SEN05006-09
BULLDOZER
D375A -6 SERIAL NUMBERS
60001
and up
Notice of revision
Notice of revision 9th. revision The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.
2012/02 Mark
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Revision number (09) (08) (08) (07) (07) (08) (08) (09) (09) (02) (04) (07) (07) (07) (07) (07) (07) (07) (07) (07) (07) (07) (02) (09) (09) (09) (09) (09)
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30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-41-1 30-41-2 30-42 30-43 30-43-1 30-43-2 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51 30-51-1 30-51-2 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76
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30-77 30-78 30-79 30-80 30-81 30-81-1 30-81-2 30-81-3 30-81-4 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97 30-98 30-99 30-99-1 30-99-2 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-117-1 30-117-2 30-118 30-119 30-120
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Revision number (03) (01) (03) (03) (01) (01) (01) (01) (01) (01) (01) (01) (01) (01) (01) (01) (01) (03) (01) (01) (01) (01) (03) (01) (01) (03) (06) (01) (01) (01) (03) (01) (01) (01) (01) (01) (01) (06) (03) (01)
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30-173 30-174 30-175 30-176 30-177 30-178 30-179 30-180 30-181 30-182 30-183 30-184 30-185 30-186 30-187 30-188 30-189 30-190 30-191 30-192 40-1 40-2 40-3 40-4 40-5 40-6 40-7 40-8 40-9 40-10 40-11 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26 40-27 40-28 40-29 40-30 40-31 40-32
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40-33 40-34 40-35 40-36 40-37 40-38 40-39 40-40 40-41 40-42 40-43 40-44 40-45 40-46 40-47 40-48 40-49 40-50 40-51 40-52 40-53 40-54 40-55 40-56 40-57 40-58 40-59 40-60 40-61 40-62 40-63 40-64 40-65 40-66 40-67 40-68 40-69 40-70 40-71 40-72 40-73 40-74 40-75 40-76 40-77 40-78 40-79 40-80 40-81 40-82 40-83 40-84
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40-85 40-86 40-87 40-88 40-89 40-90 40-91 40-92 40-93 40-94 40-95 40-96 40-97 40-98 40-99 40-100 40-101 40-102 40-103 40-104 40-105 40-106 40-107 40-108 40-109 40-110 40-111 40-112 40-113 40-114 40-115 40-116 40-117 40-118 40-119 40-120 40-121 40-122 40-123 40-124 40-125 40-126 40-127 40-128 40-129 40-130 40-131 40-132 40-133 40-134 40-135 40-136
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40-137 40-138 40-139 40-140 40-141 40-142 40-143 40-144 40-145 40-146 40-147 40-148 40-149 40-150 40-151 40-152 40-153 40-154 40-155 40-156 40-157 40-158 40-159 40-160 40-161 40-162 40-163 40-164 40-165 40-166 40-167 40-168 40-169 40-170 40-171 40-172 40-173 40-174 40-175 40-176 40-177 40-178 40-179 40-180 40-181 40-182 40-183 40-184 40-185 40-186 40-187 40-188
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40-293 40-294 40-295 40-296 40-297 40-298 40-299 40-300 40-301 40-302 40-303 40-304 40-305 40-306 40-307 40-308 40-309 40-310 40-311 40-312 40-313 40-314 40-315 40-316 40-317 40-318 40-319 40-320 40-321 40-322 40-323 40-324 40-325 40-326 40-327 40-328 40-329 40-330 40-331 40-332 40-333 40-334 40-335 40-336 40-337 40-338 40-339 40-340 40-341 40-342 40-343 40-344
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40-345 40-346 40-347 40-348 40-349 40-350 40-351 40-352 40-353 40-354 40-355 40-356 40-357 40-358 40-359 40-360 40-361 40-362 40-363 40-364 40-365 40-366 40-367 40-368 40-369 40-370 40-371 40-372 40-373 40-374 40-375 40-376 40-377 40-378 40-379 40-380 40-381 40-382 40-383 40-384 40-385 40-386 40-387 40-388 40-389 40-390 40-391 40-392 40-393 40-394 40-395 40-396
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40-397 40-398 40-399 40-400 40-401 40-402 40-403 40-404 40-405 40-406 40-407 40-408 40-409 40-410 40-411 40-412 40-413 40-414 40-415 40-416 40-417 40-418 40-419 40-420 40-421 40-422 40-423 40-424 40-425 40-426 40-427 40-428 40-429 40-430 40-431 40-432 40-433 40-434 40-435 40-436 40-437 40-438 40-439 40-440 40-441 40-442 40-443 40-444 40-445 40-446 40-447 40-448
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40-449 40-450 40-451 40-452 40-453 40-454 40-455 40-456 40-457 40-458 40-459 40-460 40-461 40-462 40-463 40-464 40-465 40-466 40-467 40-468 40-469 40-470 40-471 40-472 40-473 40-474 40-475 40-476 40-477 40-478 40-479 40-480 40-481 40-482 40-483 40-484 40-485 40-486 40-487 40-488 40-489 40-490 40-491 40-492 40-493 40-494 40-495 40-496 40-497 40-498 40-499 40-500
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40-553 40-554 40-555 40-556 40-557 40-558 40-559 40-560 40-561 40-562 40-563 40-564 40-565 40-566 40-567 40-568 40-569 40-570 40-571 40-572 40-573 40-574 40-575 40-576 40-577 40-578 40-579 40-580 40-581 40-582 40-583 40-584 40-585 40-586 40-587 40-588 40-589 40-590 40-591 40-592 40-593 40-594 40-595 40-596 40-597 40-598 40-599 40-600 40-601 40-602 40-603 40-604
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9
DRAFT D375A-6 SEN05009-00
Bulldozer Shop Manual
D375A-6
Machine model D375A-6
Serial number 60001 and up
00 Index and Foreword
D375A-6
00-1
Shop Manual Table of contents
Table of contents Notice of revision.............................................................................................................................................
1
00 Index and Foreword Table of contents............................................................................................................................................. Table of contents ......................................................................................................................................... Foreword and general information .................................................................................................................. Safety notice ................................................................................................................................................ How to read the shop manual ...................................................................................................................... Explanation of terms for maintenance standard .......................................................................................... Handling of electric equipment and hydraulic components.......................................................................... Handling of connectors newly used for engines .......................................................................................... How to read electric wire code..................................................................................................................... Precautions when carrying out work ............................................................................................................ Method of disassembling and connecting push-pull type coupler................................................................ Standard tightening torque table.................................................................................................................. List of Abbreviation ...................................................................................................................................... Conversion table ..........................................................................................................................................
00 00 00 00 00 00 00 00 00 00 00 00 00 00 -
01 Specification Specification and technical data...................................................................................................................... Specification drawing ................................................................................................................................... Specifications............................................................................................................................................... Weight table ................................................................................................................................................. Table of fuel, coolant and lubricants ............................................................................................................
01 - 3 01 - 3 01 - 4 01 - 9 01 - 11
10 Structure,function and maintenance standard Engine and cooling system ............................................................................................................................. Cooling system ............................................................................................................................................ Cooling fan pump......................................................................................................................................... Cooling fan motor......................................................................................................................................... Power train ...................................................................................................................................................... Power train................................................................................................................................................... Overall drawing of power train unit .............................................................................................................. Power train hydraulic equipment arrangement drawing............................................................................... Damper and universal joint .......................................................................................................................... Torque converter and PTO .......................................................................................................................... Torque converter control valve .................................................................................................................... Main relief valve and torque converter relief valve....................................................................................... Lockup clutch ECMV and stator clutch ECMV............................................................................................. Scavenging pump ........................................................................................................................................ Transmission control.................................................................................................................................... PCCS lever .................................................................................................................................................. Transmission................................................................................................................................................ Transmission ECMV .................................................................................................................................... Transmission lubricating oil relief valve ....................................................................................................... Steering and brake control........................................................................................................................... Transfer unit, bevel gear shaft and steering ................................................................................................ Steering control valve .................................................................................................................................. Steering clutch ECMV and Steering brake ECMV ....................................................................................... Parking brake valve ..................................................................................................................................... Sudden stop prevention valve...................................................................................................................... Final drive .................................................................................................................................................... Undercarriage and frame ................................................................................................................................ Track frame.................................................................................................................................................. Idler cushion................................................................................................................................................. Track roller bogie ......................................................................................................................................... Main frame ................................................................................................................................................... Suspension .................................................................................................................................................. Hydraulic system ............................................................................................................................................. Work equipment hydraulic piping diagram................................................................................................... PPC control piping diagram .........................................................................................................................
1010101010101010101010101010101010101010101010101010101010101010101010-
00-2
2 2 5 5 10 12 14 23 26 29 32 35 39 43
4 4 6 26 32 32 34 36 38 40 46 48 50 55 56 58 62 76 81 82 84 90 92 99 101 103 108 108 110 111 112 114 117 117 121
D375A-6 (04)
Shop Manual Table of contents
Work equipment control ............................................................................................................................... Hydraulic tank .............................................................................................................................................. Accumulator ................................................................................................................................................. PPC lock valve............................................................................................................................................. PPC valve .................................................................................................................................................... Piston valve.................................................................................................................................................. Quick drop valve .......................................................................................................................................... Pin puller switch ........................................................................................................................................... Pin puller solenoid valve .............................................................................................................................. Blade control lever (only for the machine with dual tilt specification)........................................................... Work equipment pump................................................................................................................................. Control valve ................................................................................................................................................ Self-pressure reducing valve ....................................................................................................................... Work equipment .............................................................................................................................................. Cylinder stay ................................................................................................................................................ Cab.................................................................................................................................................................. Cab mount ................................................................................................................................................... Cab .............................................................................................................................................................. Electrical system ............................................................................................................................................. Engine control .............................................................................................................................................. Engine control system.................................................................................................................................. CRI engine control system........................................................................................................................... Monitor system............................................................................................................................................. Machine monitor .......................................................................................................................................... Lamp system................................................................................................................................................ Engine preheat (electrical intake air heater) control .................................................................................... Palm command control system.................................................................................................................... Sensor.......................................................................................................................................................... Vehicle health monitoring system (VHMS) .................................................................................................. ORBCOMM system .....................................................................................................................................
101010101010101010101010101010101010101010101010101010101010-
122 124 126 127 129 140 141 142 143 145 146 158 173 180 180 181 181 182 184 184 185 194 196 198 215 216 217 220 224 230
20 Standard value table Standard service value table ........................................................................................................................... 20 Standard value table for engine ................................................................................................................... 20 Standard value table for machine ................................................................................................................ 20 -
3 3 4
30 Testing and adjusting Tools for testing, adjusting, and troubleshooting............................................................................................. Diagnosis equipment list .............................................................................................................................. Engine and cooling system ............................................................................................................................. Testing engine speed................................................................................................................................... Testing intake air pressure (boost pressure) ............................................................................................... Testing exhaust temperature ....................................................................................................................... Testing exhaust gas color ............................................................................................................................ Adjusting valve clearance ............................................................................................................................ Measuring compression pressure................................................................................................................ Testing blow-by pressure............................................................................................................................. Testing engine oil pressure.......................................................................................................................... Testing EGR valve drive oil pressure........................................................................................................... Handling of fuel system devices .................................................................................................................. Releasing residual pressure from fuel system ............................................................................................. Testing fuel pressure ................................................................................................................................... Handling of reduced cylinder mode operation ............................................................................................. Handling of no injection cranking operation ................................................................................................. Testing leakage from pressure limiter and return rate from injector ............................................................ Bleeding air from fuel circuit......................................................................................................................... Testing fuel circuit for leakage ..................................................................................................................... Replacing and adjusting alternator and air conditioner compressor belt ..................................................... Measuring fan speed ................................................................................................................................... Testing fan circuit oil pressure ..................................................................................................................... Bleeding air from fan pump.......................................................................................................................... Adjusting fuel control dial and decelerator pedal .........................................................................................
D375A-6 (07)
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4 4 6 6 8 10 12 14 16 19 21 22 24 25 26 27 27 28 31 33 34 35 36 37 38
00-3
ShopManual Table of contents
Power train ...................................................................................................................................................... Testing power train oil pressure................................................................................................................... Adjusting transmission output speed sensor ............................................................................................... Simple test procedure for brake performance.............................................................................................. Adjusting brake pedal and parking brake lever............................................................................................ Adjusting position of pccs lever console ...................................................................................................... Emergency escape method when there is failure in power train ................................................................. Undercarriage and frame ................................................................................................................................ Inspecting wear of sprocket ......................................................................................................................... Testing and adjusting track shoe tension..................................................................................................... Hydraulic system ............................................................................................................................................. Measuring and adjusting work equipment oil pressure................................................................................ Testing control circuit main pressure ........................................................................................................... Testing PPC valve output pressure ............................................................................................................. Adjusting play of PPC valve......................................................................................................................... Testing output pressure of ripper pin-puller solenoid valve ......................................................................... Checking location of cause of hydraulic drift of blade and ripper................................................................. Testing leakage inside work equipment cylinder ......................................................................................... Releasing remaining pressure in work equipment cylinders........................................................................ Bleeding air from work equipment cylinders ................................................................................................ Adjusting ripper lever position...................................................................................................................... Work equipment .............................................................................................................................................. Adjusting work equipment lock lever............................................................................................................ Adjusting blade ............................................................................................................................................ Cab and its attachments.................................................................................................................................. Testing and adjusting operator's cab ........................................................................................................... Testing and adjusting operator's seat isolator.............................................................................................. Electrial system ............................................................................................................................................... Special functions of machine monitor (EMMS) ............................................................................................ Handling of voltage circuit of engine controller ............................................................................................ Adjustment method when controller has been replaced .............................................................................. Preparation work for troubleshooting of electrical system ........................................................................... Inspection procedure of diode...................................................................................................................... Handling of optional devices ........................................................................................................................ Request for opening ORBCOMM terminal................................................................................................... Initialization procedures for VHMS controller............................................................................................... Using method of KOMTRAX functions of ORBCOMM terminal................................................................... Precautions for replacing VHMS controller .................................................................................................. Pm Clinic service............................................................................................................................................. Pm Clinic service .........................................................................................................................................
30 - 40 30 - 40 30 - 52 30 - 53 30 - 54 30 - 57 30 - 58 30 - 60 30 - 60 30 - 61 30 - 62 30 - 62 30 - 65 30 - 66 30 - 68 30 - 69 30 - 70 30 - 71 30 - 72 30 - 72 30 - 73 30 - 74 30 - 74 30 - 75 30 - 77 30 - 77 30-81-1 30 - 82 30 - 82 30 -139 30 -140 30 -144 30 -148 30 -149 30 -150 30 -152 30 -172 30 -175 30 -181 30 -181
40 Troubleshooting General Information on troubleshooting .......................................................................................................... Points to remember when troubleshooting .................................................................................................. Sequence of events in troubleshooting........................................................................................................ Checks before troubleshooting .................................................................................................................... Classification and procedures for troubleshooting ....................................................................................... Failure codes table....................................................................................................................................... Phenomena and troubleshooting numbers .................................................................................................. Information in troubleshooting table............................................................................................................. Troubleshooting method for disconnecting wiring harness of pressure sensor system............................... Connectors table and arrangement drawing................................................................................................ Connection table for connector pin numbers ............................................................................................... T-branch box and T-branch adapter table ................................................................................................... Fuse locations table ..................................................................................................................................... Troubleshooting by failure code ...................................................................................................................... Failure code [AB00MA] Battery Charge Abnormal ...................................................................................... Failure code [1380MW] Lock up clutch: Slip................................................................................................ Failure code [1500L0] Transmission clutch: Abnormal ................................................................................ Failure code [15E0MW] Transmission clutch: Slip....................................................................................... Failure code [15SAL1] Forward clutch: Fill high .......................................................................................... Failure code [15SALH] Forward clutch: Fill Low .......................................................................................... Failure code [15SBL1] Reverse clutch: Fill high ..........................................................................................
40 - 9 40 - 9 40 - 10 40 - 11 40 - 36 40 - 39 40 - 45 40 - 47 40 - 49 40 - 88 40 - 52 40 -102 40 -105 40 -109 40 -109 40 -110 40 -111 40 -111 40 -112 40 -114 40 -116
00-4
D375A-6 (07)
Shop Manual Table of contents
Failure code [15SBLH] Reverse clutch: Fill Low.......................................................................................... Failure code [15SEL1] Speed 1st clutch: Fill high ....................................................................................... Failure code [15SELH] Speed 1st clutch: Fill Low ....................................................................................... Failure code [15SFL1] Speed 2nd clutch: Fill high ...................................................................................... Failure code [15SFLH] Speed 2nd clutch: Fill Low ...................................................................................... Failure code [15SGL1] Speed 3rd clutch: Fill high....................................................................................... Failure code [15SGLH] Speed 3rd clutch: Fill Low ...................................................................................... Failure code [15SJL1] L/U: Fill high ............................................................................................................. Failure code [15SJLH] L/U: Fill low.............................................................................................................. Failure code [1800MW] P/T clutch: Slip....................................................................................................... Failure code [2201L1] Right clutch: Fill high ................................................................................................ Failure code [2201LH] Right clutch: Fill low................................................................................................. Failure code [2202L1] Left clutch: Fill high .................................................................................................. Failure code [2202LH] Left clutch: Fill low ................................................................................................... Failure code [2300NR] Brake Themal Load Abnormality............................................................................. Failure code [2301L1] Right brake: Fill high ................................................................................................ Failure code [2301LH] Right brake: Fill low ................................................................................................. Failure code [2301NR] Steering Brake RH Themal Load Abnormality ........................................................ Failure code [2302L1] Left brake: Fill high................................................................................................... Failure code [2302LH] Left brake: Fill low.................................................................................................... Failure code [2302NR] Steering Brake LH Themal Load Abnormality......................................................... Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection................................................................. Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit .................................................................... Failure code [AA10NX] Air Cleaner Clogging .............................................................................................. Failure code [B@BAZG] Eng Oil Press Low................................................................................................ Failure code [B@BAZK] Eng Oil Level Low................................................................................................. Failure code [B@BCNS] Eng Water Overheat ............................................................................................ Failure code [B@BCZK] Eng Water Level Low ........................................................................................... Failure code [B@CENS] T/C Oil Overheat .................................................................................................. Failure code [B@HANS] Hyd Oil Overheat.................................................................................................. Failure code [B@HAZK] Hyd Oil Level Low................................................................................................. Failure code [CA111] ECM Critical Internal Failure ..................................................................................... Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................ Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... Failure code [CA131] Throttle Sensor High Error ........................................................................................ Failure code [CA132] Throttle Sensor Low Error ......................................................................................... Failure code [CA135] Eng Oil Press Sensor High Error .............................................................................. Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................... Failure code [CA144] Coolant Temp Sens High Error ................................................................................. Failure code [CA145] Coolant Temp Sens Low Error.................................................................................. Failure code [CA153] Chg Air Temp Sensor High Error .............................................................................. Failure code [CA154] Chg Air Temp Sensor Low Error ............................................................................... Failure code [CA187] Sens Supply 2 Volt Low Error ................................................................................... Failure code [CA212] Eng Oil Temp Sensor High Error .............................................................................. Failure code [CA213] Eng Oil Temp Sensor Low Error ............................................................................... Failure code [CA221] Ambient Press Sens High Error ................................................................................ Failure code [CA222] Ambient Press Sens Low Error ................................................................................. Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................. Failure code [CA234] Eng Overspeed ......................................................................................................... Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................. Failure code [CA263] Fuel Temp Sensor High Error ................................................................................... Failure code [CA265] Fuel Temp Sensor Low Error .................................................................................... Failure code [CA271] IMV/PCV1 Short Error............................................................................................... Failure code [CA272] IMV/PCV1 Open Error............................................................................................... Failure code [CA273] PCV2 Short Error ...................................................................................................... Failure code [CA274] PCV2 Open Error ...................................................................................................... Failure code [CA322] Inj #1 (L#1) Open/Short Error.................................................................................... Failure code [CA323] Inj #5 (L#5) Open/Short Error.................................................................................... Failure code [CA324] Inj #3 (L#3) Open/Short Error.................................................................................... Failure code [CA325] Inj #6 (L#6) Open/Short Error.................................................................................... Failure code [CA331] Inj #2 (L#2) Open/Short Error.................................................................................... Failure code [CA332] Inj #4 (L#4) Open/Short Error....................................................................................
D375A-6 (07)
40 -118 40 -120 40 -122 40 -124 40 -126 40 -128 40 -130 40 -132 40 -134 40 -136 40 -138 40 -140 40 -142 40 -144 40 -146 40 -148 40 -150 40 -152 40 -154 40 -156 40 -158 40 -160 40 -162 40 -164 40 -166 40 -167 40 -168 40 -169 40 -170 40 -171 40 -172 40 -174 40 -176 40 -178 40 -180 40 -182 40 -184 40 -186 40 -188 40 -190 40 -192 40 -194 40 -196 40 -198 40 -200 40 -202 40 -204 40 -206 40 -208 40 -209 40 -210 40 -212 40 -214 40 -216 40 -217 40 -218 40 -219 40 -220 40 -222 40 -224 40 -226 40 -228 40 -230
00-4-1
Shop Manual Table of contents
Failure code [CA342] Calibration Code Incompatibility................................................................................ Failure code [CA351] Injectors Drive Circuit Error ....................................................................................... Failure code [CA352] Sens Supply 1 Volt Low Error ................................................................................... Failure code [CA386] Sens Supply 1 Volt High Error .................................................................................. Failure code [CA441] Battery Voltage Low Error ......................................................................................... Failure code [CA442] Battery Voltage High Error ........................................................................................ Failure code [CA449] Rail Press Very High Error ........................................................................................ Failure code [CA451] Rail Press Sensor High Error .................................................................................... Failure code [CA452] Rail Press Sensor Low Error..................................................................................... Failure code [CA553] Rail Press High Error ................................................................................................ Failure code [CA554] Rail Press Sensor In Range Error............................................................................. Failure code [CA559] Rail Press Low Error ................................................................................................. Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................................... Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................................... Failure code [CA757] All Continuous Data Lost Error.................................................................................. Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................................. Failure code [CA1228] EGR Valve Servo Error 1 ........................................................................................ Failure code [CA1625] EGR Valve Servo Error 2 ........................................................................................ Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................ Failure code [CA2185] Throt Sens Sup Volt High Error............................................................................... Failure code [CA2186] Throt Sens Sup Volt Low Error ............................................................................... Failure code [CA2249] Rail Press Very Low Error....................................................................................... Failure code [CA2271] EGR Valve Pos Sens High Error............................................................................. Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................................. Failure code [CA2351] EGR Valve Sol Current High Error.......................................................................... Failure code [CA2352] EGR Valve Sol Current Low Error........................................................................... Failure code [D110KB] Battery Relay: Drive Short Circuit ........................................................................... Failure code [D130KA] Neutral relay: Disconnection................................................................................... Failure code [D130KB] Neutral relay: Short circuit ...................................................................................... Failure code [D161KA] Back-up alarm releay: Disconnection ..................................................................... Failure code [D161KB] Back-up alarm releay: Short circuit......................................................................... Failure code [D182KZ] Preheater Relay Abnormality .................................................................................. Failure code [D190KA] ACC signal relay: Disconnection ............................................................................ Failure code [D190KB] ACC signal relay: Short circuit ................................................................................ Failure code [D1EFKA] Pre lub. motor relay: Disconnection ....................................................................... Failure code [D1EFKB] Pre lub. motor relay: Short circuit........................................................................... Failure code [DAFRKR] Monitor: Can communication lost (PT) .................................................................. Failure code [dAFRKR] Monitor: CAN communication lost (WE) ................................................................ Failure code [DAFRMC] CAN Discon (Monitor Detected) ........................................................................... Failure code [DB2RKR] ENG cont.: Can communication lost (PT).............................................................. Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ..................................................... Failure code [DB90KT] WE controller: Abnormality in controller ................................................................. Failure code [DB91KK] WE controller: Source voltage reduction ................................................................ Failure code [DB92KK] WE controller: Output voltage reduction................................................................. Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ........................................................... Failure code [DB99KQ] WE controller: Type select signal........................................................................... Failure code [DB9RKR] WE controller: Can communication lost (PT)......................................................... Failure code [DBB0KK] VHMS controller:Source voltage reduction ............................................................ Failure code [DBB0KQ] VHMS connector connection abnormality ............................................................. Failure code [DBB3KK] VHMS controller: Source voltage reduction ........................................................... Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction.............................................................. Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction............................................................... Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction............................................................... Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) .......................................................... Failure code [DBE0KT] PT controller: Abnormality in controller .................................................................. Failure code [DBE1KK] PT controller: Source voltage reduction................................................................. Failure code [DBE2KK] PT controller: Output voltage reduction ................................................................. Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction ............................................................ Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ............................................................... Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction ............................................................ Failure code [DBE9KQ] PT controller: Type select signal ........................................................................... Failure code [DBERKR] PT controller: Can communication lost (WE) ........................................................ Failure code [DD12KA] Shift up Sw: Disconnection ....................................................................................
00-4-2
40 -232 40 -233 40 -234 40 -236 40 -237 40 -238 40 -239 40 -240 40 -242 40 -244 40 -245 40 -246 40 -250 40 -252 40 -253 40 -254 40 -256 40 -257 40 -258 40 -259 40 -260 40 -261 40 -262 40 -264 40 -266 40 -268 40 -270 40 -272 40 -274 40 -276 40 -278 40 -280 40 -282 40 -284 40 -286 40 -288 40 -290 40 -291 40 -292 40 -297 40 -300 40 -301 40 -302 40 -304 40 -306 40 -308 40 -309 40 -312 40 -314 40 -316 40 -318 40 -320 40 -322 40 -323 40 -323 40 -324 40 -326 40 -328 40 -330 40 -332 40 -334 40 -335 40 -338
D375A-6 (07)
Shop Manual Table of contents
Failure code [DD12KB] Shift up Sw: Short circuit ........................................................................................ Failure code [DD13KA] Shift down Sw: Disconnection................................................................................ Failure code [DD13KB] Shift down Sw: Short circuit ................................................................................... Failure code [DD14KA] Parking lever Sw: Dissconnection.......................................................................... Failure code [DD14KB] Parking lever Sw: Short circuit ............................................................................... Failure code [DDB9L4] Reverse SW Signal disagreement.......................................................................... Failure code [DDE2KA] Pre lub. oil press sw: Disconnection ...................................................................... Failure code [DDK3L4] Forward SW Signal disagreement.......................................................................... Failure code [DDK5KA] Shift switch disconnection...................................................................................... Failure code [DDK5KB] Shift switch short circuit ......................................................................................... Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ................................................................. Failure code [DDN3LD] Blade tilt LH pressure SW abnormality .................................................................. Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection .................................................................. Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit...................................................................... Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection....................................................................... Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit .......................................................................... Failure code [DDNALD] Blade lift up pressure SW abnormality .................................................................. Failure code [DDNBLD] Ripper lift up pressure SW abnormality................................................................. Failure code [DDNCLD] Ripper lift down pressure SW abnormality ............................................................ Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.................................................................. Failure code [DDNELD] Ripper tilt back pressure SW abnormality ............................................................. Failure code [DDNFLD] Blade lift down pressure SW abnormality.............................................................. Failure code [DDNLKA] Weq lock Sw: Disconnection ................................................................................. Failure code [DDNLKB] Weq lock Sw: Short circuit..................................................................................... Failure code [DDT5KA] Neutral switch disconnection ................................................................................. Failure code [DDT5KB] Neutral switch short circuit ..................................................................................... Failure code [DDT5KQ] Lever SPEC selection signal disagreement .......................................................... Failure code [DDTSL1] S/C: Fill high ........................................................................................................... Failure code [DDTSLH] S/C: Fill low............................................................................................................ Failure code [DGE5KX] Ambient temp sensor abnormality ......................................................................... Failure code [DGS1KX] Hyd oil temp: signal abnormal ............................................................................... Failure code [DGT1KA] T/C oil temp sensor: Abnormal .............................................................................. Failure code [DGT1KX] T/C oil temp sensor: Abnormal .............................................................................. Failure code [DGT5KA] F exhaust temp sensor disconnection ................................................................... Failure code [DGT5KB] F exhaust temp sensor short circuit....................................................................... Failure code [DGT6KA] R exhaust temp sensor disconnection................................................................... Failure code [DGT6KB] R exhaust temp sensor short circuit ...................................................................... Failure code [DH21KA] Weq pressure sensor: Disconnection .................................................................... Failure code [DH21KB] Weq pressure sensor: Short circuit ........................................................................ Failure code [DHE5KB] ENG blow-by pressure sensor disconnection........................................................ Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ........................................................... Failure code [DHT3KX] T/M oil pressure sensor abnormality...................................................................... Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.................................................................. Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ..................................................................... Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................................................ Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ................................................................... Failure code [DK10KA] Fuel control Dial: Disconnection............................................................................. Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................ Failure code [DK30KA] ST lever 1: Disconnection ...................................................................................... Failure code [DK30KB] ST lever 1: Short circuit .......................................................................................... Failure code [DK30KX] ST lever: Out of normal range ................................................................................ Failure code [DK30KZ] ST lever: Disconnection or short circuit .................................................................. Failure code [DK30L8] ST lever: Signal mismatch ...................................................................................... Failure code [DK31KA] ST lever 2: Disconnection ...................................................................................... Failure code [DK31KB] ST lever 2: Short circuit .......................................................................................... Failure code [DK40KA] Brake potentiometer: Disconnection ...................................................................... Failure code [DK40KB] Brake potentiometer: Short circuit .......................................................................... Failure code [DK55KX] FR lever: Out of normal range................................................................................ Failure code [DK55KZ] FR lever: Disconnection or short circuit.................................................................. Failure code [DK55L8] FR lever: Signal mismatch ...................................................................................... Failure code [DK56KA] FR lever 1: Disconnection ...................................................................................... Failure code [DK56KB] FR lever 1: Short circuit.......................................................................................... Failure code [DK57KA] FR lever 2: Disconnection ......................................................................................
D375A-6 (07)
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00-4-3
Shop Manual Table of contents
Failure code [DK57KB] FR lever 2: Short circuit.......................................................................................... Failure code [DK60KA] Acceleration sensor: Disconnection ....................................................................... Failure code [DK60KB] Acceleration sensor: Short circuit........................................................................... Failure code [DKH1KA] Pitch angle sensor: Disconnection......................................................................... Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................ Failure code [DLF1KA] T/C out-speed sensor: Disconnection .................................................................... Failure code [DLM3KA] Fan rev. sensor: Disconnection ............................................................................. Failure code [DLM3MB] Fan control: Decline .............................................................................................. Failure code [DLT3KA] T/M out-speed sensor: Disconnection .................................................................... Failure code [DLT3KB] T/M out-speed sensor: Abnormal ........................................................................... Failure code [DW59KA] Blade dual selector SOL disconnection................................................................. Failure code [DW59KB] Blade dual selector SOL short circuit .................................................................... Failure code [DW59KY] Blade dual selector SOL hot short......................................................................... Failure code [DW5AKA] Blade pitch selector SOL disconnection ............................................................... Failure code [DW5AKB] Blade pitch selector SOL short circuit ................................................................... Failure code [DW5AKY] Blade pitch selector SOL Short circuit .................................................................. Failure code [DW7BKA] Fan rev EPC: Disconnection................................................................................. Failure code [DW7BKB] Fan rev EPC: Short circuit .................................................................................... Failure code [DWN3KA] Ssp solenoid: Disconnection................................................................................. Failure code [DWN3KB] Ssp solenoid: Short circuit .................................................................................... Failure code [DWN3KY] SSP solenoid: Short circuit ................................................................................... Failure code [DWN5KA] Fan pump solenoid 1: Disconnection.................................................................... Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ....................................................................... Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ....................................................................... Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ................................................................... Failure code [DWNCKB] Fan pump solenoid 2: Short circuit....................................................................... Failure code [DWNCKY] Fan pump solenoid 2: Short circuit....................................................................... Failure code [DXH1KA] Lock-up ECMV: Disconnection .............................................................................. Failure code [DXH1KB] Lock-up ECMV: Short circuit.................................................................................. Failure code [DXH1KY] Lock-up ECMV: Short circuit.................................................................................. Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................ Failure code [DXH4KB] 1st clutch ECMV: Short circuit ............................................................................... Failure code [DXH4KY] 1st clutch ECMV: Short circuit ............................................................................... Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .......................................................................... Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .............................................................................. Failure code [DXH5KY] 2nd clutch ECMV: Short circuit .............................................................................. Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ........................................................................... Failure code [DXH6KB] 3rd clutch ECMV: Short circuit............................................................................... Failure code [DXH6KY] 3rd clutch ECMV: Short circuit............................................................................... Failure code [DXH7KA] R clutch ECMV: Disconnection.............................................................................. Failure code [DXH7KB] R clutch ECMV: Short circuit ................................................................................. Failure code [DXH7KY] R clutch ECMV: Short circuit ................................................................................. Failure code [DXH8KA] F clutch ECMV: Disconnection .............................................................................. Failure code [DXH8KB] F clutch ECMV: Short circuit.................................................................................. Failure code [DXH8KY] F clutch ECMV: Short circuit.................................................................................. Failure code [DXH9KA] Right clutch ECMV: Disconnection ........................................................................ Failure code [DXH9KB] Right clutch ECMV: Short circuit............................................................................ Failure code [DXH9KY] Right clutch ECMV: Short circuit............................................................................ Failure code [DXHAKA] Left clutch ECMV: Disconnection .......................................................................... Failure code [DXHAKB] Left clutch ECMV: Short circuit.............................................................................. Failure code [DXHAKY] Left clutch ECMV: Short circuit.............................................................................. Failure code [DXHBKA] Right brake ECMV: Disconnection ........................................................................ Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................ Failure code [DXHBKY] Right brake ECMV: Short circuit............................................................................ Failure code [DXHCKA] Left brake ECMV: Disconnection .......................................................................... Failure code [DXHCKB] Left brake ECMV: Short circuit.............................................................................. Failure code [DXHCKY] Left brake ECMV: Short circuit.............................................................................. Failure code [DXJBKA] S/C ECMV: Disconnection ..................................................................................... Failure code [DXJBKB] S/C ECMV: Short circuit......................................................................................... Failure code [DXJBKY] S/C ECMV: Short circuit......................................................................................... Failure code [DY2HKA] Pre lub. motor: Disconnection................................................................................ Failure code [F@BBZL] ENG blow-by pressure high level .......................................................................... Failure code [F@BYNR] F exhaust temp high level (2) ...............................................................................
