Method of use The function is effective when this code is being displayed. Both steering clutches are disengaged, so the machine does not travel even if the PCCS lever is operated. ★ When this code is finished, the function becomes ineffective.

4 5A: Specification code comparison (steering controller) ¤ Always carry out this adjustment code if the steering controller has been replaced. If the adjustment is not carried out, service code [E0151] may be displayed and the system may not work normally. • This code carries out the initial setting of the specification code recognized by the steering controller. It also functions to format the set value in the memory inside the controller. • The service meter display shows the specification code in numerals. • Method of adjustment 1) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 2) Check that the specification code display changes from [202] to [222]. ★ If [222] is not displayed for the specification code, the controller wiring harness or controller itself is probably defective ★ Even when this code is finished, the setting remains effective.

D375A-5

20-175 (5) 1



5 7A: Specification code comparison (transmission controller) ¤ Always carry out this adjustment code if the transmission controller has been replaced. If the adjustment is not carried out, service code [E0486] may be displayed and the system may not work normally. • This code carries out the initial setting of the specification code recognized by the transmission controller. It also functions to format the set value in the memory inside the controller. • The service meter display shows the specification code in numerals. • Method of adjustment 1) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 2) Check that the specification code display changes from [101] to [111]. ★ If [111] is not displayed for the specification code, the controller wiring harness or controller itself is probably defective. ★ Even when this code is finished, the setting remains effective.

6 5C: Specification code comparison (machine specification) ¤ Always carry out this adjustment code if the steering controller or transmission controller has been replaced. If the adjustment is not carried out, service code [E0151] may be displayed and the system may not work normally. • This code is the function to make the controller forming the system recognize the machine specification. • The service meter display shows the specification code in letters. • Method of adjustment 1) Operate the auto shift down switch to the left and right and display the specification code to be set. Specification code

Machine specification

body00

Single tilt without SSC

body01

Single tilt with SSC

body10

Dual tilt without SSC

body11

Dual tilt with SSC

2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. ★ Even when this code is finished, the setting remains effective.

20-176 (5) 1

D375A-5



7 NA: Tilt angle sensor standard value setting • This code is the function to adjust the 0 point of the tilt angle sensor and to check the installation tolerance. • The service meter display shows the divergence compared with the specified amount from the neutral position in a voltage value (unit: mV). • Method of adjustment ★ Formatting of the existing data is carried out with adjustment code [5C]. ★ Carry out the adjustment with the machine parked on flat ground. 1) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 2) Display the divergence compared with the specified amount from the neutral position. ★ Even when this code is finished, the setting remains effective.

8 bP: Brake pedal standard position set • This code is the function to adjust the neutral position of the brake pedal. • The service meter display shows the divergence compared with the specified amount from the neutral position in a voltage value (unit: mV). • Method of adjustment ★ Formatting of the existing data is carried out with adjustment code [5C]. 1) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 2) Display the divergence compared with the specified amount from the neutral position. ★ Even when this code is finished, the setting remains effective.

D375A-5

20-177 (5) 1



9 bL: Brake release mode • This code is the function to assist the adjustment of the parking lever cable or brake pedal rod when the brake is released with the brake ECMV. • If the brake oil pressure is measured in this condition, it is possible to check the actuation status of the brake valve. • The service meter display shows the voltage value (unit: mV) of the brake pedal potentiometer. • Method of use When this code is displayed, the function becomes effective. The brake ECMV releases the brake, so measure the brake oil pressure as necessary (the brake oil pressure cannot be checked on the monitor panel). ★ When this code is finished, the function becomes ineffective.

0 b5: Sudden stop prevention valve actuation mode • This code is the function to check the actuation of the sudden stop prevention valve when the output to the clutch ECMV, brake ECMV, and sudden stop prevention solenoid valve is set to 0. If the brake oil pressure is measured in this condition, it is possible to check the actuation status of the sudden stop prevention valve. • The service meter display shows the voltage value (unit: mV) of the brake pedal potentiometer. • Method of use When this code is displayed, the function becomes effective. The clutch ECMV, brake ECMV, and sudden stop prevention solenoid valve output become 0, so measure the brake oil pressure as necessary (the brake oil pressure cannot be checked on the monitor panel). ★ When this code is finished, the function becomes ineffective.

20-178 (7) 1

D375A-5



A No: PCCS lever neutral position set • This code is the function to adjust the neutral position of the PCCS lever in the turn (steering) direction. • The service meter display shows the divergence compared with the specified amount from the neutral position of the steering potentiometer in a voltage value (unit: mV). • Method of adjustment ★ Formatting of the existing data is carried out with adjustment code [5C]. 1) Set the PCCS lever to the neutral position in the steering direction. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 3) Display the divergence compared with the specified amount from the neutral position. ★ Even when this code is finished, the setting remains effective.

B NL: PCCS lever left max. position set • This code is the function to adjust the maximum left position of the PCCS lever in the turn (steering) direction. • The service meter display shows the divergence compared with the specified amount from the maximum left position of the steering potentiometer in a voltage value (unit: mV). • Method of adjustment ★ Formatting of the existing data is carried out with adjustment code [5C]. 1) Operate the PCCS lever to the maximum left position in the steering direction. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 3) Display the divergence compared with the specified amount from the maximum left position. ★ Even when this code is finished, the setting remains effective.

D375A-5

20-179 (5) 1



C NR: PCCS lever right max. position set • This code is the function to adjust the maximum right position of the PCCS lever in the turn (steering) direction. • The service meter display shows the divergence compared with the specified amount from the maximum left position of the steering potentiometer in a voltage value (unit: mV). • Method of adjustment ★ Formatting of the existing data is carried out with adjustment code [5C]. 1) Operate the PCCS lever to the maximum right position in the steering direction. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 3) Display the divergence compared with the specified amount from the maximum right position. ★ Even when this code is finished, the setting remains effective.

D PA: Brake automatic adjustment • This code is the function to maintain the performance of the brake control by automatically adjusting any changes in the performance caused by variation or wear in the brake parts. • The service meter display shows the brake command oil pressure (unit: 0.01 kg/cm2). ¤ With this adjustment, the machine moves approx. 1 - 2 m forward, so carry out the adjustment on flat ground where it is possible to ensure safety in the surrounding area. • Method of adjustment 1 (preparatory work) ★ Check that the torque converter oil temperature is in the operating range when carrying out this adjustment. 1) Start the engine and select this code. 2) Set the parking lever to the FREE position. 3) Set the auto shift down switch to OFF 4) Run the engine at low idling. 5) Depress the brake pedal and decelerator pedal to hold the machine.

20-180 (5) 1

D375A-5


•

•


6) Operate the PCCS lever direction to F and the speed to 3. ★ Keep the steering at the neutral position. 7) Gradually release the decelerator pedal and brake pedal and check that the machine does not move. ¤ If the machine moves, there is an abnormality, so stop the adjustment immediately. ★ If it is confirmed that the machine does not move, go on to the following Method of adjustment 2. Method of adjustment 2 (adjusting left clutch) 1) Operate the PCCS lever steering fully to the left. 2) Check that the display for the tachometer graphic and command oil pressure changes automatically. ★ The tachometer graphic shows the progress of the adjustment. 3) Drive the machine forward 1 - 2 m, then stop the machine and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. ★ After completing the adjustment of the left clutch, go on to the following Method of adjustment 3. ★ It is possible to check the compensation value for the left brake oil pressure with adjustment code [N1] Method of adjustment 3 (adjusting right brake) 1) Operate the PCCS lever steering fully to the right. 2) Check that the display for the tachometer graphic and command oil pressure changes automatically. ★ The tachometer graphic shows the progress of the adjustment. 3) Drive the machine forward 1 - 2 m, then stop the machine and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. ★ It is possible to check the compensation value for the right brake oil pressure with adjustment code [N2] ★ Even when this code is finished, the setting remains effective.

D375A-5

20-181 1



E N1: Left brake oil pressure offset • This code is the function to adjust the left brake oil pressure manually. • The service meter display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.). • Method of adjustment ★ The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift up switch or shift down switch and set the offset oil pressure. • Shift up switch (10): Oil pressure increases • Shift down switch (11): Oil pressure increases ★ The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. ★ Even when this code is finished, the setting remains effective.

F N2: Right brake oil pressure offset • This code is the function to adjust the right brake oil pressure manually. • The service meter display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.). • Method of adjustment ★ The maximum permitted range for adjustment is ± kg/cm2 (display: 300). 1) Operate the shift up switch or shift down switch and set the offset oil pressure. • Shift up switch (10): Oil pressure increases • Shift down switch (11): Oil pressure increases ★ The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. ★ Even when this code is finished, the setting remains effective.

20-182 (5) 1

D375A-5



G PE: Steering clutch automatic adjustment • This code is the function to maintain the performance of the steering control by automatically adjusting any changes in the performance caused by variation or wear in the steering clutch parts. • The service meter display shows the clutch command oil pressure (unit: 0.01kg/cm2). • Method of adjustment 1 (preparatory work) ★ Check that the torque converter oil temperature is in the operating range when carrying out this adjustment. 1) Start the engine and select this code. 2) Set the parking lever to the FREE position. 3) Set the auto shift down switch to OFF 4) Run the engine at low idling. 5) Depress the brake pedal and decelerator pedal to hold the machine. 6) Operate the PCCS lever direction to F and the speed to 3. ★ Keep the steering at the neutral position. 7) Gradually release the decelerator pedal and brake pedal and check that the machine does not move. ¤ If the machine moves, there is an abnormality, so stop the adjustment immediately. ★ If it is confirmed that the machine does not move, go on to the following Method of adjustment 2. • Method of adjustment 2 (adjusting left clutch) 1) Operate the PCCS lever steering fully to the left. 2) Check that the display for the tachometer graphic and command oil pressure changes automatically. ★ The tachometer graphic shows the progress of the adjustment. 3) Raise the engine speed and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. ★ After completing the adjustment of the left clutch, go on to the following Method of adjustment 3. ★ It is possible to check the compensation value for the left clutch oil pressure with adjustment code [N3]

D375A-5

20-183 (5) 1


•


Method of adjustment 3 (adjusting right clutch) 1) Operate the PCCS lever steering fully to the right. 2) Check that the display for the tachometer graphic and command oil pressure changes automatically. ★ The tachometer graphic shows the progress of the adjustment. 3) Raise the engine speed and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. ★ It is possible to check the compensation value for the right clutch oil pressure with adjustment code [N4] ★ Even when this code is finished, the setting remains effective.

H N3: Left steering clutch oil pressure offset • This code is the function to adjust the left steering clutch oil pressure manually. • The service meter display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.). • Method of adjustment ★ The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift up switch or shift down switch and set the offset oil pressure. • Shift up switch (10): Oil pressure increases • Shift down switch (11): Oil pressure increases ★ The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. ★ Even when this code is finished, the setting remains effective.

20-184 (5) 1

D375A-5



I N4: Right steering clutch oil pressure offset • This code is the function to adjust the right steering clutch oil pressure manually. • The service meter display shows the offset oil pressure (unit: 0.01 kg/cm 2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.). • Method of adjustment ★ The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift up switch or shift down switch and set the offset oil pressure. • Shift up switch (10): Oil pressure increases • Shift down switch (11): Oil pressure increases ★ The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. ★ Even when this code is finished, the setting remains effective.

J CN: Transmission trigger compensation value overwrite count • This code is the function to check the transmission clutch learning control count and to format the learning control count (all clutches). • The service meter display shows the learning control count (unit: No. of times) • Method of checking When the code is selected, the number shown in the service meter display is the present learning control count. • Method of formatting 1) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 2) Check that the display for the learning control count has returned to [0]. ★ Even when this code is finished, the initial setting remains effective.

D375A-5

20-185 (5) 1



K Fx: Transmission F clutch trigger compensation value • This code is the function to check the transmission F clutch learning control value and to format the learning control value (all clutches). • The service meter display shows control value control value (unit: 10 ms). • Method of checking When the code is selected, the following data are displayed for 2 seconds. Speed range Service meter display (Engine condition) display

F1 F2 F3 F4

Control value H1 Low control value L1 Control value H2 - Medium (low speed) control value L2 Control value H3 Medium control value L3 (high speed) Control value H4 High speed control value L4

•

•

Control value Hx: Control value (unit: 10 ms) when torque converter oil temperature is high • Control value Lx: Control value (unit: 10 ms) when torque converter oil temperature is low Method of formatting 1) Hold the buzzer cancel switch for at least 1 sec. at the ON position and check that the alarm buzzer sounds. 2) Check that the display for the control value has returned to [00]. ★ Even when this code is finished, the initial setting remains effective.

L Rx: Transmission R clutch trigger compensation value • This code is the function to check the transmission R clutch learning control value and to format the learning control value (all clutches). • The service meter display shows control value control value (unit: 10 ms). • Method of checking When the code is selected, the following data are displayed for 2 seconds. Speed range Service meter display (Engine condition) display

R1 R2 R3 R4


•

•


20-186 (5) 1

D375A-5



M 1x: Transmission 1st clutch trigger compensation value • This code is the function to check the transmission 1st clutch learning control value and to format the learning control value (all clutches). • The service meter display shows control value control value (unit: 10 ms). • Method of checking When the code is selected, the following data are displayed for 2 seconds. Speed range Service meter display (Engine condition) display

11 12 13 14


•

•


N 2x: Transmission 2nd clutch trigger compensation value • This code is the function to check the transmission 2nd clutch learning control value and to format the learning control value (all clutches). • The service meter display shows the control value - control value (unit: 10 ms). • Method of checking When the code is selected, the following data is displayed for 2 seconds. Speed range Service meter display (Engine condition) display

21 22 23 24


•

•


D375A-5

20-187 (5) 1



O 3x: Transmission 3rd clutch trigger compensation value • This code is the function to check the transmission 3rd clutch learning control value and to format the learning control value (all clutches). • The service meter display shows the control value - control value (unit: 10 ms). • Method of checking When the code is selected, the following data is displayed for 2 seconds. Speed range Service meter display (Engine condition) display

31 32 33 34


•

•


P Pb: Steering brake I-P • This code is the function to measure the I-P characteristic value of the left and right steering brake ECMV s. • The service meter display shows the I-P measurement time (unit: 10 ms). • Method of measurement 1 (preparatory work) • Start the engine and select this code. • Method of measurement 2 (measuring left brake) 1) Operate the PCCS lever steering to the left and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the left position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. • Method of measurement 3 (measuring right brake) 1) Operate the PCCS lever steering to the right and check that the displayed value for the I-P measurement time increases continuously from [0].

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★ Hold the lever at the right position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. ★ Even when this code is finished, the setting remains effective.

Q Pc: Steering clutch I-P • This code is the function to measure the I-P characteristic value of the left and right steering clutch ECMV s. • The service meter display shows the I-P measurement time (unit: 10 ms). • Method of measurement 1 (preparatory work) Start the engine and select this code. • Method of measurement 2 (measuring left clutch) 1) Operate the PCCS lever steering to the left and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the left position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. • Method of measurement 3 (measuring right clutch) 1) Operate the PCCS lever steering to the right and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the right position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. ★ Even when this code is finished, the setting remains effective.

D375A-5

20-189 (7) 1



R Pd: Transmission F, R clutch I-P • This code is the function to measure the I-P characteristic value of the transmission F clutch ECMV and transmission R clutch ECMV. • The service meter display shows the I-P measurement time (unit: 10 ms). • Method of measurement 1 (preparatory work) • Start the engine and select this code. • Method of measurement 2 (measuring F clutch) 1) Operate the PCCS lever direction to F and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the F position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. • Method of measurement 3 (measuring R clutch) 1) Operate the PCCS lever direction to R and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the R position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. ★ Even when this code is finished, the setting remains effective.

S PF: Transmission 1st, 3rd clutch I-P • This code is the function to measure the I-P characteristic value of the transmission 1st clutch ECMV and transmission 3rd clutch ECMV. • The service meter display shows the I-P measurement time (unit: 10 ms). • Method of measurement 1 (preparatory work) Start the engine and select this code.

20-190 (7) 1

D375A-5


•

•


Method of measurement 2 (measuring 1st clutch) 1) Operate the PCCS lever direction to F and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the F position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. Method of measurement 3 (measuring 3rd clutch) 1) Operate the PCCS lever direction to R and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the R position until the displayed value reaches [4000]. 2) After checking that the displayed value has reached [4000], return the lever to the neutral position. ★ Even when this code is finished, the setting remains effective.

T PH: Transmission 2nd clutch I-P • This code is the function to measure the I-P characteristic value of the transmission 2nd clutch ECMV. • The service meter display shows the I-P measurement time (unit: 10 ms). • Method of measurement (preparatory work and measurement) 1) Start the engine and select this code. 2) Operate the PCCS lever direction to F or R and check that the displayed value for the I-P measurement time increases continuously from [0]. ★ Hold the lever at the F or R position until the displayed value reaches [4000]. 3) After checking that the displayed value has reached [4000], return the lever to the neutral position. ★ Even when this code is finished, the setting remains effective.

D375A-5

20-191 (7) 1



5. Service code display mode In the service code display mode, any problem that has occurred inside the system can be displayed as a service code. 1) Selecting mode Switch to the service mode and operate the economy mode switch to select the service code display mode. • Economy mode switch (5): 2 2) Content of display • Speed range display (1): Order of occurrence (recorded up to a maximum of 20 items) • Service meter display (2): Service code and service meter reading for time of occurrence are displayed in turn ★ Letter at head of service code E: Code for problem detected at present P: Code for problem not detected at present ★ Conditions for detecting and holding service code For service codes other than S-NET, if a problem is detected, the [E] display continues until the starting switch is turned OFF. If the starting switch is turned OFF and then turned ON again or the engine is started, the [P] display is held until the same problem is detected again. For the S-NET related service codes, even if the starting switch is not turned OFF, the display changes to the [P] display immediately the problem is removed. 3) Operation when multiple codes are recorded If multiple codes are recorded, operate the following switch to display the codesin the order of occurrence. • Slow reverse mode switch (6): Scroll forward (order of occurrence) ★ The service code cannot be scrolled in reverse. 4) Deleting code Display the code to be deleted, then operate the following switch to delete the code. • Buzzer cancel switch (4): ON (delete) ★ Only the codes headed by [P] can be deleted; the codes headed by [E] cannot be deleted.

20-192 (5) 1

D375A-5



TABLE OF SERVICE CODES Service code


Controller

User code

Warning lamp

Alarm buzzer

S/T

CALL03

q

q

MON

CALL03

q

q

E0101

Abnormality in network system (steering system)

E0104

Abnormality in network system (monitor panel system)

E0105

Abnormality in network system (steering system)

S/T

CALL03

q

q

E0111

Abnormality in steering controller power source system

S/T

CALL

q

q

E0112

Abnormality in transmission controller power source system

T/M

CALL

q

q

E0120

Short circuit in warning lamp system

MON

CALL03

q

q

E0121

Short circuit in alarm buzzer system

MON

CALL03

q

q

E0142

Abnormality in transmission controller 5V power source system

T/M

CALL03

q

q

E0143

Abnormality in steering controller 5V power source system

S/T

CALL03

q

q

E0145

Abnormality in steering controller 24V power source system

S/T

CALL03

q

q

E0146

Abnormality in transmission controller 24V power source system

T/M

E01

E0151

Abnormality in steering controller specification selection

S/T

CALL

q

q

E0152

Abnormality in network system (steering controller)

S/T

CALL03

q

q

E0160

Abnormality in transmission controller ROM

T/M

E01

E0161

Abnormality in steering controller ROM

S/T

E02

q

q

E0164

Abnormality in network system (transmission controller)

T/M

CALL03

q

q

E0176

Disconnection in battery relay system

S/T

E0177

Short circuit in battery relay system

S/T

E0178

Disconnection in neutral safety relay system

T/M

E02

q

q

E0179

Short circuit in neutral safety relay system

T/M

E02

q

q

E0211

Abnormality in torque converter oil temperature

MON

E0212

Short circuit in torque converter lock-up solenoid system

T/M

E01

E0213

Disconnection in torque converter lock-up solenoid system

T/M

E01

E0221

Disconnection, short circuit in tilt angle sensor system

T/M

E01

E0225

Slippage of power train clutch

T/M

E02

q

q

E0230

Simultaneous abnormality in directional potentiometer system (1)

T/M

CALL

q

q

E0231


T/M

CALL

q

q

E0232


T/M

CALL

q

q

E0233

Disconnection, short circuit in directional potentiometer 1 system

T/M

CALL03

q

q

E0234

Disconnection, short circuit in directional potentiometer 2 system

T/M

CALL03

q

q

E0235

Divergence of directional potentiometer system signal

T/M

CALL03

q

q

E0236

Disconnection, short circuit in shift up switch system

T/M

E02

q

q

E0237

Disconnection, short circuit in shift down switch system

T/M

E02

q

q

E0238

Disconnection, short circuit in parking lever switch system

T/M

CALL03

q

q

E0239

Mismatch in parking lever switch system signals

T/M

CALL03

q

q

E0250

Disconnection in transmission FORWARD clutch ECMV system

T/M

CALL03

q

q

E0251

Short circuit in transmission FORWARD clutch ECMV system

T/M

CALL03

q

q

E0252

Disconnection in transmission REVERSE clutch ECMV system

T/M

CALL03

q

q

D375A-5

20-193 (7) 1



Service code


Controller

User code

Warning lamp

Alarm buzzer

E0253

Short circuit in transmission FORWARD clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0254

Disconnection in transmission 1st clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0255

Short circuit in transmission 1st clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0256

Disconnection in transmission 2nd clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0257

Short circuit in transmission 2nd clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0258

Disconnection in transmission 3rd clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0259

Short circuit in transmission 3rd clutch ECMV (E-POCV) system

T/M

CALL03

q

q

E0260

Defective engagement of transmission FORWARD clutch

T/M

CALL03

q

q

E0261

Defective disengagement of transmission FORWARD clutch

T/M

CALL03

q

q

E0262

Defective engagement of transmission REVERSE clutch

T/M

CALL03

q

q

E0263

Defective disengagement of transmission REVERSE clutch

T/M

CALL03

q

q

E0264

Defective engagement of transmission 1st clutch

T/M

CALL03

q

q

E0265

Defective disengagement of transmission 1st clutch

T/M

CALL03

q

q

E0266

Defective engagement of transmission 2nd clutch

T/M

CALL03

q

q

E0267

Defective disengagement of transmission 2nd clutch

T/M

CALL03

q

q

E0268

Defective engagement of transmission 3rd clutch

T/M

CALL03

q

q

E0269

Defective disengagement of transmission 3rd clutch

T/M

CALL03

q

q

E0270

Multiple failure in transmission clutch

T/M

CALL03

q

q

E0271

Multiple failure in transmission clutch

T/M

CALL

q

q

E0306

Short circuit in blade tilt right oil pressure switch system

T/M

E02

q

q

E0307

Short circuit in blade tilt left oil pressure switch system

T/M

E02

q

q

E0308

Short circuit in ripper RAISE oil pressure switch system

S/T

E0309

Short circuit in ripper LOWER oil pressure switch system

S/T

E0310

Short circuit in ripper TILT IN oil pressure switch system

S/T

E0311

Disconnection, short circuit in blade pitch switch system

T/M

E02

q

q

E0312

Disconnection, short circuit in blade tilt switch system

T/M

E01

E0321

Disconnection in blade dual tilt selection solenoid system

T/M

E01

E0322

Short circuit in blade dual tilt selection solenoid system

T/M

E01

E0323

Disconnection in blade pitch selection solenoid system

T/M

E02

q

q

E0324

Short circuit in blade pitch selection solenoid system

T/M

E02

q

q

E0329

Abnormal hydraulic oil temperature

E0364

Disconnection in front pump oil pressure sensor system

T/M

E0365

Short circuit in front pump oil pressure sensor system

T/M

E0366

Disconnection in center pump oil pressure sensor system

T/M

E0367

Short circuit in center pump oil pressure sensor system

T/M

E0405

Disconnection, short circuit in fuel control dial system

ENG

CALL03

q

q

E0430

Engine oil: Abnormal oil pressure

ENG

CALL

E0431

Abnormal radiator coolant level

MON

CALL

E0432

Radiator coolant: Overheating

MON

E01

E0486

Abnormality in transmission controller model selection

T/M

CALL

E0501

Disconnection, short circuit in acceleration sensor system

S/T

E01

E0610

Disconnection in backup alarm relay system

T/M

E01

20-194 (6) 1

MON

q q q

q

D375A-5


Service code



Controller

User code E01

Warning lamp

Alarm buzzer

E0611

Short circuit in back-up alarm relay system

T/M

E0660

Disconnection in ACC signal drive relay system

S/T

E0661

Short circuit in ACC signal drive relay system

S/T

E0721

Disconnection, short circuit in tilt angle sensor system

S/T

CALL03

q

q

E0730

Simultaneous abnormality in steering potentiometer system (1)

S/T

CALL

q

q

E0731


S/T

CALL

q

q

E0732


S/T

CALL

q

q

E0733

Disconnection, short circuit in steering potentiometer 1 system

S/T

CALL03

q

q

E0734

Disconnection, short circuit in steering potentiometer 2 system

S/T

CALL03

q

q

E0735

Divergence in steering potentiometer system signal

S/T

CALL03

q

q

E0736

Disconnection, short circuit in brake potentiometer system

S/T

CALL03

q

q

E0750

Disconnection in right steering clutch ECMV system

S/T

CALL03

q

q

E0751

Short circuit in right steering clutch ECMV system

S/T

CALL03

q

q

E0752

Disconnection in left steering clutch ECMV system

S/T

CALL03

q

q

E0753

Short circuit in left steering clutch ECMV system

S/T

CALL03

q

q

E0754

Disconnection in right steering brake ECMV system

S/T

CALL

q

q

E0755

Short circuit in right steering brake ECMV system

S/T

CALL

q

q

E0756

Disconnection in left steering brake ECMV system

S/T

CALL

q

q

E0757

Short circuit in left steering brake ECMV system

S/T

CALL

q

q

E0760

Defective engagement of right steering clutch

S/T

CALL

q

q

E0761

Defective disengagement of right steering clutch

S/T

CALL

q

q

E0762

Defective engagement of left steering clutch

S/T

CALL

q

q

E0763

Defective disengagement of left steering clutch

S/T

CALL

q

q

E0764

Defective engagement of right steering brake

S/T

CALL

q

q

E0765

Defective disengagement of right steering brake

S/T

CALL

q

q

E0766

Defective engagement of left steering brake

S/T

CALL

q

q

E0767

Defective disengagement of left steering brake

S/T

CALL

q

q

E0779

Disconnection in sudden stop prevention solenoid system

S/T

CALL

q

q

E0780

Short circuit in sudden stop prevention solenoid system

S/T

CALL

q

q

E0781

Disconnection, short circuit parking lever switch system

S/T

CALL03

q

q

E0782

Mismatch of parking lever switch system signals

S/T

CALL03

q

q

E0930

Disconnection in engine speed sensor system

S/T

E01

E0931

Disconnection in engine speed sensor system

T/M

E01

E0932

Disconnection in transmission speed sensor system

S/T

E01

E0933

Disconnection in transmission speed sensor system

T/M

E01

E1939

Abnormality in J1939 communication system

S/T

E01

EC111

Abnormality in engine controller memory

ENG

CALL

q

q

EC112

Abnormality in timing rail actuator

ENG

CALL

q

q

D375A-5

20-195 (7) 1


Service code



Controller

User code

Warning lamp

Alarm buzzer

EC113

Abnormality in timing rail actuator system current

ENG

CALL03

q

q

EC115

Abnormality in engine speed sensor 2 system

ENG

CALL

q

q

EC116

Abnormality in timing rail pressure sensor system high level

ENG

CALL

q

q

EC117

Abnormality in timing rail pressure sensor system low level

ENG

CALL

q

q

EC118

Abnormality in fuel pump pressure sensor system high level

ENG

CALL03

q

q

EC119

Abnormality in fuel pump pressure sensor system low level

ENG

CALL03

q

q

EC121

Abnormality in engine speed sensor 1 system

ENG

CALL03

q

q

EC122

Abnormality in boost pressure sensor system high level

ENG

E01

EC123

Abnormality in boost pressure sensor system low level

ENG

E01

EC131

Abnormality in throttle sensor system high level

ENG

CALL

q

q

EC132

Abnormality in throttle sensor system low level

ENG

CALL

q

q

EC133

Abnormality in remote throttle sensor system high level

ENG

CALL

q

q

EC134

Abnormality in remote throttle sensor system low level

ENG

CALL

q

q

EC135

Abnormality in engine oil pressure sensor system high level

ENG

CALL03

q

q

EC141

Abnormality in engine oil pressure sensor system low level

ENG

CALL03

q

q

EC143

Abnormal drop in engine oil pressure

ENG

EC144

Abnormality in water temperature sensor system high level

ENG

CALL03

q

q

EC145

Abnormality in water temperature sensor system low level

ENG

CALL03

q

q

EC151

Abnormal rise in water temperature

ENG

EC153

Abnormality in intake air temperature sensor system high level

ENG

CALL03

q

q

EC154

Abnormality in intake air temperature sensor system low level

ENG

CALL03

q

q

EC221

Abnormality in atmospheric pressure sensor system high level

ENG

CALL03

q

q

EC222

Abnormality in atmospheric pressure sensor system low level

ENG

CALL03

q

q

EC234

Abnormal overspeed

ENG

EC254

Abnormality in fuel shut-off valve system voltage

ENG

E01

EC259

Abnormality in fuel shut-off valve

ENG

CALL

q

q

EC261

Rise in fuel temperature

ENG

EC263

Abnormality in fuel temperature sensor system high level

ENG

CALL03

q

q

EC265

Abnormality in fuel temperature sensor system low level

ENG

CALL03

q

q

EC316

Abnormality in fuel pump actuator system current

ENG

CALL03

q

q

EC318

Abnormality in fuel pump actuator

ENG

CALL03

q

q

EC346

Abnormal engine controller power down

ENG

CALL03

q

q

EC384

Abnormality in preheater control system

ENG

CALL03

q

q

EC423

In-range abnormality in timing rail pressure sensor system

ENG

CALL03

q

q

EC441

Abnormality in battery voltage system low level

ENG

E01

EC442

Abnormality in battery voltage system high level

ENG

E01

EC451

Abnormality in fuel rail pressure sensor system high level

ENG

CALL

q

q

EC452

Abnormality in fuel rail pressure sensor system low level

ENG

CALL

q

q

20-196 1

D375A-5


Service code



Controller

User code

EC455

Abnormality in fuel rail actuator system current

ENG

CALL

EC467

Abnormality in timing rail actuator control

ENG

CALL03

EC468

Abnormality in fuel rail actuator control

ENG

CALL03

EC514

Abnormality in fuel rail actuator

ENG

CALL

EC554

In-range abnormality in fuel rail pressure sensor system

ENG

CALL03

Warning lamp

z z z z z

Alarm buzzer

z z z z z

★ Letter at head of service code E: Code for problem detected at present P: Code for problem not detected at present ★ The controller in the Controller column indicates the controller or monitor panel responsible for the system check for the applicable code. MON: Monitor panel ENG: Engine controller T/M: Transmission controller S/T: Steering controller

D375A-5

20-197

1


PREPARATORY WORK WHEN TROUBLESHOOTING ELECTRICAL SYSTEM

PREPARATORY WORK WHEN TROUBLESHOOTING ELECTRICAL SYSTEM ★ When carrying out troubleshooting of the electric circuits related to the monitor panel, engine controller, transmission controller, and steering controller, use the following procedure to expose the applicable connector.

2. Engine controller 1) Remove engine left side cover (3).

1. Monitor panel 1) Remove cover (1). 2) Remove 2 mounting bolts, then pull monitor panel (2) out towards the operator’s seat.

2) Insert or connect the troubleshooting Tadapter to connector ECMA and connector ECMB of engine controller (4). ★ The connectors are held by screws, so loosen the screws before disconnecting. ★ When returning the connectors to their original position, tighten the screws to the specified torque. 3) Insert or connect the troubleshooting Tadapter to connector S01, connector S02, connector S03, connector CN1, connector CN2, and connector CN4 of the monitor panel.

20-198 1

Screw: 2.82 Nm {0.288 kgm}

D375A-5


3. Transmission controller 1) Remove cover (5).

2) Insert or connect the troubleshooting Tadapter to connector TMCN1, connector TMCN2, and connector TMCN3 of transmission controller (6). ★ If it is difficult to remove or install the connectors, remove the controller from the floor frame when carrying out the operation. ★ The connectors are held by screws, so loosen the screws before disconnecting. ★ When returning the connectors to their original position, tighten the screws to the specified torque.

D375A-5

Screw: 2.82 Nm {0.288 kgm}

PREPARATORY WORK WHEN TROUBLESHOOTING ELECTRICAL SYSTEM

4. Steering controller 1) Remove cover (5).

2) Insert or connect the troubleshooting Tadapter to connector NGICN1, connector NGICN2, and connector NGICN3 of steering controller (7). ★ If it is difficult to remove or install the connectors, remove the controller from the floor frame when carrying out the operation. ★ The connectors are held by screws, so loosen the screws before disconnecting. ★ When returning the connectors to their original position, tighten the screws to the specified torque.

Screw: 2.82 Nm {0.288 kgm}

20-199

1


PM CLINIC SERVICE

Pm CLINIC SERVICE Model

Serial No

Service meter

D375A-5

h

User name

Date of clinic

Serviceman

Blade

Specifications Rear attachment

Shoe width

Semi-U blade U-blade Dual tilt blade

Multi-shank ripper Variable giant ripper Counterweight

kg

610 mm 710 mm 810 mm

Operating conditions Quarry, mine Coal Gold Limestone

Construction Construction, civil engineering Roads Tunnels

Type of soil (specific gravity ) Rock Gravel Sand Clay

Type of work Dozing Side cutting Ripping Travel

% % % %

Existence of abnormalities Oil, water level check Engine coolant level Engine oil level Hydraulic oil level Engine coolant temperature Max. range

When necessary Damper case (

Power train Final drive

)

Ambient temperature

Power train oil temperature Max. range

Max. Min.

Height above sea level m Operator’s opinion

Visual check results

Service code history E

h

Content: E Content:

D375A-5

E

h

Content: h

E

h

Content:

20-201 1

TESTING AND ADJUSTING Pm-clinic

PM CLINIC SERVICE measuring points for D375A-5 (1/3)

q 2.

q 1.

q 3.

q 5.

q 4.

Reference items of measurement procedure (Pages) q1. Engine speed: Measuring engine speed (20-102 – 103 page) q2. Blow-by pressure: Measuring blow-by pressure (20-112 page) q3. Engine oil pressure: Measuring engine oil pressure (20-113 page) q4. Boost pressure: Measuring intake air pressure (boost pressure) (20-104 page) q5. Exhaust temperature: Measuring exhaust temperature (20-105 – 106 page)

20-202 (5) 1

D375A-5

TESTING AND ADJUSTING Pm-clinic

PM CLINIC SERVICE measuring points for D375A-5 (2/3)

Reference items of measurement procedure (Pages) q6. Items related to torque converter: Measuring power train oil pressure (20-123 – 131-1 page) q7. Items related to transmission: Measuring power train oil pressure (20-123 – 131-1 page) q8. Items related to steering: Measuring power train oil pressure (20-123 – 131-1 page)

D375A-5

20-203 (5) 1

203

Pm-clinic measuring points for D375A-5 (3/3)

Reference items of measurement procedure (Pages) q9. Items related to work equipment: Testing and adjusting work equipment oil pressure (20-140 – 142 page) q10. Items related to work equipment: Testing and adjusting control circuit main pressure (20-143 – 144 page)

20-203-1 (5)

D375A-5


Pm CLINIC CHECK SHEET

D375A-5

Date

Work order No.

Serial PMNoCLINIC SERVICE

Serviceman

Service meter h

Item

Engine speed

Measurement conditions Low idling Deceleration pedal depressed Decel High idling Torque converter stall

Unit

rpm

Torque converter stall + work equipment relief

Engine

Blow-by pressure

Engine at low idling

Engine oil pressure

kPa

Torque converter stall SAE10W

Engine at high idling

kPa


SAE15W-40 SAE30 Engine at high idling

Boost pressure Exhaust temperature

Torque converter stall Torque converter stall

kPa

No. 1, 2 & 3 No. 4, 5 & 6

Standard value for new machine Service limit value Measurement results Pass Fail

690 - 750 850 - 950 1870 - 1930 1470 - 1570

690 - 750 850 - 950 1870 - 1930

1240 - 1360 Max. 4.9 Min. 100 340 - 540 <3.5 - 5.5> Min. 120 380 - 590 <4.0 - 6.0> Min. 107

Min. 1430 Min. 1160 Max. 7.9 50 <0.5> 180 <1.8> 70 <0.7> 210 <2.1> Min. 93

Max. 680

700

When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to "Both steering clutches release mode (Co mode)". (Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.

Item


Unit


Service limit value

MPa

0.03 - 0.15 <0.3 - 1.5> 0.01 - 0.15 <0.1 - 1.5> 0-0 <0 - 0> 2.25 - 2.65 <23.0 - 27.0> 0.8 - 1.0 <8.0 - 10.0> 0.39 - 0.64 <4.0 - 6.5> 0-0 <0 - 0> 2.45 - 2.85 <25.0 - 29.0> 1.27 - 1.47 <13.0 - 15.0> 0-0 <0 - 0>

0.03 - 0.15 <0.3 - 1.5> 0.01 - 0.15 <0.1 - 1.5> 0-0 <0 - 0> 2.25 - 2.65 <23.0 - 27.0> 0.8 - 1.0 <8.0 - 10.0> 0.39 - 0.64 <4.0 - 6.5> 0-0 <0 - 0> 2.45 - 2.85 <25.0 - 29.0> 1.27 - 1.47 <13.0 - 15.0> 0-0 <0 - 0>

Unit


Service limit value

2.40 - 2.70 <24.5 - 27.5> 2.55 - 2.85 <26.0 - 29.0>

2.35 - 2.94 <24.0 - 30.0> 2.45 - 2.94 <25.0 - 30.0>

0.15 - 0.25 <1.5 - 2.5> 2.40 - 2.70 <24.5 - 27.5> 2.40 - 2.70 <24.5 - 27.5> 2.05 - 2.45 <21.0 - 25.0> 2.40 - 2.70 <24.5 - 27.5> 2.40 - 2.70 <24.5 - 27.5>

0.15 - 0.25 <1.5 - 2.5> 2.35 - 2.94 <24.0 - 30.0> 2.35 - 2.94 <24.0 - 30.0> 1.96 - 2.55 <20.0 - 26.0> 2.35 - 2.94 <24.0 - 30.0> 2.35 - 2.94 <24.0 - 30.0>

Inlet oil pressure Outlet oil pressure Engine at low idling Lock-up clutch pressure Torque converter

Stator clutch pressure Inlet oil pressure

Transmission: Neutral Oil temperature: 70-90

Outlet oil pressure Engine at high idling Lock-up clutch pressure Stator clutch pressure Lock-up clutch pressure

Transmission: F1 (Co mode) Stator clutch pressure Item

Raise engine speed, when lock-up lamp lights up

Measurement conditions Engine at low idling

Main relief pressure

Transmission

Lubricating oil pressure F clutch pressure R clutch pressure 1st clutch pressure 2nd clutch pressure 3rd clutch pressure

20-204 4 1

Engine at high idling Transmission: Neutral Engine at low idling Engine at high idling T/M: F3 (Co mode) T/M: R3 (Co mode) T/M: F1 (Co mode) T/M: F2 (Co mode) T/M: F3 (Co mode)

Engine at low idling Engine at low idling Engine at low idling Engine at low idling Engine at low idling

MPa

Measurement results Pass Fail

Measurement results Pass Fail

D375A-5


Pm CLINIC CHECK SHEET

D375A-5

Date

Work order No

Serial No PM CLINIC SERVICE

Serviceman

Service meter h


Item

Unit

Left clutch pressure Engine at low idling Steering clutch & brake

Left brake pressure Left clutch pressure

Transmission: Neutral Engine at high idling

Left brake pressure

MPa

Right clutch pressure Engine at low idling Right brake pressure Right clutch pressure

Transmission: Neutral Engine at high idling

Right brake pressure Brake performance

Engine at high idling, F2, brake actuated Measurement conditions

Item

Hydraulic components

Front pump

Ripper lift relief

Center pump

Blade tilt relief (single tilt only)

Front pump

Ripper lift relief

Center pump

Engine at high Blade tilt relief (single tilt only) idling

Control circuit main pressure

Neutral


MPa

q Pump oil pressure is standard value measured by monitor panel. Work equipment speed

Blade RAISE Single tilt (left

Dual tilt (left

g right)

g right)

Ripper tilt (in

g out)

Item

2.40 - 2.70 <24.5 - 27.5> 2.35 - 2.65 <24.0 - 27.0> 2.55 - 2.85 <26.0 - 29.0> 2.50 - 2.80 <25.5 - 28.5> 2.40 - 2.70 <24.5 - 27.5> 2.35 - 2.65 <24.0 - 27.0> 2.55 - 2.85 <26.0 - 29.0> 2.50 - 2.80 <25.5 - 28.5>

Min. 2.4 Min. 2.4 Min. 2.4 Min. 2.4 Min. 2.4 Min. 2.4 Min. 2.4 Min. 2.4

Machine must not move Standard value for new machine Service limit value Measurement results Pass Fail

18.6 - 20.6 <190 - 210>

Min. 17.6

18.6 - 20.6 <190 - 210>

Min. 17.6

19.6 - 21.6 <200 - 220>

Min. 18.6

19.6 - 21.6 <200 - 220>

Min. 18.6

4.22 - 4.80 <43 - 49>

Min. 3.9

When using an oil pressure gauge, see TESTING AND ADJUSTING STANDARD VALUES.


Item

Unit


Unit


Max.17


9 - 15


3.5 - 4.5

Max. 6


8 - 12

Max.16


Sec.


3-4

Max. 5

10 - 15

Max.16


4-5

Max. 6


8 - 12

Max.16


3-4

Max. 6


Unit


Hydraulic drift

Hydraulic oil temperature Blade lift cylinder

Engine stopped

Max. 100

Max. 150

Max. 15

Max. 30

mm/5 min. Ripper lift cylinder Item


Visual inspection of final drive drain plug

Unit

Engine stopped

Standard value for new machine Service limit value Measurement results Pass Fail There must be no excessive metal particles

Always fill in the record when repairing, adjusting, or replacing main parts. Date

D375A-5

Service meter

Repair record

Date

Service meter

Repair record

20-205 (5) 1

TESTING AND PmADJUSTING CLINIC

UNDERCARRIAGE CHECK SHEET Work order No.

Date

D375A-5

Serial PMNo CLINIC SERVICE

Serviceman

Service meter h

Measure the bushing temperature immediately after operations Left side of machine Measurement results

Pass Fail

Measurement results

Pass Fail

Right side of machine

Opening of track link

20-206 3 1

Left track

A: Clearance between links

Pin No.

1.4

Right track

A: Clearance between links

Pin No.

1.4

D375A-5

PM CLINIC SERVICE UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)


(Program form No.: SELA195001)

Komatsu Undercarriage Inspection

Y

Customer name: Address:

D375A-5

Model

Serial#

Location Soil condition Working condition

M

master i

Shoe width (mm)

Inspector

Shoe type (yyyy/m/d)

Wear %

New

SMR Hours on Rebuilt Parts:

Wet SINGLE

Wear type NORMAL Comments/Observation

RH 1121.2 1141.2 LH

master pin

Dealer

R

L=l/4

L

Work Order No Wet,AR,HD or Dry

Insp.Date(yy/mm/dd) New 100% Measured Wear mm LH 1121.2 1141.2

LINK PITCH

Equip#

SMR

280.30 285.30

M

l

1.3

RH 280.30 285.30

H

LINK HEIGHT1.3 BUSHIN G

d1

d D is the smallest ofd1,,d2 and,d3

d

LH

181.0

163.0

RH

181.0

163.0

LH

98.5

90.0

RH

98.5

90.0

LH

93.0

30.0

RH

93.0 210.0

30.0 185.0

210.0 210.0

185.0 185.0

210.0 23.5

185.0 36.0

23.5 23.5

36.0 36.0

LH

23.5 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 0.0

36.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 8.0

RH

0.0

8.0

New

Turned

New

Turned

1

GROUSER HIGHT H

0

LH

CARRIER CARRIER Front

RH

D

LH Rear

1.3

RH LH

IDLER IDLER Front

RH

H

LH Rear

1.3

TRACK ROLLER

D h2

h1

D=2(h1-

1.3 SPROCKET H is the smallest of h1,h2,h3 h3

h1 h2 1.3

RH 1

LH

2

LH

3

LH

4

LH

5

LH

6

LH

7

LH

8

LH

9

LH

10

LH

1

RH

2

RH

3

RH

4

RH

5

RH

6

RH

7

RH

8

RH

9

RH

10

RH

Remarks:

D375A-5

20-207 (6) 1

PM CLINIC SERVICE UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)


(Program form No.: SELA195001)

Komatsu Undercarriage Inspection

Y

Customer name: Address:

D375A-5

Model

Serial#

Location Soil condition Working condition

M

master i

Shoe width (mm)

Inspector

Shoe type (yyyy/m/d)

Wear %

New

SMR Hours on Rebuilt Parts:

Wet SINGLE

Wear type IMPACT Comments/Observation

RH 1121.2 1133.2 LH

master pin

Dealer

R

L=l/4

L

Work Order No Wet,AR,HD or Dry

Insp.Date(yy/mm/dd) New 100% Measured Wear mm LH 1121.2 1133.2

LINK PITCH

Equip#

SMR

280.30 283.30

M

l

1.3

RH 280.30 283.30

H

LINK HEIGHT1.3 BUSHIN G

d1

d D is the smallest ofd1,,d2 and,d3

d

LH

181.0

163.0

RH

181.0

163.0

LH

98.5

92.5

RH

98.5

92.5

LH

93.0

30.0

RH

93.0 210.0

30.0 185.0

210.0 210.0

185.0 185.0

210.0 23.5

185.0 36.0

23.5 23.5

36.0 36.0

LH

23.5 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 270.0 0.0

36.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 8.0

RH

0.0

8.0

New

Turned

New

Turned

1

GROUSER HIGHT H

0

LH

CARRIER CARRIER Front

RH

D

LH Rear

1.3

RH LH

IDLER IDLER Front

RH

H

LH Rear

1.3

TRACK ROLLER

D h2 h1

D=2(h1-

1.3 SPROCKET H is the smallest of h1,h2,h3 h3

h1 h2

1.3

RH 1

LH

2

LH

3

LH

4

LH

5

LH

6

LH

7

LH

8

LH

9

LH

10

LH

1

RH

2

RH

3

RH

4

RH

5

RH

6

RH

7

RH

8

RH

9

RH

10

RH

Remarks:

20-208 (6) 1

D375A-5

TROUBLESHOOTING

MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

TROUBLESHOOTING Points to remember when troubleshooting .............................................................................................. 20-302 Sequence of events in troubleshooting ................................................................................................... 20-303 Points to remember when carrying out maintenance .............................................................................. 20-304 Checks before troubleshooting ............................................................................................................. 20-307-5 Classification of and procedure for troubleshooting ................................................................................ 20-308 Connector allocation drawing and electrical circuit diagrams for each system ....................................... 20- 311 Connection table for connector pin numbers ........................................................................................... 20-330 T-Branch box and T-Branch table ............................................................................................................ 20-353 Troubleshooting when service code is displayed (Service code) ............................................................ Troubleshooting of electrical system (E-mode) ....................................................................................... Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................. Troubleshooting of the engine body (S-mode) ........................................................................................

D375A-5

20-401 20-601 20-701 20-801

20-301 (7) 1

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING ¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. ¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.

¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.

¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

2.

3.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine. 2) Check the CHECKS BEFORE STARTING items.

20-302 1

3) 4)

4.

5.

6.

Other inspection items. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. fl When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. fl The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

D375A-5

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop

Jobsite TEW00180

TEW00181

Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. • Name of customer • Type, serial number of machine • Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history, details of maintenance, etc.

Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes.

Step Repair at jobsite Hurray ! It's repalred

Step 3 Preparation of troubleshooting tools TEW00185

1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. • T-adapter • Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.

Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take

TEW00186

1) Before starting troubleshooting, locate and repair simple failures. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual, select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.

TEW00187

Step 6 Re-enacting failure •

Step 4 Go to jobsite

Drive and operate the machine to confirm the condition and judge if there is really a failure.

Step 5 Ask operator questions to failure.

TEW00189

confirm details of

Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure? TEW00190

D375A-5

20-303

1

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1. POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191

Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

1

2

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

20-304

1

D375A-5

TROUBLESHOOTING


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

TEW00194

4 High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. fl When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. fl If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

D375A-5

TEW00195

TEW00196

20-305

1

TROUBLESHOOTING


2) Removing, installing, and drying connectors and wiring harnesses ·

Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. ★ Never pull with one hand.

1

2

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

TBW00484

3

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

TEW00198

20-306

1

D375A-5

TROUBLESHOOTING

·

Connecting connectors Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. ★ If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the 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. ★ If there is any damage or breakage, replace the connector.

1

2

3

4 •


Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. ★ If the connector cannot be corrected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

TEW00200

TBW00487

Since the DT 8-pole and 12-pole heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. 1. Mail connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c

D375A-5

20-307

1

TROU TROUBLESHOOTING

•


Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows: 1 Disconnect the connector and wipe off the water with a dry cloth. ★ If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.

2 Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. ★ Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

3 Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble.

20-307-1 4

D375A-5

TROUBLESHOOTING


3) Handling control box 1 The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2 Do not open the cover of the control box unless necessary.

3 Do not place objects on top of the control box. 4 Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5 During rainy weather, do not leave the control box in a place where it is exposed to rain.

6 Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) 7 Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

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

D375A-5

20-307-2 4

TROUBLESHOOTING


5. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger or dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

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

20-307-3 4

D375A-5

TROUBLESHOOTING


5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

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

D375A-5

20-307-4 4

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Lubricating oil, coolant Hydraulic, Electrical mechanical equipment equipment

Action

Check fuel level

—

Add fuel

2.

Check for impurities in fuel

—

Clean, drain

3.

Check hydraulic oil level

—

Add oil

4.

Check oil level in damper case

—

Add oil

5.

Check power train oil level

—

Add oil

6.

Check engine oil level (engine oil pan level)

—

Add oil

7.

Check coolant level

—

Add water

8.

Check dust indicator for clogging

—

Clean or replace

9.

Check travel of brake pedal

—

Adjust

10. Check for looseness, corrosion of battery terminal, wiring

—

Tighten or replace

11. Check for looseness, corrosion of alternator terminal, wiring

—

Tighten or replace

12. Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

13. Check for abnormal noise, smell

—

Repair

14. Check for oil leakage

—

Repair

15. Carry out air bleeding

—

Bleed air

20 - 30 V

Replace

17. Check battery electrolyte level

—

Add or replace

18. Check for discolored, burnt, exposed wiring

—

Replace

19. Check for missing wiring clamps, hanging wire

—

Repair

20. Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals)

—

Disconnect connector

21. Check for water on wiring 22. Check alternator voltage (engine running at 1/2 throttle or above) 23. Check operating sound of battery relay (starting switch ON, OFF)

20-307-5 4

Judgement Value

1.

16. Check battery voltage (engine stopped)

Electrical equipment

Other check items

Checks before starting

Item

and dry

—

Replace

After running for several minutes: 27.5 - 29.5 V

Replace

—

Replace

D375A-5

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING Classification of troubleshooting Mode Service code

Contents Troubleshooting when service code is displayed

E mode

Troubleshooting for electric system

H mode

Troubleshooting for hydraulic and mechanical systems

S mode

Troubleshooting of the engine body

Procedure for troubleshooting If a possible fault is detected in the machine, narrow the troubleshooting Nos. according to the following procedure, then go to the related troubleshooting section. 1. Procedure for troubleshooting when user code is displayed on monitor panel: If a user code is displayed on the monitor panel, display the service code in the service code display mode of the monitor panel (EMMS). Carry out the troubleshooting for the displayed "service code". ★ The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning the starting switch ON, however.) ★ If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corresponding fault has been repaired. (For the method of reproducing the service code, see the troubleshooting for the service code.) 2. Procedure for troubleshooting when service code is recorded: If a user code is not displayed on the monitor panel, check the service code in the service code display mode of the monitor panel (EMMS). If the service code is recorded, carry out the troubleshooting for that "service code". ★ The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning the starting switch ON, however.) ★ If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corresponding fault has been repaired. (For the method of reproducing the service code, see the troubleshooting for the service code.) 3. Procedure for troubleshooting when user code is not displayed and service code is not recorded If a service code is not recorded on the monitor panel (EMMS), the machine may have a fault in its electric, hydraulic, or mechanical system and may not able to detect it by the self-diagnosis. In this case, check the possible fault again and select the related faults from the table of "Possible faults and troubleshooting Nos. for them" and carry out troubleshooting for the related items in the "E mode", "H mode" or "S mode".

20-308 (5) 1

D375A-5

TROUBLESHOOTING


Phenomena considered to be failures and troubleshooting No. No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Phenomena considered to be failures

Troubleshooting Service code

User code, service code related User code is displayed on monitor panel Service code is displayed in service code display mode ! Engine related Engine starting is poor (always takes time to start) Engine does not turn Engine turns but no exhaust Engine does not start smoke comes out Exhaust smoke comes out but engine does not start Engine pickup is poor (response is poor) Engine stops during operation Engine turns irregularly (hunting) Lack of output or no power Exhaust color is black (incomplete combustion) Oil consumption is excessive or exhaust color is blue Oil quickly becomes dirty Fuel consumption is excessive Oil mixed in cooling water, blows back, water level goes down Oil level rises There is abnormal noise Excessive vibration Preheating does not work Power train related No power (no drawbar pull) Does not travel (when in 2nd or 3rd) Does not move off in any speed range Moves in only one direction (forward or reverse) Excessive time lag when shifting gear or shifting between forward and reverse Cannot turn (steering) Turns in only one direction (steering) Overruns when turning (steering) Brakes do not work Torque converter does not lock up Torque converter oil overheats Work equipment related All work equipment speeds are slow No work equipment moves Blade RAISE speed is slow or lacks power Blade LOWER speed is slow or lacks power Ripper RAISE speed is slow or lacks power Ripper LOWER speed is slow or lacks power Excessive hydraulic drift of blade lift Excessive hydraulic drift of blade tilt Excessive hydraulic drift of ripper lift Ripper pin-puller cylinder does not work Blade pitch does not work Abnormal noise from around hydraulic pump

D375A-5

E mode

H mode

S mode

Check service code

S-1 S-2 1)

E-1

S-2 2) S-2 3) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-13 S-15 S-16 E-2 H-1 H-2 H-3 H-4

S-6

H-5 H-6 H-7 H-8 H-9 H-10 H-11

E-3

H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23

20-309 (5) 1

TROUBLESHOOTING

No.

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61


Phenomena considered to be failures

Troubleshooting Service code

E mode

H mode

S mode

Monitor panel related (operator mode: normal screen) Nothing lights up on monitor panel when starting switch is E-4 turned ON All lamps on monitor panel stay on and do not go out when E-5 starting switch is turned ON Basic check items flash when starting switch is turned ON E-6 Caution items flash when engine is running E-7 Warning items flash when engine is running E-8 Preheating lamp does not light up E-9 Engine water temperature gauge display is not normal E-10 Torque converter oil temperature gauge display is not normal E-11 Fuel gauge display is not normal E-12 Travel speed, engine speed, shift mode display is not normal E-13 Service meter display is not normal E-14 Switch module cannot be operated E-15 Warning lamp does not flash or does not go out E-16 Alarm buzzer does not sound or does not stop E-17 Alarm buzzer cannot be canceled E-18 Monitor panel related (service mode: special for function screen) Does not switch to service mode E-19 Others Backup alarm does not sound E-20 Panel night lighting, front lamp, working lamp, rear lamp do E-21 not light up Air conditioner does not work E-22

20-310 (5) 1

D375A-5

CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM

TROUBLESHOOTING

CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM TABLE OF CONNECTORS Conne ctor No. 101 1939 201 202 203 204 205 206 206 212 214 215 216 217 218 219 221 223 224 241 242 243 244 262 263 264 265 266 351 360 369 375 405 422 423 431 452 453 653 701 702 703

Connecto No. of r type pins 18-14 DT DT DT DT Terminal DT Terminal DT-B DT-C DT-D DT

DT DT DT DT DT DT DT X X DT Terminal Terminal DT DT DT DT DT DT DT DT DT DT Terminal Terminal Terminal

D375A-5

14 9 4 4 2 2 1 4 – 3 12 12 12 2 4 4 2 2 2 12 2 2 2 2 2 4 1 1 2 6 6 4 2 2 2 3 2 2 2 1 1 1

Place of use Intermediate connector (Engine side connector No. VHL)

Engine controller communication connector Intermediate connector Intermediate connector Right front lamp Left front lamp Horn Intermediate connector GND Buzzer cancel switch Intermediate connector Intermediate connector Intermediate connector Alarm buzzer Rear lamp switch Front lamp & working lamp switch Left working lamp Left rear lamp Ripper pin-puller solenoid valve Intermediate connector Right working lamp Right rear lamp Backup alarm Horn switch Ripper pin-puller switch Intermediate connector Horn switch Horn switch Air conditioner compressor Window washer motor (left rear) Window washer motor (right front) Warning lamp Radiator water level switch Intermediate connector Fuel level sensor Intermediate connector Hydraulic oil temperature sensor Torque converter oil temperature sensor Torque converter lock-up solenoid valve Battery relay terminal BR Battery relay terminal M Battery relay terminal B

Address 3-dimensional M circuit E circuit T circuit S circuit drawing F-1 H-7 G-2 I-4 I-8 C-1 C-1 J-8 A-4 K-8 A-5 K-9 D-1 K-8 B-2 E-1 J-7 N-4 L-3 N-6 B-2 F-8 N-3 C-8 D-7 N-2 C-7 E-7 N-2 C-3 K-6 F-7 D-7 P-1 B-3 N-5 B-2 N-6 B-2 G-2 I-8 J-4 I-8 I-3 D-8 E-8 J-8 A-5 E-8 J-9 J-9 K-9 Q-8 R-8 R-8

Y-3 K-5 J-4 N-5 B-2 K-5 I-4 K-8 e-5 h-3 e-5

B-3 K-9 I-8 I-8 J-8 E-8 F-8

G-3

K-8

20-311

1


TROUBLESHOOTING

★ The address shows the approximate position in the connector 3-dimensional allocation drawing and the circuit diagrams for each system Conne Connecto No. of ctor r type pins No. 1-pin 800 1 connector 1-pin 801 1 connector AAPR 3 ADH 4 ARC X 2 ASD 4 BB1 5 BB2 5 BB3 5 BKA 5 BRK DT 3 CAN 12 CAN 3 CB1 2 CB2 2 CB3 2 CB4 2 CB5 2 CB6 2 CLTP 2 CN1 AMP 12 CN2 AMP 8 CN4 M 2 1-pin CN-1 1 connector CN-2 Terminal 1 CN-3 Terminal 1 CN-4 4 CN-5 Terminal 1 CN-6 Terminal 1 CN-9 6 CN-10 9 CN-11 6 CN-12 6 CN-13 6 CN-14 6 CN-15 2 CN-17 4 CN-18 4 CN-19 M 4 CN-20 DT 1 CN-21 DT 1 CN-22 Terminal 2 CN-23 4 CN-24 2 1-pin CN-25 1 connector

20-312

1

Place of use

Address 3-dimensional M circuit E circuit T circuit S circuit drawing

Spare power source

N-9

Spare power source

N-9

Atmospheric pressure sensor Heater switch Air conditioner condenser Auto shift down switch Front lamp relay Front lamp relay Working lamp relay Backup alarm relay Brake potentiometer Intermediate connector CAN Terminal resistance Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Engine water temperature sensor Monitor panel Monitor panel Monitor panel

C-8 N-4 H-3 N-4 M-8 M-7 M-8 M-8 Q-1 d-4 W-7 M-9 M-9 M-9 M-9 M-8 M-8 Y-6 O-7 P-7 O-6

Lamp outlet connector [cab]

H-9

Rear right speaker [cab] Rear right speaker [cab] Rear wiper motor [cab] Rear left speaker [cab] Rear left speaker [cab] Front wiper motor [cab] Radio [cab] Left wiper switch [cab] Front wiper switch [cab] Right wiper switch [cab] Rear wiper switch [cab] Lamp switch [cab] Right door wiper motor [cab] Left door wiper motor [cab] Intermediate connector Cab power source connector [cab] Cab power source connector [cab] Cigar lighter [cab] Converter [cab] Intermediate connector [cab]

H-9 H-9 G-9 G-9 G-9 E-8 I-9 E-9 E-9 F-9 F-9 F-9 E-8 I-7 G-2 T-1 T-1 K-6 G-9 K-6

Rotating lamp outlet connector [cab]

I-9

G-8

F-8 H-1 I-1 I-3 D-8 E-8 K-6

F-1

L-3 I-2

J-1 J-1 J-1 J-3 K-3 A-6 A-5 A-6

H-1

L-5 F-8

H-2

I-2

E-9

D375A-5

TROUBLESHOOTING

Conne ctor No. CN-26 CN-81 DCL DL1 DLCO DLK ECMA ECMB EG1 EG2 ESD F1T F2T F3T FD1 FD5 FD6 FFT FLB FLC FLTP FRB FRC FRT FS1 FS2 FS4 FSB FSOFSO+ GND GND GND GND1 GND4 HEAT IMPR IMTP JC01 JC02 JC03 JC04 JC11 JC12 JC13

Connecto No. of r type pins

DT DT HD10-6

24-21 24-31 DT DT DT DT 24-23 DT-A 24-31 DT DT DT DT DT DT – – – 24-31 Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT

D375A-5

2 2 3 6 6 6 40 40 21 31 3 2 2 2 23 12 31 2 2 2 2 2 2 2 – – – 31 1 1 – – – – – 2 3 2 6 8 8 8 6 6 8


Place of use Rotating lamp switch [cab] Room lamp [cab] Decelerator pedal potentiometer Intermediate connector Data link crossover connector Intermediate connector Engine controller Engine controller Intermediate connector (Engine side connector No. POW) Intermediate connector (Engine side connector No. SIG)

Connector for option 1st clutch ECMV (fill switch) 2nd clutch ECMV (fill switch) 3rd clutch ECMV (fill switch) Intermediate connector Intermediate connector Intermediate connector F clutch ECMV (fill switch) Left steering brake ECMV (fill switch) Left steering clutch ECMV (fill switch) Fuel temperature sensor Right steering brake ECMV (fill switch) Right steering clutch ECMV (fill switch) F clutch ECMV (fill switch) Fuse box 1 Fuse box 2 Fuse box 4 Intermediate connector Fuel shut off valve Fuel shut off valve GND GND (engine) GND (engine) GND GND Intermediate connector Boost pressure sensor Intake air temperature sensor Junction connector Junction connector Junction connector Junction connector Junction connector Junction connector Junction connector

Address 3-dimensional M circuit E circuit T circuit S circuit drawing F-9 E-8 R-1 K-3 N-1 K-4 E-7 d-6 Q-1 L-4 d-2 K-6 B-8 b-8 K-5 B-5 K-4 L-8 d-5 F-5 J-7 d-5 I-5 F-5 I-4 J-6 O-7 g-7 K-6 g-7 K-5 f-6 K-5 W-3 G-6 H-5 H-5 G-7 V-2 I-2 H-5 G-2 J-6 W-4 G-5 H-4 H-4 G-6 I-3 K-7 I-3 K-4 h-7 K-5 a-7 F-8 J-7 K-3 h-7 K-4 g-7 K-6 N-9 J-2 L-5 I-2 H-2 N-9 J-2 O-9 J-2 L-4 I-1 H-1 S-1 G-4 K-5 H-3 G-3 Y-5 B-9 Y-5 B-9 C-7 Y-3 C-9 Y-3 C-9 H-3 J-4 G-5 I-2 I-5 A-2 J-8 d-5 I-6 H-8 Z-6 H-8 Z-7 G-8 d-3 K-5 C-9 c-3 K-5 C-9 a-2 D-9 d-2 E-9 b-2 E-1 b-2 D-1 c-2 C-1

20-313

1


TROUBLESHOOTING

Conne Connecto No. of Place of use ctor r type pins No. JC14 8 Junction connector JC15 KEY

M

LINK LPP

DT

Address 3-dimensional draw ing c-3

K-7

E-1

L-4

L-9

Junction connector

d-3

K-7

F-1

L-3

O-7

B-3

L-8

E-8

6

Data link crossover connector

d-4

Work equipment large pump pressure sensor

D-8

Air conditioner unit

O-1

NGICN1

24

Steering controller

U-8

NGICN2

40

Steering controller

T-9

NGICN3

40

Steering controller

T-9

OLPR

S circuit

Starting sw itch

3

DT

T circuit

6

6

NSF

E circuit

6

M26

NSW

M circuit

K-8 D-2

I-2 I-2

E-2

C-1 C-1

A-7 A-4

5

Neutral safety relay

M-7

H-1

I-3

Travel lock sw itch

O-9

G-2

G-1

3

Engine oil pressure sensor

Y-3

K-3

DT

6

Work equipment knob sw itch

Q-8

P04

DT-A

2

Intermediate connector

D-8

PAS

DT

4

Tilt angle sensor

F-2

PL1

24-23

23


W-2

E-7

H-6

PL2

24-31

31


W-3

E-7

H-7

PL3

DT-B

E-7


V-2

3

Fuel pump pressure sensor

Z-2

PPR

5

Pump pow er relay

M-7

E-2 H-8

H-7

PRE

DT

2

Prelube

O-7

DT

2

Prelube

O-8

3

Fuel pump actuator

Z-2

1


U-2

K-3

L-2

3

Fuel rail actuator

Y-3

I-1

J-8

PWR

DT

RAIL RHR

5

Preheater relay

N-7

RHT

DT

3

Electrical intake air heater timer

O-8

RPD

DT

2

Ripper LOWER oil pressure sw itch

Q-8

RPR

?

3

Fuel rail pressure sensor

d-3

RPU

DT

2

Ripper RAISE oil pressure sw itch

R-8

G-2

I-2

F-1 I-8 E-1

DT

2

Ripper tilt in oil pressure

R-8

AMP

12

Monitor panel

P-7

A-8

S02

M

2

Monitor panel

O-6

A-7

F-1

S03

AMP

16

Monitor panel

P-7

A-8

S13

DT-A

12


N-3

C-4

S1T

DT

2

1st clutch ECMV (solenoid valve)

F-6

3

SSC initial setting jumper

O-6

B-2

Terminal

6

Service sw itch

P-1

C-5

D-9 D-9 E-7

E-9

X

4

Data w rite connector (steering controller)

U-8

S26

X

4

Data w rite connector (transmission controller)

V-8

A-1

S2T

DT

2

2nd clutch ECMV (solenoid valve)

g-7

K-6

S3T

DT

K-5

2

3rd clutch ECMV (solenoid valve)

f-6

5

Engine controller pow er relay

N-7

SFT

DT

2

F clutch ECMV (solenoid valve)

h-3

SLB

DT

2

Left steering brake ECMV (solenoid valve)

J-5

20-314 (7) 1

E-7

K-6

S25

SDR

H-2

L-4

RTI

S24

I-2 J-8

S01

S21

G-5

I-8

PRS PUMP

K-2

G-8

P03

12

A-9

C-1

3

PMPR

F-8

B-9

A-1

K-1 K-7 K-4

D375A-5

TROUBLESHOOTING

Conne Connecto No. of ctor r type pins No. SLC DT 2 SOL1 DT 2 SOL2 DT 2 SP1 2 SP2 2 SPP DT 3 SRB DT 2 SRC DT 2 SRT DT 2 SS3 DT 3 STB DT 2 SX8 Terminal – TIMG 3 TL1 24-23 23 TLS DT 2 TM1 DT 2 TMCN1 24 TMCN2 40 TMCN3 40 TMV 24-23 23 TPR 3 TRS DT 2 USB DT 1 V23 DT 3 VHMS 2

D375A-5


Address 3-dimensional M circuit E circuit T circuit S circuit drawing Left steering clutch ECMV (solenoid valve) I-7 K-5 Solenoid valve for pitch B-6 K-9 Solenoid valve for dual C-7 K-9 Engine speed sensor (master) d-6 K-4 E-8 Engine speed sensor (backup) d-6 K-3 F-8 Work equipment small pump pressure sensor E-8 K-8 Right steering brake ECMV (solenoid valve) J-6 K-4 Right steering clutch ECMV (solenoid valve) h-7 K-5 F clutch ECMV (solenoid valve) g-6 K-7 Acceleration sensor F-2 H-8 Sudden stop valve solenoid I-7 K-3 GND H-3 Timing rail actuator a-8 K-8 Fuel control dial, full monolever unit S-1 D-2 C-8 Blade tilt left oil pressure switch Q-8 F-1 Transmission outlet speed sensor J-7 K-8 K-6 Transmission controller W-5 E-2 A-9 D-1 Transmission controller V-7 E-2 J-2 A-7 E-1 Transmission controller V-8 A-4 Intermediate connector g-7 J-7 Timing rail pressure sensor d-4 I-8 Blade tilt right oil pressure sensor Q-7 F-1 Intermediate connector U-1 K-2 I-1 H-2 CAN terminal resistance W-6 F-1 J-2 A-1 F-1 Intermediate connector O-9 Place of use

20-315

1

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING


20-316

1

D375A-5

TROUBLESHOOTING

D375A-5


20-317

1

TROUBLESHOOTING

20-318

1


D375A-5

TROUBLESHOOTING

D375A-5


20-319

1

TROUBLESHOOTING

20-320

1


D375A-5

TROUBLESHOOTING

D375A-5


20-321

1

TROUBLESHOOTING

CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)


20-322

1

D375A-5

TROUBLESHOOTING


★ This circuit diagram has been made by extracting the monitor panel system, engine preheating, starting, and charging system, light system, and communication network system from the overall electrical circuit diagram.

D375A-5

20-323

1

TROUBLESHOOTING

CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)


20-324

1

D375A-5

TROUBLESHOOTING


★ This circuit diagram has been made by extracting the engine controller system from the overall electrical circuit diagram.

D375A-5

20-325

1

TROUBLESHOOTING

CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)


20-326

1

D375A-5

TROUBLESHOOTING


★ This circuit diagram has been made by extracting the transmission controller system from the overall electrical circuit diagram.

D375A-5

20-327

1

TROUBLESHOOTING

CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)


20-328

1

D375A-5

TROUBLESHOOTING


★ This circuit diagram has been made by extracting the steering controller system from the overall electrical circuit diagram.