00-4-4
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D375A-6 (07)
Shop Manual Table of contents
Failure code [F@BYNS] F exhaust temp high level (1) ............................................................................... Failure code [F@BZNR] R exhaust temp high level (2)............................................................................... Failure code [F@BZNS] R exhaust temp high level (1) ............................................................................... Troubleshooting of electrical system (E-mode) ............................................................................................... Information contained in troubleshooting table ............................................................................................ E-1 Engine does not start (starting motor does not turn) ............................................................................. E-2 Preheater does not operate................................................................................................................... E-3 When starting switch is turned ON, machine monitor displays nothing................................................. E-4 When starting switch is turned ON (before starting engine), basic check item lights up....................... E-5 Precaution item lights up while engine is running ................................................................................. E-6 Emergency stop item lights up while engine is running......................................................................... E-7 Engine coolant temperature gauge does not indicate normally ............................................................ E-8 Fuel gauge does not indicate properly .................................................................................................. E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ....................................... E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ............................................. E-11 Contents of display by machine monitor are different from applicable machine ................................. E-12 Machine monitor does not display some items ................................................................................... E-13 Function switch does not work ............................................................................................................ E-14 Operation mode does not change ....................................................................................................... E-15 Gearshift mode does not change ........................................................................................................ E-16 Customize function does not operate normally ................................................................................... E-17 Customize memory function does not operate normally ..................................................................... E-18 Alarm buzzer does not sound or does not stop................................................................................... E-19 When starting switch is turned OFF, service meter is not displayed................................................... E-20 Machine monitor cannot be set in service mode ................................................................................. E-21 The ripper pin puller cylinder does not operate ................................................................................... E-22 Horn does not sound or does not stop ................................................................................................ E-23 Back-up alarm does not sound or does not stop................................................................................. E-24 Fan does not reverse .......................................................................................................................... E-25 The head lamp and rear lamp do not light up...................................................................................... E-26 Windshield wiper does not operate ..................................................................................................... E-27 Window washer does not operate ....................................................................................................... E-28 Electric priming pump does not operate or does not stop automatically ............................................. E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .......................................... E-30 Gear cannot be shifted ........................................................................................................................ Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... Information in troubleshooting table............................................................................................................. List of Failure Modes and Causes ............................................................................................................... H-1 Machine lacks power(or drawbar pull) .................................................................................................. H-2 Machine cannot travel (at 2nd or 3rd each speed)................................................................................ H-3 Machine cannot travel at any gear speeds ........................................................................................... H-4 Machine travels only in one direction, forward or reverse..................................................................... H-5 Large time lag at gear shifting or directional change ............................................................................ H-6 Machine connot turn.............................................................................................................................. H-7 Machine turns only to one side ............................................................................................................. H-8 Machine overruns at turnning................................................................................................................ H-9 Brake does not work ............................................................................................................................. H-10 Torque converter does not lock up...................................................................................................... H-11 Power train oil overheats..................................................................................................................... H-12 All work equipment operates too slow or lacks power ........................................................................ H-13 All work equipment does not operate.................................................................................................. H-14 Blade lift cylinder speed is too slow or lacks power ............................................................................ H-15 Blade tilt cylinder speed is too slow or lacks power ............................................................................ H-16 Ripper lift cylinder speed is too slow or lacks power........................................................................... H-17 Ripper tilt cylinder speed is too slow or lacks power........................................................................... H-18 Excessive hydraulic drift of blade lift cylinder...................................................................................... H-19 Excessive hydraulic drift of blade tilt cylinder...................................................................................... H-20 Excessive hydraulic drift of ripper lift cylinder ..................................................................................... H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ............................................. H-22 Blade pitch does not work (machine with dual tilt specification) ......................................................... H-23 Abnormal noise from around work equipment pump .......................................................................... H-24 Abnormal fan rotation (noise and/or vibration are abnormally large or engine overheats) ................. H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator)
D375A-6 (07)
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00-4-5
Shop Manual Table of contents
Troubleshooting of engine (S-mode)............................................................................................................... Method of using troubleshooting chart......................................................................................................... S-1 Engine does not start easily .................................................................................................................. S-2 Engine does not start ............................................................................................................................ S-3 Engine does not rev up smoothly (response-up is poor)....................................................................... S-4 Engine stops during operation............................................................................................................... S-5 Engine does not rotate smoothly (hunting)............................................................................................ S-6 Engine lacks power (or output shortage)............................................................................................... S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................ S-8 Oil is consumption is excessive(or exhaust smoke is blue) .................................................................. S-9 Engine oil becomes contaminated quickly ............................................................................................ S-10 Fuel consumption is excessive............................................................................................................ S-11 Oil mixes into coolant(coolant blows back or is reduced).................................................................... S-12 Engine pressure monitor lights up (drop in engine oil pressure) ......................................................... S-13 Oil level rises (Coolant or fuel mixes into oil) ...................................................................................... S-14 Coolant temperature rises too high (overheating) ............................................................................... S-15 Abnormal noise is heard...................................................................................................................... S-16 Vibration is excessive.......................................................................................................................... S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is and then air is bled, engine does not start or it starts but stalls)..................................................................
40 -624 40 -624 40 -628 40 -630 40 -634 40 -636 40 -637 40 -638 40 -640 40 -642 40 -643 40 -644 40 -645 40 -646 40 -647 40 -649 40 -650 40 -651 used up 40 -652
50 Disassembly and assembly General information on disassembly and assembly........................................................................................ How to read this manual .............................................................................................................................. Coating materials list.................................................................................................................................... Special tools list ........................................................................................................................................... Sketches of special tools ............................................................................................................................. Engine and cooling system ............................................................................................................................. Removal and installation of fuel supply pump assembly ............................................................................. Removal and installation of fuel injector assembly ...................................................................................... Removal and installation of cylinder head assembly ................................................................................... Removal and installation of radiator guard assembly .................................................................................. Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)................... Removal and installation of radiator............................................................................................................. Removal and installation of hydraulic oil cooler ........................................................................................... Removal and installation of aftercooler........................................................................................................ Removal and installation of engine assembly.............................................................................................. Removal and installation of engine hood assembly..................................................................................... Removal and installation of engine front seal .............................................................................................. Removal and installation of engine rear seal ............................................................................................... Removal and installation of fan drive assembly........................................................................................... Removal and installation of fan motor assembly ......................................................................................... Removal and installation of fuel tank assembly ........................................................................................... Power train ...................................................................................................................................................... Removal and installation of damper assembly ............................................................................................ Disassembly and assembly of damper assembly ........................................................................................ Removal and installation of power train unit assembly ................................................................................ Disconnection and connection of power train unit assembly ....................................................................... Disassembly and assembly of PTO assembly............................................................................................. Disassembly and assembly of torque converter assembly .......................................................................... Disassembly and assembly of TORQFLOW transmission assembly .......................................................... Disassembly and assembly of steering case assembly............................................................................... Removal and installation of power train pump and lubrication pump assembly .......................................... Removal and installation of scavenging pump assembly ............................................................................ Removal and installation of final drive assembly ......................................................................................... Disassembly and assembly of final drive assembly..................................................................................... Undercarriage and frame ................................................................................................................................ Removal and installation of track frame assembly....................................................................................... Removal and installation of idler assembly.................................................................................................. Disassembly and assembly of idler assembly ............................................................................................. Removal and installation of recoil spring assembly ..................................................................................... Disassembly and assembly of recoil spring assembly................................................................................. Removal and installation of track roller assembly........................................................................................
50 - 4 50 - 4 50 - 6 50 - 9 50 - 16 50 - 24 50 - 24 50 - 28 50 - 33 50 - 49 50 - 54 50 - 59 50 - 61 50 - 62 50 - 63 50 - 70 50 - 73 50 - 75 50 - 79 50 - 81 50 - 83 50 - 86 50 - 86 50 - 90 50 - 93 50 -100 50 -109 50 -115 50 -125 50 -153 50 -169 50 -170 50 -171 50 -173 50 -186 50 -186 50 -191 50 -192 50 -196 50 -201 50 -203
00-4-6
D375A-6 (07)
Shop Manual Table of contents
Disassembly and assembly of track roller assembly ................................................................................... 50 -206 Removal and installation of carrier roller assembly ..................................................................................... 50 -209 Disassembly and assembly of carrier roller assembly ................................................................................. 50 -210 Removal and installation of bogie assembly................................................................................................ 50 -214 Disassembly and assembly of bogie assembly ........................................................................................... 50 -219 Removal and installation of first bogie assembly ......................................................................................... 50 -221 Separation and connection of track shoe assembly .................................................................................... 50 -226 Overall disassembly and assembly of track shoe ........................................................................................ 50 -230 Link press press-fitting jig dimensions ......................................................................................................... 50 -247 Disassembly and assembly of one link assembly in the field ...................................................................... 50 -248 Disassembly and assembly of master link ................................................................................................... 50 -253 Removal and installation of pivot shaft assembly ........................................................................................ 50 -257 Removal and installation of equalizer bar .................................................................................................... 50 -258 Disassembly and assembly of equalizer bar bushing .................................................................................. 50 -262 Removal and installation of segment tooth .................................................................................................. 50 -264 Hydraulic system ............................................................................................................................................. 50 -266 Removal and installation of hydraulic tank assembly .................................................................................. 50 -266 Removal and installation of work equipment pump assembly ..................................................................... 50 -269 Removal and installation of fan pump assembly.......................................................................................... 50 -273 Removal and installation of control valve assembly .................................................................................... 50 -275 Disassembly and assembly of control valve assembly ................................................................................ 50 -277 Disassembly and assembly of blade PPC valve assembly.......................................................................... 50 -282 Disassembly and assembly of ripper PPC valve assembly ......................................................................... 50 -285 Disassembly and assembly of hydraulic cylinder assembly ........................................................................ 50 -287 Disassembly and assembly of ripper pin puller cylinder assembly .............................................................. 50 -295 Work equipment .............................................................................................................................................. 50 -298 Removal and installation of blade assembly................................................................................................ 50 -298 Disassembly and assembly of blade assembly ........................................................................................... 50 -300 Disassembly and assembly of giant ripper assembly .................................................................................. 50 -304 Cab and its attachments.................................................................................................................................. 50 -308 Removal and installation of ROPS guard .................................................................................................... 50 -308 Removal and installation of operator’s cab assembly.................................................................................. 50 -309 Removal and installation of floor frame assembly ....................................................................................... 50 -313 Removal and installation of air conditioner unit assembly ........................................................................... 50 -318 Removal and installation of operator's seat isolator ....................................................................................50-323-1 Disassembly and assembly of operator's seat isolator ................................................................................50-323-2 Electrical system ............................................................................................................................................. 50 -324 Removal and installation of transmission controller assembly and steering controller assembly................ 50 -324 Removal and installation of engine controller assembly .............................................................................. 50 -325 Removal and installation of VHMS controller assembly .............................................................................. 50 -327 Removal and installation of machine monitor assembly .............................................................................. 50 -328 60 Maintenance Standard Engine and cooling system ............................................................................................................................. Engine mount............................................................................................................................................... Cooling fan pump......................................................................................................................................... Cooling fan motor......................................................................................................................................... Power train ...................................................................................................................................................... Power train unit ............................................................................................................................................ Damper and universal joint .......................................................................................................................... Torque converter and PTO .......................................................................................................................... Main relief valve and torque converter relief valve....................................................................................... Lockup clutch ECMV and stator clutch ECMV............................................................................................. Scavenging pump ........................................................................................................................................ Transmission control.................................................................................................................................... Transmission................................................................................................................................................ Transmission lubricating oil relief valve ....................................................................................................... Power train and lubrication pump ................................................................................................................ Transfer, bevel gear shaft and steering unit ................................................................................................ Steering control valve .................................................................................................................................. Steering clutch ECMV and steering brake ECMV........................................................................................ Parking brake valve ..................................................................................................................................... Final drive ....................................................................................................................................................
D375A-6 (07)
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3 3 5 12 14 14 16 19 22 23 24 25 26 30 31 32 38 39 40 41
00-4-7
Shop Manual Table of contents
Sprocket....................................................................................................................................................... Undercarriage and frame ................................................................................................................................ Track frame.................................................................................................................................................. Idler cushion................................................................................................................................................. Idler .............................................................................................................................................................. Track roller ................................................................................................................................................... Carrier roller ................................................................................................................................................. Track roller bogie ......................................................................................................................................... Track shoe ................................................................................................................................................... Main frame ................................................................................................................................................... Suspension .................................................................................................................................................. Hydraulic system ............................................................................................................................................. PPC valve .................................................................................................................................................... Hydraulic cylinder......................................................................................................................................... Quick drop valve .......................................................................................................................................... Work equipment pump................................................................................................................................. Control valve ................................................................................................................................................ Self-pressure reducing valve ....................................................................................................................... Work equipment .............................................................................................................................................. Cylinder stay ................................................................................................................................................ Blade............................................................................................................................................................ Cutting edge and end bit.............................................................................................................................. Ripper ..........................................................................................................................................................
6060606060606060606060606060606060606060606060-
44 46 46 48 50 52 54 55 56 60 62 67 67 72 75 76 79 85 87 87 88 92 94
80 Appendix Air Conditioner................................................................................................................................................. Caution about refrigerant ............................................................................................................................. Air conditioner component ........................................................................................................................... Configuration and function of refrigeration cycle.......................................................................................... Outline of refrigeration cycle ........................................................................................................................ Air conditioner unit ....................................................................................................................................... Blower unit ................................................................................................................................................... FRESH/RECIRC air changeover damper .................................................................................................... Compressor ................................................................................................................................................. Condenser ................................................................................................................................................... Receiver drier............................................................................................................................................... Air conditioner control panel ........................................................................................................................ Procedure for testing and troubleshooting ................................................................................................... Circuit diagram and arrangement of connector pins .................................................................................... System diagram ........................................................................................................................................... Part and connector locations ....................................................................................................................... Testing temperature control ......................................................................................................................... Testing FRESH/RECIC air changeover ....................................................................................................... Testing relay ................................................................................................................................................ Troubleshooting chart 1 ............................................................................................................................... Troubleshooting chart 2 ............................................................................................................................... Information in troubleshooting table............................................................................................................. Troubleshooting for power supply system (Air conditioner does not operate) ............................................. Troubleshooting for compressor system (Air is not cooled)......................................................................... Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) ......................... Troubleshooting for temperature control...................................................................................................... Troubleshooting for FRESH/RECIRC air changeover ................................................................................. Troubleshooting with gauge pressure.......................................................................................................... Connection of service tool............................................................................................................................ Precautions for disconnecting and connecting ............................................................................................ Handling of compressor oil ..........................................................................................................................
80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 -
3 3 4 6 7 10 14 15 16 17 18 20 22 24 26 28 32 32 34 36 38 40 42 44 48 54 56 58 60 62 64
90 Diagrams and Drawings Hydraulic diagrams and drawings ................................................................................................................... Symbols used in hydraulic circuit diagrams ................................................................................................. Power train hydraulic circuit diagram ........................................................................................................... Hydraulic circuit diagram..............................................................................................................................
90 90 90 90 -
3 3 5 7
00-4-8
D375A-6 (07)
Shop Manual Table of contents
Electrical diagrams and drawings.................................................................................................................... 90 - 9 Symbols use in electric circuit diagrams ...................................................................................................... 90 - 9 Electrical circuit diagram .............................................................................................................................. 90 - 13 Index................................................................................................................................................................ ........ 1
D375A-6 (07)
00-4-9
DRAFT Table of contents
00-4-10 00-14
D375A-6 (02)
Forword and general information Safety notice
Forword and general information Safety notice
0 -3
Important safety notice Appropriate servicing and repair are extremely important to ensure safe operation of the machine.The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu.Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark "k" is indicated for matters that require special precautions for such work.The work indicated with the warning mark should be carried out along to the instructions with special attention to the precautions.Should a hazardous situation occur or be anticipated during such work, be sure to proceed it safe and take every necessary measure. 1. General precautions k Inappropriate handling creates an extreme danger.Read and understand what is described in the Operation and Maintenance Manual before operating the machine.Read and understand what is described in this manual before starting work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear the safety glasses when hitting parts with a hammer q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. D375A-6 (09)
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condition. 9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles(for cleaning or grinding work) 8 Wearing shielding goggles and protectors(for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much
00-5
Forword and general information Safety notice
2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning tag on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug,loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4) For the machine equipped with a battery disconnct switch, turn the battery disconnect switch to the OFF (O) position and pull the switch key out, before starting the work. For machines without a battery disconnct switch, remove the cable from the battery , before starting the work. Always remove the cable from the negative (-) terminal first.
00-6
5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct.
D375A-6 (09)
Forword and general information Safety notice
12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well. 4. Precautions for slinging work and making signals 1) Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, It may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
D375A-6 (09)
7) Limit the hanging angle to 60 °, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 19.6 kN {2,000 kg } load at a lifting angle of 150 ° , each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10)Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
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Forword and general information Safety notice
11)Do not use twisted or kinked wire ropes. 12)When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. q If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load at an angle. 13)When lowering a load, observe the following. q When lowering a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. 5. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead traveling crane k A hoist crane or similar device must be used for lifting a heavy load (25 kg or more).The weight of a part that is 25 kg or more is indicated with the symbol "4" in "Disassembly and assembly". 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signals for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load at an angle. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height.
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10)Place the control switch on a position where it will not be an obstacle to work and passage. 11)After operating the hoist, do not swing the control switch. 12)Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in operation state. 14)If you find an obstacle around the hoist, stop the operation. 15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 mabove the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter Allowable load of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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Forword and general information Safety notice
8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit 1) Disconnection k Although the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less destructive to the ozone layer for environmentally friendliness, it is not allowed to be vented into the atmosphere as is.Whenever disconnecting the air conditioner gas circuit, be sure to recover the refrigerant gas to reuse it. a Ask a gualified person for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight or your skin may be frozen.Whenever recovering or adding refrigerant gas, you must put on safety glasses, safety gloves and long sleeved clothes. The refrigerant gas must be recovered and added by a qualified person.
a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care to prevent dirt and water from entering into them. 2] Make sure that before installing the air conditioner hoses or tubes the O-rings (1) are fitted to their joints. 3] Check that each O-ring (1) is not damaged or deteriorated. 4] When connecting the refrigerant piping, coat the O-ring (1) with the compressor oil (Denso: ND-OIL8 or Valeo Thermal Systems Japan Corp.: ZXL100PG (PAG46 or the equivalent) for the refrigerant (R134a). a Example of O-ring (Fitted to every joint of hoses and tubes)
D375A-6 (09)
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DRAFT Forword and general information How to read the shop manual
How to read the shop manual q q q
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section contains table of contents, and safety and basic information. If any revision of the shop manual is made, the LIST OF REVISED PAGES will be added. 01. Specification This section explains the specifications of the machine. 10. Structure and function This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 60.Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 80.Appendix The section explains the equipment which can not be included in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting fo the equipment. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams.
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DRAFT Forword and general information How to read the shop manual
q
Engine volume This section explains the method of remanufacturing and repairing engine and replacing parts.
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES. q
Revision number When a manual is revised, revision number of each page is increased by 1. (Example: (1),(2),(3)...)
q
Revisions The revised pages are shown in the LIST OF REVISED PAGES.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Remarks
Special safety precautions are necessary when performing work.
Tightening torque Places that require special attention for tightening torque during assembly.
2
Coat
5
Oil, coolant
6
Drain
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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DRAFT Forword and general information Explanation of terms for maintenance standard
Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1. Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance". q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size
Tolerance - 0.022 - 0.126
120
a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
q
Example: Standard size 60
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Tolerance Shaft - 0.030 - 0.076
Hole + 0.046 0
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DRAFT Forword and general information Explanation of terms for maintenance standard
2. Standard clearance and standard value q The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value. 3. Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the "interference". q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the "standard interference". q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
5. Clearance limit q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. 6. Interference limit q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "interference limit". q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
4. Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the "repair limit". q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the "allowable value" or "allowable dimension". q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
Handling of electric equipment and hydraulic components 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 components" (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wires 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 wires. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly fitted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are connected to wires by crimping or soldering. If excessive force is applied to the wire, the joint is separated to cause defective contact or the wire is broken.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
3) Disconnections in wiring If the harness is pulled to disconnect the connector, or components are lifted with a crane with the harness still connected, or a heavy object hits the harness, the crimping of the connector may separate, or the soldering may be damaged, or the harness may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface of 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 electric contact cleaner. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] When removing from clips q Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
q
3] Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
2) Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (joint portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the connector and harness with a dryer, but be careful not to make them too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Position the connectors correctly, and then fit them securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
3) DT connector (DT 8-pole, 12-pole) Disconnection (Left of figure) While pressing both locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a),(b): Locks
00-18
q
Disconnection
q
Connection (Example of incomplete setting of (a))
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all 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. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with electric contact cleaner and reassemble.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
4. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the machine body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check all the related connectors for half fit. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality warning will be issued. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), wag the related wiring harnesses and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
Points to remember when handling hydraulic components With the increase in pressure and precision of hydraulic components, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic components, 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 components in the field, there is danger of dust entering the components. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic components should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil, so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
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DRAFT Forword and general information Handling of electric equipment and hydraulic components
5. Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7. Cleaning operations After repairing the hydraulic components (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic components cannot remove, so it is an extremely effective device.
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DRAFT Forword and general information Handling of connectors newly used for engines
Handling of connectors newly used for engines a Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3,FRAMATOME-2) q
95–170,12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125,170,12V140 engines) Oil pressure sensor: POIL (125,170,12V140 engines) Oil pressure switch (95,107,114 engines) Ne speed sensor of flywheel housing: NE(95-170,12V140 engines) Ambient pressure sensor: PAMB (125,170,12V140 engines)
Pull lock type (PACKARD-2) q 95–170,12V140 engines q Various temperature sensors Examples) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
Disconnect 1) Slide lock L1 to the right. 2) While pressing lock L2, pull out connector (1) toward you. a Even if lock L2 is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock L2 , and then pull out connector (1) toward you. Connect Insert the connector straight until it "clicks".
Connect Insert the connector straight until it "clicks".
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00-23
DRAFT Forword and general information Handling of connectors newly used for engines
Push lock type (1) q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03)
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Disconnect While pressing lock (C), pull out connector (3) in the direction of the arrow. q
114 engine
Connect Insert the connector straight until it "clicks".
q
107 engine
Push lock type (2) q 107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) Disconnect While pressing lock (D), pull out connector (4) in the direction of the arrow.
a If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. Connect Insert the connector straight until it "clicks".
00-24
D375A-6
DRAFT Forword and general information Handling of connectors newly used for engines
Push lock type (3) q 95, 125 – 170, 12V140 engines Disconnect While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
Turn-housing type (Round green connector) q 140 engine Example) Intake air pressure sensor in intake manifold. (CANNON-04): PIM etc. Disconnect 1) Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1)becomes heavy to turn. 2) Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Connect 1) Insert the connector to the end, while setting its groove. 2) Turn housing (H1) in the direction of the arrow until it "clicks".
Examples) Speed sensor of fuel supply pump:G (SUMITOMO-3) a Pull the connector straight up.
Connect Insert the connector straight until it "clicks".
D375A-6
00-25
Forword and general information How to read electric wire code
How to read electric wire code
0 -24
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L
---
Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.)
1. Type, symbol, and material AV and AVS are different only in thickness and outside diameter of the cover.CAVS has a circular compressed conductor. It differs from that of AV and AVS in the outside diameter and thickness of the cover.And AEX is similar to AV in thickness and outside diameter of the cover but different from AV and AVS in material of the cover. (Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile (type 1) Thin-cover low-voltage wire for automobile (type 2) Heat-resistant low-voltage wire for automobile
00-26
Symbol
Material Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
AV
AVS Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
CAVS
Conductor AEX Insulator
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Using temperature
Example of use General wiring (nominal No. 5 and above.)
-30 to +60
General wiring (nominal No. 3 and below.)
For mid- to small-size excavators (nominal No. 1.25 and below.) General wiring in extremely cold district, wiring at high ambient tem-50 to +110 perature place For wiring in a place of high atmo-
D375A-6 (04)
Forword and general information How to read electric wire code
2. Dimensions (Table 2) Nominal No.
Conductor
Co ver D
Number of strands/Diameter of strand Sectional area (mm2)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
–
AV
Standard
–
–
–
–
–
–
–
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
–
3.8
4.6
8
15
20
30
50/0.45
84/0.45
41/0.80
70/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
–
–
–
–
–
–
–
–
–
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Conductor
Number of strands/Diameter of strand Sectional area (mm2)
Nominal No.
Conductor
Co ver D
(0.5)
d (approx.)
Nominal No.
Co ver D
0.5f
CAVS
40
50
60
85
100
85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
0.5f
0.5
0.75f
0.85
1.25f
1.25
—
7/Circular compressed
—
11/Circular compressed
—
16/Circular compressed
—
0.56
—
0.88
—
1.29
(a)
—
0.9
—
1.1
—
1.4
Standard
—
1.6
—
1.8
—
2.1
Number of strands/Diameter of strand Sectional area (mm2)
"f" of nominal No. denotes "flexible".
D375A-6 (04)
00-27
Forword and general information How to read electric wire code
3. Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: "GW" means that the background is Green and marking is White. 4. Types of circuits and color codes (Table 4) Type of wire
AEX
Charge
R
WG
–
–
–
–
R
–
Ground
B
–
–
–
–
–-
B
–
Start
R
–
–
–
–
–
R
–
Light
RW
RB
RY
RG
RL
–
D
–
Instrument
Y
YR
YB
YG
YL
YW
Y
Gr
Signal
G
GW
GR
GY
GB
GL
G
Br
L
LW
LR
LY
LB
–
L
–
Br
BrW
BrR
BrY
BrB
–
–
–
Lg
LgR
LgY
LgB
LgW
–
–
–
O
–
–
–
–
–
–
–
Gr
–
–
–
–
–
–
–
P
–
–
–
–
–
–
–
Sb
–
–
–
–
–
–
–
Dg
–
–
–
–
–
–
–
Ch
–
–
–
–
–
–
–
Type of circuit
Others
00-28
AVS/AV/CAVS
D375A-6 (04)
DRAFT Forword and general information Precautions when carrying out work
Precautions when carrying out work When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the work. 1. Precautions when carrying out removal work q If the coolant contains antifreeze, dispose of it correctly. q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. q When draining oil, prepare a container of adequate size to catch the oil. q Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. q Check the number and thickness of the shims, and keep in a safe place. q When raising component, be sure to use lifting equipment of ample strength. q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn. q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06
Plug (nut end)
Sleeve nut (elbow end)
07376 - 70210 07376-70315 07376 - 70422 07376 - 70522 07376 - 70628
02789 - 00210 02789 - 00315 02789 - 00422 02789 - 00522 02789 - 00628
2) Split flange type hoses and tubes Nominal number 04 05
Flange (hose end)
Sleeve head (tube end)
Split flange
07379 - 00400 07379 - 00500
07378 - 10400 07378 - 10500
07371 - 30400 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27
D375A-6
Part No. 07049 - 00608 07049 - 00811 07049 - 01012 07049 - 01215 07049 - 01418 07049 - 01620 07049 - 01822 07049 - 02025 07049 - 02228 07049 - 02430 07049 - 02734
D 6 8 10 12 14 16 18 20 22 24 22.5
Dimensions d 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5
L 8 11 12 15 18 20 22 25 28 30 34
00-29
DRAFT Forword and general information Precautions when carrying out work
2. Precautions when carrying out installation work q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) . q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. q Bend the cotter pins and lock plates securely. q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with liquid gasket. q Clean all parts, and correct any damage, dents, burrs, or rust. q Coat rotating parts and sliding parts with engine oil. q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P). q After fitting snap rings, check that the snap ring is fitted securely in the ring groove. q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side. a When operating the hydraulic cylinders for the first time after reassembling cylinders, hydraulic pumps and other hydraulic component removed for repair, always bleed the air as follows: 1] Start the engine and run at low idle. 2] Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder100 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. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing work 1) Refilling with coolant, oil and grease q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system . Then check the coolant level again. q If the hydraulic component has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic component have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, "Bleeding air". q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see "Disassembly and assembly" .
00-30
D375A-6
DRAFT Forword and general information Precautions when carrying out work
3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
4) Checking muffler, exhaust pipe and their mounts for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness. If any part is loosened, retighten it. 5) Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and assembly".
D375A-6
00-31
DRAFT Forword and general information Method of disassembling and connecting push-pull type coupler
Method of disassembling and connecting push-pull type coupler k k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) With hose joint (2) pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.
2. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-32
D375A-6
DRAFT Forword and general information Method of disassembling and connecting push-pull type coupler
Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2. Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
D375A-6
00-33
DRAFT Forword and general information Method of disassembling and connecting push-pull type coupler
Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2. Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00-34
D375A-6
DRAFT Forword and general information Standard tightening torque table
Standard tightening torque table 1. Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Tightening torque Nm 11.8 - 14.7 27 - 34 59 - 74 98 - 123 157 - 196 245 - 309 343 - 427 490 - 608 662 - 829 824 - 1,030 1,180 - 1,470 1,520 - 1,910 1,960 - 2,450 2,450 - 3,040 2,890 - 3,630
kgm 1.2 - 1.5 2.8 - 3.5 6.0 - 7.5 10.0 - 12.5 16 -20 25 - 31.5 35 - 43.5 50 - 62 67.5 - 84.5 84 - 105 120 - 150 155 - 195 200 - 250 250 - 310 295 - 370
a The following table applies to the bolts in Fig. B. Thread diameter of bolt mm 6 8 10 12
a Figure A
Width across flats mm 10 12 14 17
Tightening torque Nm 5.9 - 9.8 13.7 - 23.5 34.3 - 46.1 74.5 - 90.2
kgm 0.6 - 1.0 1.4 - 2.4 3.5 - 4.7 7.6 - 9.2
a Figure B
Remarks: The widths across flats by thread diameter of flanged bolts (marked with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
D375A-6
00-35
DRAFT Forword and general information Standard tightening torque table
2. Table of tightening torques for split flanged bolts a Unless there are special instructions, tighten split flanged bolts to the torque below. Thread diameter of bolt mm 10 12 16
Width across flats mm 14 17 22
Tightening torque Nm 59 - 74 98 - 123 235 - 285
kgm 6.0 - 7.5 10.0 - 12.5 23.5 - 29.5
3. Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Nominal No. 02 03,04 05,06 10,12 14
Thread diameter mm 14 20 24 33 42
Width across flats mm Varies depending on type of connector.
Tightening torque Nm {kgm} Range Target 35 – 63 {3.5 – 6.5} 44 {4.5} 84 – 132 {8.5 – 13.5} 103 {10.5} 128 – 186 {13.0 – 19.0} 157 {16.0} 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
00-36
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D375A-6
DRAFT Forword and general information Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
22 24 27 32 36 41 46 55
Taper seal
Range
Target
Thread size (mm)
34 – 54 {3.5 – 5.5} 34 – 63 {3.5 – 6.5} 54 – 93 {5.5 – 9.5} 59 – 98 {6.0 – 10.0} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
14 18 22 24 30 33 36 42
Face seal Nominal No. Thread diame–Number of ter (mm) (Refthreads, type erence) of thread 9/16 - 18UNF 14.3 11/16 - 16UN 17.5 13/16 - 16UN 20.6 1 - 14UNS 25.4 1 - 3/16 - 12UN 30.2 -
6. Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted). Outer diameter of pipe (mm) 8 10 12 15 (16) 22 (20)
Width across flats (mm) 19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Nominal No. –Number Thread diameter (mm) of threads, type of (Reference) thread 9/16 – 18UN 14.3 11/16 – 16UN 17.5 13/16 – 16UN 20.6 1 – 14UN 25.4 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are slso used, depending on the specification. 7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
D375A-6
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 -
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 -
00-37
DRAFT Forword and general information Standard tightening torque table
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
00-38
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
D375A-6
DRAFT Forword and general information List of Abbreviation
List of Abbreviation q
q
This list of abbreviations is taken from the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning. Abbreviations that are used in general society may not be included.
q q
Special abbreviations that appear infrequently are marked in the text with an *. This list of abbreviations consists of two parts.The first part is a list of abbreviations used in the text of the manual, and the second part is a list of abbreviations used in circuit diagrams. text of the manual, and the second part is a list
List of abbreviations used in the shop manual Abbreviation
Full Spelling
Purpose of use (major applicable machine(*), or component/ system)
A.B.S.
Travel and brake Anti-skid Brake System (HD, HM)
A.I.S.S.
Automatic Idling Setting Engine System
A.J.S.S.
Advanced Joystick Steering System
Steering (WA)
A.R.A.C.
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
A.R.S.C.
Automatic Retarder Speed Control
Travel and brake (HD, HM)
A.S.R. ATT.
Automatic Spin Regula- Travel and brake tor (HD, HM) Attachment
Work equipment
B.C.V.
Breake Cooling oil con- Brake trol Valve (HD)
C.A.N.
Controller Area Network
Communication and electronic control
Closed-center Load Sensing System
Hydraulic
C.R.I.
Common Rail Injection
Engine
E.C.M.
Electronic Control ModElectronic control system ule
C.L.S.S.
E.C.M.V.
Electronic Control Mod- Transmission ulation Valve (WA, D, HD, etc.)
Electronically ConTravel E.C.S.S. trolled Suspension Sys(WA) tem
D375A-6
Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idling speed. Instead of a steering wheel, a lever is used to carry out the steering operations as well as to shift gear and change direction (forward or reverse). When the machine is traveling downhill, if the accelerator pedal is released, this function automatically applies the retarder with a constant braking force. When the machine is traveling downhill, if the accelerator pedal is released, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the rear wheels spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. A device that can be fixed onto a machine in order to enable it to do different jobs. When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump. Communications standard standardized as ISO11898. System that can simultaneously actuate multiple actuators regardless of the load (provides better ease of combined operation than O.L.S.S.). Uses engine controller to carry out electronic control of supply pump, common rail, and injector. Functions to maintain optimum fuel injection amount and fuel injection timing. Electronic control device that uses the signals from the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECU) Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. System that ensures smooth high-speed travel by using hydraulic spring effect of accumulator to absorb vibration of machine during travel.
00-39
DRAFT Forword and general information List of Abbreviation
Abbreviation
Full Spelling
Purpose of use (major applicable machine(*), or component/ system)
E.C.U.
Electronic Control Unit
E.G.R.
Exhaust Gas RecirculaEngine tion
E.M.M.S.
Electronic control system
Equipment ManageMachine monitor ment Monitoring System
E.P.C.
Electromagnetic ProporHydraulic tional Control
F-N-R
Forward-Neutral-Reverse
G.P.S.
Global Positioning Sys- Communication tem (KOMTRAX, VHMS)
H.S.S.
Hydrostatic Steering System
Steering (D)
H.S.T.
Hydro Static Transmission
Transmission (WA, D: Small size)
I.M.A.
Inlet Metering Actruator Engine
I.M.V.
Inlet Metering Valve
Engine
L.C.D.
Liquid Crystal Display
Machine monitor
L.E.D.
Light Emitting Diode
Electronic parts
Load Sensing
Hydraulic
Multimedia Messaging Service
Communication
N.C.
Normally Closed
Electronic and hydraulic
N.O.
Normally Open
Electronic and hydraulic
O.L.S.S.
Open-center Load Sensing System
Hydraulic
P.C.
Pressure Control
Hydraulic
L.S.
M.M.S.
00-40
Operation
Explanation Electronic control device that uses the signals from the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECM) Functions to recirculate part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of Nox. System that allows data (filter, oil replacement interval, abnormalities on machine, failure code, and failure history) from each sensor on the machine to be checked on monitor. Control system that moves an actuator in proportion to the amperage of an electric current passing through the solenoid. Position of the gear shift lever or switch. System that is used to determine the current location on the Earth of a ship, car, machine, etc. by receiving the radio wave signals transmitted from the navigation satellites. Steering function that uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of left and right tracks to turn machine without using steering clutch. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Same as IMV. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Described as IMV (IMA). Image display device made up of a large number of pixels filled with liquid crystal. Semiconductor element that emits light when the voltage is applied in forward direction, positive voltage to anode and negative voltage to cathode. Function that senses differential pressure of pump and controls discharge amount according to load. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. Controlling the oil pressure.
D375A-6
DRAFT Forword and general information List of Abbreviation
Abbreviation
Full Spelling
Palm Command ConP.C.C.S. trol System
Steering (D)
P.C.V.
Pump Control Valve
Engine
P.P.C.
Proportional Pressure Control
Hydraulic
P.P.M.
Piston Pump and Motor
Hydraulic (PC, D, etc.)
P.T.O.
Power Take Off
Power train
P.T.P.
Power Tilt and power Pitch dozer
Work equipment (D)
S.I.
Le System International Unit d' Unites
SOL.
Solenoid
Electronic
T.W.V.
Two Way Valve
Hydraulic and electronic
V.H.M.S.
*:
Purpose of use (major applicable machine(*), or component/ system)
Vehicle Health Monitor- Monitoring and communication ing System (PC, WA, D, HD: Large size)
Explanation System in which a controller instantly analyses data from each lever, pedal, and dial, and carries out optimum electronic control of the engine and HST. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Control system that moves an actuator in proportion to the oil pressure. Piston pump and motor. A device to take off power of the engine in order to drive a hydraulic pump, an air compressor, etc. Function that carries out hydraulic control of the tilt and pitch of the bulldozer blade. International System of Units (abbreviated SI from the French Le Systeme Internationale d'Unites) is the modern form of the metric system, and is the world's most widely used system of measurement. There're seven base units: meter (m), kilogram (kg), second (s), ampere (A), kelvin (K), candela (cd), and mole (mol). The derived units include Pascal (Pa), Newton (N), etc. Solenoid is a loop of wire. However, as a matter of fact in engineering, it refers to an actuator consists of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized. The word solenoid also often refers to a solenoid valve. Solenoid valve that switches over direction of flow. Communications system that transmits machine data, such as the present position of the machine, daily or aggregate hours of operation, fuel consumption, radiator water temperature, oil or filter replacement interval, to make it possible to collect and check this data from a distant place (Developed for use on large machines used in mines).