D375A-5

20-329

1

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. X Type Connector

Number of Pins

Male (Female housing)

Female (Male housing)

T-adapter Part Number

1

Part number: 08055-00181


799-601-7010

2

799-601-7020



3

799-601-7030



4

799-601-7040



—

Terminal part number: 79A-222-3370 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

Terminal part number: 79A-222-3390 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

—

—

Terminal part number: 79A-222-3380 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red

Terminal part number: 79A-222-3410 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red

—

20-330

1

D375A-5

TROUBLESHOOTING

Number of Pins


SWP Type Connector Male (Female housing)


6

799-601-7050



8

799-601-7060



12

799-601-7310



14

799-601-7070


D375A-5



20-331

1

TROUBLESHOOTING


SWP Type Connector

Number of Pins



16


799-601-7320



—

Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black

—

—

Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red

Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red

—

20-332

1

D375A-5

TROUBLESHOOTING


M Type Connector

Number of Pins




1



799-601-7080

2

799-601-7090



3

799-601-7110



4

799-601-7120



6

799-601-7130



8

799-601-7340


D375A-5


20-333 (5) 1

TROUBLESHOOTING

Number of Pins


S Type Connector Male (Female housing)


8

799-601-7140



10 (white)

799-601-7150



12 (white)

799-601-7350



16 (white)

799-601-7330


20-334 1



D375A-5

TROUBLESHOOTING

Number of Pins


S Type Connector Male (Female housing)


10 (blue)

—

—

—

12 (blue)

799-601-7160



16 (blue)

799-601-7170


D375A-5



20-335

1

TROUBLESHOOTING

Number of Pins


MIC Type Connector Male (Female housing)



7

Body part number: 79A-222-2640 (Quantity: 5 pieces)


—

11



—

5

799-601-2710



9

799-601-2950



13

799-601-2720


20-336

1


D375A-5

TROUBLESHOOTING

Number of Pins


MIC Type Connector Male (Female housing)


17

799-601-2730



21

D375A-5


799-601-2740



Terminal part number: 79A-222-2770 (Quantity: 50 pieces)

Terminal part number: 79A-222-2760 (Quantity: 50 pieces)

—

20-337

1

TROUBLESHOOTING

Number of Pins


AMP040 Type Connector Male (Female housing)


8


799-601-7180

—

Housing part number: 79A-222-3430 (Quantity: 5 pieces)

12

799-601-7190

—


16

799-601-7210

—


20

799-601-7220

—


★ Terminal part number: 79A-222-3470 (for all numbers of pins).

20-338

1

D375A-5

TROUBLESHOOTING

Number of Pins


AMP070 Type Connector Male (Female housing)


10

799-601-7510

—

Part number: 7821-92-7330

12

799-601-7520

—


14

799-601-7530

—


18

799-601-7540

—


20

799-601-7550

—

D375A-5



20-339 (7) 1 2

TROUBLESHOOTING

Number of Pins


L Type Connector Male (Female housing)


2

—

—

Number of Pins

—

PA Type Connector Male (Female housing)


9

—

BENDIX (MS) Type Connector Male (Female housing)


10

1


799-601-3460

—

20-340


—

—

Number of Pins


—

D375A-5

TROUBLESHOOTING

Number of Pins


KES1 Automobile Type Connector Male (Female housing)


2

—

Part number: 08027-10210 (Natural color) 08027-10220 (Black)


3

—



4

—



6

—


D375A-5



20-341

1

TROUBLESHOOTING

Number of Pins


KES1 Automobile Type Connector Male (Female housing)


8

—


20-342

1



D375A-5

TROUBLESHOOTING

Number of Pins


F Type Connector Male (Female housing)


4

—

—

Number of Pins

—

Connector for relay (Socket) Male (Female housing)


5


799-601-7360

—

—

6

799-601-7370

—

D375A-5


—

20-343 (6) 1

TROUBLESHOOTING


[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)


799-601-9210

18-8 (1)

Part number: 08191-11201, 08191-11202 08191-11205, 08191-11206 Pin (female terminal)

Part number: 08191-14101, 08191-14102 08191-14105, 08191-14106 Pin (male terminal)

799-601-9210



799-601-9220

18-14 (2)



799-601-9220

Part number: 08191-22201, 08191-22202 08191-22205, 08191-22206

20-344 1

Part number: 08191-23101, 08191-23102 08191-23105, 08191-23106

D375A-5

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)



799-601-9230

18-20 (3)

Part number: 08191-31201, 08191-31202 Pin (female terminal)

Part number: 08191-34101, 08191-34102 Pin (male terminal)

799-601-9230



799-601-9240

18-21 (4)



799-601-9240

Part number: 08191-42201, 08191-42202

D375A-5

Part number: 08191-43101, 08191-43102

20-345 1

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)



799-601-9250

24-9 (5)



799-601-9250



799-601-9260

24-23 (6)



799-601-9260

Part number: 08191-62201, 08191-62202 08191-62205, 08191-62206

20-346 1 (6)

Part number: 08191-63101, 08191-63102 08191-63105, 08191-63106

D375A-5

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)



799-601-9270

24-21 (7)

Part number: 08191-71201, 08191-71202 08191-71205, 08191-71206

Part number: 08191-74101, 08191-74102 08191-74105, 08191-74106


Pin (male terminal)

799-601-9270

Part number: 08191-72201, 08191-72202 08191-72205, 08191-72206

Part number: 08191-73102, 08191-73102 08191-73105, 08191-73106

Pin (male terminal)


799-601-9280

24-22 (8)

Part number: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-80206 Pin (female terminal)

Part number: 08191-84101, 08191-84102, 08191-84103, 18191-84104, 08191-84105, 08191-84106 Pin (male terminal)

799-601-9280

Part number: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206

D375A-5

Part number: 08191-83101, 08191-83102, 08191-83103, 18191-83104, 08191-83105, 08191-83106

20-347

1

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)



799-601-9290

24-31 (9)

Part number: 08191-91203, 08191-91204 08191-91205, 08191-91206

Part number: 08191-94103, 08191-94104 08191-94105, 08191-94106


Pin (male terminal)

799-601-9290

Part number: 08191-92203, 08191-92204 08191-92205, 08191-92206

20-348

1

Part number: 08191-93103, 08191-93104 08191-93105, 08191-93106

D375A-5

TROUBLESHOOTING


[The pin No. is also marked on the connector (electric wire insertion end)] Number of Pins

DT Series connector Body (plug)

Body (receptacle)

2

799-601-9020

Part number: 08192-12200 (normal type) 08192-22200 (fine wire type)


3

799-601-9030



4

799-601-9040



6

799-601-9050


D375A-5



20-349 1

TROUBLESHOOTING



DT Series connector Body (plug)

Body (receptacle)

8GR:799-601-9060 8B :799-601-9070 8G :799-601-9080 8BR :799-601-9080

8

Part number: 08192-1820 ! (normal type) 08192-2820 ! (fine wire type)


12GR:799-601-9110 12B :799-601-9120 12G :799-601-9130 12BR :799-601-9140

12


20-350 (5) 1



D375A-5

TROUBLESHOOTING



DTM Series connector Body (plug)

Body (receptacle)

2

799-601-9010


Number of Pins


DTHD Series connector Body (plug)

Body (receptacle)

1


—

Part number: 08192-31200 (Contact size #12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)

D375A-5


Part number: 08192-31100 (Contact size #12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)

20-351 1

TROUBLESHOOTING


[The pin No. is also marked on the connector (electric wire insertion end)] No. of pins

DRC26 Series connector Body (plug)

Body (receptacle)

24

799-601-9360

—

Part No.: 7821-93-3110

40 (A)

799-601-9350

—

Part No.: 7821-93-3120

40 (B)

799-601-9350

—

20-352 (7) 1

T-adapter Part No.

Part No.: 7821-93-3130

D375A-5

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE


D375A-5

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M S S

799-601-2900

799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 799-601-7140 799-601-7150

No. of pins

799-601-2800

Connector type or part name

799-601-2700

Part No.

799-601-2500

★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Ass’y.

Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P 1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P 8P 10P-White

20-353 (7) 1

20-354 (7) 1

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DRC26 DRC26 For NE, G sensor For fuel, boost press. PVC socket

799-601-2900

799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410 799-601-9420 799-601-9430

No. of pins

799-601-2800

Connector type or part name

799-601-2700

Part No.


799-601-2500

TROUBLESHOOTING

12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2 10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD 40P 24P 2P 3P 2P

D375A-5

TROUBLESHOOTING

20 TROUBLESHOOTING

TROUBLESHOOTING WHEN SERVICE CODE IS DISPLAYED (SERVICE CODE)

Information in troubleshooting table ........................................................................................................ Service code E0101 [Abnormality in network system (steering)] .......................................................... Service code E0104 [Abnormality in network system (monitor panel)] ................................................. Service code E0105 [Abnormality in network system (steering)] .......................................................... Service code E0111 (Abnormality in steering controller power supply system) ..................................... Service code E0112 (Abnormality in transmission controller power supply system) ............................. Service code E0120 (Short circuit in caution lamp system) .................................................................. Service code E0121 (Short circuit in caution buzzer system) ............................................................... Service code E0142 (Abnormality in transmission controller 5 V power supply system) ...................... Service code E0143 (Abnormality in steering controller 5 V power supply system) .............................. Service code E0145 (Abnormality in steering controller 24 V power supply system) ............................ Service code E0146 (Abnormality in transmission controller 24 V power supply system) .................... Service code E0151 (Abnormality in selection of steering controller specification) ............................... Service code E0152 [Abnormality in network system (steering)] .......................................................... Service code E0160 (Abnormality in transmission controller ROM) ...................................................... Service code E0161 (Abnormality in steering controller ROM) ............................................................. Service code E0164 [Abnormality in network system (transmission)] ................................................... Service code E0176 (Disconnection in battery relay system) ............................................................... Service code E0177 (Short circuit in battery relay system) ................................................................... Service code E0178 (Disconnection in neutral safety relay system) ..................................................... Service code E0179 (Short circuit in neutral safety relay system) ........................................................ Service code E0211 (Abnormal torque converter oil temperature) ........................................................ Service code E0212 (Short circuit in torque converter lock-up solenoid system) .................................. Service code E0213 (Disconnection in torque converter lock-up solenoid system) .............................. Service code E0221 (Disconnection or short circuit in pitch angle sensor system) .............................. Service code E0225 (Slip of power train clutch) .................................................................................... Service code E0230 [Abnormality in both forward-reverse potentiometer systems (1)] ........................ Service code E0231 [Abnormality in both forward-reverse potentiometer systems (2)] ........................ Service code E0232 [Abnormality in both forward-reverse potentiometer systems (3)] ........................ Service code E0233 (Disconnection or short circuit in forward-reverse potentiometer 1 system) ........ Service code E0234 (Disconnection or short circuit in forward-reverse potentiometer 2 system) ........ Service code E0235 (Deviation of forward-reverse potentiometer system signals) .............................. Service code E0236 (Disconnection or short circuit in shift-up switch systems) ................................... Service code E0237 (Disconnection or short circuit in shift-down switch systems) ............................... Service code E0238 (Disconnection or short circuit in parking brake lever switch systems) ................ Service code E0239 (Disagreement of parking brake lever switch system signals) ............................. Service code E0250 (Disconnection in transmission forward clutch ECMV system) ............................ Service code E0251 (Short circuit in transmission forward clutch ECMV system) ................................ Service code E0252 (Disconnection in transmission reverse clutch ECMV system) ............................ Service code E0253 (Short circuit in transmission reverse clutch ECMV system) ................................ Service code E0254 (Disconnection in transmission 1st clutch ECMV system) ................................... Service code E0255 (Short circuit in transmission 1st clutch ECMV system) ....................................... Service code E0256 (Disconnection in transmission 2nd clutch ECMV system) .................................. Service code E0257 (Short circuit in transmission 2nd clutch ECMV system) ...................................... Service code E0258 (Disconnection in transmission 3rd clutch ECMV system) ................................... Service code E0259 (Short circuit in transmission 3rd clutch ECMV system) ....................................... Service code E0260 (Defective engagement of transmission forward clutch) ...................................... Service code E0261 (Defective disengagement of transmission forward clutch) .................................. Service code E0262 (Defective engagement of transmission reverse clutch) ...................................... Service code E0263 (Defective disengagement of transmission reverse clutch) .................................. Service code E0264 (Defective engagement of transmission 1st clutch) ..............................................

D375A-5

20-404 20-406 20-408 20-410 20- 411 20-413 20-415 20-416 20-417 20-419 20-421 20-422 20-423 20-424 20-425 20-425 20-426 20-428 20-429 20-430 20-432 20-434 20-435 20-436 20-437 20-439 20-439 20-440 20-440 20-441 20-443 20-444 20-445 20-447 20-449 20-451 20-452 20-453 20-454 20-455 20-456 20-457 20-458 20-459 20-460 20-461 20-462 20-463 20-464 20-465 20-466

20-401 (7) 1

TROUBLESHOOTING

Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code

20-402 (7) 1

E0265 E0266 E0267 E0268 E0269 E0270 E0271 E0306 E0307 E0308 E0309 E0310 E0311 E0312 E0321 E0322 E0323 E0324 E0329 E0364 E0365 E0366 E0367 E0405 E0430 E0431 E0432 E0486 E0501 E0610 E0611 E0660 E0661 E0721 E0730 E0731 E0732 E0733 E0734 E0735 E0736 E0750 E0751 E0752 E0753 E0754 E0755 E0756 E0757 E0760 E0761 E0762 E0763 E0764 E0765 E0766 E0767 E0779 E0780 E0781

(Defective disengagement of transmission 1st clutch) .......................................... 20-467 (Defective engagement of transmission 2nd clutch) ............................................. 20-468 (Defective disengagement of transmission 2nd clutch) ........................................ 20-469 (Defective engagement of transmission 3rd clutch) .............................................. 20-470 (Defective disengagement of transmission 3rd clutch) ......................................... 20-471 [Double trouble in transmission clutch (Defective engagement)] .......................... 20-472 [Double trouble in transmission clutch (Defective disengagement)] ..................... 20-472 (Short circuit in blade tilt right oil pressure switch system) ................................... 20-473 (Short circuit in blade tilt left oil pressure switch system) ...................................... 20-474 (Short circuit in ripper lift raise oil pressure switch system) .................................. 20-475 (Short circuit in ripper lift lower oil pressure switch system) ................................. 20-476 (Short circuit in ripper tilt-in oil pressure switch system) ....................................... 20-477 (Disconnection or short circuit in blade pitch switch systems) .............................. 20-478 (Disconnection or short circuit in blade tilt switch systems) .................................. 20-480 (Disconnection in blade dual selector solenoid system) ....................................... 20-482 (Short circuit in blade dual selector solenoid system) ........................................... 20-483 (Disconnection in blade pitch selector solenoid system) ...................................... 20-484 (Short circuit in blade pitch selector solenoid system) .......................................... 20-485 (Abnormal hydraulic oil temperature) ................................................................. 20-485-1 (Disconnection in front large pump oil pressure sensor system) .......................... 20-486 (Short circuit in front large pump oil pressure sensor system) .............................. 20-487 (Disconnection in center small pump oil pressure sensor system) ....................... 20-488 (Short circuit in center small pump oil pressure sensor system) ........................... 20-489 (Disconnection or short circuit in fuel control dial system) .................................... 20-490 (Engine oil: Abnormal oil pressure) ................................................................... 20-491-1 (Abnormal radiator coolant level) ...................................................................... 20-491-1 (Radiator coolant: Overheating).......................................................................... 20-491-1 (Abnormality in selection of transmission controller specification) ........................ 20-492 (Disconnection or short circuit in acceleration sensor system) ............................. 20-493 (Disconnection in back-up alarm relay system) .................................................... 20-494 (Short circuit in back-up alarm relay system) ........................................................ 20-496 (Disconnection in ACC signal drive relay system) ................................................ 20-498 (Short circuit in ACC signal drive relay system) .................................................... 20-499 (Disconnection or short circuit in pitch angle sensor system) ............................... 20-500 [Abnormality in both steering potentiometer systems (1)] ..................................... 20-502 [Abnormality in both steering potentiometer systems (2)] ..................................... 20-502 [Abnormality in both steering potentiometer systems (3)] ..................................... 20-503 (Disconnection or short circuit in steering potentiometer 1 system) ..................... 20-504 (Disconnection or short circuit in steering potentiometer 2 system) ..................... 20-506 (Deviation of steering potentiometer system signals) ........................................... 20-507 (Disconnection or short circuit in brake potentiometer system) ............................ 20-508 (Disconnection in right steering clutch ECMV system) ......................................... 20-510 (Short circuit in right steering clutch ECMV system) ............................................. 20- 511 (Disconnection in left steering clutch ECMV system) ........................................... 20-512 (Short circuit in left steering clutch ECMV system) ............................................... 20-513 (Disconnection in right steering brake ECMV system) .......................................... 20-514 (Short circuit in right steering brake ECMV system) ............................................. 20-515 (Disconnection in left steering brake ECMV system) ............................................ 20-516 (Short circuit in left steering brake ECMV system) ............................................... 20-517 (Defective engagement of right steering clutch) ................................................... 20-518 (Defective disengagement of right steering clutch) ............................................... 20-519 (Defective engagement of left steering clutch) ...................................................... 20-520 (Defective disengagement of left steering clutch) ................................................. 20-521 (Defective engagement of right steering brake) .................................................... 20-522 (Defective disengagement of right steering brake) ............................................... 20-523 (Defective engagement of left steering brake) ...................................................... 20-524 (Defective disengagement of left steering brake) ................................................. 20-525 (Disconnection in sudden stop prevention solenoid system) ................................ 20-526 (Short circuit in sudden stop prevention solenoid system) .................................... 20-527 (Disconnection or short circuit in parking brake lever switch systems) ................. 20-528

D375A-5

TROUBLESHOOTING

Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code Service code

D375A-5

E0782 E0930 E0931 E0932 E0933 E1939 EC111 EC112 EC113 EC115 EC116 EC117 EC118 EC119 EC121 EC122 EC123 EC131 EC132 EC133 EC134 EC135 EC141 EC143 EC144 EC145 EC151 EC153 EC154 EC221 EC222 EC234 EC254 EC259 EC261 EC263 EC265 EC316 EC318 EC346 EC384 EC423 EC441 EC442 EC451 EC452 EC455 EC467 EC468 EC514 EC554

(Disagreement of parking brake lever switch system signals) ............................. (Disconnection in engine speed sensor system) .................................................. (Disconnection in engine speed sensor system) .................................................. (Disconnection in transmission speed sensor system) ........................................ (Disconnection in transmission speed sensor system) ........................................ (Abnormality in J1939 communication system) .................................................... (Abnormality in engine controller memory) ........................................................... (Abnormality in timing rail actuator) ...................................................................... (Abnormal current in timing rail actuator system) ................................................. (Abnormality in engine speed sensor 2 systems) ................................................. (Abnormally high level in timing rail pressure sensor system) .............................. (Abnormally low level in timing rail pressure sensor system) ............................... (Abnormally high level in fuel pump pressure sensor system) ............................. (Abnormally low level in fuel pump pressure sensor system) ............................... (Abnormality in engine speed sensor 1 systems) ................................................. (Abnormally high level in boost pressure sensor system) .................................... (Abnormally low level in boost pressure sensor system) ..................................... (Abnormally high level in throttle sensor system) ................................................. (Abnormally low level in throttle sensor system) .................................................. (Abnormally high level in remote throttle sensor system) ..................................... (Abnormally low level in remote throttle sensor system) ...................................... (Abnormally high level in engine oil pressure sensor system) ............................. (Abnormally low level in engine oil pressure sensor system) ............................... (Lowering of engine oil pressure) ......................................................................... (Abnormally high level in engine coolant temperature sensor system) ................ (Abnormally low level in engine coolant temperature sensor system) ................. (Rise of engine coolant temperature) ................................................................... (Abnormally high level in air intake temperature sensor system) ......................... (Abnormally low level in air intake temperature sensor system) .......................... (Abnormally high level in atmospheric pressure sensor system) ......................... (Abnormally low level in atmospheric pressure sensor system) ........................... (Over-speed) ........................................................................................................ (Abnormal voltage of fuel shut-off valve) .............................................................. (Abnormality in fuel shut-off valve) ....................................................................... (Abnormal rise of fuel temperature) ...................................................................... (Abnormally high level in fuel temperature sensor system) .................................. (Abnormally low level in fuel temperature sensor system) ................................... (Abnormal current of fuel pump actuator) ............................................................. (Abnormality in fuel pump actuator) ..................................................................... (Abnormality in power-down unit of engine controller) ......................................... (Abnormality in preheater control system) ............................................................ (Abnormality in in-range of timing rail pressure sensor system) .......................... (Abnormally low level in battery voltage system) ................................................. (Abnormally high level in battery voltage system) ................................................ (Abnormally high level in fuel rail pressure sensor system) ................................. (Abnormally low level in fuel rail pressure sensor system) ................................... (Abnormal current of fuel rail actuator) ................................................................. (Abnormality in timing rail actuator control) .......................................................... (Abnormality in fuel rail actuator control) .............................................................. (Abnormality in fuel rail actuator) .......................................................................... (Abnormality in in-range of fuel rail pressure sensor system) ..............................

20-530 20-531 20-533 20-535 20-537 20-539 20-540 20-540 20-541 20-542 20-544 20-545 20-546 20-547 20-547 20-548 20-549 20-550 20-551 20-552 20-553 20-554 20-555 20-555 20-556 20-557 20-557 20-558 20-559 20-560 20-561 20-561 20-562 20-563 20-563 20-564 20-565 20-566 20-567 20-568 20-570 20-572 20-574 20-574 20-575 20-576 20-577 20-578 20-578 20-579 20-580

20-403 1 (6)

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE

INFORMATION IN TROUBLESHOOTING TABLE ★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code

Service code

Display on panel Display on panel

Trouble

Trouble in machine

Contents of trouble Contents of trouble detected by monitor panel or controller

Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble Problem that Problem that appears on machine as result of action taken by monitor panel or controller (shown above) appears on machine Related information Information related to detected trouble or troubleshooting

Cause

1

2 Possible causes and standard value in normal state

20-404 1

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment • Disconnection Connector is connected imperfectly or harness is broken. • Short circuit with chassis ground Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Short circuit with power source Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent harnesses are in contact with each other abnormally.

Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority) 1Method of indicating connector No. and handling of T-adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 • If connector No. has no marks of “male” and “female”, disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to only male side or female side. 2Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • Connect positive (+) lead to pin No. or harness entered on front 4 side. • Connect negative (–) lead to pin No. or harness entered on rear side.

D375A-5

TROUBLESHOOTING



Part of electric circuit diagram related to trouble Connector No.: Indicates (Model Number of pins) and (Color). Arrows (⇔): Indicate rough location of connector in machine.

D375A-5

20-405 1

TROUBLESHOOTING

SERVICE CODE E0101 [ABNORMALITY IN NETWORK SYSTEM (STEERING)]

SERVICE CODE E0101 [ABNORMALITY IN NETWORK SYSTEM (STEERING)] User code

Service code

CALL03

E0101

Trouble

Abnormality in network system (steering) (Monitor panel system)

Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of steering controller.

Action of controller

Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Monitor panel may not display normally.

Problem that Once machine is stopped, engine speed is limited to medium (half). appears on machine

Once machine is stopped, travel is limited to F1 and R1.

Related information

Connection state (ON·OFF) of S-NET can be checked in monitoring mode. (Code 5N: Connection state of S-NET communication) Method of reproducing service code: Turn starting switch ON. Cause

Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between S03 (female) 9 1 (Disconnection in wiring or Resistance Max. 1 Ω NGICN2 (female) K defective contact in connecWiring harness between S03 (female) 8 tor) Resistance Max. 1 Ω NGICN2 (female) U

Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between S03 (Contact with ground circuit) (female) 9 S01 (female) 8 or NGICN2 (fe- Resistance Min. 1 MΩ male) K with chassis ground Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

4

Defective monitor panel (tachometer module)

5 Defective steering controller

20-406 1

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between S03 (female) 9 S01 (female) 8 or NGICN2 (female) K with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S03

Voltage

Between 9 8

69V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. NGICN2

Voltage

Between K U

69V

D375A-5

TROUBLESHOOTING


Circuit diagram related to S-NET communication

D375A-5

20-407 1

TROUBLESHOOTING SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]

SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)] User code

Service code

CALL03

E0104

Trouble

Abnormality in network system (monitor panel) (Monitor panel system)

Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of monitor panel (caution module).





Related information



Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting ness without turning starting switch ON. 1 (Disconnection in wiring or defective contact in connec- Wiring harness between S03 (female) @ Resistance Max. 1 Ω CN1 (female) A tor) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between S03 (Contact with ground circuit) (female) @ CN1 (female) A with chassis Resistance Min. 1 MΩ ground Possible causes and standard valShort circuit with power ue in normal state 3 source in wiring harness (Contact with 24 V circuit)

Defective monitor panel 4 (tachometer module)

5

20-408 1

Defective monitor panel (caution module)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between S03 (female) @ CN1 (female) A with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S03

Voltage

Between @ 8

69V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CN1

Voltage

Between A @

69V

D375A-5

TROUBLESHOOTING SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]


D375A-5

20-409 1

TROUBLESHOOTING



Service code

CALL03

E0105

Trouble

Abnormality in network system (steering) (Monitor panel system)

Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of steering controller.





Related information


20-410 1


Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for service code [E0101].

D375A-5

SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM) User code

Service code

CALL

E0111

Trouble

Abnormality in steering controller power supply system (Steering controller system)

Contents of trouble Source voltage of steering controller is below 17 V.


Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Monitor panel may not display normally.

Relays and solenoids may not be driven and system may not operate normally as result. Problem that appears on machine Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.

Related information

Charge level (Voltage) of battery can be checked in monitoring mode. (Code dA: Battery voltage) Method of reproducing service code: Turn starting switch ON. Cause



Defective circuit breaker 1 (CB1)

If circuit breaker is turned OFF, circuit probably has short circuit with chassis ground.

2 Defective fusible link (96A)

If fusible link is broken, circuit probably has short circuit with chassis ground.

Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NGICN3 (female) 1, Resistance Max. 1 Ω A CB1 (1) Wiring harness between CB1 (2) fusible link Resistance Max. 1 Ω battery relay terminal M Wiring harness between NGICN3 (female) K, Resistance Max. 1 Ω U, V, W chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit of wiring harness between Short circuit with chassis NGICN3 (female) 1, A CB1 (1) with chas- Resistance Min. 1 MΩ 4 ground in wiring harness sis ground (Contact with ground circuit) Short circuit of wiring harness between CB1 (2) fusible link battery relay terminal M with Resistance Min. 1 MΩ chassis ground


D375A-5


Voltage

Between 1, A K, U, V, W

20 30 V

20-411 1

TROUBLESHOOTING

SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM)

Circuit diagram related to steering controller power supply

20-412 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0112 (ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY SYSTEM)

SERVICE CODE E0112 (ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY SYSTEM) User code

Service code

CALL

E0112

Trouble

Abnormality in transmission controller power supply system (Transmission controller system)

Contents of trouble Source voltage of transmission controller is below 17 V.


Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Monitor panel may not display normally.

Relays and solenoids may not be driven and system may not operate normally as result. Problem that appears on machine Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.

Related information

Charge level (Voltage) of battery can be checked in monitoring mode. (Code dA: Battery voltage) Method of reproducing service code: Turn starting switch ON. Cause



Defective circuit breaker 1 (CB3)

If circuit breaker is turned OFF, circuit probably has short circuit with chassis ground.

2 Defective fusible link (96A)



★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) 1, Resistance Max. 1 Ω A CB3 (1) Wiring harness between CB3 (2) fusible link Resistance Max. 1 Ω battery relay terminal M Wiring harness between TMCN3 (female) K, Resistance Max. 1 Ω U, V, W chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit of wiring harness between Short circuit with chassis TMCN3 (female) 1, A CB3 (1) with chassis Resistance Min. 1 MΩ 4 ground in wiring harness ground (Contact with ground circuit) Short circuit of wiring harness between CB3 (2) fusible link battery relay terminal M with Resistance Min. 1 MΩ chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con5 troller TMCN3 Voltage Between 1, A K, U, V, W

D375A-5

20 30 V

20-413 1

TROUBLESHOOTING

SERVICE CODE E0112 (ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY SYSTEM)

Circuit diagram related to transmission controller power supply

20-414 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0120 (SHORT CIRCUIT IN CAUTION LAMP SYSTEM)

SERVICE CODE E0120 (SHORT CIRCUIT IN CAUTION LAMP SYSTEM) User code

Service code

CALL03

E0120

Trouble

Short circuit in caution lamp system (Monitor panel system)

Contents of trouble Abnormal current flowed when caution lamp circuit output GND signal.

Turns on caution buzzer. Action of controller Stops caution lamp circuit from outputting GND signal. Limits operation of engine and transmission. Caution lamp does not light up or flash.



Related information

Method of reproducing service code: Turn starting switch ON. (Lamp lights up for 2 seconds when switch is turned ON.) Cause

1

Defective caution lamp (Internal short circuit)

Possible causes Short circuit with power and standard val- 2 source in wiring harness ue in normal state (Contact with 24 V circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 375 (male)

Resistance

Between 1 2

100 400 Ω

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between 375 (female) 2 CN2 (female) 7 with power source

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective monitor panel

CN2

Caution lamp

Voltage

Between 7 chassis ground

When turned OFF

20 30 V

When turned ON

Max. 6 V

Circuit diagram related to caution lamp

D375A-5

20-415 1

TROUBLESHOOTING

SERVICE CODE E0121 (SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)

SERVICE CODE E0121 (SHORT CIRCUIT IN CAUTION BUZZER SYSTEM) User code

Service code

CALL03

E0121

Trouble

Short circuit in caution buzzer system (Monitor panel system)

Contents of trouble Abnormal current flowed when caution buzzer circuit outputted GND signal.

Turns on caution lamp. Action of controller Stops caution buzzer circuit from outputting GND signal. Limits operation of engine and transmission. Caution buzzer does not sound.



Related information

Method of reproducing service code: Turn starting switch ON. (Buzzer sounds for 1 second when switch is turned ON.) Cause

1


Defective caution buzzer (Internal short circuit)

Short circuit with power 2 source in wiring harness (Contact with 24 V circuit)


Resistance

Between 1 2

200 Ω

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between 217 (female) 1 CN2 (female) 8 with power source

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective monitor panel

CN2 Between 8 chassis ground

Caution buzzer

Voltage

When turned OFF

20 30 V

When turned ON (sounded)

Max. 3 V

Circuit diagram related to caution buzzer

20-416 1

D375A-5

SERVICE CODE E0142 (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER SUPPLY SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0142 (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER SUPPLY SYSTEM) User code

Service code

CALL03

E0142

Contents of trouble

Trouble

Abnormality in transmission controller 5 V power supply system (Transmission controller system)

Voltage of 5 V power supply circuit for sensors of transmission controller is below 4.5 V or above 5.5 V. Abnormal current flowed in 5 V power supply circuit for sensors of transmission controller.

Flashes caution lamp and turns on caution buzzer. Action of controller Stops 5 V power supply circuit from outputting if abnormal current flows. Limits operation of engine and transmission. System may not operate normally.



Related information Method of reproducing service code: Turn starting switch ON.

Cause

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL1 (male)

Defective forward-reverse 1 potentiometer (Internal short circuit)

Between L J

Sensor 1 (FR3)

Between L chassis ground Between O Q

Sensor 2 (FR4)

Between O chassis ground

Resistance 2 kΩ ± 20% Min. 1 MΩ 2 kΩ ± 20% Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes without turning starting switch ON. Short circuit with chassis and standard val2 ground in wiring harness Short circuit of wiring harness between ue in normal state (Contact with ground circuit) TMCN1 (female) L TL1 (female) L or TL1 Resistance Min. 1 MΩ (female) O with chassis ground Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN1 (female) L TL1 (female) L or TL1 (female) O with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con4 troller TMCN1 Voltage Between L K

D375A-5

4.5 5.5 V

20-417 1

TROUBLESHOOTING


Circuit diagram related to transmission controller 5 V power supply

20-418 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0143 (ABNORMALITY IN STEERING CONTROLLER 5 V POWER SUPPLY SYSTEM)

SERVICE CODE E0143 (ABNORMALITY IN STEERING CONTROLLER 5 V POWER SUPPLY SYSTEM) User code

Service code

CALL03

E0143

Contents of trouble

Trouble

Abnormality in steering controller 5 V power supply system (Steering controller system)

Voltage of 5 V power supply circuit for sensors of steering controller is below 4.5 V or above 5.5 V. Abnormal current flowed in 5 V power supply circuit for sensors of steering controller.

Flashes caution lamp and turns on caution buzzer. Action of controller Stops 5 V power supply circuit from outputting if abnormal current flows. Limits operation of engine and transmission. System may not operate normally.




1

Cause


Defective fuel control dial (Internal short circuit)

When connector shown at right is disconnected, if service code changes to P (to indicate that trouble is repaired), Fuel control dial trouble is in system. ★ Disconnect connector with starting switch OFF, then connector turn starting switch ON and carry out troubleshooting.

When connector shown at right is disconnected, if service Defective brake potentiome- code changes to P (to indicate that trouble is repaired), BRK 2 ter trouble is in system. connector ★ Disconnect connector with starting switch OFF, then (Internal short circuit) turn starting switch ON and carry out troubleshooting. When connector shown at right is disconnected, if service Defective acceleration sen- code changes to P (to indicate that trouble is repaired), SS3 3 sor trouble is in system. connector ★ Disconnect connector with starting switch OFF, then (Internal short circuit) turn starting switch ON and carry out troubleshooting. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL1 (male) Possible causes and standard value in normal state

Defective steering potenti4 ometer (Internal short circuit)

Between A G

Sensor 1 (ST1)

Between A chassis ground Between M F

Sensor 2 (ST2)

Between M chassis ground

Resistance 2 kΩ ± 20% Min. 1 MΩ 2 kΩ ± 20% Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit with chassis Short circuit of wiring harness between 5 ground in wiring harness NGICN1 (female) L TL1 (female) A, TL1 (Contact with ground circuit) (female) M, fuel control dial connector (feResistance Min. 1 MΩ male) 1, BRK (female) C, or SS3 (female) 8 with chassis ground



D375A-5

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN1 (female) L TL1 (female) A, TL1 (female) M, fuel control dial connector (female) 1, BRK (female) C, or SS3 (female) 8 with chassis ground

Voltage

Max. 1 V


Voltage

Between L K

4.5 5.5 V

20-419 1

TROUBLESHOOTING



20-420 1

D375A-5

TROUBLESHOOTING


SERVICE CODE E0145 (ABNORMALITY IN STEERING CONTROLLER 24 V POWER SUPPLY SYSTEM) User code

Service code

CALL03

E0145

Contents of trouble

Trouble

Abnormality in steering controller 24 V power supply system (Steering controller system)

• Voltage of 24 V power supply circuit for sensors of steering controller is below 17 V or above 30 V. • Abnormal current flowed in 24 V power supply circuit for sensors of steering controller.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops 24 V power supply circuit from outputting if abnormal current flows. • Limits operation of engine and transmission. • System may not operate normally.

Problem that • Once machine is stopped, engine speed is limited to medium (half). appears on machine

• Once machine is stopped, travel is limited to F1 and R1.

Related information • Method of reproducing service code: Turn starting switch ON.

Cause Defective machine inclina1 tion angle sensor (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting When connector shown at right is disconnected, if service code changes to P (to indicate that trouble is repaired), PAS trouble is in system. connector ★ Disconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes without turning starting switch ON. Short circuit with chassis and standard value in normal state 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN1 (female) F – PAS (female) C with Resistance Min. 1 MΩ chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective steering controller

NGICN1

Voltage

Between F – K

20 – 30 V

Circuit diagram related to steering controller 24 V power supply

D375A-5

20-421 1 4

TROUBLESHOOTING


SERVICE CODE E0146 (ABNORMALITY IN TRANSMISSION CONTROLLER 24 V POWER SUPPLY SYSTEM) User code

Service code

E01

E0146

Contents of trouble

Trouble

Abnormality in transmission controller 24 V power supply system (Transmission controller system)

Voltage of 24 V power supply circuit for sensors of transmission controller is below 17 V or above 20 V. Abnormal current flowed in 24 V power supply circuit for sensors of transmission controller.

Action of controller Stops 24 V power supply circuit from outputting if abnormal current flows. Problem that Work equipment oil pressure cannot be monitored in service mode. appears on machine Related information Method of reproducing service code: Turn starting switch ON.

Cause


When connector shown at right is disconnected, if service Defective work equipment code changes to P (to indicate that trouble is repaired), large pump oil pressure senLPP 1 trouble is in system. sor connector ★ Prepare with starting switch OFF, then turn starting (Internal short circuit) switch ON and carry out troubleshooting.


When connector shown at right is disconnected, if service Defective work equipment code changes to P (to indicate that trouble is repaired), SPP small pump oil pressure sen2 trouble is in system. connector sor ★ Prepare with starting switch OFF, then turn starting (Internal short circuit) switch ON and carry out troubleshooting. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) F LPP (female) B or SPP Resistance Min. 1 MΩ (female) B with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con4 TMCN1 Voltage troller Between F K

20 30 V


20-422 1

D375A-5

SERVICE CODE E0151 (ABNORMALITY IN SELECTION OF STEERING CONTROLLER SPECIFICATION)

TROUBLESHOOTING

SERVICE CODE E0151 (ABNORMALITY IN SELECTION OF STEERING CONTROLLER SPECIFICATION) User code

Service code

CALL

E0151

Contents of trouble

Trouble

Abnormality in selection of steering controller specification (Steering controller system)

Internal setting of steering controller specification is different from specification setting signal (Steering controller cannot recognize specification setting normally).

Flashes caution lamp and turns on caution buzzer. Action of controller Stops steering controller from outputting all signals. Limits operation of engine, transmission, and brake. Machine does not move at all.


Once machine is stopped, it cannot travel any more.


1

Cause


Defective adjustment of steering controller

After adjustment mode is executed, if service code changes to P (to indicate that trouble is repaired), system is normal. Adjustment code: 5A [Check of specification code (Steering controller)]

Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes ness without turning starting switch ON. and standard val- 2 (Disconnection in wiring or ue in normal state defective contact in connec- Wiring harness between NGICN3 (female) J Resistance Max. 1 Ω chassis ground tor)



Voltage

Between J chassis ground

Max. 1 V

Circuit diagram related to steering controller specification selection signal

D375A-5

20-423 1

TROUBLESHOOTING



Service code

CALL03

E0152

Trouble

Abnormality in network system (steering) (Steering controller system)

Contents of trouble Steering controller detected abnormality in S-NET.



Shoe slip control (SSC) function may not work. Problem that appears on machine Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1.

Related information


20-424 1


Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for service code [E0101].

D375A-5

TROUBLESHOOTING

SERVICE CODE E0160 (ABNORMALITY IN TRANSMISSION CONTROLLER ROM) SERVICE (ABNORMALITY IN STEERING CONTROLLER ROM) SERVICE CODECODE E0160E0161 (ABNORMALITY IN TRANSMISSION

SERVICE CODE E0160 (ABNORMALITY IN TRANSMISSION CONTROLLER ROM) User code

Service code

E01

E0160

Trouble

Abnormality in transmission controller ROM (Transmission controller system)

Contents of trouble Information in transmission controller ROM (non-volatile memory) is abnormal.

Action of controller Sets internal adjustment values to default. Problem that Gear shifting feeling of transmission may become bad. appears on machine Related information Method of reproducing service code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting Possible causes Since trouble is in system, troubleshooting cannot be carried out. and standard valDefective transmission con(If there is not visible trouble in machine, controller may be used as it ue in normal state 1 troller is.)

SERVICE CODE E0161 (ABNORMALITY IN STEERING CONTROLLER ROM) User code

Service code

E02

E0161

Trouble

Abnormality in steering controller ROM (Steering controller system)

Contents of trouble Information in steering controller ROM (non-volatile memory) is abnormal.


Flashes caution lamp and turns on caution buzzer. Sets internal adjustment values to default.

Steering performance may lower. Problem that appears on machine Braking performance may lower. Related information Method of reproducing service code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting Possible causes Since trouble is in system, troubleshooting cannot be carried out. and standard val1 Defective steering controller (If there is not visible trouble in machine, controller may be used as it ue in normal state is.)

D375A-5

20-425 1

TROUBLESHOOTING

SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)]

SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)] User code

Service code

CALL03

E0164

Trouble

Abnormality in network system (transmission) (Transmission controller system)

Contents of trouble Transmission controller detected abnormality in S-NET.



Gear shifting feeling of transmission may become bad. Problem that appears on machine Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1.

Related information



★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between CN1 (female) B Resistance Max. 1 Ω 1 (Disconnection in wiring or TMCN2 (female) K defective contact in connecWiring harness between CN1 (female) @ tor) Resistance Max. 1 Ω TMCN2 (female) U


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between CN1 (Contact with ground circuit) (female) B TMCN2 (female) K with chassis Resistance Min. 1 MΩ ground Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

4

Defective monitor panel (caution module)

Defective transmission con5 troller

20-426 1

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between CN1 (female) B TMCN2 (female) K with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CN2

Voltage

Between B @

69V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2

Voltage

Between K U

69V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)]


D375A-5

20-427 1

TROUBLESHOOTING

SERVICE CODE E0176 (DISCONNECTION IN BATTERY RELAY SYSTEM)

SERVICE CODE E0176 (DISCONNECTION IN BATTERY RELAY SYSTEM) User code

Service code

E0176

Trouble

Disconnection in battery relay system (Steering controller system)

Contents of trouble When signal is output to battery relay circuit, current does not flow.

Action of controller Stops outputting to battery relay circuit. Problem that Trouble may occur in writing data in each controller ROM (non-volatile memory). appears on machine Related information

Outputting to battery relay (Voltage) can be checked in monitoring mode. (Code dA: Battery relay drive voltage) Method of reproducing service code: Turn starting switch ON and OFF. Cause

1

Defective battery relay (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery relay

Continuity

Between terminals BR E

There is continuity.

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN3 (female) 4 Resistance Max. 1 Ω 2 (Disconnection in wiring or chassis ground defective contact in connecPossible causes Wiring harness between battery relay terminal tor) and standard valResistance Max. 1 Ω E chassis ground ue in normal state ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 3 source in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) NGICN3 (female) 4 battery relay terminal Voltage Max. 1 V BR with chassis ground


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NGICN3 (female)

Continuity



Circuit diagram related to battery relay

20-428 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0177 (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)

SERVICE CODE E0177 (SHORT CIRCUIT IN BATTERY RELAY SYSTEM) User code

Service code

—

E0177

Trouble

Short circuit in battery relay system (Steering controller system)

Contents of trouble • When signal is output to battery relay circuit, abnormal current flowed.

Action of controller • Stops outputting to battery relay circuit. Problem that • Trouble may occur in writing data in each controller ROM (non-volatile memory). appears on machine Related information

• Outputting to battery relay (Voltage) can be checked in monitoring mode. (Code dA: Battery relay drive voltage) • Method of reproducing service code: Turn starting switch ON and OFF. Cause

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

1

Defective battery relay (Internal short circuit)

Battery relay

Continuity/Resistance

Between terminals BR – E


Between terminal BR – chassis ground

Min. 1 MΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting and standard valwithout turning starting switch ON. Short circuit with chassis ue in normal state 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN3 (female) 4 – battery relay terminal Resistance Min. 1 MΩ BR with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective steering controller

NGICN3

Starting switch

Voltage

Between 4 – chassis ground

ON

20 – 30 V

Circuit diagram related to battery relay

D375A-5

20-429 1

TROUBLESHOOTING

SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)

SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM) User code

Service code

E02

E0178

Trouble

Disconnection in neutral safety relay system (Transmission controller system)

Contents of trouble • When GND signal for neutral safety relay circuit is turned off, 24 V is not generated.


• Flashes caution lamp and turns on caution buzzer. • Stops outputting GND signal for neutral safety relay circuit.

Problem that • Engine cannot be started. appears on machine

• Outputting to neutral safety relay (Voltage) can be checked in monitoring mode. (Code dN: Neutral safety relay drive voltage) • Method of reproducing service code: Related information Turn starting switch ON and operate parking brake lever (LOCK position). ★ This service code detects abnormality on primary side (coil side) of neutral safety relay and cannot detect abnormality on secondary side (contact side). Cause Defective circuit breaker 1 (CB3) Defective neutral safety re2 lay (Internal disconnection)


Standard value in normal state/Remarks on troubleshooting If circuit breaker is turned OFF, circuit probably has short circuit with chassis ground. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NSF (Male)

Resistance

Between 1 – 2

200 – 400 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN2 (female) 8 – 3 (Disconnection in wiring or Resistance Max. 1 Ω NSF (female) 2 defective contact in connecWiring harness between NSF (female) 1 – tor) Resistance Max. 1 Ω CB3 (1) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between 4 ground in wiring harness TMCN2 (female) 8 – NSF (female) 2 with (Contact with ground circuit) chassis ground Short circuit of wiring harness between NSF (female) 1 – CB3 (1) with chassis ground

Resistance Min. 1 MΩ


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5

20-430 1 (5)

Defective transmission controller

TMCN2

Parking brake lever

Voltage


When locked

Max. 1 V

When free

20 – 30 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)

Circuit diagram related to neutral safety relay

D375A-5

20-431 1

TROUBLESHOOTING

SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)

SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM) User code

Service code

E02

E0179

Trouble

Short circuit in neutral safety relay system (Transmission controller system)

Contents of trouble • When GND signal for neutral safety relay circuit is turned off, abnormal current flowed.


• Flashes caution lamp and turns on caution buzzer. • Stops outputting GND signal for neutral safety relay circuit.

Problem that • Engine cannot be started. appears on machine

• Outputting to neutral safety relay (Voltage) can be checked in monitoring mode. (Code dN: Neutral safety relay drive voltage) • Method of reproducing service code: Related information Turn starting switch ON and operate parking brake lever (LOCK position). ★ This service code detects abnormality on primary side (coil side) of neutral safety relay and cannot detect abnormality on secondary side (contact side). Cause Defective neutral safety re1 lay (Internal short circuit)

Short circuit with power Possible causes and standard val- 2 source in wiring harness (Contact with 24 V circuit) ue in normal state

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NSF (male)

Resistance

Between 1 – 2

200 – 400 Ω

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN2 (female) 8 – NSF (female) 2 with chassis ground

Voltage

Max. 1 V


20-432 1 (5)


TMCN2

Parking brake lever

Voltage


When locked

Max. 1 V

When free

20 – 30 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)

Circuit diagram related to neutral safety relay

D375A-5

20-433 1

TROUBLESHOOTING

SERVICE CODE E0211 (ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)

SERVICE CODE E0211 (ABNORMAL TORQUE CONVERTER OIL TEMPERATURE) User code

Service code

E0211

Trouble

Abnormal torque converter oil temperature (Monitor panel system)

Contents of trouble Torque converter oil temperature is above about 130°C.


Flashes caution lamp and turns on caution buzzer (Caution function of torque converter oil temperature gauge).

System does not take any particular action. If machine is used without removing cause of trouble, Problem that appears on machine however, mechanical trouble may occur. Related information

Torque converter oil temperature can be checked in monitoring mode. (Code 77: Torque converter oil temperature) Method of reproducing service code: Turn starting switch ON and start engine Cause


Overheating of torque con1 verter oil (when system is normal)

Since overheating of torque converter oil is detected, check cause and damage of machine and repair. Check torque converter oil temperature gauge. If it does not indicate real oil temperature, carry out troubleshooting for monitor panel (Emode).

Possible causes Defective torque converter and standard val2 oil temperature sensor and ue in normal state gauge system

3 Defective monitor panel

20-434 1

Torque converter oil temperature gauge

Lighting segment

Voltage

7th

Above 130°C

6th

Below approx. 130°C

5th


4th


3rd


2nd

Below approx. 90°C

1st

Below approx. 50°C

Since trouble is in system, troubleshooting cannot be carried out. (If there is not visible trouble in machine, controller may be used as it is.)

D375A-5

SERVICE CODE E0212 (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0212 (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM) User code

Service code

E01

E0212

Trouble

Short circuit in torque converter lock-up solenoid system (Transmission controller system)

Contents of trouble Abnormal current flowed when signal is output to torque converter lock-up solenoid.

Action of controller Stops outputting to torque converter lock-up solenoid. Problem that Torque converter lock-up solenoid does not work. appears on machine

Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode. (Code dL: Lock-up solenoid drive voltage) Related information Method of reproducing service code: Start engine, turn lock-up switch ON, and drive machine. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start traveling. Cause Defective torque converter 1 lock-up solenoid (Internal short circuit)


Resistance

Between 1 2

30 80 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) \ 653 (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)

4



★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) \ 653 (female) 1 with wirResistance Min. 1 MΩ ing harness between TMCN3 (female) M 653 (female) 2 ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female)

Resistance

Between \ M

30 80 Ω

Between \ chassis ground

Min. 1 MΩ

Circuit diagram related to torque converter lock-up solenoid

D375A-5

20-435 1

SERVICE CODE E0213 (DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0213 (DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM) User code

Service code

E01

E213

Trouble

Disconnection in torque converter lock-up solenoid system (Transmission controller system)

Contents of trouble Current does not flow when signal is output to torque converter lock-up solenoid.

Action of controller Stops outputting to torque converter lock-up solenoid. Problem that Torque converter lock-up solenoid does not work. appears on machine

Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode. (Code dL: Lock-up solenoid drive voltage) Related information Method of reproducing service code: Start engine, turn lock-up switch ON, and drive machine. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start traveling. Cause Defective torque converter 1 lock-up solenoid (Internal short circuit)


Resistance

Between 1 2

30 80 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN3 (female) \ Resistance Max. 1 Ω 2 (Disconnection in wiring or 653 (female) 1 Possible causes defective contact in connecand standard valWiring harness between TMCN3 (female) M tor) Resistance Max. 1 Ω ue in normal state 653 (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of TMCN3 (female) \ 653 (female) 1 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con4 TMCN3 (female) Resistance troller Between \ M

30 80 Ω

Circuit diagram related to torque converter lock-up solenoid

20-436 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0221 (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)

SERVICE CODE E0221 (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM) User code

Service code

E01

E0221

Trouble

Disconnection or short circuit in pitch angle sensor system) (Transmission controller system)

Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.

Action of controller Stops auto shift-down function. Gear shifting feeling of transmission may become bad. Problem that appears on machine Auto shift-down function does not work. ★ Since pitch angle sensor signal is input to both transmission controller and steering controller, related codes may be displayed simultaneously, depending on troubled part. (Related code: E0721) Related information Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode. (Code A8: Pitch angle sensor voltage) Method of reproducing service code: Turn starting switch ON. When only service code [E0221] is displayed Cause



Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting ness without turning starting switch ON. 1 (Disconnection in wiring or defective contact in connec- Wiring harness between TMCN2 (female) 1 Resistance Max. 1 Ω circuit branch point tor) ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con2 TMCN1 Voltage troller Between 1 chassis ground

0.15 4.85 V

When service codes [E0221] and [E0731] are displayed simultaneously Cause 1


Defective sensor 24 V power See if service code [E0145] is displayed. If it is displayed, carry out supply system troubleshooting for it first.

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective pitch angle sensor 2 (Internal trouble) PAS Voltage Between B A


0.15 4.85 V

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between PAS (female) B 3 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point defective contact in connecWiring harness between PAS (male) C tor) Resistance Max. 1 Ω NGICN1 (female) F ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between PAS (Contact with ground circuit) (female) B TMCN1 (female) 1 NGICN1 Resistance Min. 1 MΩ (female) C with chassis ground

D375A-5

20-437 1

TROUBLESHOOTING


Circuit diagram related to pitch angle sensor

20-438 1

D375A-5

SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH) SERVICE CODE E0230 [ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS (1)] SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH)

TROUBLESHOOTING

SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH) User code

Service code

E02

E0225

Contents of trouble

Trouble

Slip of power train clutch (Transmission controller system)

When torque converter is locked up, transmission speed calculated from engine speed is different more than 200 rpm from real speed.

Action of controller Flashes caution lamp and turns on caution buzzer. Problem that Auto shift-down function does not work. appears on machine

Engine speed (rpm) and transmission speed (rpm) can be checked in monitoring mode. (Code 99: Engine speed, Code 7o: Transmission speed) Related information Method of reproducing service code: Start engine, turn lock-up switch ON, and drive machine. When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start traveling. Cause


Slip of power train clutch 1 (When system is normal) Defective engine speed senPossible causes 2 sor system and standard value in normal state 3 Defective transmission speed sensor system 4

Since slip of clutch is detected, check cause and damage of machine and repair. See if service codes [EC121], [E0930], and [E0931] are displayed. If they are displayed, carry out troubleshooting for them. See if service codes [E0932] and [E0933] are displayed. If they are displayed, carry out troubleshooting for them.

Since trouble is in system, troubleshooting cannot be carried out. Defective transmission con(If there is not visible trouble in machine, controller may be used as it troller is.)

SERVICE CODE E0230 [ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS (1)] User code

Service code

CALL

E0230

Trouble

Abnormality in both forward-reverse potentiometer systems (1) (Transmission controller system)

Service codes [E0233] and [E0234] are displayed simultaneously for forward-reverse potentiometer Contents of trouble systems 1 and 2. Action of controller

Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake.

Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, it cannot travel any more. Inputting from forward-reverse potentiometers (Voltage) can be checked in monitoring mode. (Code L3: Voltage of forward-reverse potentiometer 1) Related information (Code L4: Voltage of forward-reverse potentiometer 2) Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Forward-reverse). Possible causes and standard value in normal state

D375A-5

Cause


Carry out troubleshooting for service codes [E0233] and [E0244].

20-439 1

TROUBLESHOOTING

SERVICE CODESERVICE E0231 [ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS (2)] CODE E0231 [ABNORMALITY IN BOTH FORWARD-REVERSE SERVICE CODE E0232 [ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(2)] (3)] POTENTIOMETER SYSTEMS


Service code

CALL

E0231

Contents of trouble


Trouble


Forward-reverse potentiometer systems 1 and 2 are normal when starting switch is turned ON, then service code [E0235] is displayed. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake.


Cause




Service code

CALL

E0232

Contents of trouble


Trouble


Either of forward-reverse potentiometers 1 and 2 is abnormal when starting switch is turned ON, then service codes [E0233] and [E0234] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake.


20-440 1

Cause



D375A-5

SERVICE CODE E0233 (DISCONNECTION OR SHORT CIRCUIT IN FORWARDREVERSE POTENTIOMETER 1 SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0233 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 1 SYSTEM) User code

Service code

CALL03

E0233

Trouble

Disconnection or short circuit in forward-reverse potentiometer 1 system (Transmission controller system)

Contents of trouble Signal voltage of forward-reverse potentiometer 1 (FR3) is below 0.5 V or above 4.5 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Continues controlling with signal of forward-reverse potentiometer 2 system (FR4). Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Inputting from forward-reverse potentiometer 1 (FR3) (Voltage) can be checked in monitoring mode. (Code L3: Voltage of froward-reverse potentiometer 1) Related information Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Forward-Reverse travel). Cause


Defective sensor 5 V power See if service code [E0142] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective forward-reverse potentiometer 1 2 (Internal disconnection or short circuit)


TL1 (male)

Between L J Between K L

Resistance 2 kΩ ± 20%

Between K J

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN1 (female) L 3 (Disconnection in wiring or Resistance Max. 1 Ω TL1 (female) L defective contact in connecWiring harness between TMCN1 (female) 2 tor) Resistance Max. 1 Ω TL1 (female) K ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) 2 TL1 (female) K with Resistance Min. 1 MΩ chassis ground Short circuit with power 5 source in wiring harness (Contact with 24 V circuit)


D375A-5


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN1 (female) 2 TL1 (female) K with chassis ground

Voltage

Max. 1 V


Voltage

Between 2 K

0.5 4.5 V

20-441 1

TROUBLESHOOTING


Circuit diagram related to forward-reverse potentiometers

20-442 1

D375A-5


TROUBLESHOOTING

SERVICE CODE E0234 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM) User code

Service code

CALL03

E0234

Trouble

Disconnection or short circuit in forward-reverse potentiometer 2 system (Transmission controller system)

Contents of trouble Signal voltage of forward-reverse potentiometer 2 (FR4) is below 0.5 V or above 4.5 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Continues controlling with signal of forward-reverse potentiometer 1 system (FR3). Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Inputting from forward-reverse potentiometer 2 (FR4) (Voltage) can be checked in monitoring mode. (Code L4: Voltage of froward-reverse potentiometer 2) Related information Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Forward-Reverse travel). Cause


Defective sensor 5 V power See if service code [E0142] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective forward-reverse potentiometer 2 2 (Internal disconnection or short circuit)


TL1 (male)

Between O Q Between P O


Between P Q

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN1 (female) L 3 (Disconnection in wiring or Resistance Max. 1 Ω TL1 (female) O defective contact in connecWiring harness between TMCN1 (female) I tor) Resistance Max. 1 Ω TL1 (female) P ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) I TL1 (female) P with Resistance Min. 1 MΩ chassis ground Short circuit with power 5 source in wiring harness (Contact with 24 V circuit)


D375A-5


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN1 (female) I TL1 (female) P with chassis ground

Voltage

Max. 1 V


Voltage

Between I K

0.5 4.5 V

20-443 1

TROUBLESHOOTING

SERVICE CODE E0235 (DEVIATION OF FORWARD-REVERSE POTENTIOMETER SYSTEM SIGNALS)

Circuit diagram related to forward-reverse potentiometers

SERVICE CODE E0235 (DEVIATION OF FORWARD-REVERSE POTENTIOMETER SYSTEM SIGNALS) User code

Service code

CALL03

E0235

Trouble

Deviation of forward-reverse potentiometer system signals (Transmission controller system)

Total signal voltages of forward-reverse potentiometers 1 (FR3) and 2 (FR4) is below 4.41 V or above Contents of trouble 5.59 V. Flashes caution lamp and turns on caution buzzer. Continues controlling with normal signal of forward-reverse potentiometer 1 (FR3) system or 2 (FR4) Action of controller system. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Inputting from forward-reverse potentiometers (Voltage) can be checked in monitoring mode. (Code L3: Voltage of froward-reverse potentiometer 1) Related information (Code L4: Voltage of froward-reverse potentiometer 2) Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Forward-Reverse travel). Possible causes and standard value in normal state

20-444 1

Cause



D375A-5

TROUBLESHOOTING

SERVICE CODE E0236 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)

SERVICE CODE E0236 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS) User code

Service code

E02

E0236

Trouble

Disconnection or short circuit in shift-up switch systems (Transmission controller system)

Contents of trouble • Signals of both shift-up switch circuit systems are turned ON or OFF simultaneously.


• Flashes caution lamp and turns on caution buzzer. • Assumes that switch is not pressed.

• Transmission gear cannot be shifted up. Problem that appears on machine • Auto shift-down function does not work. • NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from shift-up switch (ON·OFF) can be checked in monitoring mode. Related information (Code L5: Transmission controller input 1) • Method of reproducing service code: Turn starting switch ON and operate shift-up switch. Cause


Defective shift-up switch 1 (Internal disconnection or short circuit)

TL1 (male)

Shift-up switch OFF (Pressed)

ON (Released)

Resistance between N–U

Max. 1 Ω

Min. 1 MΩ

Resistance between N–B

Min. 1 MΩ

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)

Wiring harness between TMCN1 (female) 6 – Resistance Max. 1 Ω TL1 (female) U Wiring harness between TMCN2 (female) [ – Resistance Max. 1 Ω TL1 (female) B Wiring harness between TMCN1 (female) 4, Resistance Max. 1 Ω @ – TL1 (female) N ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes Short circuit of wiring harness between and standard valShort circuit with chassis TMCN1 (female) 6 – TL1 (female) U with ue in normal state 3 ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between TMCN2 (female) [ – TL1 (female) B with chassis ground



★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 4 source in wiring harness (Contact with 24 V circuit)

Short circuit of wiring harness between TMCN1 (female) 6 – TL1 (female) U with chassis ground

Voltage

Max. 1 V

Short circuit of wiring harness between TMCN2 (female) [ – TL1 (female) B with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN1, TMCN2 Defective transmission con5 troller Voltage between TMCN1 6 – TMCN1 4, @ Voltage between TMCN2 [ – TMCN1 4, @

D375A-5

Shift-up switch OFF (Released)

ON (Pressed)

Max. 1 V

5 – 11 V

5 – 11 V

Max. 1 V

20-445 1 (5)

TROUBLESHOOTING

SERVICE CODE E0236 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)

Circuit diagram related to shift-up switch and shift-down switch

20-446 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)

SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS) User code

Service code

E02

E0237

Trouble

Disconnection or short circuit in shift-down switch systems (Transmission controller system)

Contents of trouble • Signals of both shift-down switch circuit systems are turned ON or OFF simultaneously.



• Transmission gear cannot be shifted down. Problem that appears on machine • Auto shift-down function does not work. • NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from shift-down switch (ON·OFF) can be checked in monitoring mode. Related information (Code L5: Transmission controller input 1) • Method of reproducing service code: Turn starting switch ON and operate shift-down switch. Cause


Defective shift-down switch 1 (Internal disconnection or short circuit)

TL1 (male)

Shift-up switch OFF (Pressed)

ON (Released)

Resistance between D–V

Max. 1 Ω

Min. 1 MΩ

Resistance between D–C

Min. 1 MΩ

Max. 1 Ω


Wiring harness between TMCN3 (female) I – Resistance Max. 1 Ω TL1 (female) V Wiring harness between TMCN3 (female) S – Resistance Max. 1 Ω TL1 (female) C Wiring harness between TMCN1 (female) 4, Resistance Max. 1 Ω @ – TL1 (female) D ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes Short circuit of wiring harness between and standard valShort circuit with chassis TMCN3 (female) I – TL1 (female) V with ue in normal state 3 ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between TMCN3 (female) S – TL1 (female) C with chassis ground




Short circuit of wiring harness between TMCN3 (female) I – TL1 (female) V with chassis ground

Voltage

Max. 1 V

Short circuit of wiring harness between TMCN3 (female) S – TL1 (female) C with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN1, TMCN3 Defective transmission con5 troller Voltage between TMCN3 I – TMCN1 4, @ Voltage between TMCN3 S – TMCN1 4, @

D375A-5

Shift-up switch OFF (Released)

ON (Pressed)

Max. 1 V

5 – 11 V

5 – 11 V

Max. 1 V

20-447 1 (5)

TROUBLESHOOTING

SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)

Circuit diagram related to shift-up switch and shift-down switch

20-448 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0238 (DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH SYSTEMS)

SERVICE CODE E0238 (DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH SYSTEMS) User code CALL03 Contents of trouble

Action of controller Problem that appears on machine

Related information

Service code Disconnection or short circuit in parking brake lever switch systems Trouble (Transmission controller system) E0238 • Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously. • Flashes caution lamp and turns on caution buzzer. • Assumes that parking brake lever is at FREE position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. ★ Since parking brake switch signal is used by both transmission controller and steering controller, related codes may be displayed simultaneously, depending on troubled part. (Related codes: E0239, E0781, E0782) • NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code L5: Transmission controller input 1) • Method of reproducing service code: Turn starting switch ON and operate parking brake lever.

When only service code [E0238] is displayed Cause Standard value in normal state/Remarks on troubleshooting Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness Wiring harness between TMCN2 (female) H – 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point defective contact in connecWiring harness between TMCN2 (female) B – Resistance Max. 1 Ω tor) circuit branching point Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and and standard valcarry out troubleshooting. ue in normal state Parking brake lever TMCN2 At FREE At LOCK Defective transmission con2 Between H – chassis troller Max. 1 V 5 – 11 V ground Between B – chassis 5 – 11 V Max. 1 V ground

1

2

Possible causes and standard value in normal state 3

4

D375A-5

When service codes [E0238] and [E0781] are displayed simultaneously Cause Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective parking brake leParking brake lever ver switch NSW At FREE At LOCK (Internal disconnection or Between A – B Max. 1 Ω Min. 1 MΩ short circuit) Between A – B Min. 1 MΩ Max. 1 Ω ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harWiring harness between NSW (female) B – ness Resistance Max. 1 Ω circuit merging point (Disconnection in wiring or Wiring harness between NSW (female) C – Resistance Max. 1 Ω defective contact in connec- circuit merging point tor) Wiring harness between NSW (female) A – Resistance Max. 1 Ω chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NSW Short circuit with chassis (female) B – TMCN1 (female) H – NGICN2 Resistance Min. 1 MΩ ground in wiring harness (female) 5 with chassis ground (Contact with ground circuit) Short circuit of wiring harness between NSW (female) C – TMCN1 (female) B – NGICN2 Resistance Min. 1 MΩ (female) E with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Short circuit with power (female) B – TMCN1 (female) H – NGICN2 Voltage Max. 1 V source in wiring harness (female) 5 with chassis ground (Contact with 24 V circuit) Short circuit of wiring harness between NSW (female) C – TMCN1 (female) B – NGICN2 Voltage Max. 1 V (female) E with chassis ground

20-449 1 (5)

TROUBLESHOOTING


Circuit diagram related to parking brake switch

20-450 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0239 (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)

SERVICE CODE E0239 (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS) User code

Service code

CALL03

E0239

Contents of trouble


Trouble

Disagreement of parking brake lever switch system signals (Transmission controller system)

• Switch input signal of transmission controller disagrees with communication signal from steering controller. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission.

• Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. ★ Since parking brake switch signal is used by both transmission controller and steering controller and information is exchanged by S-NET communication, related codes may be displayed simultaneously, depending on troubled part. (Related codes: E0101, E0104, E0105, E0152, E0164, E0238, E0781, E0782) Related information • NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code L5: Transmission controller switch input 1) • Method of reproducing service code: Turn starting switch ON and operate parking brake lever. Cause


See if service codes [E0101], [E0104], [E0105], [E0152], and [E0162] Defective S-NET communi1 are displayed. If they are displayed, carry out troubleshooting for them cation system first.

Possible causes and standard value in normal state 2 Defective parking brake lever switch signal system 3

D375A-5

See if service codes [E0238] and [E0781] are displayed. If they are displayed, carry out troubleshooting for them first. (Service code [E0782] is same as [E0239].)

Defective transmission conSince trouble is in system, troubleshooting cannot be carried out. troller

20-451 1

TROUBLESHOOTING

SERVICE CODE E0250 (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH ECMV SYSTEM)

SERVICE CODE E0250 (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0250

Trouble

Disconnection in transmission forward clutch ECMV system (Transmission controller system)

Contents of trouble • When signal is output to transmission forward clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission forward clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to R1. • Outputting to forward clutch solenoid (Current) can be checked in monitoring mode. (Code P5, c5: Forward clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive forward. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not travel forward. Cause Defective forward clutch so1 lenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SFT (male)

Resistance

Between 1 – 2

5 – 15 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN3 (female) Y – Resistance Max. 1 Ω 2 (Disconnection in wiring or SFT (female) 1 defective contact in connecWiring harness between TMCN3 (female) C – tor) Resistance Max. 1 Ω SFT (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) Y – SFT (female) 1 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con4 Resistance troller TMCN3 (female) Between Y – C

5 – 15 Ω

Circuit diagram related to transmission forward clutch ECMV

20-452 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0251 (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV SYSTEM)

SERVICE CODE E0251 (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0251

Trouble

Short circuit in transmission forward clutch ECMV system (Transmission controller system)

Contents of trouble • When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission forward clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to R1. • Outputting to forward clutch solenoid (Current) can be checked in monitoring mode. (Code P5, c5: Forward clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive forward. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not travel forward. Cause Defective forward clutch so1 lenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SFT (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) Y – SFT (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) Y – SFT (female) 1 with Resistance Min. 1 MΩ wiring harness between TMCN3 (female) C – SFT (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4


TMCN3 (female)

Resistance

Between Y – C

5 – 15 Ω

Between Y – chassis ground

Min. 1 MΩ


D375A-5

20-453 (7) 1

TROUBLESHOOTING

SERVICE CODE E0252 (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV SYSTEM)

SERVICE CODE E0252 (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0252

Trouble

Disconnection in transmission reverse clutch ECMV system (Transmission controller system)

Contents of trouble • When signal is output to transmission reverse clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission reverse clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1. • Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode. (Code P6, c6: Reverse clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in reverse. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective reverse clutch so1 lenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRT (male)

Resistance

Between 1 – 2

5 – 15 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN3 (female) O – Resistance Max. 1 Ω 2 (Disconnection in wiring or SRT (female) 1 defective contact in connecWiring harness between TMCN3 (female) 3 – tor) Resistance Max. 1 Ω SRT (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) O – SRT (female) 1 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con4 Resistance troller TMCN3 (female) Between O – 3

5 – 15 Ω

Circuit diagram related to transmission reverse clutch ECMV

20-454 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0253 (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV SYSTEM)

SERVICE CODE E0253 (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0253

Trouble

Short circuit in transmission reverse clutch ECMV system (Transmission controller system)

Contents of trouble • When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission reverse clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1. • Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode. (Code P6, c6: Reverse clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in reverse. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective reverse clutch so1 lenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRT (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) O – SRT (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) O – SRT (female) 1 with Resistance Min. 1 MΩ wiring harness between TMCN3 (female) 3 – SRT (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4


TMCN3 (female)

Resistance

Between O – 3

5 – 15 Ω

Between O – chassis ground

Min. 1 MΩ


D375A-5

20-455 (7) 1

TROUBLESHOOTING

SERVICE CODE E0254 (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV SYSTEM)

SERVICE CODE E0254 (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0254

Trouble

Disconnection in transmission 1st clutch ECMV system (Transmission controller system)

Contents of trouble • When signal is output to transmission 1st clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission 1st clutch solenoid circuit. • Limits operation of engine and transmission. • Auto shift-down function does not work.



• Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode. (Code P7, c7: 1st clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in F1 or R1. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 1st clutch solenoid 1 (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S1T (male)

Resistance

Between 1 – 2

5 – 15 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN3 (female) E – 2 (Disconnection in wiring or Resistance Max. 1 Ω S1T (female) 1 defective contact in connecWiring harness between TMCN3 (female) C – tor) Resistance Max. 1 Ω S1T (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) E – S1T (female) 1 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con4 troller TMCN3 (female) Resistance Between E – C

5 – 15 Ω

Circuit diagram related to transmission 1st clutch ECMV

20-456 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0255 (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV SYSTEM)

SERVICE CODE E0255 (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0255

Trouble

Short circuit in transmission 1st clutch ECMV system (Transmission controller system)

Contents of trouble • When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission 1st clutch solenoid circuit. • Limits operation of engine and transmission. • Auto shift-down function does not work.



• Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode. (Code P7, c7: 1st clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in F1 or R1. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause


1


Defective 1st clutch solenoid (Internal short circuit)

S1T (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) E – S1T (female) 1 with Resistance Min. 1 MΩ chassis ground Short circuit in wiring harness 3 (with another wiring harness)

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) E – S1T (female) 1 with Resistance Min. 1 MΩ wiring harness between TMCN3 (female) C – S1T (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4


TMCN3 (female)

Resistance

Between E – C

5 – 15 Ω

Between E – chassis ground

Min. 1 MΩ


D375A-5

20-457 (7) 1

TROUBLESHOOTING

SERVICE CODE E0256 (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV SYSTEM)

SERVICE CODE E0256 (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0256

Trouble

Disconnection in transmission 2nd clutch ECMV system (Transmission controller system)

Contents of trouble • When signal is output to transmission 2nd clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission 2nd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode. (Code P8, c8: 2nd clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in F2 or R2. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 2nd clutch sole1 noid (Internal short circuit)



Resistance

Between 1 – 2

5 – 15 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between TMCN3 (female) Z – Resistance Max. 1 Ω S2T (female) 1 defective contact in connecWiring harness between TMCN3 (female) 3 – tor) Resistance Max. 1 Ω S2T (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) Z – S2T (female) 1 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN3 (female)

Resistance

Between Z – 3

5 – 15 Ω

Circuit diagram related to transmission 2nd clutch ECMV

20-458 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0257 (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV SYSTEM)

SERVICE CODE E0257 (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0257

Trouble

Short circuit in transmission 2nd clutch ECMV system (Transmission controller system)

Contents of trouble • When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission 2nd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode. (Code P8, c8: 2nd clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in F2 or R2. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 2nd clutch sole1 noid (Internal short circuit)


Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) Z – S2T (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) Z – S2T (female) 1 with Resistance Min. 1 MΩ wiring harness between TMCN3 (female) 3 – S2T (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4


TMCN3 (female)

Resistance

Between Z – 3

5 – 15 Ω

Between Z – chassis ground

Min. 1 MΩ


D375A-5

20-459 (7) 1

TROUBLESHOOTING

SERVICE CODE E0258 (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV SYSTEM)

SERVICE CODE E0258 (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0258

Trouble

Disconnection in transmission 3rd clutch ECMV system (Transmission controller system)

Contents of trouble • When signal is output to transmission 3rd clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission 3rd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode. (Code P9, c9: 3rd clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in F3 or R3. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 3rd clutch sole1 noid (Internal short circuit)



Resistance

Between 1 – 2

5 – 15 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between TMCN3 (female) 5 – Resistance Max. 1 Ω S3T (female) 1 defective contact in connecWiring harness between TMCN3 (female) C – tor) Resistance Max. 1 Ω S3T (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) 5 – S3T (female) 1 with chassis ground

Voltage

Max. 1 V


Resistance

Between 5 – C

5 – 15 Ω

Circuit diagram related to transmission 3rd clutch ECMV

20-460 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0259 (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV SYSTEM)

SERVICE CODE E0259 (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0259

Trouble

Short circuit in transmission 3rd clutch ECMV system (Transmission controller system)

Contents of trouble • When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to transmission 3rd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode. (Code P9, c9: 3rd clutch ECMV output current) Related information • Method of reproducing service code: Start engine and drive in F3 or R3. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 3rd clutch sole1 noid (Internal short circuit)


Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) 5 – S3T (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) 5 – S3T (female) 1 with Resistance Min. 1 MΩ wiring harness between TMCN3 (female) C – S3T (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

4


TMCN3 (female)

Resistance

Between 5 – C

5 – 15 Ω


Min. 1 MΩ


D375A-5

20-461 (7) 1

TROUBLESHOOTING

SERVICE CODE E0260 (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)

SERVICE CODE E0260 (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD CLUTCH) User code

Service code

CALL03

E0260

Contents of trouble

Trouble

Defective engagement of transmission forward clutch (Transmission controller system)

• When signal is output to transmission forward clutch solenoid circuit, fill switch signal is not turned ON.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Judges that transmission is in N (Neutral) when it is set in forward position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to R1. • Inputting from forward clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and drive forward. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective forward clutch fill 1 switch (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. FFT (male)

PCCS lever

Resistance


N

Min. 1 MΩ

F (Forward)

Max. 1 Ω

Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 2 (Disconnection in wiring or de- Wiring harness between TMCN1 (female) 5 – Resistance Max. 1 Ω fective contact in connector) FFT (female) 1 ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3


4 Defective hydraulic system

TMCN1

PCCS lever

Voltage


N

20 – 30 V

F (Forward)

Max. 1 V

If electric system does not have abnormality, hydraulic system may have. Carry out related troubleshooting (H-mode).


20-462 (7) 1

D375A-5

SERVICE CODE E0261 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)

TROUBLESHOOTING

SERVICE CODE E0261 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD CLUTCH) User code

Service code

CALL03

E0261

Contents of trouble

Trouble

Defective disengagement of transmission forward clutch (Transmission controller system)

• When outputting of signal to transmission forward clutch solenoid circuit is stopped, fill switch signal is not turned OFF.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Judges that transmission is in N (Neutral) when it is set in reverse position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1. • Inputting from forward clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and set transmission in neutral. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective forward clutch fill 1 switch (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. FFT (male)

PCCS lever

Resistance


N

Min. 1 MΩ

F (Forward)

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) TMCN1 (female) 5 – FFT (female) 1 with Resistance 1 MΩ chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage


N

20 – 30 V

F (Forward)

Max. 1 V



D375A-5

20-463 (7) 1

TROUBLESHOOTING

SERVICE CODE E0262 (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE CLUTCH)

SERVICE CODE E0262 (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE CLUTCH) User code

Service code

CALL03

E0262

Contents of trouble

Trouble

Defective engagement of transmission reverse clutch (Transmission controller system)

• When signal is output to transmission reverse clutch solenoid circuit, fill switch signal is not turned ON.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Judges that transmission is in N (Neutral) when it is set in reverse position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1. • Inputting from reverse clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and drive in reverse. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective reverse clutch fill 1 switch (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. FRT (male)

PCCS lever

Resistance


N

Min. 1 MΩ

R (Reverse)

Max. 1 Ω

Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 2 (Disconnection in wiring or de- Wiring harness between TMCN1 (female) N – Resistance Max. 1 Ω fective contact in connector) FRT (female) 1 ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between N – chassis ground

N

20 – 30 V

R (Reverse)

Max. 1 V



20-464 (7) 1

D375A-5

SERVICE CODE E0263 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE CLUTCH)

TROUBLESHOOTING

SERVICE CODE E0263 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE CLUTCH) User code

Service code

CALL03

E0263

Contents of trouble

Trouble

Defective disengagement of transmission reverse clutch (Transmission controller system)

• When outputting of signal to transmission reverse clutch solenoid circuit is stopped, fill switch signal is not turned OFF.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Judges that transmission is in N (Neutral) when it is set in forward position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to R1. • Inputting from reverse clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and set transmission in neutral. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective reverse clutch fill 1 switch (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. FRT (male)

PCCS lever

Resistance


N

Min. 1 MΩ

R (Reverse)

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) N – FRT (female) 1 with Resistance Max. 1 Ω chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between N – chassis ground

N

20 – 30 V

R (Reverse)

Max. 1 V



D375A-5

20-465 (7) 1

SERVICE CODE E0264 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)

TROUBLESHOOTING

SERVICE CODE E0264 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH) User code

Service code

CALL03

E0264

Trouble

Defective engagement of transmission 1st clutch (Transmission controller system)

Contents of trouble • When signal is output to transmission 1st clutch solenoid circuit, fill switch signal is not turned ON.


• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Auto shift-down function does not work.



• Inputting from 1st clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and drive in F1 or R1. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 1st clutch fill 1 switch (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then start engine and carry out troubleshooting. F1T (male)

PCCS lever

Resistance


Other than F1·R1

Min. 1 MΩ

F1·R1

Max. 1 Ω

Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 2 (Disconnection in wiring or de- Wiring harness between TMCN1 (female) M – Resistance Max. 1 Ω fective contact in connector) F1T (female) 1 aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between M – chassis ground

Other than F1·R1

20 – 30 V

F1·R1

Max. 1 V



20-466 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0265 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST CLUTCH)

SERVICE CODE E0265 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST CLUTCH) User code

Service code

CALL03

E0265

Contents of trouble


Trouble

Defective disengagement of transmission 1st clutch (Transmission controller system)

• When outputting of signal to transmission 1st clutch solenoid circuit is stopped, fill switch signal is not turned OFF. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission.

• Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Inputting from 1st clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and set transmission in neutral. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 1st clutch fill 1 switch (Internal short circuit)



PCCS lever

Resistance


Other than F1·R1

Min. 1 MΩ

F1·R1

Max. 1 Ω

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) M – F1T (female) 1 with chassis ground


aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between M – chassis ground

Other than F1·R1

20 – 30 V

F1·R1

Max. 1 V



D375A-5

20-467 (7) 1

SERVICE CODE E0266 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)

TROUBLESHOOTING

SERVICE CODE E0266 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH) User code

Service code

CALL03

E0266

Trouble

Defective engagement of transmission 2nd clutch (Transmission controller system)

Contents of trouble • When signal is output to transmission 2nd clutch solenoid circuit, fill switch signal is not turned ON.


• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission.

• Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Inputting from 2nd clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and drive in F2 or R2. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 2nd clutch fill 1 switch (Internal short circuit)



PCCS lever

Resistance


Other than F2·R2

Min. 1 MΩ

F2·R2

Max. 1 Ω

Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 2 (Disconnection in wiring or de- Wiring harness between TMCN1 (female) G – Resistance Max. 1 Ω fective contact in connector) F2T (female) 1 aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between G – chassis ground

Other than F2·R2

20 – 30 V

F2·R2

Max. 1 V



20-468 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0267 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND CLUTCH)

SERVICE CODE E0267 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND CLUTCH) User code

Service code

CALL03

E0267

Contents of trouble


Trouble

Defective disengagement of transmission 2nd clutch (Transmission controller system)

• When outputting of signal to transmission 2nd clutch solenoid circuit is stopped, fill switch signal is not turned OFF. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Auto shift-down function does not work.



• Inputting from 2nd clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and set transmission in neutral. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 2nd clutch fill 1 switch (Internal short circuit)



PCCS lever

Resistance


Other than F2·R2

Min. 1 MΩ

F2·R2

Max. 1 Ω

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) TMCN1 (female) G – F2T (female) 1 with Resistance 1 MΩ chassis ground aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between G – chassis ground

Other than F2·R2

20 – 30 V

F2·R2

Max. 1 V



D375A-5

20-469 (7) 1

SERVICE CODE E0268 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)

TROUBLESHOOTING

SERVICE CODE E0268 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH) User code

Service code

CALL03

E0268

Trouble

Defective engagement of transmission 3rd clutch (Transmission controller system)

Contents of trouble • When signal is output to transmission 3rd clutch solenoid circuit, fill switch signal is not turned ON.


• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission.

• Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine • Once machine is stopped, travel is limited to F1 and R1. • Inputting from 3rd clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and drive in F3 or R3. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 3rd clutch fill 1 switch (Internal short circuit)



PCCS lever

Resistance


Other than F3·R3

Min. 1 MΩ

F3·R3

Max. 1 Ω

Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 2 (Disconnection in wiring or de- Wiring harness between TMCN1 (female) A – Resistance Max. 1 Ω fective contact in connector) F3T (female) 1 aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between A – chassis ground

Other than F3·R3

20 – 30 V

F3·R3

Max. 1 V



20-470 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0269 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD CLUTCH)

SERVICE CODE E0269 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD CLUTCH) User code

Service code

CALL03

E0269

Contents of trouble


Trouble

Defective disengagement of transmission 3rd clutch (Transmission controller system)

• When outputting of signal to transmission 3rd clutch solenoid circuit is stopped, fill switch signal is not turned OFF. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Auto shift-down function does not work.



• Inputting from 3rd clutch fill switch (ON·OFF) can be checked in monitoring mode. (Code 7H: Transmission fill switch input) Related information • Method of reproducing service code: Start engine and set transmission in neutral. ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start. Cause Defective 3rd clutch fill 1 switch (Internal short circuit)



PCCS lever

Resistance


Other than F3·R3

Min. 1 MΩ

F3·R3

Max. 1 Ω

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) A – F3T (female) 1 with Resistance Max. 1 Ω chassis ground aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 3



TMCN1

PCCS lever

Voltage

Between A – chassis ground

Other than F3·R3

20 – 30 V

F3·R3

Max. 1 V



D375A-5

20-471 (7) 1

SERVICE CODE E0270 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE ENGAGEMENT)] SERVICE CODE E0270 E0271 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE SERVICE CODE [DOUBLE TROUBLE IN TRANSMISSION CLUTCH DISENGAGEMENT)] (DEFECTIVE ENGAGEMENT)]

TROUBLESHOOTING

SERVICE CODE E0270 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE ENGAGEMENT)] User code

Service code

CALL03

E0270

Contents of trouble


Trouble

Double trouble in transmission clutch (Defective engagement) (Transmission controller system)

• Following service codes related to transmission clutch are displayed simultaneously. Either of [E0254] and [E0255] and either of [E0256] and [E0257] • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Auto shift-down function does not work.



• Method of reproducing service code: Start engine and drive machine.

Related information ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-

chine will not start. Cause



Carry out troubleshooting for service codes displayed simultaneously. [E0254], [E0255], [E0256], [E0257]

SERVICE CODE E0271 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE DISENGAGEMENT)] User code

Service code

CALL

E0271

Trouble

Double trouble in transmission clutch (Defective disengagement) (Transmission controller system)

• Following service codes related to transmission clutch are displayed simultaneously. 1Either of [E0250] and [E0251] and either of [E0252] and [E0253] 2Either of [E0258] and [E0259] and [E0270] 3[E0260] and [E0262] Contents of trouble 4[E0261] and [E0263] 5[E0264], [E0266], and [E0268] 6[E0265] and [E0267] 7[E0265] and [E0269] 8[E0267] and [E0269] Action of controller

• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Auto shift-down function does not work.


• Once machine is stopped, it cannot travel any more.

• Method of reproducing service code: Start engine and drive machine.

Related information ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-

chine will not start. Cause Possible causes and standard value in normal state

20-472 1


Carry out troubleshooting for service codes displayed simultaneously. [E0250], [E0251], [E0252], [E0253], [E0258], [E0259], [E0260], [E0261], [E0262], [E0263], [E0264], [E0265], [E0266], [E0267], [E0268], [E0269], [E0270]

D375A-5

TROUBLESHOOTING

SERVICE CODE E0306 (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM)

SERVICE CODE E0306 (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM) User code

Service code

E02

E0306

Trouble

Short circuit in blade tilt right oil pressure switch system (Transmission controller system)

Contents of trouble • Signal of blade tilt right oil pressure switch circuit was kept turned ON for 180 seconds.


• Flashes caution lamp and turns on caution buzzer. • Judges that oil pressure switch is turned OFF.

• When pitch and dump operation or right dual tilt operation is performed, right single tilt mechanism Problem that appears on machine operates. • Inputting from blade tilt right oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code bH: Blade lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Service code is reproduced after 180 seconds). Cause


After reproductive operation, if service code P is still displayed (to inDefective operation of lever dicate that trouble is repaired), lever may have been so operated that 1 (Electric system is normal) error would be detected. Defective blade tilt right oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. TRS (male) Between 1 – 2

Blade lever

Resistance

Neutral

Min. 1 MΩ

Right tilt

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) TMCN2 (female) 6 – TRS (female) 1 with Resistance 1 MΩ chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4


TMCN2, TMCN1

Blade lever

Voltage

Between TMCN2 6 – TMCN1 4, @

Neutral

5 – 11 V

Right tilt

Max. 1 V

Circuit diagram related to blade tilt right oil pressure switch

D375A-5

20-473 1 (5)

SERVICE CODE E0307 (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0307 (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM) User code

Service code

E02

E0307

Trouble

Short circuit in blade tilt left oil pressure switch system (Transmission controller system)

Contents of trouble • Signal of blade tilt left oil pressure switch circuit was kept turned ON for 180 seconds.


• Flashes caution lamp and turns on caution buzzer. • Judges that oil pressure switch is turned OFF.

• When pitch and dump operation or right dual tilt operation is performed, left single tilt mechanism opProblem that appears on machine erates. • Inputting from blade tilt left oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code bH: Blade lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Service code is reproduced after 180 seconds). Cause


After reproductive operation, if service code P is still displayed (to inDefective operation of lever dicate that trouble is repaired), lever may have been so operated that 1 (Electric system is normal) error would be detected. Defective blade tilt left oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. TLS (male) Between 1 – 2

Blade lever

Resistance

Neutral

Min. 1 MΩ

Left tilt

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) TMCN2 (female) F – TLS (female) 1 with Resistance 1 MΩ chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4


TMCN2, TMCN1

Blade lever

Voltage

Between TMCN2 F – TMCN1 4, @

Neutral

5 – 11 V

Left tilt

Max. 1 V

Circuit diagram related to blade tilt left oil pressure switch

20-474 1 (5)

D375A-5

TROUBLESHOOTING

SERVICE CODE E0308 (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE SWITCH SYSTEM)

SERVICE CODE E0308 (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE SWITCH SYSTEM) User code

Service code

E02

E0308

Trouble

Short circuit in ripper lift raise oil pressure switch system (Steering controller system)

Contents of trouble • Signal of ripper lift raise oil pressure switch circuit was kept turned ON for 60 seconds.

Action of controller • Judges that oil pressure switch is turned OFF. Problem that • Shoe slip control (SSC) function does not work normally. appears on machine

• Inputting from ripper lift raise oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code R7: Ripper lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Service code is reproduced after 60 seconds). Cause


After reproductive operation, if service code P is still displayed (to inDefective operation of lever 1 dicate that trouble is repaired), lever may have been so operated that (Electric system is normal) error would be detected. Defective ripper lift raise oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. RPU (male) Between 1 – 2

Ripper lever

Resistance

Neutral

Min. 1 MΩ

Raise

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) NGICN2 (female) 3 – RPU (female) 1 with Resistance 1 MΩ chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective steering controller

NGICN2, NGICN1

Ripper lever

Voltage

Between NGICN2 3 – NGICN1 4, @

Neutral

5 – 11 V

Raise

Max. 1 V

Circuit diagram related to ripper lift raise oil pressure switch

D375A-5

20-475 1 (5)

TROUBLESHOOTING

SERVICE CODE E0309 (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE SWITCH SYSTEM)

SERVICE CODE E0309 (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE SWITCH SYSTEM) User code

Service code

E02

E0309

Trouble

Short circuit in ripper lift lower oil pressure switch system (Steering controller system)

Contents of trouble • Signal of ripper lift lower oil pressure switch circuit was kept turned ON for 60 seconds.


• Inputting from ripper lift lower oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code R7: Ripper lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Service code is reproduced after 60 seconds). Cause


After reproductive operation, if service code P is still displayed (to inDefective operation of lever 1 dicate that trouble is repaired), lever may have been so operated that (Electric system is normal) error would be detected. Defective ripper lift lower oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. RPD (male) Between 1 – 2

Ripper lever

Resistance

Neutral

Min. 1 MΩ

Lower

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) NGICN1 (female) N – RPD (female) 1 with Resistance 1 MΩ chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective steering controller

NGICN1

Ripper lever

Voltage

Between NGICN1 N – 4, @

Neutral

5 – 11 V

Lower

Max. 1 V

Circuit diagram related to ripper lift lower oil pressure switch

20-476 1 (5)

D375A-5

TROUBLESHOOTING

SERVICE CODE E0310 (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH SYSTEM)

SERVICE CODE E0310 (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH SYSTEM) User code

Service code

E02

E0310

Trouble

Short circuit in ripper tilt-in oil pressure switch system (Steering controller system)

Contents of trouble • Signal of ripper tilt-in oil pressure switch circuit was kept turned ON for 60 seconds.


• Inputting from ripper tilt-in oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code R7: Ripper lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Service code is reproduced after 60 seconds). Cause


After reproductive operation, if service code P is still displayed (to inDefective operation of lever 1 dicate that trouble is repaired), lever may have been so operated that (Electric system is normal) error would be detected. Defective ripper tilt-in oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. RTI (male) Between 1 – 2

Ripper lever

Resistance

Neutral

Min. 1 MΩ

Tilt-in

Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) NGICN1 (female) H – RTI (female) 1 with Resistance 1 MΩ chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective steering controller

NGICN1

Ripper lever

Voltage

Between NGICN1 H – 4, @

Neutral

5 – 11 V

Tilt-in

Max. 1 V

Circuit diagram related to ripper tilt-in oil pressure switch

D375A-5

20-477 1 (5)

TROUBLESHOOTING

SERVICE CODE E0311 (DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)

SERVICE CODE E0311 (DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS) User code

Service code

E02

E0311

Trouble

Disconnection or short circuit in blade pitch switch systems (Transmission controller system)

Contents of trouble • Signals of both blade pitch switch circuit systems are turned ON or OFF simultaneously.



Problem that • Blade does not pitch (When pitching operation is performed, blade tilts). appears on machine

• NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from blade pitch switch (ON·OFF) can be checked in monitoring mode. Related information (Code bD: Blade lever knob switch input) • Method of reproducing service code: Turn starting switch ON and operate blade pitch switch. Cause


Defective blade pitch switch 1 (Internal disconnection or short circuit)

P03 (male)

Blade pitch switch OFF (Released)

ON (Pressed)

Resistance between 1–5

Max. 1 Ω

Min. 1 MΩ


Min. 1 MΩ

Max. 1 Ω


Wiring harness between TMCN2 (female) E – Resistance Max. 1 Ω P03 (female) 5 Wiring harness between TMCN2 (female) 5 – Resistance Max. 1 Ω P03 (female) 2 Wiring harness between TMCN1 (female) 4, Resistance Max. 1 Ω @ – P03 (female) 1 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes Short circuit of wiring harness between Short circuit with chassis and standard valTMCN2 (female) E – P03 (female) 5 with ue in normal state 3 ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between TMCN2 (female) 5 – P03 (female) 2 with chassis ground




Short circuit of wiring harness between TMCN2 (female) E – P03 (female) 5 with chassis ground

Voltage

Max. 1 V

Short circuit of wiring harness between TMCN2 (female) 5 – P03 (female) 2 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

5

20-478 1 (5)


TMCN1, TMCN2

Blade pitch switch OFF (Released)

ON (Pressed)

Voltage between TMCN2 E – TMCN1 4, @

Max. 1 V

5 – 11 V

Voltage between TMCN2 5 – TMCN1 4, @

5 – 11 V

Max. 1 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0311 (DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)

Circuit diagram related to blade tilt switch and blade pitch switch

D375A-5

20-479 1

SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)

TROUBLESHOOTING

SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS) User code

Service code

E02

E0312

Trouble

Disconnection or short circuit in blade tilt switch systems (Transmission controller system)

Contents of trouble • Signals of both blade tilt switch circuit systems are turned ON or OFF simultaneously.


• Flashes caution lamp and turns on caution buzzer. • Assumes that switch is at SINGLE position.

• Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism Problem that appears on machine works). • NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from blade tilt switch (ON·OFF) can be checked in monitoring mode. Related information (Code bD: Blade lever knob switch input) • Method of reproducing service code: Turn starting switch ON and operate blade tilt switch. Cause


Defective blade tilt switch 1 (Internal disconnection or short circuit)

P03 (male)

Blade tilt switch SINGLE

DUAL


Max. 1 Ω

Min. 1 MΩ


Min. 1 MΩ

Max. 1 Ω


Wiring harness between TMCN2 (female) Y – Resistance Max. 1 Ω P03 (female) 6 Wiring harness between TMCN2 (female) O – Resistance Max. 1 Ω P03 (female) 4 Wiring harness between TMCN1 (female) 4, Resistance Max. 1 Ω @ – P03 (female) 3 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes Short circuit of wiring harness between Short circuit with chassis and standard valTMCN2 (female) Y – P03 (female) 6 with ue in normal state 3 ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between TMCN2 (female) O – P03 (female) 4 with chassis ground




Short circuit of wiring harness between TMCN2 (female) Y – P03 (female) 6 with chassis ground

Voltage

Max. 1 V

Short circuit of wiring harness between TMCN2 (female) O – P03 (female) 4 with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con5 troller

20-480 1 (5)

TMCN1, TMCN2

Blade tilt switch SINGLE

DUAL

Voltage between TMCN2 Y – TMCN1 4, @

Max. 1 V

5 – 11 V

Voltage between TMCN2 O – TMCN1 4, @

5 – 11 V

Max. 1 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)

Circuit diagram related to blade tilt switch and blade pitch switch

D375A-5

20-481 1

TROUBLESHOOTING

SERVICE CODE E0321 (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID SYSTEM)

SERVICE CODE E0321 (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID SYSTEM) User code

Service code

E01

E0321

Trouble

Disconnection in blade dual selector solenoid system (Transmission controller system)

Contents of trouble When signal is output to blade dual selector solenoid circuit, current does not flow.

Action of controller Stops outputting to blade dual selector solenoid circuit. Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism Problem that appears on machine works). Related information

Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode. (Code d4: Blade dual solenoid drive voltage) Method of reproducing service code: Turn starting switch ON and perform blade dual tilt operation. Cause Defective blade dual selector 1 solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SOL2 (male)

Resistance

Between 1 2

10 40 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN3 (female) G Resistance Max. 1 Ω 2 (Disconnection in wiring or SOL2 (female) 1 defective contact in connecPossible causes Wiring harness between SOL (female) 2 tor) and standard valResistance Max. 1 Ω chassis ground ue in normal state ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 3 source in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) TMCN3 (female) G SOL2 (female) 1 with Voltage Max. 1 V chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con4 TMCN3 (female) Resistance troller Between G chassis ground

10 40 Ω

Circuit diagram related to blade dual selector solenoid

20-482 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0322 (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID SYSTEM)

SERVICE CODE E0322 (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID SYSTEM) User code

Service code

E01

E0322

Trouble

Short circuit in blade dual selector solenoid system (Transmission controller system)

Contents of trouble When signal was output to blade dual selector solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to blade dual selector solenoid circuit. Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism Problem that appears on machine works). Related information

Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode. (Code d4: Blade dual solenoid drive voltage) Method of reproducing service code: Turn starting switch ON and perform blade dual tilt operation. Cause Defective blade dual selector 1 solenoid (Internal short circuit)


Resistance

Between 1 2

10 40 Ω

Between 1 chassis ground Min. 1 MΩ Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting and standard valwithout turning starting switch ON. Short circuit with chassis ue in normal state 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) G SOL2 (female) 1 with Resistance Min. 1 MΩ chassis ground Defective transmission con3 troller


Resistance

Between G chassis ground

10 40 Ω

Circuit diagram related to blade dual selector solenoid

D375A-5

20-483 1

TROUBLESHOOTING

SERVICE CODE E0323 (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID SYSTEM)

SERVICE CODE E0323 (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID SYSTEM) User code

Service code

E02

E0323

Trouble

Disconnection in blade pitch selector solenoid system (Transmission controller system)

Contents of trouble When signal is output to blade pitch selector solenoid circuit, current does not flow.


Flashes caution lamp and turns on caution buzzer. Stops outputting to blade pitch selector solenoid circuit.

Problem that Blade does not pitch (When pitching operation is performed, blade tilts). appears on machine Related information

Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode. (Code d3: Blade pitch solenoid drive voltage) Method of reproducing service code: Turn starting switch ON and perform blade pitch operation. Cause


★ Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch selecwithout turning starting switch ON. 1 tor solenoid Resistance SOL1 (male) (Internal short circuit) Between 1 2 10 40 Ω ★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN3 (female) [ Resistance Max. 1 Ω 2 (Disconnection in wiring or SOL1 (female) 1 defective contact in connecPossible causes Wiring harness between SOL1 (female) 2 tor) and standard valResistance Max. 1 Ω chassis ground ue in normal state ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 3 source in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) TMCN3 (female) [ SOL1 (female) 1 with Voltage Max. 1 V chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con4 TMCN3 (female) Resistance troller Between [ chassis ground

10 40 Ω

Circuit diagram related to blade pitch selector solenoid

20-484 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0324 (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID SYSTEM)

SERVICE CODE E0324 (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID SYSTEM) User code

Service code

E02

E0324

Trouble

Short circuit in blade pitch selector solenoid system (Transmission controller system)

Contents of trouble When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.


Flashes caution lamp and turns on caution buzzer. Stops outputting to blade pitch selector solenoid circuit.

Problem that Blade does not pitch (When pitching operation is performed, blade tilts). appears on machine Related information

Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode. (Code d3: Blade pitch solenoid drive voltage) Method of reproducing service code: Turn starting switch ON and perform blade pitch operation. Cause Defective blade pitch selec1 tor solenoid (Internal short circuit)


Resistance

Between 1 2

10 40 Ω

Between 1 chassis ground Min. 1 MΩ Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting and standard valwithout turning starting switch ON. Short circuit with chassis ue in normal state 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) [ SOL1 (female) 1 with Resistance Min. 1 MΩ chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con3 troller TMCN3 (female) Resistance Between [ chassis ground

10 40 Ω

Circuit diagram related to blade pitch selector solenoid

D375A-5

20-485 1

TROUBLESHOOTING

SERVICE CODE E0329 (ABNORMAL HYDRAULIC OIL TEMPERATURE)

SERVICE CODE E0329 (ABNORMAL HYDRAULIC OIL TEMPERATURE) User code

Service code

E01

E0329

Trouble

Hydraulic oil temperature sensor: Out of input signal range

Contents of trouble • The signal from the hydraulic oil temperature sensor is out of the normal range.

Action of controller • None in particular. Problem that • The hydraulic oil thermometer of the monitor panel may not be displayed normally. appears on machine Related information • Method of reproducing error code: Turn the starting switch ON or start the engine.

Cause


Defective hydraulic oil tem- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch. perature sensor 1 Resistance (Internal disconnection or 452 (male) short circuit) Between (1) and chassis ground Min. 1 MΩ


Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting ness without turning starting switch. 2 (Disconnection in wiring harness or defective contact in Wiring harness between CN1 (female) (8) and Resistance Max. 1 Ω 452 (female) (1) connector) ★ Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch. 3 ground in wiring harness Between CN1 (female) (8) – 452 (female) (1) (Contact with ground circuit) Resistance Min. 1 MΩ wiring harness and chassis ground Short circuit with power 4 source in wiring harness (Contact with 24-V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between CN1 (female) (8) – 452 (female) (1) wiring harness and chassis ground

Voltage

Max. 1 V

Circuit diagram related to hydraulic oil temperature sensor

20-485-1 (6)

D375A-5

TROUBLESHOOTING

SERVICE CODE E0364 (DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM)

SERVICE CODE E0364 (DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM) User code

Service code

E0364

Trouble

Disconnection in front large pump oil pressure sensor system (Transmission controller system)

Contents of trouble Signal voltage of front large pump oil pressure sensor circuit is below 0.5 V.

Action of controller Does not take any particular action. Problem that Oil pressure of front large pump cannot be monitored. appears on machine Related information

Outputting from front large pump oil pressure sensor (Voltage) can be checked in monitoring mode. (Code 4L: Voltage of front large pump oil pressure sensor) Method of reproducing service code: Turn starting switch ON. Cause


Defective sensor 24 V power See if service code [E0146] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective front large pump 2 oil pressure sensor (Internal trouble)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LPP

Between C A

Voltage 0.5 6.0 V

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN1 (female) F 3 (Disconnection in wiring or Resistance Max. 1 Ω Possible causes LPP (female) B and standard valdefective contact in connecWiring harness between TMCN1 (female) 9 ue in normal state tor) Resistance Max. 1 Ω LPP (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) 9 LPP (female) C with Resistance Min. 1 MΩ chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con5 TMCN1 Voltage troller Between 9 K

0.5 6.0 V

Circuit diagram related to front large pump oil pressure sensor

20-486 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0365 (SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM)

SERVICE CODE E0365 (SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM) User code

Service code

E0365

Trouble

Short circuit in front large pump oil pressure sensor system (Transmission controller system)

Contents of trouble Signal voltage of front large pump oil pressure sensor circuit is above 6.0 V.

Action of controller Does not take any particular action. Problem that Oil pressure of front large pump cannot be monitored. appears on machine

Outputting from work equipment large pump oil pressure sensor (Voltage) can be checked in monitoring mode. Related information (Code 4L: Voltage of front large pump oil pressure sensor) Method of reproducing service code: Turn starting switch ON. Cause


Defective sensor 24 V power See if service code [E0146] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective front large pump 2 oil pressure sensor (Internal trouble) Possible causes and standard value in normal state



★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LPP

Between C A

Voltage 0.5 6.0 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN1 (female) 9 LPP (female) C with chassis ground

Voltage

Max. 1 V


Voltage

Between 9 K

0.5 6.0 V

Circuit diagram related to front large pump oil pressure sensor

D375A-5

20-487 1

TROUBLESHOOTING

SERVICE CODE E0366 (DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE SENSOR SYSTEM)

SERVICE CODE E0366 (DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE SENSOR SYSTEM) User code

Service code

E0366

Trouble

Disconnection in center small pump oil pressure sensor system (Transmission controller system)

Contents of trouble Signal voltage of center small pump oil pressure sensor circuit is below 0.5 V.

Action of controller Does not take any particular action. Problem that Oil pressure of center small pump cannot be monitored. appears on machine Related information

Outputting from center small pump oil pressure sensor (Voltage) can be checked in monitoring mode. (Code 45: Voltage of center small pump oil pressure sensor) Method of reproducing service code: Turn starting switch ON. Cause


Defective sensor 24 V power See if service code [E0146] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective center small pump 2 oil pressure sensor (Internal trouble)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. SPP

Between C A

Voltage 0.5 6.0 V

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN1 (female) F 3 (Disconnection in wiring or Resistance Max. 1 Ω Possible causes SPP (female) B and standard valdefective contact in connecWiring harness between TMCN1 (female) 3 ue in normal state tor) Resistance Max. 1 Ω SPP (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) 3 SPP (female) C with Resistance Min. 1 MΩ chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con5 TMCN1 Voltage troller Between 3 K

0.5 6.0 V

Circuit diagram related to center small pump oil pressure sensor

20-488 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0367 (SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE SENSOR SYSTEM)

SERVICE CODE E0367 (SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE SENSOR SYSTEM) User code

Service code

E0367

Trouble

Short circuit in center small pump oil pressure sensor system (Transmission controller system)

Contents of trouble Signal voltage of center small pump oil pressure sensor circuit is above 6.0 V.

Action of controller Does not take any particular action. Problem that Oil pressure of center small pump cannot be monitored. appears on machine Related information

Outputting from center small pump oil pressure sensor (Voltage) can be checked in monitoring mode. (Code 45: Voltage of center small pump oil pressure sensor) Method of reproducing service code: Turn starting switch ON. Cause


Defective sensor 24 V power See if service code [E0146] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective center small pump 2 oil pressure sensor (Internal trouble) Possible causes and standard value in normal state


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. SPP

Between C A

Voltage 0.5 6.0 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN1 (female) 3 SPP (female) C with chassis ground

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con4 troller TMCN1 Voltage Between 3 K

0.5 6.0 V

Circuit diagram related to center small pump oil pressure sensor

D375A-5

20-489 1

TROUBLESHOOTING

SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM)

SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM) User code

Service code

CALL03

E0405

Trouble

Disconnection or short circuit in fuel control dial system (Steering controller system)

Contents of trouble Signal voltage of fuel control dial circuit is below 0.30 V or above 4.55 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Continues controlling with signal of decelerator pedal potentiometer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Related information

Inputting from fuel control dial (Voltage) can be checked in monitoring mode. (Code F6: Voltage of fuel control dial) Method of reproducing service code: Turn starting switch ON. Cause


Defective sensor 5 V power See if service code [E0143] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fuel control dial 2 (Internal disconnection or short circuit)

TL1 (male)

Resistance

Between R S

0.25 7.0 kΩ

Between R T Between S T

4.0 6.0 kΩ 0.25 7.0 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN1 (female) L Resistance Max. 1 Ω 3 (Disconnection in wiring or TL1 (female) R Possible causes defective contact in connecWiring harness between NGICN1 (female) 8 and standard valtor) Resistance Max. 1 Ω TL1 (female) S ue in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN1 (female) 8 TL1 (female) S with Resistance Min. 1 MΩ chassis ground Short circuit with power 5 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN1 (female) 8 TL1 (female) S

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con6 NGICN1 Voltage troller Between 8 K

20-490 1

0.30 4.33 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM)

Circuit diagram related to fuel control dial

D375A-5

20-491 1

SERVICE CODE E0430 (ENGINE OIL: ABNORMAL OIL PRESSURE) SERVICE CODE E0431 (ABNORMAL RADIATOR COOLANT LEVEL) SERVICE CODE E0432 (RADIATOR COOLANT: OVERHEATING)

TROUBLESHOOTING

SERVICE CODE E0430 (ENGINE OIL: ABNORMAL OIL PRESSURE) User code

Service code

CALL

E0430

Trouble

Engine oil: Abnormal oil pressure

Contents of trouble • While the engine is running, the engine oil pressure caution lamp flashes.

Action of controller • Sounds the caution buzzer (Function of monitor panel). Problem that • If the machine is operated as it is, the engine may be damaged. appears on machine Related information • Method of reproducing error code: Start the engine.

Cause Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting.

Lowering of engine oil presA phenomenon seems to have caused lowering of the engine oil pres1 sure sure. Find and stop it and repair the damaged part. (When system is normal) 2

Defective engine oil pressure caution lamp system

Carry out troubleshooting for the engine oil pressure caution lamp system according to "E-8 While engine is running, emergency stop item flashes" in E-mode.

SERVICE CODE E0431 (ABNORMAL RADIATOR COOLANT LEVEL) User code

Service code

CALL

E0431

Trouble

Abnormal radiator coolant level

Contents of trouble • When the starting switch is turned ON, the radiator coolant level caution lamp flashes.

Action of controller Problem that • If the machine is operated as it is, the engine may be damaged. appears on machine Related information • Method of reproducing error code: Turn the starting switch ON.



Lowering of radiator coolant A phenomenon seems to have caused lowering of the radiator coolant 1 level level. Find and stop it and repair the damaged part. (When system is normal) 2

Defective radiator coolant level caution lamp system

Carry out troubleshooting for the radiator coolant level caution lamp system according to "E-6 When starting switch is turned ON, basic item flashes" in E-mode.

SERVICE CODE E0432 (RADIATOR COOLANT: OVERHEATING) User code

Service code

E01

E0432

Trouble

Radiator coolant: Overheating

Contents of trouble • While the engine is running, the engine coolant temperature caution lamp flashes.

Action of controller • Sounds the caution buzzer (Function of monitor panel). Problem that • If the machine is operated as it is, the engine may be damaged. appears on machine Related information • Method of reproducing error code: Start the engine.


20-491-1 (6)


Overheating of engine coolA phenomenon seems to have caused overheating of the engine cool1 ant ant. Find and stop it and repair the damaged part. (When system is normal) Defective engine coolant 2 temperature caution lamp system

Carry out troubleshooting for the engine coolant temperature caution lamp system according to "E-8 While engine is running, emergency stop item flashes" in E-mode.

D375A-5

SERVICE CODE E0486 (ABNORMALITY IN SELECTION OF TRANSMISSION CONTROLLER SPECIFICATION)

TROUBLESHOOTING

SERVICE CODE E0486 (ABNORMALITY IN SELECTION OF TRANSMISSION CONTROLLER SPECIFICATION) User code

Service code

CALL

E0486

Contents of trouble

Trouble

Abnormality in selection of transmission controller specification (Transmission controller system)

Internal setting of transmission controller specification is different from specification setting signal (Transmission controller cannot recognize specification setting normally).

Flashes caution lamp and turns on caution buzzer. Action of controller Stops transmission controller from outputting all signals. Limits operation of engine, transmission, and brake. Machine does not move at all.


Once machine is stopped, it cannot travel any more.


1

Cause


Defective adjustment of transmission controller

After adjustment mode is executed, if service code changes to P (to indicate that trouble is repaired), system is normal. Adjustment code 7A: Check of specification code (Transmission controller)

Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes without turning starting switch ON. and standard val- 2 ness (Disconnection in wiring or deue in normal state Wiring harness between TMCN3 (female) @ Resistance Max. 1 Ω fective contact in connector) chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con3 TMCN3 Voltage troller Between @ chassis ground

Max. 1 V

Circuit diagram related to transmission controller specification selection signal

20-492 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0501 (DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM)

SERVICE CODE E0501 (DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM) User code

Service code

E01

E0501

Trouble

Disconnection or short circuit in acceleration sensor system (Steering controller system)

Contents of trouble • Signal voltage of acceleration sensor is below 0.3 V or above 4.7 V.

Action of controller • Stops shoe slip control (SSC) function. Problem that • Even if shoe slips, engine speed does not change. appears on machine Related information

• Inputting from acceleration sensor (Voltage) can be checked in monitoring mode. (Code A5: Voltage of acceleration sensor) • Method of reproducing service code: Turn starting switch ON. Cause


Defective sensor 24 V power See if service code [E0143] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective acceleration sen2 sor (Internal trouble)


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. SS3

Voltage

Between 2 – 3

0.75 – 4.25 V

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN1 (female) L Resistance Max. 1 Ω 3 (Disconnection in wiring or – SS3 (female) 1 defective contact in connecWiring harness between NGICN1 (female) 1 tor) Resistance Max. 1 Ω – SS3 (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN1 (female) 1 – SS3 (female) 2 with Resistance Min. 1 MΩ chassis ground Short circuit with power 5 source in wiring harness (Contact with 24 V circuit)


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN1 (female) 1 – SS3 (female) 2

Voltage

Max. 1 V


Voltage

Between 1 – K

0.75 – 4.25 V

Circuit diagram related to acceleration sensor

D375A-5

20-493 1

TROUBLESHOOTING

SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)

SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM) User code

Service code

E01

E0610

Trouble

Disconnection in back-up alarm relay system (Transmission controller system)

Contents of trouble • When GND signal for back-up alarm relay circuit is turned off, 24 V is not generated.

Action of controller • Stops outputting to back-up alarm relay circuit. Problem that • Back-up alarm does not sound. appears on machine

• Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode. (Code db: Back-up alarm relay drive voltage) Related information • Method of reproducing service code: Turn starting switch ON and set parking brake lever in neutral. ★ This service code detects abnormality on primary side (coil side) of back-up alarm relay and cannot detect abnormality on secondary side (contact side). Cause 1 Defective fuse FS4-1 Defective back-up alarm re2 lay (Internal disconnection)


Standard value in normal state/Remarks on troubleshooting If fuse is broken, circuit probably has short circuit with chassis ground. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKA (male)

Resistance

Between 1 – 2

200 – 400 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN2 (female) H – 3 (Disconnection in wiring or Resistance Max. 1 Ω BKA (female) 2 defective contact in connecWiring harness between BKA (female) 1 – tor) Resistance Max. 1 Ω FS4-1 outlet ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between 4 ground in wiring harness TMCN2 (female) H – BKA (female) 2 with (Contact with ground circuit) chassis ground


Short circuit of wiring harness between BKA Resistance Min. 1 MΩ (female) 1 – FS4-1 outlet with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5

20-494 1 (5)


TMCN2

PCCS lever

Voltage

Between H – chassis ground

Neutral

20 – 30 V

Reverse

Max. 1 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)

Circuit diagram related to back-up alarm

D375A-5

20-495 1

TROUBLESHOOTING

SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)

SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM) User code

Service code

E01

E0611

Trouble

Short circuit in back-up alarm relay system (Transmission controller system)

Contents of trouble • When GND signal for back-up alarm relay circuit was output, abnormal current flowed.

Action of controller • Stops outputting to back-up alarm relay circuit. Problem that • Back-up alarm does not sound. appears on machine

• Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode. (Code db: Back-up alarm relay drive voltage) Related information • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (in reverse). ★ This service code detects abnormality on primary side (coil side) of back-up alarm relay and cannot detect abnormality on secondary side (contact side). Cause Defective back-up alarm re1 lay (Internal disconnection) Short circuit with power Possible causes and standard val- 2 source in wiring harness (Contact with 24 V circuit) ue in normal state

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKA (male)

Resistance

Between 1 – 2

200 – 400 Ω

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN2 (female) H – BKA (female) 2

Voltage

Max. 1 V


20-496 1 (5)


TMCN2

PCCS lever

Voltage

Between H – chassis ground

Neutral

20 – 30 V

Reverse

Max. 1 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)


D375A-5

20-497 1

TROUBLESHOOTING

SERVICE CODE E0660 (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)

SERVICE CODE E0660 (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM) User code

Service code

E0660

Trouble

Disconnection in ACC signal drive relay system (Steering controller system)

Contents of trouble When signal is output to ACC signal drive circuit, current does not flow.

Action of controller Stops outputting to ACC signal drive relay circuit. Problem that Turbocharger timer function does not work (if equipped). appears on machine

Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode. (Code d8: Engine controller relay drive voltage) Method of reproducing service code: Related information Turn starting switch ON and OFF (when turbocharger timer is in operation). ★ This service code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot detect abnormality on secondary side (contact side). Cause Defective ACC signal drive 1 relay (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDR (male)

Resistance

Between 1 2

200 400 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN3 (female) H Resistance Max. 1 Ω 2 (Disconnection in wiring or SDR (female) 1 Possible causes defective contact in connecand standard valWiring harness between SDR (female) 2 tor) Resistance Max. 1 Ω ue in normal state chassis ground Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN3 (female) H SDR (female) 1

Voltage

Max. 1 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission con4 Resistance SGICN3 (female) troller Between H chassis ground

200 400 Ω

Circuit diagram related to ACC signal drive relay

20-498 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0661 (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)

SERVICE CODE E0661 (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM) User code

Service code

E0661

Trouble

Short circuit in ACC signal drive relay system (Steering controller system)

Contents of trouble When signal is output to ACC signal drive circuit, abnormal current flowed.

Action of controller Stops outputting to ACC signal drive relay circuit. Problem that Turbocharger timer function does not work (if equipped). appears on machine

Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode. (Code d8: Engine controller relay drive voltage) Method of reproducing service code: Related information Turn starting switch ON and OFF (when turbocharger timer is in operation). ★ This service code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot detect abnormality on secondary side (contact side). Cause Defective ACC signal drive 1 relay (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDR (male)

Resistance

Between 1 2

200 400 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes without turning starting switch ON. Short circuit with chassis and standard val2 ground in wiring harness Short circuit of wiring harness between ue in normal state (Contact with ground circuit) NGICN3 (female) H SDR (male) 1 with Resistance Min. 1 MΩ chassis ground Defective transmission con3 troller


Resistance

Between H chassis ground

200 400 Ω

Circuit diagram related to ACC signal drive relay

D375A-5

20-499 1

TROUBLESHOOTING


SERVICE CODE E0721 (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM) User code

Service code

CALL03

E0721

Trouble

Disconnection or short circuit in pitch angle sensor system (Steering controller system)

Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.


Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Steering function and braking function may lower.



★ Since pitch angle sensor signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part. (Related code: E0221) Related information Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode. (Code A8: Pitch angle sensor voltage) Method of reproducing service code: Turn starting switch ON. When only service code [E0721] is displayed Cause



Disconnection in wiring harness 1 (Disconnection in wiring or de- Wiring harness between NGICN2 (female) C Resistance Max. 1 Ω fective contact in connector) circuit branching point ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission con2 NGICN2 Resistance troller Between C chassis ground

0.15 4.85 V

When service codes [E0731] and [E0221] are displayed simultaneously Cause


Defective sensor 24 V power See if service code [E0145] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective pitch angle sensor 2 (Internal trouble) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PAS

Between B A

Voltage 0.15 4.85 V


Disconnection in wiring harness Wiring harness between PAS (female) B 3 (Disconnection in wiring or de- circuit branching point fective contact in connector) Wiring harness between PAS (male) C NGICN1 (female) F

Resistance Max. 1 Ω Resistance Max. 1 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between PAS (Contact with ground circuit) (female) B TMCN1 (female) C NGICN1 Resistance Min. 1 MΩ (female) C with chassis ground

20-500 1

D375A-5

TROUBLESHOOTING


Circuit diagram related to pitch angle sensor

D375A-5

20-501 1

SERVICE CODECODE E0730 E0730 [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS (1)] SERVICE [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(1)] (2)] TROUBLESHOOTING SERVICE CODE E0731 [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS

SERVICE CODE E0730 [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS (1)] User code

Service code

CALL

E0730

Contents of trouble


Trouble

Abnormality in both steering potentiometer systems (1) (Steering controller system)

Service codes [E0733] and [E0734] are displayed simultaneously for steering potentiometer systems 1 and 2. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake.

Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, it cannot travel any more. Inputting from steering potentiometers (Voltage) can be checked in monitoring mode. (Code L1: Voltage of steering potentiometer 1) Related information (Code L2: Voltage of steering potentiometer 2) Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Steering). Possible causes and standard value in normal state

Cause




Service code

CALL

E0731

Trouble


Steering potentiometer systems 1 and 2 are normal when starting switch is turned ON, then service Contents of trouble code [E0735] is displayed. Action of controller

Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake.


20-502 1

Cause



D375A-5

TROUBLESHOOTING

SERVICE CODE E0732 [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS (3)]


Service code

CALL

E0732

Contents of trouble


Trouble


Either of steering potentiometers 1 and 2 is abnormal when starting switch is turned ON, then service codes [E0733] and [E0734] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake.


D375A-5

Cause



20-503 1

SERVICE CODE E0733 (DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0733 (DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM) User code

Service code

CALL03

E0733

Trouble

Disconnection or short circuit in steering potentiometer 1 system (Steering controller system)

Contents of trouble Signal voltage of steering potentiometer 1 (ST1) is below 0.5 V or above 4.5 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Continues controlling with signal of steering potentiometer 2 system (ST2). Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Related information

Inputting from steering potentiometer 1 (ST1) (Voltage) can be checked in monitoring mode. (Code L1: Voltage of steering potentiometer 1) Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Steering). Cause


Defective sensor 5 V power See if service code [E0143] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective steering potentiometer 1 2 (Internal disconnection or short circuit)


Between A G Between H A


Between H G

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN1 (female) 2 TL1 (female) H with Resistance Min. 1 MΩ chassis ground


1

TL1 (male)

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN1 (female) L Resistance Max. 1 Ω 3 (Disconnection in wiring or TL1 (female) A defective contact in connecWiring harness between NGICN1 (female) 2 tor) Resistance Max. 1 Ω TL1 (female) H


20-504


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN1 (female) 2 TL1 (female) H with chassis ground

Voltage

Max. 1 V


Voltage

Between 2 K

0.5 4.5 V

D375A-5

TROUBLESHOOTING


Circuit diagram related to steering potentiometer

D375A-5

20-505 1


TROUBLESHOOTING

SERVICE CODE E0734 (DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 2 SYSTEM) User code

Service code

CALL03

E0734

Trouble

Disconnection or short circuit in steering potentiometer 2 system (Steering controller system)

Contents of trouble Signal voltage of steering potentiometer 2 (ST2) is below 0.5 V or above 4.5 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Continues controlling with signal of steering potentiometer 1 system (ST1). Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Related information

Inputting from steering potentiometer 2 (ST2) (Voltage) can be checked in monitoring mode. (Code L2: Voltage of steering potentiometer 2) Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Steering). Cause


Defective sensor power sup- See if service code [E0143] is displayed. If it is displayed, carry out 1 ply system troubleshooting for it first. Defective steering potentiometer 2 2 (Internal disconnection or short circuit)


Between M F Between E M


Between E F

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN1 (female) I TL1 (female) E with Resistance Min. 1 MΩ chassis ground


1

TL1 (male)

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN1 (female) L Resistance Max. 1 Ω 3 (Disconnection in wiring or TL1 (female) M defective contact in connecWiring harness between NGICN1 (female) I tor) Resistance Max. 1 Ω TL1 (female) E


20-506


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN1 (female) I TL1 (female) E with chassis ground

Voltage

Max. 1 V


Voltage

Between I K

0.5 4.5 V

D375A-5

SERVICE CODE E0735 (DEVIATION OF STEERING POTENTIOMETER SYSTEM SIGNALS)

TROUBLESHOOTING

Circuit diagram related to steering potentiometers

SERVICE CODE E0735 (DEVIATION OF STEERING POTENTIOMETER SYSTEM SIGNALS) User code

Service code

CALL03

E0735

Trouble

Deviation of steering potentiometer system signals (Steering controller system)

Contents of trouble Total signal voltages of steering potentiometers 1 (ST1) and 2 (ST2) is below 4.41 V or above 5.59 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Continues controlling with normal signal of steering potentiometer 1 (ST1) system or 2 (ST2) system. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. Related information Method of reproducing service code: Turn starting switch ON.


D375A-5

Cause



20-507 1

SERVICE CODE E0736 (DISCONNECTION OR SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0736 (DISCONNECTION OR SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM) User code

Service code

CALL03

E0736

Trouble

Disconnection or short circuit in brake potentiometer system (Steering controller system)

Contents of trouble Signal voltage of brake potentiometer circuit is below 0.5 V or above 4.5 V.

Flashes caution lamp and turns on caution buzzer. Action of controller Stops controlling with brake potentiometer signal. Limits operation of engine and transmission. Brake control performance of brake pedal lowers.



Related information

Inputting from brake potentiometer (Voltage) can be checked in monitoring mode. (Code L7: Voltage of brake potentiometer) Method of reproducing service code: Turn starting switch ON and operate brake pedal. Cause


Defective sensor 5 V power See if service code [E0143] is displayed. If it is displayed, carry out 1 supply system troubleshooting for it first. Defective brake potentiometer 2 (Internal disconnection or short circuit)


Resistance

Between A B

0.25 7.0 kΩ

Between A C Between B C

4.0 6.0 kΩ 0.25 7.0 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN1 (female) 3 BRK (female) B with Resistance Min. 1 MΩ chassis ground


1

BRK (male)

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN1 (female) L 3 (Disconnection in wiring or Resistance BRK (female) C defective contact in connecWiring harness between NGICN1 (female) 3 tor) Resistance BRK (female) B


20-508


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN1 (female) 3 BRK (female) B with chassis ground

Voltage

Max. 1 V


Between 3 B

Voltage 0.5 4.5 V

D375A-5

TROUBLESHOOTING

SERVICE CODE E0736 (DISCONNECTION OR SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)

Circuit diagram related to brake potentiometer

D375A-5

20-509 1

TROUBLESHOOTING

SERVICE CODE E0750 (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV SYSTEM)

SERVICE CODE E0750 (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0750

Trouble

Disconnection in right steering clutch ECMV system (Steering controller system)

Contents of trouble • When signal is output to right steering clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right.



• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code P4, c4: Right steering clutch ECMV output current) Related information • Method of reproducing service code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right). Cause Defective right steering 1 clutch solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRC (male)

Resistance

Between 1 – 2

5 – 15 Ω

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between NGICN3 (female) Y Resistance Max. 1 Ω – SRC (female) 1 defective contact in connecWiring harness between NGICN3 (female) M tor) Resistance Max. 1 Ω – SRC (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)


aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN3 (female) Y – SRC (female) 1 with chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NGICN3 (female)

Resistance

Between Y – M

5 – 15 Ω

Circuit diagram related to right steering clutch ECMV

20-510 (7) 1

D375A-5

SERVICE CODE E0751 (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0751 (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0751

Trouble

Short circuit in right steering clutch ECMV system (Steering controller system)

Contents of trouble • When signal was output to right steering clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right.



• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code P4, c4: Right steering clutch ECMV output current) Related information • Method of reproducing service code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right). Cause Defective right steering 1 clutch solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRC (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN3 (female) Y – SRC (female) 1 with Resistance Min. 1 MΩ chassis ground Short circuit in wiring harness 3 (with another wiring harness)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NGICN3 (female) Y – SRC (female) 1 with Resistance Min. 1 MΩ wiring harness between NGICN3 (female) M – SRC (female) 2 aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


NGICN3 (female)

Resistance

Between Y – M

5 – 15 Ω

Between Y – chassis ground

Min. 1 MΩ

Circuit diagram related to right steering clutch ECMV

D375A-5

20-511 (7) 1

SERVICE CODE E0752 (DISCONNECTION IN LEFT STEERING CLUTCH ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0752 (DISCONNECTION IN LEFT STEERING CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0752

Trouble

Disconnection in left steering clutch ECMV system (Steering controller system)

Contents of trouble • When signal is output to left steering clutch solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left.



• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code P3, c3: Left steering clutch ECMV output current) Related information • Method of reproducing service code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left). Cause Defective left steering clutch 1 solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLC (male)

Resistance

Between 1 – 2

5 – 15 Ω

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between NGICN3 (female) O Resistance Max. 1 Ω – SLC (female) 1 defective contact in connecWiring harness between NGICN3 (female) M tor) Resistance Max. 1 Ω – SLC (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)


aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN3 (female) O – SLC (female) 1 with chassis ground

Voltage

Max. 1 V


Resistance

Between O – M

5 – 15 Ω

Circuit diagram related to left steering clutch ECMV

20-512 (7) 1

D375A-5

SERVICE CODE E0753 (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0753 (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV SYSTEM) User code

Service code

CALL03

E0753

Trouble

Short circuit in left steering clutch ECMV system (Steering controller system)

Contents of trouble • When signal was output to left steering clutch solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left.



• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code P3, c3: Left steering clutch ECMV output current) Related information • Method of reproducing service code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left). Cause Defective left steering clutch 1 solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLC (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN3 (female) O – SLC (female) 1 with Resistance Min. 1 MΩ chassis ground Short circuit in wiring harness 3 (with another wiring harness)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NGICN3 (female) O – SLC (female) 1 with Resistance Min. 1 MΩ wiring harness between NGICN3 (female) M – SLC (female) 2 aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


NGICN3 (female)

Resistance

Between O – M

5 – 15 Ω

Between O – chassis ground

Min. 1 MΩ

Circuit diagram related to left steering clutch ECMV

D375A-5

20-513 (7) 1

SERVICE CODE E0754 (DISCONNECTION IN RIGHT STEERING BRAKE ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0754 (DISCONNECTION IN RIGHT STEERING BRAKE ECMV SYSTEM) User code

Service code

CALL

E0754

Trouble

Disconnection in right steering brake ECMV system (Steering controller system)

Contents of trouble • When signal is output to right steering brake solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to right steering brake solenoid circuit. • Limits operation of engine, transmission, and brake. • Brake is kept applied lightly during travel.



Related information

• Outputting to right steering brake solenoid (Current) can be checked in monitoring mode. (Code P2, c2: Right steering brake ECMV output current) • Method of reproducing service code: Turn starting switch ON and release parking brake lever. Cause Defective right steering 1 brake solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRB (male)

Resistance

Between 1 – 2

5 – 15 Ω

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between NGICN3 (female) E Resistance Max. 1 Ω – SRB (female) 1 defective contact in connecWiring harness between NGICN3 (female) C tor) Resistance Max. 1 Ω – SRB (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)


aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN3 (female) E – SRB (female) 1 with chassis ground

Voltage

Max. 1 V


Resistance

Between E – C

5 – 15 Ω

Circuit diagram related to right steering brake ECMV

20-514 (7) 1

D375A-5

SERVICE CODE E0755 (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0755 (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV SYSTEM) User code

Service code

CALL

E0755

Trouble

Short circuit in right steering brake ECMV system (Steering controller system)

Contents of trouble • When signal was output to right steering brake solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to right steering brake solenoid circuit. • Limits operation of engine, transmission, brake. • Brake is kept applied lightly during travel.



Related information

• Outputting to right steering brake solenoid (Current) can be checked in monitoring mode. (Code P2, c2: Right steering brake ECMV output current) • Method of reproducing service code: Turn starting switch ON and release parking brake lever. Cause Defective right steering 1 brake solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRB (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN3 (female) E – SRB (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NGICN3 (female) E – SRB (female) 1 with Resistance Min. 1 MΩ wiring harness between NGICN3 (female) C – SRB (female) 2 aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


NGICN3 (female)

Resistance

Between E – C

5 – 15 Ω

Between E – chassis ground

Min. 1 MΩ

Circuit diagram related to right steering brake ECMV

D375A-5

20-515 (7) 1

SERVICE CODE E0756 (DISCONNECTION IN LEFT STEERING BRAKE ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0756 (DISCONNECTION IN LEFT STEERING BRAKE ECMV SYSTEM) User code

Service code

CALL

E0756

Trouble

Disconnection in left steering brake ECMV system (Steering controller system)

Contents of trouble • When signal is output to left steering brake solenoid circuit, current does not flow.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to left steering brake solenoid circuit. • Limits operation of engine, transmission, and brake. • Brake is kept applied lightly during travel.



Related information

• Outputting to left steering brake solenoid (Current) can be checked in monitoring mode. (Code P1, c1: Left steering brake ECMV output current) • Method of reproducing service code: Turn starting switch ON and release parking brake lever. Cause Defective left steering brake 1 solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLB (male)

Resistance

Between 1 – 2

5 – 15 Ω

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between NGICN3 (female) 5 Resistance Max. 1 Ω – SLB (female) 1 defective contact in connecWiring harness between NGICN3 (female) C tor) Resistance Max. 1 Ω – SLB (female) 2 Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)


aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NGICN3 (female) 5 – SLB (female) 1 with chassis ground

Voltage

Max. 1 V


Resistance

Between 5 – C

5 – 15 Ω

Circuit diagram related to left steering brake ECMV

20-516 (7) 1

D375A-5

SERVICE CODE E0757 (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0757 (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV SYSTEM) User code

Service code

CALL

E0757

Trouble

Short circuit in left steering brake ECMV system (Steering controller system)

Contents of trouble • When signal was output to left steering brake solenoid circuit, abnormal current flowed.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to left steering brake solenoid circuit. • Limits operation of engine, transmission, and brake. • Brake is kept applied lightly during travel.



Related information

• Outputting to left steering brake solenoid (Current) can be checked in monitoring mode. (Code P1, c1: Left steering brake ECMV output current) • Method of reproducing service code: Turn starting switch ON and release parking brake lever. Cause Defective left steering brake 1 solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLB (male)

Resistance

Between 1 – 2

5 – 15 Ω


Min. 1 MΩ



Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) NGICN3 (female) 5 – SLB (female) 1 with chassis ground Short circuit in wiring harness 3 (with another wiring harness)


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NGICN3 (female) 5 – SLB (female) 1 with Resistance Min. 1 MΩ wiring harness between NGICN3 (female) C – SLB (female) 2 aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NGICN3 (female)

Resistance

Between 5 – C

5 – 15 Ω


Min. 1 MΩ


Circuit diagram related to left steering brake ECMV

D375A-5

20-517 (7) 1

SERVICE CODE E0779 (DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0779 (DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID SYSTEM) User code

Service code

CALL

E0779

Trouble

Disconnection in sudden stop prevention solenoid system (Steering controller system)

Contents of trouble • When signal is output to sudden stop prevention solenoid circuit, current does not flow.


• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Brake is kept applied lightly during travel.



Related information

• Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode. (Code d5: Sudden stop prevention solenoid drive voltage) • Method of reproducing service code: Turn starting switch ON. Cause Defective sudden stop pre1 vention solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STB (male)

Resistance

Between 1 – 2

5 – 25 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN3 (female) 7 2 (Disconnection in wiring or Resistance Max. 1 Ω – STB (female) 1 defective contact in connecPossible causes Wiring harness between NGICN3 (female) C tor) and standard valResistance Max. 1 Ω – STB (female) 2 ue in normal state ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 3 source in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) NGICN3 (female) 7 – STB (female) 1 with Voltage Max. 1 V chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective steering controller

NGICN3 (female)

Resistance

Between 7 – C

5 – 25 Ω

Circuit diagram related to sudden stop prevention solenoid

20-526 1

D375A-5

SERVICE CODE E0780 (SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0780 (SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID SYSTEM) User code

Service code

CALL

E0780

Trouble

Short circuit in sudden stop prevention solenoid system (Steering controller system)

Contents of trouble • When signal is output to sudden stop prevention solenoid circuit, abnormal current flowed.


• Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Brake is kept applied lightly during travel.



Related information

• Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode. (Code d5: Sudden stop prevention solenoid drive voltage) • Method of reproducing service code: Turn starting switch ON. Cause Defective sudden stop pre1 vention solenoid (Internal short circuit)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STB (male)

Resistance

Between 1 – 2

5 – 25 Ω


Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 2 ground in wiring harness (Contact with ground circuit) Short circuit of wiring harness between Resistance Max. 1 Ω NGICN3 (female) 7 – STB (female) 1 Short circuit in wiring harness 3 (with another wiring harness)

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NGICN3 (female) 7 – STB (female) 1 with Resistance Max. 1 Ω wiring harness between NGICN3 (female) C – STB (female) 2 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


NGICN3 (female)

Resistance

Between 7 – C

5 – 25 Ω


Min. 1 MΩ

Circuit diagram related to sudden stop prevention solenoid

D375A-5

20-527 1

TROUBLESHOOTING


SERVICE CODE E0781 (DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH SYSTEMS) User code CALL03 Contents of trouble

Action of controller Problem that appears on machine

Related information

Service code Disconnection or short circuit in parking brake lever switch systems Trouble (Steering controller system) E0781 • Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously. • Flashes caution lamp and turns on caution buzzer. • Assumes that parking brake lever is at FREE position. • Limits operation of engine and transmission. • Travel lock does not work (Mechanical parking brake and pedal work normally.) • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. ★ Since parking brake switch signal is used by both transmission controller and steering controller, related codes may be displayed simultaneously, depending on troubled part. (Related codes: E0238, E0239, E0782) • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code L9: Steering controller switch input 1) • Method of reproducing service code: Turn starting switch ON and operate parking brake lever.

When only service code [E0781] is displayed Cause Standard value in normal state/Remarks on troubleshooting Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness Wiring harness between NGICN2 (female) 5 Resistance Max. 1 Ω 1 (Disconnection in wiring or – circuit branching point defective contact in connecWiring harness between NGICN2 (female) E Resistance Max. 1 Ω tor) – circuit branching point Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and and standard valcarry out troubleshooting. ue in normal state Parking brake lever NGICN2 At FREE At LOCK 2 Defective steering controller Between 5 – chassis Max. 1 V 5 – 11 V ground Between E – chassis 5 – 11 V Max. 1 V ground

1

2


4

20-528 1 (5)

When service codes [E0781] and [E0238] are displayed simultaneously Cause Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective parking brake leParking brake lever ver switch NSW At FREE At LOCK (Internal disconnection or Between A – B Max. 1 Ω Min. 1 MΩ short circuit) Between A – C Min. 1 MΩ Max. 1 Ω ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harWiring harness between NSW (female) B – ness Resistance Max. 1 Ω circuit merging point (Disconnection in wiring or Wiring harness between NSW (female) C – Resistance Max. 1 Ω defective contact in connec- circuit merging point tor) Wiring harness between NSW (female) A – Resistance Max. 1 Ω chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between NSW Short circuit with chassis (female) B – NGICN2 (female) 5 – TMCN1 Resistance Min. 1 MΩ ground in wiring harness (female) H with chassis ground (Contact with ground circuit) Short circuit of wiring harness between NSW (female) C – NGICN2 (female) E – TMCN1 Resistance Min. 1 MΩ (female) B with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Short circuit with power (female) B – NGICN2 (female) 5 – TMCN1 Voltage Max. 1 V source in wiring harness (female) H with chassis ground (Contact with 24 V circuit) Short circuit of wiring harness between NSW (female) C – NGICN2 (female) E – TMCN1 Voltage Max. 1 V (female) B with chassis ground

D375A-5

TROUBLESHOOTING


Circuit diagram related to parking brake switch

D375A-5

20-529 1

TROUBLESHOOTING

SERVICE CODE E0782 (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)

SERVICE CODE E0782 (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS) User code

Service code

CALL03

E0782

Contents of trouble


Trouble

Disagreement of parking brake lever switch system signals (Steering controller system)

Switch input signal of steering controller disagrees with communication signal from steering controller. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission.

Once machine is stopped, engine speed is limited to medium (half). Problem that appears on machine Once machine is stopped, travel is limited to F1 and R1. ★ Since parking brake switch signal is used by both transmission controller and steering controller and information is exchanged by S-NET communication, related codes may be displayed simultaneously, depending on troubled part. Related information (Related codes: E0101, E0104, E0105, E0152, E0164, E0238, E0239, E0781) Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code L9: Steering controller switch input 1) Method of reproducing service code: Turn starting switch ON and operate parking brake lever. Cause Possible causes and standard value in normal state


See if service codes [E0101], [E0104], [E0105], [E0152], and [E0162] Defective S-NET communi1 are displayed. If they are displayed, carry out troubleshooting for them cation system first. 2

Defective parking brake lever switch signal system

See if service codes [E0238] and [E0781] are displayed. If they are displayed, carry out troubleshooting for them first. (Service code [E0239] is same as [E0782].)

3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.

20-530 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E0930 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)

SERVICE CODE E0930 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) User code

Service code

E01

E0930

Trouble

Disconnection in engine speed sensor system (Steering controller system)

Contents of trouble Engine speed signal is not input from engine controller.

Action of controller Cannot recognize engine speed. Tachometer graphic section is not displayed. Problem that appears on machine Steering performance may lower. ★ Since engine speed signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part. (Related code: E0931) Related information Inputting from engine speed sensor (Voltage) can be checked in monitoring mode. (Code 91: Engine speed sensor input signal) Method of reproducing service code: Start engine. When only service code [E0930] is displayed Cause


★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN2 (female) ^ 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point Possible causes defective contact in connecand standard valWiring harness between NGICN2 (female) ] tor) Resistance Max. 1 Ω ue in normal state circuit branching point


★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. NGICN2

Voltage

Between ^ ]

Approx 3.3 V



★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMB (female) O 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point Possible causes defective contact in connecand standard valWiring harness between EG2 (male) T cirtor) Resistance Max. 1 Ω ue in normal state cuit branching point

2 Defective engine controller

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. ECMB

Voltage


D375A-5

20-531 1

TROUBLESHOOTING


Circuit diagram related to engine speed sensor signal

20-532 1

D375A-5

TROUBLESHOOTING


SERVICE CODE E0931 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) User code

Service code

E01

E0931

Trouble

Disconnection in engine speed sensor system (Transmission controller system)

Contents of trouble Engine speed signal is not input from engine controller.

Action of controller Cannot recognize engine speed. Gear shifting feeling of transmission may become bad. Problem that appears on machine Auto shift-down function does not work. ★ Since engine speed signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part. (Related code: E0930) Related information Inputting from engine speed sensor (Voltage) can be checked in monitoring mode. (Code 92: Engine speed sensor input signal) Method of reproducing service code: Start engine. When only service code [E0931] is displayed Cause


★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN2 (female) ^ 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point Possible causes defective contact in connecand standard valWiring harness between TMCN2 (female) ] tor) Resistance Max. 1 Ω ue in normal state circuit branching point Defective transmission con2 troller

★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. TMCN2

Voltage

Between ^ ]

Approx 3.3 V



★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMB (female) O 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point Possible causes defective contact in connecand standard valWiring harness between EG2 (male) T cirtor) Resistance Max. 1 Ω ue in normal state cuit branching point


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECMB

Voltage


D375A-5

20-533 1

TROUBLESHOOTING


Circuit diagram related to engine speed sensor signal

20-534 1

D375A-5

SERVICE CODE E0932 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE E0932 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM) User code

Service code

E01

E0932

Trouble

Disconnection in transmission speed sensor system (Transmission controller system)

Contents of trouble Signal is not input from transmission speed sensor

Action of controller Cannot recognize transmission output speed. Gear shifting feeling of transmission may become bad. Problem that appears on machine Auto shift-down function does not work. ★ Since transmission speed signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part. (Related code: E0933) Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode. Related information (Code 94: Transmission speed sensor input signal) Method of reproducing service code: Start engine and drive machine. ¤ When troubleshooting by operating transmission, set system in adjustment mode (Code: Co) so that machine will not start. When only service code [E0932] is displayed Cause



★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between TMCN2 (female) T 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point defective contact in connecWiring harness between TMCN2 (female) S tor) Resistance Max. 1 Ω circuit branching point

2



Resistance

Between T S

500 1,000 Ω

Between T chassis ground

Min. 1 MΩ

When service codes [E0933] and [E0932] are displayed simultaneously Cause Defective transmission speed sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TM1 (male)

Resistance

Between 1 2

500 1,000 Ω


Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harPossible causes without turning starting switch ON. ness and standard valWiring harness between TM1 (female) 1 Resistance Max. 1 Ω ue in normal state 2 (Disconnection in wiring or circuit branching point defective contact in connecWiring harness between TM1 (male) 2 cirtor) Resistance Max. 1 Ω cuit branching point ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between TM1 (Contact with ground circuit) (female) 1 TMCN2 (female) T NGICN2 Resistance Min. 1 MΩ (female) T with chassis ground

D375A-5

20-535 1

TROUBLESHOOTING


Circuit diagram related to transmission speed sensor

20-536 1

D375A-5


TROUBLESHOOTING

SERVICE CODE E0933 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM) User code

Service code

E01

E0933

Trouble

Disconnection in transmission speed sensor system (Steering controller system)

Contents of trouble Signal is not input from transmission speed sensor

Action of controller Cannot recognize transmission output speed. Problem that Steering performance may lower. appears on machine

★ Since transmission speed signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part. (Related code: E0932) Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode. Related information (Code 93: Transmission speed sensor input signal) Method of reproducing service code: Start engine and drive machine. ¤ When troubleshooting by operating transmission, set system in adjustment mode (Code: Co) so that machine will not start. When only service code [E0933] is displayed Cause



★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between NGICN2 (female) T 1 (Disconnection in wiring or Resistance Max. 1 Ω circuit branching point defective contact in connecWiring harness between NGICN2 (female) S tor) Resistance Max. 1 Ω circuit branching point ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective steering controller

NGICN2 (female)

Resistance

Between T S

500 1,000 Ω

Between T chassis ground

Min. 1 MΩ

When service codes [E0933] and [E0932] are displayed simultaneously Cause Defective transmission speed sensor 1 (Internal disconnection or short circuit)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TM1 (male)

Resistance

Between 1 2

500 1,000 Ω


Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harPossible causes without turning starting switch ON. ness and standard valWiring harness between TM1 (female) 1 Resistance Max. 1 Ω ue in normal state 2 (Disconnection in wiring or circuit branching point defective contact in connecWiring harness between TM1 (male) 2 cirtor) Resistance Max. 1 Ω cuit branching point ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between TM1 (Contact with ground circuit) (female) 1 NGICN2 (female) T TMCN2 Resistance Min. 1 MΩ (female) T with chassis ground

D375A-5

20-537 1

TROUBLESHOOTING


Circuit diagram related to transmission speed sensor

20-538 1

D375A-5

TROUBLESHOOTING

SERVICE CODE E1939 (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)

SERVICE CODE E1939 (ABNORMALITY IN J1939 COMMUNICATION SYSTEM) User code

Service code

CALL

E1939

Trouble

Abnormality in J1939 communication system (Steering controller system)

Contents of trouble Steering controller cannot receive communication signal of J1939 communication.

Action of controller Cannot receive communication information from engine controller. Monitoring mode of engine controller system cannot be used.

Problem that Service codes of engine controller system cannot be recorded. appears on machine

Engine information cannot be displayed on monitor panel normally.

Related information

J1939 communication is communication circuit between engine controller and steering controller. Although transmission controller is connected to this circuit, it does not communicate. Method of reproducing service code: Turn starting switch ON. Cause


Disconnection in wiring harness 1 (Disconnection in wiring or de- Wiring harness between NGICN2 (female) L Resistance Max. 1 Ω fective contact in connector) ECMB (female) L


Reset according to following procedure, then check displayed service code to see which controller is defective. When P (reset) is displayed: Steering controller is defective. When E (detection) is displayed: Engine controller is defective. 1)With starting switch turned OFF, exchange steering controller and transmission controller. Defective steering controller 2 2)Turn starting switch ON. or engine controller 3)Set monitor panel in adjustment mode (service mode) and execute adjustment codes [5A] and [7A]. 4)Turn starting switch OFF and ON. 5)Set monitor panel in service code display mode and check displayed code. ★ After checking, return controllers to original states.

Circuit diagram related to J1939 communication

D375A-5

20-539 1

SERVICE CODE EC111 (ABNORMALITY IN ENGINE CONTROLLER MEMORY) SERVICE CODE (ABNORMALITY EC112 (ABNORMALITY IN TIMING RAIL ACTUATOR) SERVICE CODE EC111 IN ENGINE CONTROLLER MEMORY)

TROUBLESHOOTING

SERVICE CODE -+ (ABNORMALITY IN ENGINE CONTROLLER MEMORY) User code

Service code

CALL

EC111

Trouble

Abnormality in engine controller memory (Engine controller system)

Contents of trouble Memory in controller has trouble or processor in controller has communication trouble.

Action of controller Flashes caution lamp and turns on caution buzzer. Problem that Engine cannot be started. appears on machine Related information Method of reproducing service code: Turn starting switch ON.

Cause


Possible causes and standard value in normal state 1 Defective engine controller

Reset according to following procedure. If service code E is displayed at this time, engine controller is defective. 1)Keep starting switch at OFF position for 5 seconds. 2)Run engine at low idling. 3)Check service code.

SERVICE CODE -+ (ABNORMALITY IN TIMING RAIL ACTUATOR) User code

Service code

CALL

EC112

Trouble

Abnormality in timing rail actuator (Engine controller system)

Displayed fuel value of timing rail is excessively different from actual timing fuel.

Contents of trouble Judgment value (for reference):

Error is above 400 mm3/st or below 750 mm3/st (When water temperature is below 0°C).


Flashes caution lamp and turns on caution buzzer. Limits engine speed to 1,500 rpm.

Problem that Engine speed lowers. appears on machine Related information Method of reproducing service code: Start engine.

Cause 1 Defective related systems

Standard value in normal state/Remarks on troubleshooting Check displayed service codes. If code related to engine controller is displayed, carry out troubleshooting for it first.

Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping

Possible causes and standard val3 Defective timing rail actuator Check timing rail actuator directly for defective operation. ue in normal state Clogging of timing rail actua4 Check timing rail actuator screen directly for clogging. tor screen

20-540 1

5 Breakage of injector O-ring

Check injector O-ring directly for breakage.


If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D375A-5

SERVICE CODE EC113 (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE EC113 (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM) User code

Service code

CALL03

EC113

Contents of trouble

Trouble

Abnormal current in timing rail actuator system (Engine controller system)

• Current in timing rail actuator is out of normal range. • Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)

Action of controller • Flashes caution lamp and turns on caution buzzer. • Engine output lowers. Problem that appears on machine • Exhaust gas becomes white. Related information

• Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator. • Method of reproducing service code: Turn starting switch ON (or start engine). Cause


1


Defective timing rail actuator (Internal trouble)

TIMG (male)

Resistance

Between A, C – chassis ground

Min. 100 kΩ

Between A – C

7–9Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) 1 – 2 (Disconnection in wiring or Resistance Max. 10 Ω TIMG (female) A defective contact in connecWiring harness between ECMA (female) J – tor) Resistance Max. 10 Ω TIMG (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) 1 – TIMG (female) A with wiring Resistance Min. 1 MΩ harness around it Short circuit of wiring harness between ECMA (female) J – TIMG (female) C with wiring Resistance Min. 1 MΩ harness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ECMA (female)

Resistance

Between 1 – J

7–9Ω

Wiring harness between 1, J – wiring harness around it

Min. 1 MΩ


Circuit diagram related to timing rail actuator

D375A-5

20-541 (7) 1

TROUBLESHOOTING

SERVICE CODE EC115 (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)

SERVICE CODE EC115 (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS) User code

Service code

CALL

EC115

Trouble

Abnormality in engine speed sensor 2 systems (Engine controller system)

Contents of trouble • Signal is not input to either of engine speed sensor circuit 2 systems.


• Flashes caution lamp and turns on caution buzzer. • Outputs speed signal of 0 rpm.

Problem that • Engine stops. appears on machine

• Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (Code 62: Engine speed) Related information • Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor. • Method of reproducing service code: Start engine. Cause


Defective engine speed sen1 sor (Internal trouble)

SP1 (male), SP2 (male)

Resistance

Between A – A

Max. 10 Ω

Between A – B

Between B – B

Between A – chassis ground Damage of engine speed 2 sensor

1 k – 2 kΩ Max. 10 Ω Min. 10 MΩ

Check engine speed sensor directly. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ECMA (female) Q – Resistance Max. 10 Ω SP1 (female) A Wiring harness between ECMA (female) R – Resistance Max. 10 Ω SP1 (female) B Wiring harness between ECMA (female) [ – Resistance Max. 10 Ω SP2 (female) A Wiring harness between ECMA (female) \ – Resistance Max. 10 Ω SP2 (female) B


★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ECMA (female) Q – SP1 (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit in wiring harness 4 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) R – SP1 (female) B with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) [ – SP2 (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) \ – SP2 (female) B with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. ECMA (female)


20-542 1

Resistance

Between Q – R

1 k – 2 kΩ

Between Q, R – chassis ground

Min. 1 MΩ

Between [ – \

1 k – 2 kΩ

Between [, \ – chassis ground

Min. 1 MΩ

D375A-5

TROUBLESHOOTING

SERVICE CODE EC115 (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)

Circuit diagram related to engine speed sensor

D375A-5

20-543 1

TROUBLESHOOTING

SERVICE CODE EC116 (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)

SERVICE CODE EC116 (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL

EC116

Trouble

Abnormally high level in timing rail pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of timing rail pressure sensor circuit is above 4.78 V.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Opens and controls timing rail. • Limits engine speed to 1,500 rpm. Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to 1,500 rpm. appears on machine Related information

• Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor. • Method of reproducing service code: Start engine. Cause Defective timing rail pres1 sure sensor (Internal trouble)

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TPR

Between A – B Between C – B

Voltage 4.75 – 5.25 V 0.42 – 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 5 – Resistance Max. 10 Ω TPR (female) A Wiring harness between ECMA (female) H – Resistance Max. 10 Ω TPR (female) B Wiring harness between ECMA (female) W – Resistance Max. 10 Ω TPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) 5 – TPR (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) H – TPR (female) B with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) W – TPR (female) C with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA

Voltage

Between 5 – H

4.75 – 5.25 V

Between W – H

0.42 – 0.58 V

Circuit diagram related to engine speed sensor

20-544 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC117 (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)

SERVICE CODE EC117 (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL

EC117

Trouble

Abnormally low level in timing rail pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of timing rail pressure sensor circuit is below 0.30 V.

• Flashes caution lamp and turns on caution buzzer. Action of controller • Opens and controls timing rail. • Limits engine speed to 1,500 rpm. • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to Problem that appears on machine 1,500 rpm. Related information • Method of reproducing service code: Start engine.


D375A-5

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for service code [EC116].

20-545 1

TROUBLESHOOTING

SERVICE CODE EC118 (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM)

SERVICE CODE EC118 (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC118

Trouble

Abnormally high level in fuel pump pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.


• Flashes caution lamp and turns on caution buzzer. • Opens and controls fuel pump.

Problem that appears on machine Related information

• Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor. • Method of reproducing service code: Start engine. Cause Defective fuel pump pres1 sure sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PMPR (male)


Voltage 4.75 – 5.25 V 0.42 – 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 5 – Resistance Max. 10 Ω PMPR (female) A Wiring harness between ECMA (female) H – Resistance Max. 10 Ω PMPR (female) B Wiring harness between ECMA (female) V – Resistance Max. 10 Ω PMPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMA (female) 5 – PMPR (female) A with wiring Resistance Min. 1 MΩ harness around it Short circuit of wiring harness between ECMA (female) H – PMPR (female) B with wiring Resistance Min. 1 MΩ harness around it Short circuit of wiring harness between ECMA (female) V – PMPR (female) C with wiring Resistance Min. 1 MΩ harness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA (female)

Resistance

Between 5 – H

4.75 – 5.25 V

Between V – H

0.42 – 0.58 V

Circuit diagram related to fuel pump pressure sensor

20-546 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SYSTEM) SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUELSENSOR PUMP PRESSURE SERVICE CODE EC121 (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS) SENSOR SYSTEM)

SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC119

Trouble

Abnormally low level in fuel pump pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.


• Flashes caution lamp and turns on caution buzzer. • Opens and controls fuel pump.

Problem that appears on machine Related information • Method of reproducing service code: Start engine.


Cause


SERVICE CODE EC121 (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS) User code

Service code

CALL03

EC121

Trouble

Abnormality in engine speed sensor 1 systems (Engine controller system)

Contents of trouble • Signal is not input to both of engine speed sensor circuit 2 systems.

Action of controller • Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information


D375A-5

• Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (Code 62: Engine speed) • Method of reproducing service code: Start engine. Cause


20-547 1

SERVICE CODE EC122 (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE EC122 (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM) User code

Service code

E01

EC122

Trouble

Abnormally high level in boost pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of boost pressure sensor circuit is above 4.72 V.

Action of controller • When machine is accelerated sharply, exhaust gas color is bad. Problem that appears on machine • Engine output rises. Related information

• Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor. • Method of reproducing service code: Start engine. Cause Defective boost pressure 1 sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. IMPR (male)


Voltage 4.72 – 5.25 V 0.42 – 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 6 – Resistance Max. 10 Ω IMPR (female) A Wiring harness between ECMA (female) G – Resistance Max. 10 Ω IMPR (female) B Wiring harness between ECMA (female) Y – Resistance Max. 10 Ω IMPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) 6 – IMPR (female) A with wiring harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) G – IMPR (female) B with wiring harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) Y – IMPR (female) C with wiring harness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA

Voltage

Between 6 – G

4.75 – 5.25 V

Between Y – G

0.42 – 0.58 V

Circuit diagram related to boost pressure sensor

20-548 (7) 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC123 (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM)

SERVICE CODE -+ ! (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM) User code

Service code

E01

EC123

Trouble

Abnormally low level in boost pressure sensor system (Engine controller system)

Contents of trouble Signal voltage of boost pressure sensor circuit is below 0.30 V.

Action of controller Problem that Engine output lowers. appears on machine Related information Method of reproducing service code: Start engine.


D375A-5

Cause


20-549 1

SERVICE CODE EC131 (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE -+! (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM) User code

Service code

CALL

EC131

Trouble

Abnormally high level in throttle sensor system (Engine controller system)

Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is above 4.80 V.


Flashes caution lamp and turns on caution buzzer. Keeps engine speed at constant level.

Problem that Engine output and speed rise suddenly. appears on machine

Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode. Related information (Code d6: Deceleration potentiometer voltage) Method of reproducing service code: Turn starting switch ON. Cause

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective deceleration po1 tentiometer (Internal trouble)

DCL (male)

Resistance

Between A B

0.25 7.0 kΩ

Between A C Between B C



4.0 6.0 kΩ 0.25 7.0 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMB (female) P Resistance Max. 10 Ω DCL (female) A Wiring harness between ECMB (female) A Resistance Max. 10 Ω DCL (female) C Wiring harness between ECMB (female) S Resistance Max. 10 Ω DCL (female) B ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMB (female) P DCL (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMB (female) A DCL (female) C with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMB (female) S DCL (female) B with wiring har- Resistance Min. 1 MΩ ness around it


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECMB

Voltage

Between S A

0.30 4.80 V

Circuit diagram related to deceleration potentiometer

20-550 1

D375A-5

SERVICE CODE EC132 (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE -+!

(ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)

User code

Service code

CALL

EC132

Trouble

Abnormally low level in throttle sensor system (Engine controller system)

Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is below 0.30 V.



Problem that Engine speed and output lower suddenly. appears on machine

Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode. Related information (Code d6: Deceleration potentiometer voltage) Method of reproducing service code: Turn starting switch ON. Possible causes and standard value in normal state

D375A-5

Cause


20-551 1

SERVICE CODE EC133 (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE -+!! (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR SYSTEM) User code

Service code

CALL

EC133

Trouble

Abnormally high level in remote throttle sensor system (Engine controller system)

Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is above 4.80 V.



Problem that Engine speed rises suddenly. appears on machine Related information

Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode. (Code 5U: Engine command voltage) Method of reproducing service code: Turn starting switch ON. Cause


Disconnection in wiring harness 1 (Disconnection in wiring or de- Wiring harness between ECMB (female) T Resistance Max. 10 Ω fective contact in connector) NGICN2 (female) A Short circuit in wiring harness 2 (with another wiring harness) Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ECMB (female) T NGICN2 (female) A with wiring Resistance Min. 1 MΩ harness around it Reset according to following procedure, then check displayed service code to see which controller is defective. When P (reset) is displayed: Steering controller is defective. When E (detection) is displayed: Engine controller is defective.

3

Defective engine controller or steering controller

1)With starting switch turned OFF, exchange steering controller and transmission controller. 2)Turn starting switch ON. 3)Set monitor panel in adjustment mode (service mode) and execute adjustment codes [5A] and [7A]. 4)Turn starting switch OFF and ON. 5)Set monitor panel in service code display mode and check displayed code. ★ After checking, return controllers to original states.

Circuit diagram related to SSC command

20-552 1

D375A-5

SERVICE CODE EC134 (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE -+!" (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR SYSTEM) User code

Service code

CALL

EC134

Trouble

Abnormally low level in remote throttle sensor system (Engine controller system)

Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is below 0.30 V.



Problem that Engine speed lowers suddenly. appears on machine Related information


D375A-5

Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode. (Code 5U: Engine command voltage) Method of reproducing service code: Turn starting switch ON. Cause


20-553 1

TROUBLESHOOTING

SERVICE CODE EC135 (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)

SERVICE CODE -+!# (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC135

Trouble

Abnormally high level in engine oil pressure sensor system (Engine controller system)

Contents of trouble Signal voltage of engine oil pressure sensor circuit is above 4.88 V.

Action of controller Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information

Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor. Method of reproducing service code: Start engine. Cause Defective engine oil pres1 sure sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OLPR

Between A B Between C B

Voltage 4.75 5.25 V 0.42 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 6 Resistance Max. 10 Ω OLPR (female) A Wiring harness between ECMA (female) G Resistance Max. 10 Ω OLPR (female) B Wiring harness between ECMA (female) N Resistance Max. 10 Ω OLPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) 6 OLPR (female) A with wiring harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) G OLPR (female) B with wiring harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) N OLPR (female) C with wiring harness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECMA

Voltage

Between 6 G

4.75 5.25 V

Between N G

0.42 0.58 V


Circuit diagram related to engine oil pressure sensor

20-554 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM) SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SERVICE CODE EC143 (LOWERING OF ENGINE OIL PRESSURE) SENSOR SYSTEM)

SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC141

Trouble

Abnormally low level in engine oil pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine oil pressure sensor circuit is below 0.31 V.

Action of controller • Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information • Method of reproducing service code: Turn starting switch ON.


Cause


SERVICE CODE EC143 (LOWERING OF ENGINE OIL PRESSURE) User code

Service code

—

EC143

Trouble

Lowering of engine oil pressure (Engine controller system)

• Engine oil pressure sensor detected pressure lower than pressure set in controller. • Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm Contents of trouble Max. 0.15 MPa {1.5 kg/cm2} at 1,500 rpm Max. 0.18 MPa {1.85 kg/cm2} at 1,800 rpm Max. 0.21 MPa {2.1 kg/cm2} at 2,000 rpm Action of controller • Limits fuel injection rate to 50% after 10 seconds. Problem that appears on machine Related information • Method of reproducing service code: Start engine.

Cause 1 Defective related systems Possible causes and standard value in normal state 2 Defective engine oil pressure sensor system 3 Defective engine

D375A-5

Standard value in normal state/Remarks on troubleshooting Check displayed service codes. If code related to engine controller is displayed, carry out troubleshooting for it first. Carry out troubleshooting for service codes [EC135] and [EC141]. See S mode.

20-555 (5) 1

SERVICE CODE EC144 (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE EC144 (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM) User code

Service code

CALL03

EC144

Trouble

Abnormally high level in engine coolant temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.


• Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor. • Method of reproducing service code: Start engine. Cause Defective engine coolant 1 temperature sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CLTP

Between A – B

Resistance 600 – 36 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) L – 2 (Disconnection in wiring or Resistance Max. 10 Ω CLTP (female) A defective contact in connecWiring harness between ECMA (female) G – tor) Resistance Max. 10 Ω CLTP (female) B ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) L – CLTP (female) A with wiring Resistance Min. 1 MΩ harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) G – CLTP (female) B with wiring harness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between N – G

600 – 36 kΩ

Circuit diagram related to engine coolant temperature sensor

20-556 1

D375A-5

SERVICE CODE EC145 (ABNORMALLY LOW LEVEL IN ENGINE COOLANT SENSORCOOLANT SYSTEM) SERVICE CODE EC145 (ABNORMALLYTEMPERATURE LOW LEVEL IN ENGINE SERVICE CODE EC151 (RISE OF ENGINE COOLANT TEMPERATURE) TEMPERATURE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE EC145 (ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM) User code

Service code

CALL03

EC145

Trouble

Abnormally low level in engine coolant temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.

Action of controller • Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information • Method of reproducing service code: Start engine.


Cause


SERVICE CODE EC151 (RISE OF ENGINE COOLANT TEMPERATURE) User code

Service code

—

EC151

Contents of trouble

Trouble

Rise of engine coolant temperature (Engine controller system)

• Engine coolant temperature sensor detected temperature higher than temperature set in controller. • Criterion (for reference): Min. 105°C

Action of controller • Limits fuel injection rate to 50% after 10 seconds. Problem that appears on machine Related information • Method of reproducing service code: Start engine.

Cause


1 Defective related systems Possible causes and standard value in normal state 2 Defective engine coolant Carry out troubleshooting for service codes [EC144] and [EC145]. temperature sensor system 3 Defective engine

D375A-5

See S mode.

20-557 (5) 1

TROUBLESHOOTING

SERVICE CODE EC153 (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)

SERVICE CODE EC153 (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM) User code

Service code

CALL03

EC153

Trouble

Abnormally high level in air intake temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of air intake temperature sensor circuit is above 4.88 V.


• Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor. • Method of reproducing service code: Start engine. Cause Defective air intake tempera1 ture sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. IMTP (female)

Between A – B

Resistance 36 – 600 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) M – Resistance Max. 10 Ω 2 (Disconnection in wiring or IMTP (female) A defective contact in connecWiring harness between ECMA (female) G – tor) Resistance Max. 10 Ω IMTP (female) B ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) M – IMTP (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) G – IMTP (female) B with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between M – G

36 – 600 Ω

Circuit diagram related to air intake temperature sensor

20-558 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC154 (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)

SERVICE CODE -+#" (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM) User code

Service code

CALL03

EC154

Trouble

Abnormally low level in air intake temperature sensor system (Engine controller system)

Contents of trouble Signal voltage of air intake temperature sensor circuit is below 0.08 V.

Action of controller Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information Method of reproducing service code: Start engine.


D375A-5

Cause


20-559 1

TROUBLESHOOTING

SERVICE CODE EC221 (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)

SERVICE CODE -+ (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC221

Trouble

Abnormally high level in atmospheric pressure sensor system (Engine controller system)

Contents of trouble Signal voltage of atmospheric pressure sensor circuit is above 4.78 V.


Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor. Method of reproducing service code: Turn starting switch ON. Cause Defective atmospheric pres1 sure sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. AAPR


Voltage 4.75 5.25 V 0.42 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 6 Resistance Max. 10 Ω AAPR (female) A Wiring harness between ECMA (female) G Resistance Max. 10 Ω AAPR (female) B Wiring harness between ECMA (female) X Resistance Max. 10 Ω AAPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) 6 AAPR (female) A with wiring harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) G AAPR (female) B with wiring harness around it Short circuit of wiring harness between ECMA Resistance Min. 1 MΩ (female) X AAPR (female) C with wiring harness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECMA

Voltage

Between 6 G

4.75 5.25 V

Between X G

0.42 0.58 V


Circuit diagram related to atmospheric pressure sensor

20-560 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM) SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SERVICE CODE EC234 (OVER-SPEED) SENSOR SYSTEM)

SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC222

Trouble

Abnormally low level in atmospheric pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.

Action of controller • Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information • Method of reproducing service code: Turn starting switch ON.


Cause


SERVICE CODE EC234 (OVER-SPEED) User code

Service code

—

EC234

Contents of trouble

Trouble

Over-speed (Engine controller system)

• Engine speed sensor detected speed higher than speed set in controller. • Criterion (for reference): Min. 2,400 rpm

Action of controller • Closes fuel rail actuator fully (Cuts out fuel). Problem that appears on machine Related information • Method of reproducing service code: Start engine.

Cause Possible causes and standard val- 1 Defective related systems ue in normal state 2 Defective engine

D375A-5

Standard value in normal state/Remarks on troubleshooting Check displayed service codes. If code related to engine controller is displayed, carry out troubleshooting for it first. See S mode.

20-561 (5) 1

TROUBLESHOOTING

SERVICE CODE EC254 (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)

SERVICE CODE EC254 (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE) User code

Service code

E01

EC254

Trouble

Abnormal voltage of fuel shut-off valve (Engine controller system)

Contents of trouble • Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 Ω).

Action of controller • Turns off power for fuel shut-off valve. Problem that • Engine stops. appears on machine Related information • Method of reproducing service code: Turn starting switch ON.

Cause


1


Defective fuel shut-off valve (Internal trouble)

FSO (Valve side)

Resistance

Between (+) – (–)

23 – 40 Ω

Between (+) – chassis ground

100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) T – 2 (Disconnection in wiring or Resistance Max. 10 Ω FSO (wiring harness side) (+) defective contact in connecWiring harness between FSO (wiring harness tor) Resistance Max. 10 Ω side) (–) – chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) T – FSO (wiring harness side) (+) Resistance Min. 1 MΩ with wiring harness around it Short circuit of wiring harness between FSO Resistance Min. 1 MΩ (wiring harness side) (–) – chassis ground with wiring harness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA

Resistance

Between T – chassis ground

23 – 40 Ω

Circuit diagram related to fuel shut-off valve

20-562 1

D375A-5

SERVICE CODE EC259 (ABNORMALITY IN FUEL SHUT-OFF VALVE) SERVICE RISEINOF FUEL TEMPERATURE) SERVICECODE CODE EC261 EC259 (ABNORMAL (ABNORMALITY FUEL SHUT-OFF VALVE)

TROUBLESHOOTING

SERVICE CODE EC259 (ABNORMALITY IN FUEL SHUT-OFF VALVE) User code

Service code

CALL

EC259

Trouble

Abnormality in fuel shut-off valve (Engine controller system)

Contents of trouble • Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).


• Flashes caution lamp and turns on caution buzzer. • Turns off power for fuel shut-off valve.

Problem that • Engine cannot be stopped. appears on machine Related information • Method of reproducing service code: Start engine.

Cause


1 Defective related systems

Check displayed service codes. If code related to engine controller is displayed, carry out troubleshooting for it first.

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly. Possible causes Clogging, looseness, breakand standard valCheck fuel filter/piping directly for clogging, looseness, breakage, and 3 age, or leakage of fuel filter/ ue in normal state leakage. piping 4 Trouble in injector

Check inside of injector directly.


If causes 1 – 4 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

SERVICE CODE EC261 (ABNORMAL RISE OF FUEL TEMPERATURE) User code

Service code

—

EC261

Contents of trouble

Trouble

Abnormal rise of fuel temperature (Engine controller system)

• Fuel temperature sensor detected temperature lower than temperature set in controller. • Criterion (for reference): Min. 76°C

Action of controller • Limits engine speed to 800 rpm after 30 seconds. Problem that appears on machine Related information • Method of reproducing service code: Start engine.

Cause 1 Defective related systems Possible causes and standard value in normal state 2 Defective fuel temperature sensor system 3 Defective engine

D375A-5

Standard value in normal state/Remarks on troubleshooting Check displayed service codes. If code related to engine controller is displayed, carry out troubleshooting for it first. Carry out troubleshooting for service codes [EC263] and [EC264]. See S mode.

20-563 (5) 1

SERVICE CODE EC263 (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE EC263 (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM) User code

Service code

CALL03

EC263

Trouble

Abnormally high level in fuel temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel temperature sensor circuit is above 4.95 V.


• Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor. • Method of reproducing service code: Turn starting switch ON. Cause Defective fuel temperature 1 sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FLTP (female)

Between A – B

Resistance 600 – 36 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) P – Resistance Max. 10 Ω 2 (Disconnection in wiring or FLTP (female) A defective contact in connecWiring harness between ECMA (female) G – tor) Resistance Max. 10 Ω FLTP (female) B ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) P – FLTP (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) G – FLTP (female) B with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between P – G

600 – 36 kΩ

Circuit diagram related to fuel temperature sensor

20-564 1

D375A-5

SERVICE CODE EC265 (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)

TROUBLESHOOTING

SERVICE CODE -+ $# (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM) User code

Service code

CALL03

EC265

Trouble

Abnormally low level in fuel temperature sensor system (Engine controller system)

Contents of trouble Signal voltage of fuel temperature sensor circuit is below 0.21 V.

Action of controller Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information Method of reproducing service code: Turn starting switch ON.


D375A-5

Cause


20-565 1

TROUBLESHOOTING

SERVICE CODE EC316 (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)

SERVICE CODE -+!$ (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR) User code

Service code

CALL03

EC316

Contents of trouble

Trouble

Abnormal current of fuel pump actuator (Engine controller system)

Current of fuel pump actuator circuit is out of normal range. Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)


Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator. Method of reproducing service code: Start engine. Cause

1

Defective fuel pump actuator (Internal trouble)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PUMP (male)

Between A C

Between A, C chassis ground


Resistance 79Ω Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) A 2 (Disconnection in wiring or Resistance Max. 10 Ω PUMP (female) A defective contact in connecWiring harness between ECMA (female) ^ tor) Resistance Max. 10 Ω PUMP (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) A PUMP (female) A with wiring Resistance Min. 1 MΩ harness around it Short circuit of wiring harness between ECMA (female) ^ PUMP (female) C with wiring Resistance Min. 1 MΩ harness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between A ^

79Ω

Between A, ^ another wiring harness

Min. 1 MΩ

Circuit diagram related to fuel pump actuator

20-566 1

D375A-5

TROUBLESHOOTING

SERVICE CODE EC318 (ABNORMALITY IN FUEL PUMP ACTUATOR)

SERVICE CODE EC318 (ABNORMALITY IN FUEL PUMP ACTUATOR) User code

Service code

CALL03

EC318

Contents of trouble

Trouble

Abnormality in fuel pump actuator (Engine controller system)

• Displayed pressure of fuel pump is excessively different from actual value. • Criteria for difference (for reference): ±0.21 MPa {2.1 kg/cm2} (when water temperature is 38°C)

Action of controller • Flashes caution lamp and turns on caution buzzer. Problem that • Engine speed is unstable. appears on machine Related information • Method of reproducing service code: Start engine.



Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping 3

Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level fuel level in tank gauge is in red range, supply fuel. Suction resistance of fuel filter may be large. Check fuel filter directly.

Possible causes and standard valLarge suction resistance of 4 ue in normal state fuel filter

D375A-5

Fuel pump inlet pressure

Engine high idling

When new filter is used


Normal condition


5

Trouble in fuel pump actuaFuel pump actuator may malfunction. Check it directly. tor

6

Defective electric system of Carry out troubleshooting for service codes [EC118] and [EC119]. fuel pump pressure sensor

7 Trouble in injector

Inside of injector may be defective. Check it directly.


If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

20-567 (5) 1

SERVICE CODE EC346 (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER)

TROUBLESHOOTING

SERVICE CODE EC346 (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER) User code

Service code

CALL03

EC346

Trouble

Abnormality in power-down unit of engine controller (Engine controller system)

Contents of trouble • Data recorded in power-down unit of engine controller has error.

Action of controller • Flashes caution lamp and turns on caution buzzer. • Power-down data (maintenance information, current controller information, engine operating hours, Problem that appears on machine etc.) are lost. Related information

• Charge level of battery (Voltage) can be checked in monitoring mode. (Code dA: Battery voltage) • Method of reproducing service code: Turn starting switch ON. Cause


1 Defective fusible link (34 A)


2

Defective fuse (FS1-1, FS1-4)

If fuse is broken, circuit probably has short circuit with chassis ground. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Wiring harness between ECMB (female) 3 – Resistance Max. 10 Ω FS1-3 outlet Wiring harness between ECMA (female) 4, 5 – FS1-4 outlet

Resistance Max. 10 Ω

Wiring harness between FS1 inlet – fusible link – battery relay terminal B

Resistance Max. 10 Ω



Short circuit of wiring harness between ECMB (female) 3 – FS1-3 outlet with wiring harness Resistance Min. 1 MΩ around it Short circuit of wiring harness between ECMA (female) 4, 5 – FS1-4 outlet with wiring har- Resistance Min. 1 MΩ ness around it Wiring harness between FS1 inlet – fusible link – battery relay terminal B with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


20-568 1

ECMA, ECMB

Voltage

Between ECMB 3, 4, 5 – ECMA 7, 8

17.3 – 34.7 V

D375A-5

TROUBLESHOOTING

SERVICE CODE EC346 (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER)

Circuit diagram related to engine controller power supply

D375A-5

20-569 1

TROUBLESHOOTING

SERVICE CODE EC384 (ABNORMALITY IN PREHEATER CONTROL SYSTEM)

SERVICE CODE -+!&" (ABNORMALITY IN PREHEATER CONTROL SYSTEM) User code

Service code

CALL03

EC384

Trouble

Abnormality in preheater control system (Engine controller system)

Contents of trouble Disconnection or short circuit was detected in preheater control circuit.

Action of controller Flashes caution lamp and turns on caution buzzer. Problem that appears on machine Related information Method of reproducing service code: Turn starting switch ON.

Cause Defective preheater relay 1 (Internal trouble)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RHR (male)

Resistance

Between 1 2

200 400 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) 2 Resistance Max. 10 Ω 2 (Disconnection in wiring or RHR (female) 1 defective contact in connecWiring harness between RHR (female) 2 tor) Resistance Max. 10 Ω chassis ground Possible causes and standard value in normal state

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) 2 RHR (female) 1 with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between RHR (female) 2 chassis ground with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


20-570 1

ECMA (female)

Resistance


200 400 Ω

Between 2 another wiring harness

Min. 1 MΩ

D375A-5

TROUBLESHOOTING

SERVICE CODE EC384 (ABNORMALITY IN PREHEATER CONTROL SYSTEM)

Circuit diagram related to preheater control

D375A-5

20-571 1

TROUBLESHOOTING

SERVICE CODE EC423 (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM)

SERVICE CODE EC423 (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL03

EC423

Contents of trouble


Trouble

Abnormality in in-range of timing rail pressure sensor system (Engine controller system)

• Timing rail pressure sensor detected abnormal pressure. • Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on • Flashes caution lamp and turns on caution buzzer. • Limits high idling speed to 1,500 rpm.


• Special cable (799-795-5460) is necessary for troubleshooting for timing rail pressure sensor. • Method of reproducing service code: Turn starting switch ON. Cause Defective timing rail pres1 sure sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TIMG (male)

Voltage

Between C – B

4.75 – 5.25 V

Between A – B

0.42 – 0.58 V


Wiring harness between ECMA (female) 5 – Resistance Max. 10 Ω TPR (female) A Wiring harness between ECMA (female) H – Resistance Max. 10 Ω TPR (female) B Wiring harness between ECMA (female) W – Resistance Max. 10 Ω TPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Short circuit of wiring harness between ECMA (female) 5 – TPR (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) H – TPR (female) B with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) W – TPR (female) C with wiring har- Resistance Min. 1 MΩ ness around it Suction resistance of fuel filter may be large. Check fuel filter directly.

4

Large suction resistance of fuel filter

Fuel pump inlet pressure

Engine high idling

When new filter is used


Normal condition


★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

20-572 (5) 1

ECMA (female)

Resistance

Between 5 – H

4.75 – 5.25 V

Between W – H

0.42 – 0.58 V

D375A-5

TROUBLESHOOTING

SERVICE CODE EC423 (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM)

Circuit diagram related to timing rail pressure sensor

D375A-5

20-573 1

SERVICE CODE EC441 (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM) SERVICE CODE EC441 (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SERVICE CODE EC442 (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGESYSTEM) SYSTEM)

TROUBLESHOOTING

SERVICE CODE -+"" (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM) User code

Service code

E01

EC441

Trouble

Abnormally low level in battery voltage system (Engine controller system)

Contents of trouble Voltage of controller power supply circuit is below 12 V.

Action of controller Problem that appears on machine Related information Method of reproducing service code: Turn starting switch ON.


Cause


SERVICE CODE -+"" (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM) User code

Service code

E01

EC442

Trouble

Abnormally high level in battery voltage system (Engine controller system)

Contents of trouble Voltage of controller power supply circuit is below 38 V.

Action of controller Problem that appears on machine Related information Method of reproducing service code: Turn starting switch ON.


20-574 1

Cause


D375A-5

TROUBLESHOOTING

SERVICE CODE EC451 (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)

SERVICE CODE -+"# (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL

EC451

Trouble

Abnormally high level in fuel rail pressure sensor system (Engine controller system)

Contents of trouble Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.


Flashes caution lamp and turns on caution buzzer. Opens and controls fuel rail.


Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. Method of reproducing service code: Start engine. Cause Defective fuel rail pressure 1 sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RPR


Voltage 4.75 5.25 V 0.42 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 5 Resistance Max. 10 Ω RPR (female) A Wiring harness between ECMA (female) H Resistance Max. 10 Ω RPR (female) B Wiring harness between ECMA (female) U Resistance Max. 10 Ω RPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMA (female) 5 RPR (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) H RPR (female) B with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) U RPR (female) C with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA

Voltage

Between 5 H

4.75 5.25 V

Between U H

0.42 0.58 V

Circuit diagram related to fuel rail pressure sensor

D375A-5

20-575 1

TROUBLESHOOTING

SERVICE CODE EC452 (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)

SERVICE CODE -+"# (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL

EC452

Trouble

Abnormally low level in fuel rail pressure sensor system (Engine controller system)

Contents of trouble Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.


Flashes caution lamp and turns on caution buzzer. Reduces current for fuel rail actuator to 0 A.

Problem that appears on machine Related information Method of reproducing service code: Start engine.


20-576 1

Cause


D375A-5

TROUBLESHOOTING

SERVICE CODE EC455 (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)

SERVICE CODE -+"## (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR) User code

Service code

CALL

EC455

Contents of trouble


Trouble

Abnormal current of fuel rail actuator (Engine controller system)

Current of fuel rail actuator circuit is out of normal range. Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped) Flashes caution lamp and turns on caution buzzer. Limits engine speed to 1,500 rpm.


Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator. Method of reproducing service code: Turn starting switch ON or start engine. Cause

1

Defective fuel rail actuator (Internal trouble)

Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RAIL (male)

Between A C

Between A, C chassis ground


Resistance 79Ω Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) 3 2 (Disconnection in wiring or Resistance Max. 10 Ω RAIL (female) A defective contact in connecWiring harness between ECMA (female) @ tor) Resistance Max. 10 Ω RAIL (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) 3 RAIL (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) @ RAIL (female) C with wiring har- Resistance Min. 1 MΩ ness around it ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between 3 @

79Ω

Between 3, @ another wiring harness

Min. 1 MΩ

Circuit diagram related to fuel rail actuator

D375A-5

20-577 1

TROUBLESHOOTING

SERVICE CODE EC467 (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL) SERVICE CODEEC467 EC468(ABNORMALITY (ABNORMALITY FUEL RAIL ACTUATOR CONTROL) SERVICE CODE ININ TIMING

SERVICE CODE -+"$% (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL) User code

Service code

CALL03

EC467

Contents of trouble


Trouble

Abnormality in timing rail actuator control (Engine controller system)

Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot be obtained. Flashes caution lamp and turns on caution buzzer. Limits engine speed to 1,500 rpm.



Cause


SERVICE CODE -+"$& (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL) User code

Service code

CALL03

EC468

Contents of trouble


Trouble

Abnormality in fuel rail actuator control (Engine controller system)

Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be obtained. Flashes caution lamp and turns on caution buzzer. Limits maximum injection rate to 217 mm3/st.




Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping

Possible causes and standard val3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly. ue in normal state Clogging of fuel rail actuator 4 Fuel rail actuator screen may be clogged. Check it directly. screen

20-578 1

5 Breakage of injector O-ring

Injector O-ring may be broken. Check it directly.


If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

D375A-5

TROUBLESHOOTING

SERVICE CODE EC514 (ABNORMALITY IN FUEL RAIL ACTUATOR)

SERVICE CODE -+#" (ABNORMALITY IN FUEL RAIL ACTUATOR) User code

Service code

CALL

EC514

Contents of trouble


Trouble

Abnormality in fuel rail actuator (Engine controller system)

Displayed injection rate of fuel rail is excessively different from actual injection rate. Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec. Flashes caution lamp and turns on caution buzzer. Limits maximum injection rate to 217 mm3/st.



D375A-5

Cause


20-579 1

TROUBLESHOOTING

SERVICE CODE EC554 (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM)

SERVICE CODE -+##" (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM) User code

Service code

CALL05

EC554

Contents of trouble


Trouble

Abnormality in in-range of fuel rail pressure sensor system (Engine controller system)

Fuel rail pressure sensor detected abnormal pressure. Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on Flashes caution lamp and turns on caution buzzer. Limits maximum injection rate to 270 mm3/st.


Special cable (799-795-5460) is necessary for troubleshooting for fuel rail pressure sensor. Method of reproducing service code: Turn starting switch ON. Cause Defective fuel rail pressure 1 sensor (Internal trouble)



Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPR


Voltage 4.75 5.25 V 0.42 0.58 V

★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) 5 Resistance Max. 10 Ω RPR (female) A Wiring harness between ECMA (female) H Resistance Max. 10 Ω RPR (female) B Wiring harness between ECMA (female) U Resistance Max. 10 Ω RPR (female) C ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMA (female) 5 RPR (female) A with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) H RPR (female) B with wiring har- Resistance Min. 1 MΩ ness around it Short circuit of wiring harness between ECMA (female) U RPR (female) C with wiring har- Resistance Min. 1 MΩ ness around it

4

Large suction resistance of fuel filter

Suction resistance of fuel filter may be large. Check fuel filter directly. Negative suction pressure (Tank side)

27 kPa {203 mmHg}

★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

20-580 1

ECMA

Voltage

Between 5 H

4.75 5.25 V

Between U H

0.42 0.58 V

D375A-5

TROUBLESHOOTING

SERVICE CODE EC554 (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM)

Circuit diagram related to fuel rail pressure sensor

D375A-5

20-581 1

TROUBLESHOOTING

20 TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)

Information in troubleshooting table ......................................................................................................... E-1 The engine does not start ................................................................................................................ E-2 Preheat does not operate (Manual preheating function) .................................................................. E-3 The ripper pin puller cylinder does not operate ................................................................................ E-4 When the starting switch is on, none of the monitor panels come on .............................................. E-5 When the starting switch is on, all the monitor panels are kept coming on and do not come out ............ E-6 When the starting switch is on, the basic check item flashes .......................................................... E-7 When the engine is operating, the caution item flashes .................................................................. E-8 When the engine is operating, the emergency alarm item flashes .................................................. E-9 The preheating lamp does not come on .......................................................................................... E-10 The display of the engine water temperature gauge is not normal ................................................ E-11 The display of the torque converter oil temperature gauge is not normal ...................................... E-12 The display of the fuel gauge is not normal ................................................................................... E-13 The display of the gear speed/engine speed/shift mode is not normal .......................................... E-14 The display of the service meter is not normal .............................................................................. E-15 The switch module cannot be operated ......................................................................................... E-16 The alarm lamp does not flash or come out ................................................................................... E-17 The alarm buzzer does not sound or stop ..................................................................................... E-18 The alarm buzzer cannot be cancelled .......................................................................................... E-19 The service mode cannot be selected ........................................................................................... E-20 Back-up alarm does not sound ...................................................................................................... E-21 Instrument panel night lamp, headlamp, working lamp and rear lamp do not come on ................. E-22 Air conditioner does not operate ....................................................................................................

D375A-5

20-602 20-603 20-605 20-607 20-608 20- 609 20-610 20-611 20-613 20-616 20-617 20-618 20-619 20-620 20-620 20-622 20-623 20-624 20-625 20-626 20-627 20-628 20-632

20-601 1

TROUBLESHOOTING


INFORMATION IN TROUBLESHOOTING TABLE ★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Trouble in machine Related information Information related to detected trouble or troubleshooting Cause

Standard value in normal state to judge possible causes Remarks on judgment

1

Disconnection Connector is connected imperfectly or harness is broken. Short circuit with chassis ground Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Short circuit with power source Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. Short circuit Independent harnesses are in contact with each other abnormally.

2



Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority) 1Method of indicating connector No. and handling of T-adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 If connector No. has no marks of male and female, disconnect connector and insert T-adapters in both male side and female side. If connector No. has marks of male and female, disconnect connector and connect T-adapter to only male side or female side. 2Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified. Connect positive (+) lead to pin No. or harness entered on front 4 side. Connect negative () lead to pin No. or harness entered on rear side.


Part of electric circuit diagram related to trouble Connector No.: Indicates (Model Number of pins) and (Color). Arrows (⇔): Indicate rough location of connector in machine.

20-602 1

D375A-5

TROUBLESHOOTING

E-1 THE ENGINE DOES NOT START

E-1 THE ENGINE DOES NOT START Trouble

The engine does not start. Because the neutral safety function is provided in the engine starting circuit, the engine can be started only when the parking lever is in the lock position. Related information If the Monitor panel does not come on or the Operating sound of the battery relay is not heard when the starting switch is ON, a main power system abnormality is assumed. So inspect it. Cause

1

2

3

4

5


7

8

D375A-5

Standard value in normal state/Remarks on troubleshooting Battery voltage Battery specific gravity Insufficient battery capacity Min. 24 V Min. 1.26 ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Starting switch failure Key (male) Switch position Resistance value (Internal disconnection) OFF Min. 1 MΩ Between 5 and 3 START Max. 1 Ω ★ Prepare the engine with the starting switch OFF and diagnose it with the engine start. Neutral safety relay failure If the engine is started by the engine starting operation by replacing (Internal disconnection) this relay with another relay with the starting switch OFF, the neutral safety relay (NSF) is faulty. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Diode failure (Internal short circuit) D03 (female) Resistance value Between 1 and 2 Min. 1 MΩ ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Diode failure (Internal short circuit) Alternator Voltage Between R terminal and ground Max. 1 V ★ Prepare the engine with the starting switch OFF and diagnose it with the engine start. Starter Voltage Power: Between B terminal 20 30 V and ground Starter failure Charge: Between R terminal (Internal fault) Max. 1 V and ground Start: Between C terminal 20 30 V and ground If each voltage of power, charge, or start is normal and the starter is not turned, the starter is faulty. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness disconnection failure Between the harnesses between key (female) Resistance Max. 1 Ω 3 and NSF (female) 3 value (Disconnection/connector contact failure) Between harnesses between NSF (female) 5 Resistance Max. 1 Ω and top and bottom starter C terminal value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Between alternator R terminal and top and bottom starter C terminal, between alternator Harness hot short-circuiting R terminal and D03 (female) 2, between alfailure ternator R terminal and S03 (female) 4, be(24 V circuit and contact) tween alternator R terminal and CN1 (female) Voltage Max. 1 V 4, and between harness and ground (Note: If hot short-circuiting occurs, the charge level lamp comes on when the starting switch is ON.)

20-603 1

TROUBLESHOOTING

E-1 THE ENGINE DOES NOT START

Engine start/charge-related circuit diagram

20-604 1

D375A-5

TROUBLESHOOTING

E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)

E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) Trouble

Preheat does not operate. ★ This troubleshooting describes the procedures when the electrical intake air heater mounting unit is not heated (if only the preheating lamp does not come on, execute the diagnosis indicating that the Preheating lamp does not come on.) Related information Preheat includes the Automatic preheating function and the Manual preheating function. Even if which function is operated, the preheating lamp comes on. If the Monitor panel does not come on or No operating sound of the battery relay is heard when the starting switch is ON, a main power system abnormality is assumed. So inspect it. Cause

1

2

3


5

6

7

D375A-5

Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Starting switch failure Key (male) Switch position Resistance value (Internal disconnection) OFF Min. 1 MΩ Between 5 and 2 HEAT Max. 1 Ω If the fuse is damaged by fire, the possibility of a ground fault having Fuse (FS4-4) failure occurred in the circuit is great. ★ Prepare the engine with the starting switch OFF and diagnose it with HEAT. Preheater relay failure (Internal disconnection) If the engine is preheated by the heat operation by replacing this relay with the starting switch OFF, the preheater relay (RHR) is faulty. ★ Prepare the engine with the starting switch OFF and diagnose it with HEAT. Preheater Voltage Power: Between power supHeater relay failure ply terminal and 20 30 V (Internal fault) ground Signal: Between signal termi20 30 V nal and ground If each voltage of power and signal is normal and no operation sound is heard, the heater relay is faulty. ★ Prepare the engine with the starting switch OFF and diagnose it Electrical intake air heater with the starting switch OFF as is. failure Electrical intake air heater Continuity (Internal fault) Between terminals Continue ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between FS4-5 exit and Resistance Max. 1 Ω value Harness disconnection fail- RHR (female) 5 ure Between RHR (female) 3 and key (female) Resistance (Disconnection/connector Max. 1 Ω 2, and between harnesses RHR (female) 3 value contact failure) and heater relay Between harnesses between battery relay M Resistance terminal and starter and between the batter Max. 1 Ω value relay M terminal and heater relay ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness ground fault (GND circuit and contact) Between FS4-5 (exit side)-related harnesses Resistance Min. 1 MΩ and between grounds value

20-605 1

TROUBLESHOOTING

E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)

Engine preheat-related circuit diagram

20-606 1

D375A-5

TROUBLESHOOTING

E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE

E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE Trouble The ripper pin puller cylinder does not operates. Related information Cause 1 Fuse (FS4-1) failure Pin puller switch failure 2 (Internal disconnection/short circuit)

Pin puller solenoid failure 3 (Internal disconnection/short circuit)


Harness disconnection failure 4 (Disconnection/connector contact failure)

5

Harness ground fault (GND circuit and contact)

Harness hot short-circuiting 6 failure (24 V circuit and contact)

Standard value in normal state/Remarks on troubleshooting If the fuse is damaged by fire, the possibility of a ground fault having occurred in the circuit is great. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. 263 (male) Switch Resistance value Draw-in Max. 1 Ω Between 1 and 2 Pull-in Min. 1 MΩ ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. 224 (male) Resistance value Between 1 and 2 10 80 Ω Between 1 and groud Min. 1 MΩ ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch Off as is. Between harnesses between FS4-1 exit and Resistance Max. 1 Ω 263 (female) 1 value Between harnesses between 263 (female) 2 Resistance Max. 1 Ω and 224 (female) 1 value Between harnesses between 224 (female) 2 Resistance Max. 1 Ω and ground value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between FS4-1 (exit side)-related harnesses Resistance Min. 1 MΩ and between grounds value Between harness and ground between 263 Resistance Min. 1 MΩ (female) 2 and 224 (female) 1 value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Between harness and ground between 263 Voltage Max. 1 V (female) 2 and 224 (female) 1

Ripper pin puller solenoid-related circuit diagram

D375A-5

20-607 1

TROUBLESHOOTING

E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS COME ON

E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS COME ON Trouble (1) The caution module (gauge portion/lamp portion) does not come on. Related information When the starting switch is ON, all the monitor panels come on for three seconds. Cause

1

2 Possible causes and standard value in normal state 3

4

Standard value in normal state/Remarks on troubleshooting If the circuit breaker is disconnected, the possibility of a ground fault Circuit breaker (CB2) failure having occurred in the circuit is great. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness disconnection failure Between harnesses between CN1 (female) 1 Resistance Max. 1 Ω value (Disconnection/connection and CB2 exit contact failure) Resistance Between harnesses between CN1 2 and Max. 1 Ω value ground ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness ground fault (GND circuit and contact) Resistance Between CB2 (exit side)-related harnesses Min. 1 MΩ value and between grounds ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Monitor panel failure (Caution module) CN1 Voltage Between 1 and 2 20 30 V

Trouble (2) The tachometer module (tachometer portion/service meter portion) does not come on. Related information When the starting switch is ON, all the monitor panels come on for three seconds. Cause Circuit breaker (CB2, CB6) 1 failure

Harness disconnection failure 2 (Disconnection/connector contact failure) Possible causes and standard value in normal state

20-608 1

3

Harness fault ground (GND circuit and contact)

4

Monitor panel failure (Tachometer module)

Standard value in normal state/Remarks on troubleshooting If the circuit breaker is disconnected, the possibility of a ground fault having occurred in the circuit is great. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between S03 (female) 1 Resistance Max. 1 Ω value and CB2 exit Between harnesses between S03 (female) 7 Resistance Max. 1 Ω value and CB6 exit Between harnesses between S03 (female) 2 Resistance Max. 1 Ω value and ground ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Resistance Between CB2 (exit side)-related harnesses Min. 1 MΩ value and between grounds Resistance Between CB6 (exit side)-related harnesses Min. 1 MΩ value and between grounds ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. CN1 Voltage Between 1 and 2 20 30 V Between 7 and 2 20 30 V

D375A-5

TROUBLESHOOTING

E-5 WHEN THE STARTING SWITCH IS ON, ALL THE MONITOR PANELS ARE KEPT COMING ON AND DO NOT COME OUT

Monitor panel power supply-related circuit diagram

E-5 WHEN THE STARTING SWITCH IS ON, ALL THE MONITOR PANELS ARE KEPT COMING ON AND DO NOT COME OUT Trouble (1) The caution module (gauge portion/lamp portion) does not come out. Related information When the starting switch is ON, all the monitor panels come on for three seconds, they come out. Cause Possible causes and standard valMonitor panel failure ue in normal state 1 (Caution module)

Standard value in normal state/Remarks on troubleshooting Because the monitor panel is internally faulty, it cannot be diagnosed.

Trouble (2) The tachometer module (tachometer portion/service meter portion) does not come out. Related information When the starting switch is ON, all the monitor panels come on for three seconds, they come out. Cause Possible causes and standard valMonitor panel failure 1 ue in normal state (Tachometer module)

D375A-5


20-609 1

TROUBLESHOOTING

E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES

E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES Trouble The radiator water level lamp flashes. Related information The basic check item flashes when an abnormality is detected before the engine starts. Cause Radiator water level de1 crease (When system is normal)


Radiator water level failure (Internal disconnection)

Harness disconnection failure 3 (Disconnection/connector contact failure)

4

Monitor panel failure (Caution module)

Standard value in normal state/Remarks on troubleshooting Because the radiator water level decrease is detected, inspect the radiator water level (the lamp flashes below the specified level). ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. 405 (male) Radiator water level Resistance value At normal time Max. 1 Ω Between 1 and 2 At decreased time Min. 1 MΩ ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between CN1 (female) 5 Resistance Max. 1 Ω value and 405 (female) 1 Between harnesses between 405 (female) 2 Resistance Max. 1 Ω value and ground ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. CN1 Radiator water level Voltage At normal time Max. 1 V Between 1 and 2 At decreased time 20 20 V

Radiator water level sensor-related circuit diagram

20-610 1

D375A-5

TROUBLESHOOTING

E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES

E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES Trouble The charge level lamp flashes. Related information The caution item flashes if an abnormality is detected when the engine is operating. Cause

1


4

D375A-5

Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it starting the engine. Alternator failure (Insufficient power generaAlternator Engine speed Voltage tion) Between R terminal Above intermediate 20 30 V and ground speed (half) Harness disconnection fail- ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. ure (Disconnection/connector Between harnesses between CN1 (female) 4 Resistance Max. 1 Ω contact failure) and alternator R terminal value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between CN1 4 and S03 (female) 4, Between CN1 (female) and alternator R terminal, Harness ground fault between CN1 (female) 4 and top and bottom (GND circuit and contact) Resistance starter R terminal, between CN1 (female) 4 Min. 1 MΩ value and NGICN3 (female), between harness and ground between CN1 (female) 4 and battery relay BR terminal ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Monitor panel failure CN1 Engine speed Voltage (Caution module) Between 4 and Above intermediate 20 30 V ground speed (half)

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TROUBLESHOOTING

E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES


20-612 1

D375A-5

TROUBLESHOOTING

E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES

E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES Trouble (1)

The fuel temperature lamp flashes. The emergency alarm item flashes if an abnormality is detected when the engine is operating and Related information sounds the alarm buzzer. Cause Fuel temperature rises ab1 normally (When system is normal) Possible causes Fuel temperature sensor and standard val2 system failure ue in normal state (Engine controller system) 3


Standard value in normal state/Remarks on troubleshooting Inspect the fuel temperature since abnormal increase of fuel temperature has been detected. (When fuel temperature exceeds the specified temperature: Lamp flashes.) Execute the service codes [EC261], [EC263] and [EC265]. If there is an abnormality in Causes 1 and 2, a monitor panel failure is assumed (because the monitor panel is internally faulty, it cannot be diagnosed).

Trouble (2)

Engine oil pressure lamp flashes. The emergency alarm item flashes if an abnormality is detected when the engine is operating and Related information sounds the alarm buzzer. Cause Engine oil pressure de1 crease (When system is normal) Possible causes Engine oil pressure sensor and standard val2 system failure ue in normal state (engine controller system) 3


Standard value in normal state/Remarks on troubleshooting Because the engine oil pressure decrease is detected, inspect the engine oil pressure (below specified pressure: Lamp flashes). Execute the service codes [EC135] [EC141], and [EC143]. If there is an abnormality in Causes 1 and 2, a monitor panel failure is assumed (because the monitor panel is internally faulty, it cannot be diagnosed).

Trouble (3)

The engine water temperature lamp flashes. The emergency alarm item flashes if an abnormality is detected when the engine is operating and sounds the alarm buzzer. Related information The engine water temperature lamp flashes/comes out being linked with the display of the engine water temperature gauge. Cause Engine water temperature 1 overheat (When system is normal)

Possible causes Engine water temperature and standard val2 system failure ue in normal state (engine controller system)

3

D375A-5


Standard value in normal state/Remarks on troubleshooting Because the engine water temperature overheat is detected, inspect the engine oil pressure (above water temperature of 108°C; Lamp flashes) Check the display of the engine water temperature gauge. If the display is not normal, execute the diagnosis indicating that the Display of the engine water temperature gauge is not normal. Engine water Water temperature Gauge segment temperature lamp 7th stage 108°C Flashes 6th stage Approx. 108°C 5th stage Approx. 102°C 4th stage Approx. 98°C Comes out 3rd stage Approx. 94°C 2nd stage Approx. 83°C 1st stage Approx. 70°C If there is no abnormality in Causes 1 and 2, a monitor panel failure is assumed (because the monitor panel is internally faulty, it cannot be diagnosed).

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TROUBLESHOOTING


Trouble (4)

The torque converter oil temperature lamp flashes. The emergency alarm item flashes if an abnormality is detected when the engine is operating and sounds the alarm buzzer. Related information The torque converter oil temperature lamp flashes/comes out being linked with the display of the torque converter oil temperature gauge. Cause Standard value in normal state/Remarks on troubleshooting Torque converter oil temper- Because the torque converter overheat is detected, inspect the torque 1 ature overheat converter oil temperature (above water temperature of 130°C; Lamp (When system is normal) flashes) Check the display of the torque converter oil temperature gauge. If the display is not normal, execute the diagnosis indicating that the Display of the torque converter oil temperature gauge is not normal. Torque converter oil Gauge segment Oil temperature lamp temperature Possible causes 7th stage 130°C Flashes and standard valTorque converter oil temper2 6th stage Approx. 130°C ue in normal state ature system failure 5th stage Approx. 120°C 4th stage Approx. 116°C Comes out 3rd stage Approx. 110°C 2nd stage Approx. 90°C 1st stage Approx. 50°C If there is no abnormality in Causes 1 and 2, a monitor panel failure is Monitor panel failure 3 assumed (because the monitor panel is internally faulty, it cannot be (Caution module) diagnosed).

20-614 1

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TROUBLESHOOTING


Trouble (5)

The hydraulic oil temperature lamp flashes. The emergency alarm item flashes if an abnormality is detected when the engine is operating and Related information sounds the alarm buzzer. Cause Standard value in normal state/Remarks on troubleshooting Abnormal hydraulic oil tem- Because the abnormal hydraulic oil temperature rise is detected, in1 perature rise spect the hydraulic oil temperature (When system is normal) (Above specified temperature: Lamp flashes) ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Hydraulic oil temperature Hydraulic oil 452 (male) Continuity 2 sensor failure temperature (Internal short circuit) Max. 105°C No continuity Between 1 and Possible causes ground Min. 105°C Continue and standard val★ Prepare the engine with the starting switch OFF and diagnose it ue in normal state with the starting switch OFF as is. Harness ground fault 3 (GND circuit and contact) Between harness and ground between CN1 Resistance Min. 1 MΩ (female) 8 and 452 (female) 1 value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Hydraulic oil Monitor panel failure CN1 Voltage 4 temperature (Caution module) Max. 105°C 20 30 V Between 8 and ground Min. 105°C Max. 1 V

Hydraulic oil temperature sensor-related circuit diagram

D375A-5

20-615 1

TROUBLESHOOTING

E-9 THE PREHEATING LAMP DOES NOT COME ON

E-9 THE PREHEATING LAMP DOES NOT COME ON Trouble

The preheating lamp does not come on. ★ This troubleshooting describes the procedures when the preheating lamp does not come on (if the electrical intake air heater mounting portion is not heated, execute the diagnosis indicating that the Related information Preheat lamp does not operate. Preheat includes the Automatic preheat function and the Manual preheat function. Even if which function operates, the preheating lamp comes on. Cause Harness disconnection failure 1 (Disconnection/connector contact failure) Possible causes Harness ground fault and standard val- 2 (GND circuit and contact) ue in normal state

3


Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between CN2 (female) 5 Resistance Max. 1 Ω value and heater relay terminal ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harness and ground between CN2 Resistance Min. 1 MΩ value (female) 5 and heater relay terminal ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. CN2 Starting switch Voltage ON Max. 1 V Between 5 and ground HEAT 20 30 V

Engine preheat-related circuit diagram

20-616 1

D375A-5

TROUBLESHOOTING

E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL

E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL Trouble

The display of the engine water temperature gauge is nor normal. The signal of the engine water temperature gauge is received by the communication from the engine Related information controller.


Cause Engine water temperature 1 system failure (Engine controller system) 2

D375A-5


Standard value in normal state/Remarks on troubleshooting Execute the diagnosis of the service codes [EC144] and [EC145]. If there is an abnormality in Cause 1, a monitor panel abnormality is assumed (because the monitor panel is internally faulty, it cannot be diagnosed).

20-617 1

E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT NORMAL

TROUBLESHOOTING

E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT NORMAL Trouble The display of the torque converter oil temperature gauge is not normal. Related information Cause

Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Torque converter oil Torque converter oil temper453 (male) Resistance value temperature ature sensor failure 1 (Internal disconnection/short Approx. 80 k Between 1 and 2 circuit) approx. 3.8 kΩ 10 100°C Between 1 and Min. 1 MΩ ground ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness disconnection failure Between harnesses between CN2 (female) 2 Resistance 2 Max. 1 Ω value (Disconnection/connector and 453 (female) 1 contact failure) Possible causes Between harnesses between 453 (female) 2 Resistance Max. 1 Ω and standard valvalue and ground ue in normal state ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness ground fault 3 (GND circuit and contact) Between harness and ground between CN2 Resistance Min. 1 MΩ value (female) 2 and 453 (female) 1 ★ Prepare the engine with the starting switch OFF and diagnose it Harness hot short-circuiting with the starting switch ON. 4 failure Between harness and ground beytween CN2 (24 V circuit and contact) Voltage Max. 1 V (female) 2 and 453 (female) 1 ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Monitor panel failure Torque converter oil 5 CN2 (female) Resistance value (Caution module) temperature Between 2 and Approx. 80 k 10 100°C ground approx. 3.8 kΩ

Torque converter oil temperature-related circuit diagram

20-618 1

D375A-5

TROUBLESHOOTING

E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL

E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL Trouble The display of the fuel gauge is not normal. Related information Cause

Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Fuel level sensor failure 423 (male) Remaining fuel level Resistance value 1 (Internal disconnection/short circuit) Full Max. approx. 12 Ω Between 1 and 2 (ground) Empty Approx. 85 110 Ω ★ Prepare the engine with the starting switch OFF and diagnose it Harness disconnection failwith the starting switch OFF as is. ure 2 (Disconnection/connector Between harnesses between CN2 (female) 3 Resistance Max. 1 Ω contact failure) and 423 (female) 1 value Possible causes ★ Prepare the engine with the starting switch OFF and diagnose it and standard valwith the starting switch OFF as is. Harness ground fault ue in normal state 3 (GND circuit and contact) Between harness and ground between CN2 Resistance Min. 1 MΩ (female) 3 and 423 (female) 1 value ★ Prepare the engine with the starting switch OFF and diagnose it Harness hot short-circuiting with the starting switch ON. 4 failure Between harness and ground between CN2 (24 V circuit and contact) Voltage Max. 1 V (female) 3 and 423 (female) 1 ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Monitor panel failure CN2 (female) Remaining fuel level Resistance value 5 (Caution module) Full Max. approx. 12 Ω Between 3 and ground Empty Approx. 85 110 Ω

Fuel level sensor-related circuit diagram

D375A-5

20-619 1

TROUBLESHOOTING

E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT IS NOT NORMAL E-13 THE DISPLAY OF THE GEAR SPEED/ENGINEMODE SPEED/SHIFT MODE IS E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL

E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT MODE IS NOT NORMAL Trouble

The display of the gear speed/engine speed/shift mode is not normal. The signal of the gear speed/engine speed/shift mode is received by the communication from the Related information transmission controller and steering copntroller. Cause Possible causes and standard valMonitor panel failure 1 ue in normal state (Tachometer module)


E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL Trouble (1)

When the engine is operating, the time of the service meter does not run too fast. Clock the time of the service meter using an engine operating signal (alternator voltage/engine oil Related information pressure). Cause 1 Alternator system failure Engine oil pressure sensor 2 system failure (Engine controller system)

Possible causes Harness disconnection failand standard valure ue in normal state 3 (Disconnection/connector contact failure)

4

Monitor panel failure (Tachometer module)

Standard value in normal state/Remarks on troubleshooting If the charge level lamp flashes when the engine is operating, execute the diagnosis indicating that the Caution item flashes when the engine is operating. If the engine oil pressure lamp flashes when the engine is operating, execute the diagnosis indicating that the Emergency alarm item flashes when the engine is operating. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between S03 (female) 3 Resistance Max. 1 Ω value and circuit merging point ★ Prepare the engine with the starting switch OFF and diagnose it with the engine start. S03 Engine speed Voltage Between 4 and Above intermediate 20 30 V ground speed (half)

Trouble (2) The service meter is not displayed fully. Related information Cause Possible causes and standard valMonitor panel failure 1 ue in normal state (Tachometer module)

20-620 1


D375A-5

TROUBLESHOOTING

E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL


D375A-5

20-621 1

TROUBLESHOOTING

E-15 THE SWITCH MODULE CANNOT BE OPERATED

E-15 THE SWITCH MODULE CANNOT BE OPERATED Trouble (1) Even if the switch is operated, the lamp is not switched. Related information Cause Possible causes and standard valMonitor panel failure ue in normal state 1 (Switch module)


Trouble (2) Even if the switch is operated, the system setting is not switched. Related information The signal of the switch module is sent to each controller by communication. Cause


Harness disconnection failure 1 (Disconnection/connector contact failure) 2

Monitor panel failure (Switch module)

Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between S013 (female) Resistance Max. 1 Ω value 8 and circuit merging point ★ Prepare the engine with the starting switch OFF and diagnose it with the engine start. S01 Voltage Between 8 and ground 69V

S-NET communication-related circuit diagram

20-622 1

D375A-5

TROUBLESHOOTING

E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT

E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT Trouble

The alarm lamp does not flash or come out. If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any Related information service code cannot be displayed. Cause

1

2

Possible causes 3 and standard value in normal state

4

5

Standard value in normal state/Remarks on troubleshooting If the circuit breaker is disconnected, the possibility of a ground fault Circuit breaker (CB2) failure having occurred in the circuit is great. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Alarm lamp failure 375 (male) Resistance value (Internal disconnection/short circuit) Between 1 and 2 100 400 Ω Between 1 and ground Min. 1 MΩ ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness disconnection failBetween harnesses between CN2 (female) 7 Resistance ure Max. 1 Ω and 375 (female) 2 value (Disconnection/connector contact failure) Between harnesses between 375 (female) 1 Resistance Max. 1 Ω and CB2 exit value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness ground fault (GND circuit and contact) Between CB2 (exit side)-related harnesses Resistance Min. 1 MΩ and grounds value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. Monitor panel failure CN2 Alarm lamp Voltage (Caution module) Coming out 20 30 V Between 7 and ground Coming on Max. 6 V

Alarm lamp-related circuit diagram

D375A-5

20-623 1

TROUBLESHOOTING

E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP

E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP Trouble

The alarm buzzer does not sound or stop. If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any Related information service code cannot be displayed. Cause

1

2

Possible causes 3 and standard value in normal state

4

5

Standard value in normal state/Remarks on troubleshooting If the circuit breaker is disconnected, the possibility of a ground fault Circuit breaker (CB2) failure having occurred in the circuit is great. ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Alarm lamp failure 217 (male) Resistance value (Internal disconnection/short circuit) Between 1 and 2 200 Ω Between 2 and ground Min. 1 MΩ ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness disconnection failBetween harnesses between CN2 (female) 8 Resistance ure Max. 1 Ω value and 217 (female) 1 (Disconnection/connector contact failure) Between harnesses between 217 (female) 2 Resistance Max. 1 Ω value and CB2 exit ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness ground fault (GND circuit and contact) Resistance Between CB2 (exit side)-related harnesses Min. 1 MΩ value and grounds ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. CN2 Alarm buzzer Voltage Monitor panel failure (Caution module) At stoppage time 20 30 V Between 8 and At operating ground Max. 3 V (sounding) time

Alarm buzzer-related circuit diagram

20-624 1

D375A-5

TROUBLESHOOTING

E-18 THE ALARM BUZZER CANNOT BE CANCELLED

E-18 THE ALARM BUZZER CANNOT BE CANCELLED Trouble • The alarm buzzer cannot be cancelled. Related information Cause

1


2

3

4

Standard value in normal state/Remarks on troubleshooting ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Buzzer cancel switch failure 212 (male) Buzzer cancel switch Resistance value (Internal disconnection) OFF Min. 1 MΩ Between 1 and 2 Between 1 and 3 ON Max. 1 Ω ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Between harnesses between NGICN2 Z and Resistance Harness disconnection failMax. 1 Ω 212 (female) 1 value ure (Disconnection/connector Between harnesses between 212 (female) 2 Resistance Max. 1 Ω contact failure) and ground value Between harnesses between 212 (female) 3 Resistance Max. 1 Ω and ground value ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch OFF as is. Harness ground fault (GND circuit and contact) Resistance Between harness and ground between Min. 1 MΩ value NGICN Z and 212 (female) 1 ★ Prepare the engine with the starting switch OFF and diagnose it with the starting switch ON. NGICN2 Buzzer cancel switch Voltage Steering controller failure OFF 20 – 30 V Between Z and ground ON Max. 1 V

Buzzer cancel switch-related circuit diagram

D375A-5

20-625 1

TROUBLESHOOTING

E-19 THE SERVICE MODE CANNOT BE SELECTED

E-19 THE SERVICE MODE CANNOT BE SELECTED Trouble • The service mode cannot be selected. Related information Cause

1


3

4

5

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and troubleshoot while keeping the switch OFF. Defective service switch S24 Switch Resistance value (Internal disconnection) OFF Min. 1 MΩ Between 1 and 3 Between 4 and 6 ON Max. 1 Ω ★ Set the starting switch to OFF for preparation and troubleshoot while keeping the switch OFF. Resistance Harness between S03 (female) 5 and S24 3 Max. 1 Ω value Disconnection of harness Resistance (Disconnection, defective Max. 1 Ω Harness between S24 1 and ground value contact of connector) Harness between NG1CN1 (female) 6 and Resistance Max. 1 Ω S24 6 value Resistance Max. 1 Ω Harness between S24 5 and ground value ★ Set the starting switch to OFF for preparation and set the switch to ON for troubleshooting. Defective monitor panel S03 Service switch Voltage (Tachometer module) OFF 20 – 30 V Between 5 and ground ON Max. 1 V ★ Set the starting switch to OFF for preparation and set the switch to ON for troubleshooting. NGICN1 Service switch Voltage Defective steering controller OFF 20 – 30 V Between 6 and ground ON Max. 1 V The buzzer cancel switch The buzzer cancel switch system is supposed to be defective. Execute system is defective the troubleshooting of “Alarm buzzer cannot be cancelled.”