Code for machine family HD: Dump truck HM: Articulate dump truck WA: Wheel loader D: Bulldozer PC: Hydraulic excavator
D375A-6
00-41
DRAFT Forword and general information List of Abbreviation
List of abbreviations used in the circuit drawings Abbreviation
Full Spelling
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actruator
NC
No Connection
S/T Steering STRG SIG
Signal
SOL
Solenoid
STD
Standard
OPT Option OP
00-42
SW
Switch
T/C
Torque Converter
T/M
Transmission
D375A-6
DRAFT Forword and general information Conversion table
Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches
(A)
D375A-6
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.017 2.441 2.835 3.228 3.622
2.087 2.480 2.847 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-43
DRAFT Forword and general information Conversion table
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
5 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.017 2.441 2.835 3.228 3.622
2.087 2.480 2.847 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
6 13.23 35.27 57.32 79.37 101.41
7 15.43 37.48 59.53 81.57 103.62
1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
0 10 20 30 40
0 0 2.642 5.283 7.925 10.567
1 0.264 2.906 5.548 8.189 10.831
2 0.528 3.170 5.812 8.454 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
5 1.321 3.963 6.604 9.246 11.888
6 1.585 4.227 6.869 9.510 12.152
7 1.849 4.491 7.133 9.774 12.416
1l= 0.2642 U.S.Gal 8 9 2.113 2.378 4.755 5.019 7.397 7.661 10.039 10.303 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
00-44
15.586 18.228 20.870 23.511 26.153
D375A-6
DRAFT Forword and general information Conversion table
Liters to U.K. Gallons 1l = 0.21997 U.K.Gal 8 9 1.760 1.980 3.950 4.179 6.159 6.379 8.359 8.579 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
6 1.320 3.520 5.719 7.919 10.119
7 1.540 3.740 5.939 8.139 10.339
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.5
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.2
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
D375A-6
00-45
DRAFT Forword and general information Conversion table
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
00-46
D375A-6
DRAFT Forword and general information Conversion table
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C –40.4 –37.2 –34.4 –31.7 –28.9
°F 114.8 116.6 118.4 120.2 122.0
°C 27.2 27.8 28.3 28.9 29.4
1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0
54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 68 69 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
–40 –35 –30 –25 –20
°F –40.0 –31.0 –22.0 –13.0 –4.0
°C –11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
°F 51.8 53.6 55.4 57.2 59.0
°C 7.8 8.3 8.9 9.4 10.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 47 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
D375A-6
46 47 48 49 50
00-47
DRAFT Forword and general information Conversion table
00-48
D375A-6
DRAFT D375A-6 SEN05011-00
Bulldozer Shop Manual
D375A-6
Machine model D375A-6
Serial number 60001 and up
01 Specification Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 2 Specification drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 3 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 4 Weight table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 9 Table of fuel, coolant and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 11
D375A-6
01-1
DRAFT Contents
Contents 01 Specification Specification and technical data Specification drawing ................................................................................................................................... Specifications............................................................................................................................................... Weight table ................................................................................................................................................. Table of fuel, coolant and lubricants ............................................................................................................
01-2
01 3 01 4 01 9 01 - 11
D375A-6
DRAFT Specification and technical data Specification drawing
Specification and technical data Specification drawing
Item A B C
Overall length Overall height (with ROPS) Overall width
D375A-6
Unit
Sem i - U tilt dozer + Giant ripper
Full - U tilt dozer + Giant ripper
Semi - U tilt dozer + Full - U tilt dozer + Multi - shank ripper Multi - shank ripper
mm
10,485
10,845
10,195
10,555
mm
4,265 (4,285)
4,265 (4,285)
4,265 (4,285)
4,265 (4,285)
mm
4,774
5,215
4,774
5,215
01-3
DRAFT Specification and technical data Specifications
Weight
Specifications Machine model
D375A-6
Serial number
60001 and up
Machine weight q Bare tractor q Ditto with semi - U dozer q Ditto with variable multi - shank ripper q Ditto with ROPS cab + Air conditioner + Seat belt + Perforated side cover + SSC q q
53,200 64,160 70,960 72,230 kg 65,665
Bare tractor with full - U dozer Ditto with variable giant ripper
71,865 73,135
q
m deg. deg.
4.2 30 35
Forward
1st 2nd 3rd (low speed) 3rd
km/h
0 – 3.5 0 – 6.8 0 – 8.0 0 – 11.8
Reverse
1st 2nd 3rd (low speed) 3rd
km/h
0 – 4.6 0 – 8.9 0 – 9.7 0 – 15.8
Forward
1st 2nd 3rd
km/h
0 – 3.5 0 – 6.8 0 – 11.8
Reverse
Transmission speed ranges (man- Transmission speed ranges (autoual gear shift mode) matic gear shift mode)
Performance
Ditto with ROPS cab + Air conditioner + Seat belt + Perforated side cover + SSC Min. turning radius Gradeability Stability (front, rear, left, right)
1st 2nd 3rd
km/h
0 – 4.6 0 – 8.7 0 – 14.7
Ground pressure (610 shoe)
q q
01-4
q q q
q q
Bare tractor With semi - U dozer With full - U dozer With semi - U dozer and variable multi-shank ripper
107.87 {1.10} 129.45 {1.32} 132.39 {1.35} 143.18 {1.46}
Ditto with ROPS cab + Air conditioner + Seat belt + Perforated side cover + kPa {kg/cm2} SSC belt, perforated side cover, and SSC With full-U dozer and variable giant ripper Ditto with ROPS cab + Air conditioner + Seat belt + Perforated side cover + SSC
146.12 {1.49}
145.14 {1.48} 148.08 {1.51}
D375A-6
Dimensions
Overall height Overall width
Dimensions
Overall length
Specification dimension drawings Specifications
Machine model
D375A-6
Serial number
60001 and up
Bare tractor With semi-U dozer With full-U dozer With semi-U dozer + variable multi-shank ripper With full-U dozer + variable multi-shank ripper
mm
5,905 7,780 8,140 10,195 10,845
Bare tractor With semi-U dozer With full-U dozer
mm
3,240 4,695 5,140
To tip of exhaust pipe To top of air intake duct
mm
4,265 3,525
mm
2,500 3,980 610 662
Track gauge Length of track on ground Track shoe width Maximum ground clearance Model Type
Performance
Engine
No. of cylinders – bore x stroke Piston displacement Flywheel horsepower (ISO 9249) Max. torque Max. high idle speed Min. low idle speed Min. fuel consumption ratio
Starting motor Alternator Battery Radiator core type Torque converter
Power train
Transmission
Bevel gear shaft Steering clutch
Steering brake
Final drive
D375A-6 (04)
mm l {cc} kW {HP} /rpm Nm {kgm} / rpm rpm rpm g/kWh {g/HPh}
SAA6D170E-5 4-cycle, water-cooled, in-line vertical, direct injection type with turbocharger and aftercooler 6 - 170 x 170 23.15 {23,150} 455 {609} / 1,800 2,730 {278} / 1,300 1,900 750 208 {155} 24 V, 7.5 kW x 2 24 V, 60 A 12 V, 170 Ah x 2 Rectangle corrugated fin 3 - element, 1 - stage, 1 - phase (with lockup clutch) Planetary gear and multiple disc clutch type, hydraulically actuated forced lubricated, forward 3 - speed, reverse 3 speed Spiral bevel gear type, splash lubrication type Wet, multiple disc clutch type, spring loaded and hydraulically released (lever operated), interconnected with brake Wet, multiple disc clutch type, spring actuated, hydraulically released (pedal / lever operated ), interconnected with clutch Single reduction spur gear single reduction , planetary gear , lubricating oil splash lubrication type
01-5
DRAFT
Undercarriage
Specification and technical data Specifications
Machine model
D375A-6
Serial number
60001 and up Rigid, equalizer bar 2 each side 8 each side Assembly type, single grouser, 41 each side, pitch: 280.0 mm , width: 610 mm
Suspension Carrier roller Track roller Track shoe
Power train + Lubricating oil pump (tandem)
Gear type (BAL180 + 112)
Scavenging pump (tandem)
Gear type (BAR63 + 277)
Cooling fan pump
MPa {kg/cm2} l/min / rpm
Cooling fan motor
MPa {kg/cm2}
Variable swash plate type (LPV90 + 30) Max. delivery pressure: 18.1 {184} Theoretical delivery: 231/1,926 Fixed swash plate type (LMF 150) Max. allowable working pressure: 18.1 {184}
MPa {kg/cm2}
27.5 {280}
l/min
Variable swash plate type (HPV190) 366
Hydraulic pump
Type Delivery (engine speed at 1,800rpm)
Control valve
Machines with single tilt blade and variable ripper q For ripper tilt cylinder q For ripper lift cylinder q For blade tilt cylinder q For blade lift cylinder q For blade lift cylinder Machines with dual tilt blade and variable ripper q For ripper tilt cylinder q For ripper lift cylinder q For blade tilt L.H cylinder q For blade tilt R.H cylinder q For blade lift cylinder q For blade lift cylinder
01-6
1 + 1 + 1 + 2 spool type, hydraulic assisted, PPC type + Ripper tilt (in, back) + Ripper tilt (raise, lower) + Blade tilt + Blade lift × 2 (raise, lower) 1 + 1 + 2 + 2 spool type, hydraulic assisted, PPC type + Ripper tilt (in, back) + Ripper lift (raise, lower) + Blade tilt (single, dual and pitch) + Blade tilt (dual and pitch) + Blade lift × 2 (raise, lower)
Dimensions of blade lift cylinder
double acting piston
Cylinder bore Piston rod outside diameter Piston stroke Max. between pins distance Min. between pins distance
Dimensions of blade tilt cylinder
Type
Hydraulic cylinder
Work equipment hydraulic system
Max. pressure
Cylinder bore Piston rod outside diameter Piston stroke Max. between pins distance Min. between pins distance
mm
140 90 1,721 2,495 774
mm
200 110 240 1,703 1,463
D375A-6
Dimensions of ripper tilt cylinder Dimensions of ripper lift cylinder
Hydraulic cylinder
Work equipment hydraulic system
Dimensions of blade dual tilt cylinder
Specification dimension drawings Specifications
Machine model
D375A-6
Serial number
60001 and up
Cylinder bore
200
Piston rod outside diameter (both right and left)
110
Piston stroke (both right and left)
mm
Max. distance between pins (both right and left) Min. distance between pins (both right and left)
Cylinder bore Piston rod outside diameter Piston stroke Max. between pins distance Min. between pins distance
Cylinder bore Piston rod outside diameter Piston stroke Max. between pins distance Min. between pins distance
1,675 1,490
mm
200 110 495 1,855 1,360
mm
180 110 550 1,800 1,250
Hydraulic tank
Box type (control valve externally installed) Hydraulic semi-U tilt dozer Hydraulic full-U tilt dozer
Type
Single tilt Left: Brace type Right: Tilt cylinder type Dual tilt Left: Tilt cylinder type (for single tilt/dual tilt pitch) Right: Tilt cylinder type (for dual tilt pitch)
Performance
Max. lift above ground Max. drop below ground Max. adjustment tilt Hydraulic oil tilt (single) Blade cutting angle adjustment Blade capacity
mm mm mm mm deg. m3
Dimensions
Semi-U dozer
Work equipment
Blade supporting method
D375A-6 (04)
185
Blade width Blade height Blade cutting angle
mm mm deg.
1,660 715 990 770 ±5 24.0
4,774 2,265 (with spill guard: 2,525) 55
01-7
DRAFT Specification and technical data Specifications
Machine model
D375A-6
01-8
Performance
Max. lift above ground Max.drop below ground Max. adjustment tilt Hydraulic oil tilt (single) Blade cutting angle adjustment Blade capacity
1,660 715 1,080 840 ±5 26.3
Dimensions
Blade width Blade height Blade cutting angle
mm mm deg.
5,215 2,265 (with spill guard: 2,525) 55
Performance
Max. hydraulic oil tilt Max. pitch angle Blade cutting angle
mm deg. deg.
1,185 Forward 4.7 / Backward 5.2 55
Dimensions
60001 and up mm mm mm mm deg. m3
Max. hydraulic oil tilt Max. pitch angle Blade cutting angle
mm deg. deg.
1,295 Forward 4.7 / Backward 5.2 55
Max. digging depth Max. lift above ground Point digging angle
mm mm deg.
1,140 1,135 45 (Stepless adjustment between 31.4 – 54.7)
mm No. of holes
2,910 2
mm mm deg.
1,485 1,100 45 (Stepless adjustment between 31.6 – 55.0)
mm No. of holes
1,600 3
Dimensions Performance Dimensions Performance
Full - U dozer + Pitch Semi - U dozer + Pitch Giant ripper
Multi - shank ripper
Work equipment
Full - U dozer
Serial number
Max. beam width Shank positions
Max. digging depth Max. lift above ground Point digging angle
Max. beam width Shank positions
D375A-6
Specification dimension drawings Weight table
Weight table k
01-9
This weight table is prepared for your reference when handling or transporting the components. Unit: kg Machine model
D375A-6
Serial number
60001 and up
Engine, damper assembly q Engine assembly q Damper assembly q Engine mounting parts Radiator assembly Oil cooler assembly Fuel tank assembly (when full) Power train unit q Torque converter and PTO assembly q Transmission assembly q Transmission valve assembly q Steering clutch and brake assembly q Steering valve assembly Final drive assembly Main frame assembly
Track group assembly (each side) q Track frame q Idler assembly q Track roller assembly (each single flange x each side) q Track roller assembly (each double flange x each side) q Carrier roller assembly (each x each side) q First bogie and track roller assembly q Each of second – fourth bogie and track roller assembly q Final bogie and track roller assembly
Track shoe assembly (610 mm ) Pivot shaft Equalizer bar assembly Hydraulic tank assembly (excluding oil ) Control valve (for single tilt) Control valve (for dual tilt)
D375A-6 (06)
3,320 3,065 185 70 465 92 580 (1,600) 4,220 795 1,000 13 1,712 13 2,200 × 2 5,541
7,902 1,896 478 159 × 2 160 × 6 71 × 2 457 742 × 3 359
4,305 × 2 210 × 2 500 236 119 125
01-9
Specification dimension drawings Weight table
Unit: kg Machine model
D375A-6
Serial number
60001 and up
Semi-U dozer assembly (excluding oil) q Single tilt q Dual tilt Reinforced type semi-U dozer assembly q Single tilt q Dual tilt Reinforced type full-U dozer assembly q Single tilt q Dual tilt Semi-U blade assembly Reinforced type semi-U blade assembly Reinforced type full-U blade assembly (with spill guard) Straight frame Tilt cylinder (excluding oil) q Single tilt q Dual tilt Variable multi-shank ripper assembly (excluding oil) q Shank assembly q Ripper lift cylinder assembly q Ripper tilt cylinder assembly Variable giant ripper assembly (excluding oil) q Shank assembly q Ripper lift cylinder assembly q Ripper tilt cylinder assembly Radiator guard assembly (including cylinder yoke) q Radiator guard q Blade lift cylinder assembly Radiator mask Engine underguard Power train underguard (front) Power train underguard (rear) Hood and side cover assembly (including air cleaner) Fender (left) Fender (right) ROPS assembly Floor frame assembly Cab assembly Operator seat assembly (with mechanical suspension) Operator seat assembly (with air suspension)
01-10
10,100 10,180 10,470 18,650 11,500 11,680 6,750 7,220 8,250 1,350 × 2 275 270 × 2 6,755 470 × 3 270 × 2 240 × 2 6,155 650 × 1 270 × 2 240 × 2 2,870 1,342 290 × 2 140 275 220 320 337 331 372 703 591 570 64 58
D375A-6 (06)
DRAFT Specification and technical data Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D375A-6
01-11
DRAFT Specification and technical data Table of fuel, coolant and lubricants
Unit: l D375A-6 Refilling points Specified capacity
Refill capacity
Engine oil pan
87
86
Damper case
2.1
2.1
Power train case
275
150
Final drive case (both sides)
61
61
Hydraulic oil system q Single tilt, without ripper q Single tilt with variable rippers q Dual tilt with variable rippers
230 275 280
130
Cooling system
120
-
1,200
-
Fuel tank
01-12
D375A-6
DRAFT D375A-6 SEN05013-00
Bulldozer Shop Manual
D375A-6
Machine model D375A-6
Serial number 60001 and up
10 Structure and function
D375A-6
10-1
Table of contents
Table of contents 10 Structure, function and maintenance standard Engine and cooling system ..................................................................................................... Cooling system .................................................................................................................... Cooling fan pump................................................................................................................. Cooling fan motor................................................................................................................. Power train.............................................................................................................................. Power train........................................................................................................................... Overall drawing of power train unit ...................................................................................... Power train hydraulic equipment arrangement drawing....................................................... Damper and universal joint .................................................................................................. Torque converter and PTO .................................................................................................. Torque converter control valve ............................................................................................ Main relief valve and torque converter relief valve............................................................... Lockup clutch ECMV and stator clutch ECMV..................................................................... Scavenging pump ................................................................................................................ Transmission control............................................................................................................ PCCS lever .......................................................................................................................... Transmission........................................................................................................................ Transmission ECMV ............................................................................................................ Transmission lubricating oil relief valve ............................................................................... Steering and brake control................................................................................................... Transfer unit, bevel gear shaft and steering ........................................................................ Steering control valve .......................................................................................................... Steering clutch ECMV and Steering brake ECMV ............................................................... Parking brake valve ............................................................................................................. Sudden stop prevention valve.............................................................................................. Final drive ............................................................................................................................ Undercarriage and frame ........................................................................................................ Track frame.......................................................................................................................... Idler cushion......................................................................................................................... Track roller bogie ................................................................................................................. Main frame ........................................................................................................................... Suspension .......................................................................................................................... Hydraulic system..................................................................................................................... Work equipment hydraulic piping diagram........................................................................... PPC control piping diagram ................................................................................................. Work equipment control ....................................................................................................... Hydraulic tank ...................................................................................................................... Accumulator ......................................................................................................................... PPC lock valve..................................................................................................................... PPC valve ............................................................................................................................ Piston valve.......................................................................................................................... Quick drop valve .................................................................................................................. Pin puller switch ................................................................................................................... Pin puller solenoid valve ...................................................................................................... Blade control lever (only for the machine with dual tilt specification)................................... Work equipment pump......................................................................................................... Control valve ........................................................................................................................ Self-pressure reducing valve ............................................................................................... Work equipment...................................................................................................................... Cylinder stay ........................................................................................................................
10-2
10-2 10- 4 10- 4 10- 6 10- 26 10- 32 10- 32 10- 34 10- 36 10- 38 10- 40 10- 46 10- 48 10- 50 10- 55 10- 56 10- 58 10- 62 10- 76 10- 81 10- 82 10- 84 10- 90 10- 92 10- 99 10- 101 10- 103 10- 108 10- 108 10- 110 10- 111 10- 112 10- 114 10- 117 10- 117 10- 121 10- 122 10- 124 10- 126 10- 127 10- 129 10- 140 10- 141 10- 142 10- 143 10- 145 10- 146 10- 158 10- 173 10- 180 10- 180
D375A-6 (04)
Table of contents
Cab ......................................................................................................................................... Cab mount ........................................................................................................................... Cab ...................................................................................................................................... Electrical system ..................................................................................................................... Engine control...................................................................................................................... Engine control system ......................................................................................................... CRI engine control system................................................................................................... Monitor system .................................................................................................................... Machine monitor .................................................................................................................. Lamp system ....................................................................................................................... Engine preheat (electrical intake air heater) control ............................................................ Palm command control system............................................................................................ Sensor ................................................................................................................................. Vehicle health monitoring system (VHMS) .......................................................................... ORBCOMM system .............................................................................................................
D375A-6 (04)
10- 181 10- 181 10- 182 10- 184 10- 184 10- 185 10- 194 10- 196 10- 198 10- 215 10- 216 10- 217 10- 220 10- 224 10- 230
10-3
DRAFT Engine and cooling system Cooling system
Engine and cooling system Cooling system
10-4
D375A-6
DRAFT Engine and cooling system Cooling system
A: Power train oil cooler inlet B: Power train oil cooler outlet C: Hydraulic oil cooler inlet D: Hydraulic oil cooler outlet 1. Hydraulic oil cooler 2. Radiator cap 3. Pressure valve 4. Aftercooler outlet hose 5. Radiator inlet hose 6. Aftercooler inlet tube 7. Radiator 8. Aftercooler 9. Power train oil cooler 10. Radiator outlet hose 11. Drain plug (Power train oil cooler) 12. Cooling fan motor 13. Cooling fan 14. Reservoir tank 15. Drain plug (Radiator) 16. Reservoir tank cap 17. Reservoir tank sight gauge Specifications Radiator
Power train oil cooler
Core type
Rectangle corrugated fin
PTO-OL
Fin pitch(mm)
8.0/2
-
8.0/2
8.0/2
Total heat dissipation surface(m2)
49.09 × 3
3.77
4.09
27.39 × 2
88.3 ± 14.7 {0.9 ± 0.15}
-
-
-
0 – 4.9 {0 – 0.05}
-
-
-
Cracking pressure of pressure valve (kPa {kg/cm2}) Cracking pressure of vacuum valve (kPa {kg/cm2})
D375A-6
Hydraulic oil cooler
Aftercooler
Rectangle corrugated Rectangle straight fin fin
10-5
DRAFT Engine and cooling system Cooling fan pump
Cooling fan pump Model : LPV90 + 30
Appearance
1. LPV90 Hydraulic pump 2. LPV30 Hydraulic pump
10-6
D375A-6
DRAFT Engine and cooling system Cooling fan pump
LPV90 Hydraulic pump Appearance
D375A-6
10-7
DRAFT Engine and cooling system Cooling fan pump
Sectional view
IM: Control current input connector PA: Pump discharge port PDI: Drain port PD2: Drain port (Plug) PDA: Breather PEN: Control pressure pickup port (Plug) PEPC: EPC source pressure input port PS: Pump suction port
10-8
1. Shaft 2. Cradle 3. Case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. Spring 10. Servo piston
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Function q The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump converts the rotation and torque into hydraulic pressure and discharges pressurized oil according to the load. q The delivery of this pump can be changed by changing the swash plate angle. Structure q Cylinder block (7) is connected to shaft (1) through spline (c). q Shaft (1) is supported by the front and rear bearings (9). q The tip of piston (6) has a spherical hollow in which shoe (5) is being held by crimping. q Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) is kept pressed against plane (A) of rocker cam (4) and slids circularly. q Rocker cam (4) pivots on cylindrical face (B) of cradle (2) witch is fixed to case (3). q Piston (6) in each cylinder of cylinder block (7) reciprocates in the axial direction. q Cylinder block (7) rotates relatively against valve plate (8), while sealing the pressurized oil.
D375A-6
q q
The hydraulic balance is maintained properly on this face. The oil is sucked into and discharged from each cylinder in cylinder block (7) through valve plate (8).
10-9
DRAFT Engine and cooling system Cooling fan pump
Operation Operation of pump q Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A). q Rocker cam (4) moves along cylindrical face (B). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. q Angle (a) is called the swash plate angle.
q
q
q q
q
q q
q
If center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle = 0), the difference between volumes (E) and (F) in cylinder block (7) is 0. No oil is sucked or discharged and a pumping action is not performed. (The swash plate angle is not set to 0 actually, however.)
The pump delivery is in proportion of swash plate angle (a).
If angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A) works as a cam for shoe (5). Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) of cylinder chamber in cylinder block (7). Each piston (6) sucks and discharges oil by (F) (E). If cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from chamber (E) during this process. The volume of chamber (F) is increased and the oil is sucked in chamber (F) during this process.
10-10
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Control of delivery q If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or delivery (Q) is increased. q Swash plate angle (a) is changed with servo piston (1). q Servo piston (1) reciprocates straight according to the signal pressure of the PC valve. q This straight motion is transmitted to rocker cam (4). q Then, rocker cam (4) supported on the cylindrical surface of cradle (2) is tilted in the axial direction. q The pressure receiving area of the top of servo piston (1) is different from that of the bottom. Main pump discharge pressure (self-pressure) (PA) is kept led in the pressure chamber on the small-diameter piston side (upper side). q PC valve output pressure (PEN) is led in the pressure chamber on the large-diameter piston side (lower side). q The movement of servo piston (1) is controlled according to the difference between pressure (PA) on the small-diameter piston side and pressure (PEN) on the large-diameter piston side and the ratio of the pressure receiving area of the small-diameter piston to that of the large-diameter piston.
D375A-6
10-11
DRAFT Engine and cooling system Cooling fan pump
PC valve, EPC valve, and servo piston
IM: Control current input connector PA: Pump discharge port PEPC: EPC source pressure input port Servo piston 1. Servo piston 2. Lever 3. Spring
PC valve 4. Piston 5. Seat 6. Spring 7. Spool 8. Sleeve 9. Plug EPC valve 10. EPC valve
10-12
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Function q The PC valve controls the servo piston so that the delivery (swash plate angle) is related to the current input to the EPC valve is as shown in the figure below.
D375A-6
10-13
DRAFT Engine and cooling system Cooling fan pump
When EPC output pressure is high [When EPC current (i) is large]
10-14
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Operation q The relationship between the EPC valve input current (i) and EPC valve output pressure (F) is as shown in the figure below.
q
q
q
q
q
q
q
If the EPC discharge pressure rises, spool (7) is pushed to the left because of the difference in sectional areas between parts (S1) and (S2) of the spool (S1 > S2). Port (f) is connected to port (g) and the pump discharge oil at pressure (PA) flows through port (g) to port (f). Port (f) is disconnected from the drain circuit. The pump discharge oil at pressure (PA) from port (f) of the PC valve enters chamber (X) on the large diameter side of servo piston (1). Pump pressure (PA) is also constantly applied to chamber (Y) on the small diameter side of servo piston (1). Since a larger force is applied to the large diameter side because of the difference in area between both ends of servo piston (1), however, servo piston (1) moves toward the minimum swash plate angle side (upper side). If servo piston (1) moves up, piston (4) is moved to the right through lever (2). Accordingly, spring (6) is compressed and spool (7) moves to the right. If spool (7) moves to the right and port (f) is disconnected from port (g), servo piston (1) stops moving up. At this time, servo piston (1) stops at a place higher (nearer to the minimum swash plate angle) than when the EPC discharge pressure is low.
D375A-6
10-15
DRAFT Engine and cooling system Cooling fan pump
When EPC output pressure is low [When EPC current (i) is small]
10-16
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Operation q If EPC current (i) reduces and the EPC output pressure lowers, spool (7) is pushed to the right by the force of spring (6). q Port (g) is disconnected from port (f) and at the same time port (f) is connected to the drain circuit. q The oil in chamber (X) on the large diameter side of servo piston (1) flows through port (f) of the PC valve to the drain circuit. q Servo piston (1) is moved toward the maximum swash plate angle side (lower side) by the pressure of chamber (Y) on the small diameter side.
D375A-6
10-17
DRAFT Engine and cooling system Cooling fan pump
LPV30 Hydraulic pump
Appearance
IM: Control electric current input connector P1: Pump discharge port PAEPC: EPC output pressure pickup port PE: Servo piston control pressure input port PEPC: EPC valve source pressure input port PH: Pump discharge pressure output port PS: Pump suction port TO: Drain port
10-18
1. 2. 3. 4.
piston pump Servo valve Bleeder EPC value
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Sectional view
1. Shaft 2. Oil seal 3. Case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. Spring 10. Servo piston 11. Ball
D375A-6
10-19
DRAFT Engine and cooling system Cooling fan pump
Function q
q
The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump converts the rotation and torque into hydraulic energy and discharges hydraulic oil according to the load. The discharge of this pump can be changed by changing the swash plate angle in it.
q
The oil is sucked into and discharged from each cylinder chamber of cylinder block (7) through valve plate (8).
Structure q q q q q q q q q
Cylinder block (7) is connected to shaft (1) through splines (B). Shaft (1) is supported by the front and rear bearings (12). The tip of piston (6) has a spherical hollow in which shoe (5) is being held by crimping. Piston (6) and shoe (5) form a spherical bearing. Shoe (5) is kept pressed against plane (A) of rocket cam (4) and slids circularly. Rocker cam (4) pivot on ball (11). Piston (6) in each cylinder of cylinder block (7) reciprocates in the axial direction. Cylinder block (7) rotates relatively against valve plate (8) sealing the hydraulic oil. The hydraulic balance on the valve plate is maintained properly.
10-20
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Operation Operation of pump q Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A). q Rocker cam (4) pivots on ball (11). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. q Angle (a) is called the swash plate angle. q If angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A) works as a cam for shoe (5). q Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder block (7) q Each piston (6) sucks and discharges oil by (F) (E). q If cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from chamber (E). q The volume of chamber (F) is increased and the oil is sucked in chamber (F).
D375A-6
q
If center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is 0), there is no difference between volumes (E) and (F) in cylinder block (7). The hydraulic oil is not sucked or discharged. (The swash plate angle is not set to 0 actually, however.)
q
The pump delivery is in proportion to swash plate angle (a) .
10-21
DRAFT Engine and cooling system Cooling fan pump
Control of discharge q If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or delivery (Q) is increased. q Swash plate angle (a) is changed with servo piston (10). q Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. q This linear motion is transmitted to rocker cam (4). q Then, rocker cam (4) supported on ball (11) pivots on ball (11).
10-22
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Servo valve
P: EPC valve source pressure input port PE: Servo piston control pressure output port PH: Pump discharge pressure input port T: Drain port
D375A-6
1. 2. 3. 4. 5. 6. 7.
Plug Lever Retainer Seat Spool Piston Sleeve
10-23
DRAFT Engine and cooling system Cooling fan pump
A: Drain side B: Pump discharge pressure input side C: EPC output pressure receiving pressure
10-24
D: EPC output pressure side P: EPC source pressure input side
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Function q The servo valve controls the servo piston so that the delivery (swash plate angle) is related to the current input to the EPC valve as shown in the figure below.
q
The relationship between the EPC valve input current (i) and EPC valve output pressure (F) is as shown in the figure below.
D375A-6
Operation q The output oil of the EPC valve flows in the piston chamber (C) to push piston (6). Piston (6) moves spool (5) to a position where the thrust is balanced with the force of the spring. q Then, port (PE) of the servo piston pressure passage is connected to the pump discharge passage by the notch of spool (5) and the oil at pump discharge pressure is led to the servo piston. q The servo piston raises the rocker cam. The position feedback is applied and the lever moves to compress the spring. q If spool (5) is pushed back, the pump discharge pressure passage is disconnected from the servo piston circuit. The pressure in the servo piston chamber lowers and the rocker cam returns toward the position for the maximum swash plate angle. q These processes are repeated until the swash plate stabilizes at an angle where the EPC output pressure is balanced with the force exerted by the spring force. q Accordingly, as the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure lowers, the swash plate angle increases.
10-25
Engine and cooling system Cooling fan motor
Cooling fan motor
10-26
Type: LMF180 (150) Appearance
P: From fan pump T: To tank through cooler TC: To tank
10-26
10-26
10-26 Type: LMF150 Capacity: 150 cm3/rev Rated speed: 1,225 rpm Rated flow: 184 l/min Check valve cracking pressure: 68.6 kPa {0.7 kg/cm2} Specifications
D375A-6 (04)
DRAFT Engine and cooling system Cooling fan motor
Sectional view
1. 2. 3. 4. 5. 6.
Output shaft Case Thrust plate Shoe Piston Cylinder block
D375A-6
7. Valve plate 8. End cover 9. Center spring 10. Suction safety valve 11. ON/OFF pilot valve 12. Reversible valve spool 13. Speed sensor
10-27
DRAFT Engine and cooling system Cooling fan motor
Hydraulic motor Function q This hydraulic motor is called a swash plate type axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation q The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). This oil can flow into the cylinder chambers on only one side (supply side) (Y - Y) line connecting the top dead center and bottom dead center of the stroke of piston (4) q The oil sent to one side of cylinder block (5) presses piston (4) [2 or 3 pieces] and generates force (F1) [F1 = P × xD2/4]. q This force is applied to thrust plate (2). Since thrust plate (2) is fixed at an angle of (a °) degrees to the output shaft (1), the force is divided into components (F2) and (F3). q The radial component (F3) generates torque [T = F3 x ri] relative to the (Y - Y) line connecting the top dead center and bottom dead center. q The resultant of the torque [T = s (F3 × ri)] rotates cylinder block (5) through the piston. q Since this cylinder block (5) is splined to the output shaft, the output shaft rotates to transmit the torque.
10-28
D375A-6
DRAFT Engine and cooling system Cooling fan motor
Suction safety valve Function of suction valve q If the fan pump stops, the hydraulic oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the oil stops flowing in from inlet port (P), suction safety valve (1) sucks in the oil on the outlet side and supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.
When the pump is stopped q If the engine is stopped and the shaft speed of the fan pump lowers to 0rpm, the pressurized oil from the pump is not supplied to port (P) any more. As the pressurized oil is not supplied to the (MA) side of the motor, the motor speed lowers gradually to stop. q If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing, the oil in port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.
Operation When pump is started q
If the pressurized oil from the pump is supplied to port (P) and the pressure on (MA) side rises and starting torque is generated in the motor, the motor starts revolution.The pressurized oil on the motor outlet (MB) side of the motor returns through port (T) to the tank.
D375A-6
10-29
DRAFT Engine and cooling system Cooling fan motor
Function as safety valve q The pressure in port (P) of the fan motor may rise abnormally as in starting engine. q Suction safety valve (1) is installed to protect the fan system circuit in such a case. Operation If the pressure in port (P) rises above the cracking pressure of suction safety valve (1), valve (2) of suction safety valve (1) opens to release the pressurized oil into port (T). q By this operation, generation of abnormally high pressure in port (P) is prevented. q
10-30
D375A-6
DRAFT Engine and cooling system Cooling fan motor
Operation of reversible valve When the ON/OFF solenoid is de-energized q If ON/OFF solenoid (1) is "de-energized", the pressurized oil from the pump is blocked by ON/OFF selector valve (2), and port (C) connects to the tank circuit. q Spool (3) is pushed to the right by spring (4). q Motor port (MA) connects to port (P) and pressurized oil flows in to revolve the motor in normal direction (clockwise).
D375A-6
When the ON/OFF solenoid is energized q If ON/OFF solenoid (1) is "energized", ON/OFF selector valve (2) switches to allow the pressurized oil from the pump to flow through port (C) to spool chamber (D). q The pressurized oil in chamber (D) pushes valve spool (3) to the left against spring (4) . q Motor port (MB) connects to port (P) and pressurized oil flows in to revolve the motor in reverse (counterclockwise).
10-31
DRAFT Power train Power train
Power train Power train
Outline q The power generated by engine (1) is transmitted through universal joint (3) to torque converter (8) while (2) reduces torsional vibration. The torque converter (8) that uses oil as a medium for power transmission transmits the power from the engine to the input shaft (turbine shaft) of transmission (9) in accordance with the change in load. The torque converter is equipped with a lockup clutch, and when the speed of the output shaft of the transmission that receives the power from the torque converter becomes higher, the lockup clutch is automatically engaged. When this happens, the drive case and turbine are combined as a unit to transmit the power from the engine directly to the transmission input shaft. Transmission (9) uses a combination of planetary gear mechanisms and hydraulic clutches to give three forward speeds and three reverse speeds. When a gear speed is selected with the PCCS (gearshift) lever according to the change in load, two clutches are engaged to transmit the power from the torque converter to transfer (15) through its output shaft.
10-32
Transfer (15) reduces the speed of the power transmitted, and then the combination of the bevel pinion and bevel gear of the bevel gear shaft unit reduces the speed further and divides the power at right angles to the left and right to send to the respective steering clutches (10). Steering clutch (10) stops transmission of the power from the bevel gear shaft unit to the final drive to steer the machine. Moving the PCCS (steering) lever in the direction to which the machine turns disengages the steering clutch on the side and the machine turns to the direction. The turning angle is adjusted by controlling steering brake (11) installed to the outside of the steering clutch. Steering brake (11) is the same disc type as that for the steering clutch. The power output from the steering clutch goes to final drive (12) , where the speed is reduced to drive sprocket (13). Double-reduction type final drive (12) consists of single-reduction spur gear train and single-reduction planetary gear train. The sprocket drives track shoe (14) to make the machine travel.
D375A-6
DRAFT Power train Power train
1. Engine (SAA6D170E-5) 2. Damper 3. Universal joint 4. Cooling fan pump (LPV90 + 30) 5. Power train pump (BAL180+112) 6. PTO 7. Work equipment pump (HPV190) 8. Torque converter 9. Transmission
D375A-6
10. Steering clutch 11. Steering brake 12. Final drive 13. Sprocket 14. Track shoe 15. Transfer 16. Scavenging pump (BAR63+277) 17. Cooling fan motor (LMF150) 18. Bevel gear and pinion gear
10-33
Power train Overall drawing of power train unit
Overall drawing of power train unit
10-34
10-34
D375A-6 (04)
Power train Overall drawing of power train unit
A: Torque converter inlet oil pressure pickup port (IN) B: Torque converter outlet pressure pickup port (OUT) C: Lockup clutch pressure pickup port (LU) D: Stator clutch oil pressure pickup port (SC) E: Left steering clutch pressure pickup port (LC) F: Left steering brake pressure pickup port (LB) G: Transmission 2nd clutch pressure pickup port (2ND) H: Transmission R clutch pressure pickup port (REV) J: Power train lubricating oil pressure pickup port (LUB) K: Transmission 3rd clutch pressure pickup port (3RD) L: Transmission F clutch pressure pickup port (FWD) M: Right steering brake pressure pickup port (RB) Specification q
q
N: Right steering clutch pressure pickup port (RC) P: Transmission 1st clutch pressure pickup port (1ST) R: Main relief pressure pickup port (TM) 1. Centralized pressure pickup port 2. Oil level gauge 3. Oil filler pipe 4. Power train and lubrication pump 5. PTO 6. Torque converter 7. Torque converter control valve 8. Transmission control valve 9. Transmission 10. Steering clutch and brake 11. Steering control valve 12. Transmission lubricating oil filter 13. Power train oil filter 14. Power train oil strainer 15. Scavenging pump 10-35
The power train unit consists of torque converter, transmission unit, and steering unit by rough classification. Accordingly, after removing power train unit, it can be divided into torque converter, transmission unit, and steering unit. The steering unit consists of transfer, bevel gear shaft, steering clutch, and steering brake.
D375A-6 (04)
10-35
Power train Power train hydraulic equipment arrangement drawing
Power train hydraulic equipment arrangement drawing
1. Oil cooler 2. Power train oil filter 3. Transmission lubricating oil filter 4. Centralized pressure pickup port 5. Torque converter valve 6. Transmission control valve (ECMV) 7. Steering control valve (ECMV) 8. Power train oil tank 9. Power train oil strainer 10. Power train pump (BAL180+112) 11. Scavenging pump (BAR63+277) 12. Cooling fan pump (LPV90+30)
10-36
10-36
A: Torque converter lock-up pressure pickup port B: Torque converter stator clutch pressure pickup port C: Left steering clutch pressure pickup port D: Left steering brake pressure pickup port E: Transmission 2nd clutch pressure pickup port F: Transmission R clutch pressure pickup port G: Transmission 3rd clutch pressure pickup port H: Transmission F clutch pressure pickup port J: Right steering brake pressure pickup port K: Right steering clutch pressure pickup port L: Transmission 1st clutch pressure pickup port M: Transmission 1st clutch pressure pickup port N: Torque converter regulator pressure pickup port P: Torque converter relief pressure pickup port R: Main relief pressure pickup port
D375A-6 (06)
DRAFT Power train Power train hydraulic equipment arrangement drawing
D375A-6
10-37
DRAFT Power train Damper and universal joint
Damper and universal joint
10-38
D375A-6
DRAFT Power train Damper and universal joint
1. Outer body 2. Engine flywheel 3. Output shaft 4. Coupling 5. Universal joint 6. Flange 7. Rubber coupling 8. Cover 9. Breather (for damper bearing case) 10. Oil fitter pipe 11. Breather (for fly wheel housing)
D375A-6
Outline q 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 couplings on the damper effciently absorbs vibrations by rubber material's 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 q The power of engine is transmitted from flywheel (2) through outer body (1) to rubber couplings (7). After absorption of torsional vibrations of the engine by the rubber coupling, power is then transmitted to the coupling (4) via output shaft (3). Then, power is further transmitted from the coupling to the torque converter input shaft through universal joint (5).
10-39
DRAFT Power train Torque converter and PTO
Torque converter and PTO a PTO: Abbreviation for Power Take Off
10-40
D375A-6
DRAFT Power train Torque converter and PTO
D375A-6
10-41
DRAFT Power train Torque converter and PTO
A: To transmission control valve B: To transmission lubrication circuit C: To transmission oil pan D: From steering case E: To power train oil filter F: To transmission lubricating oil filter G: To transmission oil pan H: To scavenging pump J: To scavenging pump K: To power train oil filter L: To transmission lubricating oil filter M: To transmission control valve N: To transmission lubrication circuit P: Torque converter outlet oil pressure pickup port (OUT) R: To power train oil cooler
10-42
1. Cooling fan pump mounting location 2. Torque converter outlet oil pressure sensor mounting location 3. Work equipment pump mounting location 4.Power train and lubricating oil pump mounting location 5.Scavenging pump mounting location 6.Torque converter control valve 7. Torque converter outlet oil temperature sensor mounting port 8.Coupling 9. Retainer 10. Input shaft (number of teeth: 61) 11. Front housing 12. PTO idler gear (number of teeth: 77) 13.PTO idler gear shaft 14.Lockup clutch housing 15. Drive case 16.Turbine 17. Rear housing 18.Stator 19.Pump 20.Stator shaft 21. Guide 22.Retainer 23.Pump shaft 24.Transmission input shaft 25. Stator clutch hub gear 26.Stator clutch housing 27. Return spring 28. Stator clutch plate 29. Stator clutch disc 30. Stator clutch piston 31. Turbine boss 32. Lockup clutch plate 33. Lockup clutch disc 34. Lockup clutch piston 35.Scavenging pump drive gear (number of teeth: 63) 36. Sleeve 37. Bearing race 38.Power train pump, lubricating oil pump and cooling fan pump drive gear (number of teeth: 57) 39. Cover 40.Cover 41. Work equipment pump drive gear (number of teeth: 57) 42.Cover 43. Strainer
D375A-6
Power train Torque converter and PTO
10-43 The torque converter is a 3-element, 1-stage and 1-phase type, and is integral with the transmission.The torque converter is equipped with a wet double-disc clutch type lockup unit and a stator clutch unit in order to reduce fuel consumption, to increase the operability, and to reduce captive consumption of the engine horsepower. For higher efficiency of continuous light dozing and leveling operation, the torque converter is locked up to transmit the engine power directly to the transmission input shaft. Even when the torque converter is locked up (the pump is united with the turbine), the oil is still supplied from the torque converter relief valve. The oil sent from the pump to the turbine returns to the stator. The flow of oil is obstructed by the stator blades and becomes turbulent (it is agitated), producing resistance against the rotation of the pump and turbine. To reduce the resistance against the rotation of the pump and turbine, the stator clutch is disengaged simultaneously with lockup of the torque converter, allowing the stator to rotate freely. As the stator turns along with the pump and turbine, the oil returns from the turbine to the pump smoothly with less resistance.
10-43 Pump (19) is united with coupling (8), input shaft (10), lockup clutch housing (14), and drive case (15), and is rotated by the engine power. Turbine (16) is united with the turbine boss (31) and transmission input shaft (turbine shaft) (24) and is rotated by the oil from the pump. Stator (18) is united with the stator shaft (20) and stator boss (25) and is fixed to rear housing (17) through the stator clutch unit. The lock-up clutch unit consists of clutch plate (28) meshed with drive case (15), clutch discs (33) meshed with the turbine boss (31) and clutch piston (30) that slides inside housing (14) united with the drive case. The stator clutch unit consists of clutch discs (29) meshed with boss (25) splined to stator shaft (20), clutch plate (28) supported on clutch housing (26) and rear housing (17) with the pins, and clutch piston (30) that slides inside the rear housing. The PTO unit consists of input shaft (10), idler gear (12), scavenging pump drive gear (35), cooling fan pump and work equipment pump drive gear (41) and power train pump drive gear (38).
Outline
Structure
q
q
q
q
q
q
q
q
Conditions for lockup mode and torque converter mode Gear speed
Forward 1st
Torque converter output shaft speed: (rpm) Lockup mode
Torque converter mode
Min. 1,320 Max. 1,830
Min. 1,256 Max. 1,830
Forward 2nd
Min. 1,584
Max. 1,555
Forward 3rd
Min. 1,350
Max. 1,320
Reverse 1st Reverse 2nd Reverse 3rd
Min. 1,255 Min. 1,359 Min. 1,373
Max. 1,226 Max. 1,330 Max. 1,343
a While the transmission is shifting gears, the torque converter comes into the torque converter drive mode.
D375A-6 (04)
10-43
DRAFT Power train Torque converter and PTO
Power transmitting route When lockup clutch is "disengaged" and stator clutch is "engaged"
When lockup clutch is "engaged" and stator clutch is "disengaged"
As drive case (4) and turbine (6) are disconnected from each other, the torque converter works as an ordinary torque converter. Rear housing (9) and stator shaft (10) are connected to each other to lock stator (11).
Drive case (4) is connected to turbine (6) and torque converter is locked up. Rear housing (9) and stator shaft (10) are connected to each other to fix stator (11).
Engine power O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Oil is used as medium O Turbine (6) and boss (7) O Transmission input shaft (8)
10-44
Engine power O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Lockup clutch (9) O Turbine (6) and boss (7) O Transmission input shaft (8)
D375A-6
DRAFT Power train Torque converter and PTO
Oil flow
q
q
q
The oil flows through the main relief valve and its pressure is regulated to the set pressure or below by the torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of rear housing (1) and pump shaft (2), and flows into pump (3) . The oil is given centrifugal force by pump (3) and flows in turbine (4) to transfer its energy to turbine (4). The oil from turbine (4) is sent to stator (5) and flows into pump (3) again.However, a part of the oil is sent from outlet port (B) to oil cooler through turbine (4) and stator (5).
D375A-6
10-45
DRAFT Power train Torque converter control valve
Torque converter control valve
A: From power train pump B: Lockup clutch oil pressure pickup port (LC) C: Stator clutch oil pressure pickup port (SC) 1. Main relief valve and torque converter relief valve 2. Stator clutch ECMV 3. Lockup clutch ECMV 4. Torque converter inlet oil pressure sensor
10-46
D375A-6
DRAFT Power train Torque converter control valve
Outline q The torque converter valve is installed at the top of the rear housing of the toque converter, and consists of the following four types of valves. q Two types of ECMV are installed; the identifications and differences are shown in the table below. Stamp of the nameplates (A)
Identification Pressure control color valve (B)
A*******
Yellow
Without slit
E*******
Pink
With slit
Main relief valve The main relief valve maintains each hydraulic circuit pressure of the transmission, steering clutch, steering brake and the lockup clutch and stator clutch of torque converter constantly at the set pressure. Set pressure : 2.63 – 2.92 MPa {26.8 – 29.8 kg/cm2 } (At rated engine speed)
q
Fill switch (Operation pressure: MPa{kg/cm2}) Equipped (0.26 {2.7}) Equipped (0.26 {2.7})
Operated clutches Stator Lockup
Lockup clutch ECMV The lockup clutch modulating valve maintains the clutch pressure at the set pressure or below to protect the lockup clutch circuit from abnormally high pressure, as well as increasing the clutch pressure gradually to the set pressure. Set pressure: 1.3 MPa {13 kg/cm2}
q
Torque converter relief valve The torque converter relief valve maintains the oil pressure at the torque converter inlet always at the set pressure or below in order to protect the torque converter from abnormally high pressure.) Set pressure: 1.00 MPa {10.2 kg/cm2} (cracking pressure)
q
Stator clutch ECMV The stator clutch modulating valve maintains the clutch pressure at the set pressure or below to protect the stator clutch circuit from abnormally high pressure, as well as increasing the clutch pressure gradually to the set pressure. Set pressure: 2.7 MPa {27 kg/cm2}
q
D375A-6
10-47
DRAFT Power train Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve
1. Valve body 2. Torque converter relief valve 3. Main relief valve 4. Cover 5. Piston 6. Piston
10-48
D375A-6
DRAFT Power train Main relief valve and torque converter relief valve
Operation of main relief valve
q
The oil from the hydraulic pump flows through the filter, port (A) of the torque converter valve, and orifice (a) of torque converter relief valve (1) to chambe (B).
Operation of torque converter relief valve
q
q
q
The oil from the main relief valve flows through port (C) to the torque converter, and at the same time, also flows through orifice (b) of torque converter relief valve (3) to chamber (D) . When the oil pressure on the torque converter exceeds the set pressure, the oil in chamber (D) pushes piston (4), the reaction force of which moves torque converter relief valve (3) to the right to open port (C) and port (E). Then the oil in port (C) is drained from port (E) to the oil tank.
When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (B) pushes piston (2), the reaction force of which moves spool (1) to the left to open port (A) and port (C). Above operation conducts the oil from port (C) to the torque converter.
D375A-6
10-49
DRAFT Power train Lockup clutch ECMV and stator clutch ECMV
Lockup clutch ECMV and stator clutch ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve a Don't try to disassemble it since the adjustment for maintaining the performance will be required.
A: To clutch P: From pump T: Drain DR: Drain P1: Clutch oil pressure pickup port P2: Pilot oil pressure pickup port 1. Fill switch connector 2. Proportional solenoid connector 3. Oil pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Oil pressure control valve 7. Nameplate
10-50
D375A-6
DRAFT Power train Lockup clutch ECMV and stator clutch ECMV
ECMV for lockup clutch
Operation When traveling with torque converter working
Outline q This valve is used to switch the clutch in addition to regulate the clutch oil pressure to the set pressure. It forms a modulation wave pattern, so the stator clutch is engaged smoothly to reduce the shock when shifting gear. In addition, it prevents generation of peak torque in the power train. As a result, it provides a comfortable ride for the operator and greatly increases the durability of the power train. When changing from traveling in torque converter drive mode to traveling in lockup drive mode
At gear shift (traveling in lockup drive mode)
D375A-6
q
When traveling in torque converter drive mode, current does not blow to proportional solenoid (1). Pressure control valve (3) drains the oil from clutch port (A) through drain port (T), and lockup clutch is "released". Also at this time, fill switch (5) is turned "off" because oil pressure is not applied to pressure detection valve (4).
10-51
DRAFT Power train Lockup clutch ECMV and stator clutch ECMV
When traveling in lockup drive mode (Traveling in torque converter drive mode to traveling in lockup drive mode) During filling In pressure regulation
q
When traveling in lockup drive mode, current flows in proportional solenoid (1), the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. As a result, pump port (P) and clutch port (A) open. When the clutch is filled with oil, oil pressure pickup port (4) actuates and fill switch (5) is turned "ON".
10-52
q
q
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), and then the pressure is regulated. While shifting gears, the lockup clutch oil pressure is reduced temporarily to reduce the shock when shifting gear. Oil pressure at this time is controlled so that the lockup piston pushing force balances with the inside pressure of torque converter.
D375A-6
DRAFT Power train Lockup clutch ECMV and stator clutch ECMV
ECMV for stator clutch
Operation When traveling in lockup drive mode
Outline q This valve is used to switch the clutch in addition to regulate the clutch oil pressure to the set pressure. It forms a modulation wave pattern, so the stator clutch is engaged smoothly to reduce the shock when shifting gear. In addition, it prevents generation of peak torque in the power train. As a result, it provides a comfortable ride for the operator and greatly increases the durability of the power train. Lockup drive mode travel to torque converter drive mode travel
q
D375A-6
When traveling in lockup drive mode, current does not flow to proportional solenoid (1). Pressure control valve (3) drains the oil from clutch port (A) through drain port (T), and stator clutch is "released". Also at this time, fill switch (5) is turned "off" because oil pressure is not applied to pressure detection valve (4).
10-53
DRAFT Power train Lockup clutch ECMV and stator clutch ECMV
When traveling in torque converter drive mode (Lockup drive mode travel o torque converter drive mode travel) During filling In pressure regulation
q
When traveling in torque converter drive mode current flows in proportional solenoid (1), the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left.As a result, pump port (P) and clutch port (A) open. When the clutch is filled with oil, oil pressure pickup port (4) actuates and fill switch (5) is turned "ON".
10-54
q
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), and then the pressure is regulated.
D375A-6
DRAFT Power train Scavenging pump
Scavenging pump Type: BAR(3) 63+277
A: Discharge port B: Small pump suction port C: Large pump suction port 1. Small pump 2. Large pump
D375A-6
10-55
DRAFT Power train Transmission control
Transmission control a Regarding the steering-related description of the PCCS lever, refer to the "Steering and brake control". a PCCS: Palm Command Control System
1. Brake pedal 2. Lock lever 3. PCCS lever (Steering, forward-reverse, gearshift) 3A. Upshift switch (Gear upshifts each time this switch is pressed) 3B. Downshift switch (Gear downshifts each time this switch is pressed) 4. Transmission neutral switch 5. Cable 6. Transmission control valve 7. Power train controller
10-56
Lever position [1]: Neutral [2]: Forward [3]: Reverse [4]: OFF [5]: Upshift [6]: Downshift [7]: Free [8]: Lock
D375A-6
DRAFT Power train Transmission control
Outline q The transmission is controlled with PCCS lever (3). The PCCS lever is used to perform steering operation, directional changes and gear shift operation. q The machine has a safety mechanism that activates transmission neutral switch (4) to allow the engine to start only when the lock lever (2) is set to the "Lock" position.
D375A-6
10-57
Power train PCCS lever
PCCS lever
10-58
a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage output and operating efforts.
1. 2. 3. 4.
Boot Bracket Plate Bolt
10-58
5. Screw 6. Lever 7. Connector
D375A-6 (04)
Power train PCCS lever
Function Operating effort characteristics Operation for forward and reverse travel
q
The control lever is held at 3 positions: "FORWARD" , "NEUTRAL" and "REVERSE".
D375A-6 (04)
Operation for left and right steering
q
10-59 10-59
Free return
10-59
DRAFT Power train Transmission control
2. Output voltage characteristics q The lever is installed to the left control stand and the control lever (knob) is fixed directly onto it. q The operating angle (stroke) of the control levers sensed with potentiometers and signal voltages are output to the transmission, steering controller. q A potentiometer is installed to detect each of longitudinal displacement and lateral displacement. Each potentiometer outputs two signal voltages which are opposite in phase as shown in the figure on the right.
10-60
D375A-6
Power train PCCS lever
10-61 Since gear shift during travel is possible, there is no need to stop the machine to shift gears. Gear shift of the machine
10-61 Gear shift operation becomes available by pushing switch (1) or (2) when Joystick (steering, directional and gear shift lever) is in the FORWARD or REVERSE position. (1) The gear upshifts by one each time the "Upshift" switch is pressed. (2) The gear downshifts by one each time the" Downshift" switch is pressed. a If you carry out the gear shift, the gear speed is indicated on the display panel. Neutral: Indicates "N". Forward 2nd: Indicates "F2" on the display. Reverse 3rd: Indicates "R3". "P" is indicated when the lock lever is placed at the "Lock" position. Gear shift operation
D375A-6 (04)
10-61
DRAFT Power train Transmission
Transmission
10-62
D375A-6
DRAFT Power train Transmission
A: B: C: D: E:
1st clutch oil pressure pickup port 3rd clutch oil pressure pickup port R clutch oil pressure pickup port 2nd clutch oil pressure pickup port F clutch oil pressure pickup port
1. 2. 3. 4.
Transmission control valve Front case Rear case Lubricating oil relief valve
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10-63
DRAFT Power train Transmission
10-64
D375A-6
DRAFT Power train Transmission
5. Transmission input shaft 6. Front cover 7. Sun gear for reverse clutch (34 teeth) 8. Ring gear for reverse (hub) (91 teeth) 9. Planetary pinion for reverse clutch (25 teeth) 10. Ring gear for reverse clutch (84 teeth) 11. Sun gear for forward clutch (41 teeth) 12. Planetary pinion for forward clutch (25 teeth) 13. Ring gear for forward clutch ( 91 teeth) 14. Ring gear for 3rd clutch (91 teeth) 15. Planetary pinion for 3rd clutch (25 teeth) 16. Sun gear for 3rd clutch (41 teeth) 17. Ring gear for 2nd clutch (93 teeth) 18. Planetary pinion for 2nd clutch (23 teeth) 19. 2nd sun gear(47 teeth ) 20. 1st clutch gear 21. 1st clutch piston 22. 1st clutch piston housing 23. Output shaft 24. Spacer 25. Collar 26. 1st clutch spring 27. 2nd carrier 28. Plate 29. Carrier for forward and 3rd clutches 30. Piston housing for forward and 3rd speed gear 31. Carrier for reverse clutch 32. Carrier for reverse clutch 33. Clutch piston 34. Clutch spring 35. Clutch plate 36. Clutch disc 37. Washer spring 38. Pin 39. Tie bolt
D375A-6
Outline q The transmission is a "forward 3-speed and reverse 3-speed" transmission which consists of the planetary gear trains and the disc clutches. q Transmission selects and locks two clutches out of the five sets of planetary gear trains and disc clutches hydraulically by using the control valve to select one travel direction and one gear speed. q The transmission transfers the power received by the transmission input shaft to the output shaft by changing the gear speed (forward 1st-3rd or reverse 1st-3rd) with any combination of the forword or reverse clutch, and one of three speed clutches. No. of plates and discs used Clutch No. R clutch F clutch 3rd clutch 2nd clutch 1st clutch
Number of plates Number of discs 6 6 5 6 4 4 3 3 5 6
Combinations of clutches at respective gear speeds and reduction ratio Gear speed Forward 1st Forward 2nd Forward 3rd Neutral Reverse 1st Reverse 2nd Reverse 3rd
Clutches engaged F × 1st F × 2nd F × 3rd (*1) R × 1st R × 2nd R × 3rd
Reduction ratio 3.220 1.745 1.000 2.471 1.339 0.769
*1: The 1st or 2nd clutch is filled with low-pressure oil.
10-65
DRAFT Power train Transmission
Disc clutch Structure
q
q q
The disc clutch consists of piston (2), plates (3), discs (4), pin (5), return spring (6), and washer spring (7) to fix ring gear (1). Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). Plate (3) and clutch housing (8) are assembled with pin (5).
Operation When clutch is "engaged" (locked)
The oil from ECMV is routed to the back of piston (2) through oil passage of clutch housing (8) and pushes piston (2) leftward. q Piston (2) presses plate (3) closely against disc (4) to stop rotation of disc (4) by using friction force generated between them. q Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), the ring gear (1) is locked. When clutch is "disengaged" (released) q
q
q q
10-66
When the supply of oil from ECMV is shut off, piston (2) is returned rightward by the force of return spring (6). This relieves the frictional force between plates (3) and discs (4), making the ring gear (1) free. Washer spring (7) installed at pin portions between the plates acts to speed up the return of the piston when the clutch is disengaged, and also to separate the plates and discs cleanly to prevent drag turning.
D375A-6
DRAFT Power train Transmission
Oil passage in speed clutch
q q
q
q
q
When the PCCS lever is in the "Neutral" position , the 1st or 2nd gear speed is kept selected. The piston chamber of the clutch corresponding to the selected gear speed is filled with oil by electronically controlling the oil circuit of each clutch. When the PCCS lever is shifted from the "Neutral" position to the "Forward" or "Reverse" position, the pump is required to supply oil enough to fill the piston chamber of the forward or reverse clutch. When the gear speed is changed from "Forward 1st" to "Forward 2nd", the pump is required to supply oil enough to press the plates and discs of the 2nd clutch since the forward clutch has been filled with the oil. The time lag at shifting gears is reduced by controlling the oil circuit as explained above.
D375A-6
10-67
DRAFT Power train Transmission
Operation of transmission Forward 1st
10-68
D375A-6
DRAFT Power train Transmission
F clutch ring gear (4) and 1st clutch gear (16) are locked hydraulically. The power from torque converter O Input shaft (1) O F clutch sun gear (2) O F clutch planetary pinion (3) O F clutch and 3rd carrier (10) O 3rd planetary pinion (11) o O O O 3rd ring gear (12) O O 2nd carrier (13) O O 2nd planetary pinion (14) O O 2nd ring gear (15) O O O 1st clutch gear (16) 3rd sun gear (18) O O Output shaft (19)i i
D375A-6
10-69
DRAFT Power train Transmission
Forward 2nd
10-70
D375A-6
DRAFT Power train Transmission
F ring gear (4) of F clutch and 2nd ring gear (15) of 2nd clutch are locked hydraulically. The power from torque converter O Input shaft (1) O F clutch sun gear (2) O F clutch planetary pinion (3) O F clutch and 3rd clutch carrier O 3rd clutch planetary pinion (11) o O O O 3rd clutch ring gear (12) O O 2nd clutch carrier (13) O O 2nd clutch planetary pinion (14) O O 3rd clutch sun gear (18) 2nd clutch sun gear (17) O O Output shaft (19)i i
D375A-6
10-71
DRAFT Power train Transmission
Forward 3rd
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D375A-6
DRAFT Power train Transmission
F ring gear (4) of F clutch and 3rd ring gear (12) of 3rd clutch are locked hydraulically. The power from torque converter O Input shaft (1) O F clutch sun gear (2) O F clutch planetary pinion (3) O F clutch and 3rd clutch carrier (10) O 3rd clutch planetary pinion (11) O 3rd clutch sun gear (18) O Output shaft (19)
D375A-6
10-73
DRAFT Power train Transmission
Reverse 1st
10-74
D375A-6
DRAFT Power train Transmission
R ring gear (7) of R clutch and 1st clutch gear (16) of 1st clutch are locked hydraulically. The power from torque converter O Input shaft (1) O R clutch sun gear (5) O R clutch planetary pinion (6) O R clutch ring gear (9) (R clutch carrier (8) is locked with R clutch ring gear (7) = R clutch ring gear (9) rotation direction is opposite to that of input shaft (1)) O F clutch and 3rd clutch carrier O 3rd clutch planetary pinion (11)o O O O 3rd clutch ring gear (12) O O 2nd clutch carrier (13) O O 2nd clutch planetary pinion (14) O O 2nd clutch ring gear (15) O O 1st clutch gear (16) 3rd sun gear (18) O O Output shaft (19)i i
D375A-6
10-75
DRAFT Power train Transmission ECMV
Transmission ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve a Don't try to disassemble it since adjustment for maintaining the performance will be required
10-76
D375A-6
DRAFT Power train Transmission ECMV
A: 1st clutch oil pressure pickup port B: 3rd clutch oil pressure pickup port C: R clutch oil pressure pickup port D: 2nd clutch oil pressure pickup port E: F clutch oil pressure pickup port F: To clutch P: From pump T: Drain 1. 3rd clutch proportional solenoid 2. 1st clutch proportional solenoid 3. R clutch proportional solenoid 4. 2nd clutch proportional solenoid 5. F clutch proportional solenoid 6. 3rd clutch fill switch 7. 2nd clutch fill switch 8. 1st clutch fill switch 9. R clutch fill switch 10. F clutch fill switch 11. Connector for 1st clutch proportional solenoid 12. Connector for 3rd clutch proportional solenoid 13. Connector for R clutch proportional solenoid 14. Connector for 2nd clutch proportional solenoid 15. Connector for F clutch proportional solenoid 16. Connector for 3rd clutch fill switch 17. Connector for 2nd clutch fill switch 18. Connector for 1st clutch fill switch 19. Connector for R clutch fill switch 20. Connector for F clutch fill switch 21. Block 22. Pressure control valve 23. Oil pressure detection valve 24. Spring for pressure control valve
D375A-6
10-77
DRAFT Power train Transmission ECMV
Outline of ECMV q The ECMV consists of a pressure control valve and a fill switch. q Pressure control valve A proportional solenoid in this valve receives the current sent from the controller and this valve converts it to oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller while oil pressure is applied to the clutch to notify whether oil pressure is applied or not .
ECMV and proportional solenoid q For each ECMV, a proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, controlling the command current that changes the thrust to operate the pressure control valve allows for controlling the oil flow and pressure to the clutch. Current - thrust characteristics of proportional solenoid
Thrust - Oil pressure characteristics of proportional solenoid
Phase A: Before shifting gear (oil is drained) Phase B: Filling phase Phase C: Pressure build-up phase Phase D: Filling phase (during triggering) Point E: Start of filling Point F: Finish of filling a The logic is so made that the controller does not recognize completion of filling even if the fill switch is turned "ON" during triggering (phase D).
10-78
ECMV and fill switch For each ECMV, a fill switch is installed. When the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure starts to build up according to this signal.
q
D375A-6
DRAFT Power train Transmission ECMV
Operation of ECMV q ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal change with time shown below.
Before shifting gear (oil is drained) (Phase A in chart)
q
Phase A: Before shifting gear (oil is drained) Phase B: Filling phase Phase C: Pressure build-up phase Phase D: Filling phase (during triggering) Point E: Start of filling Point F: Finish of filling a The logic is so made that the controller does not recognize completion of filling even if the fill switch is turned "ON" during triggering (phase D). q When gear is shifted with gear shift switch, the clutch discs and plates are pressed by piston. If high pressure is suddenly applied, the piston suddenly engages the clutch, causing sudden start of the machine and excessive shock. ECMV reduces a shock at the start of the machine by increasing the oil pressure applied to the piston gradually to set pressure, and allows the clutch to be smoothly "engaged". It aims to increase durability of the components on the power transmitting route and enhances an operator comfort.
D375A-6
Under the condition where any current is not sent to the proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). Also at this time, fill switch (5) is turned "off" because oil pressure is not applied to pressure detection valve (4).
10-79
DRAFT Power train Transmission ECMV
Filling phase (Phase B in chart)
q
When current is supplied to proportional solenoid (1) with no oil in the clutch, the force exerted by the oil pressure, that is equal to the thrust of the solenoid, develops in chamber (B) and pushes pressure control valve (3) to the right. As a result, pump port (P) and clutch port (A) are opened and oil starts filling the clutch. When the clutch is filled with oil, pressure detection value (4) actuates to turn "ON" fill switch (5).
10-80
Pressure adjustment (Range C in chart)
q
When current flows through proportional solenoid (1), the solenoid generates thrust in proportion to the current. The clutch circuit pressure builds up until the thrust of the solenoid is balanced with the sum of the force exerted by the oil pressure in clutch port and the force of pressure control valve spring (2), and then the pressure is settled.
D375A-6
DRAFT Power train Transmission lubricating oil relief valve
Transmission lubricating oil relief valve
1. Lubricating oil pressure measurement plug 2. Lubricating oil relief value spool 3. Valve body
Outline q The lubricating oil 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}
D375A-6
10-81
DRAFT Power train Steering and brake control
Steering and brake control a Regarding the transmission-related description of the operation of the PCCS lever, refer to the "Transmission control". a PCCS: Palm Command Control System
10-82
D375A-6
DRAFT Power train Steering and brake control
1. Brake pedal 2. Lock lever 3. PCCS lever(steering, forward-reverse, gear shift) 4. Power train controller 5. Limit switch 6. Steering ECMV 7. Brake valve 8. Parking brake lever (from lock lever) 9. Cable 10. Rod (from brake pedal) 11. Potentiometer
Outline q PCCS lever (3) sends electric signals to power train controller (4). After receiving the signals, power train controller (4) sends a proportional current to the steering ECMV (6) to operate the steering clutch and brake. q Brake pedal (1) sends electric signals to power train controller (4) through the potentiometer (11). Upon receiving those signals, power train controller (4) sends a proportional current to steering ECMV (6) to operate the brake. In this case, the right and left brakes operate at the same time to activate braking. Rod (10), as an emergency brake operating device, operates the brake through brake valve (7). (only when the brake pedal is depressed fully) q If you completely tilt PCCS lever (3) If you slightly tilt PCCS lever (3) leftward, the left steering clutch is partially disengaged, causing the machine to make a gradual left turn.
D375A-6
Positions of levers and pedals [1]: Neutral [2]: Forward straight-travel [3]: Reverse straight-travel [4]: Left clutch OFF [5]: Left clutch OFF, Left brake ON [6]: Right clutch OFF [7]: Right clutch OFF, Right brake ON [8]: Brake "released" [9]: Brake ON [10]: Free [11]: Lock
q
q
If you completely tilt PCCS lever (3) leftward, the left steering clutch is "disengaged" completely and the left steering brake is "applied" , causing the machine to make a sharp left turn. The lock lever (2) is connected to parking brake lever (8) and serves as a parking brake lever.
10-83
DRAFT Power train Transfer unit, bevel gear shaft and steering
Transfer unit, bevel gear shaft and steering Machines without VHMS controller
1. Transmission 2. Input shaft 3. Steering unit 4. Breather 5. Parking brake valve 6. L.H. steering brake ECMV 7. R.H. steering brake ECMV 8. Transmission output shaft speed sensor 9. Filter
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10. L.H. steering clutch ECMV 11. R.H. steering clutch ECMV 12. Sudden stop prevention valve
D375A-6
DRAFT Power train Transfer unit, bevel gear shaft and steering
Machines equipped with VHMS controller
1. Transmission 2. Input shaft 3. Steering unit 4. Breather 5. Parking brake valve 6. L.H. steering brake ECMV 7. R.H. steering brake ECMV 8. Transmission output shaft speed sensor 9. Filter
D375A-6
10. L.H. steering clutch ECMV 11. R.H. steering clutch ECMV 12. Sudden stop prevention valve
10-85
DRAFT Power train Transfer unit, bevel gear shaft and steering
Transfer unit and bevel pinion Machines without VHMS controller
1. Input shaft 2. Drive gear (35 teeth) 3. Transmission output shaft speed sensor 4. Rear cover 5. Bearing cage 6. Driven gear (33 teeth) 7. Bevel pinion (23 teeth) 8. Bevel gear (40 teeth)
10-86
Outline q The transfer unit and bevel pinion are installed at the rear part inside the steering case, and input shaft (1) receives the power from the transmission output shaft. q The transfer unit consists of drive gear (2) and driven gear (6) to reduce the power speed from input shaft (1), transferring it to bevel pinion (7). q It is equipped with transmission output shaft speed sensor (3) to send the electric signals of speed of drive gear (2) to the power train controller.
D375A-6
DRAFT Power train Transfer unit, bevel gear shaft and steering
Machines equipped with VHMS controller
1. Input shaft 2. Drive gear (35 teeth) 3. Transmission output shaft speed sensor 4. Rear cover 5. Torque converter output speed sensor 6. Bearing cage 7. Driven gear (33 teeth) 8. Bevel pinion (23 teeth) 9. Bevel gear (40 teeth)
D375A-6
Outline q The transfer unit and bevel pinion are installed at the rear part inside the steering case, and input shaft (1) receives the power from the transmission output shaft. q The transfer unit consists of drive gear (2) and the driven gear (7) to reduce the power speed from the input shaft (1), transferring it to bevel pinion (8). q It is equipped with transmission output shaft speed sensor (3) to send the electric signals of speed of drive gear (2) to the power train controller.
10-87
DRAFT Power train Transfer unit, bevel gear shaft and steering
Bevel gear shaft, steering clutch and brake
10-88
D375A-6
DRAFT Power train Transfer unit, bevel gear shaft and steering
1. Output shaf 2. Sleeve 3. Brake cage 4. Brake spring 5. Brake case 6. Brake piston 7. Torque pin 8. Blake plate (each side: 9 plates) 9. Spacer 10. Brake disc (each side: 9 discs) 11. Brake hub 12. Brake stopper 13. Pipe 14. Bearing cage 15. Bevel gear shaft 16. Bevel gear shaft 17. Bevel gear (40 teeth) 18. Bearing cage 19. Clutch hub 20. Clutch stopper 21. Spacer 22. Clutch plate (each side: 9 plates) 23. Clutch disc (each side: 9 discs) 24. Torque pin 25. Clutch piston 26. Clutch spring 27. Clutch housing 28. Clutch cage
D375A-6
Outline q The steering clutch is wet-type, multiple-disc, spring-applied type. If you operate the PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering clutch ECMV. The steering clutch works in conjunction with the steering brake. q The steering brake is wet type multiple-disc, spring-applied type. If you operate the brake pedal and PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering brake ECMV. The steering brake works in conjunction with the steering clutch. q When the engine is stopped, the steering brake is "applied" since the pressure acting on the back of the brake piston lowers, even if you do not depress the brake pedal. Since the brake is released as the oil pressure in the circuit goes up when the engine restarts, the parking brake lever must be set to "LOCK" position. q The lubrication method is forced lubrication type, 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 discs and plates.
10-89
DRAFT Power train Steering control valve
Steering control valve
10-90
D375A-6
DRAFT Power train Steering control valve
A: Left clutch pressure pickup port B: Right clutch pressure pickup port C: Left brake pressure pickup port D: Right brake pressure pickup port E: To left clutch F: To left lubrication circuit G: To left brake H: To right clutch J: To right lubrication circuit K: To right brake L: Bevel gear shaft lubricating oil inlet port M: To pin puller solenoid valve N: From pin puller solenoid valve P: From pump 1. Left steering clutch ECMV 2. Right steering clutch ECMV 3. Sudden stop prevention valve 4. Parking brake valve 5. Left steering brake ECMV 6. Right steering brake ECMV 7. Filter 8. Valve seat
D375A-6
Outline q Four ECMV's are installed on the valve seat of the steering control valve to control the steering clutch and steering brake. q The steering control valve is located in the circuit between the power train pump and the pistons of the steering clutch and steering brake. It consists of two sets of the steering clutch ECMV (L.H. and R.H.) and two sets of the steering brake ECMV (L.H. and R.H.). q The steering control valve sends the oil from the power train pump to the both left and right sides of steering clutches and steering brakes to control respective disc clutches and disc brakes. q When the PCCS lever is leaned to the right or left, the steering clutch is disengaged. The steering brake will operate by leaning further the PCCS lever. q The controller sends signals to each ECMV according to the right or left travel of the PCCS lever and controls the clutch and brake for the gradual or sharp turns. q When the brake pedal is depressed, the controller sends the command current to the steering brake ECMV according to the pedal travel to apply the L.H. and R.H. brakes to stop the machine. q The controller that is connected electrically to the PCCS lever and brake pedal operates the steering clutch and steering brake by controlling each ECMV. q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when a failure occurs in the electrical system. q When the parking brake lever is set in the "lock" position, the parking brake valve port is switched to drain the oil between the L.H. and R.H. steering brake ECMV and the brake piston to apply the brake. The parking brake valve is connected to the brake pedal by the linkage.