Circuit diagram related to service switch

20-626 1 (5)

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TROUBLESHOOTING

E-20 BACK-UP ALARM DOES NOT SOUND

E-20 BACK-UP ALARM DOES NOT SOUND Trouble

The back-up alarm does not sound. When a failure occurs on the primary side (coil side) of the back-up alarm relay, a service code is disRelated information played, but in case of a failure on the secondary side (contact side), no service code cannot be displayed. Cause 1 Defective fuse (FS4-1)

2

Defective back alarm relay (Internal disconnection)

Possible causes Disconnection of harness and standard val- 3 (Disconnection, defective ue in normal state contact of connector)

4

Ground fault of harness (contact with GND circuit)

5

Defective back-up alarm (internal defect)

Standard value in normal state/Remarks on troubleshooting When the fuse is blown, there is a high possibility that the circuit was short-circuited with ground. ★ Set the starting switch to OFF for preparation and set to ON for troubleshooting. Replace this relay with another relay while the starting switch is set to OFF, set the starting switch to ON and reverse this machine. If the back-up alarm sounds, the back-up alarm relay (BKA) is defective. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between FS4-1 outlet and BKA (fe- Resistance Max. 1 Ω male) 3 value Harness between BKA (female) 5 and 244 Resistance Max. 1 Ω (female) 2 value Resistance Harness between 244 (female) 1 and ground Max. 1 Ω value ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Between harness (between FS4-1 outlet and Resistance Min. 1 MΩ BKA (female) 3) and ground value Between harness (between BKA (female) 5 Resistance Min. 1 MΩ and 244 (female) 2) and ground value When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.


D375A-5

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TROUBLESHOOTING

E-21 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND REAR LAMP DO NOT COME ON

E-21 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND REAR LAMP DO NOT COME ON Trouble (1) Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on. Related information Cause 1 Defective fuse (FS2-5) Disconnection of harness 2 (Disconnection, defective contact of connector)



Standard value in normal state/Remarks on troubleshooting When the fuse is blown, there is a high possibility that the circuit was short-circuited with ground. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between FS2-5 (outlet side) and cir- Resistance Max. 1 Ω value cuit branched portion ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Resistance Between harness related to FS2-5 (outlet Min. 1 MΩ value side) and ground Between harnesses (between 219 (female) 3 and CN4 (female) 1, between 219 (female) 3 and S03 (female) 1, between 219 (female) Resistance Min. 1 MΩ value 3 and S02 (female) 1, between 219 (female) 3 and S01 (female) @ and between 219 (female) 3 and BB1 (female) 1) and ground Between harnesses (between 218 (female) 3 Resistance Min. 1 MΩ and 223 (female) 1 and between 218 (fevalue male) 3 and 243 (female) 1) and ground

Trouble (2) Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on. Related information Cause

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Headlamp and working lamp 219 (male) Switch Resistance value 1 switches (Internal disconnection) OFF Min. 1 MΩ Between 2 and 3 ON Max. 1 Ω ★ Set the starting switch to OFF for preparation and troubleshoot Possible causes while keeping it to OFF. and standard valHarness between 219 (female) 2 and circuit Resistance ue in normal state Max. 1 Ω value branched portion Disconnection of harness Harnesses between 219 (female) 3 and BB1 2 (Disconnection, defective Resistance (female) 1 and between 219 (female) 3 and Max. 1 Ω contact of connector) value BB3 (female) 1 Harnesses between BB1 (female) 2 and Resistance ground and between BB3 (female) 2 and Max. 1 Ω value ground

20-628 1

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TROUBLESHOOTING


Trouble (3) Only the instrument panel night lamp does not come on. Related information Cause Defective night lamp 1 (Burnt bulb)

Disconnection of harness 2 (Disconnection, defective contact of connector) Possible causes and standard value in normal state

3

Defective monitor panel (Switch module)

4

Defective monitor panel (Tachometer module)

5

Defective monitor panel (Caution module)

Standard value in normal state/Remarks on troubleshooting The night lamp is supposed to be defective. Check if the light bulb is burned out. ★ Set the starting switch to OFF for preparation Resistance Max. 1 Ω value and troubleshoot while keeping it to OFF. Harness between S01 (female) 8 and circuit Resistance Max. 1 Ω branched portion value Harness between S02 (female) 1 and circuit Resistance Max. 1 Ω branched portion value Resistance Harness between S02 (female) 2 and ground Max. 1 Ω value Harness between S03 (female) 6 and circuit Resistance Max. 1 Ω branched portion value Harness between CN4 (female) 1 and circuit Resistance Max. 1 Ω branched portion value Resistance Harness between S04 (female) 2 and ground Max. 1 Ω value ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Between S01 @ and 2 Between S01 1 and 2

Light switch ON

20 30 V

★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Between S03 6 and 2 Light switch ON 20 30 V ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Between CN4 1 and 2 Light switch ON 20 30 V

Trouble (4) Only the headlamp does not come on. Related information Cause Defective headlamp 1 (Burnt bulb) Defective circuit breaker 2 (CB5) 3


Disconnection of harness 4 (Disconnection, defective contact of connector)

5

D375A-5

Defective headlamp relay (Internal disconnection)


Standard value in normal state/Remarks on troubleshooting The headlamp is supposed to be defective. Check if the light bulb is burned out. When the circuit breaker is cut off, there is a high possibility that the circuit was short-circuited with ground. ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. When the starting switch is set to OFF, replace the relay with another relay. Set the starting switch to ON and set the light switch to ON. If the headlamp comes on, the headlamp relay (BB1) is defective. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between CB5 outlet and BB1 (feResistance Max. 1 Ω male) 3 value Harnesses between BB1 (female) 5 and 203 Resistance Max. 1 Ω (female) 1 and between BB1 (female) 5 and value 204 (female) 1 ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Between harness related to CB5 (outlet side) Resistance Min. 1 MΩ and ground value Between harnesses (between BB1 (female) Resistance 5 and 203 (female) 1, between BB1 (female) Min. 1 MΩ value 5 and 204 (female) 1) and ground

20-629 1

TROUBLESHOOTING


Trouble (5) Only the working lamp does not come on. (Both right and left, or one side only) Related information Cause Defective working lamp 1 (Burnt bulb) 2

3


4

5

Standard value in normal state/Remarks on troubleshooting The working lamp is supposed to be defective. Check if the light bulb is burned out. When the fuse is blown, there is a high possibility that the circuit was Defective fuse (FS2-4) short-circuited with ground. ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Defective working lamp relay When the starting switch is set to OFF, replace the relay with another (Internal disconnection) relay. Set the starting switch to ON and set the light switch to ON. If the working lamp comes on, the working lamp relay (BB3) is defective. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between FS2-4 outlet and BB3 (fe- Resistance Disconnection of harness Max. 1 Ω value male) 3 (Disconnection, defective contact of connector) Harnesses between BB3 (female) 5 and 221 Resistance (female) 1 and between BB3 (female) 5 and Max. 1 Ω value 241 (female) 1 ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Resistance Between harness related to FS2-4 (outlet Ground fault of harness Min. 1 MΩ value side) and ground (contact with GND circuit) Between harnesses (between BB3 (female) Resistance 5 and 221 (female) 1, between BB3 (female) Min. 1 MΩ value 5 and 241 (female) 1) and ground

Trouble (6) Only the rear lamp does not come on. (Both right and left, or one side only) Related information Cause Defective rear lamp 1 (Burnt bulb)


Defective rear lamp switch (Internal disconnection)


20-630 1

Standard value in normal state/Remarks on troubleshooting The rear lamp is supposed to be defective. Check if the light bulb is burned out. ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. 218 (male) Switch Resistance value OFF Min. 1 MΩ Between 2 and 3 ON Max. 1 Ω ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between 18 (female) 2 and circuit Resistance Max. 1 Ω value branched portion Harnesses between 218 (female) 3 and 223 Resistance (female) 1 and between 218 (female) 3 and Max. 1 Ω value 243 (female) 1

D375A-5

TROUBLESHOOTING


Circuit diagram related to instrument panel night lamp, headlamp, working lamp and rear lamp

D375A-5

20-631 1

TROUBLESHOOTING

E-22 AIR CONDITIONER DOES NOT OPERATE

E-22 AIR CONDITIONER DOES NOT OPERATE Trouble (1) No airflow occurs Related information Cause Defective circuit breaker 1 (CB4)

Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off, there is a high possibility that the circuit was short-circuited with ground. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Defective blower main relay 2 CN-R1 (male) Resistance value (coil side) Between (1) and (2) 240 ± 40 Ω ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Defective blower main relay 3 CN-R1 Voltage (contact side) Between (6C) and ground 20 30 V ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Defective blower Hi relay 4 CN-R2 (male) Resistance value (coil side) Between (1) and (2) 240 ± 40 Ω ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Defective blower Hi relay 5 (contact side) Set the starting switch to ON and set the blower Hi switch to ON. If the motor rotates, the relay is normal. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Defective blower Mi relay 6 CN-R3 (male) Resistance value (coil side) Between (1) and (2) 240 ± 40 Ω ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. Defective blower Mi relay 7 (contact side) Set the starting switch to ON and set the blower Mi switch to ON. If the motor rotates, the relay is normal. Possible causes ★ Set the starting switch to OFF for preparation and set it to ON for and standard valtroubleshooting. ue in normal state 8 Defective blower motor Set the starting switch to ON and set the blower Lo switch to ON. If the motor rotates, the relay is normal. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between CR-R3 (female) (0B), CNResistance Max. 1 Ω AC1 (female) (0C), CN-R (female) (0D) or value CCN-R2 (female) (0E) and ground Harness between CN-B (female) (10A) and Resistance Max. 1 Ω value CN-R (female) (10B) Harnesses between CN-B (female) (11A) and Resistance CN-R2 (female) (11B) and between CN-B (feMax. 1 Ω value male) (11A) and CN-R (female) (11C) Harnesses between CB4 outlet and CNAC1 Disconnection of harness (female) (13C), between CB4 outlet and CN9 (Disconnection, defective Resistance Max. 1 Ω R1 (female) (13D), between CB4 outlet and contact of connector) value CN-R2 (female) (13E) and between CB4 outlet and CN-R3 (female) (13H) Harness between CN-R1 (female) (14A) and Resistance Max. 1 Ω value CN-AC1 (female) (14B) ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harness between CN-R3 (female) (17A) and Resistance Max. 1 Ω value CN-AC1 (female) (17B) Harness between CN-R2 (female) (18A) and Resistance Max. 1 Ω value CN-AC1 (female) (18B) When cases 1 to 9 are not applicable, the control panel is supposed to be 10 Defective control panel defective. Mistake of failure phenome- When any specific cause cannot be determined, failure phenomena might 11 non have been mistaken. Execute the troubleshooting of No cooling.

20-632 1

D375A-5

TROUBLESHOOTING


Trouble (2) No cooling Related information Cause

1 Defective pressure switch

Defective compressor clutch 2 relay (coil side) Defective compressor clutch 3 relay (contact side)

4

Condenser relay (contact side)

5 Defective thermistor

6

Defective condenser blower resistor

Possible causes and standard value in normal state 7 Defective condenser motor 8

Defective compressor magnet clutch

9 Defective compressor


11 Defective control panel

D375A-5

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. CN-P Blower switch Voltage Between (26A) and ON 20 30 V ground ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. CN-R4 (male) Resistance value Between (1) and (2) 240 ± 40 Ω ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. CN-R4 Voltage Between (9B) and ground 20 30 V ★ Set the starting switch to OFF for preparation and set it to ON for troubleshooting. CN-R5 Voltage Between (7B) and ground 20 30 V ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. CN-AC1 (male) Resistance value Between (15B) and (16C) Max. 3,500 Ω ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Condenser blower resistor Resistance value Between terminals 2.8 Ω ± 5% ★ Set the starting switch to ON for troubleshooting. Set the air conditioner switch to ON. If the motor rotates, it is normal. ★ Start the engine for troubleshooting. The compressor magnet clutch is supposed to be defective. Check it directly. ★ Start the engine for troubleshooting. The compressor is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and troubleshoot while keeping it to OFF. Harnesses between CB4 outlet and CN-R5 Resistance (female) (6B) and between CB4 outlet and Max. 1 Ω value CN-R4 (female) (6D) Harness between CN-R5 (female) (7B) and Resistance Max. 1 Ω ARC (female) 2 value Harness between CN-R4 (female) (9B) and Resistance Max. 1 Ω 351 (female) 1 value Harnesses between CB4 outlet and CN-R4 Resistance Max. 1 Ω (female) (131) value Harness between CN-T (female) (15A) and Resistance Max. 1 Ω CN-AC1 (female) (15B) value Harness between CN-P (female) (19A) and Resistance Max. 1 Ω CN-R4 (female) (19C) value Harness between CN-P (female) (26A) and Resistance Max. 1 Ω CN-AC1 (female) (26B) value Harness between ARC (female) 1 and Resistance Max. 1 Ω ground value When cases 1 to 10 are not applicable, the control panel is supposed to be defective.

20-633 1

TROUBLESHOOTING


Circuit diagram related to air conditioner

20-634 1

D375A-5

TROUBLESHOOTING

20 TROUBLESHOOTING

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) Information in troubleshooting table ......................................................................................................... H-1 No force (No drawbar pull) ............................................................................................................... H-2 No travel (At 2nd or 3rd speed) ........................................................................................................ H-3 No travel at all gear speeds ............................................................................................................. H-4 Large time lag at gear speed shifting or forward-reverse shifting .................................................... H-5 Large time lag at gear speed shifting or forward-reverse shifting .................................................... H-6 Steering is not possible .................................................................................................................... H-7 Steering is possible only on one side .............................................................................................. H-8 Steering overrun occurs ................................................................................................................... H-9 Brake does not work ........................................................................................................................ H-10 Torque converter is not lock-up ...................................................................................................... H-11 Torque converter oil is overheated ................................................................................................. H-12 All work equipment operates slowly ............................................................................................... H-13 All work equipment does not operate ............................................................................................ H-14 Blade lift raising speed is slow or the blade lift has no power ........................................................ H-15 Blade tilt raising speed is slow or the blade tilt has no power ........................................................ H-16 Ripper lift raising speed is slow or the ripper lift has no power ...................................................... H-17 Ripper tilting speed is slow or the blade tilt has no power ............................................................. H-18 Hydraulic drift of blade lift is large .................................................................................................. H-19 Hydraulic drift of blade tilt is large .................................................................................................. H-20 Hydraulic drift of ripper lift is large ................................................................................................. H-21 Ripper pin puller cylinder does not operate ................................................................................... H-22 Blade pitch does not operate ......................................................................................................... H-23 Abnormal noise occurs around the work equipment pump ............................................................

D375A-5

20-702 20-703 20-704 20-705 20-706 20-707 20-708 20-708 20-709 20-709 20-710 20-710 20-711 20-712 20-713 20-713 20-714 20-714 20-715 20-715 20-716 20-716 20-717 20-717

20-701 1

TROUBLESHOOTING


INFORMATION IN TROUBLESHOOTING TABLE ★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Trouble in machine Related information Information related to detected trouble or troubleshooting Cause


1


2

3

Possible causes of trouble (Given numbers are refer Standard value in normal state to judge possible causes ence numbers, which do not Remarks on judgment indicate priority)

4

20-702 1

D375A-5

TROUBLESHOOTING

H-1 NO FORCE (NO DRAWBAR PULL)

H-1 NO FORCE (NO DRAWBAR PULL) Trouble • No force (No drawbar pull) Related information • Before troubleshooting, check that the power train oil level is normal. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting (after checking that the transmission main relief pressure is normal). Internal defect of torque con2 Torque converter Torque converter verter PCCS lever inlet pressure outlet pressure 39.2 – 63.7 MPa 0.8 – 1.0 MPa Full neutral {4.0 – 6.5 kg/cm2} {8.0 – 10.0 kg/cm2} ★ Set the starting switch to OFF for preparation and idle the engine at Incorrect pressure set to a high speed for troubleshooting. 3 transmission main relief PCCS lever Transmission main relief pressure valve 2.45 – 2.94 MPa {25.0 – 30.0 kg/cm2} Full neutral ★ Set the starting switch to OFF for preparation and troubleshoot Defective operation of trans- while keeping it to OFF. 4 mission main relief valve Check it directly that the spring free length (120.3 mm) is normal and that the spool moves smoothly. ★ Set the starting switch to OFF for preparation and idle the engine at a low speed for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Defective operation of trans2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} FWD 5 mission valve (ECMV) 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} REV 1.96 – 2.55 MPa {20.0 – 26.0 kg/cm2} 1ST Possible causes 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} 2ND and standard val2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} 3RD ue in normal state ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Internal defect of transmisMeasuring conditions Engine speed 6 sion F3 stall 1,430 rpm F3 stall + Work equipment relief 1,160 rpm ★ Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (drag7 Idle the engine at a low speed and operate F2. Unless the machine ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting (after checking that the transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Right clutch pressure 8 Defective steering clutch {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Left brake pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Right brake pressure {0} {Min. 24 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of “Steering is not possible.”

D375A-5

20-703 1 4

TROUBLESHOOTING

H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)

H-2 NO TRAVEL (AT 2ND OR 3RD SPEED) Trouble

• No travel (at 2nd or 3rd speed) • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

1

2

3 4 Possible causes and standard value in normal state 5

6

20-704 1 4

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Torque converter Torque converter Internal defect of torque conPCCS lever inlet pressure outlet pressure verter 0.8 – 1.0 MPa 39.2 – 63.7 MPa Full neutral {8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2} ★ Set the starting switch to OFF for preparation and idle the engine at a low speed for troubleshooting. Defective operation of transTransmission clutch Clutch pressure mission valve (ECMV) 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} 2ND 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} 3RD Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed sion clutch to be defective. Check it directly. Defective operation (dragDefective operation (dragging) is supposed, check linkage valves. ging) of parking brake ★ Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (dragIdle the engine at a low speed and operate F2. Unless the machine ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end Min. 2.4 MPa 0 Left clutch pressure {Min. 24 kg/cm2} {0} 0 Min. 2.4 MPa Defective steering clutch, Right clutch pressure {0} {Min. 24 kg/cm2} brake 0 Min. 2.4 MPa Left brake pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Right brake pressure {0} {Min. 24 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of “Steering is not possible.”

D375A-5

TROUBLESHOOTING

H-3 NO TRAVEL AT ALL GEAR SPEEDS

H-3 NO TRAVEL AT ALL GEAR SPEEDS Trouble • No travel at all gear speeds Related information • Before troubleshooting, check that the power train oil level is normal. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at Incorrect pressure set to a high speed for troubleshooting. 2 transmission main relief PCCS lever Transmission main relief pressure valve 2.45 – 2.94 MPa {25.0 – 30.0 kg/cm2} Full neutral ★ Set the starting switch to OFF for preparation and troubleshoot Defective operation of trans- while keeping it to OFF. 3 mission main relief valve Check it directly that the spring free length (120.3 mm) is normal and that the spool moves smoothly. ★ Set the starting switch to OFF for preparation and idle the engine at a low speed for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Defective operation of trans2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} FWD 4 mission valve (ECMV) 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} REV 1.96 – 2.55 MPa {20.0 – 26.0 kg/cm2} 1ST 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} 2ND 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2} 3RD Possible causes Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed and standard val- 5 sion clutch to be defective. Check it directly. ue in normal state ★ Move the machine to a flat ground and idle the engine at a high speed for troubleshooting (after checking that the transmission main relief pressure is normal). 6 Defective operation of brake Brake pedal Brake oil pressure (right and left) Release Min. 2.4 MPa {Min. 24 kg/cm2} Step on 0 {0} ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting (after checking that the transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} Defective seal of steering 7 clutch 0 Min. 2.4 MPa Right clutch pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Left brake pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Right brake pressure {0} {Min. 24 kg/cm2} Internal defect of steering The inside of the steering clutch is supposed to be defective, check it 8 clutch directly.

D375A-5

20-705 1 4

TROUBLESHOOTING

H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING

H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING Trouble Large time lag at gear speed shifting or forward-reverse shifting Related information Before troubleshooting, check that the power train oil level is normal. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Incorrect pressure set to PCCS lever Transmission main relief pressure 2 transmission main relief 2.45 2.94 MPa {25.0 30.0 kg/cm2} Full neutral valve When the oil pressure is abnormal, clean the valve and then check the oil pressure again. ★ Set the starting switch to OFF for preparation and troubleshoot Defective operation of trans- while keeping it to OFF. 3 mission main relief valve Check it directly that the spring free length (120.3 mm) is normal and that the spool moves smoothly. ★ Set the starting switch to OFF for preparation and idle the engine at a low speed for troubleshooting (after checking that the transmisPossible causes sion main relief pressure is normal). and standard valTransmission clutch Clutch pressure ue in normal state Defective operation of trans2.35 2.94 MPa {24.0 30.0 kg/cm2} FWD 4 mission valve (ECMV) 2.35 2.94 MPa {24.0 30.0 kg/cm2} REV 1.96 2.55 MPa {20.0 26.0 kg/cm2} 1ST 2.35 2.94 MPa {24.0 30.0 kg/cm2} 2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2} 3RD Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to be 5 sion clutch defective. Check it directly. Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, 6 sion clutch check it directly. ★ Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (drag7 Idle the engine at a low speed and operate F2. Unless the machine ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.)

20-706 1

D375A-5

TROUBLESHOOTING

H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING

H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING Trouble Large time lag at gear speed shifting or forward-reverse shifting Related information Before troubleshooting, check that the power train oil level is normal. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Transmission main relief pressure Defective operation of trans2 mission main relief valve 2.45 2.94 MPa {25.0 30.0 kg/cm2} Full neutral When the oil pressure is abnormal, clean the valve and then check the oil pressure again. ★ Set the starting switch to OFF for preparation and idle the engine at a low speed for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Possible causes Defective operation of trans2.35 2.94 MPa {24.0 30.0 kg/cm2} FWD and standard val- 3 mission valve (ECMV) 2.35 2.94 MPa {24.0 30.0 kg/cm2} REV ue in normal state 1.96 2.55 MPa {20.0 26.0 kg/cm2} 1ST 2.35 2.94 MPa {24.0 30.0 kg/cm2} 2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2} 3RD Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to be 4 sion clutch defective. Check it directly. Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, 5 sion clutch check it directly. ★ Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (drag6 Idle the engine at a low speed and operate F2. Unless the machine ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.)

D375A-5

20-707 1

H-6 STEERING IS NOT POSSIBLE H-7 STEERING H-6 IS POSSIBLE ONLY ONPOSSIBLE ONE SIDE STEERING IS NOT

TROUBLESHOOTING

H-6 STEERING IS NOT POSSIBLE Trouble

• Steering is not possible. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

1


3 4

Standard value in normal state/Remarks on troubleshooting ★ Start the engine for preparation and idle it at a low speed for troubleshooting. Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for F3 travel (or R3 travel). If the track shoe stops, the brake is defective. (Execute the troubleshooting of “Brake does not work.”) ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end Min. 2.4 MPa 0 Left clutch pressure {Min. 24 kg/cm2} {0} Defective operation of steer0 Min. 2.4 MPa ing clutch valve (ECMV) Right clutch pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Left brake pressure {0} {Min. 24 kg/cm2} Min. 2.4 MPa 0 Right brake pressure {Min. 24 kg/cm2} {0} Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to be clutch defective. Check it directly. Internal defect of steering The inside of the steering clutch is supposed to be defective, check it clutch directly.

H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE Trouble

• Steering is possible only on one side. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} Defective operation of steer1 0 Min. 2.4 MPa ing clutch valve (ECMV) Possible causes Right clutch pressure {0} {Min. 24 kg/cm2} and standard val0 Min. 2.4 MPa ue in normal state Left brake pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Right brake pressure {0} {Min. 24 kg/cm2} Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to be 2 clutch defective. Check it directly. Internal defect of steering The inside of the steering clutch is supposed to be defective, check it 3 clutch directly.

20-708 1 4

D375A-5

H-8 STEERING OVERRUN OCCURS H-9 BRAKE DOES NOT WORK H-8 STEERING OVERRUN OCCURS

TROUBLESHOOTING

H-8 STEERING OVERRUN OCCURS Trouble

• Steering overrun occurs. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

Standard value in normal state/Remarks on troubleshooting ★ Start the engine for preparation and idle it at a low speed for troubleshooting. Possible causes 1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for and standard valF3 travel (or R3 travel). If the track shoe stops, the brake is defective. ue in normal state (Execute the troubleshooting of “Brake does not work.”) When the track shoe does not stop in the troubleshooting of the cause Defective operation of steer2 1, the steering clutch is defective. (Execute the troubleshooting of ing clutch “Steering is not possible.”)

H-9 BRAKE DOES NOT WORK Trouble

• Brake does not work. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause

1

2


4 5

D375A-5

Standard value in normal state/Remarks on troubleshooting ★ Start the engine for troubleshooting. Step on the brake pedal, shift the gear to F2 and idle the engine at a Degradation of brake high speed. When the machine moves, the brake performance is degraded. Defective operation of brake The brake pedal and the brake valve are supposed not to work norpedal mally. Check them directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} Defective operation of steer0 Min. 2.4 MPa ing brake valve (ECMV) Right clutch pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Left brake pressure {0} {Min. 24 kg/cm2} 0 Min. 2.4 MPa Right brake pressure {0} {Min. 24 kg/cm2} When the brake seal is not normal in the troubleshooting of the cause Defective brake seal 3, the brake seal is supposed to be defective. Check it directly. Internal defect of brake The inside of the brake is supposed to be defective. Check it directly.

20-709 1 4

H-10 TORQUE CONVERTER IS NOT LOCK-UP H-11H-10 TORQUE CONVERTER OIL IS OVERHEATED TORQUE CONVERTER NOT LOCK-UP

TROUBLESHOOTING

H-10 TORQUE CONVERTER IS NOT LOCK-UP Trouble

The torque converter is not lock-up. Before troubleshooting, check that the power train oil level is normal. Related information Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Defective operation of 2 torque converter lock-up Torque converter Clutch pressure valve Min. 1.27 1.47 MPa At lock-up time {Min. 13.0 15.0 kg/cm2} Possible causes Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up and standard val- 3 clutch clutch seal is supposed to be defective. Check it directly. ue in normal state Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check it 4 clutch directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Internal defect of torque conMeasuring conditions Engine speed 5 verter F3 stall 1,430 rpm F3 stall + Work equipment relief 1,160 rpm

H-11 TORQUE CONVERTER OIL IS OVERHEATED Trouble

The torque converter oil is overheated. Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the indication of the torque converter oil temperature gauge agrees with actual temperature of the torque converter oil. (When the indication does not agree with actual Related information temperature, execute the troubleshooting of The indication of torque converter oil temperature gauge is abnormal.) Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause 1 Rise of engine output


20-710 1

2

Defective power train pump or air entry in suction circuit

3

Internal defect of torque converter

4

Defective operation (slide) of transmission clutch

5

Defective operation (dragging) of brake

6

Defective operation (slide) of steering clutch

Standard value in normal state/Remarks on troubleshooting Engine output is supposed to have increased abnormally. Troubleshoot referring to the shop manual for engine. The power train pump is supposed to be defective, or air is supposed to have entered from the suction circuit. Check them directly. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Torque converter Torque converter PCCS lever inlet pressure outlet pressure 39.2 63.7 MPa 0.8 1.0 MPa Full neutral {4.0 6.5 kg/cm2} {8.0 10.0 kg/cm2} The inside of the transmission clutch is supposed to be defective (the clutch slides). Check it directly. ★ Start the engine for troubleshooting. Idle the engine at a low speed and operate F2. Unless the machine moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.) The inside of the steering clutch is supposed to be defective (the clutch slides). Check it directly.

D375A-5

TROUBLESHOOTING

H-12 ALL WORK EQUIPMENT OPERATES SLOWLY

H-12 ALL WORK EQUIPMENT OPERATES SLOWLY Trouble All work equipment operates slowly. Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

1 2 3 4 5


8

9

10 11

D375A-5

Cause Defective PTO (work equipment pump drive) Defective work equipment large pump Defective work equipment small pump Defective PPC charge pump

Standard value in normal state/Remarks on troubleshooting The work equipment pump drive of the PTO is supposed to be defective. Check it directly. The work equipment large pump is supposed to be defective. Check it directly. The work equipment small pump is supposed to be defective. Check it directly. The PPC charge pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade lift Blade lever Main relief pressure valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be valve for blade lift valve defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade tilt Blade lever Main relief pressure ripper Lo valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo posed to be defective. Check it directly. valve ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Improper pressure set to charge relief valve Work equipment lever Control relief pressure Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2} Internal defect of charge re- The inside of the charge relief valve is supposed to be defective. lief valve Check it directly. Internal leak of PPC valve Internal leak of PPC valve is supposed. Check it directly.

20-711 1

TROUBLESHOOTING

H-13 ALL WORK EQUIPMENT DOES NOT OPERATE

H-13 ALL WORK EQUIPMENT DOES NOT OPERATE Trouble All work equipment does not operate. Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

1 2 3 4 5


6

7

8

9

10 11

20-712 1

Cause Defective PTO (work equipment pump drive) Defective work equipment large pump Defective work equipment small pump Defective PPC charge pump

Standard value in normal state/Remarks on troubleshooting The work equipment pump drive of the PTO is supposed to be defective. Check it directly. The work equipment large pump is supposed to be defective. Check it directly. The work equipment small pump is supposed to be defective. Check it directly. The PPC charge pump is supposed to be defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade lift Blade lever Main relief pressure valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be valve for blade lift valve defective. Check it directly. ★ Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade tilt Blade lever Main relief pressure ripper Lo valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo posed to be defective. Check it directly. valve ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Improper pressure set to Work equipment lever Control relief pressure charge relief valve Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2} Internal defect of charge re- The inside of the charge relief valve is supposed to be defective. lief valve Check it directly. Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the lelock valve ver linkage or the lock valve directly.

D375A-5

TROUBLESHOOTING

H-14 BLADE RAISING SPEED IS SLOWIS OR THE OR BLADE HASLIFT NO HAS POWER H-14 LIFT BLADE LIFT RAISING SPEED SLOW THELIFT BLADE NO H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER

H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER Trouble

Related information

Blade lift raising speed is slow or the blade lift has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Check if the blade has been modified. In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade lift is large. Cause

1

Possible causes 2 and standard value in normal state 3

4

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Defective operation of PPC valve Blade lever PPC valve output pressure Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2} Defective operation of blade The spool of the blade lift control valve is suppose to operate abnorlift control valve (spool) mally. Check it directly. The suction valve of the blade lift control valve is suppose to operate Defective operation of blade abnormally. Check it directly. lift control valve ★ It is also acceptable to replace the suction valve on the head side (suction valve) with the one on the bottom side to check change of the phenomenon as another method. Air is supposed to enter the blade lift cylinder. Bleed air and check the Air entry in blade lift cylinder change of phenomenon.

H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER Trouble

Related information

Blade tilt raising speed is slow or the blade tilt has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Check if the blade has been modified. In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade lift is large. Cause

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Defective operation of PPC 1 Blade lever PPC valve output pressure valve Possible causes and standard valTilt stroke end Min. 3.9 MPa {Min. 40 kg/cm2} ue in normal state Defective operation of blade The spool of the blade tilt control valve is suppose to operate abnor2 tilt control valve (spool) mally. Check it directly. Air is supposed to enter the blade tilt cylinder. Bleed air and check the 3 Air entry in blade tilt cylinder change of phenomenon.

D375A-5

20-713 1

TROUBLESHOOTING

H-16 RIPPER RAISING SPEED IS SLOWIS OR THE OR RIPPER HASLIFT NO HAS POWER H-16 LIFT RIPPER LIFT RAISING SPEED SLOW THE LIFT RIPPER NO H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER

H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER Trouble

Related information

Ripper lift raising speed is slow or the ripper lift has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Check if the ripper has been modified. In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade lift is large. Cause

1

Defective operation of PPC valve

Defective operation of ripper Possible causes 2 lift control valve (spool) and standard value in normal state Defective operation of ripper lift control valve 3 (constant differential pressure valve) 4 Air entry in ripper lift cylinder

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Ripper lever PPC valve output pressure Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2} The spool of the ripper lift control valve (Lo, Hi) is suppose to operate abnormally. Check it directly. The constant differential pressure valve of the ripper lift control valve (Hi) is suppose to operate abnormally. Check it directly. ★ It is also acceptable to replace the constant differential pressure valve on the head side with the one on the bottom side to check change of the phenomenon as another method. Air is supposed to enter the ripper lift cylinder. Bleed air and check the change of phenomenon.

H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER Trouble

Ripper tilting speed is slow or the ripper has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Related information Check if the ripper has been modified. Cause 1

Defective operation of PPC valve

Defective operation of ripper Possible causes 2 tilt control valve (spool) and standard value in normal state Defective operation of ripper tilt control valve 3 (constant differential pressure valve) 4 Air entry in ripper tilt cylinder

20-714 1

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Ripper lever PPC valve output pressure Tilt end Min. 3.9 MPa {Min. 40 kg/cm2} The spool of the ripper tilt control valve (Lo, Hi) is suppose to operate abnormally. Check it directly. The constant differential pressure valve of the ripper tilt control valve (Hi) is suppose to operate abnormally. Check it directly. ★ It is also acceptable to replace the constant differential pressure valve on the head side with the one on the bottom side to check change of the phenomenon as another method. Air is supposed to enter the ripper tilt cylinder. Bleed air and check the change of phenomenon.

D375A-5

H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE H-19 HYDRAULIC DRIFT OF BLADE LIFT TILT IS LARGE H-18

TROUBLESHOOTING

H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE Trouble

Hydraulic drift of the blade lift is large Check if the blade has been modified. Related information Before troubleshooting, check that no oil leaks from the work equipment circuit. Cause

Possible causes Defective seal of blade lift 1 and standard valcontrol valve (spool) ue in normal state

2

Defective seal of blade lift cylinder

Standard value in normal state/Remarks on troubleshooting ★ Start the engine for preparation and stop it for troubleshooting. Follow the procedures below for the troubleshooting. When the hydraulic drift speed becomes fast, the spool seal of the blade lift control valve is defective: 1)Stretch the blade lift on the ground and push up the front of the machine. 2)Stop the engine and release the safety lock lever. 3)Move the blade lever to the lift lowering side, and check the phenomenon. The seal of the blade lift cylinder is supposed to be defective. Check it directly.

H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE Trouble

Hydraulic drift of the blade tilt is large Check if the blade has been modified. Related information Before troubleshooting, check that no oil leaks from the work equipment circuit. Cause


D375A-5

1

Defective seal of blade tilt control valve (spool)

2

Defective seal of blade tilt cylinder

Standard value in normal state/Remarks on troubleshooting ★ Start the engine for preparation and stop it for troubleshooting. Follow the procedures below for the troubleshooting. When the hydraulic drift speed becomes fast, the spool seal of the blade tilt control valve is defective: 1)Stretch the blade tilt on the ground and push up the right side of the machine. 2)Stop the engine and release the safety lock lever. 3)Move the blade tilt to the right tilt side, and check the phenomenon. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Blade tilt cylinder Leakage from cylinder Right tilt stroke end 12 cc/min

20-715 1

H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE H-21 RIPPER PIN PULLERDRIFT CYLINDER DOES NOT H-20 HYDRAULIC OF RIPPER LIFT OPERATE IS LARGE

TROUBLESHOOTING

H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE Trouble

Hydraulic drift of the ripper lift is large Check if the ripper has been modified. Related information Before troubleshooting, check that no oil leaks from the work equipment circuit. Cause


1

Defective seal of blade lift control valve (spool)

2

Defective seal of ripper lift cylinder

Standard value in normal state/Remarks on troubleshooting ★ Start the engine for preparation and stop it for troubleshooting. Follow the procedures below for the troubleshooting. When the hydraulic drift speed becomes fast, the spool seal of the ripper lift control valve (Hi) is defective: 1)Stretch the ripper lift on the ground and push up the rear of the machine. 2)Stop the engine and release the safety lock lever. 3)Move the ripper lever to the lift lowering side, and check the phenomenon. ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Ripper lift cylinder Leakage from cylinder Lowering stroke end 12 cc/min

H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE Trouble Ripper pin puller cylinder does not operate. Related information Before troubleshooting, check that transmission main relief pressure is normal. Cause

Defective operation of pin Possible causes 1 puller solenoid and standard value in normal state 2

20-716 1

Internal defect of pin puller cylinder

Standard value in normal state/Remarks on troubleshooting ★ Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Pin puller operating Pin puller switch Measuring position pressure Push-in Cylinder bottom side Min. 2.4 MPa {Min. 24 kg/cm2} Pull-in Cylinder head side The inside of the pin puller cylinder is supposed to be defective. Check it directly.

D375A-5

TROUBLESHOOTING

H-22 BLADE PITCH DOES NOT OPERATE H-23 ABNORMAL NOISE OCCURSH-22 AROUND THE WORK EQUIPMENT PUMP BLADE PITCH DOES NOT OPERATE

H-22 BLADE PITCH DOES NOT OPERATE Trouble Blade pitch does not operate. Related information Cause Standard value in normal state/Remarks on troubleshooting Defective operation of blade Operate both the blade pitch and the blade tilt. When only the pitch opPossible causes 1 pitch selection solenoid eration is not possible, the pitch selection solenoid valve is operating and standard valvalve abnormally. ue in normal state Operate both the blade pitch and the blade tilt. When both the pitch Defective operation of blade 2 operation and the tilt operation are not possible, the pitch cylinder (tilt pitch cylinder cylinder) is operating abnormally.

H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP Trouble Abnormal noise occurs around the work equipment pump. Related information Before troubleshooting, check that the oil level in the hydraulic tank is normal. Cause 1 Improper oil is used Clogging of hydraulic tank 2 strainer

Possible causes and standard value in normal state 3 Air entry in suction circuit 4

D375A-5

Internal defect of work equipment pump

Standard value in normal state/Remarks on troubleshooting Improper oil is supposed to be used. Check it directly. The hydraulic tank strainer is supposed to be clogged. Check it directly. Air is supposed to have entered the suction circuit of the work equipment pump. Check the piping directly. The inside of the work equipment pump is supposed to be defective. Check it directly.

20-717 1

TROUBLESHOOTING

20 TROUBLESHOOTING

TROUBLESHOOTING OF THE ENGINE BODY (S-MODE)

Points to remember when troubleshooting .............................................................................................. Method of using troubleshooting charts ................................................................................................... S-1 Starting performance is poor (starting always takes time) ............................................................. S-2 Engine does not start ..................................................................................................................... 1) Engine does not turn ................................................................................................................ 2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ............................. 3) Exhaust smoke comes out but engine does not start (fuel is being injected) ........................... S-3 Engine does not pick up smoothly (follow-up is poor) .................................................................... S-4 Engine stops during operations ...................................................................................................... S-5 Engine does not rotate smoothly (hunting) ..................................................................................... S-6 Engine lacks output (or lacks power) .............................................................................................. S-7 Exhaust smoke is black (incomplete combustion) .......................................................................... S-8 Oil consumption is excessive (or exhaust smoke is blue) .............................................................. S-9 Oil becomes contaminated quickly ................................................................................................. S-10 Fuel consumption is excessive ....................................................................................................... S-11 Oil is in cooling water, or water spurts back, or water level goes down .......................................... S-12 Oil pressure caution lamp lights up (drop in oil pressure) .............................................................. S-13 Oil level rises .................................................................................................................................. S-14 Water temperature becomes too high (overheating) ...................................................................... S-15 Abnormal noise is made ................................................................................................................. S-16 Vibration is excessive .....................................................................................................................

D375A-5

20-802 20-803 20-806 20-809 20-809 20-810 20-812 20-814 20-816 20-818 20-820 20-822 20-824 20-825 20-826 20-827 20-828 20-829 20-830 20-831 20-832

20-801 (5)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING k k k k k k

Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the water temperature to go down before removing the radiator cap. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing a plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

20-802 (5)

D375A-5

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under C in the chart on the right correspond to this. The serviceman narrows down the causes from information A that he has obtained from the user and the results of C that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with Q, and of these, causes that have a high probability are marked with w. Check each of the [Questions] and [Check items] in turn, and marked the Q or w in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the E in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.

D375A-5

20-803 (5)

TROUBLESHOOTING

•


Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) General causes why exhaust smoke is black • Insufficient intake of air • Defective condition of fuel injection • Excessive injection of fuel

20-804 (5)

D375A-5

TROUBLESHOOTING


Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.

Three symptoms

Step 2 Add up the total of and marks where the horizontal limes for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Defective contact of valve, valve seat: (3) Leakage of air between turbocharger and head: (4) Worn piston ring, cylinder liner: (5) Defective timing rail pressure sensor:

Step 3 The calculation in Step 2 show that the closest relationship is with [Worn piston ring, cylinder liner]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

D375A-5

20-805 (5)

TROUBLESHOOTING

S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)

S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel • Defective HPI sensor • Defective HPI actuator

Defective fuel pump

Defective shut-off valve

Clogged timing rail actuator screen

Defective injector

Defective injector check ball

Cut, worn injector O-ring

Defective or deteriorated battery

Replace

Replace

Clean

Replace

Replace

Replace

Replace

Defective alternator regulator

Loose piping, fuel filter, entry of air Clean

Defective alternator

Clogged fuel filter, strainer Clean

Replace

Clogged fuel tank cap Correct

Defective preheating circuit (when starting in low temperatures)

Worn piston ring, cylinder liner Replace

Replace

Defective contact of valve, valve seat Correct

Replace

Clogged air cleaner element Clean

Causes

Confirm recent repair history Degree of use of machine

Operated for long period

Questions

Starting performance became worse gradually Engine starts easily when warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Charge caution lamp lights up When preheating, preheating indicator lamp does not light up Dust indicator is red Air breather hole in fuel tank cap is clogged

Check items

Starting motor cranks engine slowly When engine is Little fuel comes out even when injection pump sleeve nut is loosened cranked with Little fuel comes out even when fuel filter air bleed plug is loosened starting motor, When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Difficult to stop engine Inspect air cleaner element directly When compression pressure is measured, it is found to be low Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high

When pressure at outlet port of fuel pump is measured, it is found to vary When pressure at outlet port of fuel pump is measured, it is found to be low Troubleshooting

Inspect fuel pump directly Inspect fuel shut-off valve directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low Inspect injector directly When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is turned to HEAT, heater mount does not become warm Is voltage 26 - 30V between alternator terminal B and terminal E with engine at low idling?

Yes No

Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging)

Remedy

20-806 (5)

D375A-5

TROUBLESHOOTING

S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)

Defective fuel rail pressure sensor

Defective timing rail pressure sensor

Defective fuel pump pressure sensor

Defective water temperature sensor

Defective intake manifold temperature sensor

Defective fuel rail actuator (Marked

Defective timing rail actuator (Marked

Defective fuel pump actuator (Marked

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

1)

1)

Defective boost pressure sensor Replace

D375A-5

1)

Defective atmospheric pressure sensor Replace

Causes

1. If the following service codes are displayed, carry out the troubleshooting in “Service code”. (If any of the following service codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [EC514]: Abnormality in fuel rail actuator [EC112]: Abnormality in timing rail actuator [EC318]: Abnormality in fuel pump actuator

20-807 (5)

TROUBLESHOOTING

S-2 ENGINE DOES NOT START

S-2 ENGINE DOES NOT START 1) Engine does not turn

Causes

Defective starting motor

Defective safety relay or safety switch Replace

Defective battery relay

Replace

Defective starting switch

Replace

Defective battery terminal connection Correct

Defective starting circuit wiring

Defective or deteriorated battery Replace

Replace

Broken flywheel ring gear Replace

General causes why engine does not turn • Internal parts of engine seized a See Troubleshooting S-4. • Defective electrical system • Problem in power train (troubleshooting in chassis volume)

Questions



Condition of horn when starting switch is turned ON

Horn does not sound Horn volume is low

Battery electrolyte is low Battery terminal is loose When starting switch is turned to ON, there is no clicking sound from battery relay Check items

When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is turned to START, starting pinion moves out, but

Makes grating noise Soon disengages again Makes rattling noise and does not turn

When specific gravity of electrolyte and voltage of battery are measured, one of them is low When terminal B and terminal C of starting switch are connected, engine starts Turn starting switch OFF, connect cord, and carry out troubleshooting at ON

There is no 24V between battery relay terminal B and terminal E When terminal B and terminal C of starting motor are connected, engine starts When terminal B and terminal C of safety relay are connected, engine starts

1.

Troubleshooting

Inspect flywheel ring gear directly

Remedy

—

When terminal of safety switch and terminal B of starting motor are connected, engine starts

1. Carry out troubleshooting in chassis volume

D375A-5

20-809 (5)


2) Engine turns but no exhaust smoke comes out (fuel is not being injected)

Broken fuel pump drive shaft

Defective fuel shut-off valve

Replace

Replace

Defective atmospheric pressure sensor


Clogged timing actuator screen


Replace


Defective fuel shut-off valve wiring

Insufficient fuel in tank Add

General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) • Defective HPI sensor • Defective HPI actuator

Replace

Causes

Replace

TROUBLESHOOTING

Questions



Exhaust smoke suddenly stopped coming out (when starting again) Starting performance became worse gradually Starts when engine is warm Replacement of filters has not been carried out according to Operation Manual When fuel tank is inspected, it is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained

Check items

When fuel filter is drained, fuel does not come out There is leakage from fuel piping Wiring of fuel shut-off valve is loose Cylinder block ground wiring is loose When engine is cranked with starting motor, and

Fuel pump outlet port coupler is pushed, almost no fuel comes out Fuel pump outlet port coupler is pushed, air comes out together with fuel

When negative pressure at inlet port of fuel pump is measured, it is found to be high Troubleshooting

Inspect fuel filter, strainer directly Inspect fuel pump drive shaft directly Inspect fuel shut-off valve directly When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector pins Inspect timing rail actuator screen directly Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Remedy

20-810 (5)

D375A-5

TROUBLESHOOTING


1)



Defective water temperature sensor

Defective intake manifold temperature sensor

1)





Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

D375A-5

1)


Causes


20-811 (5)


3) Exhaust smoke comes out but engine does not start (fuel is being injected)

Clogged fuel filter, strainer

Defective fuel pump

Clogged timing actuator screen

Clean

Replace

Replace

Defective preheating heater circuit


Defective or deteriorated battery

Clogged fuel tank cap Clean

Correct


Defective injector

Defective dynamic valve system (valve, rocker arm, etc.) Replace

Replace


General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel and oil • Defective HPI sensor • Defective HPI actuator

Causes

Replace

TROUBLESHOOTING



Questions

Suddenly failed to start Starting performance became worse gradually Starts when engine is warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently When preheating, preheating indicator lamp does not light up Dust indicator is red Air breather hole in fuel tank cap is clogged Check items

Rust and water are found when fuel tank is drained When fuel filter is drained, no fuel comes out There is leakage from fuel piping Starting motor cranks engine slowly When engine is cranked, abnormal noise is generated around cylinder head When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and Inspect air cleaner element directly Inspect dynamic valve system directly When compression pressure is measured, it is found to be low Troubleshooting

When negative pressure at inlet port of fuel pump is measured, it is found to be high When fuel filter, strainer directly Inspect fuel pump directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is at HEAT, heater mount does not become warm Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator directly Remedy

20-812 (5)

D375A-5

D375A-5 1)

Defective fuel rail pressure sensor Defective timing rail pressure sensor Defective fuel pump pressure sensor Defective water temperature sensor Defective intake manifold temperature sensor

1)

Defective boost pressure sensor

Defective fuel rail actuator (Marked Defective timing rail actuator (Marked Defective fuel pump actuator (Marked Clogged fuel rail actuator

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

1)


Replace

TROUBLESHOOTING S-2 ENGINE DOES NOT START

Causes


20-813

(5)

TROUBLESHOOTING

S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)

S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Defective condition of fuel spray • Improper fuel used • Abnormality in fuel control system • Defective HPI sensor • Defective HPI actuator • Normal output is not applied o See Troubleshooting S-6

Loose piping, fuel filter, entry of air


Clean

Clean

Failure boost pressure sensor


Defective injector


Replace

Improper valve clearance Correct

Defective fuel pump

Defective contact of valve and valve seat Replace

Replace

Seized turbocharger Correct

Replace


Causes

Confirm recent repair history

Questions

Degree of use of machine


Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel is drained There is leakage from fuel piping When engine is cranked with starting motor, and


Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas

Blue under light load Black

Clanging sound is heard from around cylinder head Noise of interference is heard from around turbocharger High idling speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner element directly When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low

Troubleshooting

Inspect valve clearance directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low When intake air pressure (boost pressure) is measured, it is found to be normal Inspect actuator directly (Resistance and filter for clogging) Inspect sensor directly (Output voltage and resistance) Inspect for air leakage

Remedy

20-814 (5)

D375A-5

TROUBLESHOOTING



Air leakage from piping between turbocharger and cylinder head

Replace

Replace

Replace

1)

1)

Defective timing rail actuator (Marked Replace

1) Defective fuel rail actuator (Marked Replace

Causes

D375A-5

S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)


20-815 (5)

TROUBLESHOOTING

S-4 ENGINE STOPS DURING OPERATIONS

S-4 ENGINE STOPS DURING OPERATIONS General causes why engine stops during operations • Seized parts inside engine • There is overheating a See Troubleshooting S-14. • Problem in power train (troubleshooting in chassis volume) • Defective HPI sensor • Defective HPI actuator

Insufficient fuel in tank

Clogged fuel tank cap



Broken fuel pump drive shaft

Defective injector

Correct

Correct

Clean

Replace

Replace


Broken, seized gear train

Add

Failure in power train (troubleshooting in chassis volume)

Broken, seized main bearing, connecting rod bearing

Replace

Broken auxiliary equipment (pump, compressor, etc.)

Broken, seized piston, connecting rod

Replace

Broken dynamic valve system (valve, rocker arm, etc.)

Replace

Causes


Operated for long period Abnormal noise was heard and engine stopped suddenly

Questions

Condition when engine stopped

Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Fuel level caution lamp lights up When fuel tank is inspected, it is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained Metal particles are found when oil is drained

Check items

Does not turn at all When it is attempted to turn by hand using barring tool

Turns in opposite direction Moves amount of gear backlash

Fuel pump shaft does not turn When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and Engine turns, but stops when load is applied to machine Inspect dynamic valve system directly Inspect piston, connecting rod directly

Troubleshooting

Inspect main bearing, connecting rod directly Inspect gear train directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed

1.

Inspect sensor directly (Output voltage and resistance)

Replace

—

Replace

Remedy

Replace

Inspect actuator directly (Resistance and filter for clogging)


20-816 (5)

D375A-5

TROUBLESHOOTING

S-4 ENGINE STOPS DURING OPERATIONS








Defective fuel shut-off valve

Clogged fuel inlet circuit

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Clean

1)


1)

1)

Causes

D375A-5

20-817 (5)

TROUBLESHOOTING

S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)

S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) General causes why engine does not rotate smoothly • Air in fuel system • Defective governor mechanism • Defective HPI sensor • Defective HPI actuator • Normal output is not applied o See Troubleshooting S-6

Defective injector Replace

High resistance, clogged fuel return circuit

Defective actuation of timing rail actuator Replace


Defective actuation of fuel rail actuator Replace

Clean

Defective fuel pump Replace

Defective injector check ball


Replace


Replace

Insufficient fuel in tank Replace

Causes

Confirm recent repair history Questions


Operated for long period Occurs at a certain speed range

Condition of hunting

Occurs at low idling Occurs even when speed is raised Occurs on slopes

When fuel tank is inspected, it is found to be empty Rust, water are found when fuel tank is drained

Check items

Leakage from fuel piping When engine is cranked with starting motor, and


When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine speed sometimes rises too far Engine is difficult to stop Inspect fuel filter, strainer directly

Troubleshooting

When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to vary When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low When flow of spill fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator screen directly Inspect timing rail actuator screen directly Remedy

20-818 (5)

D375A-5

D375A-5 Clogged fuel rail actuator screen Clogged timing rail actuator screen

Replace


Replace

Defective in speed sensor


Replace

Replace


Replace

Replace


Replace

Defective in throttle sensor


Replace

—


Replace

1)

TROUBLESHOOTING S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)

Causes

1. If the following service code is displayed, carry out the troubleshooting in “Service code”. (If it is not displayed, it is not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [EC318]: Abnormality in fuel pump actuator

20-819

(5)

TROUBLESHOOTING

S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)


Defective injector



Replace

Replace

Replace

Defective fuel pump

Clogged fuel tank cap

Replace

Worn piston ring, cylinder liner

Correct


Improper adjustment of valve clearance

Replace


Defective contact of valve and valve seat

Adjust

Clean

Seized turbocharger, interference

Replace

Clean

Clogged air cleaner element

Replace

Causes

Clean

a Measure the engine speed and judge if the problem is in the engine or on the machine. General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Improper fuel used (if non-specified fuel is used, output drops) • There is overheating a See Troubleshooting S-14. • Defective HPI sensor • Defective HPI actuator


Questions


Operated for long period Suddenly

Power was lost

Gradually

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator lamp is red When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Check items

Color of exhaust gas

Black Blue under light load

Clanging sound is heard from around cylinder head Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is irregular There is hunting from engine (rotation is irregular) High idling speed of engine is low Blow-by gas is excessive Inspect air cleaner element directly When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low Inspect valve clearance directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low

Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Check part No. of controller calibration data Remedy

20-820 (5)

D375A-5

TROUBLESHOOTING




High resistance or clogged fuel circuit

Replace

Replace

Clean

Defective controller calibration data

Defective fuel rail actuator (Marked Replace

—

Defective fuel pump pressure sensor Replace

Defective throttle sensor

Defective timing rail pressure sensor Replace

D375A-5

—

Defective fuel rail pressure sensor Replace

1)


1)

1)

Causes


20-821 (5)

TROUBLESHOOTING

S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) General causes why exhaust smoke is black • Insufficient intake of air • Defective condition of fuel injection • Excessive injection of fuel • Defective HPI sensor • Defective HPI actuator • Normal output is not applied o See Troubleshooting S-6

Seized turbocharger, interference

Defective contact of valve and valve seat

Improper adjustment of valve clearance

Leakage of air between turbocharger and cylinder head

Crushed, clogged muffler


Defective fuel pump

Defective injector

Replace

Replace

Adjust

Correct

Replace

Replace

Replace

Replace


Failure timing rail pressure sensor


Replace

Replace

Replace

1)


Causes


Operated for long period Suddenly became black

Questions

Color of exhaust gas

Gradually became black Blue under light load

Non-specified fuel is being used Engine oil must be added more frequently Power was lost

Suddenly Gradually

Dust indicator is red Muffler is crushed Leakage of air between turbocharger and head, loose clamp Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Noise of interference is heard from around turbocharger Clanging sound is heard from around cylinder head Exhaust noise is abnormal Engine pickup is poor and combustion is irregular Blow-by gas is excessive Inspect air cleaner directly When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low Inspect valve clearance directly When muffler is removed, exhaust sound improves Inspect between turbocharger and cylinder head directly When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low Abnormality in timing rail pressure sensor system is indicated ( 2) Inspect sensor directly (Output voltage) Inspect actuator directly (Resistance and filter for clogging) Remedy

20-822 (5)

D375A-5

TROUBLESHOOTING

S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

1. If the following service codes are displayed, carry out the troubleshooting in “Service code”. (If any of the following service codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [EC112]: Abnormality in timing rail actuator 2. If a service code of the timing rail pressure sensor system is displayed, carry out the troubleshooting in “Service code”.

D375A-5

20-823 (5)

TROUBLESHOOTING

S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)

S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) a To prevent the oil from leaking up or down in the turbocharger, do not run the engine at idling for more than 20 minutes continuously (both low and high idling). General causes why oil consumption is excessive • Abnormal combustion of oil • External leakage of oil • Wear of parts in lubrication system

Broken oil cooler Replace

Leakage from oil pan or cylinder head

Leakage from oil drain plug Correct

Leakage from oil piping

Too much engine oil added Correct

Correct

Worn, broken rear oil seal Correct

Leakage from oil filter or oil cooler

Clogged breather or breather hose Clean

Correct

Broken piston ring Replace

Correct


Worn seal at blower end

Worn, damaged valve (stem, guide, seal) Correct

Worn seal at turbine end

Turbocharger

Dust sucked in from intake system

Causes

Questions



Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Oil level is above H level on gauge Outside of engine is dirty with oil There are loose piping clamps in intake system

Check items

Inside of turbocharger intake pipe is dirty with oil Inside of exhaust pipe is dirty with oil There is oil in engine cooling water Oil level in clutch chamber or damper chamber rises Exhaust smoke is blue under light load Amount of blow-by gas

Excessive None

Troubleshooting

When intake manifold is removed, dust is found inside Excessive play of turbocharger shaft When intake manifold is removed, inside is found to be dirty with oil When compression pressure is measured, it is found to be low Inspect breather element directly Inspect rear oil seal directly There is external leakage of oil from engine

20-824 (5)

Replace

Replace

Remedy

Correct

Pressure-tightness test of oil cooler shows there is leakage

D375A-5

TROUBLESHOOTING

S-9 OIL BECOMES CONTAMINATED QUICKLY

S-9 OIL BECOMES CONTAMINATED QUICKLY General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Defective combustion • Improper fuel used • Operation under excessive load • Oil change interval is too long

Defective seal at turbocharger turbine end

Worn valve (stem, guide, seal)


Clogged breather, breather tube

Too much engine oil added

Clogged oil cooler

Clogged oil filter

Defective oil filter safety valve

Replace

Replace

Replace

Clean

Correct

Clean

Replace

eplace

Exhaust smoke is black

Clogged turbocharger lubrication drain tube Clean

Causes

Questions



Non-specified oil is being used Engine oil must be added more frequently Oil level is above H level on gauge When oil filter is inspected, metal particles are found

Check items

When exhaust pipe is removed, inside is found to be dirty with oil Even when engine oil temperature rises, oil filter caution lamp lights up (machines equipped with caution lamp)

Engine oil temperature rises quickly Color of exhaust gas Amount of blow-by gas

Blue under light load Black Excessive None Carry out Troubleshooting S-7

Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather element directly Inspect oil cooler directly Inspect oil filter directly Inspect safety valve directly Remedy

D375A-5

—

Troubleshooting

Inspect turbocharger lubrication drain tube directly

20-825 (5)

TROUBLESHOOTING

S-10 FUEL CONSUMPTION IS EXCESSIVE

S-10 FUEL CONSUMPTION IS EXCESSIVE General causes why fuel consumption is excessive • Leakage of fuel • Defective condition of fuel injection • Excessive injection of fuel • Defective HPI sensor

Failure timing rail pressure sensor Replace


Failure fuel rail pressure sensor Replace


Cut, worn injector O-ring Replace

Replace

Defective injector Replace

High resistance, clogged fuel return circuit

Defective fuel pump Replace

Replace


Clean

Leakage of fuel inside head cover Correct

Causes

Confirm recent repair history Questions


Operated for long period More than for other machines of same model

Condition of fuel consumption

Gradually increased Suddenly increased

There is external leakage of fuel from engine

Check items

Engine oil level rises and smells of diesel fuel When engine is cranked with starting motor, and


When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Exhaust smoke color

Black White

Inspect inside of head cover directly Troubleshooting

When negative pressure at inlet port of fuel pump is measured, it is found to be high Inspect fuel pump directly When temperature of injector of each cylinder is measured, there are some cylinders that are low When pressure at outlet port of fuel pump is measured, it is found to be low Abnormality in fuel rail pressure sensor system is indicated ( 1) Abnormality in timing rail pressure sensor system is indicated ( 1) When flow of return fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage)

1. If a service code of the fuel rail pressure sensor system or timing rail pressure sensor system is displayed, carry out the troubleshooting in "Service code".

20-826 (5)

Remedy

D375A-5

TROUBLESHOOTING

S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN

S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN General causes why oil is in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system

Broken oil cooler core, O-ring Replace

Broken power train oil cooler (troubleshooting in chassis volume)

Damaged cylinder liner O-ring, holes caused by pitting Replace

Broken water pump seal

Insufficient protrusion of cylinder liner Replace

Replace

Internal cracks in cylinder block Replace

Replace

Broken cylinder head, head gasket Replace

Causes

Questions

Confirm recent repair history Degree of use of machine Oil level

Operated for long period Suddenly increased Gradually increased

Troubleshooting

Check items

Hard water is being used as cooling water (or corrosion resistor valve is closed) Excessive air bubbles inside radiator, spurts back Engine oil level has risen, oil is cloudy white Hydraulic oil, transmission oil on machine side is cloudy white When hydraulic oil, transmission oil on machine side is drained, water is found Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect cylinder liner directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Remedy

D375A-5

20-827 (5)

TROUBLESHOOTING

S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)

S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) General causes why oil pressure caution lamp lights up • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper selection of fuel (insufficient viscosity) • Deterioration of oil due to overheating

Defective oil level sensor Defective oil pressure sensor

Water, fuel in oil

Confirm recent repair history Degree of use of machine Operated for long period Non-specified oil is being used Replacement of filters has not been carried out according to Operation Manual Engine oil pressure caution lamp lights up Lights up at low idling Lights up at low, high idling Condition when oil pressure lamp lights up Lights up on slopes Sometimes lights up Oil level caution lamp lights up (machines equipped with caution lamp) There is crushing, external leakage from hydraulic piping Oil level in oil pan is low Oil is cloudy white or smells of diesel oil When oil is drained, metal particles are found When oil filter is inspected, metal particles are found

20-828 (5)

Replace Replace

Remedy

Carry out Troubleshooting S-13

Inspect oil filter directly Inspect suction strainer, pipe directly Oil pump rotation is heavy, there is play Inspect relief valve, regulator valve directly Inspect oil filter directly When engine oil level sensor is replaced, oil pressure lamp goes out (machines equipped with oil level sensor) When oil pressure is measured, it is found to be normal

Clean Add Clean Clean Correct Replace Adjust Replace Clean Correct

Troubleshooting

Check items

Questions

Worn crankshaft journal Lack of oil in oil pan Clogged oil pan suction strainer Clogged, broken oil pump suction pipe Broken oil pump suction pipe brazing Defective oil pump Defective oil pump relief valve Clogged oil cooler Clogged oil filter Leaking, crushed hydraulic piping

Causes

D375A-5

TROUBLESHOOTING

S-13 OIL LEVEL RISES

S-13 OIL LEVEL RISES

Defective thermostat seal Worn fuel pump seal Cut, worn injector O-ring Defective auxiliary equipment (pump, compressor) seal

Broken aftercooler core Broken cylinder head, head gasket Defective cylinder head injector sleeve Cracks inside cylinder block Damaged cylinder liner O-ring, holes caused by pitting Broken, broken rear oil seal face Broken oil cooler core, O-ring

Clogged water pump drain hole (breather hole), defective seal

Causes

Confirm recent repair history Degree of use of machine Operated for long period Fuel must be added more frequently Engine oil smells of diesel fuel There is oil in cooling water When engine is first started, drops of water come from muffler When radiator cap is removed and engine is run at low idling, an abnormal number of bubbles appear, or water spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, water comes out Oil level goes down in clutch or damper chamber Oil level goes down in hydraulic tank Carry out pressure-tightness test of aftercooler When compression pressure is measured, it is found to be low Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect rear oil seal directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Inspect thermostat directly Inspect fuel pump directly Inspect injector directly Inspect pump auxiliary equipment (pump, compressor) directly Remedy

D375A-5

Replace Replace Replace Replace Replace Correct Replace Replace Correct Replace Correct Replace

Troubleshooting

Check items

Questions

a If there is oil in the cooling water, carry out Troubleshooting S-11. General causes why oil level rises • Cooling water in oil (milky white) • Fuel in oil (diluted, and smells of diesel fuel) • Entry of water or oil from other component

20-829 (5)

TROUBLESHOOTING

S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)

S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Rise in oil temperature in power train (troubleshooting in chassis volume)

Clogged, crushed radiator fins

Defective radiator cap (pressure valve)

Fan belt slipping, worn fan pulley

Broken water pump

Replace

Correct

Replace

Rise in power train oil temperature (troubleshooting in chassis volume)

Clogged radiator core

Correct

Defective water temperature gauge

Lack of cooling water

Correct

Defective operation of thermostat

Clogged, broken oil cooler

Add

Replace

Damaged cylinder liner O-ring, holes caused by pitting

Replace

Replace

Cracks inside cylinder block

Replace

Broken cylinder head, head gasket

Replace

Causes


Questions

Degree of use of machine Condition of overheating Water temperature gauge

Operated for long period Suddenly overheated Always tends to overheat Rises quickly Does not go down from red range

Radiator water level caution lamp lights up (machines equipped with caution lamp) Engine oil level has risen, oil is cloudy white Cloudy white oil is floating on cooling water Excessive air bubbles inside radiator, water spurts back

Check items

When light bulb is held behind radiator, no light passes through Radiator shroud, inside of underguard are clogged with dirt or mud Water is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose Fan belt whines under sudden load Cooling water flows out from overflow hose Power train oil temperature enters red range faster than engine water temperature When compression pressure is measured, it is found to be low Carry out pressure-tightness test of cylinder head

Troubleshooting

Inspect cylinder block, liner directly Inspect oil cooler directly Inspect radiator core directly When temperature difference between top and bottom radiator tanks is measured, it is found to be slight Carry out function test on radiator cap (cracking pressure) When temperature difference between top and bottom radiator tanks is measured, it is found to be excessive

1.

Carry out function test on thermostat (cracking temperature)

Remedy

Replace

When water temperature is measured, it is found to be normal


20-830 (5)

D375A-5

TROUBLESHOOTING

S-15 ABNORMAL NOISE IS MADE

S-15 ABNORMAL NOISE IS MADE

Seized turbocharger, internal interference Leakage of air between turbocharger and head Broken dynamic valve system (valve, rocker arm, etc.) Defective adjustment of valve clearance Defect inside muffler (dividing board out of position) Excessive wear of piston ring, cylinder liner Seized crankshaft bearing Missing, seized gear bushing Improper gear train backlash Deformed cooling fan, fan belt interference Defective injector Air leakage from auxiliary equipment (pump, compressor)

Causes

Confirm recent repair history Degree of use of machine Operated for long period Gradually occurred Condition of abnormal noise Suddenly occurred Non-specified fuel is being used Engine oil must be added more frequently Seal on injection pump has come off Metal particles are found in oil filter Leakage of air between turbocharger and head, loose clamp Noise of interference is heard from around turbocharger Clanging sound is heard from around cylinder head Vibrating noise is heard from around muffler

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Blue under light load Color of exhaust gas Black Engine pickup is poor and combustion is abnormal Abnormal noise is loud when accelerating engine Blow-by gas is excessive

When turbocharger is rotated by hand, it is found to be heavy Inspect dynamic valve system directly Inspect valve clearance directly When muffler is removed, abnormal noise disappears When compression pressure is measured, it is found to be low Inspect crankshaft bearing directly Inspect front gear and rear gear directly Inspect cooling fan, belt directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly Remedy

D375A-5

Replace Correct Replace Adjust Replace Replace Replace Replace Correct Correct Replace Replace

Troubleshooting

Check items

Questions

a Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion noise • Air sucked in from intake system

20-831 (5)

TROUBLESHOOTING

S-16 VIBRATION IS EXCESSIVE

S-16 VIBRATION IS EXCESSIVE

Worn cam bushing

Improper gear train backlash

Defective vibration damper


Clogged injector

Worn front support spigot joint portion

Loose engine mounting bolts, broken cushion

Replace

Correct

Replace

Adjust

Replace

Replace

Replace

(troubleshooting for machine)

Worn main bearing, connecting rod Replace

Internal damage in clutch chamber or damper chamber

Defective dynamic valve system (valve, rocker arm, etc. stuck)

Causes

Replace

a If there is abnormal noise together with the vibration, carry out Troubleshooting S-15 also. General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment between engine and chassis • Abnormal combustion

Questions

Confirm recent repair history Degree of use of machine Condition of vibration

Operated for long period Suddenly increased Gradually increased

Non-specified fuel is being used Seal on injection pump has come off Metal particles are found in oil filter

Check items

Metal particles are found when oil is drained Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Troubleshooting

Inspect main bearing, connecting rod directly Inspect cam bushing directly Inspect front gear train and rear gear train directly Inspect vibration damper directly Injection pump test shows that injection amount is incorrect Inspect front support spigot joint directly Inspect engine mounting bolts, cushions directly

Remedy

20-832 (5)

Replace

Inspect clutch chamber or damper chamber directly (troubleshooting for machine)

D375A-5

30 DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY

30 DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL ................. 30- 5 Removal and installation of assemblies 30- 5 Disassembly and assembly of assemblies ........................................... 30- 6 PRECAUTIONS WHEN CARRYING OUT OPERATION ...................................... 30- 7 SPECIAL TOOL LIST ................................. 30- 8-1 SKETCHES OF SPECIAL TOOLS ............ 30-8-10 REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY ........................... 30- 9 Removal ............................................... 30- 9 Installation ............................................. 30- 9 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL .............................. 30- 10 Special tools ......................................... 30- 10 Removal ............................................... 30- 10 Installation ............................................. 30- 10 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL ................................. 30- 12 Special tools ......................................... 30- 12 Removal ............................................... 30- 12 Installation ............................................ 30- 12 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY .................. 30- 14 Special tools ......................................... 30- 14 Removal ............................................... 30- 14 Installation ............................................ 30- 17 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY ............................ 30- 19 Removal ............................................... 30- 19 Installation ............................................ 30- 19 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ............................ 30- 20 Removal ............................................... 30- 20 Installation ............................................ 30- 21 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY ............... 30- 22 Special tools ......................................... 30- 22 Removal ............................................... 30- 22 Installation ............................................ 30- 24 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY .................................. 30- 25 Special tools ......................................... 30- 25 Removal ............................................... 30- 25 Installation ............................................. 30- 28 D375A-5

REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY ................................. Special tools .......................................... Removal ................................................ Installation ............................................. DISASSEMBLY AND ASSEMBLY OF DAMPER ..................................................... Disassembly of damper assembly ........ Disassembly of damper cover assembly Assembly of damper assembly ............. Assembly of damper cover assembly ... REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY ............. Removal ................................................ Installation ............................................. DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY ............. CONNECTION OF POWER TRAIN UNIT ASSEMBLY ................................................. DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY ....................................... Disassembly .......................................... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY ......... Special tools .......................................... Disassembly .......................................... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY ................................................. Special tools .......................................... Disassembly .......................................... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY .................. Disassembly .......................................... Assembly .............................................. REMOVAL AND INSTALLATION OF POWER TRAIN, LUBRICATION PUMP ASSEMBLY ..................................... Removal ................................................ Installation .............................................

30303030-

29 29 29 31

3030303030-

33 33 33 34 35

30- 36 30- 36 30- 39 30- 40 30- 45 30- 47 30- 47 30- 50 30303030-

54 54 54 58

30303030-

64 64 64 79

30- 96 30- 96 30-102 30- 113 30- 113 30- 113

30-1 2(7)c

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY ............. Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY .......................... Special tools .......................................... Removal ................................................ Installation ............................................. DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY .......................... Special tools .......................................... Disassembly .......................................... Assembly .............................................. REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY ...................... Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF IDLER ASSEMBLY ..................................... Removal ................................................ Installation ............................................. DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY .................................... Special tools .......................................... Disassembly .......................................... Assembly .............................................. Sketch of special tool ............................ REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY .................... Special tools .......................................... Removal ................................................ Installation ............................................. DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY ................... Special tools .......................................... Disassembly .......................................... Assembly .............................................. REMOVAL AND INSTALLATION TRACK ROLLER ASSEMBLY ..................... Special tools .......................................... Removal ................................................ Installation ............................................. Sketch of special tool ............................ DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY .................... Special tools .......................................... Disassembly .......................................... Assembly .............................................. Sketch of special tool ............................ REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY .................................... Special tools .......................................... Removal ................................................ Installation ............................................. Sketch of special tool ............................

30-2 "

2 "

30-114 30-114 30-114 30-115 30-115 30-115 30-115 30-116 30-116 30-116 30-122 30-131 30-131 30-132 30-133 30-133 30-133 30-134 30-134 30-134 30-135 30-138 30-139 30-139 30-139 30-142 30-143 30-143 30-143 30-144 30-145 30-145 30-145 30-146 30-148 30-149 30-149 30-149 30-150 30-152 30-153 30-153 30-153 30-155 30-158

DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY ..................................... 30-159 Special tools .......................................... 30-159 Disassembly .......................................... 30-159 Assembly ............................................... 30-160 REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY ............................. 30-161 Special tools .......................................... 30-161 Removal ................................................ 30-161 Installation ............................................. 30-163 Sketch of special tool ............................ 30-166 EXPANDING AND ASSEMBLY TRACK SHOE INSTALLATION ................................. 30-167 Check before expanding track shoe assembly ...................................... 30-167 Expanding track shoe assembly ............ 30-168 Expanding track shoe assembly ............ 30-168 Installation of track shoe assembly ........ 30-169 WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ....................................... 30-170 Special tools .......................................... 30-170 Whole disassembly ............................... 30-171 Whole assembly .................................... 30-173 1. When recycling for lubricated track ................................................. 30-173 2. When recycling for greasefilled track ........................................ 30-182 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS ................................... 30-187 DISASSEMBLY AND ASSEMBLY OF 1 LINK IN THE FIELD .................................. 30-188 Special tools .......................................... 30-188 Disassembly .......................................... 30-188 Assembly ............................................... 30-190 DISASSEMBLY AND ASSEMBLY OF MASTER LINK ............................................. 30-192 Special tools .......................................... 30-192 Disassembly .......................................... 30-193 Assembly ............................................... 30-194 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY ......................... 30-197 Special tools .......................................... 30-197 Removal ................................................ 30-197 Installation ............................................. 30-197 Sketch of special tool ............................ 30-198 REMOVAL AND INSTALLATION OF EQUALIZER BAR ........................................ 30-199 Special tools .......................................... 30-199 Removal ................................................ 30-199 Installation ............................................. 30-201 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING ...................... 30-202 Special tools .......................................... 30-202 Disassembly .......................................... 30-202 Assembly ............................................... 30-203 Sketch of special tool ............................ 30-204

D375A-5


REMOVAL AND INSTALLATION OF SEGMENT TOOTH .................................... Removal ............................................... Installation ............................................ REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY ................ Removal ............................................... Installation ............................................ REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND PPC PUMP ASSEMBLY ..................................... Removal ............................................... Installation ............................................ REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY ............... Removal ............................................... Installation ............................................ DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY ............... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF BLADE TILT AND RIPPER LOW VALVE ASSEMBLY .................................... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY ........... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF PPC CHARGE VALVE ASSEMBLY ........... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY ............... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF RIPPER PPC VALVE ASSEMBLY ............. Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ....... Special tools ......................................... Disassembly ......................................... Assembly .............................................. DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULLER CYLINDER ASSEMBLY ................................................ Special tools ......................................... Disassembly ......................................... Assembly .............................................. REMOVAL AND INSTALLATION OF BLADE ASSEMBLY .................................... Removal ............................................... Installation ............................................ DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY .................................... Disassembly ......................................... Assembly ..............................................

D375A-5

30-205 30-205 30-205 30-206 30-206 30-208

30-209 30-209 30-209 30-210 30-210 30-211 30-212 30-212

30-214 30-215 30-216 30-217 30-218 30-218

DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY ...................... Disassembly .......................................... Assembly .............................................. REMOVAL AND INSTALLATION OF ROPS GUARD ............................................ Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY ................ Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF FLOOR FRAME .......................................... Special tools .......................................... Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF DASHBOARD ASSEMBLY ......................... Special tools .......................................... Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY ................... Removal ................................................ Installation ............................................. REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY ...... Removal ................................................ Installation .............................................

30-237 30-237 30-238 30-240 30-240 30-240 30-241 30-241 30-242 30-243 30-243 30-243 30-246 30-248 30-248 30-248 30-249 30-250 30-250 30-250 30-251 30-251 30-253

30-219 30-219 30-221 30-221 30-222 30-222 30-222 30-225

30-228 30-228 30-228 30-229 30-231 30-231 30-232 30-233 30-233 30-235

30-3 2 "

"


HOW TO READ THIS MANUAL

HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES Special tools • Special tools that are deemed necessary for removal or installation of parts are listed. • List of the special tools contains the following kind of information. 1) Necessity ": Special tools which cannot be substituted, should always be used. # Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blanks: Tools already available for other models, used without any modification. 3) Circle mark (!) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. ★ Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T---xxx---xxxx.

Installation of parts • Except where otherwise instructed, install parts is the reverse order of removal. • Instructions and precautions for installing parts are shown with q 1 mark in the INSTALLATION Section, identifying which step the instructions are intended for. • Marks shown in the INSTALLATION Section stand for the following. ¤ This mark indicates safety-related precautions which must be followed when doing the work. ★ This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5

This mark indicates an amount of oil or water to be added.

Sketches of special tools • Various special tools are illustrated for the convenience of local manufacture.

Removal of parts • The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the REMOVAL Section are explained and listed below. ¤ This mark indicates safety-related precautions which must be followed when doing the work. ★ This mark gives guidance or precautions when doing the procedure. This mark shows that there are instrucq1 tions or precautions for installing parts. This mark shows oil or water to be 6 drained. 4 Mass of a part or component.

D375A-5

30-5 2 ! 4

!


HOW TO READ THIS MANUAL

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES Special tools • Special tools which are deemed ncessary for disassembly and assembly are listed in this section. • List of the special tools contains the following kind of information. 1) Neccessity ": Special tools which cannot be substituted, should always be used. # Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blanks: Tools already available for other models, used without any modification. 3) Circle mark (!) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. ★ Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T---xxx---xxxx.

Assembly • Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Section are explained and listed below. ¤ This mark indicates safety-related precautions which must be followed when doing the work. ★ This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5

This mark indicates an amount of oil or water to be added.

Sketches of special tools • Various special tools are illustrated for the convenience of local manufacture.

Disassembly • The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the DISASSEMBLY Section are explained and listed below. ¤ This mark indicates safety-related precautions which must be followed when doing the work. ★ This mark gives guidance or precautions when doing the procedure. This mark shows that there are instrucq1 tions or precautions for installing parts. 6 This mark shows oil or water to be drained. 4 Mass of a part or component.

30-6 !

2 ! 4

D375A-5

PRECAUTIONS WHEN CARRYING OUT OPERATION


PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.]

1. Precautions when carrying out removal work • • • • • • • • • •

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

★ Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number

Plug (nut end)

Nut (elbow end)

02

07376-70210

02789-00210

03

07376-70315

02789-00315

04

07376-70422

02789-00422

05

07376-70522

02789-00522

06

07376-70628

02789-00628

2) Split flange type hoses and tubes Nominal number

Flange (hose end)

Sleeve head (tube end)

Split flange

04

07379-00400

07378-10400

07371-30400

05

07379-00500

07378-10500

07371-30500

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

Part Number

06

07049-00608

Dimensions (mm) D

d

L

6

5

8

08

07049-00811

8

6.5

11

10

07049-01012

10

8.5

12

12

07049-01215

12

10

15

14

07049-01418

14

11.5

18

16

07049-01620

16

13.5

20

18

07049-01822

18

15

22

20

07049-02025

20

17

25

22

07049-02228

22

18.5

28

24

07049-02430

24

20

30

27

07049-02734

27

22.5

34

D375A-5

30-7 2 ! 4

!


PRECAUTIONS WHEN CARRYING OUT OPERATION

2. Precautions when carrying out installation work • • • • • • • • • • • • •

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operation • • • •

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-8 "

2 "

D375A-5

DISA SPECIAL TOOL LIST


SPECIAL TOOL LIST ★ Tools with part number 79!T-!!!-!!!! cannot be supplied (they are items to be locally manufactured). ★ Necessity: ": Cannot be substituted, should always be installed (used). #: Extremely useful if available, can be substituted with commercially available part. ★ New/remodel: N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank: Tools already available for other models, used without any modification. ★ Tools marked ! in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component

Symbol 1

3

2 A Engine assembly

4 5

6

A Torque converter assembly

C

1 2

3 Torquflow transmission assembly

D

4

5

D375A-5

Part No.

Part name

Nature work remarks

795-902-1410

Sleeve

"

1

01050-32240

Bolt

"

3

795-902-1430

Push tool

"

1

01050-32235

Bolt

"

3

795-902-1420

Sleeve

"

1

795-902-1450

Bolt

"

2

01582-02016

Nut

"

2

795-902-1440

Push tool

"

1

Removal, installation of engine front seal

Removal, installation of engine rear seal

01050-32050

Bolt

"

4

790-331-1110

Wrench

"

1

791-451-1000

Remover

"

1

790-101-2102

Puller (294 kN {30 ton})

"

1

790-101-1102

Pump

"

1

795-799-5410

Adapter

"

1

795-799-5420

Remover

"

1

790-413-1010

Bracket

"

1

790-501-5000

Repair stand (100 V)

"

1

790-415-1011

Bracket

"

1

750-501-5000

Repair stand (100 V)

"

1

Disassembly, assembly of torquflow transmission assembly Removal, installation of snap ring

791-615-1130

Push tool

"

1

791-615-1200

Ring assembly

"

1

• 791-615-1210

• Ring

Tightening of cylinder head bolt Removal, installation of radiator guard assembly

Removal, installation of injector assembly Disassembly, assembly of torque converter assembly

1

• 135-A90-1150

• Bolt

1

• 01580-01008

• Nut

1

• 01641-51032

• Washer

791-615-1101

Ring assembly

• 791-615-1111

• Ring

Installation of No. 3 ring gear

2 "

1 1

• 135-A90-1150

• Bolt

1

• 01580-01008

• Nut

1

• 01641-51032

• Washer

2

799-301-1600

Oil leak tester

"

1

Installation of No. 1 ring gear

Operation check of clutch piston

30-8-1 4

SPECIAL TOOL LIST


Component

Symbol 1

Pivot shaft assembly

Equalizer bar

P

N

Part No. 791T-650-2330

N ! N !

Plate

"

1

Bolt

"

2

4

790-101-2510

Block

"

1

5

790-101-2570

Washer

"

2

6

01580-01613

Nut

"

2

7

01643-31645

Washer

"

2

8

790-105-2300

Jack assembly

"

1

9

790-101-1102

Pump

"

1

791-650-1300

Remover

#

1

• 791-735-1123

• Sleeve

1

• 790-434-1050

• Screw

1

• 01580-02419

• Nut

1

• 01643-32460

• Washer

790-101-2102


#

1

1

2

3 U 4

5

6

4

1

791T-650-2340

2

30-8-8

"

790-201-3310

1

Hydraulic cylinder assembly

Sleeve

2

Removal, installation of pivot shaft assembly

Removal, installation of equalizer bar

Pump

#

1

Bracket

"

1

N !

2 791T-650-2420

Bracket

"

1

N !

3 790-438-1110

Screw

"

1

4 791-112-1180

Nut

"

2

5 790-101-2540

Washer

"

2

6 790-101-2102


"

1

7 791-101-1102

Pump

"

1

790-502-1003

Cylinder Repair stand

#

1

790-201-1702

Push tool KIT

"

1

• 790-201-1841

• Push tool

• 790-201-1861

• Push tool

1

• 790-101-5021

• Clip

1

• 01010-50816

• Bolt

1

790-201-1500

Push tool KIT

• 790-201-1650

• Plate

1

• 790-201-1670

• Plate

1

• 790-101-5021

• Clip

1

• 01010-50816

• Bolt

1

790-720-1000

Expander

"

1

796-720-1680

Ring

"

1

07281-01589

Clamp

"

1

796-720-1720

Ring

"

1

07281-02429

Clamp

"

1

796-720-1690

Ring

"

1

07281-02169

Clamp

"

1

790-102-2302 or 790-330-1100

Wrench "

1

790-101-1102

Pump

"

1

790-101-1102

N

Nature work remarks

3

1 791T-650-2410

Equalizer bar bushing

Part name

Disassembly, assembly of equalizer bar for bushing

Disassembly, assembly of hydraulic cylinder assembly

1

"

Press fitting of bushing

1

Multi wrench

Press fitting of seal

Installation of piston ring

Tightening of cylinder head

D375A-5


SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS Note: komatsu cannot accept any responsibility for special tools manufactured according to these sketches. L1

Plate

L8

Plate

30-8-10 (7) 4

D375A-5


L10

Push tool

L13

Plate

D375A-5


30-8-11 (7) 4



L17 Guide

L21 Sling tool

30-8-12 (7) 4

D375A-5



L21 Tube

L21 Plate

D375A-5

30-8-13 (7) 4



P1 Sleeve

P2 Plate

30-8-14 (7) 4

D375A-5



N2-1 Bracket

N2-2 Bracket

D375A-5

30-8-15 (7) 4

REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY


REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY REMOVAL

INSTALLATION

1. Close fuel supply valve.

•

2. Remove engine left side covers (1) and (2).

Carry out installation in the reverse order to removal.

★ Bleed air from fuel circuit. 1) Remove air bleed valve (1). 2) Fill with clean fuel through hole in valve until it overflows. ★ Amount of fuel: Approx. 300 cc (reference) 3) Install air bleed valve (1). 3 Air bleed valve:

12.7 Nm {1.3 kgm} 4) Crank engine with starting motor.

3. Disconnect fuel tubes (3) and (4). 4. Remove fuel hose (5). 5. Disconnect wiring connector (6). 6. Remove clamps (7) and (8). 7. Loosen fuel pump mounting bolt (9) and remove fuel pump assembly (10).

D375A-5

30-9 2 "

"

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL


REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL SPECIAL TOOLS Symbol 1 A 3

Part No.

Part name

INSTALLATION Ne- Q'ty New/Re- Sketch cessity model

795-902-1410 Sleeve

1

01050-32240

3

795-902-1430 Push tool

1

01050-32235

3

Bolt Bolt

•

q1

a Align the crankshaft pulley with the dowel pin when installing. a Tighten the mounting bolts in the order shown in the diagram below. 3 Crankshaft pulley mounting bolt: 1st step: 73.5 ± 19.6Nm {7.5 ± 2kgm} 2nd step: 245 ± 19.6Nm {25 ± 2kgm} 3rd step: 637 ± 19.6Nm {65 ± 2kgm}

REMOVAL 1. Remove radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY. 2. Remove crankshaft pulley (1).

q1

3. Remove front seal (2).

q2

q2

•

30-10 2 c (7)


Procedure for assembling standard seal a Fill the lip portion with approx. 5 cc of lithium grease (G2-LI). a Using tool A3, press fit front seal (2) to front cover (3). a After press fitting, check installation dimension a. Front seal installation dimension a: 66 mm (standard)

D375A-5


•

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

Procedure of assembling front seal with sleeve (for repair) 1) Using tool A1, guide bolt 1 , and nut 2 , press fit sleeve (4) to crankshaft (5). ★ Tighten 3 nuts 2 uniformly. ★ Press fit until tool A1 contacts the end face of the crankshaft. ★ After press fitting, check that sleeve installation dimension b is the specified dimension. Sleeve installation dimension b: 68 ± 0.1mm

2) Using tool A3, press fit front seal (6) to front cover (3). a Fill the lip portion with approx. 5 cc lithium grease (G2-LI). a After press fitting, check installation dimension c. Front seal installation dimension c: 66 mm (standard)

D375A-5

30-11 2 (7) c

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL


REMOVAL AND INSTALLATION OF ENGINE REAR SEAL SPECIAL TOOLS Symbol

Part No.

Part name

795-902-1420 Sleeve

1

2

2

795-902-1440 Push tool

1

01050-32050

4

01582-02016 4

Ne- Q'ty New/Re- Sketch cessity model

2 795-902-1450 Bolt A

5. Remove rear seal (2).

Nut Bolt

REMOVAL 1. Remove damper assembly. For details, see REMOVAL OF DAMPER ASSEMBLY. 2. Remove 1 mounting bolt of flywheel (1) and install guide bolt 1 . 3. Using eyebolts 2 , sling flywheel (1), then remove remaining mounting bolts. q1 4. Move flywheel towards you, then lift off. ¤ The spigot portion of the flywheel is shallow and it may suddenly fall, so be careful not to get your fingers caught. q2 4

30-12 c

2 c

INSTALLATION q1

★ Coat the thread and seat of the flywheel mounting bolts with anti-friction compound (LM-P). ★ Secure the flywheel and the housing with stopper 3 , then tighten the mounting bolts.

Flywheel: 45kg

D375A-5

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL


a Tighten the flywheel mounting bolts in the order shown in the diagram below. 3 Flywheel mounting bolt: 1st step: 98 ± 19.6Nm {10 ± 2kgm} 2nd step: 294 ± 19.6Nm {30 ± 2kgm} 3rd step: 539 ± 19.6Nm {55 ± 2kgm}

q2

•

Procedure for assembling standard seal. a Using tool A4, press fit the rear seal (2) until it contacts the flywheel housing.

•

Assembly procedure for seal with sleeve (for maintenance) 1) Using tool A2, guide bolt 5 , and nut 6 , press fit sleeve (3) to crankshaft (4). a Tighten 2 nuts 6 uniformly. a Press fit until tool A2 contacts the crank. a After press fitting, check that mounting dimension a of sleeve is the specified dimension. Sleeve mounting dimension a:27 ± 1mm

a After installing the flywheel, use dial gauge 4 to measure the radial and face runout of the flywheel. • Face runout: Max. 0.15 mm • Radial runout: Max. 0.20 mm

2) Using tool A4, press fit rear seal (5) until it contacts flywheel housing (6).

D375A-5

30-13 2 (7) c

REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY


REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY SPECIAL TOOLS Symbol A A5

Part No.

5. Disconnect water tube (3). Part name

Ne- Q'ty New/Re- Sketch model cessity

795-799-5410

Adapter

"

1

795-799-5420

Remover

"

1

790-331-1110

Wrench

"

1

6. Remove wiring (4) and wiring clamp.

REMOVAL ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Drain coolant. 2. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 3. Remove engine right side cover (1).

7. Remove air cleaner dust discharge tube, hose, and clamp (5). 8. Remove dust indicator hose (6). 9. Remove suction tube (7). 10. Remove left and right air cleaner assembly mounting bolts (8). 11. Remove hose (9) and tube (10) between turbocharger and aftercooler. 12. Lift off air cleaner assembly (11). 4

Air cleaner assembly: 45 kg

4. Remove engine left side cover (2).

30-14 !

2 ! 4

D375A-5



13. Remove alternator (12).

21. Remove adiabatic cover (24).

14. Remove U-bolt, and disconnect bracket (13) and water tube (14). 15. Remove tube (15).

22. Lift off muffler assembly (25).

16. Remove fuel tube (16), fuel hose (17), and fuel filter assembly (18). 17. Disconnect corrosion hose (19), and remove corrosion resistor assembly (20). 18. Disconnect electrical intake air heater wiring (21). 19. Disconnect fuel tube (22). 20. Lift off aftercooler assembly (23).

q1 q2

23. Disconnect turbocharger inlet lubrication tube (26) and outlet tube (27), then disconnect exhaust temperature wiring.

D375A-5

30-15 2 ! 4

!



24. Sling turbocharger assembly and exhaust manifold (28) as one unit, then loosen mounting bolts q3 and remove. 4

Turbocharger, exhaust manifold assembly:

27. Remove cylinder head cover (32).

30-16 2 ! 4

q7

31. Remove mounting bolts, then remove rocker arm housing (37). q8

q4

28. Remove rocker arm assembly (33). q5 ★ Loosen the locknut, then loosen the adjustment screws 2 or 3 turns.

!

q6

30. Using tool A, remove injector assembly (36).

60kg

25. Remove air cleaner bracket and wiring clamp. 26. Remove spill hose (30).

29. Remove crosshead (34) and push rod (35).

32. Loosen cylinder head mounting bolts (38), then using eyebolts, remove cylinder head assembly (39). q9 4

Cylinder head assembly: 60kg

D375A-5



INSTALLATION •


q1

3 Delivery tube sleeve nut: 92.5 ± 2.5Nm {9.45 ± 0.25kgm}

q2

★ Tighten the aftercooler mounting bolts in the order shown in the diagram below. 3 Mounting bolt: 66.15 ± 7.35Nm {6.75 ± 0.75kgm}

q4

3 Cylinder head cover mounting bolt: 31.85 ± 2.45Nm {3.25 ± 0.25kgm} q5

★ Clean the hole of the mounting bolts and install. ★ Check that the ball portion of the adjustment screw is fitted securely in the socket portion of the push rod. 3 Rocker arm mounting bolt: 98 ± 4.9Nm {10 ± 0.5kgm}

3 Locknut: 67.62 ± 9.8Nm {6.9 ± 1kgm} q6

★ Adjust the crosshead as follows. 1) Loosen the locknut, then turn back the adjustment screw. 2) Hold down the top surface of the crosshead lightly, and screw in the adjustment screw. 3) After the adjustment screw contacts the valve stem, screw it in a further 20°. 4) Tighten the locknut to hold the adjustment screw in position. 3 Locknut: 58.8 ± 5.88Nm {6 ± 0.6kgm}

q3

★ Tighten the turbocharger and exhaust manifold mounting bolts in the order shown in the diagram below.

3 Turbocharger, exhaust manifold assembly mounting bolt: 110.35 ± 12.25Nm {11.25 ± 1.25kgm}

D375A-5

q7

3 Injector mounting bolt: 1st step : 29.4 ± 4.9Nm {3 ± 0.5kgm} 2nd step : Tighten 90 - 120° q8

3 Rocker arm housing mounting bolt: 98 ± 4.9Nm {10 ± 0.5kgm}

30-17 2 ! 4

!



q9

★ Check that there is no dirt or dust on the cylinder head mounting surface or inside the cylinder. ★ Check that the grommet does not come out when installing the gasket. ★ Tighten the cylinder head mounting bolts in the order shown in the diagram.

★ After tightening, make one punch mark a on the main bolt head (if the bolt is new, do not make any punch mark).

2 Mounting bolt: Anti-friction compound (LM-P)

3 Cylinder head mounting bolts (1 - 7 ): 1st step: 245 ± 9.8Nm {25 ± 1kgm} 2nd step: 382.5 ± 9.8Nm {39 ± 1kgm} 3rd step: Make marks with paint on bolt and head, then tighten a further 90 - 120°° . (The mounting bolts may be tightened to the above angle with tool A5.)

3 Mounting bolts (8 - 9 ) 98.1 ± 4.9Nm {10 ± 0.5kgm}

30-18 !

2 ! 4

•

Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

D375A-5

REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY


REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY REMOVAL ¤ Disconnect the cable from the negative (–) terminal of the battery.

5. Disconnect fuel return hose (7) and hose clamp (8).

1. Remove covers (1) and (2).

6. Lift off fuel tank assembly (9). 4

Fuel tank assembly: Approx. 500 kg (when empty) Approx. 1350 kg (when full)

2. Disconnect wiring connector (CN-422) (3). 3. Close fuel supply valve and disconnect fuel supply hose (4). 4. Disconnect brackets (5) and (6).

INSTALLATION •

Carry out installation in the reverse order to removal. 3 Fuel tank mounting bolt: 927 ± 98Nm {94.5 ± 10kgm}

D375A-5

30-19 2 "

"


REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY REMOVAL

8. Disconnect sub tank hose (7).

¤ Disconnect the cable from the negative (–) terminal of the battery.

9. Disconnect radiator water level sensor connector (CN-405) (8).

1. Drain coolant.

10. Remove windbreaker plate (9).

2. Remove inspection cover (17).

11. Using eyebolts, sling radiator assembly, then remove 2 each of left and right top mount bolts (10).

3. Disconnect front lamp connector (CN-202) (1). 4. Using eyebolts, lift off radiator top cover (2). 4

Radiator top cover: 76kg

12. Remove 2 covers (11). 13. Open guard (12). 5. Disconnect radiator inlet hose (3) and aeration hose (4). 6. Remove ground wiring (CN-GND4) (5). 7. Disconnect wiring clamps (6) (4 places), and move wiring towards left side of radiator.

30-20 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY


14. Remove windbreaker plate (13).

INSTALLATION •

Carry out installation in the reverse order to removal. 3 Radiator inlet hose clamp: 882 ± 98Ncm {90 ± 10kgcm}

3 Aeration hose clamp: 333.2 ± 49Ncm {34 ± 5kgcm} Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. 15. Disconnect radiator outlet tube (14). 16. Remove bottom mount bolt (15).

17. Lift off radiator assembly (16). 4

D375A-5

Radiator assembly: 390kg

30-21 2 "

"

REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY


REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY SPECIAL TOOLS Symbol

Part No.

Part name

791-451-1000 Remover A

6 790-101-2102

Puller (294kN {30ton})

790-101-1102 Pump

Ne- Q'ty New/Re- Sketch model cessity #

1

#

1

#

1

2. Disconnect hose (2). ¤ Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit. ★ Fit a blind plug to prevent any dirt or dust from entering.

REMOVAL 1. Remove cap (1) of blade lift cylinder. ★ Check the number and thickness of the shims, and keep in a safe place. ¤ Start the engine, and retract the piston rod, then tie the piston rod with wire to prevent it from coming out.

3. Sling blade lift cylinder assembly (3), then fit cylinder holder and secure to radiator guard. 4. Drain coolant. 5. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY.

30-22 "

2 "

D375A-5


6. Disconnect radiator inlet hose (4). ★ Disconnect at the radiator end and move it towards the engine. 7. Disconnect aeration hose (5) and hose (6) from reserve tank. ★ Disconnect at the radiator end, then remove 2 clamps and move towards the engine.


10. Open engine underguard. 11. Remove right undercover of radiator guard, then remove radiator outlet tube (11). ★ Loosen the clamp at the hose portion, then remove the tube.

12. Disconnect wiring connector (12) (CN-21), and remove cover (13). 8. Disconnect PPC oil cooler piping (7) and (8).

13. Disconnect blade piping (14) and (15).

9. Disconnect fuel cooler piping (9) and (10).

D375A-5

30-23 2 "

"



14. Loosen tension of tension pulley (16) and remove fan belt (17).

17. Lift off radiator guard assembly (20). ¤ Be careful not to damage the wiring and piping when removing. 4

15. Sling radiator and guard assembly, remove lock bolt, then using tool A6, push rear pin (18) to inside radiator guard, and remove. 16. Remove lock plate, and using tool A6, pull front pin (19) to outside of radiator guard, and remove.

Radiator guard assembly: 2,700kg

INSTALLATION •

Carry out installation in the reverse order to removal. ★ Standard shim thickness: 4mm

3 Radiator inlet hose clamp: 882 ± 98Ncm {90 ± 10kgcm}

3 Aeration hose clamp: 333.2 ± 49Ncm {34 ± 5kgcm}

3Radiator outlet hose clamp: 882 ± 98Ncm {90 ± 10kgcm}

Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

30-24 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY


REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY SPECIAL TOOLS Symbol

Part No.

Part name


799-703-1200 Service tool kit

X

1

5. Remove air cleaner dust discharge tube hose clamp (3). 6. Remove air cleaner band (4). 7. Remove air supply tube clamp (5), then remove air supply tube (6).

799-703-1100 Vacuum pump

1


1


1

8. Disconnect dust indicator hose (7).

1

9. Lift off air cleaner assembly (8).

799-703-1401

Gas leak detecter

4 Air cleaner assembly: 22kg

REMOVAL ¤ Disconnect the cable from the negative (–) terminal of the battery.1. 1. Drain coolant. 2. Remove engine hood assembly. 3. Remove engine right side cover (1).

10. Disconnect ground connection wiring (9). 11. Disconnect starting motor wiring (10). 12. Close heater valve (11), and move engine to rear.

4. Remove engine left side cover (2).

D375A-5

30-25 2 (7) c


13. Remove torque converter oil cooler connector (12). 14. Disconnect radiator outlet tube (13).

15. Disconnect air conditioner hoses (16) and (17). a Collect air conditioner gas (R134a) completely before disconnecting the hoses. a Fit blind plugs to prevent dirt, dust, or moisture from getting inside the hoses. a Disconnect all clamps of hoses (16) and (17).


16. Disconnect fuel supply hose (18). 17. Disconnect fuel return hose (19) and remove hose clamp.

18. Disconnect wiring connectors (CN-101) (20), (CU-EG1) (21), and (CU-EG2) (22).

19. Disconnect radiator inlet hose (23). Disconnect aeration hose (24).

30-26 2 c (7)

D375A-5



20. Remove fan net (22). 21. Loosen tension of tension pulley (23) and remove fan belt (24).

26. Lift off bracket assembly (32). 4

Bracket assembly: 170kg

27. Remove damper case oil level gauge (33). 22. Remove right covers (25) and (26).

28. Remove bracket (34).

23. Remove left covers (27) and (28). 24. Remove cover (29).

29. Sling universal joint (35), remove mounting bolts, then lift off. 25. Disconnect wiring connectors (CN206) (30) and (CN-201) (31).

D375A-5

30-27 2 "

"



30. Remove front mount bolt (36) and rear mount bolt (37). 31. Raise engine assembly (38), and remove right rear mount cap (39). 4

Engine assembly: 3,200kg

32. Move engine assembly (38) to above chassis and operate chain block to raise front of engine assembly and set assembly at an angle. 33. Pass chassis parts through front and rear of engine assembly (38), then rotate engine assembly (38) 90° to right of chassis and remove. ★ When removing, be careful not to damage the wiring and hoses.

INSTALLATION ★ Be careful to prevent the entry of moisture, dust or dirt into the air conditioner circuit hoses when installing. ★ Check that there are O-rings at the portion of the air conditioner hoses connecting to the piping, then tighten. Coat the O-rings thoroughly with compressor oil (Showa-Shell Suniso 4G or 5G).

3 Air conditioner gas piping tightening torque Thread size

Tightening torque

16 × 1.5

13.23 ± 1.47Nm {1.35 ± 0.15kgm}

22 × 1.5

22.05 ± 2.45Nm {2.25 ± 0.25kgm}

24 × 1.5

31.85 ± 2.45Nm {3.25 ± 0.25kgm}

M6 bolt (receiver portion)

5.39 ± 1.47Nm {0.55 ± 0.15kgm}

M6 bolt 9.8 ± 1.96Nm {1.0 ± 0.2kgm} (compressor portion)

3 Radiator inlet hose clamp: 882 ± 98Ncm {90 ± 10kgcm}

3 Aeration hose clamp: 333.2 ± 49Ncm {34 ± 5kgcm}

3 Universal joint mounting bolt: 176.4 ± 19.6Nm {18 ± 2kgm}

3 Engine mount bolt: 926.1 ± 102.9Nm {94.5 ± 1kgm} Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. Charging air conditioner with gas Using tool X, charge the air conditioner circuit with air conditioner gas (R134a).

30-28 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY


REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY SPECIAL TOOLS Symbol

X

Part No.

Part name

5. Remove right covers (5) and (6). Ne- Q'ty New/Re- Sketch cessity model

799-7.3-1200 Service tool kit

1


1


1


1

Gas leak de799-703-1401 tector

1

6. Remove left covers (7) and (8). 7. Remove cover (9).

REMOVAL ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 2. Disconnect ground connection wiring (1).

8. Disconnect wiring connector (CN-206) (10).

3. Disconnect starting motor wiring (2). 4. Close heater valve, then remove heater hose clamp, and disconnect heater hoses (3) and (4). q1

D375A-5

30-29 2 (7) c



9. Disconnect air conditioner hoses (11) and (12). a Collect air conditioner gas (R134a) completely before disconnecting the hoses. a Fit blind plugs to prevent dirt, dust, or moisture from getting inside the hoses.

13. Open power train underguard (front). 14. Sling universal joint (27), then remove mounting bolts, and lift off.D q2 4 Universal joint: 45kg

10. Lift off bracket (13).

4 Bracket assembly: 170kg

15. Remove drain plug and drain oil from damper case. 11. Remove damper case oil level gauge (25). 12. Remove bracket (26).

6

Damper case: Approx. 2.1¬

16. Remove holder (28) and coupling (29).

q3

17. Remove retainer (30).

30-30 2 c (7)

D375A-5



18. Using eyebolts 1 , sling damper cover (31), then q4 use forcing screws to remove. ¤ To prevent the damper cover from coming out suddenly, set guide bolt 2 (¬=200mm). 4

Damper cover: 75kg

19. Using eyebolts 3 , remove damper assembly (32). q5 ¤ To prevent the damper assembly from comi n g o u t s u d d e n l y, s e t g u i d e b o l t 4 (¬=200mm). 4

Damper assembly: 70kg

20. Remove bearing (33) from flywheel.

q6

INSTALLATION •


q1

★ Install the hoses without twisting or interference. ★ Be careful to prevent the entry of moisture, dust or dirt into the air conditioner circuit hoses when installing. ★ Check that there are O-rings at the portion of the air conditioner hoses connecting to the piping, then tighten. Coat the O-rings thoroughly with compressor oil (Showa-Shell Suniso 4G or 5G).

3 Air conditioner gas piping tightening torque Thread size

Tightening torque

16 × 1.5

13.23 ± 1.47Nm {1.35 ± 0.15kgm}

22 × 1.5

22.05 ± 2.45Nm {2.25 ± 0.25kgm}

24 × 1.5

31.85 ± 2.45Nm {3.25 ± 0.25kgm}

q2

3 Universal joint mounting bolt: 176.4 ± 19.6Nm {18 ± 2kgm}

q3

2 Holder mounting bolt thread portion: Thread tightener (LT-2) 3 Holder mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm}

D375A-5

30-31 2 "

"



q4

★ Using guide bolt 2 (¬=200 mm), dtermine the position of the damper cover.

q5

★ Using guide bolt 4 (¬=200 mm), dtermine the position of the damper assembly.

q6

★ Fill approx.50% (approx. 11 g) of the hatched portion a in the diagram with grease (G2-LI).

•

Refilling with oil ★ Fill with oil to the specified level.

•

Charging air conditioner with gas ★ Using tool X, charge the air conditioner circuit with air conditioner gas (R134a).

30-32 "

2 "

D375A-5


DISASSEMBLY AND ASSEMBLY OF DAMPER

DISASSEMBLY AND ASSEMBLY OF DAMPER DISASSEMBLY OF DAMPER ASSEMBLY

6. Remove seal (7) from flanges (2) and (5).

1. Set damper assembly to block 1 . 2. Remove mounting nut (1), then using forcing screws 2 , remove flange (2).

DISASSEMBLY OF DAMPER COVER ASSEMBLY 3. Remove shaft (3).

7. Remove bearing (8) and oil seal (9) from cover (10).

4. Remove rubber (4).

8. Remove oil seal (11) from retainer (12).

5. Using forcing screws 2 , remove flange (5) from body (6).

D375A-5

30-33 2 "

"


ASSEMBLY OF DAMPER ASSEMBLY 1. Install seals (7) to flanges (2) and (5). ★ Install the seal with the lip facing the inside as shown in the diagram.


3. Set flange and body assembly to block, then set shaft (3) in position. 4. Assemble rubber (4). ★ When assembling the rubber, coat the whole surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI). ★ After assembling to the rubber, fill approx. 30% of the clearance (16 places) between the flange and body with grease (G2-LI).

2. Align bolt holes with body (6) and install flange (5). 2 Mating surface of flange: Gasket sealant (LG-4)

★ Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both faces of the flange and body with gasket sealant.

5. Install flange (2).

2 Mating surface of flange: Gasket sealant (LG-4) ★ Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both faces of the flange and body with gasket sealant.

6. Set bolt in position, and tighten mounting nut (1).

30-34 "

2 "

D375A-5


ASSEMBLY OF DAMPER COVER ASSEMBLY 7. Using push tool 3 , press fit oil seal (11) to retainer (12). 2 Oil seal press-fitting surface: Gasket sealant (LG-1)

★ Coat the inside surface of the retainer thinly with gasket sealant and wipe off any sealant that is squeezed out.


9. Using push tool 5 , press fit oil seal (9) to cover (10). 2 Oil seal press-fitting surface: Gasket sealant (LG-1)

★ Coat the inside surface of the retainer thinly with gasket sealant and wipe off any sealant that is squeezed out. 2 Lip of oil seal: Grease (G2-LI)

2 Lip of oil seal: Grease (G2-LI)

8. Using push tool 4 , press fit bearing (8) to cover (10).

D375A-5

30-35 2 "

"


REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY

REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY REMOVAL 1. Drain oil from hydraulic tank and power train case. 6

¬ Hydraulic tank: Approx. 120¬

6

¬ Power train case: 150¬

9. Disconnect wiring connectors (CN-PL1) (7), (CN-PL2) (8), and (CN-PL3)(9). 10. Loosen locknut and remove from bracket.

2. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 3. Remove fuel tank. For details, see REMOVAL OF FUEL TANK ASSEMBLY. 4. Remove 2 clamps (1) of hydraulic and PPC pump inlet tube coupling. ★ Move the coupling towards the power train unit and disconnect the tube. 5. Disconnect PPC drain hose (2). ★ Disconnect at the pump inlet tube end, and move it to the right side of the chassis.

11. Disconnect torque converter oil cooler hose (10).

6. Disconnect 2 PPC oil cooler hoses (3), then disconnect clamps (2 places). ★ Move the 2 hoses together to the outside of the oil level gauge, then move them to the right side of the chassis. 7. Disconnect hydraulic and PPC pump outlet hose (4). ★ Disconnect at the pump end. 8. Disconnect wiring connectors (CN-241) (5) and (CN-404) (6), then disconnect clamps (2 places). 12. Disconnect right rear lamp connector (CN-243) (11), then disconnect clamps at top of frame (3 places) and at bottom of frame (1 place). 13. Remove frame (12).

30-36 "

2 "

D375A-5


14. Disconnect torque converter oil cooler hose (13), then disconnect bracket at frame end. ★ Move the hose towards the front of the chassis.


18. Disconnect universal joint (18) at torque converter end. ★ After disconnecting, move it towards the damper end.

15. Disconnect ripper low valve hose (14), then disconnect bracket (1 place) on top of steering case. ★ Move the hose towards the power train unit end. 16. Disconnect 2 pin puller solenoid hoses (15), then disconnect clamp. ★ Disconnect the hose at the steering case end, and move it towards the ripper end.

19. Remove cover (19), then using eyebolts, pull out left and right drive shaft (30). ★ If the shaft does not come out, push up the shoe grouser from the ground surface with a jack and move the sprocket backwards or forwards to adjust to a position where the shaft can be removed, then pull the shaft out. ★ Pull the shaft out to a point where it contacts the sprocket. 17. Disconnect clamps (16) and (17) and remove bracket. ★ Move the hose towards the right side of the chassis.

D375A-5

30-37 2 "

"


20. Remove right floor frame rear mount (21). ★ Remove at this point because the right floor frame rear mount will interfere when the power train unit is raised.

21. Remove left floor frame mount (22) and right floor frame mount (23). ★ The front mount of the power train unit is tightened together with the front mount of the floor frame. 4

30-38 "

2 "


22. Remove left and right rear mount caps (24).

23. Loosen left and right rear coupling clamps (25). ★ Move the clamps towards the main frame, open the joint of the coupling, then move the seal towards the main frame.

Left floor frame mount: 38kg Right floor frame mount: 37kg

D375A-5



24. Lift off power train unit assembly (26). ★ Check that all the wiring and piping has been disconnected before removing the power train unit assembly. 4

Power train unit assembly: 4,200kg

•

Refilling with oil (power train case, hydraulic tank) ★ Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 5

¬ Power train case: Approx.150¬ ¬ Hydraulic tank: Approx.120¬

INSTALLATION •


3 Universal joint mounting bolt: 176.4 ± 19.6Nm {18 ± 2kgm} ★ If the shaft does not go in, push up the shoe grouser from the ground surface with a jack and move the sprocket backwards or forwards to adjust to a position where the shaft meshes, then assemble the shaft. 3 Rear mount cap mounting bolt: 367.5 ± 61.25Nm {43.75 ± 6.25kgm} 3 Rear coupling clamp mounting bolt: 6.85 ± 1.96Nm {0.7 ± 0.2kgm}

★ When installing the power train unit assembly, pay attention to the mating surface of the coupling and be careful not to damage the coupling seal at the rear mount.

D375A-5

30-39 2 "

"


DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY

DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY 1. Draining oil Before setting power train unit assembly in position, drain oil from oil pan. 2. Raise power train unit assembly (1) and set to block 1 . ★ Set blocks under the front of the oil pan, under the transmission rear case, and under the steering case.

6. Disconnect 14 pressure detection hoses (5) and remove central pressure detection bracket (6) as one unit. ★ Before removing, mark all the hoses with tags to prevent mistakes in the mounting position when installing.

7. Remove oil level gauge (7). 8. Remove oil filler pipe (8). 3. Remove brake rod (2). 4. Remove parking brake cable (3). ★ Measure the dimension of the mounting bracket portion. 5. Remove control cable and bracket assembly (4). ★ Disconnect the directional control cable and speed control cable together with the lever at the control valve end.

30-40 "

2 "

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9. Lift off filter assembly (9) together with bracket. 4

Filter assembly: 120kg

12. Lift off scavenging pump assembly (12). 4

Scavenging pump assembly: 41kg

10. Lift off strainer assembly (10) together with suction tube. 4

Strainer assembly:50kg

13. Lift off front mount (13). 4

Front mount: 150kg

11. Lift off power train and lubrication pump assembly (11). 4

Power train, lubrication pump assembly: 50kg

14. Remove outlet hose of hydraulic and PPC pump. 15. Lift off hydraulic and PPC pump assembly (14) together with inlet tube. 4

D375A-5

Work equipment, PPC pump assembly: 65kg

30-41 2 "

"



16. Disconnect hydraulic hoses (35) and (36) of servo valve (34).

20. Remove block from under oil pan, and sling oil pan (17).

17. Disconnect bolts (37) and (38).

21. Remove mounting bolts, then remove oil pan (17). ★ In addition to the mounting bolts at the front, rear, left, and right, there are also bolts installed inside the holes at 4 places under the oil pan.

18. Remove 3 bolts (39), then remove servo valve (34).

4

Oil pan: 110kg

19. Disconnect steering control rod (15) at control valve end, and remove together with lever assembly (16). 22. Remove bearing cage (18) together with torque converter speed sensor. 23. Remove case (19).

30-42 "

2 "

D375A-5


24. Remove shaft (20).


28. Set PTO, torque converter, and transmission assembly (22) with PTO side at top, then set on block 3 .

25. Set block 2 under PTO. 26. Sling steering case assembly (21), and remove block from under steering case.

29. Remove coupling (23). 30. Remove retainer (24). ★ Check the number and thickness of the shims, and keep in a safe place.

27. Remove mounting bolts, then remove steering case assembly (21). 4

D375A-5

Steering case assembly: 1,750kg

31. Remove snap ring (25), then remove spacer (26).

30-43 2 "

"



32. Using eyebolts, lift off PTO assembly (27). 4

PTO assembly: 290kg

33. Lift off torque converter assembly (28). 4

30-44 "

2 "

Torque converter assembly: 550kg

D375A-5


CONNECTION OF POWER TRAIN UNIT ASSEMBLY

CONNECTION OF POWER TRAIN UNIT ASSEMBLY •

Carry out connection in the reverse order to disconnection.

★ Bend the cotter pin securely. ★ Set the installation dimension of the bracket to the dimension measured when removing. ★ Adjust the limit switch and the lever of the directional control linkage as follows. 1) Set lever (29) to N position and insert. 2) Set up and down lever (29) at a height where roller of up and down limit switch (30) contacts groove in lever (29), then tighten temporarily. 3) Move lever (29) to F and R positions and check that roller is pushed in securely [F: top limit switch], [R: bottom limit switch], then tighten lever (29) fully. ★ Bend the cotter pin securely.

D375A-5

★ Check that the tip of shaft (20) is fitted securely in drum (31) of bearing cage (18).

★ Check that shaft (20) is fitted securely in boss (32) at the tip of the transmission input shaft.

30-45 2 "

"


3 Steering case mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm} ★ Adjust the retainer shim as follows. 1) Without fitting shim, install retainer (24) and tighten 6 mounting bolts to following torque. 2 Oil seal: Grease (G2-LI)

3 Mounting bolt: 9.8Nm {1kgm} 2) Using clearance gauge, measure clearance a between retainer (24) and PTO housing (33).

CONNECTION OF POWER TRAIN UNIT ASSEMBLY

3) Select shim thickness. Shim thickness = a + 0 - 0.05 mm Types of shim thickness = 0.15 mm, 0.2 mm, 0.5 mm 4) Assemble selected shim thickness and tighten mounting bolts of retainer (24) to specified torque. 3 Mounting bolt: 66.15 ± 7.35Nm {6.75 ± 0.75kgm}

★ Check that the number and thickness of the shims is the same on both the left and right sides. ★ Assemble the shims (34) as shown in the diagram below so that they do not block the forcing screw tap H hole in the retainer.

★ Measure clearance a at 4 places (A, B, C, D) around the circumference and calculate the average. ★ Coat portion P of the PTO shaft with anti-friction compound (LM-P) and the spline portion Q with grease (G2-LI).

30-46 "

2 "

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DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY DISASSEMBLY 1. PTO lubrication tube Sling PTO assembly and remove lubrication tube (1). ★ Remove 3 lubrication tubes on the opposite side, then set the torque converter side at the bottom and lower the assembly.

3) Using puller 2 , remove bearings (5) and (6) from gear (7).

3. Power train pump gear assembly 1) Using forcing screws 1 , pull out cover assembly (8) and remove. 2) Using puller, remove gear assembly (10) from cover (9). 2. Hydraulic, PPC pump gear assembly 1) Using forcing screws 1 , pull out cover assembly (2) and lift off. 2) Using puller 2 , remove gear assembly (3) from cover (4).

D375A-5

30-47 2 "

"


3) Using puller 2 , remove bearings (11) and (12) from gear (13).

4) Turn over PTO case, and remove cover (14). 4. Scavenging pump gear 1) Remove snap ring (15) at bottom of PTO case, then remove gear (16).

30-48 "

2 "


5. Idler gear assembly 1) Remove plate (17).

2) Turn over PTO case, then using forcing screws 1 , remove shaft assembly (18). ★ The bearing outer race and gear assembly will come out from the bottom of the PTO case, so set a wooden block and take care not to cause damage. 3) Remove plug (19), then using forcing screws, push out bearing inner race (20). ★ After removing the bearing, install the plug.

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4) Remove bearing outer races (21) and (22) from gear (23).

6. PTO race 1) Remove race assembly (24) and bearing outer race (25) as one unit.


3) Remove bearing outer race (29). 4) Remove sleeve (30).

7. Bearing Remove snap ring (31), then remove bearing (32).

2) Remove bearing inner races (26) and (27) from race (28).

D375A-5

30-49 2 "

"


ASSEMBLY ★ Wash all parts clean and check that there are no scratches or dirt before assembling. ★ Check that the snap ring is fitted securely in the groove.


3) Using push tool, press fit bearing inner races (27) and (26) to race (28).

1. Bearing 1) Using push tool, press fit bearing (32) to case. ★ Drop approx. 6 cc of engine oil (SAE10W-CD or SAE30-CD) on the bearing, and rotate it 10 times. 2) Install snap ring (31).

4) Install race assembly (24).

2 Inside surface of race: Anti-friction compound (LM-P)

5) Using push tool, press fit bearing outer race (25). ★ Drop approx. 6 cc of engine oil (SAE10W-CD or SAE30-CD) on the bearing, and rotate it 10 times.

2. PTO case 1) Install sleeve (30) to case. ★ Install the sleeve with the chamfered portion on the inside circumference facing down. ★ Expand fit the sleeve. 2) Using push tool, press fit bearing outer race (29).

30-50 "

2 "

D375A-5


3. Idler gear 1) Using push tool 3 , press fit bearing outer races (22) and (21) to gear (23).


4) Turn over PTO case and install gear assembly (33). 5) Press fit bearing spacer (34) and bearing inner race (35). ★ Drop approx. 6 cc of engine oil (SAE10W-CD or SAE30-CD) on the bearing, and rotate it 10 times.

2) Using push tool 4 , press fit bearing inner race (20) to shaft. 3) Fit O-ring and install shaft assembly (18). 6) Install plate (17).

2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt:

110.35 ± 12.25Nm {11.25 ± 1.25kgm} 4. Scavenging pump gear 1) Install gear (16).

2 Spline portion: Grease (G2-LI)

D375A-5

30-51 2 "

"


2) nstall snap ring (15) from bottom of PTO case. 5. Power train pump gear assembly 1) Fit O-ring and install cover (14).


3) Using push tool 6 , press fit gear assembly (10) to cover (9). 2 Gear spline portion: Grease (G2-LI)

4) Fit O-ring, then raise cover assembly (8) and install to case. ★ If the cover assembly is stiff and it is difficult to insert into the case, tap uniformly around the circumference with a plastic hammer to install. ★ Drop approx. 6 cc of engine oil (SAE10W-CD or SAE30-CD) on the bearing, and rotate it 10 times.

2) Using push tool 5 , install bearings (11) and (12) to gear (13).

6. Hydraulic, PPC pump gear assembly 1) Using push tool 5 , press fit bearings (5) and (6) to gear (7).

30-52 "

2 "

D375A-5



2) Using push tool 6 , press fit gear assembly (3) to cover (4). ★ At one end, the end face of the bearing is level with the end face of the gear. Install so that this end is facing the cover. 2 Gear spline portion:

7. Lubrication tube Sling PTO assembly, and install lubrication tube (1). ★ Install the 3 lubrication tubes on the opposite side also.

Grease (G2-LI) 3) Fit O-ring, then raise cover assembly (2) and install to case. ★ If the cover assembly is stiff and it is difficult to insert into the case, tap uniformly around the circumference with a plastic hammer to install. ★ Drop approx. 6 cc of engine oil (SAE10W-CD or SAE30-CD) on the bearing, and rotate it 10 times.

D375A-5

30-53 2 "

"

DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY SPECIAL TOOLS Symbol

C

Part No.

Part name


790-413-1010

Bracket

#

1

790-501-5000

Repair stand (100V)

#

1

DISASSEMBLY •

Preparatory work Set torque converter assembly (56) to tool C.

1. Torque converter valve assembly Remove torque converter valve assembly (1). 2. Draining oil Remove 2 drain plugs (2) and drain oil from pump case. ★ After draining the oil, tighten the plugs. 3. Lock-up clutch, drive case assembly 1) Leaving 2 mounting bolts (3), remove other mounting bolts, then set with input shaft at top and remove remaining 2 mounting bolts.

2) Using eyebolts 1 , remove lock-up clutch and drive case assembly (4). 3) Disassemble lock-up clutch and drive case assembly as follows. i) Remove 2 seal rings (5). ii) Using forcing screws 2 , remove input shaft (6).

30-54 "

2 "

D375A-5


iii) Remove snap ring (7), then remove plate (8). iv) Set with clutch housing at bottom, then using forcing screws 3 , remove turbine (9).


vii) Remove seal ring (13) from piston. viii) Remove seal ring (14) from housing.

ix) Using push tool 5 , remove bearing (15) from housing. v)

Set with clutch housing at top, then using eyebolts 4 , remove housing and piston assembly (10). ★ When the assembly is removed, the piston will come out, so support it by hand when removing. vi) Remove piston (11) from housing (12).

x)

D375A-5

Remove 2 discs (16) and 1 plate (17) from drive case (18). ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

30-55 2 "

"


4. Stator assembly 1) Remove snap ring (19), then remove stator assembly (20). 2) Disassemble stator assembly as follows. i) Remove snap ring (21), then remove race (22) from stator (23).

ii)


5. Pump assembly 1) Remove snap ring (25). 2) Remove pump assembly (26). 3) Disassemble pump assembly as follows. i) Remove retainer (27). ii) Remove bearing and guide assembly (28) from pump (29).

Remove snap ring (24) from stator (23). iii) Remove bearing outer race (30) from guide (31). 6. Stator clutch housing Set with stator clutch housing side at top, then remove stator clutch housing (32).

30-56 "

2 "

D375A-5


7. Spring Remove spring (33).


2) Remove seal ring (42) from piston. 3) Remove seal ring (43) from case.

8. Spring, discs, plate Remove spring (34), 2 discs (35), and 1 plate (36). ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

9. Pin Remove pin (37).

12. Stator shaft assembly 1) Tap stator shaft assembly (44) with plastic hammer to remove from case (45). 2) Disassemble stator shaft assembly as follows. i) Using push tool 6 , remove shaft assembly (45) from stator shaft assembly.

10. Inner gear Remove snap ring (38), then remove inner gear (39). 11. Piston 1) Remove piston (40) from case (41).

D375A-5

30-57 2 "

"



ii)

Remove snap ring (47), then remove bearing inner race (48), bushing (49), and seal shaft (50) from shaft. iii) Remove seal ring (51), then remove plate (54). iv) Remove snap ring (35), then remove plate (54).

v)

ASSEMBLY ★ Wash all parts clean and check that there are no scratches or dirt before assembling. ★ Check that the snap ring is fitted securely in the groove. •

Preparatory work Set case (41) to tool C.

Using push tool 7 , remove bearing (55). 1. Stator shaft assembly 1) Assemble stator shaft assembly as follows. i) Using push tool, press fit bearing (55) to stator shaft (52). ii) Install plate (54) and secure with snap ring (53). iii) Install seal ring (51). ★ After installing the seal ring, coat with grease (G2-LI) and fit securely to shaft.

30-58 "

2 "

D375A-5


iv) Install seal ring (50) to shaft. ★ After installing the seal ring, coat with grease (G2-LI) and fit securely to the shaft. v) Using push tool 9 , press fit bushing (49). ★ Be careful not to deform the bushing when press fitting.

vi) Using push tool 0, press fit bearing inner race (48). vii) Install snap ring (47) and secure bearing inner race.


2) Tap stator shaft (52) with plastic hammer to press fit bearing portion to case. 3) Set shaft (46) to stator shaft, then using push tool, press fit bearing portion. 4) Turn over case, and tighten mounting bolts of shaft from case end. 2 Outer circumference of seal ring: Grease (G2-LI) 3 Mounting bolt: 66.15 ± 7.35Nm {6.75 ± 0.75kgm}

2. Piston 1) Install seal ring (43) to case.

2 Outer circumference of seal ring: Grease (G2-LI)

★ The seal ring must be installed facing in the correct direction. Assemble as shown in the diagram. 2) Install seal ring (42) to piston. 2 Outer circumference of seal ring: Grease (G2-LI)

D375A-5

30-59 2 "

"


★ The seal ring must be installed facing in the correct direction. Assemble as shown in the diagram.


7. Stator clutch housing Install stator clutch housing (32). ★ Check that the spring is fitted securely in the piston and housing holes. 2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt:

110.35 ± 12.25Nm {11.25 ± 1.25kgm}

3) Install piston (40) to case (41).

2 Mating surface of seal ring: Grease (G2-LI)

8. Pump assembly 1) Assemble pump assembly as follows. i) Using push tool, press fit bearing outer race (30) to guide (31). ★ Drop approx.6 cc of engine oil (SAE10WCD or SAE30-CD) on the bearing, and rotate it 10 times.

3. Inner gear Install inner gear (39), and secure with snap ring (38).

4. Pin Install pin (37). 5. Plate, discs, spring Install 1 plate (36), 2 discs (35), and spring (34). 6. Spring Install spring (33).

30-60 "

2 "

D375A-5


ii)

Set bearing and guide assembly (28) to pump (29), then tap with plastic hammer to press fit bearing portion. iii) Install retainer (27).


9. Stator assembly 1) Assemble stator assembly as follows. i) Install snap ring (24) to stator (23).

2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt: 66.15 ± 7.35Nm {6.75 ± 0.75kgm} 2) Install pump assembly (26). ★ When installing the pump, be careful not to damage the seal ring assembled to the shaft. 3) Install snap ring (25). ii)

Assemble race (22) in stator (23), then secure with snap ring (21). 2) Install stator assembly (20) to stator shaft, then secure with snap ring (19).

D375A-5

30-61 2 "

"


10. Lock-up clutch, drive case assembly 1) Assemble lock-up clutch and drive case assembly as follows. i) Set turbine (9) to block A , then set drive case (18) to turbine.

ii)


iii) Install seal ring (14) to housing.

2 Outer circumference of seal Grease (G2-LI) ring:

iv) Install seal ring (13) to piston.

2 Outer circumference of seal Grease (G2-LI) ring:

Install 2 discs (16) and 1 plate (17). v)

Install piston (11) to housing (12).

2 Mating surface of seal ring: Grease (G2-LI)

★ When installing, be careful not to damage the seal ring. vi) Using eyebolts 4 , install housing and piston assembly (10). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 110.35 ± 12.25Nm {11.25 ± 1.25kgm}

30-62 "

2 "

D375A-5


vii) Using push tool, press fit bearing (15). viii) Install plate (8) and secure with snap ring (7). ix) Install input shaft (6). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt:

x)

277.0 ± 31.9Nm {28.5 ± 3.25kgm} Install 2 seal rings (5).


3) Tighten mounting bolts (3). ★ Check that drain plug (2) has been tightened. 3 Mounting bolt: 53.9 ± 4.9Nm {5.5 ± 0.5kgm}

3 Drain plug: 11.25 ± 1.45Nm {1.15 ± 0.15kgm} 11. Torque converter valve assembly Install torque converter valve assembly (1). ★ Tighten the mounting bolts equally to prevent unbalanced tightening. 3 Mounting bolt: 49.0 ± 4.9Nm {5.0 ± 0.5kgm}

2) Using eyebolts 1 , install lock-up clutch and drive case assembly (4). ★ Align the tturbine oil groove (marked a) and drain plug (2) when installing.

D375A-5

30-63 2 "

"

DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY SPECIAL TOOLS Symbol

1

Part No.

Bracket

#

1

750-501-5000

Repair stand (100V)

#

1

Push tool

#

1

Ring assembly

#

1

791-615-1200

D

4

NeNew/ReQ'ty Sketch cessity model

790-415-1011

2 791-615-1130

3

Part name

791-615-1210

Ring

1

135-A90-1150

Bolt

1

01580-01008

Nut

1

01641-51032

Washer

2

791-615-1101

Ring assembly

791-615-1111

Ring

1

135-A90-1150

Bolt

1

01580-01008

Nut

1

01641-51032

Washer

2

5 799-301-1600

Oil leak tester

#

#

2. Control valve assembly 1) Remove tube. 2) Remove cover (2), then remove sleeve inside. 3) Remove cover (3).

1

1

4) Remove control valve assembly (4) as one unit with seat. ★ Remove the 4 mounting bolts marked *. Do not remove any other bolts.

DISASSEMBLY 1. Preparatory work Set transmission assembly (1) to tool D1.

3. Lubrication valve assembly Remove lubrication valve assembly (5).

30-64 "

2 "

D375A-5


4. Front case 1) Set input shaft end at top and stand transmission assembly. 2) Using eyebolts, remove front case (6).

5. Input shaft, No. 1 carrier assembly 1) Remove 17 tie bolts (7). 2) Using forcing screws 1 , disconnect input shaft and No. 1 carrier assembly (8). ★ Tighten the forcing screws uniformly, and be careful not to twist the input shaft and No. 1 carrier assembly.

D375A-5


3) Using eyebolts 2 , lift off input shaft and No. 1 carrier assembly (8). 4) Turn over input shaft and No. 1 carrier assembly, and remove seal ring (9).

5) Disassemble input shaft and No. 1 carrier assembly as follows. i) Remove snap ring (10), then remove No. 2 sun gear (11). ii) Remove spacer and bearing assembly (12).

30-65 2 "

"


iii) Using push tool, remove ball bearings (13) and (14) from spacer (15).


vi) Using eyebolts 3 , sling housing and No. 1 carrier assembly (18) and set on block. ★ Put the tip of the input shaft in contact with the ground and separate the housing and No. 1 carrier assembly from the block by approx. 20 mm. vii) Remove snap ring (19).

iv) Remove No. 1 sun gear (16). v) Remove spacer (17).

viii) Tap housing with plastic hammer and drop housing and No. 1 carrier assembly (20) on block to remove input shaft assembly (21). ix) Using press, remove ball bearing (22) from input shaft (23).

30-66 "

2 "

D375A-5


x)

Remove snap ring (24) from housing and No. 1 carrier assembly (20). xi) Set housing and No. 1 carrier assembly on block, then using push tool 4 , remove housing (25) from No. 1 carrier assembly (26).

xii) Remove snap ring (27) from housing (25). xiii) Turn over housing and set on block, then remove seal ring (146).

D375A-5


xiv) Using push tool 5 , remove ball bearing (28) from housing. xv) Remove spacer (29) from No. 1 carrier assembly (26).

xvi) Turn over No. 1 carrier assembly, remove snap ring (30), then remove collar (31). xvii) Turn over No. 1 carrier assembly, pull out shaft (33) partially from carrier (32), remove ball (34), then remove shaft (33). ★ Keep the ball in a safe place and be careful not to lose it.

30-67 2 "

"


xviii) Remove gear (34) and thrust washer (35) from carrier. xix) Remove needle bearing (36) from gear (34).

6. No. 1 discs, plates, springs 1) Remove 12 springs (37). 2) Remove 6 discs (38), 6 springs (40), and 5 plates (39) in turn, then remove guide plate. ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

30-68 "

2 "


7. No. 1 clutch ring gear Remove No. 1 clutch ring gear (41).

8. No. 1 housing 1) Using eyebolts 5 , remove No. 1 housing assembly (42).

D375A-5


2) Disassemble No. 1 housing assembly as follows. i) Remove piston (43) from housing (44).


9. No. 2 discs, plates, springs 1) Remove 12 springs (47). 2) Remove 6 discs (48), 5 plates (49), and 6 springs (50) in turn. ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

ii) Remove seal ring (45) from piston (43). iii) Remove seal ring (46) from housing (44).

3) Remove 17 sleeves (51).

D375A-5

30-69 2 "

"


4) Remove seal ring (52) from No. 2 and No. 3 carrier. 5) Remove 6 torque pins (53). 6) Remove 12 guide pins (54).

2) Disassemble No. 1 ring gear and No. 2, No. 3 carrier assembly as follows. i) Remove seal rings (57) and (58). ii) Remove ring (59).

10. No. 1 ring gear, No. 2, No. 3 carrier assembly 1) Using eyebolts 6 , lift off No. 1 ring gear and No. 2, No. 3 carrier assembly (55).

iii) Pull out shaft (61) partially from carrier (60), remove ball (62), then remove shaft (61). ★ Keep the ball in a safe place and be careful not to lose it.

30-70 "


2 "

D375A-5


iv) Remove gear (63) and thrust washer (64) from carrier. v) Remove needle bearing (65) from gear (63). ★ No. 2, No. 3 carrier (60) and No. 1 ring gear (66) are secured by an internal embedded ring, so they cannot be disassembled.

11. No. 2 ring gear Remove No. 2 ring gear (67).

D375A-5


12. No. 2, No. 3 housing assembly 1) Using eyebolts 7 , remove No. 2 and No. 3 housing assemblies (68) as one unit with top and bottom pistons. ★ Tie the bottom piston with wire to prevent it from falling out.

2) Disassemble No. 2 and No. 3 housing assemblies as follows. i) Remove pistons (69) and (70) from housing (71).

30-71 2 "

"


ii) Remove seal ring (72) from piston (69). iii) Remove seal ring (73) from piston (70).


13. No. 3 discs, plates, springs 1) Remove guide plate, then remove 12 springs (76). 2) Remove 4 discs (77), 4 springs (79), and 3 plates (78) in turn. ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

iv) Remove seal rings (74) and (75) from housing (71).

14. No. 3, No. 4 clutch plate Using eyebolts 8 , remove plate (80).

30-72 "

2 "

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15. No. 4 discs, plates, springs 1) Remove 3 discs (81), 3 springs (83), and 2 plates (82) in turn, then remove guide plate (147). ★ Store the discs and plates in a flat place to prevent them from becoming deformed. 2) Remove 6 torque pins (84).


2) Disassemble No. 4 housing assembly as follows. i) Remove piston (86) from housing (87).

ii) Remove seal ring (88) from piston (86). iii) Remove seal ring (89) from housing (87).

16. No. 4 housing assembly 1) Using eyebolts 9 , remove housing assembly (85) as one unit with piston.

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30-73 2 "

"


17. No. 3 ring gear, No. 4 carrier, No. 5 clutch assembly 1) Rotate tool D1, and set transmission facing sideways. 2) Remove plate (90). 3) Remove snap ring (91), then remove plate (92).

4) Remove snap ring (93), then remove spacer (94).

30-74 "

2 "


5) Set No. 4 carrier end at top and stand transmission assembly. 6) Using eyebolts 0 , sling No. 3 ring gear and No. 4 carrier, No. 5 clutch assembly (95), then tap bottom part of output shaft with a copper hammer and remove.

7) Disassemble No. 3 ring gear and No. 4 carrier, No. 5 clutch assembly as follows. i) Remove 2 seal rings (56) from housing. ii) Remove seal ring (118) from input shaft.

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iii) Remove snap ring (96), then remove No. 3 sun gear (97). iv) Remove collar and bearing assembly (98).

v)


vi) Using eyebolts A , remove No. 3 ring gear and No. 4 carrier assembly (101) as one unit with No. 4 sun gear. vii) Remove No. 4 sun gear (102) from No. 3 ring gear and No. 4 carrier assembly (101).

Using push tool, remove ball bearing (99) from collar (100). viii) Turn over No. 3 ring gear and No. 4 carrier assembly and remove hub (103). ix) Remove seal rings (104) and (105) from hub (103).

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30-75 2 "

"


x)

Remove snap ring (106), then remove collar (107) from No. 3 ring gear and No. 4 carrier assembly (101). xi) Remove seal ring (108) from collar (107).

xii) Pull out shaft (110) partially from carrier (109), remove ball (111), then remove shaft (110). ★ Keep the ball in a safe place and be careful not to lose it. xiii) Remove gear (112) and thrust washer (113) from carrier. xiv) Remove needle bearing (114) from gear (112).

30-76 "

2 "


xv) Turn over carrier (109) and remove snap ring (115). xvi) Turn over carrier, then using push tool, remove ball bearing (116). ★ No. 3 ring gear (117) and No. 4 carrier (109) are secured by an internal embedded ring, so they cannot be disassembled.

xvii) Set output end of output shaft at top, and put output shaft and housing assembly (118) on top of block. xviii) Using forcing screws, disconnect input shaft and housing assembly (118), then use eyebolts B to remove. ★ Tighten the forcing screws uniformly and disconnect the output shaft and housing.

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xix) Remove 6 discs (119), 6 springs (121), and 5 plates (120) from housing (122) in turn. ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

xx) Set output shaft and housing assembly to press, then using push tool C , remove housing assembly (123) from output shaft assembly (124). ★ To prevent the housing assembly from falling out, set block D under the housing assembly.

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xxi) Set housing assembly (123) to press, then using tool D2, tighten spring, and remove snap ring (125). ★ Operate the press slowly and push up the springs uniformly. xxii) Remove retainer (126) and spring (127) from housing (128).

xxiii) Remove piston (129) from housing, then remove seal ring (130) from piston (129).

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"


xxiv)Remove seal ring (131) from housing (128). xxv) Remove snap ring (132) from housing. xxvi)Using push tool, remove ball bearing (133) from housing.


18. Rear case assembly 1) Remove collar (138) from rear case (139).

2) Remove seal ring (140) from collar (138).

xxvii) Remove snap ring (134), then remove needle bearing (135) from input shaft (124). xxviii)Turn over output shaft, remove snap ring (136), then remove roller bearing (137) from output shaft.

3) Turn over rear case, remove snap ring (141), then remove ball bearing (142).

30-78 "

2 "

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ASSEMBLY ★ Wash all parts clean, dry them (especially the oil holes), check that there are no scratches or dirt, then coat the sliding parts with engine oil before assembling. ★ Coat each spline portion with grease (G2-LI).


2) Turn over rear case (139) and install to collar (138). ★ Be careful not to get the seal ring caught.