10-91
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
Steering clutch ECMV and Steering brake ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve a Don't try to disassemble ECMV since adjustment for maintaining the performance will be required.
A: To clutch or brake P: From pump T: Drain Dr: Drain P1: Clutch or brake oil pressure pickup port
*1:
1. Fill switch connector 2. Proportional solenoid connector 3. Pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve 7. Nameplate (*1)
Outline q Each ECMV keeps the steering clutch pressure and steering brake pressure to the set pressure and switches the circuit to the piston chamber of the steering clutch and steering brake.
10-92
Clutch to use ECMV
Stamp of the name plate
Steering clutch, Steering brake
R*******
D375A-6
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
Outline of ECMV q The ECMV consists of a pressure control valve and a fill switch. q Pressure control valve A proportional solenoid in this valve receives a current sent from the steering controller and this valve converts it to an oil pressure. q Fill switch This is a switch to detect that a clutch or brake is filled with oil and has the following functions. 1. At the moment when the clutch or brake is filled with oil, the fill switch outputs the signal (fill signal) to the controller to notify the finishing of filling. 2. While the oil pressure is applied to the clutch or brake, the fill switch outputs the signal (fill signal) to the controller to notify the presence of the oil pressure. ECMV and proportional solenoid Each ECMV is equipped with a proportional solenoid. The solenoid generates thrust according to the command current from the controller. The thrust generated by the proportional solenoid acts on the spool of the pressure control valve and the valve generates the oil pressure. Accordingly, controlling the command current that changes the thrust to operate the pressure control valve allows for controlling the oil flow and oil pressure.
q
ECMV and fill switch Each ECMV is equipped with a fill switch. If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal allows the oil pressure to build up.
q
Operation of ECMV ECMV is controlled by the command current sent from the controller to the proportional solenoid and the fill switch output signal.
q
D375A-6
10-93
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in "free" position: Straight travel (L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "released", and parking brake is "released".)
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When the PCCS lever is in "neutral" position and the brake pedal is "released", proportional solenoid (1) of the clutch ECMV is de-energized and the sealing part by ball (2) is opened. The oil from the power train pump flows through port (Pc) of the clutch ECMV to orifice (a), then it is drained through the sealing part by ball (2). Valve (3) is moved to the right by the force of spring (4) to disconnect port (Pc) from port (C), and connect port (C) to port (Dr). At this time, the oil from the port behind the clutch piston is drained through port (C) and the clutch is "engaged" by the force of the clutch spring. The oil pressure in the brake circuit, etc. is maintained by orifice (a). Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left to close the sealing part.
10-94
q
q
The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left to connect port (Pb) to port (B) and disconnect port (B) from port (Dr). At this time, the oil flows in the port behind the brake piston. As the oil pressure rises, the brake piston is pushed to the left to compress the brake spring, then the brake is “released”. When the parking brake lever is in "free" position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
D375A-6
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
When PCCS lever is "operated to the left halfway", brake pedal is "released", and parking brake lever is in "free" position: Gradual left turn (L.H. clutch is "disengaged", L.H. brake is "semi-released", R.H. clutch is "engaged", R.H. brake is "released", and parking brake is "released".)
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When the PCCS lever is "operated halfway to left" and the brake pedal is "released", proportional solenoid (1) of the L.H. clutch ECMV is energized and the sealing part by ball (2) is closed. The oil from the power train pump flows through port (Pc) of the clutch EMCV and orifice (a) to port (F) and pushes valve (3) to the left to connect port (Pc) to port (C) and disconnect port (C) from port (Dr). At this time, the oil flows in the port behind the clutch piston. As the oil pressure rises, the clutch piston is pushed to the left to compress the clutch spring, then the clutch is "disengaged". Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left to close the sealing part.
D375A-6
q
q
q
The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left. The circuit pressure after port (B) depends on the command current output from the controller to proportional solenoid (5) according to the travel of the PCCS lever. Proportional solenoid (5) generates the thrust in proportion to the command current. When this thrust is balanced with the sum of the force generated by the pressure in the port behind the brake piston and the force of spring (8), the brake pressure that determines braking force is set up. Accordingly, if the travel of the PCCS lever is short, the cricuit pressure after port (B) is set high and the brake is turned from "released" to "semi-released". If the travel of the PCCS lever is long, the circuit pressure after port (B) is set low and the brake is turned from "semi-released" to "applied".
10-95
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
q
When the parking brake lever is in "free" position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
10-96
D375A-6
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
When PCCS lever is "operated fully to the left", brake pedal is "released", and parking brake lever is in "free" position: Sharp left turn (L.H. clutch is "disengaged", L.H. brake is "applied", R.H. clutch is "engaged", R.H. brake is "released", and parking brake is "released".)
q
q
q
When the PCCS lever is moved from "halfway to left" to "fully to left" position, proportional solenoid (5) of the L.H. brake ECMV is de-energized and the sealing part by ball (6) is fully opened. Since the oil in port (E) is drained through the sealing part, valve (7) is moved to the right by the force of spring (8) to disconnect port (Pb) from (B) and connect port (B) to port (Dr). At this time, the oil from the port behind the brake piston is drained through port (B) and the brake is "applied" by the force of the brake spring. The oil from the power train pump flows through port (Pb) of the brake ECMV and orifice (b), then it is drained through sealing part by ball (6).
D375A-6
q q
The oil pressure in the clutch circuit, etc. is maintained by orifice (b). When the parking brake lever is in "free" position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
10-97
DRAFT Power train Steering clutch ECMV and Steering brake ECMV
When PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free" position: Stop (L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "released".)
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q
q
q
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When the brake pedal is depressed fully, proportional solenoids (5) of L.H. and R.H. brake ECMVs are de-energized to open the sealing part by ball (6). The controller outputs the command current to proportional solenoids (5)according to the brake pedal travel. Proportional solenoid (5) generates the thrust in proportion to the command current. When this thrust is balanced with the sum of the thrust exerted by the pressure in the port behind the brake piston and the force of spring (8), the brake pressure that determines the braking force is set up. Since the PCCS lever is in "neutral" position, proportional solenoid (1) of L.H. and R.H. clutch ECMVs are de-energized and L.H. and R.H. clutch are "engaged". When the brake pedal is depressed, the parking brake valve connected to the pedal by the linkage operates to connect the brake circuit to the drain circuit, allowing the oil to drain.
10-98
D375A-6
DRAFT Power train Parking brake valve
Parking brake valve
1. Spool 2. Valve body
D375A-6
Outline q The parking brake valve is installed to the steering control valve, and spool (1) operates with the parking brake lever. q When the parking brake lever is in “lock" position, the brake is applied by draining the pressurized oil for the L.H. and R.H. steering brakes.
10-99
DRAFT Power train Parking brake valve
When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in "lock" position : Parking (L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "applied".)
q
q q
q
q
When the parking brake lever is set to the "lock" position, spool (1) is moved to the left to connect ports (A) and (B) to port (C) . The oil in the port behind the brake piston is drained from port (C) through ports (A) and (B) . The oil pressure in the port behind the brake piston continues to decrease, then the brake is fully "applied" and kept "applied" . When the engine is started again, as ports (A) and (B) are still connected to port (C) , the brake is kept "applied" . When the parking brake lever is moved to "free" position, spool (1) moves to the right to disconnect port (A) and (B) from (C) . Then the oil from the brake ECMV flows to the port behind the brake piston and the brake is "released".
10-100
D375A-6
DRAFT Power train Sudden stop prevention valve
Sudden stop prevention valve
Outline q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when an abnormality takes place in the electric system. q Sudden stop prevention valve (1) is installed in the drain circuit of the brake ECMV so that the pressure of port (DR) does not drop suddenly when brake ECMV coil (2) is de-energized, and consequently the sudden braking can be avoided when coil (2) of brake ECMV is de-energized. q If an abnormality takes place in the electric system, coil (3) of the sudden stop prevention valve (1) is de-energized. Then, the oil in port (DR) is drained through orifice (a) so that the brake is applied gradually.
D375A-6
10-101
DRAFT Power train Sudden stop prevention valve
10-102
D375A-6
DRAFT Power train Final drive
Final drive
Outline q The final drive consists of a single-reduction spur gear set and a singal-reduction planetary gear train. The lubrication is of splash type using the rotation of the gears. The final drive can be removed and installed as a single unit. q Floating seal (1) is installed to the rotating portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.
D375A-6
10-103
DRAFT Power train Final drive
10-104
D375A-6
DRAFT Power train Final drive
1. Floating seal 2. Sun gear 3. Carrier 4. Hub 5. Cover 6. Sprocket boss 7. Sprocket teeth 8. Floating seal guard 9. Cover 10. Planetary pinion 11. Ring gear 12. Cover 13. No.1 gear 14. No.1 gear hub 15. No.1 pinion 16. Final drive case 17. Bearing cage 18. Boss 19. Shaft 20. Wear guard 21. Pivot shaft
D375A-6
10-105
DRAFT Power train Final drive
Path of power transmission
10-106
D375A-6
DRAFT Power train Final drive
q
The power from the bevel gear shaft 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 planetary pinions (10), but ring gear (11), which is meshed with the planetary pinions, is fixed to cover (9), so the planetary pinions rotate along the ring gear while moving around the sun gear. Then, the rotating force of sun gear (2) functions as the rotating force of carrier (3) , which supports the planetary pinions, and is transmitted to sprocket hub (4). The rotating direction 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-6
10-107
DRAFT Undercarriage and frame Track frame
Undercarriage and frame Track frame
1. Idler 2. Recoil spring assembly 3. Idler cushion 4. Track frame 5. Sprocket 6. Sprocket cover 7. Track roller bogie 8. Track roller 9. Cap 10. Idler yoke 11. Cylinder 12. Guide
Outline q The track rollers are mounted on the K-shaped bogies, thereby increasing the actual contact area between ground and the track even on an uneven ground to increase drawbar pull. q Because a rubber pad is mounted on a K-shaped bogie, the shock from a road surface is absorbed. Track roller arrangement Track roller flange type 1st
2nd
3rd
4th
5th
6th
7th
8th
S
D
D
D
D
D
D
S
S: Single flange type D: Double flange type
10-108
D375A-6
DRAFT Undercarriage and frame Track frame
D375A-6
10-109
Undercarriage and frame Idler cushion
Idler cushion
1. Yoke 2. Nut 3. Retainer 4. Recoil spring 5. Rod 6. Spring cylinder 7. Retainer 8. Holder 9. Piston 10. Lubricator (for pumping in and discharging grease) 11. Grease chamber cylinder
10-110
10-1 0
10-1 0 Outline Pumping in or discharging grease from lubricator (10) moves rod (5) forward or backward to adjust track tension. The recoil spring (4) acts to dampen any sudden shock brought to bear on the idler.
D375A-6 (04)
Undercarriage and frame Track roller bogie
Track roller bogie
1. Guide 2. Cap 3. Track roller assembly (double flange type) 4. Major bogie 5. Rubber mount 6. Miner bogie 7. Track roller assembly 8. Cover
D375A-6 (04)
10-1 1
10-1 1 Outline q The track roller is mounted on the miner bogie (6) so that the track roller and track shoe can be touched constantly. q The vibration from a road surface is absorbed by the rubber mount (5).
10-111
DRAFT Undercarriage and frame Main frame
Main frame
10-112
D375A-6
DRAFT Undercarriage and frame Main frame
1. Main frame 2. Bracket 3. Cap 4. Cushion 5. Plate 6. Cage 7. Clamp 8. Seal 9. Cover 10. Coupling 11. Cap 12. Cushion 13. Bushing 14. Flange 15. Cushion spacer
D375A-6
10-113
DRAFT Undercarriage and frame Suspension
Suspension
10-114
D375A-6
DRAFT Undercarriage and frame Suspension
1. Equalizer bar 2. Pivot shaft assembly 3. Cover 4. Thrust plate 5. Thrust plate 6. Pivot shaft 7. Seal cage cover 8. Cover 9. Seal 10. Bushing
D375A-6
11. Side pin 12. Center pin 13. Bushing Outline q The track frame allows its front part to move up and down on the pivot shaft (6) at the tail connected to its rear part. The equalizer (1) can rock on the center pin (12) and is connected to the left and right track frames with side pins (11).
10-115
DRAFT Undercarriage and frame Suspension
*1 *2
. Indicates the left suspension of single tilt specification machines. . Indicates the right suspension of single tilt specification machines. Indicates the left and right suspension of dual tilt specification machines.
10-116
D375A-6
Hydraulic system Work equipment hydraulic piping diagram
Hydraulic system
10-1 7
Work equipment hydraulic piping diagram
10-1 7
Blade system
10-1 7
Semi-U dozer + Single tilt
1. Blade tilt cylinder 2. R.H. blade lift cylinder 3. Control valve 4. Hydraulic tank 5. Work equipment pump (HPV190) 6. L.H. blade lift cylinder
D375A-6 (04)
10-117
DRAFT Hydraulic system Work equipment hydraulic piping diagram
q
Full U - Dozer with dual tilt function
1. Blade tilt cylinder 2. R.H. blade lift cylinder 3. Control valve 4. Hydraulic tank 5. Work equipment pump (HPV190) 6. L.H. blade lift cylinder 7. Blade pitch cylinder
10-118
D375A-6
Hydraulic system Work equipment hydraulic piping diagram
Ripper system
10-1 9
Variable multi-shank ripper (Figure shows a dual tilt specification machine)
1. Control valve 2. Ripper tilt cylinder 3. Ripper lift cylinder
D375A-6 (04)
10-119
Hydraulic system Work equipment hydraulic piping diagram
Variable giant ripper (Figure shows a dual tilt specification machine)
1. Control valve 2. Steering control valve 3. Ripper tilt cylinder 4. Ripper lift cylinder 5. Pin puller cylinder (from power train hydraulic circuit) 6. Solenoid valve (for pin-puller)
10-120
D375A-6 (04)
Hydraulic system PPC control piping diagram
PPC control piping diagram
10-121
Blade and ripper control (Figure shows a dual tilt specification machine)
10-121
1. Accumulator 2. Check valve 3. Blade control PPC valve 4. Ripper control PPC valve 5. PPC lock valve 6. Cooling fan pump 7. Self-pressure reducing valve 8. Hydraulic pump
D375A-6 (04)
10-121
DRAFT Hydraulic system Work equipment control
Work equipment control q
The drawing shows a dual tilt dozer and pin puller installed machine.
10-122
D375A-6
DRAFT Hydraulic system Work equipment control
1. Work equipment lock lever 2. Blade control lever 3. Tilt/pitch selector switch (only for dual tilt dozer specification) 4. Ripper control lever (only for ripper installed machine) 5. Pin puller swith (only for giant ripper installed machine) 6. PPC lock valve 7. Work equipment lock switch Lever positions [1] : Blade "HOLD" [2] : Blade "LOWER" [3] : Blade "FLOAT" [4] : Blade "RAISE" [5] : Blade "LEFT TILT/*PITCH BACK" [6] : Blade "RIGHT TILT/*PITCH DUMP" * Activated when the pitch selector switch is turned "ON" (dual tilt specification only) [7] : Ripper "HOLD" [8] : Ripper "RAISE" [9] : Ripper "LOWER" [10] : Ripper "TILT IN" [11] : Ripper "TILT BACK" [12] : FREE [13] : LOCK [14] : Dual tilt selector switch "OFF" [15] : Dual tilt selector switch "ON" [16] : Pitch selector switch "OFF" auto return [17] : Pitch selector switch "ON" [18] : Pin puller switch "PUSH OUT" [19] : Pin puller switch "PUSH IN" Outline q The work equipment control employs a PPC system which uses PPC valves to move respective spools of the control valve. q Work equipment lock lever (1) is interconnected with PPC lock valve (6), and when it is set to the "LOCK" position, the flow of oil in the PPC circuit is stopped. q Work equipment lock lever (1) is also interlocked with work equipment lock switch (7). When work equipment lock lever (1) is set to "LOCK" position, work equipment lock switch (7) is turned "OFF" and engine is ready to start. When work equipment lock lever (1) is set to "FREE" position, work equipment lock switch (7) is turned "ON" and engine is not ready to start in this circuit.
D375A-6
10-123
DRAFT Hydraulic system Hydraulic tank
Hydraulic tank
10-124
D375A-6
DRAFT Hydraulic system Hydraulic tank
1. Oil filler port cap 2. Hydraulic oil filter element 3. Spring 4. Suction valve 5. Cover 6. Cover 7. Hydraulic tank 8. Strainer (suction) 9. Sight gauge 10. Pressure valve and Breather 11. Drain valve 12. Drain plug 13. Strainer (over flow)
Specified value Tank capacity (l) Hydraulic tank Level inside tank
210
Hi (l)
144
Center (l)
130
Low (l)
112
Cracking pressure of pressure valve (kPa {kg/cm2}) Breather Operating pressure of vacuum valve (kPa {kg/cm2})
17 ± 2.5 {0.17 ± 0.025} 2 ± 0.3 {0.02 ± 0.003} Specified value
Cracking pressure (kPa{kg/cm2})
150 ± 30 {1.5 ± 0.3}
Mesh size (mm)
30/8
Filtering area (cm2)
17600
Filtering oil flow (l/min)
720
Strainer (over flow)
Mesh size (mm)
40
Strainer (suction)
Mesh size (mm) Filtration area (cm2)
Hydraulic oil filter
D375A-6
105 3,600
10-125
DRAFT Hydraulic system Accumulator
Accumulator For ppc valve
1. Gas plug 2. Shell 3. Poppet 4. Holder 5. Bladder 6. Oil port Specifications Type of gas: Nitrogen gas Gas volume: 300 cc Max. working pressure: 3.1 MPa {32 kg/cm2} Min. working pressure: 1.2 MPa {12 kg/cm2}
Function The accumulator is installed between the self-pressure reducing valve and the PPC valve. Even if the engine is stopped with the work equipment 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 lower under its own weight. Operation q After the engine is stopped, when the PPC valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B). q When the PPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30 kg/cm2}, and the pressure of the nitrogen gas in chamber (A) expands the bladder, so the oil in chamber (B) acts the pilot pressure and actuates the main control valve. q
10-126
D375A-6
DRAFT Hydraulic system PPC lock valve
PPC lock valve 1. Lever 2. End cap 3. Ball 4. Sheet 5. Valve body
Outline q The PPC lock valve is installed in the PPC circuit between the PPC charge valve and PPC valve. If the work equipment lock lever is placed at the LOCK position, the PPC lock valve interlocked with the work equipment lock lever is actuated to stop the oil in the PPC circuit, preventing the work equipment from moving.
D375A-6
10-127
DRAFT Hydraulic system PPC lock valve
10-128
D375A-6
DRAFT Hydraulic system PPC valve
PPC valve Blade PPC valve General view
P: From self-pressure reducing valve P1: To blade lift valve(LOWER) PPC port P2: To blade lift valve(RAISE) PPC port P3: To blade tilt valve(LEFT TILT) PPC port P4: To blade tilt valve(RIGHT TILT) PPC port T: To hydraulic tank
D375A-6
10-129
DRAFT Hydraulic system PPC valve
Sectional view
1. Spool 2. Metering spring 3. Centering spring 4. Piston 5. Disc 6. Nut (for lever connection) 7. Joint
10-130
8. Plate 9. Retainer 10. Valve body 11. Filter
D375A-6
DRAFT Hydraulic system PPC valve
Operation When in Neutral Blade lift valve q Ports (A) and (B) of the blade lift valve of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
D375A-6
Blade tilt valve q Ports (C) and (D) of the blade tilt valve of the control valve and ports (P3) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
10-131
DRAFT Hydraulic system PPC valve
When blade control lever is in fine control range (Neutral o Fine control range) q When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. q Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (B). q 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). q As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the force exerted by the pressure at port (P1). q The positional relationship between spool (1) and valve body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). q Since metering spring (2) is compressed in proportion to the travel of the control lever, the pressure in port (P1) rises in proportion to the travel of the control lever. q Accordingly, the control valve spool moves to a position at which the pressure in port (B) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.
10-132
D375A-6
DRAFT Hydraulic system PPC valve
When blade control lever is in fine control range (When blade control lever is returned) q When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force exerted by the pressure at port (P1) . q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q When the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the oil at the pump pressure is supplied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. q When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f') of the valve which is not operated and then flows through port (P2) into port (A) to supply oil.
D375A-6
When blade control lever is operated to stroke end q When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). q Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes the control valve spool. q The oil returning from port (A) flows through port (P2) and fine control (f') into drain chamber (D).
10-133
DRAFT Hydraulic system PPC valve
When blade control lever is operated to "Float" q When piston (4) for blade "Lower" side of port (P1) is pushed down by disc (5), ball (11) touches projection (a) of the piston in the middle of the stroke (The detent starts to operate). q When piston (4) is pushed down further, ball (11) pushes up collar (12) supported on detent spring (13) and moves outward to allow projection (a) of the piston to pass. q At this time, piston (4') on the opposite side is pushed up by spring (14). q As a result, the oil in chamber (F) flows through ports (b) and (c) to chamber (E) , allowing piston (4') to follow disc (5). Since passage (d) is connected to port (P1), almost the same pressure is applied to passage (d) and port (P1). q Chamber (E) is normally connected to drain chamber (D). When projection (a) of the piston passes ball (11) , passage (d) is connected to chamber (E) and the oil starts flowing to chamber (E). q At this time, the control valve moves to the "Float" position and the circuit comes into "Float" condition. q Since piston (4') is pushed up by the force exerted by the pressure in chamber (E) , the "Float" condition is kept even if the lever is released. When canceling "Float" condition q Disc (5) is returned with a force large than the force exerted by the pressure in chamber (E) to cancel the "Float" condition. q As a result, chamber (E) is disconnected from passage (d) and connected to the drain chamber. Accordingly, the pressure in chamber (E) lowers to contact the "Float" condition.
10-134
D375A-6
DRAFT Hydraulic system PPC valve
Ripper PPC valve General view
P: From self-pressure reducing valve P1: To ripper tilt valve PPC port P2: To ripper tilt valve PPC port P3: To ripper lift valve PPC port P4: To ripper lift valve PPC port T: To tank
D375A-6
10-135
DRAFT Hydraulic system PPC valve
Sectional view
10-136
D375A-6
DRAFT Hydraulic system PPC valve
1. Spool 2. Piston 3. Disc 4. Nut (for lever connection) 5. Joint 6. Plate 7. Retainer 8. Valve body 9. Filter
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10-137
Hydraulic system PPC valve
10-138 Operation When ripper control lever is in Neutral 10-138 Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) of spool (1) .
q
q
q
As a result, spool (1) moves up and down so that the force of metering spring (2) is balanced with the force exerted by pressure in port (P1).The positional relationship between spool (1) and valve body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). Since metering spring (2) is compressed in proportion to the travel of the control lever, the pressure in port (P1) rises in proportion to the travel of the control lever. The control valve spool moves to a position where the pressure of port (A) (same as pressure at port (P1)] and the force of the return spring of the control lever.
When ripper control lever is in fine control range10-138 (Neutal o Fine control range) 10-138 q When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed down through metering spring (2). q Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) to port (A) through fine control hole (f). q 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).
10-138
D375A-6 (06)
DRAFT Hydraulic system PPC valve
When ripper control lever is in fine control range (When ripper control lever is returned) q When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force exerted by the pressure at port (P1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q When the pressure at port (P1) goes down too far, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and almost simultaneously, it is connected to pump pressure chamber (PP). The oil at pump pressure is supplied until the pressure at port (P1) recovers to a pressure equivalent to the position of the lever. q When the spool of the control valve returns, the oil in drain chamber (D) flows in through fine control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and enters port (B) to replenish the port with pressurized oil.
D375A-6
When ripper control lever is operated to stroke end q When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). q Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (A) and pushes the control valve spool. q The oil returning from port (B) flows through port (P2) and fine control hole (f') into drain chamber (D).
10-139
DRAFT Hydraulic system Piston valve
Piston valve For blade lift cylinder Outline q The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the work equipment 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.
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 has been sealed in by piston valve (3), escapes through piston valve seats (4) and (5), and the pressure inside the cylinder stops rising.
Operation 1. Piston valve CLOSED Pressurized oil from the work equipment pump acts on piston (2) and piston valve (3). Then, piston valve (3) is pushed to the right and contacts the tapered part of piston valve seat (4) to seal in the oil. As a result, the pressure in the cylinder rises to move piston (2) to the right.
10-140
D375A-6
DRAFT Hydraulic system Quick drop valve
Quick drop valve For blade lift cylinder Outline q The quick drop valve installed to both right and left blade lift cylinders serves to increase the blade lowering speed and to reduce the occurrence of vacuum at the cylinder bottom end when the blade is lowering, thereby shortening the time lag between lever operation and start of digging. The blade lowering speed, which is generally determined by the pump delivery, 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 control lever is operated to the LOWER, the oil from the control valve flows through port (A) to the cylinder bottom end and pushes the piston. The oil on the cylinder head end is pushed out by the piston into port (B), and then flows through port (C) and control valve to the hydraulic tank.
2. While lowering Pressurized oil from the cylinder head end flows into port (C) through port (B). At this time, the oil flow is restricted by orifice (A) provided along the way, causing a differential pressure accross the 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 connecting parts (B) and (A) is made, part of the oil flowing from the cylinder head end to port (C) enters the passage that connects part (A) to the cylinder bottom end, and merged with the oil from the control valve, and flows to the cylinder bottom end. 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 end of the cylinder. D375A-6
10-141
DRAFT Hydraulic system Pin puller switch
Pin puller switch
Function q The pin puller solenoid valve is controlled by turning the pin puller switch ON/OFF. This switches the oil circuit to the pin puller cylinder and sets the shank mounting pin to the PUSH IN or PULL OUT position.
10-142
1. Connector 2. Wire 3. Switch 4. Knob
D375A-6
DRAFT Hydraulic system Pin puller solenoid valve
Pin puller solenoid valve
1. Plug 2. Spring 3. Spring retainer 4. Valve body 5. Spool 6. Spring retainer 7. Spring 8. Push pin 9. Solenoid assembly
D375A-6
A: To pin puller cylinder bottom end B: To pin puller cylinder head end P: From power train pump T: To steering case
10-143
DRAFT Hydraulic system Pin puller solenoid valve
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 de-energized. For spool (5), ports (P) and (B) connect to ports (A) and (T) respectively, 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). The oil in the bottom end of the cylinder extends the cylinder to push shank mounting pin (11) into shank (12) when the circuit pressure builds up sufficiently.
10-144
2. Pin puller switch at PULL OUT position When the pin puller switch is set to the PULL OUT position, current flows to solenoid (9) and it is energized. Then, the solenoid pushes out push pin (8) and spool (5) moves to the left. At this point, ports (P) and (B) disconnect from ports (A) and (T) respectively, and ports (P) and (A) connect to ports (B) and (T) respectively, 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). The oil in the cylinder head end retracts the cylinder to pull shank mounting pin (11) out of shank (12) when the circuit pressure builds up sufficiently.
D375A-6
Hydraulic system Blade control lever (only for the machine with dual tilt specification)
Blade control lever (only for the machine with dual tilt specification)
1. Switch (Dual/single tilt selector) 2. Switch (pitch) 3. Cover Outline q The blade is raised, lowered, and tilted to the right or left respectively by moving the blade control lever forward and backward or to the right or left.Dual tilt operation can be performed by moving the lever to the right and left with switch (1) set to the "DUAL" position.Pitch operation can also be performed by moving the lever to the right and left with switch (2) being pressed. q When the lever is operated with switch (2) being pressed, the blade pitches.When the lever is moved to the left, the blade pitches backward, and when moved to the right, the blade pitches forward. D375A-6 (06)
10-145
4. Connector (male) 5. Connector (female)
q
q
10-145 When the switch (1) is set to the "DUAL" position and the lever is operated, the blade is dual tilted.When the lever is moved to the left, the blade is dual tilted to the left. When the lever is moved to the right, the blade is dual tilted to the right. Even when switch (1) is set to either "DUAL" or "SINGLE" position, if the lever is moved to the right or left with the switch (2) kept pressed, the blade pitches.
10-145
DRAFT Hydraulic system Work equipment pump
Work equipment pump Type: HPV190 General view
10-146
D375A-6
DRAFT Hydraulic system Work equipment pump
Outline q This pump consists of a variable displacement swash plate type piston pump and LS valve. PA: Pump discharge port PB: Pump pressure inlet port PD1: Case drain port PD2: Drain plug PEN: Control pressure pickup port PLS: Load pressure inlet port PLSC: Load pressure pickup port PS: Pump suction port 1. Front pump 2. LS valve
D375A-6
10-147
DRAFT Hydraulic system Work equipment pump
Sectional view
1. Shaft 2. Cradle 3. Case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. End cap 10. Servo piston
10-148
D375A-6
DRAFT Hydraulic system Work equipment pump
Function q The pump converts the engine rotation transmitted to its shaft to oil pressure and oil flow, corresponding to the load. q It is possible to change the discharge amount by changing the swash plate angle.
q
Structure Cylinder block (7) is supported by shaft (1) on splined area (12). q Shaft (1) is supported by each bearing (13). q Tip of piston (6) is concaved and shoe (5) is crimped to it to form one unit. q Piston (6) and shoe (5) constitute a spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular pattern. q Rocker cam (4) conducts high pressure oil to cylinder surface (2) with cradle (B), which is secured to the case, and forms a static pressure bearing when it slides.
q
q
D375A-6
q q
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside the respective cylinder chambers of cylinder block (7) is sucked and discharged through valve plate (8).
10-149
DRAFT Hydraulic system Work equipment pump
Operation of pump q Cylinder block (1) rotates together with shaft (7), and shoe (5) slides on flat surface (A). q Rocker cam (4) moves along cylindrical surface (B), so angle (4) between center line (X) of rocker cam (7) and the axial direction of cylinder block (a) changes. q (a) is called the swash plate angle.
q
q
q q
q
q
q
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). Piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and ((F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) - (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. The volume of chamber (F) grows larger and, in this process, the oil is sucked.
10-150
D375A-6
DRAFT Hydraulic system Work equipment pump
Control of delivery q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. q Servo piston (10) is used for changing swash plate angle (a). q Servo piston (10) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) through slider (14). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) pivots on the surface while continuing revolving movement. q The area of servo piston (10) for receiving the pressure are not identical on the left side and right side. Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the pressure chamber of the large diameter piston side. q The movement of servo piston (10) is controled by the relationship of pressure between small diameter piston side (PP) and large diameter side (PEN) and by the ratio of the area receiving the pressure between small diameter piston and large diameter piston.
D375A-6
10-151
DRAFT Hydraulic system Work equipment pump
LS valve
PA: Pump port PDP: Drain port PLP:LS control pressure output port PLS: LS pressure input port PP: Pump port PPL: Drain port PSIG: Drain port
1. Sleeve 2. Piston 3. Spool 4. Spring 5. Sheet 6. Sleeve 7. Plug 8. Lock nut
Function q The LS (load sensing) valve detects the load and controls the pump delivery. q This valve controls main pump delivery (Q) according to differential pressure (dPLS) [= (PP) (PLS)], called the LS differential pressure [the difference between main pump discharge pressure (PP) and control valve outlet port pressure (PLS)]. q Main pump discharge pressure (PP), pressure (PLS) [called LS pressure] coming from the control valve output enter this valve. q The relationship between LS differential pressure (dPLS) [= (PP) - (PLS)], which is a diffential pressure between main pump discharge pressure (PP) and LS pressure (PLS) , and delivery (Q) is as shown in the diagram.
10-152
D375A-6
DRAFT Hydraulic system Work equipment pump
Operation When the control lever is operated to Neutral
q
q
q q
q q q
The LS valve is a three-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and pump discharge pressure (PP) brought to port (H) of sleeve (8) Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge pressure (self pressure) (PP) determine the position of spool (6). Before the engine is started, servo piston (10) is pushed to the right. (See right drawing) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool) Spool (6) is pushed to the right, and port (C) and port (D) will be connected. Pump pressure (PP) is conducted to the larger diameter end from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end from the port (J).
D375A-6
q
According to the difference in the areas on servo piston (10), the servo piston is moved in the direction which makes the swash plate angle minimum.
10-153
DRAFT Hydraulic system Work equipment pump
Mechanism to make the pump delivery maximum
q
q q q
When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other words, LS differential pressure (dPLS) becomes smaller [for example, when the area of opening of the control valve becomes larger and pump discharge pressure (PP) drops], spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4). When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve. The pressure across circuits (D) and (K) becomes drain pressure (PT). The pressure at the large piston diameter end of servo piston (10) becomes drain pressure (PT) and pump discharge pressure (PP) always is conducted to the small diameter end port (J) so servo piston (10) is pushed to the left, and moves the swash plate in the direction to make the delivery larger.
10-154
D375A-6
DRAFT Hydraulic system Work equipment pump
Mechanism to make the pump delivery minimum
q
q
q
When LS differential pressure (dPLS) becomes larger [for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises] because of the rightward move (it reduces pump delivery) of servo piston (10) , pump pressure (PP) pushes spool (6) to the right. The movement of spool (6) transmits pump discharge pressure (PP) to the large diameter end of the piston through port (C) , port (D) and port (K). Pump pressure (PP) is also conducted to port (J) of the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end on servo piston (10), it is pushed to the right. As the result, the servo piston (10) moves into the direction to make the swash plate angle smaller.
D375A-6
10-155
DRAFT Hydraulic system Work equipment pump
When servo piston is balanced
q
q
q
q
The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of the piston, the area receiving the pressure at the small diameter end and the pressure conducted to the large diameter end of the piston, respectively. When the force generated by main pump pressure (PP) in the LS valve is balanced with the combined force of spring (4) and LS pressure (PLS) , and the relationship becomes (A0) × (PP) = (A1) × (PEN), servo piston (10) is stopped in that position. The swash plate of the pump is held at the intermediate position. [Spool (6) is stopped at a position where the opening area from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] The relationship between the area receiving the pressure at both ends of servo piston (10) is (A0) : (A1) = 3 : 5 so the pressure applied accross the piston when it is balanced becomes (PP):(PEN) C 5:3.
10-156
q
Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) is determined when (PP) - (PLS) = 1.96 MPa {20 kg/cm2} at the median of the specified value.