1. Preparatory work Set rear case (139) to tool D1.

3. Output shaft assembly 1) Using push tool, press fit needle bearing (135) to output shaft (124), then secure with snap ring (134).

2. Rear case assembly 1) Install seal ring (149) to collar (138). ★ Install the seal ring in the direction shown in the diagram below.

2) Using push tool, press fit ball bearing (142) to output shaft.

2 Seal ring: Grease (G2-LI)

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30-79 2 "

"


3) Install spacer (94) and secure with snap ring (93). 4) Install plate (90).


8) Install plate (92) and secure with snap ring (91).

2 Mounting bolt:

Thread tightener (LT-2)

3 Mounting bolt: 66.15 ± 7.35Nm {6.75 ± 0.75kgm} 5) Install seal ring (118). 2 Seal ring: Grease (G2-LI)

6) Turn over rear case (139) and set output shaft assembly (124) in position, then using push tool, press fit bearing portion. 7) Install snap ring (141).

30-80 "

2 "

4. No. 3 ring gear, No. 4 carrier, No. 5 clutch assembly 1) Assemble No. 3 ring gear, No. 4 carrier, and No. 5 clutch assembly as follows. • When No. 3 ring gear, No. 4 carrier is supplied as an individual part. Using tool D3, compress ring (143), then set No. 3 ring gear (117) on top of No. 4 carrier (109), and tap No. 3 ring gear (117) with a plastic hammer to assemble. ★ Check that the ring is fitted securely in the groove.

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i)

Using push tool, press fit ball bearing (116) to carrier (109), and secure with snap ring (115).

ii) Turn over carrier. iii) Assemble needle bearing (114) to gear (112), then fit thrust washers (113) to both ends and set carrier in position. iv) Fit ball (111) and install shaft (110) to carrier. ★ Check that the gear rotates smoothly.


v)

Install seal ring (108) to collar (107). 2 Seal ring: Grease (G2-LI)

vi) Align collar (107) with dowel pin, then install No. 3 ring gear and No. 4 carrier assembly (101) and secure with snap ring (106). ★ Knock in the dowel pin portion with a plastic hammer until there is no clearance at the mating surface.

vii) Install seal rings (105) and (104) to hub (103). 2 Seal ring: Grease (G2-LI)

viii) Install hub (103) to No. 3 ring gear and No. 4 carrier assembly (101). ★ Be careful not to get the seal ring caught.

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30-81 2 "

"



ix) Using eyebolts E , install housing (122) to No. 3 ring gear and No. 4 carrier assembly.

xi) Using push tool, press fit ball bearing (133) to housing (128), and secure with snap ring (132).

x)

xii) Install seal ring (131) to housing. ★ Install the seal ring in the direction shown in the diagram below.

Install 6 discs (119), 6 springs (121), and 5 plates (120) in turn.

2 Seal ring:

Grease (G2-LI)

30-82 "

2 "

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xiii) Install seal ring (130) to piston (129). ★ Install the seal ring in the direction shown in the diagram below. 2 Seal ring: Grease (G2-LI)

xiv) Install piston (129) to housing (128). ★ Be careful not to get the seal ring caught.


xvii) Using eyebolts F , install housing assembly (123). 2 Mounting bolt:

Thread tightener (LT-2)

3 Mounting bolt: 176.4 ± 19.6Nm {18 ± 2kgm} xviii) Install 2 seal rings (56) to housing.


xv) Set spring (127) and retainer (126) to housing. ★ Set the 3 springs as shown in the diagram below. xvi) Set housing assembly (123) to press, and using tool D2, compress spring, then install snap ring (125). ★ Spring installed load: 2,175N {222kg}

D375A-5

2) Turn over rear case (139), and No. 3 ring gear, No. 4 carrier, and No. 5 clutch assembly (95). 3) Using eyebolts 0 , set No. 3 ring gear, No. 4 carrier assembly, and No. 5 clutch assembly (95) to rear case and output shaft. ★ Be careful not to get the seal ring caught.

30-83 2 "

"


4) Using push tool G , press fit bearing portion of No. 3 ring gear, No. 4 carrier, and No. 5 clutch assembly (95) to output shaft.

5. No. 4 sun gear Install No. 4 sun gear (102).

30-84 "

2 "


6. No. 3 sun gear 1) Using push tool, press fit ball bearing (99) to collar (100).

2) Install collar and bearing assembly (98). ★ Install with the flanged side of the collar at the top. 3) Install No. 3 sun gear (97) and secure with snap ring (96).

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7. No. 4 housing assembly 1) Install seal ring (89) to housing (87). ★ Install the seal ring in the direction shown in the diagram below. 2 Seal ring: Grease (G2-LI)


4) Using eyebolts 9 , align dowel pin and install No. 4 housing assembly (85). ★ Knock in the dowel pin portion with a plastic hammer until there is no clearance at the mating surface.

2) Install seal ring (88) to piston (86). ★ Install the seal ring in the direction shown in the diagram below. 2 Seal ring: Grease (G2-LI)

8. No. 4 discs, plates, springs 1) Install 6 torque pins (84). ★ Length of torque pin: 162mm 2) Fit guide plate (147), and install 3 discs (81), 3 springs (83), and 2 plates (82) in turn. 3) Install piston (86) to housing (87). ★ Be careful not to get the seal ring caught.

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30-85 2 "

"


9. No. 3, No. 4 clutch plate Using eyebolts 8 , align plate (80) with dowel pin and install. ★ Knock in the dowel pin portion with a plastic hammer until there is no clearance at the mating surface.

10. No. 3 discs, plates, springs 1) Install 4 discs (77), 3 springs (79), and 3 plates (78) in turn. 2) Install 12 guide pins (54). ★ Length of guide pin: 360mm 3) Fit 12 springs (76) and install guide plate. ★ Free length of spring: 97mm


11. No. 1 ring gear, No. 3 housing assembly 1) Install seal rings (74) and (75) to housing (71). ★ Install the seal ring in the direction shown in the diagram below. 2 Seal ring: Grease (G2-LI)



30-86 "

2 "

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4) Install pistons (70) and (69) to housing (71). ★ Be careful not to get the seal ring caught. ★ Tie piston (70) with thin wire to prevent it from falling out when the housing is raised.

5) Align dowel pin and install housing assembly (68). ★ Knock in the dowel pin portion with a plastic hammer until there is no clearance at the mating surface.

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12. No. 2 ring gear Install ring gear (67).

13. No. 1 ring gear, No. 2, No. 3 carrier assembly 1) Assemble No. 1 ring gear and No. 2, No. 3 carrier assembly as follows. • When No. 1 ring gear and No. 2, No. 3 carrier is supplied as an individual part. Using tool D4, compress ring (144), then set No. 1 ring gear (66) on top of No. 2, No. 3 carrier (60), and tap No. 1 ring gear (66) with a plastic hammer to assemble. ★ Check that the ring is fitted securely in the groove.

30-87 2 "

"


i)

Assemble needle bearing (65) to gear (63), then fit thrust washers (64) to both sides and set to carrier (60).


iii) Install ring (59) to carrier. ★ Check that the ring is fitted securely in the groove. iv) Install seal rings (58) and (57) to carrier. 2 Seal ring: Grease (G2-LI)

★ Center seal ring (58) with the carrier and secure in position with grease (G2-LI).

ii)

Fit ball (62) and install shaft (61) to carrier. ★ Check that the gear rotates smoothly. 2) Using eyebolts 6 , install No. 1 ring gear and No. 2, No. 3 carrier assembly (55). ★ Be careful not to get the seal ring caught.

30-88 "

2 "

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3) Using push tool H , press fit bearing portion of No. 1 ring gear and No. 2, No. 3 carrier assembly (55).


3) Install 17 sleeves (51).

★ Set the sleeve with the slit at the bottom and install it in the bolt hole marked q. 14. No. 2 discs, plates, springs 1) Install 6 torque pins (53). ★ Length of torque pin:199mm 2) Install seal ring (52) to No. 2, No. 3 carrier. 2 Seal ring: Grease (G2-LI)

4) Install 12 springs (47). ★ Free length of spring: 70mm 5) Install 6 discs (48), 6 springs (50), and 5 plates (49) in turn. ★ Align the notches in the oil groover on the outside circumference of the discs.

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30-89 2 "

"


15. No. 1 housing assembly 1) Install seal ring (46) to housing (44). ★ Install the seal ring in the direction shown in the diagram below. 2 Seal ring: Grease (G2-LI)

2) Install seal ring (45) to piston (43). ★ Install the seal ring in the direction shown in the diagram below.


4) Using eyebolts 5 , align dowel pin and install housing (42). ★ Check that the spring is fitted securely in the hole in the housing. ★ Knock in the dowel pin portion with a plastic hammer until there is no clearance at the mating surface.


16. No. 1 clutch ring gear Install No. 1 clutch ring gear (41). 3) Install piston (43) to housing (44). ★ Be careful not to get the seal ring caught.

30-90 "

2 "

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17. No. 1 discs, plates, springs 1) Fit guide plate and install 12 springs (37). ★ Free length of spring: 66mm 2) Install 6 discs (38), 6 springs (40), and 5 plates (39) in turn.

18. Input shaft, No. 1 carrier assembly 1) Assemble input shaft and No. 1 carrier assembly as follows. i) Assemble needle bearing (36) to gear (34), then fit thrust washers (35) to both ends and set to carrier (32).

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ii)

Fit ball (34) and install shaft (33) to carrier. iii) Install collar (31) to carrier and secure with snap ring (30).

iv) Using push tool I , press fit ball bearing (28) to plate (25), then secure with snap ring (27).

30-91 2 "

"


v)

Turn over plate and install seal ring (146). ★ Align the center of the plate and use grease (G2-LI) to hold the seal ring in position. vi) Install spacer (29) to No. 1 carrier assembly (26).

viii) Using press, install ball bearing (22) to input shaft assembly (23). ix) Set housing and No. 1 carrier assembly (20) to block. x) Using eyebolts 3 , install input shaft assembly (18) to housing and No. 1 carrier assembly.

vii) Set plate (25) to No. 1 carrier (26), then using push tool J , press fit bearing portion and secure with snap ring (24).

xi) Install snap ring (19).

30-92 "


2 "

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xii) Set input shaft and No. 1 carrier assembly facing sideways, and install spacer (17). xiii) Install No. 1 sun gear (16).


xv) Install spacer and bearing assembly (12). ★ Install the small diameter bearing facing the No. 1 sun gear. xvi) Install No. 2 sun gear (11) and secure with snap ring (10).

xiv) Using push tool, press fit ball bearings (13) and (14) to spacer (15). xvii) Install seal ring (9) to No. 1 carrier. ★ Align with the center of the carrier and use grease (G2-LI) to hold the seal ring in position. 2) Turn over input shaft and No. 1 carrier assembly (8), then using eyebolts 2 , set to No. 1 housing. ★ Be careful not to get the seal ring caught. ★ Check that the tip of the input shaft does not interfere with the output shaft bearing, and lower slowly.

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30-93 2 "

"



3) Tighten 4 tie bolts (12) uniformly on diagonally opposite sides. 4) Tighten remaining bolts (12). 3 Tie bolt: 259.7 ± 14.7Nm {26.5 ± 1.5kgm}

19. Air check Using tool D5, check stroke of each clutch piston. ★ Air pressure: 490-588KPa {5-6kg/cm2} ★ Standard stroke of piston Piston Stroke (mm)

30-94 "

2 "

No. 1 No. 2 No. 3 No. 4 No. 5 6.7

7.0

5.6

4.7

7.0

20. Front case Fit O-ring and use eyebolts to install front case (6). ★ Check that the front case does not interfere and lower gradually.

21. Output shaft bearing 1) Set output shaft end at top and stand transmission assembly. 2) Using push tool, press fit roller bearing (137) to output shaft, and secure with snap ring (136). ★ Be careful not to hit or damage the bearing cage or roller. Use a push tool of a size that pushes only the outer race.

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22. Lubrication valve assembly Install lubrication valve assembly (5).


2) Install cover (3). ★ Remove plug (145) and check that the linkage pin on the inside of the cover is meshed with the yoke of the control valve spool. After checking, install plug (145). 3) Fit O-ring and install sleeve, then install cover (2). 4) Install tube.

23. Control valve assembly 1) Install control valve assembly (4) as one unit with seat. 3 Mounting bolt: 49.0 ± 4.9Nm {5.0 ± 0.5kgm}

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30-95 2 "

"


DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY DISASSEMBLY 1. Steering control valve assembly 1) Remove steering control valve assembly (1). 4

Steering control valve assembly: 25kg

iii) Using forcing screws 1 , remove sleeve (7). iv) Using puller 2 , pull out bearing inner race (8) from sleeve.

2) Remove seat (2). 2. Clutch, brake assembly 1) Using eyebolts, sling clutch and brake assembly, then remove mounting bolts, and remove clutch and brake assembly (3). ★ Remove the clutch and brake assembly on the opposite side in the same way. ★ When pulling out the clutch and brake assembly, be careful not to damage the discs and plates. v)

Turn over clutch and brake assembly, then using eyebolts 3 , disconnect clutch assembly (9) and brake assembly (10).

2) Disconnect clutch and brake assembly as follows. i) Remove plate (4), then remove collar (5). ii) Remove plate (6).

30-96 "

2 "

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3) Disassemble clutch assembly as follows. i) Remove stopper (11). ii) Remove discs (12), springs (13), and plates (14) in turn. ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

iii) Remove torque pin (15). iv) Using eyebolts, remove clutch hub (16). v) Using forcing screws 4 , remove plate (17).

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vi) Remove outer race (18) from plate. vii) Remove bearing and cage assembly (19).

viii) Remove plate (21) and nut (22) from cage (20). ix) Remove bearing and inner race (23), spacers (24) and (25), and bearing outer race (26).

30-97 2 "

"


x) xi) xii) xiii)

Using eyebolts, remove clutch cage (27). Remove seal ring (28) from clutch cage. Remove piston (29). Remove seal ring (30) from piston.

xiv) Remove bearing outer race (31) from clutch cage. xv) Remove belleville spring (32).

30-98 "

2 "


xvi) Using eyebolts 6 , remove brake hub (33). xvii) Remove bearing (34) from brake hub.

4) Disassemble brake assembly as follows. i) Remove stopper (35). ii) Remove discs (36), springs (37), and plates (38) in turn. ★ Store the discs and plates in a flat place to prevent them from becoming deformed.

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iii) Using eyebolts 7 , remove brake cage (39). iv) Remove bearing outer race (40) and seal ring (41) from brake cage.

v) Remove torque pin (42). vi) Remove piston (43). vii) Remove seal ring (44) from piston.


3. Shafts Remove left and right shafts (46). 4. Lubrication tube Remove lubrication tube (47).

5. Pipes 1) Remove left and right pipes (48). 2) Remove pipe (49).

viii) Remove belleville spring (45).

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30-99 2 "

"


6. Transfer, gear housing assembly 1) Fit guide bolt 8 , raise with eyebolts 9 , then remove housing assembly (50). 2) Disassemble transfer gear housing assembly as follows. i) Set transfer gear housing assembly on block. ii) Remove lubrication tube (51).

iii) Using push tool, remove bearing (53). iv) Remove drive gear (54).

30-100 "

2 "


Using puller 0 , remove both bearing inner races (55). vi) Remove lubrication tube (56). v)

vii) Using eyebolts A , remove pinion housing assembly (57). ★ Check the number and thickness of the shims, and keep in a safe place. viii) Using forcing screws, remove cover (58). ix) Remove holder (59).

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x)

Push pinion shaft with press, then pull out pinion gear (60). xi) Remove holder, then using puller B , remove bearing inner race (61) from pinion gear (60). xii) Remove cage and bearing assembly (62).

xiii) Remove collar (63) from gear (64). xiv) Using push tool C , remove bearing outer races (65) and (69), bearing inner races (66) and (67), and collar (68).

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xv) Remove bearing (70) from case. xvi) Remove bearing (71) from case.

7. Right cage 1) Turn over steering case so that right cage is at top. 2) Remove cage and bearing assembly (72). ★ Check the number and thickness of the shims, and keep in a safe place. 3) Remove bearing outer race from cage and bearing assembly. 4) Using eyebolts D , remove cage (73).

30-101 2 "

"


8. Bevel gear, shaft assembly 1) Using eyebolts, remove bevel gear and shaft assembly. 2) Disassemble bevel gear and shaft assembly as follows. i) Pull out reamer bolt, then remove bevel gear (75) from shaft (76).


2) Remove bearing outer race (80) from cage and bearing assembly.

ASSEMBLY

ii)

Using puller E , remove bearing inner races (77) and (78) from shaft.

9. Left cage 1) Turn over steering case so that left side of steering case is at top, then remove cage and bearing assembly (79). ★ Check the number and thickness of the shims, and keep in a safe place.

★ Wash all parts clean and check that there are no scratches or dirt before assembling. ★ Coat the rotating portion of the bearing with engine oil and rotate it several times. ★ Coat the sliding parts with engine oil, then assemble. ★ Check that the snap ring is fitted securely in the groove. 1. Left cage 1) Using push tool, press fit bearing outer race (80). 2) Assemble shims, and install cage and bearing assembly (79). ★ Standard shim thickness: 2mm 3 Cage, bearing assembly mounting bolt: 176.4 ± 19.6Nm {18 ± 2kgm}

30-102 "

2 "

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2. Bevel gear, shaft assembly 1) Assemble bevel gear and shaft assembly as follows. i) Using push tool F , press fit bearing inner races (78) and (77). ii) ii) Set bevel gear (75) to shaft (76) and tighten reamer bolt. 3 Reamer bolt: 274.4 ± 29.4Nm {28 ± 3kgm}


2) Assemble shim and install cage and bearing assembly (72). ★ Standard shim thickness: 2mm 3 Cage, bearing assembly mounting bolt: 176.4 ± 19.6Nm {18 ± 2kgm}

2) Using eyebolts, install bevel gear and shaft assembly (74).

3. Right cage 1) Using eyebolts D , install cage (73).

4. Adjusting preload Adjust shim thickness at cage to adjust rotating force of bevel gear shaft. ★ Rotate the bevel gear 2 - 3 times and put the push-pull scale in contact with the tip of the tooth. ★ Rotating force (with bevel gear not meshed): 4.9 - 5.88 N {0.5 - 0.6 kg} (Rotating torque: 23.52 - 28.42 Nm {2.4 - 2.9 kgm})

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30-103 2 "

"


5. Transfer, gear housing assembly 1) Assemble transfer and gear housing assembly as follows. i) Using push tool F , press fit transfer gear bearing (71) to case. ii) Using push tool G , press fit pinion bearing (70) to case.

iii) Using push tool, press fit bearing outer race (69) to cage. iv) Assemble bearing inner races (67) and (66) and collar (68). v) Using push tool, press fit bearing outer race (65).

30-104 "

2 "


vi) Using push tool H , press fit inner race (61) to pinion gear (60). vii) Install holder.

3 Holder mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm}

viii) Install gear (64) and collar (63) to pinion gear.

ix) Using push tool I , press fit cage and bearing assembly (62). x) Install holder (59).

3 Holder mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm}

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xi) Tighten mounting bolts of cover (58) in the order given in diagram and to tightening torque given below, and temporarily assemble cover (58). 3 Mounting bolt: 49Nm {5kgm}

xii) Check clearance A between cover and cage, and check that it is as given below. ★ Clearance A : 0.48 ± 0.27mm ★ Check that the variation around the whole circumference is less than 0.05 mm and that the bearing is completely press fitted and is not at an angle.

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xiii) Tighten mounting bolts of cover (58) in order given in diagram. 3 Mounting bolt:

66.15 ± 7.35Nm {6.75 ± 0.75kgm}

xiv) Assemble shims to pinion housing assembly (57), then use eyebolts A to install. ★ Standard shim thickness: 2mm xv) Install lubrication tube (56).

30-105 2 "

"


xvi) Using push tool J , press fit bearing inner race (55) to both sides of drive gear. xvii) Set drive gear (54) to case.


2) Fit guide bolt 8 to steering case, then using eyebolts 9 , install transfer and gear housing assembly (50). 3 Mounting bolt:

276.85 ± 31.85Nm {28.25 ± 3.25kgm} 6. Lubrication tube Install lubrication tube (47).

xviii) Using push tool K , press fit bearing (53). xix) Install bearing assembly (52) to case. xx) Install lubrication tube (51) as one unit with block.

7. Adjusting backlash, tooth contact 1) Adjusting backlash Testing Put the probe of dial gauge L in contact with the tooth face at the tip of the bevel gear, fix the bevel pinion in position, and read the scale when the bevel gear is moved backward and forward. ★ Standard value of backlash: 0.3-0.4mm ★ Measure at 3 places on diametrically opposite sides.

30-106 "

2 "

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Adjusting If the result of the measurement shows that the backlash is not correct, adjust as follows. i) When backlash is too small: Adjust the shim thickness at the bevel pinion end and move the bevel pinion in direction A. Or, adjust the shim thickness at the bearing cage of the bevel gear shaft and move the bevel gear in direction B.


2) Adjusting tooth contact Testing i)

Coat the tooth face of the bevel pinion lightly with red lead (minium), then rotate the bevel gear forward and backward and inspect the pattern left on the teeth.

ii)

ii)

When backlash is too large: Adjust the shim thickness at the bevel pinion end and move the bevel pinion in direction C. Or, adjust the shim thickness at the bearing cage of the bevel gear shaft and move the bevel gear in direction D. ★ When adjusting the shim thickness at the bearing cage of the bevel gear shaft, do not change the preload of the bearing. Adjust by moving shims from one side to the opposite side. Always keep the same total thickness of shims.

D375A-5

The standard value for the tooth contact is as follows (from small end of pinion) a) Width of tooth contact: 30 - 75 % b) Center of tooth contact: 25 - 50 % c) Position of tooth contact: 25 - 50 % ★ When preload is applied to the taper roller bearing supporting the bevel gear, it should be within the standard value with only the bevel pinion meshed and under no load. ★ The tooth contact should be at the center of the tooth height and there should be no strong contact at the root of the gear tooth. In addition, the contact should be more or less the same for forward and reverse.

30-107 2 "

"


Adjusting If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. i) When bevel pinion is too far from center line of bevel gear: Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. [Adjusting] Adjust the shim thickness at the bevel pinion end and move the bevel pinion in direction A. Or, adjust the shim thickness at the bearing cage of the bevel gear shaft and move the bevel gear in direction B. After adjusting, check the tooth contact pattern and backlash again.


ii)

When bevel pinion is too close to center of bevel gear: Contact is at the big end of the convex tooth face of the bevel gear and the small end of the concave tooth face. [Adjusting] Follow the same procedure as in Step i) but move the bevel pinion in direction A and the bevel gear in direction B. ★ When adjusting the movement in and out of the bevel gear, do not change the preload of the bearing. Adjust by moving shims from one side to the opposite side. Always keep the same total thickness of shims.

8. Pipes 1) Install pipe (49). 2) Install left and right pipes (48).

30-108 "

2 "

D375A-5


9. Clutch, brake assembly 1) Assemble brake assembly as follows. i) Install belleville spring (45). ★ Install the belleville springs back to back. ii) Install seal ring (44) to piston (43).

iii) Install piston (43). iv) Install torque pin (42). v) Using push tool, install seal ring (41) and bearing outer race (40) to brake cage.


vi) Using eyebolts 7 install brake cage (39). 3 Mounting bolt: 110.25 ± 12.25Nm {11.25 ± 1.25kgm}

vii) Install plates (38), springs (37), and discs (36). ★ Check that there is no dirt or damage to the mating faces of the discs and plates, and coat thinly with engine oil before assembling.

viii) Install stopper (35).

3 Mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm}

2) Assemble clutch assembly as follows. i) Using push tool, install bearing (34) to brake hub.

D375A-5

30-109 2 "

"


Using eyebolts 6 , install brake hub (33) to clutch housing. iii) Install belleville spring (32). ★ Install the belleville springs back to back. ii)


ix) Install bearing inner race (26), spacers (25) and (24), and bearing inner race (23) to cage (20). x) Tighten nut (22), and install plate (21). ★ Use a push tool, hold the cage in a press, and use a hook wrench to tighten the nut.

iv) Install outer race (31) to clutch cage. v) Install seal ring (30) to piston. vi) Install piston (29).

vii) Install seal ring (28) to clutch cage. viii) Using eyebolts, install clutch cage (27) to housing.

30-110 "

2 "

D375A-5


xi) Install bearing and cage assembly (19). xii) Using push tool, install outer race (18) to plate.


xvii) Install plates (14), springs (13), and discs (12) in turn. ★ Check that there is no dirt or damage to the mating faces of the discs and plates, and coat thinly with engine oil before assembling. xviii) Install stopper (11). 3 Mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm}

xiii) Install plate (17).


xiv) Set guide bolt to housing. xv) Using eyebolts, install clutch hub (16). ★ Check that the rotating force of the housing is less than 29.4N {3 kg} and that it rotates smoothly. xvi) Install torque pin (15).

D375A-5

3) Connect clutch and brake assembly as follows. i) Using eyebolts C , install brake assembly (10) to clutch assembly (9). ii) Using push tool D , press fit bearing inner race (8) to sleeve.

30-111 2 "

"


iii) Set sleeve (7) to clutch and brake assembly.


10. Shafts Install left and right shafts (46). ★ If the bevel gear is locked in position and it is difficult to insert the shaft, release the steering brake before inserting. Remove plug (81), then remove mounting bolt (82), and screw the mounting bolt into the plug hole to compress the clutch spring and release the brake.

iv) Install plate (6).


v) Fit collar (5) and install plate (4). 4) Using eyebolts, install clutch and brake assembly. 3 Mounting bolt: 276.85 ± 31.85Nm {28.25 ± 3.25kgm}

11. Steering control valve 1) Install seat (2). 2) Raise steering control valve assembly (1) and install. 3 Mounting bolt:

30-112 "

2 "

49.0 ± 4.9Nm {5.0 ± 0.5kgm}

D375A-5


REMOVAL AND INSTALLATION OF POWER TRAIN, LUBRICATION PUMP ASSEMBLY

REMOVAL AND INSTALLATION OF POWER TRAIN, LUBRICATION PUMP ASSEMBLY REMOVAL 1. Remove power train underguard (front). 4

Power train underguard (front): 280kg


3. Disconnect tube (2). 4. Lift off power train and lubrication pump assembly (3). 4

Power train, lubrication pump assembly: 50kg

INSTALLATION •


D375A-5

30-113 2 "

"


REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY

REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY REMOVAL 1. Remove power train underguard (front). 4

Power train underguard (front): 280kg

2. Disconnect inlet tube (1). ★ The oil in the piping will leak out, so use a container to catch it. 3. Disconnect outlet tube (2). 4. Remove scavenging pump assembly (3).

INSTALLATION •


•

Refilling with oil (power train case) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-114 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY


REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY 5. Remove 3 bolts of final drive, and install tool J1.

SPECIAL TOOLS Symbol J

Part No.

1 790-337-1001

Part name


Lifting tool

#

6. Sling final drive assembly (5), then remove mounting bolts and lift off. q2 4

1

Final drive assembly: 2,300kg

REMOVAL 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Raise chassis with jack or ripper, then set stand 1 under frame. 3. Remove covers (1) and (2).

INSTALLATION •


q1

4. Remove cover (3), then using eyebolts, pull out q1 drive shaft (4). ★ If the shaft does not come out, push up the shoe grouser from the ground surface with a jack and move the sprocket backwards or forwards to adjust to a position where the shaft can be removed, then pull the shaft out. ★ Pull the shaft out to a point where it contacts the sprocket.

★ If the shaft does not go in, push up the shoe grouser from the ground surface with a jack and move the sprocket backwards or forwards to adjust to a position where the shaft meshes, then assemble the shaft.

q2

2 Final drive assembly mounting bolt: Thread tightener (LT-2) 3 Final drive assembly mounting bolt: 1,720 ± 190Nm {175 ± 20kgm}

•

Refilling with oil (final drive case) Add oil through oil filler to the specified level.

5

D375A-5

¬ (SAE 30CD) Final drive case: 65¬

30-115 2 "

"

DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY SPECIAL TOOLS Symbol

Part No.

Ne- Q'ty New/Re- Sketch model cessity "

1


"

1

790-101-1102

Pump

"

1

791-580-3300

Installer

"

1

3 790-101-2102


"

1

Pump

"

1

Installer

"

1

Remover

"

1


"

1

790-101-1102

Pump

"

1

791-580-3500

Installer

"

1

6 790-101-2102


"

1

790-101-1102

Pump

"

1

790-431-1230

Remover & installer

"

1

790-101-2102


"

1

790-101-1102

Pump

"

1

8 790-431-1250

Guide

"

1

2 790-101-2102

790-101-1102 4 790-431-1071 791-580-3400 5 790-101-2102

7

30-116 !

Part name Remover

791-580-3200

J

DISASSEMBLY

2 ! 4

1. Draining oil Remove drain plug and drain oil from final drive case. 6

Final drive case: Approx.61¬ ¬

2. Sprocket 1) Set final drive assembly to block (height: approx. 50 mm). 2) Remove sprocket (1).

N

3. Cover Using eyebolts 1 , remove cover (2).

D375A-5


4. Hub 1) Remove plate (3). 2) Using eyebolts 2 , lift off hub (4).


2) Using tool J2, disconnect sprocket hub assembly (6) and bearing (7). 3) Using eyebolts 3 , remove sprocket hub assembly (6).

5. Sprocket hub assembly 1) Remove holder (5).

4) Remove bearing inner race (8) from sprocket hub assembly.

D375A-5

30-117 2 "

"


5) Turn over sprocket hub assembly, and remove floating seal cover (9) and bearing outer races (10) and (11). 6) Remove floating seal (12) from floating seal cover. ★ Be careful not to damage the floating seal and keep it in a safe place.

6. Wear guard Lift off wear guard (13).


2) Disassemble cover assembly as follows. i) Remove floating seal cover (15). ii) Remove floating seal (16) from floating seal cover. ★ Be careful not to damage the floating seal and keep it in a safe place.

iii) Remove spacer (17) and bearing inner race (18).

7. Cover assembly 1) Using eyebolts 4 , lift off cover assembly (14).

30-118 "

2 "

D375A-5


iv) Remove plate, then remove ring gear (19). 8. Carrier assembly 1) Using eyebolts 5 , remove carrier assembly (20).


iv) Remove planetary gear (23), bearing inner races (24A) and (24B), and spacer (24C).

v)

Remove bearing outer race (24D).

2) Disassemble carrier assembly as follows. i) Set carrier assembly to block (approx. 100mm). ii) Remove holder (21). iii) Using tool J7, remove planetary gear shaft (22).

9. Sun gear 1) Remove plate (25), button (26), and sun gear (27).

D375A-5

30-119 2 "

"


10. Hub, shaft assembly 1) Remove plate (28).


3) Disassemble hub assembly as follows. i) Remove gear (32) from hub (33). ii) Remove hub (33) from boss (34). iii) Using puller, remove bearing outer race (35) from boss (34).

2) Using tool J5, pull out hub assembly (29) and bearing inner race (30) from shaft assembly (31). 4) Using eyebolts 6 , pull out shaft assembly (31) from case. 5) Disassemble shaft assembly as follows. i) Remove collar (36). ii) Remove bearing inner race (37) and collar (38).

30-120 "

2 "

D375A-5


11. Cage assembly 1) Using eyebolts 7 , remove cage assembly (39). 2) Remove shims (40). ★ Check the number and thickness of the shims, and keep in a safe place.

3) Disassemble cage assembly as follows. i) Using puller 8 , remove bearing outer race (41). ii) Remove oil seals (42) and (43).

D375A-5


12. Gear assembly 1) Remove gear assembly (44). 2) Using puller 9 , remove bearing inner races (45) and (46) from gear.

13. Outer race, oil seals 1) Using puller 0 , remove bearing outer race (48). 2) Remove oil seals (49) and (50) from case.

30-121 2 "

"


ASSEMBLY ★ Wash all parts clean, check that there are no dents or dirt, then coat the sliding parts with engine oil before assembling.


2) Using push tool C , press fit bearing outer race (48).

1. Oil seals, bearing outer race 1) Using push tools A and B , install oil seals (50) and (49). ★ Install the bottom seal with the side receiving the pressure at the bottom and the top seal with the side receiving the pressure at the top. 2 Lip of oil seal: Grease (G2-LI)

2 Press-fitting surface of oil seal: Gasket sealant (LG-1) ★ Coat the inside surface of the case thinly with gasket sealant and wipe off any sealant that is squeezed out.

30-122 "

2 "

2. Gear assembly 1) Using push tool D , press fit bearing inner races (46) and (45) to gear. 2) Set tool J8 to case, and install gear assembly (44). ★ Leave tool J8 in position. (Remove it after installing the cage.)

D375A-5



3. Cage assembly 1) Assemble cage assembly as follows. i) Using push tools A and B , install oil seals (43) and (42). ★ Install the bottom seal with the side receiving the pressure at the bottom and the top seal with the side receiving the pressure at the top.

ii)

Using push tool E , press fit bearing outer race (41).

2 Lip of oil seal:

Grease (G2-LI)

2 Press-fitting surface of oil seal: Gasket sealant (LG-1) ★ Coat the inside surface of the case thinly with gasket sealant and wipe off any sealant that is squeezed out. 2) Using eyebolts 7 , set cage assembly (39) to case, then tighten portions C and D uniformly with mounting bolts. 3 Mounting bolt: 14.7Nm {1.5kgm}

D375A-5

30-123 2 "

"



3) In this condition, use thickness gauge F as shown in the diagram below and measure clearances a and b between cage A and case B. 4) Use table to set thickness c of shim to insert. 5) Assemble shims selected in Step 4), then tighten 4 cage mounting bolts.

From

Less than

1.6

1.8

1.8

2.0

227.3 ± 80.85Nm {23.25 ± 8.25kgm}

2.0

★ Rotate the gear and tighten uniformly, then remove tool J8.

3 Mounting bolt:

30-124 "

a + b [mm]

2 "

No. of shims to use t = 0.1

t = 0.5

Total shim thickness t = 1.0 c [mm] 1

1.0

1

1

1.1

2.2

2

1

1.2

2.2

2.4

3

1

1.3

2.4

2.6

4

1

1.4

2.6

2.8

1

1

1.5

2.8

3.0

1

1

1

1.6

3.0

3.2

2

1

1

1.7

3.2

3.4

3

1

1

1.8

3.4

3.6

4

1

1

1.9

3.6

3.8

2

2.0

3.8

4.0

1

2

2.1

4.0

4.2

2

2

2.3

4.2

4.4

3

2

2.3

4.4

4.6

4

2

2.4

4.6

4.8

1

2

2.5

4.8

5.0

1

1

2

2.6

5.0

5.2

2

1

2

2.7

5.2

5.4

3

1

2

2.8

5.4

5.6

4

1

2

2.9

5.6

5.8

5

1

2

3.0

D375A-5


4. Hub, shaft assembly 1) Assemble shaft assembly as follows. i) Install collar (38). ii) Using push tool (17), press fit bearing inner race (37). iii) Install collar (38).


ii) Set boss (34) to hub (33). 4) Set shaft assembly (31) and hub assembly (29) in position, then using tool J6, press fit bearing portion (30).

5) Tighten mounting bolts of hub assembly (29). 2) Using eyebolts 6 , install shaft assembly (31) to case. 3) Assemble hub assembly as follows. i) Using push tool, press fit bearing outer race (35) to boss (34).

3 Mounting bolt:

276.85 ± 31.85Nm {28.25 ± 3.25kgm}

6) Install plate (28).

2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt: 548.8 ± 58.8Nm {56 ± 6kgm} 7) Install gear (32).

3 Mounting bolt: 539 ± 49Nm {55 ± 5kgm}

D375A-5

30-125 2 "

"


5. Sun gear 1) Install sun gear (27) to hub assembly. 2) Install button (26) and plate (25).

i)

Install ring and spacer to planetary gear, then using push tool H , press fit top and bottom bearing outer races (24D).

6. Carrier assembly 1) Assemble carrier assembly as follows. ★ The bearing for the planetary gear consists of a set, so match the distinguishing marks on the inner race, outer race, and spacer when assembling. q1.Distinguishing mark for bearing q2.Distinguishing mark for bearing spacer

ii)

Assemble spacer (24C) and bearing inner races (24B) and (24A) to planetary gear (23), and set to carrier.

30-126 "


2 "

D375A-5


iii) Using tool J7, press fit planetary gear shaft (22). ★ Align the bearing and spacer hole, then gradually press fit the shaft. iv) Install holder (21).


Using tool J3, press fit bearing inner race (18). iii) Install spacer (17). ii)

3 Mounting bolt: 548.8 ± 58.8Nm {56 ± 6kgm}

★ After tightening the bolts, check that the gear rotates smoothly.

2) Using eyebolts 5 , install carrier assembly (20).

iv) Using tool J4, press fit floating seal (16) to floating seal cover. ★ Remove all oil and grease from the O-ring and O-ring contact surface, and dry before installing. ★ After installing the floating seal, check that the angle of the seal is less than 1 mm.

7. Cover assembly 1) Assemble cover assembly as follows. i) Fit ring gear (19), and install plate. ★ Install the plate so that the chamfered side is at the top.

D375A-5

30-127 2 "

"


v)

Install floating seal cover (15). ★ Fit a cork plug in the forcing tap.


2) Using eyebolts 4 , raise cover assembly (14) and install. ★ Coat the mating faces with Three Bond 1216. 8. Wear guard Raise wear guard (13) and install.

★ Install the floating seal cover with the notch facing down as shown in the diagram below. 9. Sprocket hub assembly 1) Using tool J4, install floating seal (12) to floating seal cover. ★ Remove all oil and grease from the Oring and O-ring contact surface, and dry before installing. ★ After installing the floating seal, check that the angle of the seal is less than 1 mm.

30-128 "

2 "

D375A-5


2) Using push tool, press fit bearing outer races (11) and (10). 3) Install floating seal cover (9).


5) Using eyebolts 3 , sling sprocket hub assembly (6) and set to cover. ★ Check that there is no dirt on the sliding surface of the floating seal, then coat thinly with engine oil.

4) Set bearing (8) to sprocket hub assembly. 6) Using tool J3, press fit bearing portion (7). ★ Rotate the sprocket hub assembly while press fitting.

D375A-5

30-129 2 "

"


7) Install holder (5).

2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt:


11. Cover Using eyebolts 1 , install cover (2).

276.85 ± 31.85Nm {28.25 ± 3.25kgm}

12. Sprocket Install sprocket (1).

2 Mounting bolt: Anti-friction compound (LM-P)

10. Hub 1) Using eyebolts 2 , lift off hub (4). 2) Install plate (3).

3 Mounting bolt: 1,813 ± 98Nm {185 ± 10kgm} 13. Refilling with oil Tighten drain plug and add engine oil through oil filler to the specified level.

5 Final drive case: Approx. 61¬ ¬ ★ Carry out the final check of the oil level after installing the final drive assembly to the chassis, and check that the oil is at the specified level.

30-130 !

2 ! 4

D375A-5


REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY

REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY REMOVAL


1. Expand the track shoe assembly. For details, see EXPANDING TRACK SHOE ASSEMBLY.


2. Raise the machine body with a jack or the ripper and set stands 1 under the frame to float the rear part of the machine body. 3. Set hydraulic jack 2 under the center of the equalizer bar to float the front part of the machine body. 4. Sling the track frame assembly temporarily.

8. Apply a pad to pin (6) from rear and drive out the pin with a hammer. ★ If the equalizer bar hole and track frame hole are not aligned, the pin cannot be removed easily. Adjust the hanging height of the track frame properly.

5. Loosen front bolt (1) and rear bolt (2).

9. Remove the mounting bolts and cover (7) from the track frame.

D375A-5

30-131 2 "

"

REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY


10. Remove cover (8). ★ For the right track frame, disconnect the 4 hoses for the blade tilt cylinder from the cover. 11. Remove seal (9) and washer (10) together. ★ Perform this procedure for only the right track frame. 12. Remove washer (11) and spacer (12).

INSTALLATION •

2 Inside surface of bushing : Grease (G2-LI) ★ Before installing the pin, adjust the height of the track frame and align the center of the equalizer bar hole and track frame hole. ★ Set the pin with the grease hole facing the outside of the machine. ★ Fit pin (4) and bushing (3), install cover (2), then install the cover and cushion. ★ After removing the grease from the press fitting surface of the seal, coat with gasket sealant (LG6). ★ Be careful not to install with the seal displaced in the direction of twisting. ★ Be careful not to install the track frame with seal (14) displaced in the direction of twisting. •

13. Lift off track frame assembly (13). ★ Receive the oil flowing out of the pivot case with an oil pan, etc. 6

4

30-132 "

2 "


Refilling with oil (pivot case) Add oil through oil filler to the specified level.

5

Pivot case : 18 ¬ (SAE30)

Pivot case: 18 ¬ Track frame: 7,260 kg

D375A-5

REMOVAL AND INSTALLATION OF IDLER ASSEMBLY


REMOVAL AND INSTALLATION OF IDLER ASSEMBLY REMOVAL

INSTALLATION

1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY ¤ To prevent danger, never stand in front of the idler yoke assembly.

•

2. Remove scraper (1). ★ Remove the inside scraper also. 3. Remove cover (2). ★ Remove the inside cover also.

Carry out installation in the reverse order to removal. ★ For both the left and right idler assemblies, install with the oil filler plug facing the left side of the machine. ★ Tighten the idler cap mounting bolts in the following order. Tightening order: 1) 2 bolts at a 2) 2 bolts at b 3) 2 bolts at a 4) Tighten all bolts to specified torque. 2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt :

1641.5 ± 171.5 Nm {167.5 ± 17.5 kgm} ★ After tightening the idler cap mounting bolts, check that clearance c between the bottom of the idler cap and the yoke is 0. 4. Sling idler assembly and remove idler cap (3). ★ For both the left and right idler assemblies, there is a ball assembled to the left idler cap, so keep it in a safe place and be careful not to lose it. 5. Lift off idler assembly (4). 4

D375A-5

Idler assembly : 478 kg

30-133 2 "

"

DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY SPECIAL TOOLS Symbol

Part No.

4. Turn over idler assembly (1). Part name


791T-630-2210

Plate

#

1

792-530-1630

Stud

#

2

790-101-2510

Block

#

1

790-101-2570

Washer

#

2

Nut

#

2

Washer

#

2

790-101-2102


#

1

790-101-1102

1 01580-01613 01643-31645 L

Pump

#

1

2 791-515-1520

Installer

#

1

3 791-685-8310

Push tool

#

1

4 791-601-1000

Oil pump

"

5. Remove mounting bolts, then using eyebolts 3 , remove shaft (5) as one unit with retainer. 6. Using puller 4 , remove seal guides (2) and (6), and plate (8).

1

DISASSEMBLY 1. Remove oil filler plug and drain oil. 6

Idler: 0.95 - 1.05 ¬

7. Remove seal guides (2) and (6) from retainers (3) and (7).

2. Set idler assembly (1) on blocks 1 . 3. Remove mounting bolts, then using forcing screws 2 , remove seal guide (2) as one unit with retainer (3) and plate (4).

30-134 "

2 "

D375A-5


8. Remove floating seal (9) from seal guides (2) and (6). ★ Be careful not to damage the floating seal and keep it in a safe place. 9. Remove floating seal (10) from seal guides (3) and (7). ★ Be careful not to damage the floating seal and keep it in a safe place.


ASSEMBLY ★ Wash all parts clean and check that there are no scratches or dirt before assembling. 1. Set bushing (11) and tool L1 to idler (12), and press fit bushing (11). ★ First, use a plastic hammer to center the bushing, then press fit it with a puller. ★ Press fit the bushing so that press-fitting dimension a from the end face of the idler to the top face of the bushing is the dimension below. • Press-fitting dimension a: 17 ± 0.5 mm

10. Remove bushing (11) from idler (12).

2. Using tool L2, install floating seal (10) to retainers (3) and (6). 3. Fit O-ring and install retainer (3) and plate (4) to idler. ★ Check that the plate rotates smoothly by hand.

D375A-5

30-135 2 "

"


4. Using eyebolts 3 , set idler (12) to shaft (5). ★ Set block (approx. 140 mm) under the idler. 5. Turn over idler assembly. ★ Tie the shaft with wire to prevent it from falling out.


8. Set seal guide (2) to shaft, then using tool L3, press fit seal guide (2). ★ Press-fitting force of seal guide: 43 - 71 kN {4.4 - 7.2 ton})

6. Fit O-ring and install retainer (7) and plate (8) to idler.

7. Using tool L2, install floating seal (8) to seal guides (2) and (6).

30-136 "

2 "

★ Press fit the seal guide so that press-fitting dimension b from the end face of the shaft to the top face of the seal guide is the dimension below. • Press-fitting dimension b: 102 ± 0.2 mm ★ Turn over the idler assembly and repeat the procedure above to press fit seal guide (6) on the opposite side.

D375A-5



9. Using tool L4, charge with specified amount of oil, then tighten oil filler plug. 6

Idler: 0.95 - 1.05 ¬

3 Oil filler plug: 206 ± 49 Nm {21 ± 5 kgm}

D375A-5

30-137 2 "

"



SKETCH OF SPECIAL TOOL Note: We will not be liable for any result caused by a special tool made according to this drawing. L1 Plate

30-138 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY


REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY SPECIAL TOOLS Symbol M

1

Part No.

Part name


791-730-1110

Bolt

#

4

01580-12722

Nut

#

4

6. Remove covers (4). ★ Remove both the inside and outside covers.

REMOVAL 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. ¤ To prevent danger, never stand in front of the idler yoke assembly. 2. Drain oil from recoil cylinder chamber using oil pump. 6

Recoil cylinder chamber : Approx. 50 ¬

3. Using eyebolt 1 , remove cover (1). 4

Cover : 40 kg

4. Remove cover (2). 5. Lift off trunnion (3). 4

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7. Using tool M1, remove pins (5). ★ Remove both the inside and outside pins.

Trunnion : 75 kg

8. Lift off idler and recoil spring assembly (6). ★ Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at the track frame end. 4

Idler, recoil spring assembly : 2,180 kg

30-139 2 "

"



9. Disconnect recoil cylinder assembly (8) from idler yoke assembly (7) as follows. 1) Pit idler yoke assembly (7) in contact with ground, then raise recoil cylinder assembly (8). ★ When doing this, check that there is no damage to the weld of recoil cylinder assembly (7). ★ Wrap cloth around the chrome plated bushing to protect it.

2) Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides. ¤ To prevent danger, never stand in front of the idler yoke assembly. ¤ The recoil spring inside the recoil cylinder is applying a pushing force of approx. 500 kN (approx. 51 tons) on the idler yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke is 8 – 12 mm.

30-140 "

2 "

3) When the bolts are loosened, the torque will suddenly drop. Check that the installed load of the recoil spring is not applying any pushing force on the mounting bolts, then remove all bolts. ★ If the torque increases (the installed load of the recoil spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows. ¤ If the torque does not drop during steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolts (10), or nut (11) at the tip of the shaft has fallen off, so there is danger that the idler yoke assembly may fly off to the front. For this reason, disassemble as follows. ¤ When disconnecting the idler yoke assembly and recoil cylinder assembly, do not stand in front of the idler yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed.

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i)

Prepare the following parts. • Bolt 1 (×6) : 791-730-1110 • Nut 2 (×6) : 01580-12722 • Washer 3 (×6) : 01643-32780 (use again)

Remove 6 bolts marked q, then install bolts 1 , nuts 2 , and washers 3 . ★ Check that dimension L is less than 30 mm. ★ Screw in bolts 1 until they contact the bottom of the yoke thread. iii) Remove remaining 12 bolts (those not marked q). iv) Hold bolts 1 with a wrench to prevent them from turning, and loosen 2 nuts 2 simultaneously on diagonally opposite sides. ★ Be careful not to let the road bear on only one bolt. ii)


v)

When recoil spring is fully extended and torque has completely dropped in loosening direction of nut 2 , remove bolt 1 . ★ When clearance b is approx. 230 mm, the spring is fully extended.

10. Remove ring (12).

11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15).

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30-141 2 "

"



12. Disassemble piston assembly (15) as follows. 1) Remove wear ring (16) from piston. 2) Remove snap ring (17), then remove packing (18).

13. Remove recoil spring assembly (19). 4

Recoil spring assembly : 550 kg

INSTALLATION •

Carry out installation in the reverse order to removal. 3 Cover mounting bolt: 277 ± 32 Nm {28.25 ± 3.25 kgm}

★ Before installing the pin, align the center of the hole in the track frame and the dowel pin at the recoil cylinder end with a bar. ★ Using a lever block, keep horizontal and be careful not to damage the oil seal at the track frame end when installing. ★ Adjust the clearance. For details, see TESTING AND ADJUSTING, Adjusting clearance of idler. ★ If the recoil spring set bolt is broken or the nut at the tip of the shaft has fallen off, see ASSEMBLY OF RECOIL SPRING ASSEMBLY when assembling. 2 Idler yoke assembly mounting bolt : Thread tightener (LT-2)

3 Idler yoke assembly mounting bolt : 1641.5 ± 171.5 Nm {167.5 ± 17.5 kgm} ★ To prevent air from accumulating inside the cylinder, fill with grease as follows. 1) Fill the inside of the cylinder with approx. 1.3 ¬ of grease. 2) Set with the cylinder drain hole facing up, then loosen the lubricator. 3) Push the piston until it contacts the stopper. This will push out the air and any extra grease. 14. Remove holder (20) from recoil spring assembly.

30-142 "

2 "

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DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY SPECIAL TOOLS Symbol

Part No.


Compressor

#

1

Cylinder (686kN {70ton})

#

1

790-101-1102

Pump

#

1

791-635-3160

Extension

#

1

791-685-8501

M

Part name

2 790-101-1600

2. Apply hydraulic pressure slowly to compress spring, then remove lock plate (2) and remove nut (3). 3. Release hydraulic pressure gradually and relieve tension of spring.

DISASSEMBLY 1. Remove recoil spring assembly (1) with tool M2. ¤ The spring is under high installed load, so be careful to set it correctly. ★ Installed load of spring: Approx. 500 kN {approx. 51 ton} 4. Remove rear pilot (5), spacer (6), bolt (7), and front pilot (8) from spring (4).

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30-143 2 "

"


ASSEMBLY 1. Assemble front pilot (8), bolt (7), spacer (6), and rear pilot (5) to spring (4), then set in tool M2.

DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

2. Apply hydraulic pressure slowly to compress spring, and set so that installed length of spring is specified value. ★ Installed length a of spring : 1,230.5 mm ★ Installed load of spring : Approx. 500 kN {approx. 51 ton}

¤ The spring is under high installed load, so be careful to set all parts correctly. 3. Fit nut (3), then install lock plate (2). ★ Make clearance b of 0 - 10 mm between the nut and lock plate to prevent the nut from protruding from the end face of bolt (7). ★ Bring lock plate (2) and bolt (7) into tight contact, and secure in position. 2 Lock plate mounting bolt : Thread tightener (LT-2)

4. Gradually release hydraulic pressure to completely relieve tension of spring, then remove recoil spring assembly (1) from tool M2.

30-144 "

2 "

D375A-5

REMOVAL AND INSTALLATION TRACK ROLLER ASSEMBLY


REMOVAL AND INSTALLATION TRACK ROLLER ASSEMBLY SPECIAL TOOLS Symbol

Part No.

L


Lifting tool

#

1

790-401-1761

Adapter

#

1

790-401-1540

Shackle

#

2

790-401-1770

T-Bolt

#

2

791T-630-2320

Plate

#

3

Bolt

#

6

Washer

#

6

790-401-1700 12

Part name

13 01011-62700 01673-32780

N

4. Set steel plate 1 on track shoe, and operate blade and ripper to lower chassis to a point where track roller assembly contacts steel plate. ★ Run the engine at low idling and operate the blade and ripper slowly.

"

REMOVAL 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Install tool L13 and secure bogie assembly (1).

q1

3. Operate blade and ripper, and jack up chassis to a point where track roller assembly (2) comes up from track shoe.

5. Remove mounting bolts, and leave track roller assembly (2) on steel plate 1 . 6. Operate blade and ripper, and jack up chassis to a point where track roller assembly (2) separates from bogie.

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30-145 2 "

"



7. Using a crane and bar, pull out track roller assembly (2) from steel plate to outside of body. 4

Track roller assembly: 150 kg (single flange) 160 kg (double flange)

INSTALLATION •


q1

After removing tool L3, replace mounting bolts of cover (3) with normal parts. 3 Cover mounting bolt: 927 ± 103 Nm {94.5 ± 10.5 kgm}

★ Note that the installation location differs for the single flange track roller assembly and double flange track roller assembly. S: Single flange D: Double flange ★ Install the track roller assembly with the oil filler plug on the outside.

30-146 "

2 "

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★ After fitting the track shoe assembly temporarily, align the position of dowel pin (4). 3 Track roller assembly mounting bolt: 1,325 ± 145 Nm {135 ± 15 kgm}

•

When using assembly tool Set tool L12 to bottom of track roller assembly, then raise track roller assembly (2) and set to track frame.

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30-147 2 "

"




30-148 "

2 "

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DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

★ Press-fitting force of seal guide: 36 - 63 kN {3.7 - 6.4 ton}) ★ Press fit the seal guide so that press-fitting dimension b from the end face of the shaft to the top face of the seal guide is the dimension below. ★ Press-fitting dimension b: 77 ± 0.2 mm

7. Using tool L11, charge with specified amount of oil, then tighten oil filler plug. 5

Track roller: 1.4 - 1.5 ¬ (SAE140)

3 Oil filler plug: 206 ± 49 Nm {21 ± 5 kgm}

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30-151 2 "

"


DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY


L10 Push tool

30-152 "

2 "

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REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY

3. Operate the blade and ripper to raise the machine body until the track roller is floated above the track link. ¤ Set a block between the track roller and track link so that the machine body will not lower. 4. Set block 1 out of the track shoe according to the height of the track link. 5. Set steel plate 2 on the track shoe and block 1 . 6. Operate the blade and ripper to lower the machine body until the track roller of the bogie assembly (1) comes in contact with steel plate 2 . ★ Operate the blade and ripper slowly with the engine at low idling speed.

3) Remove floating seals (5) from the ends of rings (4) and (7). ★ Keep the floating seals so that they will not be damaged.

7. Remove cover (2). 4) Set tool L15. 5) Pull out spacer (6) and rings (7) and (8). ★ Pulling out force: 205.8 - 382.2 kN {21 - 39 tons}

8. Remove the shaft and ring. 1) Set tool L14. 2) Push shaft (3) and ring (4) simultaneously to the opposite side. ★ Pushing force: 137.2 - 274.4 kN {14 - 28 tons}

30-154 "

2 "

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6) Remove spacer (6). 7) Remove spacer (9) and floating seal (10) between rings (7) and (8). ★ Keep the floating seals so that they will not be damaged. 8) Remove the shaft and rings from the bogie on the opposite side according to steps 1) 7) above.

INSTALLATION 1. Assemble the pin assembly. 1) Using tool L18, install floating seals (5) to rings (4) and (7) and install floating seal (10) to the opposite side of ring (7) and ring (8). ★ When installing the floating seals, thoroughly degrease the O-rings and the Oring contact surfaces of the mating parts. ★ Check that the slant of each floating seal is within 1mm.

9. Remove tool L13. 10. Place bogie assembly (1) on steel plate 2 . 11. Operate the blade and ripper to raise the machine body until the bogie assembly can be pulled out. ¤ Set a block between the track roller and track link so that the machine body will not lower. 12. Sling bogie assembly (1) and slide it out on steel plate 2 and remove it. 4

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2) 3) 4) 5) 6)

Press fit shaft (3) to ring (8). Install spacer (9). Press fit ring (7) to shaft (3). Install spacer (6). Press fit ring (4) to shaft (3).

2 Apply Anti-friction compound (LMP) to parts "a" (about 10 mm) of rings (8) and (4).

Bogie assembly: 720 kg

30-155 2 "

"



2. Apply lever block 3 between the guard of bogie assembly (1) and that of the bogie assembly on the opposite side and slide bogie assembly (1) on the steel plate to the mounting position.

2) Press fit pin assembly. ★ Insert the pin assembly with arrow "a" on its end face up (in the mounting state on the machine body). ★ Push in the pin assembly with cover (2). ★ Press fit the pin assembly to machined surface "b" of the bogie.

2 Apply Anti-friction compound (LMP) to the all outside surface of the pin. ★ Total press fitting force for pin assembly: 245 - 441 kN {25 - 45 tons}

3. Align the pin holes of the track frame and bogie and set guide tool L17.

5. Refilling with oil Using tool L19, supply the specified quantity of oil. ★ Oil supply pressure: 0.49 MPa {5 kg/cm2} 5

Pin assembly: 95 - 115 cc (GO-140)

4. Press fit the pin assembly. 1) Set tool L16 and cover (2).

30-156 "

2 "

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6. Press fit the pin assembly on the opposite side according to steps 3 - 4 above. 7. Tighten the mounting bolts of pin assembly covers (2). (Install 2 covers, outside and inside ones.) 3 Cover mounting bolt: 927 ± 103 Nm {94.5 ± 10.5 kgm}

8. Adjust the track shoe tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.

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30-157 2 "

"




L17 Guide

30-158 "

2 "

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DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY


ASSEMBLY 1. Assembly of pin assembly Assemble the pin assembly according to the procedure in Installation of bogie assembly. (Steps 3 - 5)

4. Refilling with oil Using tool L19, supply the specified quantity of oil. ★ Oil supply pressure: 0.49 MPa {5 kg/cm2} 5


2. Set inner bogie (4) to outer bogie (5). 3. Press fitting of pin assembly 1) Set tool L16 and cover (3). 2) Press fit the pin assembly. ★ Insert the pin assembly with arrow "a" on its end face up (in the mounting state on the machine body). ★ Push in the pin assembly with cover (3). ★ Press fit the pin assembly to machined surface "b" of the bogie and secure level difference "b" of 5 mm between the bogie and pin assembly. 2 Anti-friction compound (LM-P) to the all outside surface of the pin. ★ Total press fitting force for pin assembly: 245 - 441 kN {25 - 45 tons}

5. Press fit the pin assembly on the opposite side according to steps 3 - 4 above. ★ After press fitting the pin assembly, rock the smaller bogie. 6. Tighten the mounting bolts of pin assembly covers (3). (Install 2 covers, outside and inside ones.) 3 Cover mounting bolt: 824 - 1,030 Nm {84 - 105 kgm}

7. Track roller assembly Sling 2 track roller assemblies (2) and install them to bogie assembly (1). 2 Track roller mounting bolt: Thread tightener (LT-2)

3 Track roller mounting bolt: 1,180 - 1,470 Nm {120 - 150 kgm}

30-160 "

2 "

D375A-5


7. Using tool L20, sling and hold 1st bogie (5). 8. Remove cover (6).

9. Pull out the shaft and ring. 1) Set tool L14. 2) Push shaft (7) and ring (8) simultaneously to the opposite side. ★ Pushing force: 137.3 - 274.6 kN {14 - 28 tons} ★ When the ring is pushed out, it interferes with the idler. To prevent this, supply grease to the track tension adjuster in advance to push out the idler cushion assembly forward.

30-162 "

2 "

REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY

3) Remove floating seals (9) from the end faces of rings (8) and (12). ★ Keep the floating seals so that they will not be damaged.

4) Set tool L15.

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5) Pull out spacer (11) and rings (12) and (13). ★ Pulling out force: 205.8 - 382.2 kN {21 - 37 tons} 6) Remove spacer (11). 7) Remove spacer (14) and floating seal (10) between rings (12) and (13). ★ Keep the floating seals so that they will not be damaged.

INSTALLATION 1. Assemble the pin assembly. 1) Using tool L18, install floating seals (9) to rings (8) and (12) and install floating seal (10) to the opposite side of ring (12) and ring (13). ★ When installing the floating seals, thoroughly degrease the O-rings and the Oring contact surfaces of the mating parts. ★ Check that the slant of each floating seal is within 1mm.

10. Lower bogie (5) on the steel plate and pull it out. 4

Bogie assembly: 110 kg 2) 3) 4) 5) 6)

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Press fit shaft (7) to ring (13). Install spacer (14). Press fit ring (12) to shaft (7). Install spacer (11). Press fit ring (8) to shaft (7).

2 Apply Anti-friction compound (LM-P) to parts "a" (about 10 mm) of rings (13) and (8).

30-163 2 "

"



2. Place bogie assembly (5) on steel plate 1 and slide it to the center. 3. Using tool L20, set the bogie in position.

2) Press fit pin assembly . ★ Insert the pin assembly with arrow "a" on its end face up (in the mounting state on the machine body). ★ Push in the pin assembly with cover (6). ★ Press fit the pin assembly to machined surface "b" of the bogie and secure level difference "b" of 5 mm between the bogie and pin assembly. 2 Apply Anti-friction compound (LM-P) to the all outside surface of the pin. ★ Total press fitting force for pin assembly: 245 - 441 kN {25 - 45 tons}

4. Align the pin holes of the track frame and bogie and set guide tool L17.

6. Refilling with oil Using tool L19, supply the specified quantity of oil. ★ Oil supply pressure: 0.49 MPa {5 kg/cm2} 5. Press fit the pin assembly. 1) Set tool L16 and cover (6).

30-164 "

2 "

5


D375A-5



7. Press fit the pin assembly on the opposite side according to steps 5 - 6 above. 8. Install covers (6). (Install 2 covers, outside and inside ones.) 9. Install eyebolts to the pad mounting bolts (M12 x 2 pieces) of bogie (5) and pull up and hold the bogie.

13. Adjust the track shoe tension. For details, see testing and adjusting, TESTING AND ADJUSTING TRACK SHOE TENSION.

10. Using tool L21, insert the shaft in track roller assembly (4), then sling and set it on the track shoe, balancing it. 4

Track roller assembly: 150 kg

11. Lower the machine body slowly. When the clearance between bogie (5) and shaft (3) becomes about 20 mm, install cap (15) and secure it with bolt (2) temporarily. 12. Align the dowel pin hole and tighten bolt (2) securely. 2 Cap mounting bolt: Thread tightener (LT-2) 3 Cap mounting bolt: 1,180 - 1,470 Nm {120 - 150 kgm}

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30-165 2 "

"



SKETCH OF SPECIAL TOOL Note: We will not be liable for any result caused by a special tool made according to this drawing. L17 Guide

L21 Tube

30-166 !

2 ! 4

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L21 Plate

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30-166-1 4


EXPANDING AND ASSEMBLY TRACK SHOE INSTALLATION

EXPANDING AND ASSEMBLY TRACK SHOE INSTALLATION CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY ¤ Since it may be very dangerous to expand the track shoe assembly, check the following items in advance. ¤ Do not loosen the lubricator more than 1 turn. • Loosen lubricator (1) of the adjustment cylinder to discharge the grease and move the machine in reverse a little and check that the track shoe is loosened. ★ After the shoe is loosened, perform EXPANDING TRACK SHOE ASSEMBLY (NORMAL). • If the track shoe is not loosened by the above work, the track frame may have an internal trouble (damage of the recoil spring or recoil spring set bolt, fall of the shaft end nut, etc.) ★ If the track shoe is not loosened, perform EXPANDING TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE).

D375A-5

1. Sling the end of the master link and move the machine slowly in reverse to expand track shoe assembly (4). ★ Length of track shoe: Approx. 12.5 m

30-167 2 "

"



EXPANDING TRACK SHOE ASSEMBLY

EXPANDING TRACK SHOE ASSEMBLY

(When track frame has internal trouble). ★ If any abnormality is detected by CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY, perform the following procedure. ¤ If the track shoe is removed while the track frame has an internal trouble, it may spring back. Even if the track shoe is removed, the idler may jump out, and that can cause a serious result. Accordingly, expand the track shoe according to the following procedure.

(Normal) ★ If any abnormality is not detected by CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY, perform the following procedure.

1. Remove the work equipment. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY.

1. Set the master link in position. ★ Set the master link above the idler (a little after the idler center). ★ Set a block (1) and (2) between the front side of the idler and carrier roller so that the mating part of the master link will not open until the master bolt is pulled out.

2. Loosen lubricator (1) and move the machine forward and in reverse to discharge the grease. ¤ Do not loosen lubricator (1) more than 1 turn. ★ Check that the all grease has been discharged.

2. Loosen the track shoe. ¤ Do not loosen lubricator (1) more than 1 turn. ★ Loosen all of them by 1 - 2 turns first until they are turned lightly, then pull them out. Do not loosen and pull out the bolts 1 by 1. ★ If the bolts are turned forcibly before they become light, the threads of them and master link may be damaged.

30-168 "

2 "

D375A-5



3. Move the machine slowly forward against large block 1 or a wall (or the blade of another machine of the similar size of the machine to be repaired, if available) to press the track shoe on the idler side. When the recoil spring is distorted, stop and apply the brake. At this time, set the master link between the idler and front carrier roller. For safe work, apply a lever block between the carrier roller support and link. 4. Remove track shoe (5) and disconnect master link (6). 5. Move the machine slowly in reverse to expand track shoe assembly.

INSTALLATION OF TRACK SHOE ASSEMBLY •

Carry out installation in the reverse order to EXPANDING.

q1

★ Adjust the track shoe tension. For details, see testing and adjusting, TESTING AND ADJUSTING TRACK SHOE TENSION. ★ Tighten the all 4 bolts with fingers until the master link mating faces are fitted. ★ If the bolts are tightened forcibly before the master link mating faces are fitted, the threads of the bolts and master link may be damaged. q2

★ Tighten the shoe mounting bolts for the master link in the following order.

2 Shoe mounting bolt: Anti-seizure agent (Maruzen MOLYMAX No. 2 or equivalent) 3 Shoe mounting bolt: 1st time: 686 ± 68.6 Nm {70 ± 7 kgm} 2nd time: Retighten by 180°° ± 10°°

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30-169 2 !

!


WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE

WHOLE DISASSEMBLY ★ When disassembling the track shoe, see "Parts judgment guide, Undercarriage, Lubricated track" and "Parts judgment guide, Undercarriage, Reversing procedure for pin bushing". 1. Removal of shoe Sling the shoe assembly and set it with the shoe up on the floor and remove the shoe by using a shoe bolt impact wrench. ★ If a shoe bolt is not loosened after it is unscrewed by 1 turn (If its torque is not reduced to 0), loosen the other bolts first, and it will be removed smoothly. ★ If a shoe bolt is turned forcibly while its torque is not 0, it and link will adhere to each other and they will need to be repaired. ★ When moving the shoe assembly, take care not to damage the master link. ★ If it is obliged to cut a shoe nut with gas, keep the seal temperature below 80°C to prevent thermal deterioration of the seal and take measures to prevent the spatters from entering through the clearances among the links.

2) Operate the left cylinder to pull out the pin and bushing from the left link simultaneously. ★ Check the pulling out force of the pin and bushing which will be reversed and assembled again, then pull out them simultaneously. ★ The wedge link is broken with a bang. This sound does not indicate abnormality.

2. Disassembly of link 1) Set the link assembly on a link press and hit it with a hammer so that the bushing will be fitted to the jaw. ★ If the link tread, outside of the bushing, etc. are worn, adjust the height of the jaw or guide plate and align the pin and bushing with the disassembly jig so that the link hole will not be damaged during disassembly work. ★ If the pin and bushing are not aligned well, the link hole may be damaged and the pin and bushing may be broken during disassembly work. ★ Using tool R1, drive the small plug of the pin inward after the disassembly work so that the workplace will not become dirty.

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30-171 2 "

"


3) Return the left cylinder and operate the right cylinder to pull out the pin and bushing from the right link simultaneously.


2) Measure the outside diameter of the press fitting parts of the pin and bushing and the inside diameter of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the allowable fitting allowance is obtained. When using the pin, bushing, and link for a lubricated track, however, secure the standard fitting allowance between the pin and link. ★ If the allowable fitting allowance is not obtained, replace the parts with new one. ★ For the dimensional criteria, see MAINTENANCE STANDARD.

4) Return the right cylinder and take out the links, pins, bushings, and spacers on both sides and feed the next 1 set of the link assembly to the jaw. ★ If the bushing ends and sealing surfaces are damaged, oil will leak. Accordingly, handle them carefully. ★ Since the broken wedge link has sharp edges, take care not to cut your hands with them.

3. Inspection Check the parts for the following items to see if they can be used for a lubricated track or a grease-filled track, then examine them generally and determine to use them for a lubricated track or grease-filled track. ★ For judgment of reuse of the parts, see "Parts judgment guide, Undercarriage, Lubricated track". 1) Check the parts visually for damage. If a part seems to be damaged, check it by dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used again. Discard it.

30-172 "

2 "

D375A-5


★ Precautions for storage 1) Store the seal without removing it from the link so that the counterbore portion will not be rusted and take care not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing fitting parts, shoe mating surface, and master link mating surface of the link. 3) When storing, apply rust-preventive oil to the all surfaces of the pin, bushing, and spacer. Take care not to damage the ends of the bushing in particular.


2) When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the nodules sticking to the press fitting parts with the grinder, too. ★ If the ends are worn and sharpened, they may scuff the press fitting parts and cause oil leakage. 3) If the link, pin, bushing, and spacer are dirty, clean them. Remove the nodules sticking to the link and bushing with the grinder, too. ★ Since these parts rust easily, clean them just before assembling them. ★ Do not polish the bushing ends. If they are polished, oil may leak.

WHOLE ASSEMBLY ★ For the whole assembly of the track shoe, see "Parts judgment guide, Undercarriage, Reversing procedure for pin bushing".

1. WHEN RECYCLING FOR LUBRICATED TRACK 1. Preparation work 1) Cleaning seal assembly Remove the seal assembly from the link and divide it into the seal ling and load ring, then clean them. ★ Since the seal ring and load ring are deteriorated easily by the cleaning liquid (trichloroethylene etc.), clean them quickly. After cleaning them, wipe off the cleaning agent from them.

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30-173 2 "

"


4) If the large plug was pulled out, drive it in by using tool R3. In this case, clean the pin hole in advance by using tool R2. i) Insert the plug through the plug insertion window into the guide hole. ii) Push the bar with the hand until the plug stops. iii) Push the plug with the bar to press the guide against the pin. iv) Drive in the bar with a hammer. ★ Driving distance "a" from pin end: 11 ± 2 mm ★ If the chamfered part of the pin hole has been worn, chamfer it with a small-sized grinder (grindstone tip angle: 45°- 60°) so that the plug will not be damaged. ★ Coat the plug with GO90 and drive it with the small diameter end ahead.

30-174 "

2 "


5) Installation of seal assembly Clean the counterbore portion of the link carefully and push in the seal to the bottom by using tool R6. ★ If oil is sticking to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any oil. When inserting the seal in the counterbore portion, take care that oil not stick to the seal and counterbore portion.

D375A-5


6) Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. ★ For the standard dimensions, see DIMENSIONS TABLE OF FITTING JIG OF LINK. ★ If the pin end (part P) or link sides (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on both sides will be even.


7) Adjust the relief pressure of the link press so that the pressing force of the press will not exceed the standard value. ★ If the pressing force is too strong, the spacer will be pressed forcibly against the bushing. As a result, the spacer may be broken and it and bushing may be worn abnormally. ★ Pushing force of pin and bushing: 980 kN {170 tons} Pushing force = 1.8 x Average pressure (Adjust the relief pressure of the link press to set the pushing force.)

2. Assembly of link 1) Apply oil (GO90) to the mating surfaces of the pin and bushing with a clean brush and assemble them, then set them before the jaw of the link press. ★ When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).

D375A-5

30-175 2 "

"


2) Press fit the master links on both bushing sides to the bushing with the shoe fitting faces up. ★ At this time, use the master links on the pin side as supports. ★ Press fitting force for bushing: 196 - 343 kN {20 - 35 tons}

4) Turn over the master links and check that they are press fitted in parallel. 5) Measure the projections of the bushing on both sides with a depth gauge. ★ Adjust the press fitting jig of the link press so that the projections on both sides will be even.

3) Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. ★ Remove the all steel chips caused by press fitting of the bushing with compressed air.

6) Send the master links and set the next pin and bushing. ★ When reusing a pin, install it so that its side hole will be the link tread side similarly to a new one. If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of the side hole on the end face to prevent a mistake.

30-176 "


2 "

D375A-5


7) Apply gasket sealant (198-32-19890) to the pin fitting hole of the links to prevent oil from oozing out of the scuffed parts of the pin fitting parts.


9) Set the right jig on the receiving side and the left one on the pushing side and press fit the pin and bushing simultaneously. ★ If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, then star t press fitting again. ★ Press fitting force for pin and bushing: 392 - 686 kN {40 - 70 tons}

8) Set the right link and install the spacer to the pin. ★ Check that the seal surface and bushing end are free from dir t and apply oil (GO90) to them with a clean cloth or brush. ★ When installing the spacer, wipe it with a clean cloth. 10) Using the spacer for fine adjustment, press fit the pin and bushing until the pin end is fitted to the bottom of the receiving jig. ★ Adjust the depth of the receiving jig hole so that the projections of the pin on both sides will be even.

D375A-5

30-177 2 "

"


11) Set the left link and install the spacer to the pin. ★ Apply oil similarly to the right link.


13) Press fit until the link, spacer, and bushing are fitted together. ★ Actually, you cannot see from outside if the above parts are fitted. Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the hydraulic pressure to that level. For setting of the relief pressure, see PREPARATION WORK. ★ Check that adjacent 2 links can turn around each other.

12) Set the left jig on the receiving side and the right one on the pushing side and press fit the left link. ★ When press fitting, take care that both seals and spacers will not come off. ★ Press fitting force for link: 392 - 686 kN {40 - 70 tons} 14) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes and check that the result is within the standard range. ★ If the distance between the shoe bolt holes is longer than the standard range, disassemble and check for abnormality, then press fit again. ★ If the distance between the shoe bolt holes is shorter than the standard range and the shoe cannot be installed, the spacer or bushing end may be worn more than the allowable limit. In this case, disassemble and replace the parts.

30-178 "

2 "

D375A-5


15) Install the ring to jig R8.


18) Using jig R10, push in the ring. ★ Pushing force for ring: 294 - 372 kN {30 - 38 tons}

16) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove. ★ A sound is made when the ring is inserted in the pin groove.

19) After each link is assembled, bleed air from the pin by using tool R4 and check the sealing performance. ★ Keep the degree of vacuum inside the pin at 86.7 - 93.3 kPa {650 - 700 mmHg} for 5 seconds and check that the pressure does not change. If the pressure changes, disassemble and check the seal. If the seal is free from abnormality, assemble again.

17) Using jig R9, insert the ring in the pin groove on the opposite side similarly.

D375A-5

30-179 2 "

"


20) Using tool R4, supply oil (G090) until the oil supply pressure rises to 196.1 - 294.2 kPa {2 - 3 kg/cm2}.

★ In a cold or very cold district, supply Komatsu genuine oil (150-09-19270 or 19532-61990) having better low-temperature characteristics instead of G090. ★ If the oil pressure is heightened too much, it has bad effects on the seal. Take care. ★ Supply oil so that depth L of the hollow of the pin hole will be in the following range when the link is left with the small plug side up (when the link assembly is placed on its side) for 30 minutes. Dimension L: 40 - 70 mm

30-180 "

2 "


21) After supplying oil, drive in the small plug to the specified position, using tool R4. ★ Apply G090 around the small plug. ★ Drive in the plug to the following depth. Driving depth from end face: 7.5 ± 1 mm

22) Assemble the master link on the pin side at last. ★ Check that the master links on both sides are press fitted in parallel.

D375A-5


3. Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. 3 Shoe bolt (Regular link) Initial torque: 1,372 ± 137.2 Nm {140 ± 14 kgm} Retightening angle: 120°° ± 10°° 2 Shoe bolt: Anti-friction compound (LM-P)


2) When installing a double track, place the assembled double shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) on the links and check that shoe bolt (4) can be tightened easily until the mating faces of the links are fitted together, then connect the links with the master bolts. 2 Shoe bolt: Anti-friction compound (LM-P)

3 Shoe bolt (Master link) Initial torque: 686 ± 68.6 Nm {70 ± 7 kgm} Retightening angle: 180°° ± 10°° ★ Tighten the bolts in the order of 1 - 4 .

D375A-5

30-181 2 "

"


2. WHEN RECYCLING FOR GREASEFILLED TRACK 1. Preparation work 1) Cleaning seal assembly • Remove the seal assembly from the link and divide it into the seal ling and load ring, then clean them. ★ Since the seal ring and load ring are deteriorated easily by the cleaning liquid, clean them quickly. After cleaning them, wipe off the cleaning agent from them.


3) Drive in the large and small plugs by using tools R3 and R5. i) Insert each plug through the plug insertion window into the guide hole (Apply oil to the plug). ii) Push the bar with the hand until the plug stops. iii) Push the plug with the bar to press the guide against the pin. iv) Drive in the bar with a hammer. ★ Driving distance "a" from pin end: Small plug: 7.5 ± 1 mm Large plug: 11 ± 2 mm ★ If the plugs were not pulled out when the shoe was disassembled, reuse them as they are.

2) When reusing the pin, chamfer its end corners carefully with a grinder so that it will be press fitted smoothly.

30-182 "

2 "

D375A-5


4) If the outside of the pin, surfaces of the spacer, and ends and inside of the bushing are dirty, clean them. 5) Apply grease to the outside of the pin and surfaces of the spacer. 6) Installation of seal assembly • Clean the counterbore portion of the link carefully and push in the seal to the bottom by using tool R6. ★ If grease is sticking to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any oil.

7) Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. ★ For the standard dimensions, see DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS. ★ If the pin end (part P) or link sides (parts Q and R) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on both sides will be even.

D375A-5


2. Assembly of link 1) Apply lithium grease (G2-LI) to the mating surfaces of the pin and bushing and assemble them, then set them before the jaw of the link press. ★ When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).

2) Press fit the master links on both bushing sides to the bushing with the shoe fitting faces up. ★ At this time, use the master links on the pin side as supports. ★ Press fitting force for bushing: 196 - 343 kN {20 - 35 tons}

30-183 2 "

"


3) Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. ★ Remove the all steel chips caused by press fitting of the bushing with compressed air. 4) Turn over the master links and check that they are press fitted in parallel.

5) Measure the amount of protrusion of the left and right bushing with a depth gauge. ★ Adjust the press fitting jig of the link press so that the projections on both sides will be even.


★ If the outside of the pin is worn, install it so that the un-worn surface will be on the traction side. In this case, install the pin so that its side hole will be the link tread side, too.

7) Set both links and operate both pushing jigs to press fit the pin and bushing simultaneously. ★ If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, then star t press fitting again. ★ Pushing force of pin and bushing: 980 kN {100 tons} Pushing force ≈ 1.8 x Average pressure ★ (Adjust the relief pressure of the link press to set the pushing force.)

6) Send the master links and set the next pin and bushing. ★ When reusing a pin, install it so that its side hole will be the link tread side similarly to a new one. If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of the side hole on the end face to prevent a mistake.

30-184 "

2 "

D375A-5


8) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes. When the distance is in the standard range, stop press fitting.

9) Install the ring to jig R8.


11) Using jig R10, push in the ring. ★ Pushing force for ring: 294 - 372 kN {30 - 38 tons}

12) Assemble the master link on the pin side at last. ★ Check that the master links on both sides are press fitted in parallel. 3. Shoe (regular link portion) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. 2 Shoe bolt : Lubricant containing molybdenum disulfide (LM-P)

10) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove. Using jig R9, install the ring on the opposite side similarly. ★ A sound is made when the ring is inserted in the pin groove.

D375A-5

3 Shoe bolt (Regular link): 1,372 ± 137.2 Nm Initial torque: {140 ± 14 kgm} 120°° ± 10°° Retightening angle:

30-185 2 "

"



4. Assembly of 1/2 track Place the assembled 2 shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) on the links and check that shoe bolt (4) can be tightened easily until the mating faces of the links are fitted together, then connect the links with the master bolts. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P)

3 Shoe bolt (Master link) Initial torque: 686 ± 68.6 Nm {70 ± 7 kgm} Retightening angle: 180°° ± 10°° ★ Tighten the bolts in the order of 1 - 4 .

30-186 "

2 "

D375A-5


DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS

DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS

Unit: mm Dimensions of jig a

4.2

b

2.0

c

52.1

Precaution The link receiving faces of the jaw (1) must be vertical. Replaceable wear plate (2) type shown below is desirable.

D375A-5

30-187 2 "

"

DISASSEMBLY AND ASSEMBLY OF 1 LINK IN THE FIELD


DISASSEMBLY AND ASSEMBLY OF 1 LINK IN THE FIELD SPECIAL TOOLS Symbol

Part No.

Symbol

Part No.

Part name


791-646-7351

Push tool

#

1

21 • 791-680-5551

• Guide

1

2

791-660-7460

Pin Brush

#

1

22 • 791-680-9630

• Adapter

1

791-646-7900

Push tool (L burash)

23 • 791-632-1160

• Guide

1

24 195-32-61210

Bolt

2

791-701-3000

Seal checker

791-601-1000

Oil pump

5

791-932-1110

6

791-632-1021

#

1

#

2

Push tool (S burash)

#

1

Installer

#

1

1 791-632-1100

Remover and installer assembly

#

1

2 • 791-632-1130

• Adapter

1

3 • 790-434-1610

• Guide

1

4 • 01010-51440

• Bolt

2

5 • 791-685-9510

• Frame

1

6 • 791-685-9530

• Rod

1

7 • 791-685-9520

• Frame

1

8 • 791-685-9550

• Nut

3

9 • 04530-12030 7 10 • 791-685-9560

• Eye bolt

1

• Bolt

4

11 • 791-126-0150

• Adapter

1

12 • 791-685-9540

• Rod

1

13 • 791-632-1140

• Adapter

1

14 • 791-680-5520

• Guide

1

15 • 01010-51030

• Bolt

1

16 • 791-632-1150

• Pusher

1

17 • 791-685-9620

• Extention

1

18 • 791-632-1180

• Adapter

1

19 • 791-680-5543

• Adapter

1

20 • 791-632-1170

• Guide

1

4

30-188 "


1

3

R

Part name

2 "

Cylinder (1,470kN {150ton})

#

1

26 790-101-1102

Pump

#

1

27 790-101-4200

Cylinder (294kN {30ton})

#

1

28 791-680-1630

Spacer

#

1

R 7 25 790-101-4300

N

"

DISASSEMBLY 1. Install tool R7-2 to link (1) with tool R7-24 and install tool R7-3 with tool R7-4. ★ Use the shoe bolts for tool R7-24.

D375A-5



2. Assemble tools R7-25 and R7-5 - R7-11, then sling and set them on the shoe.

★ If the cylinder reaches the stroke end, connect tool R7-17 and repeat the work.

3. Insert tool R7-12 from the cylinder side and install it with 2 tools R7-8.

5. Set tools R7-27 and R7-28 to the center on the roller tread side of the link to be disassembled and connect tool R7-26. Apply hydraulic pressure to open the link by 5 - 6 mm and disconnect it.

4. Set tools R7-13 - R7-16 and connect them by tool R7-26. Apply hydraulic pressure and pull out pin (2). 6. Repeat steps 1 - 4 to pull out pin (3) on the opposite side.

D375A-5

30-189 2 "

"


7. Repeat step 5 to remove link (4).


2) Set tool R7-19 to the pin-side end of the link and press fit pin (7). ★ Set the pin with its side hole on the link tread side. ★ Press fitting force of pin: 206 - 323 kN {21 - 33 tons}

ASSEMBLY 1. Assemble the link sub-assembly according to the following procedure. 1) Set tool R7-18 to the bushing-side end of link (5) and press fit bushing (6). ★ Press fitting force of bushing: 196 - 294 kN {20 - 35 tons}

2. Set link sub-assembly (8) to the link to be connected.

3. Set link (9) on the opposite side and support it with tool R7-20.

30-190 "

2 "

D375A-5


4. Similarly to the disassembly procedure, set tools R7-25, R7-5 - R7-12, and R7-17 to the link. 5. Use R7-19 and R7-21 to press fit the pin. Use tools R7-22, R7-18, and R7-21 to press fit the bushing. Press fit the pin and bushing alternately. ★ Press fit the pin first. After the bushing is engaged with the link, remove tool R7-20 installed in step 3, then press fit the bushing. ★ Press fitting force of pin: 206 - 323 kN {21 - 33 tons} ★ Press fitting force of bushing: 196 - 294 kN {20 - 30 tons}


7. Set link (11) to be connected to link (10) and connect them with tool R7-23, then remove tools R727 and R7-28.

8. Similarly to the disassembly procedure, set tools R7-2 - R7-12 and press fit pin (12) to the link. 2 Pin fitting hole of link: Gasket sealant (198-32-19890)

6. Similarly to the disassembly procedure, push open link (10) to be connected by using tools R727 and R7-28.

D375A-5

★ Set the pin with its side hole on the link tread side. ★ Press fitting force of pin: 412 - 646 kN {42 - 66 tons} ★ If the cylinder reaches the stroke end, insert tools R7-17 and R7-14 - R7-16 and repeat the work.

30-191 2 "

"


DISASSEMBLY ★ For the method of using tool R7, see DISASSEMBLY OF 1 LINK IN THE FIELD. 1. Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see EXPANDING TRACK SHOE ASSEMBLY. 2. Disassembly of shoe Disconnect the all master links and divide the shoes into 4 parts. 3. Removal of master link • Master pin type 1) Cutting of regular link with gas Cut the parts marked with gas and remove the parts marked . • Necessary special tool: Gas cutting machine

2) Removal of regular link Push pin (1) in the direction of with a press to remove it from link (2), then pull pin (1) and link (3) together out of bushing (4).

D375A-5

DISASSEMBLY AND ASSEMBLY OF MASTER LINK

• Master link type 1) Cutting and removal of master link on bushing side with gas Cut the parts marked with gas and remove the parts marked . Move master links (5) and (6) in the direction of and to pull them out. Then, push pins (8) and (9) out of regular link (7) in the directions of and with a press. • Necessary special tools: 1. Gas cutting machine 2. Tool R7

2) Removal of master link on pin side Cut the parts marked with gas and remove the parts marked . Push pin (10) out of link (11) in the direction of with a press. Then, pull pin (10) and link (12) together out of bushing (13). • Necessary special tools: 1. Gas cutting machine 2. Tool R7

30-193 2 "

"



ASSEMBLY ★ For the method of using tool R7, see DISASSEMBLY of 1 link in the field.

2. Installation of link at bushing end 1) Expand the center of the link tread with tool R7 as shown in the figure. (Expand the link end by 10 mm.)

1. Assembly of link at bushing end 1) Press fit bushing-side master link (1) at bushing end to bushing (2) with a press. ★ When press fitting both master links, take care that they will be in parallel with each other. ★ Do not damage the mating surfaces of the master links and end faces of the bushing. Unit: mm L1

184 ± 0.7

L2

253.4 ± 0.7

D1

Drill 33 in diameter

D2

30 × 2.0

2) Set spacer (3) and seal assembly (4) to the counterbore of the link of the connecting part.

3) Match the pin hole and bushing hole to each other and connect the pin and bushing with guide pin 1 .

30-194 "

2 "

D375A-5


4) Press fit pin (5) with tool R7 and install at bushing end master link (1).

2 Apply gasket sealant (198-3219890) to the pin hole of the link.

★ Set the pin with its side hole on the link tread side. 5) Using tools R7, R8, R9, and R10, install the ring.

6) Install the shoe to the link of the connecting part. 7) Drive large plug (6) with tool R3 and supply oil with tool R4, then drive small plug (7) with tool R5.


★ Adjust the end play of the connecting part (the thrust play between the links before and after the pin) to 0 - 0.13 mm. ★ Take care that dirt and sand will not stick to the seal, spacer, end of bushing, and tap-hole mating face of the master link. 3. Assembly of at pin end link 1) Set spacer (3) and seal assembly (4) to the counterbore of the master link.

2) Pass pin (9) through bushing (8) and set and press fit pin-side master links (10) at pin end from both sides with tool R7. 3) Using tools R7, R8, R9, and R10, install the ring. 4) Drive large plug (11) with tool R3 and supply oil with tool R4, then drive small plug (12) with tool R5.

★ When press fitting both master links, take care that they will be in parallel with each other (Bushing side and pin side). ★ Do not damage the mating surfaces of the master links and end faces of the bushing.

D375A-5

30-195 2 "

"



4. Connection of master links Place the assembled 2 shoes on a level place in 1 line with the shoe side up. Pull master link (13) at pin end and bushing-side master link (14) together and set them to each other by the mating faces. Place the shoe on the links and check that the shoe bolt can be tightened easily until the mating faces of the links are fitted together, then connect the links with the master bolts. 3 Shoe bolt (Master link) Initial torque: 686 ± 68.6 Nm {70 ± 7 kgm} Retightening angle: 180°° ± 10°°

30-196 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY


REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY SPECIAL TOOLS Symbol

P

Part No.

Part name


1 791T-650-2330

Sleeve

#

1

N

"

2 791T-650-2340

Plate

#

1

N

"

3 790-201-3310

Bolt

#

2

4 790-101-2510

Block

#

1

5 790-101-2570

Washer

#

2

6 01580-01613

Nut

#

2

7 01643-31645

Washer

#

2

8 790-105-2300

Jack assembly

#

1

9 790-101-1102

Pump

#

1

REMOVAL

INSTALLATION

1. Track frame assembly ★ Remove the track frame assembly. For details, see REMOVAL OF TRACK FRAME ASSEMBLY.

•

2. Sling pivot shaft assembly (1) temporarily and remove the mounting bolts. Using forcing screw q1 1 , pull out the pivot shaft assembly. 4

q2

3. Remove seal (2) and cover (3).

Pivot shaft assembly: 390 kg


q1

2 Press fitting face of pivot shaft: Anti-friction compound (LM-P)

q2

★ Using tool P, press fit seal (2) to the pivot shaft. 2 Press fitting face of seal: Gasket sealant (LG-6)

★ Check that press fitting dimension "a" of the seal from the shaft end is in the standard range. • Press fitting dimension "a": 655 ± 1.0 mm

D375A-5

30-197 2 "

"


REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY

SKETCH OF SPECIAL TOOL Note: We will not be liable for any result caused by a special tool made according to this drawing. P1 Sleeve

P2 Plate

30-198 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF EQUALIZER BAR


REMOVAL AND INSTALLATION OF EQUALIZER BAR SPECIAL TOOLS Symbol

N

1

Part No.

Part name

Ne- Q'ty New/Re- Sketch model cessity !

791-650-1300

Remover

1

• 791-735-1123

• Sleeve

1

• 790-434-1050

• Screw

1

• 01580-02419

• Nut

1

• 01643-32460

• Washer

790-101-2102

Puller (294kN {ton})

!

1

790-101-1102

Pump

!

1

3. Remove seal (2) and washer (3) together. q 1 ★ Perform this procedure for only the right track frame. 4. Remove washer (4) and spacer (5). ★ Receive the oil flowing out of the pivot case with an oil pan, etc. 6

Pivot case: 18 ¬

5. Set hydraulic jack 1 (490 kN (50 tons}) under the radiator guard.

REMOVAL 1. Remove the engine underguard and power train underguard (front). 4

Engine underguard: 290 kg Power train underguard (front): 280 kg

2. Remove cover (1). ★ For the right track frame, disconnect the 4 hoses for the blade tilt cylinder. ★ Since the whole machine body will be raised by using the blade, plug the hoses on the tilt cylinder side securely.

D375A-5

6. Remove cover (6). 7. Remove cover (7) and loosen bolt (8).

30-199 2 "

"


8. Loosen clamping bolt (9) of the rear equalizer bar side pin.

q2 q3 9. Remove side pin (10). ★ If the equalizer bar hole is not aligned with the track frame hole, the pin cannot be pulled out easily. Accordingly, adjust the height of the equalizer bar with hydraulic jack 1 .


12. Disconnect lubrication tube (12). 13. Remove 2 lock plates (13).

q4

14. Using tool N1, remove center pin (14). q5 ★ If the equalizer bar hole is not aligned with the main frame hole, the pin cannot be pulled out easily. Accordingly, adjust the height of the main frame with hydraulic jack 1 .

10. Repeat steps 6 - 9 and remove the side pin on the opposite side. 11. Operate hydraulic jack 1 slowly to lower the machine body until the equalizer bar touches both track frames.

30-200 "

2 "

D375A-5



15. Operate the blade to raise the front part of the machine body and set stand 3 under the radiator guard.

INSTALLATION •


q1

★ After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). ★ Be careful not to install with the seal displaced in the direction of twisting.

q2

2 Inside surface of bushing : Grease (G2-LI)

16. Sling equalizer bar (15) and remove it over the main frame and track frame. ¤ After removing the equalizer bar, do not lower the machine body. 4

★ Before installing the pin, operate hydraulic jack 1 to adjust the height of the main frame and align the center of the equalizer bar hole and track frame hole. ★ Set the pin with the grease hole facing the outside of the machine.

q3

★ Fit pin and bushing, install cover, then install the cover and cushion. ★ Tighten bolt (8), then tighten cover mounting bolt.

Equalizer bar assembly: 500 kg

q4

3 Lock plate mounting bolt : 549 ± 59 Nm {56 ± 6 kgm}

q5

2 Equalizer bar bushing and main frame Grease (G2-LI) bushing : ★ Before installing the pin, operate the crane to align the center of the main frame hole and the equalizer bar hole.

•

Refilling with oil (pivot case) Add oil through oil filler to the specified level.

5

D375A-5

Pivot case : 18 ¬ (SAE30)

30-201 2 "

"

DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING


DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING SPECIAL TOOLS Symbol

Part No.


Bracket

#

1

N

"

2 791T-650-2420

Bracket

#

1

N

"

3 790-438-1110

Screw

#

1

4 791-112-1180

Nut

#

2

5 790-101-2540

Washer

#

2

6 790-101-2102


#

1

7 790-101-1102

Pump

#

1

1 791T-650-2410

N 2

Part name

2. Guide bushing 1) Remove seal (2). 2) Remove snap ring (3).

DISASSEMBLY 1. Center bushing 1) Remove center bushing (1).

30-202 "

2 "

3) Set tool N2 and remove side bushing (4) from equalizer bar (5).

D375A-5


ASSEMBLY 1. Side bushing 1) Set side bushing (4) and tool N2 and press fit side bushing (4) to equalizer bar (5). 2 Outside of side bushing: Anti-friction compound (LM-P)

★ Press fit the side bushing in the direction shown below.


2) Install snap ring (3). ★ After installing the snap ring, fill parts "c" before and after the side bushing with grease (G2-LI). 2 Amount of grease to be supplied to side bushing: 0.3 ¬

3) Using a press, press fit seal (2). ★ Press fitting force for seal: 9.8 - 29.4 kN {1 - 3 tons} ★ Press fit the seal so that its metallic part will not be projected from the equalizer bar end. 2 Seal lip: Grease (G2-LI)

i)

Set split (mating) face "a" of the outer bushing on the level. ii) Set grease holes "b" of the inner bushing and outer bushing diagonally. ★ Press fitting force for side bushing: 34.3 - 73.5 kN {3.5 - 7.5 tons}

2. Center bushing Using the press, press fit bushing (1).

2 Outside of center bushing: Anti-friction compound (LM-P) ★ Press fitting force for center bushing: 4.9 - 186.2 kN {5 - 19 tons}

D375A-5

30-203 2 "

"



SKETCH OF SPECIAL TOOL Note: We will not be liable for any result caused by a special tool made according to this drawing. N2-1 Bracket

N2-2 Bracket

30-204 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF SEGMENT TOOTH


REMOVAL AND INSTALLATION OF SEGMENT TOOTH REMOVAL

INSTALLATION

1. Stop the machine in a position where the segment tooth can be removed (between the chute and track frame).

•


Carry out installation in the reverse order to removal. 2 Seat of segment tooth mounting nut: Anti-friction compound (LM-P) 3 Segment tooth mounting nut: 1,813 ± 98 Nm {185 ± 10 kgm}

3. Remove the mounting bolts and segment tooth (3). ★ Before removing the all mounting bolts, insert bar 1 in the upper mounting bolt hole and move and remove the segment tooth outward. 4

D375A-5

Segment tooth: 35 kg

30-205 2 "

"


REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY

REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY REMOVAL ¤ Lower the work equipment to the ground and release the residual pressure from the piping, refe r r i n g t o T E S T I N G A N D A D J U S T I N G , Releasing residual pressure from hydraulic circuit. Then, loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank.

5. Disconnect the 2 PPC hoses and 3 main hoses (5) from the blade lift valve. ★ The PPC hoses are classified by the color q1 bands.

1. Drain the oil from the hydraulic tank. 6

Hydraulic tank: 230 ¬

2. Remove operator's cab right cover (1).

6. Open hydraulic tank front cover (6) and disconnect hoses (7) and (8) from the blade lift valve. ★ Move the disconnected hoses toward the operator's cab.

3. Disconnect PPC charge valve (2) from the hydraulic tank. ★ Move the PPC charge valve toward the floor frame. 4. Remove bracket (3).

30-206 "

2 "

D375A-5


7. Disconnect 6 PPC hoses (9), 4 rear main hoses (10), and 4 front main hoses/tubes (11) from the blade tilt and ripper Lo valve. ★ The PPC hoses are classified by the color q2 bands.


10. Lift off hydraulic tank assembly (16). 4

Hydraulic tank assembly: 380 kg

q3

8. Disconnect return hose (12) and suction tube (13) from the hydraulic tank.

9. Remove hydraulic tank front cover (14) and disconnect return hose (15).

D375A-5

30-207 2 "

"



INSTALLATION •


q1

q2

★ The connecting positions of the PPC hoses are indicated by the band colors on their quick couplers. When connecting them, confirm them by the band colors.

3 Hydraulic tank mounting bolt: 151.9 ± 24.5 Nm {15.5 ± 2.5 kgm} q3

•

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

•

Bleeding air Bleeding the air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

Distinguishing color bands (View from operator’s cad) A. Transparent B. Red/White C. Black/Blue D. Brown E. Black F. Green G. White H. Yellow

30-208 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND PPC PUMP ASSEMBLY


REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND PPC PUMP ASSEMBLY REMOVAL ¤ Lower the work equipment to the ground and release the residual pressure from the piping, refe r r i n g t o T E S T I N G A N D A D J U S T I N G , Releasing residual pressure from hydraulic circuit. Then, loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank. ¤ Disconnect the cable from the negative (–) terminal of the battery.

7. Sling work equipment pump assembly (5) temporarily and remove the mounting bolts, then remove the work equipment pump assembly. 4

Work equipment and PPC pump assembly: 45 kg



2. Remove the floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 3. Disconnect hydraulic oil temperature sensor connector (CN-452) (1). 4. Disconnect 2 hoses (2). 5. Disconnect 4 delivery hoses (3).

INSTALLATION •

6. Disconnect suction tube (4). ★ Remove the 2 clamps and move the coupling toward the pump to disconnect the suction tube.

3 Suction tube clamp bolt: 26.95 ± 2.45 Nm {2.75 ± 0.25 kgm} •

D375A-5



30-209 2 "

"


REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY

REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY REMOVAL ¤ Lower the work equipment to the ground and release the residual pressure from the piping, refe r r i n g t o T E S T I N G A N D A D J U S T I N G , Releasing residual pressure from hydraulic circuit. Then, loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank.

4. Open hydraulic tank front cover (4) and disconnect hoses (5) and (6).



2. Remove operator's cab right cover (1).

5. Sling work blade lift valve (7) temporarily and remove the mounting bolts. Then, remove the blade lift valve assembly. 4

Blade lift valve assembly: 60 kg

3. Disconnect 2 PPC hoses (2) and 3 main hoses (3). ★ The PPC hoses are classified by the color q1 bands.

30-210 "

2 "

D375A-5


REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY

INSTALLATION •


q1


Distinguishing color bands (View from operator’s cad) A. Transparent B. Red/White

•


•

Bleeding air Bleed air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinders.

D375A-5

30-211 2 "

"


DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY


★ This chapter deals only with precautions to be followed when reassembling the Blade Lift Valve Assembly.

ASSEMBLY ★ Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Assembly of shuttle valve assembly Install ball (31) and fit the O-ring and plug (30). 3 Plug:

34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}

4. Assembly of main relief and shuttle valve assembly Fit the O-ring and main relief and shuttle valve assembly (18). ★ Tighten the mounting bolts in the order of 1 -4. 3 Mounting bolt: 1st time: 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm} 2nd time: 66.15 ± 7.35 {6.75 ± 0.75 kgm}

2. Assembly of check valve assembly Install valve (29) and spring (28) and fit the Oring and plug (27). 3 Plug:367.5 ± 24.5 Nm {37.5 ± 2.5 kgm}

3. Assembly of suction valve assembly Install valve (26) and spring (25) and fit the Oring and plug (24). 3 Plug:514.5 ± 24.5 Nm {52.5 ± 2.5 kgm}

30-212 "

2 "

D375A-5



★ If the main relief valve was disassembled, adjust it after installing the valve assembly to the machine body, referring to TESTING AND ADJUSTING, Measuring and adjusting work equipment oil pressure. 5. Assembly of demand valve assembly 1) Install seal (17), spool (16), O-ring, and case (15). 3 Mounting bolt: 186.2 ± 9.8 Nm {19 ± 1 kgm}

2) Install spring (14) and case (13).

3 Mounting bolt: 186.2 ± 9.8 Nm {19 ± 1 kgm}

6. Assembly of main spool assembly 1) Install spool (12), O-ring, and case (11). 2) Install retainer (10), spring (9), O-ring, and case (8). 3) Install retainer (7), spacer (6), spring (5), retainer (4), and washer (3) and tighten bolts (2). 3 Mounting bolt:

110.25 ± 12.25 Nm {11.25 ± 1.25 kgm} ★ Tighten the bolts with the spool installed in the body. 4) Install the O-ring and case (1).

D375A-5

30-213 2 "

"


DISASSEMBLY AND ASSEMBLY OF BLADE TILT AND RIPPER LOW VALVE ASSEMBLY


30-214 "

2 "

D375A-5



★ This chapter deals only with precautions to be followed when reassembling the Blade Tilt and Ripper Low Valve Assembly.

ASSEMBLY ★ Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Assembly of shuttle valve assembly 1) Install ball (20) and seat (19) to plug (18). 2) Install the O-ring and plug (18).

3 Plug: 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}

2. Assembly of check valve assembly 1) Install valve (17) and spring (16). 2) Install the O-ring, seat (15), and bar (14) and tighten bolts (13). 3. Assembly of main relief valve assembly Install the O-ring and main relief valve assembly (12). 3 Main relief valve assembly: 83.3 ± 14.7 Nm {8.5 ± 1.5 kgm}

★ If the main relief valve was disassembled, adjust it after installing the valve assembly to the machine body, referring to TESTING AND ADJUSTING, Measuring and adjusting work equipment oil pressure. 4. Assembly of spool assembly 1) Install spool (10) to body (11). 2) Set retainer (9), spacers (8) and (7), spring (6), retainer (5), and washer (4) and tighten bolts (3). ★ Tighten the bolts with the spool installed in the body. 3 Mounting bolt: 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}

3) Install the O-ring and case (2). 4) Install the O-ring and case (1).

D375A-5

30-215 2 "

"


DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY


30-216 "

2 "

D375A-5


★ This chapter deals only with precautions to be followed when reassembling the Ripper High Valve Assembly.

ASSEMBLY ★ Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Install valve (23), spring (22), seat (21), O-ring, and plug (20). 3 Plug: 514.5 ± 24.5 Nm {52.5 ± 2.5 kgm}


5. Assembly of constant-differential pressure valve assembly 1) Install spool (9). 2) Set retainer (8), spring (7), and retainer (6) to the spool and install plug (5). ★ Be sure to tighten the plug with the spool installed in the valve. 6. Install ball (4), O-ring, and plug (3).

3 Plug: 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}

7. Install the O-ring and blocks (2) and (1).

2. Install check valve (19), spring (18), O-ring, and plug (17). 3 Plug: 127.4 ± 19.6 Nm {13 ± 2 kgm}

3. Assembly of ripper lift high valve assembly 1) Install spool (16). 2) Set retainer (15) and spring (14) to the spool and install the O-ring and plug (13). 3 Plug: 66.15 ± 7.35 {6.75 ± 0.75 kgm}

3) Set retainer (12) and spring (11) to the spool and install the O-ring and plug (10). 3 Plug: 66.15 ± 7.35 {6.75 ± 0.75 kgm}

★ Be sure to tighten the plugs with the spool installed in the valve. 4. Assembly of ripper tilt high valve assembly Assemble the ripper tilt high valve assembly according to the assembly procedure for the ripper lift high valve assembly.

D375A-5

30-217 2 "

"


DISASSEMBLY AND ASSEMBLY OF PPC CHARGE VALVE ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF PPC CHARGE VALVE ASSEMBLY ★ This chapter deals only with precautions to be followed when reassembling the PPC Charge Valve Assembly.

ASSEMBLY ★ Check the all parts for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Install plugs (13) and (12). 2. Install poppet (11) and spring (10) to valve body (1), then tighten plug (9). ★ When installing the spring, check its free length. Free length of spring: 25.3 mm 3. Install poppet (8) and spring (7) to valve body (1), then tighten plug (6). ★ When installing the spring, check its free length. Free length of spring: 20.6 mm 4. Install strainer (5) and plug (4). ★ Tighten the strainer to the following torque and caulk it by 2 places. 3 Strainer: 7.35 ± 0.49 Nm {0.75 ± 0.05 kgm}

5. Tighten relief valve (3) into valve body (1).

3 Relief valve: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}

6. Install accumulator (2) to valve body (1).

30-218 "

2 "

D375A-5


DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY ★ This chapter deals only with precautions to be followed when reassembling the Blade PPC Valve Assembly.

ASSEMBLY 1. Install the blade RAISE valve 1) Install the blade RAISE valve 2) Install the blade RAISE valve ★ Install spring (37) with its small seat diameter (inside diameter) end on the shim (38) side. 3) Install spring (36), retainer (35), piston (34), spring (33), and piston (32). ★ When installing piston (34), apply grease (G2-LI) to the outside of the piston and the inside of the body hole. ★ When installing piston (32), apply grease (G2-LI) to the inside of the body hole. 2. Install the blade LOWER valve. 1) Install valve (31) to body (18). 2) Install shim (30) and spring (29) to valve (31). ★ Install spring (29) with its small seat diameter (inside diameter) end on the shim (30) side. 3) Install spring (28), retainer (27), piston (26), shim (25), retainer (24), ball (23), collar (22), spring (21), spacer (20), and piston (19). ★ When installing piston (26), apply grease (G2-LI) to the outside of the piston and the inside of the body hole. ★ When installing piston (19), apply grease (G2-LI) to the inside of the body hole. 3. Install the blade tilt valve. 1) Install valve (17) to body (18). 2) Install shim (16) and spring (15) to valve (17). ★ Install spring (15) with its small seat diameter (inside diameter) end on the shim (16) side.

D375A-5

30-219 2 "

"


DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY

3) Install spring (14), retainer (13), and pistons (12) and (11). ★ When installing piston (12), apply grease (G2-LI) to the outside of the piston and the inside of the body hole. ★ When installing piston (11), apply grease (G2-LI) to the inside of the body hole. 4. Install orifice (10). 3 Orifice:

11.8-14.7 Nm {1.2-1.5 kgm} 5. Install the O-ring and plate (9). 6. Install the O-ring and body (8). 7. Install the O-ring to collar (7) and install them to body (8), then install seal (6). 8. Install plate (5).

3 Mounting bolt: 11.8-14.7 Nm {1.2-1.5 kgm}

9. Install joint (4). ★ When installing the joint, apply adhesive (LT2) to the female threads hole of body (8). 3 Joint: 44.1 ± 4.9 Nm {3.5 ± 0.5 kgm}

★ Apply grease (G2-LI) to the rocking part of the joint. 10. Install boot (3) and disc (2) and secure them with nut (1). ★ Apply grease (G2-LI) to the contact surfaces of disc (2) and pistons (32), (19), and (11). 3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}

★ After installing the disc, adjust its height, referring to TESTING AND ADJUSTING, Adjusting PPC valve.

30-220 "

2 "

D375A-5

DISASSEMBLY AND ASSEMBLY OF RIPPER PPC VALVE ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF RIPPER PPC VALVE ASSEMBLY ★ This chapter deals only with precautions to be followed when reassembling the Ripper PPC Valve Assembly.

ASSEMBLY 1. Install valve (13) to body (14). 2. Install shim (12) and spring (11) to valve (13). ★ Install spring (11) with its small seat diameter (inside diameter) end on the shim (12) side. 3. Install spring (10), retainer (9), and piston (8). ★ Springs (10) having different number of turns are used for the following hydraulic ports. Take care when installing them. Port

Total number of turns

P1, P2

9

P3, P4

10.5

★ Each port position is stamped on the underside of the valve body. 2 Piston: Grease (G2-LI)

★ When installing piston (8), apply grease to the outside of the piston and the inside of the body hole. 4. Install the O-ring to collar (7) and install them to body (14), then install seal (6). 5. Install plate (5).

3 Mounting bolt: 13.72 ± 1.96 Nm {1.4 ± 0.2 kgm}

6. Install joint (4).

2 Rocking part of joint: Grease (G2-LI) 2 Joint: Thread tightener (LT-2)

3 Joint: 44.1 ± 5 Nm {4.5 ± 0.5 kgm} ★ Observe the tightening torque for the joint. 7. Install boot (3) and disc (2) and secure them with nut (1).

3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm} ★ After installing the disc, adjust its height, referring to TESTING AND ADJUSTING, Adjusting PPC valve.

D375A-5

30-221 2 "

"

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY SPECIAL TOOLS Symbol

Part No.

3 U

Ne- Q'ty New/Re- Sketch model cessity !

1

790-201-1702

Push tool kit

#

1

• 790-201-1841

• Push tool

1

• 790-201-1861

• Push tool

1

• 790-101-5021

• Clip

1

• 01010-50816

• Bolt

1

790-201-1500

Push tool kit

• 790-201-1650

• Plate

1

• 790-201-1670

• Plate

1

• 790-101-5021

• Clip

1

• 01010-50816

• Bolt

#

1

796-720-1680

Ring

#

1

07281-01589

Clamp

#

1

796-720-1720

Ring

#

1

07281-02429

Clamp

#

1

796-720-1690

Ring

#

1

07281-02169

Clamp

#

1

790-102-2302

Wrench

6 790-330-1100

Multiwrench

#

1

#

1

790-101-1102

30-222 2 "

Pump

2. Quick drop valve assembly ★ Perform this procedure for only the blade lift cylinder. 1) Remove quick drop valve assembly (1).

1 #

5

1. Cylinder tube Remove the cylinder tube.

1

Expander

4 790-720-1000

"

Part name Cylinder repair stand

1 790-502-1003

2

DISASSEMBLY

2) Disassemble the quick drop valve assembly according to the following procedure. i) Remove elbow (2). ii) Remove spring (3), washer (4), and valves (5) and (6), then pull out collar (7).

D375A-5


3. Piston rod assembly 1) Set cylinder assembly (8) to tool U1. 2) Remove head assembly (9). 3) Pull out piston rod assembly (10). ★ Put an oil pan under the cylinder to receive the oil.

4. Piston assembly 1) Set piston rod assembly (10) to tool U1.

D375A-5


2) Remove spacer (11). 3) Remove the piston assembly. 4) Remove backup rings (13) and (14) and Oring (15). 5) Remove retainer (16).

6) Disassemble the piston assembly according to the following procedure. i) Remove wear ring (17). ii) Remove piston ring (18).

30-223 2 "

"


5. Cylinder head assembly 1) Remove cylinder head assembly (19) from the piston rod.


ii) Remove snap ring (22) and tool (23). iii) Remove packing (24) and bushing (25).

2) Disassemble the cylinder head assembly according to the following procedure. i) Remove O-ring (20) and backup ring (21).

30-224 "

2 "

D375A-5


ASSEMBLY


v)

Install backup ring (21) and O-ring (20).

★ Apply engine oil to the sliding surfaces of each part and install the packings, dust seals, and Orings, taking care not to damage them. 1. Cylinder head assembly 1) Assemble the cylinder head assembly according to the following procedure.

2) Install cylinder head assembly (19) to the piston rod.

Using tool U2, press fit bushing (25) to the head. ii) Install packing (24). iii) Using tool U3, press fit seal (23). iv) Install snap ring (22). i)

D375A-5

30-225 2 "

"


2. Piston assembly 1) Assemble the piston assembly according to the following procedure. i) Using tool U4, expand piston ring (18). ★ Set the piston ring to the tool and turn the handle of the tool by 8 - 10 turns to expand the piston ring. ii) Remove piston ring (18) from tool U4 and install it to the piston.


2) Install retainer (16). 3) Install the O-ring and backup rings (14) and (13). ★ Apply grease to the O-ring and backup rings so that the backup rings will not open. 4) Install piston assembly (12). 5) Install spacer (11) and tighten the mounting bolts. 2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt: Blade lift: 66.5 ± 7.5 Nm {6.75 ± 0.75 kgm} Blade tilt, ripper lift, ripper tilt: 176.5 ± 19.5 Nm {18 ± 2 kgm}

iii) Set tool U5 and shrink piston ring (18). iv) Install wear ring (17) to the piston.

3. Piston rod assembly 1) Set cylinder (8) to tool U1.

30-226 "

2 "

D375A-5


2) Install piston rod (10) to cylinder (8). ★ Apply grease to the sealing part of the piston. ★ Push in the piston rod fully. 3) Push head assembly (9) in the cylinder and tighten the mounting bolts. ★ Apply grease to the backup rings.


2) Install quick drop valve assembly (1). 5. Cylinder tube Install the cylinder tube.

4. Quick drop valve assembly ★ Perform this procedure for only the blade lift cylinder. 1) Assemble the quick drop valve assembly according to the following procedure. i) Install collar (7), valves (6) and (5), washer (4), and spring (3).

D375A-5

30-227 2 "

"

DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULLER CYLINDER ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULLER CYLINDER ASSEMBLY SPECIAL TOOLS Symbol

Part No.

1 790-502-1003 790-201-1702 2 • 790-201-1721 • 790-101-5021

U

Part name


Cylinder repair stand

!

1

Push tool kit

#

1

• Push tool

1

• Clip

1

• 01010-50816

• Bolt

1

790-201-1500

Push tool kit

3 • 790-201-1530 • 790-101-5021 • 01010-50816

#

• Plate

1

• Grip

1

• Bolt

1 #

1

796-720-1630

Ring

#

1

07281-00709

Clamp

#

1

#

1

790-102-2302 6 790-330-1100 790-101-1102

1. Cylinder assembly 1) Set pin puller cylinder assembly (1) to tool U1. 2) Using tool U6, remove cylinder head assembly (2). 3) Remove piston rod (3) and cylinder head assembly (2) together. ★ Put an oil pan under the cylinder to receive the oil.

1

Expander

4 790-720-1000 5

DISASSEMBLY

Wrench Multiwrench Pump

2. Cylinder head assembly 1) Remove cylinder head assembly (2) from piston rod (3).

30-228 "

2 "

D375A-5


2) 3) 4) 5)

Remove O-ring (5) and backup ring (6). Remove O-ring (7). Remove snap ring (8) and dust seal (9). Remove rod packing (10) and bushing (11).


ASSEMBLY ★ Apply engine oil to the sliding surfaces of each part and install the packings, dust seals, and Orings, taking care not to damage them. 1. Piston rod assembly 1) Using tool U4, expand piston ring (12). ★ Set the piston ring to the tool and turn the handle of the tool by 8 - 10 turns to expand the piston ring. 2) Remove piston ring (12) from the tool and install it to piston rod (3). 3) Using tool U5, shrink piston ring (12).

3. Piston rod assembly Remove piston ring (12) from piston rod (3).

D375A-5

30-229 2 "

"


2. Cylinder head assembly 1) Using tool U2, press fit bushing (11) to cylinder head (4).

2) Using tool U3, press fit dust seal (9) to cylinder head (4).


6) Install cylinder head assembly (2) to piston rod (3).

3. Cylinder assembly 1) Set the cylinder to tool U1 and support it with block 1 . 2) Install piston rod (3) and cylinder head assembly (2) together. ★ Apply grease to the sealing part of the piston. ★ Apply grease to the backup ring. ★ Push in the piston fully. 3) Using tool U6, tighten cylinder head assembly (2). 3 Cylinder head assembly: 441 ± 44.1 Nm {45 ± 4.5 kgm}

3) Install snap ring (8) and rod packing (10). 4) Install O-ring (7). 5) Install backup ring (6) and O-ring (4).

30-230 "

2 "

D375A-5


REMOVAL AND INSTALLATION OF BLADE ASSEMBLY

REMOVAL AND INSTALLATION OF BLADE ASSEMBLY REMOVAL ¤ Lower the work equipment to a level place and set blocks 1 under both straight frames (6) securely. q1 1. Remove cap (1) from the lift cylinder. ★ Check the quantity and thickness of the inserted shims.

3. Remove both covers (3). 4. Disconnect hose (4). ★ Plug the openings so that dirt will not enter the piping. 5. Remove both trunnion caps (5).

6. Remove blade assembly (6). q2 ★ Start the engine and move the machine in reverse slowly to disconnect the blade assembly from the trunnion.

2. Sling lift cylinder assembly (2) temporarily. Start the engine and retract the piston rod fully. Install the cylinder fixing tool and fix the cylinder to the radiator guard. ★ Bind the piston rod with wires so that it will not come out. ★ Similarly, disconnect the cylinder on the opposite side from the blade. ¤ Release the residual pressure from the piping, referring to TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. Then, loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank.

D375A-5

30-231 2 "

"


REMOVAL AND INSTALLATION OF BLADE ASSEMBLY

INSTALLATION •


q1

★ Referring to TESTING AND ADJUSTING, Adjusting semi-U tiltdozer, adjust the shims.

q2

★ Adjust height "b" and width "c" of both straight frames to the following values with block 1 , etc. • Trunnion height "b": Approx. 863 mm • Frame width "c": Approx. 3,484 mm

•


30-232 "

2 "

D375A-5

DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY


DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY DISASSEMBLY ¤ Set blocks 1 and stands 2 securely under both straight frames and blade to stabilize the blade.

3. Sling tilt cylinder assembly (4) temporarily and remove the lock plate and pin (5). 4. Remove the lock plate and pin (6) and lift off tilt cylinder assembly (4). 4

Tilt cylinder assembly: 380 kg

1. Remove right frame covers (1) and (2). 2. Disconnect tilt cylinder hose (3). 5. Set block 3 under right center brace (7) and remove the mounting bolts of cap (8) on the center frame side. ★ Check the quantity and thickness of the shims inserted under the cap.

D375A-5

30-233 2 "

"



6. Sling right straight frame (9) temporarily and disconnect right center brace (7). 7. Remove the lock plate and pin (10) and lift off right straight frame (9). 4

Straight frame: 1,150 kg

8. Sling tilt brace (11) temporarily and remove the lock plate and pin (12). 9. Remove the lock plate and pin (13) and lift off tilt brace (11). 4

11. Sling center brace (15) temporarily and remove the mounting bolts and cap (16) and lift off both center braces (15) and (7). ★ Check the quantity and thickness of the shims inserted under the cap. 4

Center brace: 220 kg

12. Sling blade (17) and bring down the blade. 4

Blade: 4,900 kg

Tilt brace: 200 kg

10. Disconnect the left center brace and remove left straight frame (14) similarly to steps 5 - 7 above.

30-234 "

2 "

D375A-5



ASSEMBLY ★ Check the thickness and quantity of the shims removed from each part during disassembly and insert those shims to their original position. ★ For adjustment of the shims, see TESTING AND ADJUSTING, Adjusting blade.

3. Sling right straight frame (9) and install pin (10) and secure it with the lock plate. 4

Straight frame: 220 kg

4. Sling right straight frame (9) temporarily and set the ball of right center brace (7) to right straight frame (9).

1. Sling blade (17) and put a block, stand, etc. under it securely to stabilize it. 4

Blade: 4,900 kg

5. Insert the shims under cap (8) of right center brace (7) and tighten the mounting bolts. ★ Standard shim thickness: 4.5 mm 2. Sling center brace (15) and set the shims and tighten the mounting bolts of cap (16). ★ Set a block under the center brace according to the height of the straight frame. ★ Standard shim thickness: 4.5 mm 4

Center brace: 220 kg

★ Install center brace (7) on the opposite side similarly.

D375A-5

30-235 2 ! 4

!



6. Sling tilt cylinder assembly (4) and install pin (6) and secure it with the lock plate.

10. Install left straight frame (14) similarly to steps 3 - 5 above and connect the left center brace.


11. Sling tilt brace (11) and install pin (13) and secure it with the lock plate.

4

7. Install pin (5) and secure it with the lock plate.

4

Tilt brace: 200 kg

12. Install pin (12) and secure it with the lock plate.

8. Connect tilt cylinder hose (3). 9. Install right frame covers (2) and (1). 13. Supplying grease After finishing the assembly work, supply sufficient amount of grease to the parts shown in the following figure. 2 Each part of work equipment: Grease (G2-LI)

30-236 "

2 "

D375A-5


DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY DISASSEMBLY 1. Drive the machine over block 1 and lower the blade to the ground. ¤ Lock the brake securely. 2. Sling the shank temporarily and operate the pin puller switch to pull out the shank pin. 3. Raise the ripper fully and lower and remove shank (1) slowly. 4

Shank: 470 kg

★ Start the engine and retract the piston rod fully and lower it onto the lift cylinder. ¤ After stopping the engine, release the residual pressure from the piping, referring to TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. Then, loosen the hydraulic oil filler cap to release the internal pressure of the hydraulic tank. 7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder hoses (5), and 2 pin puller cylinder hoses (6).

4. Set stand 2 between the arm and beam.

5. Sling the lift cylinder assembly and remove pin (2). ★ Start the engine and retract the piston rod fully and lower it onto the arm.

8. Sling tilt cylinder assembly (7) temporarily and remove pin (8) and lift off tilt cylinder assembly (7). 4


6. Sling the tilt cylinder assembly and remove pin (3).

D375A-5

30-237 2 "

"


9. Sling lift cylinder assembly (9) temporarily and remove pin (10) and lift off lift cylinder assembly (9). 4

Lift cylinder assembly: 350 kg


ASSEMBLY 1. Sling and set arm (13) in position and install both pins (14) and secure them with the lock plates. 4

Arm: 1,000 kg

★ Set a stand under the arm.

10. Sling beam (11) temporarily and remove both pins (12) and lift off beam (11). 4

Beam: 2,000 kg

2. Sling and set beam (11) in position and install both pins (12) and secure them with the lock plates. 4

Beam: 2,000 kg

★ Set a stand under the beam.

11. Sling arm (13) temporarily and remove both pins (14) and lift off arm (13). 4

30-238 "

2 "

Arm: 1,000 kg

D375A-5


3. Sling and set lift cylinder assembly (9) in position and install pin (10) and secure it with the lock plate. 4

Lift cylinder assembly: 350 kg


6. Sling the tilt cylinder assembly temporarily. Start the engine and extend the piston rod to align it with the pin hole. Install pin (3) and secure it with the lock plate. 7. Sling the lift cylinder assembly temporarily. Start the engine and extend the piston rod to align it with the pin hole. Install pin (2) and secure it with the lock plate. 8. Drive the machine over block 1 and lower the blade to the ground. ¤ Lock the brake securely.

4. Sling and set tilt cylinder assembly (7) in position and install pin (8) and secure it with the lock plate. 4


9. Raise the ripper a little and remove stand 2 . 10. Raise the ripper fully. Pass a wire through the shank holder and raise shank (1) slowly to align it with the pin hole. Operate the pin puller switch to insert the shank pin. 11. Raise the blade and lower the machine body from block 1 .

5. Connect 2 pin puller cylinder hoses (6), 4 tilt cylinder hoses (5), and 4 lift cylinder hoses (4).

D375A-5

12. Bleed air from the cylinders. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinders.

30-239 2 "

"


REMOVAL AND INSTALLATION OF ROPS GUARD

REMOVAL AND INSTALLATION OF ROPS GUARD REMOVAL 1. Sling ROPS guard (1) and remove 12 mounting bolts (2). q1 2. Lift off ROPS guard (1). 4

q2

ROPS guard: 766 kg

INSTALLATION •


q1

3 ROPS guard mounting bolt: 1,715 ± 196 Nm {175 ± 20 kgm}

q2

★ Install the ROPS guard so that the fire extinguisher seats (3 pieces) will be on the right of the machine body.

30-240 !

2 ! 4

D375A-5


REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY

REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY REMOVAL

6. Remove garnishes (7), (8), and (9).

¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Remove the ROPS guard. For details, see Removal of ROPS guard. 2. Remove the operator's cab left cover. 3. Disconnect wiring connectors (CN-19) (2) and (CN-20, CN-21) (3). ★ Pull out the wires from inside of the operator's cab. q1 4. Disconnect 4 window washer hoses (4). ★ Pull out the hoses from inside of the operator's cab.

7. Remove covers (10) on both sides and covers (12) and (13).

5. Remove steps (5) and covers (6). 8. Remove angle (14) and in-cab angle (15).

D375A-5

30-241 2 ! 4

!


9. Remove 19 mounting bolts and lift off operator's cab assembly (16). 4

Operator's cab assembly: 420 kg


INSTALLATION ★ Before installing the cab, loosen the mounting bolts of angle bar (14) and in-cab angle bar (15).

1. Seal 1) Fit seal (17) to guide plate (18) of the air conditioner box. 2 Part A on outside of seal (Sealing face against cab): Grease (G2-LI)

2) Sling operator's cab assembly (16) and stick seal (19) to the mating face of the former.

30-242 !

2 ! 4

D375A-5

DISA DISASSEMBLY AND ASSEMBLY

2. Operator’s cab assembly 1) Lower the operator’s cab assembly to the floor slowly. ★ Take care not to shift or damage the seal. ★ Check that the air conditioner duct seal on the cab side is fitted to the air conditioner duct on the dashboard side and no clearance is made. ★ Lower the cab carefully, since the clearance between the air conditioner duct on the cab side and the monitor is little. 2) Tighten the mounting bolts temporarily. ★ Note that the bolt length and washer at the door inlet are different. ★ Check that the seal between air conditioner bracket (20) and cab (21) is fitted securely. ★ Check the joint B of the seal and floor frame for gap. If there is a clearance, remove the cab, and then install it correctly. If the clearance is little, fill it with sealant, however.

D375A-5


★ Check that clearance a between cabside air conditioner duct (22) and monitor (23) is the same on both sides. Furthermore, check that seals (25) of cab-side air conditioner ducts (22-1) are fitted to both faces C of dashboard-side air conditioner duct (26) and are not shifted laterally.

30-242-1 4



★ If the clearance between cab-side air conditioner duct (22-1) and monitor (23) is not the same on both sides, loosen mounting screws (27) of the cab-side air conditioner duct and adjust the duct so that the clearance will be the same on both sides. If cab-side air conditioner duct and dashboard-side air conditioner duct are shifted laterally, adjust their positions similarly to the above.

3) Securely tighten the mounting bolts tightened temporarily in step 2). 4) Securely tighten the mounting bolts of angle bar (14) and in-cab angle bar (15). ★ After the above work, carry out installation from step 7 in reverse order to removal. q1

★ When connecting the window washer hoses, match the colors of their bands.

30-242-2 4

D375A-5


8. Disconnect blade PPC hoses (15), (16), (17), q2 (18), and (19). ★ Move the hoses together toward the floor frame.

REMOVAL AND INSTALLATION OF FLOOR FRAME

12. Remove window washer hose clamp (33).

9. Disconnect ripper PPC hoses (20), (21), (22), (23), and (24). q3 ★ Move the hoses together toward the floor frame. 10. Disconnect PPC hose (25).

13. Disconnect parking brake cable (34) from the lever and remove it from the bracket. ★ Before disconnecting the cable, check its inq4 stalled length.

11. Remove wiring connectors CN-FD5 (26), CNBWR (27), CN-USB (28), CN-FSB (29), CN-TL1 (30), CN-19 (31), and CN-SX8 (32). ★ Disconnect CN-TL1 from inside of the floor.

30-244 "

2 "

14. Disconnect brake pedal linkage (35) from the turnbuckle. q5 ★ Before disconnecting the linkage, check the installed length of the brake rod. ★ The turnbuckle has opposite threads.

D375A-5



15. Remove armrest (36).

19. Disconnect ground wire (40).

16. Remove right console (37). ★ Disconnect wiring connectors (CN-262, CN263) inside the console. ★ Before removing the console, remove the lever boot from the console.

20. Remove 4 left front mounting bolts (41). 21. Remove 4 right front mounting bolts (42).

q7 q8

17. Remove left console cover (38).

22. Lift off floor frame assembly (45). 4

18. Remove 4 rear mounting bolts (39) from each q6 side.

D375A-5

Floor frame assembly: 600 kg

★ Using a chain block, sling the floor frame assembly slowly, balancing it carefully. ★ After removing the floor frame assembly, remove the spacers on the right front floor mount.

30-245 2 "

"


q2

INSTALLATION •



q1

q3


★ Connect the hoses so carefully that they will not be twisted. ★ When installing the air conditioner circuit hoses, take care that dirt, dust, or water will not enter them. ★ When connecting the air conditioner hoses, check that the O-rings are fitted to their adapters. Apply sufficient amount of compressor oil (Showa-Shell Suniso 4G or 5G) to the Orings.

Distinguishing color bands (View from operator’s cad) A. Transparent B. Red/White C. Black/Blue D. Brown E. Black F. Green G. White H. Yellow 3 Tightening torque for air conditioner refrigerant piping Thread size

Tightening torque

16 × 1.5

12.23 ± 1.47Nm {1.35 ± 0.15kgm}

22 × 1.5

22.05 ± 2.45Nm {2.25 ± 0.25kgm}

24 × 1.5

31.85 ± 2.45Nm {3.25 ± 0.25kgm}

M6 bolt (for receiver) 5.39 ± 1.47Nm {0.55 ± 0.15kgm} M6 bolt (for compressor)

30-246 "

2 "

9.8 ± 1.96Nm {1.0 ± 0.2kgm}

D375A-5



q4

★ Adjust the parking brake lever linkage. For details, see TESTING AND ADJUSTING, Adjusting PCCS (Steering, Forward/Reverse travel, Gear shifting), parking brake lever linkage. q5

★ Adjust the brake pedal linkage. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage. 3 Brake pedal linkage turnbuckle: 45.56 ± 12.25 Nm {4.76 ± 1.25 kgm}

q6

q7

3 Rear mounting bolt: 338.1 ± 39.2 Nm {34.5 ± 4kgm}

3 Front mounting bolt: 338.1 ± 39.2 Nm {34.5 ± 4kgm}

q8

•

•

Charging air conditioner with refrigerant gas Using tool X, charge the air conditioner circuit with refrigerant (R134a). Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.

D375A-5

30-247 2 "

"

REMOVAL AND INSTALLATION OF DASHBOARD ASSEMBLY


7. Lift off dashboard assembly (9). 4

Dashboard assembly: 95 kg

3 Tightening torque for air conditioner refrigerant piping Thread size

Tightening torque

16 × 1.5

12.23 ± 1.47Nm {1.35 ± 0.15kgm}

22 × 1.5

22.05 ± 2.45Nm {2.25 ± 0.25kgm}

24 × 1.5

31.85 ± 2.45Nm {3.25 ± 0.25kgm}


•

INSTALLATION •


q1

★ Connect the hoses so carefully that they will not be twisted. ★ When installing the air conditioner circuit hoses, take care that dirt, dust, or water will not enter them. ★ When connecting the air conditioner hoses, check that the O-rings are fitted to their adapters. Apply sufficient amount of compressor oil (Showa-Shell Suniso 4G or 5G) to the Orings.

D375A-5

•

9.8 ± 1.96Nm {1.0 ± 0.2kgm}

Charging air conditioner with refrigerant gas Using tool X, charge the air conditioner circuit with refrigerant (R134a). Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.

30-249 2 "

"


REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY

REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY REMOVAL ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Remove mounting bolts, then open monitor panel assembly (1).

2. Disconnect connectors (CN-1, CN-2, CN-3, CN4, CN-5, CN-S01, CN-S02) (2).

3. Remove monitor panel assembly.

INSTALLATION •


30-250 "

2 "

D375A-5


REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY

9. Remove ducts (17) and (18).

12. Disconnect bracket (22) and clamp (23).

10. Remove monitor (19) and cover (20).

13. Disconnect relays (CN-R1) (24), (CN-R2) (25), and (CN-R3) (26) in the right part of the dashboard and connector (CN-M26) (27).

11. Remove inside filter (21). 14. Remove air conditioner unit (28). 15. Remove blower motor (29).

30-252 "

2 "

D375A-5

REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY


INSTALLATION •

•

Charging air conditioner with refrigerant gas Using tool X, charge the air conditioner circuit with refrigerant (R134a).

•

Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.


q1

★ Connect the hoses so carefully that they will not be twisted. ★ When installing the air conditioner circuit hoses, take care that dirt, dust, or water will not enter them. ★ When connecting the air conditioner hoses, check that the O-rings are fitted to their adapters. Apply sufficient amount of compressor oil (Showa-Shell Sniso 4G or 5G) to the Orings.

3 Tightening torque for air conditioner refrigerant piping Thread size

Tightening torque

16 × 1.5

12.23 ± 1.47Nm {1.35 ± 0.15kgm}

22 × 1.5

22.05 ± 2.45Nm {2.25 ± 0.25kgm}

24 × 1.5

31.85 ± 2.45Nm {3.25 ± 0.25kgm}


D375A-5

9.8 ± 1.96Nm {1.0 ± 0.2kgm}

30-253 2 "

"

90 OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................... POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................... WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ................................................... WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ................................................... WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) ......................................... WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) ......................................... ELECTRICAL CIRCUIT DIAGRAM 1/5 ..................................................................................................... ELECTRICAL CIRCUIT DIAGRAM 2/5 ..................................................................................................... ELECTRICAL CIRCUIT DIAGRAM 3/5 ..................................................................................................... ELECTRICAL CIRCUIT DIAGRAM 4/5 ..................................................................................................... ELECTRICAL CIRCUIT DIAGRAM 5/5 ..................................................................................................... DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER ........................................................... ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB ....................................................................................

90- 2 90- 3 90- 4 90- 5 90- 6 90- 7 90- 9 90-11 90-13 90-15 90-17 90-19 90-20

D375A-5

90-1 4

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

1. Oil tank

37. R.H steering clutch

2. Power train oil strainer

38. R.H steering brake

3. Power train pump (BAL180)

39. L.H steering brake

4. Power train oil filter Set pressure: 0.29 MPa {3.0 kg/cm2}

40. L.H steering clutch

5. Transmission lubrication pump (BAL112)

42. Transmission lubrication valve Set pressure: 0.26 MPa {2.7 kg/cm2}

6. Power train lubricating oil filter

41. Brake prevention valve

7. Main relief valve Set pressure: 2.65 ± 0.1 MPa {27.0 ± 1.0 kg/cm2}

43. Transmission lubrication

8. Modulating relief valve (ECMV) for R clutch

45. Scavenging pump (BAR63 + 277)

9. Modulating relief valve (ECMV) for F clutch 10. Modulating relief valve (ECMV) for 3rd clutch 11. Modulating relief valve (ECMV) for 2nd clutch 12. Modulating relief valve (ECMV) for 1st clutch 13. Fill switch Operating pressure: 0.26 MPa {2.7 kg/cm2} 14. 1st clutch

44. PTO lubrication 46. Solenoid valve (for ripper pin puller) 47. Pin puller cylinder 48. Steering case A. Torque converter lockup pressure pick-up port B. Torque converter stator clutch pressure pick-up port C. L.H steering clutch operating pressure pick-up port

15. 2nd clutch

D. L.H steering brake operating pressure pick-up port

16. 3rd clutch 17. R clutch

E. Transmission 2nd clutch operating pressure pickup port

18. F clutch 19. Pilot filter 20. Torque converter relief valve Set pressure: 0.88 ± 0.1 MPa {9.0 ± 1.0 kg/cm2} 21. Torque converter 2 +1 Set pressure: 1.3 +0.1 0 MPa {13 0 kg/cm } 22. Oil cooler

23. Steering clutch/brake lubrication 24. Torque converter case 25. Torque converter lockup valve 26. Lockup clutch modulating valve Set pressure: 1.3 +0.1 MPa {13 +1 kg/cm2}

F. Transmission R clutch operating pressure pick-up port G. Transmission 3rd clutch operating pressure pickup port H. Transmission F clutch operating pressure pick-up port J. R.H steering brake operating pressure pick-up port K. R.H steering clutch operating pressure pick-up port

27. Torque converter lockup solenoid valve

L. Transmission 1st clutch operating pressure pickup port

28. Torque converter lockup clutch

M. Transmission main relief pressure pick-up port

29. Stator clutch modulating valve Set pressure: 2.65 ± 0.1 MPa {27.0 ± 1.0 kg/cm2}

N. Torque converter regulator pressure pick-up port

0

30. Stator clutch lubrication

0

P. Torque converter relief pressure pick-up port

31. Stator clutch 32. Parking brake valve 33. R.H steering ECMV 34. R.H brake ECMV 35. L.H brake ECMV 36. L.H steering ECMV

90-2

D375A-5

90

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

D375A-5

90-3

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

(TILTDOZER)

TILTDOZER 1. Hydraulic tank 1A. Oil filler cap

13E. Ripper lift constant differential pressure valve

2. Strainer

13F. Shuttle valve

3. PPC charge pump (SAR(1) 022)

13G. Shuttle valve

4. PPC charge valve Set pressure: 4.46 MPa {45.5 kg/cm2}

13H. Suction valve (for ripper lift)

5. Accumulator 6. Oil cooler (for PPC)

13K. Ripper tilt constant differential pressure valve

7. PPC lock valve

13L. Ripper tilt constant differential valve

8. Blade control PPC valve

13M. Shuttle valve

8A. For blade lift 8B. For blade tilt 9. Ripper control PPC valve

13J. Ripper tilt HI valve

13N. Shuttle valve 14. Quick drop valve 15. R.H blade lift cylinder

9A. For ripper lift

16. L.H blade lift cylinder

9B. For ripper tilt

17. Blade tilt cylinder

10. Work equipment pump (SAR(4) 140 + (3) 071)

18. R.H ripper tilt cylinder

11. Blade control valve

19. R.H ripper lift cylinder

11A. Demand valve

20. L.H ripper lift cylinder

11B. Main relief valve Set pressure: 20.6 MPa {210 kg/cm2}

21. L.H ripper tilt cylinder

11C. Shuttle valve

22. Hydraulic oil filter Set pressure: 0.15 MPa {1.5 kg/cm2}

11D. Check valve 11E. Check valve 11F. Blade lift valve 11G. Suction valve (for blade lift) 11H. Shuttle valve 12. Blade tilt, ripper LO valve 12A. Main relief valve Set pressure: 20.6 MPa {210 kg/cm2} 12B. Check valve 12C. Blade tilt valve 12D. Check valve 12E. Ripper tilt valve 12F. Check valve 12G. Ripper lift valve 12H. Shuttle valve 13. Ripper HI valve 13A. Check valve 13B. Check valve 13C. Ripper lift (HI) valve 13D. Ripper lift constant differential pressure valve

90-4 4

D375A-5

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM TILTDOZER ★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.

D375A-5

90-5 4

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

(DUAL TILTDOZER)

DUAL TILTDOZER 1. Hydraulic tank 1A. Oil filler cap

13E. Ripper lift constant differential pressure valve

2. Strainer

13F. Shuttle valve

3. PPC charge pump (SAR(1) 022)

13G. Shuttle valve

4. PPC charge valve Set pressure: 4.46 MPa {45.5 kg/cm2}

13H. Suction valve (for ripper lift)

5. Accumulator

13K. Ripper tilt constant differential pressure valve

6. Oil cooler (for PPC) 7. PPC lock valve 8. Blade control PPC valve 8A. For blade lift 8B. For blade tilt 9. Ripper control PPC valve 9A. For ripper lift 9B. For ripper tilt 10. Work equipment pump (SAR(4) 140 + (3) 071) 11. Blade lift control valve 11A. Demand valve 11B. Main relief valve Set pressure: 20.6 MPa {210 kg/cm2}

13J. Ripper tilt HI valve

13L. Ripper tilt constant differential pressure valve 13M. Shuttle valve 13N. Shuttle valve 14. Quick drop valve 15. R.H blade lift cylinder 16. L.H blade lift cylinder 17. Pitch selector solenoid valve 18. Dual tilt selector solenoid valve 19. Blade tilt cylinder 20. Blade pitch cylinder 21. R.H ripper tilt cylinder

11C. Shuttle valve

22. R.H ripper lift cylinder

11D. Check valve

23. L.H ripper lift cylinder

11E. Check valve

24. L.H ripper tilt cylinder

11F. Blade lift valve

25. Hydraulic oil filter Set pressure: 0.15 MPa {1.5 kg/cm2}

11G. Suction valve (for blade lift) 11H. Shuttle valve 12. Blade tilt, ripper LO valve 12A. Main relief valve Set pressure: 20.6 MPa {210 kg/cm2} 12B. Check valve 12C. Blade valve 12D. Check valve 12E. Ripper tilt valve 12F. Check valve 12G. Ripper lift valve 12H. Shuttle valve 13. Ripper HI valve 13A. Check valve 13B. Check valve 13C. Ripper lift (HI) valve 13D. Ripper lift constant differential pressure valve

90-6 4

D375A-5

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM DUAL TILTDOZER ★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.

D375A-5

90-7 4

ELECTRICAL CIRCUIT DIAGRAM 1/5

D375A-5

90-9 4


D375A-5

90-11 4


D375A-5

90-13 4


D375A-5

90-15 4


D375A-5

90-17 4

DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER

D375A-5

90-19

ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB

90-20

D375A-5

D375A 5 Workshop Manual

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