D375A-6
DRAFT Hydraulic system Work equipment pump
D375A-6
10-157
Hydraulic system Control valve
Control valve 6-spool valve for dual tilt General view
10-158
10-158 10-158 10-158
D375A-6 (04)
DRAFT Hydraulic system Control valve
A1: To blade lift cylinder head A2: To blade lift cylinder head A3: To blade tilt right cylinder head A4: To blade tilt left cylinder head A5: To ripper cylinder head A6: To ripper tilt cylinder bottom B1: To blade lift cylinder bottom B2: To blade lift cylinder bottom B3: To blade tilt right cylinder bottom B4: To blade tilt left cylinder bottom B5: To ripper lift cylinder bottom B6: To ripper tilt cylinder head LS: To work equipment pump LS valve LSI: LS pressure pickup port P: From work equipment pump PA1: From blade PPC valve port P1 PA2: From blade PPC valve port P1 PA3: From blade PPC valve port P3 PA4: From blade PPC valve port P4 PA5: From ripper PPC valve port P3 PA6: From ripper PPC valve port P2 PB: PPC basic pressure PB1: From blade PPC valve port P2 PB2: From blade PPC valve port P2 PB3: From blade PPC valve port P4 PB4: From blade PPC valve port P3 PB5: From ripper PPC valve port P4 PB6: From ripper PPC valve port P1 P1: Pump pressure pick-up port T: Drain port
D375A-6
10-159
DRAFT Hydraulic system Control valve
Sectional view (1/4)
1. Ripper tilt valve 2. Ripper lift valve 3. Blade right tilt valve 4. Blade left tilt valve 5. Blade lift valve 6. Blade lift spool 7. Blade lift spool 8. Blade left tilt spool 9. Blade right tilt spool 10. Ripper lift spool 11. Ripper tilt spool 12. Load check valve 13. Pressure compensation valve
10-160
D375A-6
DRAFT Hydraulic system Control valve
(2/4)
1. LS check valve 2. Preset plug
D375A-6
10-161
DRAFT Hydraulic system Control valve
(3/4)
1. Main relief valve 2. LS relief valve 3. Unload valve 4. Suction valve 5. Check valve (built - in to spool)
10-162
D375A-6
DRAFT Hydraulic system Control valve
(4/4)
1. Suction safety valve 2. Check valve (built - in to spool) 3. Suction valve 4. Suction valve
D375A-6
10-163
Hydraulic system Control valve
5-spool valve for single tilt General view
10-164
10-164 10-164
D375A-6 (04)
Hydraulic system Control valve
A1: To blade lift cylinder head A2: To blade lift cylinder head A3: To blade tilt cylinder head A4: To ripper cylinder head A5: To ripper tilt cylinder bottom B1: To blade lift cylinder bottom B2: To blade lift cylinder bottom B3: To blade tilt cylinder bottom B4: To ripper lift cylinder bottom B5: To ripper tilt cylinder head LS: To work equipment pump LS valve LSI: LS pressure pickup port P: From work equipment pump PA1: From blade PPC valve port P1 PA2: From blade PPC valve port P1 PA3: From blade PPC valve port P3 PA4: From ripper PPC valve port P3 PA5: From ripper PPC valve port P2 PB: PPC basic pressure PB1: From blade PPC valve port P2 PB2: From blade PPC valve port P2 PB3: From blade PPC valve port P4 PB4: From ripper PPC valve port P4 PB5: From ripper PPC valve port P1 P1: Pump pressure pick-up port T: Drain port
D375A-6 (04)
10-164-1
Hydraulic system Control valve
Sectional view (1/4)
10-164-2
1. Ripper tilt valve 2. Ripper lift valve 3. Blade tilt valve 4. Blade lift valve 5. Blade lift spool 6. Blade lift spool 7. Blade tilt spool 8. Ripper lift spool 9. Ripper tilt spool 10. Load check valve
10-164-2
D375A-6 (04)
Hydraulic system Control valve
(2/4)
10-164-3
1. LS check valve 2. Preset plug
D375A-6 (04)
10-164-3
Hydraulic system Control valve
(3/4)
10-164-
1. Main relief valve 2. LS relief valve 3. Unload valve 4. Suction valve 5. Check valve (built-in to spool)
10-164-4
D375A-6 (04)
Hydraulic system Control valve
(4/4)
10-164-5
1. Suction safety valve 2. Check valve (built-in to spool) 3. Suction valve 4. Suction valve
D375A-6 (04)
10-164-5
Hydraulic system Control valve
Operation of control valve
10-164-6
10-164-6 When the main spool is at the HOLD position, it drains the excess oil discharged by the pump, and prevents the pressure from being formed in the circuit from rising. Operation 10-164-6 Function
When set to "HOLD" position (operation of unload valve) 10-164-6 q
q
q
q q
When the main spool is at the HOLD position, the pump pressure passes from chamber (A) through oriffice (4) to chamber (D). Chambers (C) and (C') are connected to the drain circuit. When oil is supplied from the pump, the pressure in chamber (D) rises, and spool (1) is pushed to the right by pressure (FO) which is determined by the cross-sectional area of piston (3) receiving the pressure. When (FO) becomes larger than set force (FS) of spring (2), the spool moves to the right and connects the passage between chamber (A) and chamber (B), so the oil from the pump is drained. Therefore, spool (1) is balanced at a position that matches the supply of oil from the pump. Actually, the amount of oil supplied from the pump is small, so the pressure in the circuit is almost the same as the set force of spring (2).
10-164-6
D375A-6 (04)
Hydraulic system Control valve
Control of flow rate
10-165
Work equipment valve
Use of the CLSS circuit (Closed - Center Load Sensing System) makes it possible to control the oil flow by adjusting the area of opening of the spool driven by the PPC valve, regardless of the load. When set to "HOLD" position (blade right tilt cylinder circuit on dual tilt specification machine)
q
q
When the spool is set to the "HOLD" position, the pump pressure is sent from chamber (A) to pressure compensation valve spool (3) through its notch, and then conducted through chamber (B) to chamber (C). The oil in chamber (G) is drained through chamber (H) to chamber (F).
D375A-6 (04)
q
q
10-165
When this happens, the pump pressure is acting on the left end of spool (3) of the pressure compensation valve, so it pushes against the force of spring (4) and moves rightward to the maximum stroke position. At this condition, the area of the opening for spool (1) of the blade tilt valve is at its minimum.
10-165
Hydraulic system Control valve
When set to "HOLD" position (blade tilt cylinder circuit on single tilt specification machine)
q
q q
10-16
When the spool is se to "HOLD" position, the pump pressure is sent from chamber (A) through chamber (B) to chamber (C). Pressure in chamber (H) is drained to chamber (F). At this condition, the area of the opening for spool (1) of the blade tilt valve is at its minimum.
10-166
D375A-6 (04)
Hydraulic system Control valve
When set to RIGHT TILT position (blade right tilt cylinder circuit on dual tilt specification machine)
q
q
When the tilt lever is operated to right tilt position, pilot pressure (PB1) acts on the right end of spool (1) through the PPC valve. when the pressure becomes greater than the set force of spring (2), the spool (1) begins to move leftward. It is balanced at a position corresponding to PPC output pressure (PB1.
D375A-6 (04)
q
q q
10-16 -1
dPLS = differential pressure between ports (L) and (K) = 1.96 {20 kg/cm2} dPLS' = differential pressure between ports (J) and (D) dPLS C dPLS'
10-166-1
Hydraulic system Control valve
q
q
q
q
q
q
q
q
q
Chamber (C) and chamber (D) are connected, and the oil from the pump flows through ports (A), (B), (C) and (D) to tilt cylinder (6). At the same time, the load pressure in chamber (D) passes through LS orifice (5) and chamber (H), and is sent to chamber (G). It is also sent from the LS circuit (O) to pump servo valve (7). The condition of the pressure of spool (3) is chamber (B) pressure C chamber (C) pressure, and chamber (G) pressure C chamber (D) pressure, so spool (3) is controlled by the differential pressure of spool (1) (chamber (C) pressure chamber (D) pressure), and balances with the force of spring (4). If the oil flow is too large, the differential pressure of spool (1) becomes larger, so spool (3) moves in the direction to throttle the oil flow. On the other hand, if the oil flow is too small, spool (3) moves in the direction to increase the oil flow. Pump servo valve (7) is controlled so that the differential pressure [LS differentical pressure: (dPLS)] between pump pressure (P) and LS pressure (LS) remains constant. A suitable amount of oil flows to ensure that the loss of pressure at the control valve (dPLS') is equal to (dPLS). The loss of pressure in the control valve is determined by the area of the opening of the main spool, so the oil flow matches the area of the opening of the spool. The return oil flow from the tilt cylinder passes through chamber (E) and chamber (F), and is drained.
10-166-2
D375A-6 (04)
Hydraulic system Control valve
When set to RIGHT TILT position (blade tilt cylinder circuit on single tilt specification machine)
q
q
When the tilt lever is operated to right tilt position, pilot pressure (PB3) acts on the right end of spool (1) through the PPC valve. when the pressure becomes greater than the set force of spring (2), the spool (1) begins to move leftward. It is balanced at a position corresponding to PPC output pressure (PB3.
D375A-6 (04)
q
q q
10-167
dPLS = differential pressure between ports (K) and (J) = 1.96 {20 kg/cm2} dPLS' = differential pressure between ports (H) and (D) dPLS C dPLS'
10-167
Hydraulic system Control valve
q
q
q
q
q
q
Chamber (C) and chamber (D) are connected, and the oil from the pump flows through ports (A), (B), (C) and (D) to tilt cylinder (4). Part of the load pressure in chamber (D) is sent through LS orifice chambers (3) and (G), and part of it is also conducted through LS circuit (O) to LS valve (5). LS valve (5) is controlled in such that the differential pressure [LS differential pressure: (dPLS)] between pump pressure (P) and LS pressure (LS) becomes constant. A suitable amount of oil flows to ensure that the loss of pressure at the control valve (dPLS') is equal to (dPLS). The loss of pressure in the control valve is determined by the area of the opening of the main spool, so the oil flow matches the area of the opening of the spool. The return oil flow from the tilt cylinder passes through chamber (E) and chamber (F), and is drained.
10-168
D375A-6 (04)
Hydraulic system Control valve
When set to relief (blade lift, blade tilt, ripper lift, ripper tilt)
a The diagram shows the condition when work equipment LS valve (5) is relieved at blade tilt stroke end.
q q q
dP1 = dP3 + dP4 = Differential pressure between ports (M) and (P) dP2 = Differential pressure between ports (P) and (N) dP3 = Differential pressure between ports (M) and (B)
D375A-6 (04)
q q
10-169
dP4 = Differential pressure between ports (B) and (P) dLS = dP1 + dP2 = Differential pressure between ports (M) and (N) = 1.96 {20 kg/cm2}
10-169
Hydraulic system Control valve
q
q
q
q
q
q
q
q
If blade tilt valve (1) is moved, and the pressure of tilt cylinder (8) becomes higher, work equipment LS relief valve (5) will open and oil will be drained from LS circuit (O). (Ports (P), (F), (G), (J) and (K)) As a result, there will be a drop in pressure in LS passage (O) starting from LS sensing hole (F), and (dP2) will become larger. For the same reason, if the pressure in chamber (I) and (H) drops, spool (2) will push against spring (3) and move to the right, and will make the opening between chambers (B) and (C) smaller, so the flow between chambers (B) and (C) will be throttled and (dP4) will become larger. Because of the pump swash plate control, the system circuit is balanced at a circuit pressure which makes the pressure loss generated by the flow at work equipment LS relief valve (5) (dP1) + (dP2) equal to LS differential pressure (dLS). When this happens, pump LS valve (6) detects the differential pressure generated by LS relief valve (5), and moves the pump swash plate from the maximum to the minimum position. The swash plate is balanced at a position where the LS differential pressure is 1.96 {20 kg/cm2}. When the pump is at the minimum swash plate angle (minimum oil flow), if the minimum oil flow is greater than the LS relief oil flow + leakage at any part, the pressure resides in the pump circuit [the pump and chambers (A) and chamber (B)] through pressure compensation valve (7), so the differential pressure rises. If this differential pressure goes above the set pressure for unload valve (4), the unload valve is actuated to relieve the excess oil flow and balance the circuit.
10-170
D375A-6 (04)
Hydraulic system Control valve
Pitch system on dual tilt specification machine
a A dual tilt specification machine is configured with the dual tilt and pitch system circuits. When single tilt operation is carried out
q
q
In the single tilt mode, solenoid selector valve (1) is in the neutral position and connected to (PA4) and (PB4) of the control valve as shown in the figure. PPC circuits (2) and (3) are separated from output circuits (4) and (5) of the PPC valve.
D375A-6 (04)
q
10-171 10-171
As a result, the right tilt cylinder does not move and only the left tilt cylinder moves to carry out the single tilt operation.
10-171
Hydraulic system Control valve
When dual tilt operation is carried out
q
q
10-172
In the dual tilt mode, the position of solenoid selector valve (1) is changed as shown in the figure. At this time, PPC circuit (2) connected to (PB3) of the control valve is connected to output circuit (4) of the PPC valve.
10-172
q
q
PPC circuit (3) connected to (PA3) of the control valve is connected to output circuit (5) of the PPC valve. Accordingly, both tilt cylinders move in the opposite directions each other to carry out the dual tilt operation.
D375A-6 (04)
Hydraulic system Control valve
When pitch operation is carried out
q q
10-172-1
In the pitch mode, the position of solenoid selector valve (1) is changed as shown in the figure. At this time, PPC circuit (2) connected to (PB3) of the control valve is connected to output circuit (5) of the PPC valve.
D375A-6 (04)
q
q
PPC circuit (3) connected to (PA3) of the control valve is connected to output circuit (4) of the PPC valve. Accordingly, both tilt cylinders move in the same direction to carry out the pitch operation.
10-172-1
Hydraulic system Control valve
10-172-2
D375A-6 (04)
DRAFT Hydraulic system Self-pressure reducing valve
Self-pressure reducing valve General view
P1: From fan pump P2: To fan motor PR: To PPC valve and EPC valve, etc. T: To tank
D375A-6
10-173
DRAFT Hydraulic system Self-pressure reducing valve
Sectional view
1. Valve (sequence valve) 2. Spring 3. Valve (pressure reducing valve) 4. Spring (pressure reducing valve main) 5. Filter
10-174
6. Screw 7. Poppet 8. Spring (for pressure reducing valve pilot) 9. Spring (safety valve) 10. Ball
D375A-6
DRAFT Hydraulic system Self-pressure reducing valve
Function q
The self-pressure reducing valves reduce the discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as the control pressure.
D375A-6
10-175
DRAFT Hydraulic system Self-pressure reducing valve
Operation At engine stop (both pressure are low)
q q q
Spring (6) pushes the poppet (5) the seat, and port (PR) is disconnected from port (T). Spring (7) pushes the valve (8) to the left, and port (P1) is connected to port (PR). Spring (3) pushes the valve (2) to the left, and port (P1) is disconnected from port (P2) .
10-176
D375A-6
DRAFT Hydraulic system Self-pressure reducing valve
When the load pressure (P2) is lower than the output pressure (PR) of the self pressure reducing valve
q
q
The force of spring (3) and the force of exerted by the (PR) pressure [0MPa {0 kg/cm2} at the time of engine stop] push valve (2) in the direction to block the passage between the ports (P1) and (P2). When the hydraulic oil enters (P1) port, the value balances at a position where the expression [Force exerted by pressure (P1) C Force of spring (3) + Force (area (d) × Pressure (PR) ] holds, and the area of the opening between ports (P1) and (P2) is adjusted so that pressure (P1) is maintained higher than pressure (PR) . When the (PR) pressure rises above set pressure, the poppet (5) opens and the hydraulic oil flows through the route, from (PR) port, through hole (a) in the spool (8), through the opening of the poppet (5) , through to the tank port (T).
D375A-6
q
Therefore, differential pressure is developed across hole (a) in spool (8) to move spool (8) in the direction to block the opening between ports (P1) and (PR) . Thus this valve uses the area of the opening to regulate pressure (P1) to a certain level (set pressure) and supplies it as pressure (PR).
10-177
DRAFT Hydraulic system Self-pressure reducing valve
When load pressure (P2) is high
q
q
When load pressure (P2) rises due to digging or other operations, pump delivery increases and pressure (P1) rises. When the expression {Force exerted by pressure (P1) > Force of spring (3) + Force [area (d) × pressure (PR)]} holds, and valve (2) moves downward to its stroke end. As a result, the opening between the ports (P1) and (P2) increases, the passage resistance becomes smaller to reduce engine horsepower loss. When pressure (PR) rises above the set pressure, poppet (5) opens and hydraulic oil flows through the route, from port (PR) , through hole (a) in spool (8), and the opening of poppet (5) to the tank port (T).
10-178
q
Therefore, differential pressure is developed across hole (a) in spool (8) to move spool (8) to block the opening between ports (P1) and(PR) . Thus this valve uses the area of the opening to regulate pressure (P1) to a certain level (set pressure) and supplies it as pressure (PR).
D375A-6
DRAFT Hydraulic system Self-pressure reducing valve
When abnormally high pressure is generated
q
When the (PR) pressure of the self-pressure reducing valve rises abnormally high, the ball (10) separates from the seat against the spring (9) to allow the oil from port (PR) to flow to port (T) so as to reduce the pressure (PR). As a result, the equipment (PPC valve, solenoid valve, etc.), to which the oil pressure is supplied, is protected from the abnormal high pressure.
D375A-6
10-179
DRAFT Work equipment Cylinder stay
Work equipment Cylinder stay
1. Yoke 2. Oil seal 3. Bushing 4. Bushing
10-180
D375A-6
DRAFT Cab and its attachments Cab mount
Cab and its attachments Cab mount
1. Support 2. Damper mount (front) 3. Damper mount (rear)
D375A-6
Outline q The cab mounts are installed at two places in the front section and at two places in the rear section of the floor frame to secure the cab to the floor frame. q Oil-filled cab mounts are used to absorb vibration.
10-181
DRAFT Cab and its attachments Cab
Cab Cab assembly
1. Front wiper 2. Front glass 3. Rear wiper 4. Door
10-182
D375A-6
DRAFT Cab and its attachments Cab
ROPS
1. ROPS
D375A-6
10-183
DRAFT Electrical system Engine control
Electrical system Engine control
1. Decelerator pedal 2. Deceleration potentiometer 3. Starting switch 4. Work equipment controller 5. Power train controller 6. Fuel control dial 7. Battery 8. Circuit breaker 9. Battery relay 10. Starting motor 11. Engine controller 12. Alternator
10-184
Outline q The throttle signal of the fuel control dial is input to the power train controller and processed together with the other information, then the result is sent as the throttle command to the engine controller. The engine controller controls the fuel supply pump according to the command.
D375A-6
DRAFT Electrical system Engine control system
Engine control system
Outline q The engine throttle controller receives the fuel control dial signal of the 1st throttle, decelerator pedal signal of the 2nd throttle, and 3rd throttle signal which is the control signal from the power train controller, and then controls the fuel supply pump according to the command signal having the lowest engine speed. The control signals of the 3rd throttle are as follows. 1) Automatic-deceleration (F3, R3, F2, R2) 2) Neutral deceleration 3) Shoe slip control (if equipped) q The power train controller calculates a proper engine speed from information items (1), (2), etc. and sends it as the 3rd throttle signal to the engine throttle controller.
D375A-6
q
q
The information of the engine controller is possessed jointly by the other controllers through the network and used for the optimum control of the engine and power train. The automatic deceleration is a function of lowering the engine speed temporarily when the travel direction is changed from F3, R3, F2 or R2 (for protection of the transmission clutch).
10-185
DRAFT Electrical system Engine control system
Engine controller
Outline Engine controller mounted on engine q Since the engine controller is mounted on the engine, it is easy to be maintained. q In order to secure the reliability of mounted engine controller, engine controller cooler is installed to cool the engine controller by fuel. q Rubber vibration isolator reduces vibration. Common engine controller q The common engine controller CM850 is adopted which is co-developed by Komatsu and Cummins.
10-186
D375A-6
DRAFT Electrical system Engine control system
q
Meanings of signal classes in the terminal table shown below are as follows. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication
1
Signal name NC (*)
Pin No.
Signal name
Input/output
37
Sensor power source (5 V)
A
38
GND
C
39
NC (*)
-
40
NC (*)
-
41
NC (*)
-
Input/output
42
NC (*)
-
-
43
NC (*)
-
Boost pressure sensor
D
CN-CE01 Pin No.
CN-CE01
2
NC (*)
-
44
3
Ambient pressure sensor
D
45
Injector #1 (+)
B
4
Supply pump #1 (+)
B
46
Injector #5 (+)
B
5
Supply pump #1 (–)
C
47
Sensor GND
C
6
CAN (-)
C
48
Ne sensor (–)
C
7
NC (*)
-
49
NC (*)
-
8
CAN(+)
B
50
NC (*)
-
9
Supply pump #2 (+)
B
51
Injector #2 (–)
C
10
Supply pump #2 (–)
C
52
Injector #3 (–)
C
11
EGR valve (–)
C
53
Injector #1 (–)
C
12
NC (*)
-
54
Injector #2 (+)
B
Injector #3 (+)
B
13
Engine oil pressure sensor
D
55
14
NC (*)
-
56
Injector #4 (+)
B
15
Coolant temperature sensor
D
57
Injector #6 (+)
B
16
Sensor power source (5 V)
A
58
Injector #4 (–)
C
17
Engine oil temperature sensor
D
59
Injector #6 (–)
C
18
NC (*)
-
60
Injector #5 (–)
C
19
EGR valve position sensor
D
20
NC (*)
-
21
NC (*)
-
22
EGR valve (+)
B
23
Boost temperature sensor
D
24
NC (*)
-
25
Common rail pressure sensor
D
26
BKup sensor (+)
D
27
NE sensor (+)
D
28
NC (*)
-
29
Bypass valve position sensor
B
30
Fuel temperature sensor
D
31
Bypass valve (+)
D
32
NC (*)
-
33
Sensor power source (5 V)
A
34
NC (*)
-
35
NC (*)
-
36
NC (*)
-
D375A-6
*: Never connect to NC, or malfunctions or failures will occur.
10-187
DRAFT Electrical system Engine control system
CN-CE02
CN-CE02 Pin No.
Signal name
Input/output
Pin No.
Signal name
Input/output
1
NC (*)
-
43
NC (*)
-
2
NC (*)
-
44
NC (*)
-
3
NC (*)
-
45
NC (*)
-
4
NC (*)
-
46
CAN(+)
E
5
NC (*)
-
47
CAN (-)
E
6
NC (*)
-
48
NC (*)
-
7
NC (*)
-
49
NC (*)
-
8
NC (*)
-
50
NC (*)
-
9
Decelerator signal
B
10
NC (*)
-
11
NC (*)
-
12
NC (*)
-
13
NC (*)
-
14
NC (*)
-
2
GND
C
15
NC (*)
-
3
Power source (+24 V constant)
A
16
NC (*)
-
4
Power source (+24 V constant)
A
17
NC (*)
-
18
NC (*)
-
19
NC (*)
-
20
NC (*)
-
21
NC (*)
-
22
Sensor power source (5 V)
A
23
GND
C
24
NC (*)
-
25
NC (*)
-
26
NC (*)
-
27
NC (*)
-
28
NC (*)
-
29
NC (*)
-
30
NC (*)
-
31
NC (*)
-
32
NC (*)
-
33
GND
C
34
NC (*)
-
35
NC (*)
-
36
NC (*)
-
37
CAN shield
C
38
NC (*)
-
39
Key switch (ACC) Electrical intake air heater relay (+) NC (*) Electrical intake air heater relay return
B
40 41 42
10-188
*: Never connect to NC, or malfunctions or failures will occure. CN-CE03 Pin No. 1 GND
Signal name
Input/output C
*: Never connect to NC, or malfunctions or failures will occur.
D C
D375A-6
DRAFT Electrical system Engine control system
Sensors Fuel temperature sensor q The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. q The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
D375A-6
10-189
Electrical system Engine control system
EGR valve position sensor This sensor senses the opening and closing positions of the EGR valve.
10-20
q
1. EGR valve position sensor The following graph shows the output characteristics of the position sensor.
q
10-190
D375A-6 (06)
DRAFT Electrical system Engine control system
NE speed sensor (Crank angle sensor) q If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes. q If the magnetic line of force changes, the output of the Hall element sensor changes linearly and it is converted into pulse of 0 – 5 by the wave form shaping circuit in the sensor, and then output.
Bkup speed sensor (G sensor) (Cylinder No. sensor) q Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 – 5 generated by the change of the magnetic line crossing the sensor unit. q The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts) around it at intervals of 60 °. q In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine. q The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.
Ambient pressure sensor This sensor is used to correct altitude.
q
Oil pressure sensor
D375A-6
10-191
DRAFT Electrical system Engine control system
Boost temperature sensor q The boost temperature sensor senses the intake air temperature (boost temperature) and sends it to the engine controller. q The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
10-192
Coolant temperature sensor q The coolant temperature sensor senses the coolant temperature and sends it to the engine controller. q The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
D375A-6
DRAFT Electrical system Engine control system
Deceleration potentiometer
1. Connector 2. Lever 3. Body 4. Potentiometer 5. Coupling 6. Shaft 7. Stopper
D375A-6
Outline q The deceleration potentiometer is installed to the front lower part of the operator's cab and connected to the decelerator pedal by linkage. q
When the decelerator pedal is depressed, the throttle potentiometer shaft is rotated by the linkage and the potentiometer resistance changes. Constant voltage is applied between pins (A) and (C) of the potentiometer and an electric signal is sent through pin (B) to the engine controller according to the position of the decelerator pedal.
10-193
DRAFT Electrical system CRI engine control system
CRI engine control system a "CRI" is an abbreviation for Common Rail Injection. System diagram
10-194
D375A-6
Electrical system CRI engine control system
1. NE speed sensor 2. Engine throttle controller 3. Injector assembly 3A. Orifice 3B. Control chamber 3C. Hydraulic piston 3D. Injector 3E. Nozzle 4. Orifice (for air bleeding) 5. Fuel tank 6. Pre fuel filter 7. Main fuel filter 8. Overflow valve 9. Fuel supply pump 9A. PCV 9B. High pressure pump 9C. Priming pump 9D. Feed pump 9E. Bkup speed sensor (G sensor) 10. Common rail 11. High pressure injection pipe 12. Flow damper 13. Pressure limiter 14. Electric priming pump 15. Engine throttle controller cooler 10-205 Outline q The signals detected by various sensors are input to the engine controller. q The engine controller processes input signals and output command signals to each actuator to control the fuel injection rate and fuel injection timing.
D375A-6 (06)
10-205 System configuration q The CRI system consists of fuel supply pump (9), common rail (10), injectors (3), engine throttle controller (2) to control them, and sensors. q The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel delivery from the supply pump. The discharge rate is controlled by turning on and off PCV (discharge control valve) (9A) of the fuel supply pump according to the electric signals from the engine throttle controller. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail and controlled by the feedback method so that the actual fuel pressure corresponds to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to the nozzle (3E) and control chamber (3B) of the injector through the high-pressure fuel pipe of each cylinder. q The injector controls the fuel injection rate and fuel injection timing by energizing and de-energizing the TWV (2-way solenoid valve). If the TWV is energized, the fuel circuit is so changed that the high-pressure fuel in the control chamber flows out through orifice (3A). As the result, the force exerted by the pressure of the high-pressure fuel on the nozzle side raises the needle valve to start fuel injection. If the TWV is de-energized, the fuel circuit is so changed that the pressure of the fuel applies to the control chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to energize the TWV and the duration of energizing the TWV.
10-195
DRAFT Electrical system Monitor system
Monitor system
q
The monitor system monitors the machine condition with the sensors installed to various parts of the machine and processes and displays the obtained information on the monitor panel quickly to notify the operator of the machine condition. The main display sections and functions of the panel are as follows.
1. Monitor unit which turns on the alarm when the machine has a trouble. 2. Gauge unit which constantly displays the machine condition (coolant temperature, torque converter oil temperature, fuel level, etc.) 3. Function of displaying error codes. 4. Function of monitoring the current and voltage of the sensors and solenoids,
q
The CPU (Central Processing Unit) in the monitor panel displays and outputs various information processed by the power train controller. The display unit is LCD (Liquid Crystal Display)
10-196
D375A-6
Electrical system Monitor system
Processing on machine monitor (common to all specifications) Display of machine monitoer Contents and conditions of processing 1. Display of travel direction and gear speed. q F1, R3, etc. are notified by CAN according to information of power train controller. 2. Display of gauges of fuel level, engine coolant temperature, etc. q Controller converts the sensor signals into gauge numbers and sends them to the machine monitor by CAN. 3. Display of problem q When the machine has a trouble, the corresponding failure code is notified to the machine monitor through CAN signal. q The command to sound the buzzer or to light up the caution lamp is notified, too. 1) In standard screen Action code, failure code 2) In abnormality record screen The failure code (6-digit code) and the following items are displayed q SMR at first occurrence q SMR at latest occurrence q Number of past occurrences Display of monitoring condition Contents and conditions of processing 1. The communication conditions of each sensor, each solenoid, and CAN are displayed. q The item Nos. and device conditions are notified to the machine monitor by CAN. q The machine monitor displays the items and each value. 2. Each items is selected by using the cursor switches and confirmation switch.
10-197
Method
Flow of signals
CAN
CAN Each sensor, solenoid O Controller O Machine monitor CAN
Method
CAN
CAN
Flow of signals Each sensor O Controller O Machine monitor
Other items Contents and conditions of processing 1. Monitoring 2. Abnormality record 3. Maintenance record 4. Maintenance mode change 5. Phone number setting 6. Default 7. Adjustment 8. PM clinic 9. Cylinder cutout mode operation 10. No injection cranking 11. Fuel consumption display 12. Load memory display 13. VHMS setting 14. Snap shot 86. Setting of shoe slip control (if equipped) 87. Setting of pre-lubrication 88. Screen adjustment a
Method
Flow of signals
–
–
a Since this item is included in the service menu, it is not usually displayed.For details of the operating method, see "Special functions of monitor panel (EMMS)" section of Testing and adjusting.
D375A-6 (04)
10-197
DRAFT Electrical system Machine monitor
Machine monitor
Outline q The machine monitor has the display function, mode selection function and switch function for electrical parts. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.
10-198
Precautions on the machine monitor display q The liquid crystal display panel may have black spots (which do not light up) or bright spots (which stay on). Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal. q When the engine is started, the battery voltage may suddenly drop depending on the temperature and the battery condition. If this happens, the display on the machine monitor may momentarily go out, but this does not indicate any abnormality. q Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. The screen normally displayed on the monitor has a blue or white background. For this reason, blue spots will not cause any problem (since the liquid crystal lights up red, blue, and green spots when displaying white).
D375A-6
DRAFT Electrical system Machine monitor
Input and output signals CN-CM01 Pin No.
CN-CM03 Signal name
1 2 3 4
Battery power (+24 V constant) Battery power (+24 V constant) Battery power GND Battery power GND
5
Wake-up
6 7 8 9 10 11 12 13 14 15 16 17 18
Relay output Chassis signal GND Hydraulic oil pressure Fuel level NC (*) Battery charge Chassis analog signal GND Light switch Key switch (ACC) Key switch (C) Preheating NC (*) NC (*)
Input/out put Input Input Input/out put Output Input Input Input Input Input Input -
*: Never connect to NC, or malfunctions or failures will occur. CN-CM02 Pin No.
Signal name
1 2 3 4 5 6 7 8
NC (*) NC (*) Coolant level sensor NC (*) NC (*) NC (*) Chassis signal GND CAN terminating resistance
9
COMM_CAN_H_0
10
COMM_CAN_L_0
11 12
NC (*) NC (*)
Input/out put Input Input/out put Input/out put -
*: Never connect to NC, or malfunctions or failures will occur.
Pin No.
Signal name
1 2 3
RS232C CD for communication terminal RS232C RXD for communication terminal RS232C SG for communication terminal GND for communication terminal control signal Communication terminal selection signal RS232C RTS for communication terminal RS232C TXD for communication terminal RS232C DTR for communication terminal RS232C DSR for communication terminal RS232C CTS for communication terminal RS232C RI for communication terminal GND for communication terminal power Input CH1 for communication terminal status Output for communication terminal power control Output CH1 for communication terminal control Output CH2 for communication terminal control Input CH2 for communication terminal status Power supply for communication terminal
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Input/out put Input Input Input Output Output Output Input Input Input Input Output Output Output Input Output
CN-CM04 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
Signal name NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*)
Input/out put -
*: Never connect to NC, or malfunctions or failures will occur. CN-CM05 Pin No. 1 2 3 4 5 6 7 8
D375A-6
Signal name Power supply for camera Camera NTSC signal input 1 Camera NTSC signal input 2 Camera NTSC signal input 3 Electric power supply GND for camera Camera signal GND1 Camera signal GND2 Camera signal GND3
Input/out put Output Input Input Input -
10-199
DRAFT Electrical system Machine monitor
Monitor control portion
1. Gearshift mode selector switch 2. Buzzer cancel switch 3. Operation mode switch 4. Engine coolant temperature gauge 5. Multi gauge 6. Pilot display 7. Service meter/clock 8. Mode display
10-200
9. Fuel level gauge 10. Gearshift mode and preset gearshift pattern 11. Guidance icon 12. Function switch 13. Customization switch 14. Customization memory switch
D375A-6
Electrical system Machine monitor
Machine monitor display Display category
Symbol
10-201 Display item
Contents
Radiator coolant level Below "low" line
Check
Oil pressure
D375A-6 (04)
Description Displays when engine is stopped and starting switch is set to ON position Display when normal: OFF Display when abnormal: ON
When sensor is abnormal or Display when normal: OFF when wiring harness is disDisplay when abnormal: ON connected
Battery charge condiWhen charge is defective tion
Engine oil level (if equipped)
Lights up at low level or below
Hydraulic oil level (if equipped)
Lights up when oil level is below suction limit
Displays when starting switch is set to ON position and engine is running Display when normal: OFF Display when abnormal: ON CAUTION lamp flashes Displays when starting switch is turned to ON position with engine stopped. Display when abnormal: OFF Display when normal: ON Displays when starting switch is turned to ON position with engine stopped. Display when normal: ON Display when abnormal: OFF
10-201
Electrical system Machine monitor
Display category
Symbol
Display item
Oil pressure
Contents
Description
Lights when it becomes 49.0 kPa {0.5 kg/cm2} and below
Lights when it becomes 7.8 V Battery charge condiand below while engine is tion running
Radiator coolant level
Cautions
Engine coolant temperature
Torque converter oil temperature
Lights when it becomes below "low" line
Engine coolant temperature When highest gauge segment is; Above 102 °C: Symbol ON Above 105 °C: Symbol ON + buzzer sounds Torque converter oil temperature When highest gauge segment is; Above 120 °C: Symbol ON Above 130 °C: Symbol ON + buzzer sounds
Displays when starting switch is set to ON position and engine is running Display when normal: OFF Display when abnormal: ON Alarm buzzer sounds
Pilot
Above 100 °C: Symbol ON Hydraulic oil temperaAbove 110 °C: Symbol ON + ture buzzer sounds
10-202
Maintenance
Lights up for 30 seconds after starting key is turned to ON position Lights up in yellow from 30h before the filter and oil replacement time, and lights up in red if replacement time expires
Air cleaner clogging
Lights up when -7,470 ± 490 Pa {-762 ± 50 mmH2O} is reached.
Hydraulic oil level (if equipped)
Lights up when oil level is below suction limit
Preheating
When preheating
Lights according to required time determined by engine controller. It also lights up at the time of manual preheat by setting the starting switch at the preheat position (turning the switch counterclockwise).
D375A-6 (04)
Electrical system Machine monitor
Display category
Symbol
Display item
Contents
Description
Engine coolant temperature
Reads the temperature
Gauge
Torque converter oil temperature
Hydraulic oil temperature
D375A-6 (04)
Fuel level
Reads the level
Service meter (Hours From 0 to 99999 meter)
Progresses when the engine is running
10-203
Electrical system Machine monitor
10-204
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to disconnection of CAN. Gauge Engine coolant temperature (°C)
Power train oil temperature (°C)
Hydraulic oil temperature (°C)
Fuel level (l)
10-204
Range A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 C1 C2 C3 C4 C5 C6 D1 D2 D3 D4 D5 D6
Temperature or volume 105 102 100 85 60 30 130 120 118 90 50 0 110 100 98 70 20 0 1000 755 550 395 275 145
Indicator Red Red Off Off Off White Red Red Off Off Off White Red Red Off Off Off White Off Off Off Off Off Red
Buzzer sounds.
Q
Q
Q
D375A-6 (04)
Electrical system Machine monitor
10-205
Machine speed
1. 0 km/h 2. 5 km/h
3. 10 km/h 4. 15 km/h
1. 0 MPa 2. 10 MPa 3. 20 MPa
10-205
D375A-6 (04)
4. 0.4 MPa 5. 0.5 MPa 6. 0.7 MPa
4. 25 V 5. 30 V 6. 31 V
10-205
Engine speed
1. 500 rpm 2. 1000 rpm 3. 1500 rpm
4. 30 MPa 5. 40 MPa 6. 50 MPa
Engine oil pressure
1. 0 MPa 2. 0.2 MPa 3. 0.3 MPa
1. 0 V 2. 17 V 3. 20 V
10-205
Hydraulic pump oil pressure
10-205
Battery voltage
4. 2000 rpm 5. 2500 rpm 6. 3000 rpm
10-205
Drawbar pull
1. 0 W 2. 0.2 W 3. 0.4 W
4. 0.6 W 5. 0.8 W 6. 1.0 W
10-205
Electrical system Machine monitor
10-206 Guidance icon and function switch The function of the function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it. Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below. Symbol
10-206
Switch power
Item
Function
F6
Enter
Enters selected/set item.
F5
Return
Returns to previous screen or condition.
F4
Select service meter/clock
Switches service meter and clock display alternatively.
F5
Selection of maintenance screen
Switches to Maintenance List screen.
F6
Select user mode screen
Switches to Use Menu screen.
F3
Select item
Selects item on left side (Selects right end item after left end item).
F4
Select item
Selects item on right side (Selects left end item after right end item).
F3
Select item
Selects item on lower side (Selects top item after bottom item)/Resets holding of monitoring.
F4
Select item
Selects item on upper side (Selects bottom item after top item)/Holds monitoring.
F1
Select item
Displays next page for selection (Selects top page after last page).
F2
Select item
Displays previous page for selection (Selects last page after top page).
F2
Return to default setting
Returns selected item to default setting. (Used for screen adjustment.)
F1
Start
Starts operation. (Used to start measurement of split fuel consumption on fuel consumption display screen.)
F1
Stop
Stops operation. (Used to stop measurement of split fuel consumption on fuel consumption display screen.)
F1/F2
Clear
Clears selected / displayed item
F1
Set
Executes setting
F2
Change of multi-gauge
Changes display item for multi gauge
D375A-6 (04)
Electrical system Machine monitor
Service meter and clock switching function10-207 Pressing F4 on the standard screen when the service meter is displayed in the top center of the screen switches the display to the clock, and doing so when the clock is displayed switches the display to the service meter.
Maintenance reminder function
10-207 Pressing F5 on the standard screen switches to the Maintenance List screen.
F1: Displays the next page. Displays the top page when the last page is displayed. F2: Displays the previous page. Displays the last page when the top page is displayed. F3: Selects (highlights) an item one down. F4: Selects (highlights) an item one up. F5: Returns to the standard screen. F6: Hold down the button to switch to the Maintenance Time Reset screen. No operation at least 30 sec.: Returns to the standard screen. q On the Maintenance List screen, if the time remaining until maintenance for any item is less than thirty hours, the remaining time display is highlighted in yellow. If the time remaining until maintenance becomes 0 hours, the remaining time display is highlighted in red. q On the Maintenance Time Reset screen, the remaining time for the selected item can be reset and returned to the default.
D375A-6 (04)
10-207
Electrical system Machine monitor
F5: Cancels the reset to return to the Maintenance List screen. F6: Resets the remaining time and returns to the standard screen. No operation at least 30 sec.: Returns to the standard screen. q
The defailt password is “000000”. Enabling the password lock on an attachmentequipped machine locks the attachment setting screen at the same time. a For information on changing the maintenance password, see "Function of changing maintenance password" of "Testing and adjusting".
q q
The table below shows the maintenance items and replacement intervals. The time remaining to maintenance is reduced as the machine is operated.
No. 01 02 03 41 04 07 08 10 19 20
Item Engine oil Engine oil filter Fuel main filter Fuel pre-filter Hydraulic oil filter Damper case oil Finaldrive case oil Hydraulic oil P/L oil P/L oil filter
Replacement interval (Hours) 500 500 500 500 2000 2000 2000 2000 1000 500
P/L: Power train q
The display of the maintenance monitor differs according to the remaining time. The relationship is as shown in the table below. Display
Condition Remaining time for maintenance Not displayed for all items is more than 30 hours. Notice display (black There is one or more items with symbol on yellow less than 30-hour remaining time background) for maintenance. There is one or more items with Warning display (white symbol on red less than 0-hour remaining time for maintenance. background) q
To prevent careless reset of the maintenance interval, the screen is password protected.
10-208
D375A-6 (04)
Electrical system Machine monitor
User mode q q
10-209 Pressing F6 on the standard screen enters the user mode, switching to the User Menu screen. In user mode, you can perform setting for items relating to the machine monitor and machine shown below. Utility screen select Multi-gauge Screen adjustment Time adjustment Language setting Reverse-interlok Enabled Mode (When camera is set) Fan reverse mode Skipping pre-lubrication
Normal q
10-209
The standard screen is displayed. 10-209 The horizontal axis indicates the time and the vertical axis indicates the drawbar pull. The machine should be operated with the drawbar pull kept in the green range. The graph on the screen is updated and scrolled to the left at intervals of several seconds.
Load display q
q
10-209 The horizontal axis indicates the time and the vertical axis indicates the pitch angle of the body. The graph on the screen is updated and scrolled to the left at intervals of several seconds.
Body pitch display q q
F3: Selects (highlights) an item one down. F4: Selects (highlights) an item one up. F5: Returns to the normal screen. F6: Switches to the setting screen for the selected item. No operation at least 30 sec.: Returns to the standard screen. (In user mode, no switch operation at least 30 sec. returns to the previous screen.) 10-209 If Utility Screen Select is selected with switch F6, (1) Standard Display, (2) Load Display, or (3) Body Pitch Display can be selected. Select the desired item with switch F3 or F4 and enter that item with switch F6.
Utility screen select q
q
D375A-6 (04)
10-209 On this screen, the display item assigned to the gauge at the center can be selected.
Multi gauge select q
10-209
Electrical system Machine monitor
q
Select desired item with switch F3 or F4 and enter that item with switch F6.
q
The following items can be selected.
Sellectable item for multi gauge No. Selected item Remarks 1 PL oil temperature With caution Hydraulic oil tempera2 With caution ture 3 Vehicle speed Hydraulic pump pres4 sure 5 Engine oil pressure With caution 6 Battery voltage 7 Engine speed 8 Traction force 9 Clock Engine coolant temper10 For Utility Screen Select ature 11 Fuel level For Utility Screen Select
10-210 Selecting the Screen Adjustment on the User Menu screen and pressing F6 switches to the Screen Adjustment screen. From this menu, you can adjust the brightness, contrast, and luminance of the machine monitor screen. When the light switch is set to "Night mode ON", the night mode screen is adjustable. When the light switch is set to "Daytime mode ON" or OFF, the daytime mode screen is adjustable.
Screen adjustment q
q
q q
F2: Returns all adjusted values to the defaults. F3: Decreases the value indicated by the indicator one graduation left. F4: Increases the value indicated by the indicator one graduation right. F5: Cancels changes you made before entering them with F6 and returns to the User Menu screen. F6: Enter the changes and moves to the next item. q For machines equipped with a camera, the brightness, contrast, and illuminance of the camera screen are also adjustable. q Select Screen Adjustment from the User Menu screen to switch to the screen for selecting a camera screen you want to adjust.
F3: Selects (highlights) an item one down. F4: Selects (highlights) an item one up. F5: Cancels changes you made before entering them with F6 and returns to the User Menu screen. F6: Moves to the setup screen of the selected (highlighted) item. q The adjustment methods for the camera screen and standard screen are the same. q The background when adjusting the camera screen is the No.1 camera image.
F3: Selects (highlights) an item one down. F4: Selects (highlights) an item one up. F5: Cancels changes you made before entering them with F6 and returns to the User Menu screen. F6: Enter the changes and moves to the next item.
10-210
D375A-6 (04)
Electrical system Machine monitor
10-21 Select the Clock Adjustment on the User Menu screen and press F6 to switch to the Clock Adjustment screen. On this screen, you can change the setting of the time displayed on the standard screen.
F5: Cancels change you made before entering them with F6 and returns to the User Menu screen. F6: Enters the changes and moves to the Time setting.
Clock adjustment q
q
a Summer time (daylight saving time) is a system to lead a life according to the one-hour advanced time in order to make efficient use of daylight time. 10-21 Select the Language on the User Menu screen and press F6 to switch to the Language setting screen. From this menu, you can change the language to be displayed on the monitor. Available languages are as follows. English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, and Turkish
Language setting q
q
1) Time setting Adjust the clock time. If the item of Time is not highlighted, press F6 to highlight it. The hour display part is highlighted. F3: Advances the hour display one hour. F4: Sets the hour display back one hour. F5: Cancels change you made before entering it with F6 and returns to the User Menu screen. F6: Enters the change and moves to minute setting. The minute display part is highlighted. F3: Advances the minute display one minutes. F4: Set the minute display back one minutes. F5: Cancels the change you made before entering it with F6 and returns to the User Menu screen. F6: Enters the change and moves to the 12/24 Mode setting.
F3: Selects (highlights) an item one down. F4: Selects (highlights) an item one up. F5: Cancels the change and returns to the User Menu screen. F6: Enters the change to return to the User Menu screen.
2) 12h/24h Mode Specify 12-hour clock (AM/PM) or 24-hour clock for time display. If the item of "12h/24h Mode " is not highlighted, press F6 to highlight it. F3: Moves to the item one right. F4: Moves to the item one left. F5: Cancels the change you made and returns to the User Menu screen. F6: Enter the change and moves to Daylight Saving Time setting. 3) Daylight Saving Time Selecting ON for this sets the time forward 1 hour. Setting OFF returns to the ordinary time. F3: Moves to the item one right. F4: Moves to the item one left.
D375A-6 (04)
10-211
Electrical system Machine monitor
Setting of camera for reverse-interlock enabled mode (applied to machines equipped with rear view camera) 10-212
When reversing the machine, the image of rear view camera can be displayed on the multi monitor. q Turn "ON" the starting switch, select "Pre-lubrication Skip Mode" on the screen (A) with F3 or F4 key, then fix it with F6 key. q Select "camera 1 or 2, 3, 1+2" with F3 or F4 key while the screen (B) is displayed. a If the connected camera is only one, "camera 1" is only displayed on the menu. q The selected camera is set by pushing F6 key, and return to the screen (A). q When shifting the travel lever to reverse, the multi display switches to a view from camera (screen (C) o(D)) q
Function of the function keys F3: Selects (highlights) an item one down. F4: Selects (highlights) an item one up. F5: Return to former screen. F6: Fix the selection.
q
a The setting whether cameras are installed or not can be done on the service menu. Only the cameras set on the service menu are available. a This function is still available even though the mode is terminated. a While the view from camera is displayed, travel/work equipment lock monitor is displayed on the upper left of the screen (a), gear speed and gearshift working mode etc. are displayed under right of the screen (b) (screen (D)). a The view range of camera is limited. Watch out rear side carefully when traveling reverse. a For safe reverse traveling, be careful to check the rear side by using brake and deceleration pedal.
10-212
D375A-6 (04)
Electrical system Machine monitor
10-213 In this mode, the fan can be set to drive in reverse to clean the radiator core. While the starting switch is set to OFF, select the menu with switch F3 or F4 and enter it with switch F6. While screen (A) is displayed, press switch F6, and the fan is ready to run in reverse. While screen (B) is displayed, start the engine.
Fan reverse mode q q
q q
10-213 The rotation direction of the fan cannnot be changed while the engine is running. When running the fan in reverse, set the lock lever to the LOCK position. While the fan is running in reverse, the machine cannot travel. When canceling the reverse mode, set the starting switch to OFF position to stop the engine. When using this mode, warm up the engine sufficiently. If the engine is not warmed up, the fan may not supply sufficient air.
Precautions for using fan reverse mode q q q q q
D375A-6 (04)
10-213
Electrical system Machine monitor
Pre-lubrication skip mode (applied to machines equipped with pre-lubrication) q q
q
q
10-214 This mode is used for starting engine without activating pre-lubrication. Turn "ON" the starting switch, select The item on the screen (A) with F3 or F4 key while engine is not started, then fix it with F6 key. Press F6 on screen (B) to complete pre-lubrication skip. After setting the mode, the display returns to user menu automatically. Setting the starting switch to "START" position initiates the starter rotation and starts up the engine without turning on the pre-lubrication operation.
Function of checking service meter q
10-214 If you continuously pressing working mode selector switch (1) and buzzer cancel switch (2) at the same time when setting the starting switch to the OFF position, the service meter will appear on the screen in 3 to 5 seconds.
When these switches are released, the LCD goes out. a Continuous operation of the machine monitor may display blue bright spots on this screen; it is quite normal.
q
10-214
D375A-6 (04)
Electrical system Machine monitor
Function of checking display LCD q
q
q
10-214-1 Continuously pressing the buzzer cancel switch (1) and F2 at the same time on the standard screen causes all the LCD elements to light in white. Release F2 and buzzer cancel switch in order. One of the features of liquid crystal display panel is that there may be black spots (spots that do not light up) or white spots (spots that stay lit up) on the screen. If there are fewer than ten black or white spots, the monitor is normal.
Pressing any function switch returns to the previous screen.
D375A-6 (04)
10-214-1
Electrical system Machine monitor
10-214-2
D375A-6 (04)
DRAFT Electrical system Lamp system
Lamp system Operation
Relate electric circuit diagram
D375A-6
10-215
DRAFT Electrical system Engine preheat (electrical intake air heater) control
Engine preheat (electrical intake air heater) control Operation
Relate electric circuit diagram
10-216
D375A-6
DRAFT Electrical system Palm command control system
Palm command control system
1. Machine monitor (Multi-information) 2. Gearshift mode switch 3. Engine controller 4. Power train controller 5. Engine speed sensor 6. Transmission control valve 7. Steering control valve 8. Transmission output shaft speed sensor
D375A-6
10-217
DRAFT Electrical system Palm command control system
Gearshift mode function Outline There are the auto gearshift mode and manual gearshift mode in the gearshift mode. These modes are changed to each other each time gearshift mode switch (1) is pressed. 1. Auto gearshift mode (Heavy duty dozing mode) q If a load is applied, the gear is shifted down automatically. When the load is removed, the gear is shifted up to the set maximum usable gear speed automatically. q The torque converter lockup operates according to loads and the maximum usable gear speed is selected automatically. In this mode, less fuel is consumed and more production is obtained. 2. Manual gearshift mode (General dozing mode, ripping mode) q If a load is applied, the gear is shifted down automatically. When the load is removed, however, the gear is not shifted up automatically. 3. Shoe slip control mode (if equipped) q If a load is applied, the gear is shifted down automatically. When the load is removed, however, the gear is not shifted up automatically. q Automatic deceleration of the engine during the ripping operation reduces operator's fatigue and prevents grousers from useless wearing caused by shoe slippage.
6. Preset gearshift pattern(gear speed at start) 7. Mark of "Dozing 2" (which indicates manual gearshift mode) C:Shoe slip control mode (if equipped) 8. Gear speed used currently 9. Preset gearshift pattern (gear speed at start) 10. Mark of "Ripping "(which indicates shoe slip control mode)
Gear shift operation q Select a gear by pressing (a) or (b) on the PCCS lever (steering / directional / gearshift lever). (a): Shift-up switch (b): Shift-down switch
Display of screen The gearshift mode is displayed in the gearshift mode display section of the monitor panel as shown below. A: Auto gearshift mode 1. Gear speed used currently 2. Preset gearshift pattern (gear speed at start) or maximum usable gear speed 3. Mark of AUTO (which indicates auto gearshift mode) 4. Mark of "Dozing 1" (which indicates automatic gearshift mode) B: Manual gearshift mode 5. Gear speed used currently 10-218
D375A-6
DRAFT Electrical system Palm command control system
Setting preset gearshift pattern by using gearshift switches with travel control lever in neutral q Set the preset gearshift pattern (gear speed at start) or the maximum usable gear speed (for only the auto gearshift mode) by using the gearshift switches with travel control lever in neutral. A: Auto gearshift mode Setting preset gearshift pattern (gear speed at start) or maximum usable gear speed
B: Manual gearshift mode Setting preset gearshift pattern (gear speed at start)
C:Shoe slip control mode (if equipped) Setting preset gearshift pattern (gear speed at start)
D375A-6
a When the starting switch is set to ON position, the auto gearshift mode ([F1 – R1]) is set. When the gearshift mode is changed, [F1 – R1] is selected initially. Changing gear speed by using gearshift switches during travel q The maximum usable gear speed (in the auto gearshift mode) or the current gear speed (in the manual gearshift mode) can be changed with the gearshift switches while the machine is traveling. A: Auto gearshift mode Changing maximum usable gear speed During forward travel: The maximum usable gear speed can be set to F1 - F2. During reverse travel: The maximum usable gear speed can be set to R1 – R3. Shift-up switch: Each time this switch is pressed, the maximum usable gear speed is shifted up to the next range. Shift-down switch: Each time this switch is pressed, the maximum usable gear speed is shifted down to the next range. B: Manual gearshift mode Changing current gear speed During forward travel: The current gear speed can be set to F1 - F2. During reverse travel: The current gear speed can be set to R1 - R2. Shift-up switch: Each time this switch is pressed, the current gear speed is shifted up to the next range. Shift-down switch: Each time this switch is pressed, the current gear speed is shifted down to the next range. C: Shoe slip control mode(if equipped) Changing current speed During forward travel: The current gear speed is fixed to F1. During reverse travel: The current gear speed can be set to R1 - R2. Shift-up switch: Each time this switch is pressed, the current gear speed is shifted up to the next range. Shift-down switch: Each time this switch is pressed, the current gear speed is shifted down to the next range.
10-219
Electrical system Sensor
Sensor
10-2 0
Sensor name
Type of sensor
When normal
When abnormal
Torque converter oil temperature sensor
Resistive
-
-
Hydraulic oil temperature sensor
Resistive
-
-
Coolant level sensor
Contact
ON (Closed)
OFF (Open)
Fuel level sensor
Resistive
-
-
Transmission output shaft R speed sensor
Resistive
-
-
Pitch angle sensor
Resistive
-
-
Acceleration sensor
Resistive
-
-
Speed sensor
Resistance
—
—
Engine oil level sensor
Contact
ON (Closed)
OFF (Open)
Air cleaner clogging sensor
Contact
OFF (Closed)
ON (Open)
Hydraulic oil level sensor
Contact
OFF (Closed)
ON (Open)
Torque converter oil temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
10-220
10-2 0 10-2 0
4. Tube 5. Wire 6. Connector
D375A-6 (04)
DRAFT Electrical system Sensor
Radiator coolant level sensor
1. Float 2. Sensor 3. Tube
4. Wire 5. Connector
Fuel level sensor
1. Connector 2. Float 3. Arm 4. Body 5. Spring 6. Contact 7. Spacer
D375A-6
Function q The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm to the variable resistor to change its 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.
10-221
DRAFT Electrical system Sensor
Transmission output shaft speed sensor
1. Magnet 2. Terminal 3. Case 4. Boot 5. Connector Pitch angle sensor
1. Body 2. Tube 3. Wire 4. Connector
10-222
D375A-6
DRAFT Electrical system Sensor
Acceleration sensor
1. Sensor portion 2. Wire 3. Connector Outline q The acceleration sensor is installed under the front of the operator's cab. q The position of the ball inside the sensor changes according to the acceleration. The coil inside the sensor detects the position of the ball. The change in the position is amplified by the amp and is sent as a voltage change to the power train controller. q The input and output characteristics of the sensor are shown in the figure on the right.
D375A-6
10-223
Electrical system Sensor
Speed sensor
10-2 3-1
1. Sensor 2. O-ring 3. Connector 4. Wire 10-2 3-1 Speed sensor, which is installed in the case of the cooling fan motor, detects gear speed as pulse signals from cylinder block spline inside the motor and sends them as converted electric signals to the controller. Since the clearance between the sensor and spline is controlled to the specified dimension, adjustment at installation is not necessary.
Function q
q
10-223-1
D375A-6 (04)
Electrical system Sensor
Engine oil level sensor
1. Connector 2. Bracket
10-2 3-2
3. Float 4. Switch
Air cleaner clogging sensor
1. Spring 2. Switch 3. Hose
10-2 3-2
4. Sensor 5. O-ring 6. Connector
Hydraulic oil level sensor
1. Float 2. Sensor 3. Tube
D375A-6 (04)
4. Wire 5. Connector
10-223-2
DRAFT Electrical system Vehicle health monitoring system (VHMS)
Vehicle health monitoring system (VHMS) Outline q The VHMS consists of the VHMS controller and various sensors (some of which are used by other systems, too) and records the operating condition of the machine. It collects and records the position information and operation information of the machine, data from measuring instruments, etc. for later maintenance and service. The data to be checked are downloaded to a personal computer.
q
If the "ORBCOMM terminal system" is installed to the machine, it can transmit the data recorded in the VHMS by satellite communication to the administrator or the service department, allowing for remote machine management. For the use of the VHMS, see "30 Testing and adjusting" of this manual.
VHMS controller
Note 1. VHMS is an abbreviation of Vehicle Health Monitoring System.
10-224
D375A-6
DRAFT Electrical system Vehicle health monitoring system (VHMS)
Input and output signals CN1 [CN 1] Pin No.
Signal name
CN2 [CN2 A, B] Input/output
Pin No.
Signal name
Input/output
-
CN2-A1
NC
-
CN1-1
NC
CN1-2
Sensor power supply (24 V)
Output
CN2-A2
NC
-
CN1-3
Sensor power supply (12 V)
Output
CN2-A3
NC
-
CN1-4
Sensor power supply (5 V)
Output
CN2-A4
NC
-
CN1-5
Sensor power supply (5 V)
Output
CN2-A5
Exhaust temperature (Rear)
Input
CN2-A6
NC
Input
CN2-A7
Exhaust temperature (Front)
CN1-6 CN1-7
Power supply (Constant power supply) (24 V) Power supply (Constant power supply) (24 V)
Input Input
CN1-8
BR power supply (24 V)
Input
CN2-A8
NC
CN1-9
BR power supply (24 V)
Input
CN2-A9
CONNECTOR SEL0 (OPEN)
Input
CN1-10
NC
-
CN2-A10
Ambient temperature
Input
CN1-11
GND
-
CN2-A11
NC
-
CN1-12
GND
-
CN2-A12
Sensor GND
-
CN1-13
NC
-
CN2-A13
Sensor GND
-
CN1-14
NC
-
CN2-A14
NC
-
CN1-15
NC
-
CN2-A15
Transmission, main oil pressure
CN1-16
NC
-
CN2-A16
NC
CN1-17
Start signal
Input
CN2-A17
WAKE UP (Low)
Input
CN1-18
NC
-
CN2-A18
Blowby pressure
Input
CN1-19
GND
-
CN2-B1
NC
-
CN1-20
GND
-
CN2-B2
NC
-
CN2-B3
NC
-
CN2-B4
NC
-
CN2-B5
NC
-
CN2-B6
WAKE UP (Hi)
CN2-B7
NC
-
CN2-B8
NC
-
CN2-B9
GND
-
CN2-B10
NC
-
CN2-B11
NC
-
CN2-B12
CONNECTOR SEL1 (GND)
D375A-6
-
Input -
Input
Input
10-225
DRAFT Electrical system Vehicle health monitoring system (VHMS)
CN3 [CN3 A, B] Pin No.
CN4 [CN4 A, B] Signal name
Input/output
Pin No.
-
CN4-A1
NC
-
Input
CN4-A2
NC
-
Signal name
Input/output
CN3-A1
NC
CN3-A2
CAB out D/L Sw
CN3-A3
NC
-
CN4-A3
NC
CN3-A4
NC
-
CN4-A4
CAN (1) H (KOM-NET/c)
CN3-A5
Model selection (See ORB connection)
Input
CN4-A5
CAN (0) shield (MMS)
CN3-A6
NC
-
CN4-A6
CAN (0) H (MMS)
CN3-A7
NC
-
CN4-A7
NC
-
CN3-A8
NC
-
CN4-A8
NC
-
CN3-A9
CONNECTOR SEL2 (GND)
Input
CN4-A9
GND
-
CN3-A10
NC
-
CN4-A10
RS232C RXD (PC Tool)
Input
CN3-A11
NC
-
CN4-A11
RS232C TXD (PC Tool)
Output
CN3-A12
NC
-
CN4-A12
CAN (1) L (KOM-NET/c)
Input/output
CN3-A13
NC
-
CN4-A13
CAN (1) SH (KOM-NET/c)
CN3-A14
NC
-
CN4-A14
CAN (0) L (MMS)
CN3-A15
NC
-
CN4-B1
NC
-
CN3-A16
NC
-
CN4-B2
NC
-
CN3-A17
NC
-
CN4-B3
GNG (Orbcomm)
-
CN3-A18
NC
-
CN4-B4
RS232C TX1 (Orbcomm)
CN3-B1
NC
-
CN4-B5
NC
-
CN4-B6
NC
-
CN3-B2
NC
CN4-B7
NC
-
CN3-B3
NC
CN4-B8
NC
-
CN3-B4
NC
-
CN4-B9
GND (Orbcomm)
-
CN3-B5
NC
-
CN4-B10
RS232C RX1 (Orbcomm)
CN3-B6
NC
-
CN3-B7
NC
-
Pin No.
CN3-B8
NC
-
CN5-1
LAN TX+
Output
CN3-B9
NC
-
CN5-2
LAN TX-
Output
CN3-B10
NC
-
CN5-3
LAN RX+
Input
CN3-B11
NC
-
CN5-4
LAN RT3
-
CN3-B12
CONNECTOR SEL3 (OPEN)
CN5-5
LAN RT4
-
CN5-6
LAN RX-
Input
CN5-7
LAN RT1
-
CN5-8
LAN RT2
-
CN5-9
NC
-
CN5-10
NC
-
CN5-11
PWR (LAN5 V)
CN5-12
GND (LAN)
10-226
Input
Input/output Input/output
Input/output
Output
Input
CN5 Signal name
Input/output
Output -
D375A-6
DRAFT Electrical system Vehicle health monitoring system (VHMS)
Sensors
Exhaust temperature sensor/amplifier
Engine oil temperature sensor Specification Type of sensor: Thermistor Measurement range : 40 – 130 °C 80 – 130 °C (Assured accuracy: ±2 °C) Max. power consumption:0.5 mW Pressure capacity: 4.9 MPa {50 kg/cm2} Operating temperature: -30 °C – +140 °C Performance table
Specification Rated voltage: 24V DC Delectable temperature range: 100 – 1,000 °C 300 – 800 °C (Assured accuracy: ±10 °C) Output voltage characteristics (Ambient temperature: 20 °C) Reference values
Tem-pe Resis-ta Tem-pe Resis-ta Tem-pe Resis-ta ra-ture nce ra-ture nce ra-ture nce (°C) (kΩ) (°C) (kΩ) (°C) (kΩ) 30
35.27
80
6.571
110
2.887
40
24.28
85
5.682
115
2.544
50
17.05
90
4.931
120
2.248
60
12.20
95
4.293
125
1.992
70
8.884
100
3.750
130
1.769
a. Heat sensing part of sensor Outside diameter of mounting part: R1/4
Sensed tempera50 100 400 700 800 ture (°C) Output voltage 1.191 1.397 2.626 3.899 4.316 (V)
Operating temperature range: - 40 – +110 °C Current consumption: Max. 30 mA a. Heat sensing part of sensor Outside diameter of mounting part: R1/8 b. Amplifier c. Connector (power supply side) d. Connector (sensor side) Function The exhaust temperature sensor/amplifier is a thermocouple-type temperature sensor, which is installed to the turbocharger inlet. It outputs the exhaust temperature data to the VHMS controller.
Function The engine oil temperature sensor is installed to the engine oil filter. It inputs the change of the temperature as the change of the thermistor resistance to the VHMS controller.
D375A-6
10-227
DRAFT Electrical system Vehicle health monitoring system (VHMS)
Ambient temperature sensor Specification Power consumption: Max. 0.5 mW Pressure capacity: 0.98 MPa {10 kg/cm2} Delectable temperature range (ambient): - 30 – + 120 °C Storage temperature range: - 50 – + 140 °C Performance table Detected temperature (°C) Resistance (kΩ)
-20
-10
0
10
20
50
30.32 18.58 11.74 7.623 5.077 1.712
a. Heat sensing part of sensor Outside diameter of mounting part: 16 × 1.5 Function The ambient temperature sensor inputs the change of the ambient temperature as the change of the thermistor resistance to the VHMS controller.
10-228
D375A-6
DRAFT Electrical system Vehicle health monitoring system (VHMS)
Engine blowby pressure sensor
1. Sensor 2. Connector 3. Ambient pressure intake tube A: GND (Black) B: Power supply (Red) C: Output (White)
Specifications and function Pressure range: 0 – 20 kPa {0 – 2,040 mmH2O} Allowable pressure: -20 – 100 kPa {-2,040 – 10,200 mmH2O} Source voltage: 5 ± 0.25 V Output characteristics: See graph. q The blowby pressure sensor is a minute relative pressure type sensor, which measures the difference between the pressure in the crankcase and ambient pressure. q The pressure in the crankcase is introduced to the tip of the sensor and the ambient pressure is introduced to the wiring harness side.
Transmission main oil pressure sensor 1. Sensor 2. Connector
D375A-6
10-229
DRAFT Electrical system ORBCOMM system
ORBCOMM system
Outline q The ORBCOMM terminal system is a communication system to use the satellite communication service of ORBCOMM Co., Ltd. (USA). If this system is installed to the machine, the data recorded in the VHMS controller and various information obtained through the network in the machine can be transmitted by the satellite communication. q It is required to sign up for the ORBCOMM terminal system before using its functions. For details, including the sign-up test, see "30 Testing and adjusting" of this manual. q The ORBCOMM terminal system may or may not be installed to the machine, depending on the user's purchase specification.
10-230
D375A-6
DRAFT Electrical system ORBCOMM system
ORBCOMM terminal system
1. Communication antenna connection 2. DRC connector connection (40 poles) Outline q The ORBCOMM terminal obtains various kinds of machine information from the network signals and input signal in the machine and transmits them via the wireless communication antenna. It contains a CPU (Central Processing Unit) and has wireless communication function. q This terminal has a LED lamp unit and a 7-segment display lamp unit used for inspection and troubleshooting. Input/Output signal q DRC conector
18
NC
19
NC
20
NC
21
NC
22
NC
23
NC
24
NC
25
NC
26
NC
1
NC
27
NC
2
NC
28
NC
3
NC
29
DOUT (GND)
4
COMM 232C RXD
30
NC
5
COMM 232C TXD
31
NC
6
NC
32
NC
7
NC
33
NC
8
NC
34
NC
9
NC
35
NC
10
NC
36
ACC Input
11
RS232C GND
37
DIS_SEL0 (GND)
12
NC
38
DIS_SEL0 (GND)
13
NC
39
Constant power supply (24 V)
14
NC
40
Constant power supply (24 V)
15
NC
16
NC
17
NC
D375A-6
10-231
DRAFT Electrical system ORBCOMM system
Antenna Specification Type: Helical whip antenna (1) Impedance: 50 Ω Input terminal: M-P type Length: 165 ± 20 mm a. Communication antenna mounting part Function Transmits data collected and stored by the VHMS controller to the computer center via communications satellites.
10-232
D375A-6
DRAFT
D375A-6 SEN05175-00
BULLDOZER D375A-6 Shop Manual
Machine model D375A-6
Serial number 60001 and up
20 Standard value table Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-
2 Standard value table for engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-
3 Standard value table for machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-
4
D375A-6 (01)
20-1
DRAFT Contents
Contents 20 Standard value table Standard service value table ............................................................................................................................ 20Standard value table for engine .................................................................................................................... 20Standard value table for machine ................................................................................................................. 20-
20-2
3 3 4
D375A-6 (01)
Standard service value table Standard value table for engine
Standard service value table
20-3
Standard value table for engine
20-3
Machine model
D375A-6
Engine Item
Measurement conditions
Engine speed
High idle Low idle Rated speed
Boost pressure
At rated horsepower
Exhaust temperature Exhaust gas color Valve clearance (Normal temperature) EGR valve drive oil pressure (Oil temperature: 40 – 60 °C) Compression pressure (SAE15W-40 or SAE30 oil) Blow-by pressure (SAE15W-40 or SAE30 oil) Oil pressure (Oil temperature: 90 – 110 °C) Oil temperature Alternator belt tension Air conditioner compressor belt tension
D375A-6 (06)
Whole speed range (Ambient temperature: 20 °C) At sudden acceleration At high idle Intake valve Exhaust valve At low speed At high idle Engine oil temperature: 40 – 60 °C (Engine speed) At rated horsepower (Coolant temperature: Within operating range) EOS0W30 At high idle EOS5W40 EO10W30-DH EO15W40-DH At low speed EO30-DH Whole speed range (inside oil pan) Deflection when pressed with finger force of approximately 58.8 N {6 kg} Deflection when pressed with finger force of approximately 98 N {10 kg}
SAA6D170E-5
kPa {mmHg}
Standard value for new machine 1,900 (0/-50) 750 ± 50 1,800 Min. 155 {Min. 1,160}
Permissible value 1,900 (0/-50) 750 ± 50 1,800 Max. 141 {Max. 1,060}
°C
Max. 700
Min. 730 Min. 3.5 Min. 2.0 — —
MPa {kg/cm2} (rpm)
Max. 2.5 Max. 1.0 0.32 0.62 Min. 1.18 {Min. 12} Min. 1.43 {Min. 14.6} Min. 2.94 {Min. 30} (210 – 250)
Max. 2.1 {Max. 21} —
kPa {mmH2O}
Max. 3.43 {Max. 350}
Min. 9.41 {Min. 960}
Min. 392.27 {Min. 4.0}
Max. 235.36 {Max. 2.4}
Min. 117.68 {Min. 1.2}
Max. 78.45 {Max. 0.8}
°C
90 – 110
Min. 120
mm
(Auto-tension)
—
mm
(Auto-tension)
—
Unit rpm
Bosch index mm MPa {kg/cm2}
kPa {kg/cm2}
— —
20-3
DRAFT Standard service value table Standard value table for machine
Standard value table for machine Machine model Category
Item
Engine speed
Decelerator pedal low speed
Measuring condition
q q q q
Torque converter stall speed
q q q
Torque converter stall + Work equipment relief speed
q q
Control lever/pedal stroke
PCCS Lever
q
Forward and reverse
q
Engine stopped Center of lever knob
q q q
Brake pedal
Engine stopped Center of pedal Engine low idle Center of pedal
q q
mm
mm Full stroke Until oil pressure becomes zero
q
rpm
Neutral o Forward Neutral o Reverse All stroke (Neutral – Right/Left) Until clutch is fully disengaged
q
Blade control lever
Unit
Working mode: P-mode Gear shift mode: Manual Engine coolant temperature: Within operating range Torque converter oil temperature: Within operating range Hydraulic oil temperature: 45 – 55 °C Decelerator pedal low speed: Pedal pressed Torque converter stall speed: F3 Torque converter + Work equipment speed: F3 + Ripper RAISE Measure with adjustment ID: 0530 (Stall mode)
Steering
Decelerator pedal
D375A-6
Engine low idle Hydraulic oil temperature: 45 – Neutral – Raise 55 °C Center of lever knob Neutral – Float
q
Ripper control lever q
20-4
Engine low idle Neutral – Hydraulic oil temperature: 45 – Raise/Lower 55 °C Neutral – Tilt Center of lever knob forward/back
Permissible value
900 ± 50
900 ± 50
1,530 ± 50
1,450
1,500 ± 50
1,400
30 ± 5
Max. 8.0
30 ± 5
30 ± 5
40 ± 5 40 ± 5 (Play: Max. (Play: Max. 3) 3) 9±5
9±5
45 ± 15
45 ± 15
75 ± 5
75 ± 5
54 ± 5
54 ± 5
60 ± 10
60 ± 10
85 ± 10
85 ± 10
53 ± 10
53 ± 10
78 ± 10
78 ± 10
81 ± 10
81 ± 10
mm
mm
Neutral – Left/Right tilt q
Standard value for new machine
mm
D375A-6 (03)
Standard service value table Standard value table for machine
Machine model Cate gory
Item
Left
Engine stopped Center of lever knob
Right
PCCS lever
Control lever/pedal operating effort Control lever/pedal operating effort
q
Steering
q
Brake pedal
q q q q q
Blade control lever
q
q q
Ripper control lever
Min. speed Fan
Permissible value
Neutral o Forward
56.9 ± 6.9 {5.8 ± 0.7}
56.9 ± 6.9 {5.8 ± 0.7}
Neutral o Reverse
56.9 ± 6.9 {5.8 ± 0.7}
56.9 ± 6.9 {5.8 ± 0.7}
12.8 ± 3.9 {1.3 ± 0.4}
12.8 ± 3.9 {1.3 ± 0.4}
16.7 ± 4.9 {1.7 ± 0.5}
16.7 ± 4.9 {1.7 ± 0.5}
Until clutch is fully disengaged
13.7 ± 3.9 {1.4 ± 0.4}
13.7 ± 3.9 {1.4 ± 0.4}
At stroke end
19.6 ± 4.9 {2 ± 0.5}
19.6 ± 4.9 {2 ± 0.5}
Until clutch is fully disengaged At stroke end
Decelerator pedal
Max. speed Circuit oil pressure
D375A-6 (06)
Standard value for new machine
Measuring condition q
Forward and reverse
D375A-6
q
q q
Unit
N {kg}
Engine stopped Center of pedal
N {kg}
49.0 ± 9.8 {5.0 ± 1.0}
49.0 ± 9.8 {5.0 ± 1.0}
Engine at low idle Center of pedal
N {kg}
460.6 ± 49.0 {47.0 ± 5.0}
460.6 ± 49.0 {47.0 ± 5.0}
39.2 ± 5.9 {4.0 ± 0.6}
39.2 ± 5.9 {4.0 ± 0.6}
82.3 ± 9.8 {8.4 ± 1.0}
82.3 ± 9.8 {8.4 ± 1.0}
Neutral – Left/Right tilt
28.4 ± 4.9 {2.9±0.5}
28.4 ± 4.9 {2.9±0.5}
Engine at low idle Neutral – Hydraulic oil temperature: 45 – Raise/Lower 55 °C Center of lever knob Neutral – Tilt forward/back
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}
350 ± 100
-
1,210 ± 25
Max. 1,110
15.7 ± 2.5 {160±25}
15.7 ± 2.5 {160±25}
Engine at low idle Hydraulic oil temperature: 45 – Neutral o Raise 55 °C Center of lever knob Neutral o Float
Fan 100 % mode Engine at low Hydraulic oil temperature: Min. idle 40 °C Engine at high idle Engine at high idle
N {kg}
N {kg}
rpm
MPa {kg/cm2}
20-5
Standard service value table Standard value table for machine
Machine model Cate gory
Item
Standard value for new machine
Permissible value
Engine at low idle
0.03 – 0.25 {0.3 – 2.5}
0.03 – 0.25 {0.3 – 2.5}
Engine at high idle
0.69 – 1.05 {7.0 – 10.7}
0.69 – 1.05 {7.0 – 10.7}
Engine at low idle
0.03 – 0.20 {0.3 – 2.0}
0.03 – 0.20 {0.3 – 2.0}
0.44 – 0.70 {4.5 – 7.0}
0.44 – 0.70 {4.5 – 7.0}
-
-
Engine at high idle
1.29 – 1.54 {13.2 – 15.7}
1.29 – 1.54 {13.2 – 15.7}
Engine at low idle
2.25 – 2.87 {23.0 – 29.3}
2.25 – 2.87 {23.0 – 29.3}
Engine at high idle
2.55 – 2.87 {26.0 – 29.3}
2.55 – 2.87 {26.0 – 29.3}
Engine at low idle
2.48 – 2.87 {25.3 – 29.3}
2.38 – 3.07 {24.3 – 31.3}
Engine at high idle
2.68 – 2.87 {27.3 – 29.3}
2.58 – 3.07 {26.3 – 31.3}
Adjustment ID: 5535 Engine at low Measure in (both idle steering clutch disenEngine at high gage modes) idle
2.25 – 2.84 {23.0 – 29.0}
2.06 – 3.13 {21.0 – 31.9}
2.55 – 2.87 {26.0 – 29.3}
2.35 – 3.16 {23.9 – 32.2}
2.25 – 2.84 {23.0 – 29.0}
2.06 – 3.13 {21.0 – 31.9}
Engine at high idle
2.55 – 2.87 {26.0 – 29.3}
2.35 – 3.16 {23.9 – 32.2}
Engine at low idle
2.06 – 2.35 {21.0 – 24.0}
1.86 – 2.55 {18.9 – 26.0}
Engine at high idle
2.06 – 2.35 {21.0 – 24.0}
1.86 – 2.55 {18.9 – 26.0}
Measuring condition q
Torque converter inlet pressure
Power train oil temperature: Within operating range
Torque converter outlet pressure
Engine at high idle Engine at low idle
Power train oil pressure
Torque converter lockup clutch pressure
Torque converter stator clutch pressure q
Transmission main relief pressure
Power train oil temperature: Within operating range
q
Transmission F clutch pressure
Transmission R clutch pressure
Transmission 1st clutch pressure
20-6
D375A-6
Engine at low idle
Unit
MPa {kg/cm2}
MPa {kg/cm2}
D375A-6 (06)
DRAFT Standard service value table Standard value table for machine
Machine model Category
Item
D375A-6
Measuring condition q
Transmission 2nd clutch pressure
Adjustment ID: 5535 Measure in (both steering clutch disengage modes)
Unit
Power train oil pressure
Transmission lubricating oil pressure
2.25 – 2.84 2.06 – 3.13 {23.0 – 29.0} {21.0 – 31.9}
Engine high idle
2.55 – 2.87 2.30 – 3.16 {26.0 – 29.3} {23.4 – 32.2}
Engine high idle
2.55 – 2.87 2.30 – 3.16 {26.0 – 29.3} {23.4 – 32.2}
Power train oil temperature: Within operating range
Engine high idle
0.08 – 0.25 {0.8 – 2.5}
q
Power train oil temperature: Within operating range
Engine low idle
2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0}
Engine high idle
2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3}
Engine low idle
2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0}
Engine high idle
2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3}
Steering left brake pressure
Engine low idle Steering right clutch pressure
Steering right brake pressure Power train oil temperature: Within operating range
q
Flat ground Engine coolant temperature: Within operating range Power train oil temperature: Within operating range Engine high idle Run up distance: 10 - 30 m Measurement distance: 20 m
Power train performance
q
q q
D375A-6 (03)
q
MPa {kg/cm2}
0.08 – 0.25 {0.8 – 2.5}
2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0}
Engine high idle
2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3}
Engine low idle
2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0}
Engine high idle
2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3}
Engine high idle
Automatic gear shift mode
q
q
Travel speed
MPa 2.25 – 2.84 2.06 – 3.13 {kg/cm2} {23.0 – 29.0} {21.0 – 31.9}
q
Steering left clutch pressure
Pin puller operating pressure
Permissible value
Engine low idle
Engine low idle Transmission 3rd clutch pressure
Standard value for new machine
MPa {kg/cm2}
2.55 ± 0.10 {26.0 ± 1.0}
Min. 2.2 {Min. 22}
F1
20.6 ± 1.0 {3.5 ± 0.2}
20.6 ± 1.0 {3.5 ± 0.2}
F2
10.6 ± 0.6 {6.8 ± 0.3}
10.6 ± 0.6 {6.8 ± 0.3}
F3L
9.0 ± 0.4 {8.0 ± 0.4}
9.0 ± 0.4 {8.0 ± 0.4}
F3
6.1 ± 0.3 {11.8 ± 0.6}
6.1 ± 0.3 {11.8 ± 0.6}
R1
15.7 ± 0.8 {4.6 ± 0.2}
15.7 ± 0.8 {4.6 ± 0.2}
R2
8.1 ± 0.4 {8.9 ± 0.4}
8.1 ± 0.4 {8.9 ± 0.4}
R3L
7.4 ± 0.3 {9.7 ± 0.5}
7.4 ± 0.3 {9.7 ± 0.5}
R3
4.9 ± 0.3 {15.8 ± 0.7}
4.9 ± 0.3 {15.8 ± 0.7}
sec {km/h}
20-7
DRAFT Standard service value table Standard value table for machine
Machine model
Item q
Power train performance
q
q
Travel speed
q q q
q
Unload pressure
q
Work equipment oil pressure
Blade tilt relief pressure
Ripper tilt relief pressure
LS pressure (Load sensing pressure)
20-8
Permissible value
Flat ground Engine coolant temperature: Within operating range Power train oil temperature: Within operating range Engine high idle Run up distance: 10 - 30 m Measurement distance: 20 m
F1
20.6 ± 1.0 {3.5 ± 0.2}
20.6 ± 1.0 {3.5 ± 0.2}
F2
10.6 ± 0.6 {6.8 ± 0.3}
10.6 ± 0.6 {6.8 ± 0.3}
6.1 ± 0.3 {11.8 ± 0.6}
6.1 ± 0.3 {11.8 ± 0.6}
15.7 ± 0.7 {4.6 ± 0.3}
15.7 ± 0.7 {4.6 ± 0.3}
R2
8.2 ± 0.4 {8.7 ± 0.4}
8.2 ± 0.4 {8.7 ± 0.4}
R3
4.9 ± 0.3 {14.7 ± 0.7}
4.9 ± 0.3 {14.7 ± 0.7}
―
―
Unit
F3 R1
q q q q
sec {km/h}
Hydraulic oil temperature: 45 – Engine low idle 55 °C Cylinder stroke end Engine high idle
2.45 (+1.37/0) {25 (+14/0)}
2.45 (+1.37/0) {25 (+14/0)} 26.4 – 29.4 {270 – 300}
Engine low idle
26.4 – 28.4 {270 – 290}
Engine high idle
27.4 – 29.4 27.4 – 29.4 {280 – 300} {280 – 300}
Engine low idle
Ripper lift relief pressure
Control circuit oil pressure PPC valve output pressure
Standard value for new machine
Measuring condition
Manual gear shift mode
Category
D375A-6
MPa {kg/cm2}
26.4 – 28.4 {270 – 290}
26.4 – 29.4 {270 – 300}
Engine high idle
27.4 – 29.4 27.4 – 29.4 {280 – 300} {280 – 300}
Engine low idle
26.4 – 28.4 {270 – 290}
Engine high idle
27.4 – 29.4 27.4 – 29.4 {280 – 300} {280 – 300}
Engine low idle
25.48 ± 1.27 {260 ± 13}
25.48 ± 1.27 {260 ± 13}
25.48 ± 1.27 {260 ± 13} 3.43 – 4.12 {35 – 42} 3.43 – 4.12 {35 – 42}
25.48 ± 1.27 {260 ± 13} 3.43 – 4.12 {35 – 42} Min. 3.33 {Min. 34}
Engine high idle Hydraulic oil temperature: 45 – 55 °C Engine high idle Circuit oil pressure: Lever in neutral Output pressure: Lever at stroke end
MPa {kg/cm2}
26.4 – 29.4 {270 – 300}
D375A-6 (03)
DRAFT Standard service value table Standard value table for machine
Machine model Category
Item
D375A-6 Standard value for new machine
Permissible value
7 – 13
20
3.7 – 4.7
6
Engine low idle
1.3 – 1.7
1.3 – 1.8
Engine high idle
1.3 – 1.7
1.3 – 1.8
2–4
6
2.5 – 3.5
5
2–4
6
2.5 – 3.5
5
4–6
7
2.5 – 3.5
5
4–6
7
2.5 – 3.5
5
2–4
5
2.5 – 3.5
5
2–4
5
2.5 – 3.5
5
Measuring condition
Unit
Raise
Engine low idle Engine high idle
Blade lift q q
L.H. tilt
q
Hydraulic oil temperature: 45 – 55 °C Apply no load to blade. Between ground level and rising end of blade
Lower
sec
Engine low idle Engine high idle sec
q
L.H. tilt q
Single tilt specification
Hydraulic oil temperature: 45 – 55 °C Apply no load to blade. Between left tilt end and right tilt end
L.H. tilt
q
Engine low idle Engine high idle
Engine high idle
Engine low idle Engine high idle sec
q q q
D375A-6 (03)
Engine high idle
sec
q
Blade dual tilt
Engine low idle
Engine low idle R.H. tilt
Dual tilt specification
q
Hydraulic oil temperature: 45 – 55 °C Apply no load to blade. Between left tilt end and right tilt end
Hydraulic oil temperature: 45 – 55 °C Apply no load to blade. Between left tilt end and right tilt end
R.H. tilt
Work equipment speed
Work equipment
q
R.H. tilt
Blade tilt
Engine low idle Engine high idle
20-9
DRAFT Standard service value table Standard value table for machine
Machine model Category
Measuring condition
Dump
Item
D375A-6
Blade pitch
q
q q
Tilt in
Work equipment
q
Hydraulic oil temperature: 45 – 55 °C Apply no load to ripper. Between ground level and rising end of ripper
q q q
q q
Time lag
Blade
q
Hydraulic oil temperature: 45 – 55 °C Apply no load to blade. Between forward tilt end and backward tilt end
Engine high idle
Engine high idle
Engine low idle Engine high idle
sec
7
2.5 – 3.5
5
3–5
6
2.5 – 3.5
5
*G
4–6
*M
4–6
*G
2–3
7 5
*M 2.5 – 3.5
Engine low idle
1.5 – 2.5
1.5 – 2.5
Engine high idle
1.5 – 2.5
1.5 – 2.5
Engine low idle
10 – 16
20
Engine high idle
4.5 – 5.5
7
6 – 10
15
2.8 – 3.8
6
Max. 8
12
Max. 1.8
2.0
―
―
Engine low idle Engine high idle
Hydraulic oil temperature: 45 – 55 °C Engine low idle Lever full stroke Start lowering operation at blade max. raising position and mea- Engine high sure time from when blade idle reaches ground until idler rises.
sec Hydraulic oil temperature: 45 – 55 °C Engine low idle q Lever full stroke q Start lowering operation at ripper Ripper max. raising position and measure time from when ripper Engine high reaches ground until sprocket idle rises. * G: Variable giant ripper specification, M: Variable multi-shank ripper specification
20-10
4–6
Engine low idle
sec Tilt back
Ripper tilt
Permissible value
sec
RAISE Ripper lift
Standard value for new machine
Engine low idle
LOWER
Work equipment speed
q
Hydraulic oil temperature: 45 – 55 °C Apply no load to blade. Between dump end and back end
Back
q
Unit
q
*G Max. 1.0 *G
1.5
*M Max. 1.5 *M
2
D375A-6 (03)
Standard service value table Standard value table for machine
Machine model Cate gory
Item
Measuring condition
Hydraulic drift of lifted blade q q q
Hydraulic drift
Work equipment
q q
q q
q q
D375A-6 (06)
Permissible value
mm
Max. 65 mm
130 mm
mm
Max. 50 mm
100 mm
mm
Max. 50 mm
80 mm
mm
Max. 25 mm
50 mm
Hydraulic oil temperature: 45 – 55 °C Engine stopped Measuring reduction of track shoe bottom height "h" (for 5 minutes).
Hydraulic drift of lifted ripper q
Standard value for new machine
Hydraulic oil temperature: 45 – 55 °C Engine stopped Measure reduction of idler center height "h" (for 5 minutes).
Hydraulic drift of machine tilted by blade q
Unit
Hydraulic oil temperature: 45 – 55 °C Engine stopped Measuring reduction of blade bottom height "h" (for 5 minutes).
Hydraulic drift of lifted blade q
D375A-6
Hydraulic oil temperature: 45 – 55 °C Engine stopped Measuring reduction of height of bottom end of shank "h" (for 5 minutes).
20-11
DRAFT Standard service value table Standard value table for machine
Machine model
20-12
Hydraulic drift
Item
Measurement condition
Hydraulic drift of machine lifted by ripper q q q
Cylinder internal leakage
Work equipment
Category
Blade tilt cylinder Ripper lift cylinder Ripper tilt cylinder
q q q
Hydraulic oil temperature: 45 – 55 °C Engine stopped Measure reduction of sprocket center height "h" (for 5 minutes). Engine running at low idle Hydraulic oil temperature: 45 – 55 °C Relieve cylinder and measure leakage for 1 minute.
D375A-6 Unit
Standard value for new machine
Permissible vable
mm
Max. 30 mm per 5 minutes
60 mm per 5 minutes
Max. 3.0
12
Max. 3.6
12
Max. 3.2
12
cc/min
D375A-6 (01)
DRAFT
D375A-6 SEN05176-00
BULLDOZER D375A-6 Shop Manual
Machine model D375A-6
Serial number 60001 and up
30 Testing and adjusting Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 2 Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 4 Testing intake air pressure (boost pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 8 Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 12 Adjusting valve clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 14 Measuring compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 16 Testing blow-by pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 19 Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 21 Handling of fuel system devices- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 24 Releasing residual pressure from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 25 Bleeding air from fuel circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 31 Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 26
D375A-6 (01)
30-1
Contents
Contents 30 Testing and adjusting Tools for testing, adjusting and troubleshooting ..................................................................... Diagnosis equipment list ...................................................................................................... Engine and cooling system ..................................................................................................... Testing engine speed........................................................................................................... Testing intake air pressure (boost pressure) ....................................................................... Testing exhaust temperature ............................................................................................... Testing exhaust gas color .................................................................................................... Adjusting valve clearance .................................................................................................... Measuring compression pressure........................................................................................ Testing blow-by pressure..................................................................................................... Testing engine oil pressure.................................................................................................. Testing EGR valve drive oil pressure................................................................................... Handling of fuel system devices .......................................................................................... Releasing residual pressure from fuel system ..................................................................... Testing fuel pressure ........................................................................................................... Handling of reduced cylinder mode operation ..................................................................... Handling of no injection cranking operation ......................................................................... Testing leakage from pressure limiter and return rate from injector .................................... Bleeding air from fuel circuit................................................................................................. Testing fuel circuit for leakage ............................................................................................. Replacing and adjusting alternator and air conditioner compressor belt ............................. Measuring fan speed ........................................................................................................... Testing fan circuit oil pressure ............................................................................................. Bleeding air from fan pump.................................................................................................. Adjusting fuel control dial and decelerator pedal ................................................................. Power train.............................................................................................................................. Testing power train oil pressure........................................................................................... Adjusting transmission output speed sensor ....................................................................... Simple test procedure for brake performance...................................................................... Adjusting brake pedal and parking brake lever.................................................................... Adjusting position of pccs lever console .............................................................................. Emergency escape method when there is failure in power train ......................................... Undercarriage and frame ........................................................................................................ Inspecting wear of sprocket ................................................................................................. Testing and adjusting track shoe tension............................................................................. Hydraulic system..................................................................................................................... Measuring and adjusting work equipment oil pressure........................................................ Testing control circuit main pressure ................................................................................... Testing PPC valve output pressure ..................................................................................... Adjusting play of PPC valve................................................................................................. Testing output pressure of ripper pin-puller solenoid valve ................................................. Checking location of cause of hydraulic drift of blade and ripper......................................... Testing leakage inside work equipment cylinder ................................................................. Releasing remaining pressure in work equipment cylinders................................................ Bleeding air from work equipment cylinders ........................................................................ Adjusting ripper lever position.............................................................................................. Work equipment...................................................................................................................... Adjusting work equipment lock lever.................................................................................... Adjusting blade .................................................................................................................... Cab and its attachments .........................................................................................................
30-2
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D375A-6 (07)
Contents
Testing and adjusting operator's cab ................................................................................... Testing and adjusting operator's seat isolator ..................................................................... Electrical system ..................................................................................................................... Special functions of machine monitor (EMMS).................................................................... Handling of voltage circuit of engine controller .................................................................... Adjustment method when controller has been replaced...................................................... Preparation work for troubleshooting of electrical system ................................................... Inspection procedure of diode ............................................................................................. Handling of optional devices................................................................................................ Request for opening ORBCOMM terminal .......................................................................... Initialization procedures for VHMS controller....................................................................... Using method of KOMTRAX functions of ORBCOMM terminal .......................................... Precautions for replacing VHMS controller.......................................................................... Pm Clinic service .................................................................................................................... Pm Clinic service .................................................................................................................
D375A-6 (07)
30- 77 30- 81-1 30- 82 30- 82 30- 139 30- 140 30- 144 30- 148 30- 149 30- 150 30- 152 30- 172 30- 175 30- 181 30- 181
30-3
Tools for testing, adjusting and troubleshooting Diagnosis equipment list
Tools for testing, adjusting and troubleshooting
30-4
Diagnosis equipment list
30-4
Testing/Adjusting item
Symbol
Measuring intake air pressure (boost pressure) Measuring exhaust gas temperature Checking exhaust gas color
Remarks
1
-101 – 200 kPa {-760 – 1,500 mmHg}
B -
799-101-1502 799-201-1150 799-201-9001 Commerciallyavailable Commerciallyavailable 795-502-1590 795-611-1220 6261-71-6150 795-799-5410 795-799-5420 799- 201-1504
Digital thermometer Adapter connector Handy smoke checker
1 1 1
-99.9 – 1,299°C For Pm clinic specification
Smoke meter
1
Clearance gauge
1
Compression gauge Adapter Gasket Adapter Remover Blow-by checker
1 1 1 1 1 1
1 2 D
E 2 3
Testing blow-by pressure
Q'ty
799-201-2202 Boost gauge kit
1 Testing compression pressure
Part Name
A
C
Adjustment of valve clearance
Part No.
F
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-401-2320 799-101-5230 6215-81-9720 795T-690-1110 01435-00835 07000-E2012
1 1 1 1 2 3
1 Testing engine oil pressure
G 2 3
Testing drive pressure of EGR valve
4
Gauge Nipple O-ring Block Bolt O-ring
H 2 3 1 2 3
Testing fuel return rate and leakage
J
4 5 6
Testing power train oil pressure
K
1 2
Emergency retrieval method when power train L has trouble
1
2 Measuring and adjusting 1 work equipment oil presM sure, Testing control cir2 cuit main pressure Testing PPC valve output pressure
30-4
Intake side: 0.32 mm, Exhaust side: 0.62 mm 0 – 7 MPa {0 – 70 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-401-2320 799-101-5160 795-471-1450 07005-00812 6167-11-6640 6206-71-1770 Commerciallyavailable Commerciallyavailable Commerciallyavailable Commerciallyavailable 799-101-5002 790-261-1204 799-401-2320 19M-06-32820 7824-66-6430 195-06-71220 790-190-1601 799-101-5002 790-261-1204 799-101-5220 07002-11023
Gauge Nipple Adapter Gasket Spacer Joint
1 1 1 1 1 1
*As common as G2 R 1/8 M8 × 1.25
Hose
1
f 5 mm (Inside diameter) x 2 – 3 m
Hose
1
f 16 mm (Inside diameter) x 2 – 3 m
Measuring cylinder
1
Stopwatch
1
Hydraulic tester Digital hydraulic tester Gauge Switch assembly Resistor Wiring harness Pump assembly Hydraulic tester Digital hydraulic tester Nipple O-ring
1 1 1 1 1 1 1 1 1 2 2
1 Testing fuel pressure
Bosch index: 0 to 9
*As common as G1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
N 1
Inside diameter: 10 mm Joint diameter: 10 mm
*As common as G1 *As common as G2
*As common as G1 M10 × 1.25
*As common as G1
D375A-6 (06)
Tools for testing, adjusting and troubleshooting Diagnosis equipment list
Testing/Adjusting item Testing ripper pin puller solenoid valve output pressure
Symbol
Part Name
Q'ty
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-401-3200 Adapter CommerciallyMeasuring cylinder available
1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
1
P
2
Testing for leakage inside work equipment cylinder
Part No.
Q
*As common as G1
S
Testing operating effort and depressing force Testing stroke and hydraulic drift Testing work equipment speed Testing voltage and resistance Initialization of VHMS controller
2 3 4 T U V
W
Z
Diagnosis sensor and harness
D375A-6 (06)
-
*As common as G1 790-301-1330 07372-21055 07000-13035 79A-264-0021 79A-264-0091 Commerciallyavailable Commerciallyavailable Commerciallyavailable
q Flange Bolt O-ring Push-pull scale Push-pull scale
1 4 1 1 1
Ruler
1
Stopwatch
1
Multimeter
1
1
799-608-3211 Discket
1
2
799-608-3220 Wiring harness
1
3
Size 03
1
1 Testing fan circuit oil pressure
Remarks
Commerciallyavailable 799-601-7400 799-601-7500 799-601-9000 799-601-9300 799-601-7360 799-601-3450 799-601-4100 795-799-5530 795-799-5540 799-601-4130 799-601-4150 799-601-4211 799-601-4220 799-601-4240 799-601-4250 799-601-4260 799-601-9020 799-601-9040 799-601-9420 799-601-9430 799-601-9030
Lap top type personal computer T-adapter assembly T-adapter assembly T-adapter assembly T-adapter assembly Adapter Adapter T-adapter assembly q T-adapter q T-adapter q T-adapter q T-adapter q T-adapter q T-adapter q Socket q Socket q T-adapter q T-adapter q T-adapter q T-adapter q T-adapter T-adapter
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Size: 10
0 – 294 N {0 – 30 kg} 0 – 490 N {0 – 50 kg}
OS: Windoes98/2000/Me/XP/VISTA [With RS232C terminal] AMP040 Connector AMP040 Connector DT, HD30 connector DRC26-24, 40-pin Relay (5 pins) VHMS download harness Connected with engine Engine coolant, oil, fuel temperature Boost air temperature sensor Ne sensor Oil pressure sensor Controller (50 poles) Controller (60 poles) Ambient pressure sensor Boost pressure sensor Controller (4 poles) EGR EGR valve, injector EGR valve potentiometer sensor Common rail pressure sensor Supply pump PCV G sensor
30-5
DRAFT Engine and cooling system Testing engine speed
Engine and cooling system Testing engine speed k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Measure the engine speed under the following conditions. q Coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: 45 – 55°C q Working mode: P-mode q Gear shift mode: Manual 1. Preparation work Measure the engine speed with the Adjustment function in the service mode of the machine monitor. a For the operating method, see "Special functions of machine monitor (EMMS)". q Adjustment ID: 0530 (Stall mode) a When stalling the torque converter for a purpose other than measuring the engine speed, be sure to use this adjustment code, too.
2. Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.
30-6
3. Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position. 4. Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral, press the decelerator pedal to the stroke end, and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position. 5. Measuring torque converter stall speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 3) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering unit in neutral. 4) Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 5) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 6) Right after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 °C, return the PCCS lever to the neutral position.
D375A-6 (03)
DRAFT Engine and cooling system Testing engine speed
a The top of the green range of the power train oil temperature gauge indicates about 118 – 120 °C. 7) Repeat above steps 3) – 6) 3 times. 8) Perform steps 3) - 5) again and measure the engine speed when the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 °C. a Immediately after finishing measuring, return the PCCS lever to the neutral position and lower the power train oil temperature with the engine at high idle. 6. Measuring torque converter stall speed (Inspection on Pm clinic screen) 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
3) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F2-R2]. 4) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. 5) Shift to 3rd gear by operating the shift-up (UP) switch of PCCS lever. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering unit in neutral. 6) Repeat the measuring process in a similar way by following Step 4) and later of "5. Measuring torque converter stall speed". 7. Measuring torque converter stall + work equipment relief speed (Full stall speed)
1) Start the engine and set the fuel control dial in the low idle (MIN) position.
D375A-6 (03)
2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 3) Set the work equipment lock lever in the free position and operate the ripper control lever to set the ripper lift cylinder to the raise stroke end. 4) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering unit in neutral. 5) Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 6) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 7) Right after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 °C, return the PCCS lever to the neutral position. a The top of the green range of the power train oil temperature gauge indicates about 118 – 120 °C. 8) Repeat above steps 4) – 7) 3 times. 9) Perform steps 4) - 6) again, operate the ripper control lever to relieve the ripper raise system, and measure the engine speed when the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 °C. a Immediately after finishing measuring, return the PCCS lever to the neutral position and lower the power train oil temperature with the engine at high idle. 8. Measuring torque converter stall + Work equipment relief speed (Full stall speed) (Inspection on Pm clinic screen) 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
30-7
DRAFT Engine and cooling system Testing engine speed
3) Operate the shift up (UP) switch of the PCCS lever and set the preset mode display section to [F2-R2]. 4) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. 5) Shift to 3rd gear by operating the shift-up (UP) switch of PCCS lever. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering unit in neutral. 6) Repeat the measuring process in a similar way by following Step 5) and later of "7. Measuring torque converter stall + Work equipment relief speed (Full stall speed)".
30-8 30-7-1
D375A-6 (03)
DRAFT Engine and cooling system Testing engine speed
D375A-6 (03)
30-7-2
DRAFT Engine and cooling system Testing intake air pressure (boost pressure)
Testing intake air pressure (boost pressure) a Testing instruments of intake air pressure (boost pressure) Symbol A
Part No. 799-201-2202
Part name Boost gauge kit
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. k When installing and removing the testing instrument, take care not to touch a hot part of the engine. a A nipple (quick coupler) is installed to the intake air pressure (boost pressure) pickup port of the Pm clinic specification machine. a Measure the intake air pressure (boost pressure) under the following condition. q Coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: 45 – 55°C q Working mode: P-mode q Gear shift mode: Manual a Normally, the intake air pressure (boost pressure) should be tested while the engine is running at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter.
2) Test the boost pressure when the torque converter is stalled at high idle speed. a For the torque converter stall procedure, see Step 3) and later in "6. Measuring torque converter stall speed (Inspection on Pm clinic screen)" of "Testing engine speed". 2. Testing with boost gauge kit 1) Open the engine left cover. 2) Remove boost pressure pickup plug (1) at the rear of the air intake manifold.
3) Install nipple [1] of boost gauge kit A and connect gauge [2].
1. Testing using machine monitor (Pm clinic) 1) Turn the starting switch to the ON position and switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)". a The VHMS specification machine is shown as an example in the figure.
4) Run the engine at middle or higher speed and bleed oil from the hose.
30-10 30-8
D375A-6 (03)
DRAFT Engine and cooling system Testing intake air pressure (boost pressure)
a Install the connecting parts of the gauge and hose about a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you use the air-bleeding coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. 5) Switch the machine monitor to the "Adjustment" function display of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
6) Test the intake air pressure (boost pressure) while the engine is running at high idle and the torque converter is stalling. a For the torque converter stall procedure, see "5. Measuring torque converter stall speed" of "Testing engine speed". 7) After finishing measuring, remove all test tools in order to return the machine status as it was. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: LT-2 or LG-5 3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
D375A-6 (03)
30-9 30-11
DRAFT Engine and cooling system Testing exhaust temperature
Testing exhaust temperature a Checking tools for exhaust gas temperature Symbol B
Part No. 799-101-1502
Part name Digital thermometer
a Checking tools for exhaust gas temperature (for Pm clinic specification machine) Because each Pm clinic specification machine has an exhaust gas temperature sensor, prepare an adapter for the electrical connection between the exhaust gas temperature sensor and the digital temperature gauge. Symbol B ―
Part No. 799-101-1502 799-201-1150
Part name Digital thermometer Adapter connector
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. k Remove and install the testing tools after the exhaust manifold temperature has lowered. a Test the exhaust temperature under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: 45 – 55 °C q Working mode: P-mode q Gear shift mode: Manual 1. Measuring with the digital temperature gauge 1) Open the engine right side cover, and remove the heat insulation cover. 2) Remove the exhaust inspection plug.
gas
temperature
3) Install sensors [1] of digital temperature gauge B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer not to come into contact with any hot parts during measuring.
30-12 30-10
4) Procedure for measuring at maximum temperature while troubleshooting Check the maximum exhaust gas temperature during actual operations. a Use the digital temperature gauge in the PEAK mode. a The exhaust gas temperature largely depends on the ambient air temperature (intake air temperature of engine). Accordingly, if any abnormal value is obtained, correct it using the following calculation. q Corrected value [°C] = Measured value + 2 x (20 - Ambient temperature) 2. Periodic measurement procedure using the preventive maintenance service (Pm clinic) a If the torque converter alone has stalled, the torque converter oil will overheat before the exhaust gas temperature stabilizes. Therefore, check the exhaust gas temperature according to the following procedure. 1) Turn the starting switch to the ON position and switch the machine monitor to the "Adjustment" function display of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)" section.
D375A-6 (03)
DRAFT Engine and cooling system Testing exhaust temperature k
2) Run the engine to warm it up. a The standard warm-up operation is as follows. q Low idle: 3 minutes q Run at a medium speed: 1 minute q High idle: 1 minute 3) Set the fuel control dial to the low idle (MIN) position. 4) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 5) Set the work equipment lock lever in the free position and operate the ripper control lever to set the ripper lift cylinder to the raise stroke end. 6) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering unit in neutral. 7) Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 8) Slowly release the decelerator pedal and stall the torque converter at engine high idle speed. Relieve the ripper raise system, and measure the maximum exhaust gas temperature when the power train oil temperature (T/C TEMPERATURE) shows 118 °C. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 9) Depress the decelerator pedal again. 10)Repeat Steps 8) and 9) several times and record the highest exhaust gas temperature.
D375A-6 (03)
When the power train oil temperature (T/C TEMPERATURE) reaches 118 °C, return the PCCS lever to the neutral position immediately and lower the power train oil temperature while the engine is running at high idle speed.
11)After finishing measuring, remove all test tools in order to return the machine status as it was. 3. Testing for VHMS specifications 1) Turn the starting switch to the ON position and switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
2) Run the engine to warm it up. a The standard warm-up operation is as follows. q Low idle: 3 minutes q Run at a medium speed: 1 minute q High idle: 1 minute
30-11 30-13
DRAFT Engine and cooling system Testing exhaust temperature
3) Set the fuel control dial to the low idle (MIN) position. 4) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F2-R2]. 5) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. 6) Shift to 3rd gear by operating the shift-up (UP) switch of the PCCS lever. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering unit in neutral. 7) Repeat the measuring process in the similar way by following Step 5) and later of "2. Periodic measurement procedure using the preventive maintenance service (Pm clinic)".
30-14 30-11-1
D375A-6 (03)
DRAFT Engine and cooling system Testing exhaust temperature
D375A-6 (03)
30-11-2 30-15
DRAFT Engine and cooling system Testing exhaust gas color
Testing exhaust gas color a Checking tools for exhaust gas color Symbol 1 — 2
Part No. 799-201-9001 Commercially available
Part name Handy smoke checker
2. Checking with smoke meter C2 1) Insert probe [1] of the smoke meter C2 into the outlet of the exhaust pipe and fix it to the exhaust pipe using a clip.
Smoke meter
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. k Be careful not to touch any hot part when removing or installing the checking tools. a If an air source and an electric power source are not available in the field, use a handy smoke checker C1. When recording official data, use a smoke meter C2. a Check the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range q Working mode: P-mode q Gear shift mode: Manual 1. Checking with a handy smoke checker C1 1) Stick a sheet of filter paper to smoke checker C1. 2) Insert the exhaust gas intake pipe into the exhaust pipe. 3) Start the engine. 4) Accelerate the engine suddenly or run it at high idle and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.
2) Connect the probe hose, receptacle of the accelerator switch, and air hose to the smoke meter C2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. 3) Connect the power cable to an AC receptacle. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. 4) Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. 5) Turn on the power switch of smoke meter C2.
5) Remove the filter paper and compare it with the attached scale. 6) After finishing checking, remove all test tools.
30-12
D375A-6 (03)
DRAFT Engine and cooling system Testing exhaust gas color
6) Start the engine. 7) Accelerate the engine suddenly or run at high idle, and depress the accelerator switch of smoke meter C2 at the same time to collect the exhaust gas color on the filter. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. 9) After testing, remove measuring tools and reset the machine to its original status.
D375A-6 (01)
30-13
DRAFT Engine and cooling system Adjusting valve clearance
Adjusting valve clearance a Adjusting tool for valve clearance
k
Symbol
Part No.
D
Commercially available
Part name Feeler gauge
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
1. Remove the engine hood. 2. Remove cylinder head cover. a Remove covers (1) and (2), bracket (3) and 6 cylinder head covers (4). For details, see Disassembly and assembly volume, "Removal and installation of cylinder head assembly".
3. Remove inspection hole plug (5) from the front side of the timing gear case and rotate the crankshaft forward to set notch (a) of the supply pump drive gear to the center of the inspection hole. a Rotate the engine with the cranking device (6) on the rear left of engine. a On the right of figure upper, the compres-sion top dead center of No. 1 cylinder is shown and on the right, the top dead cen-ter of No. 6 cylinder is shown. a When the No. 1 cylinder is at the compres-sion top dead center, the rocker arm can be moved by the valve clearance with the hand.
30-14
4. When the No. 1 cylinder is at the compression top dead center, adjust the valve clearance indicated by q of the valve layout plan. a Loosen locknut (8) of adjustment screw (7), insert feeler gauge D between crosshead (9) and rocker arm (10), and rotate adjustment screw (7) so that the feeler gauge will be hitched a little. a Valve clearance q Air intake valve: 0.32 mm q Exhaust valve: 0.62 mm 5. While fixing adjustment screw (7), tighten lock-nut (8). 3 Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm} a After tightening the lock nut, check the valve clearance again.
D375A-6 (01)
DRAFT Engine and cooling system Adjusting valve clearance
6. Rotate the crackshaft forward one turn and adjust the valve clearance indicated by Q of the valve layout plan. a The adjustment method is the same as above.
7. After finishing adjustment, return the removedparts. 3 Cylinder head cover mounting bolt : {No. 1, 3, 4, 5, 6 cylinders} 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} {No.2 cylinder} 58.8 – 73.5 Nm {6 – 7.5 kgm}
D375A-6 (01)
30-15
DRAFT Engine and cooling system Measuring compression pressure
Measuring compression pressure a Testing tools for compression pressure Symbol 1 E
2 4
Part No. 795-502 1590 795-611-1220 6261-71-6150 795-799-5410 795-799-5420
Part name Compression gauge Adapter Gasket Adapter Remover
a Remove the terminal on the injector side and the mounting bolt on the rocker housing side, and remove the injector wiring harness from the injector. a Loosen the 2 terminal nuts alternately. 5. Remove injector holder (7), and remove injector (8).
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. k When testing the compression pres-sure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. a Measuring the compression pressure under the following condition. (Engine oil temperature:40 – 60°C) 1. Remove the engine hood. 2. Remove cylinder head cover. a Remove covers (1) and (2), bracket (3) and cylinder head cover (4) to test the compression pressure. For details, see Disassembly and assembly volume, "Removal and installation of cylinder head assembly".
a Insert the pin (indicated by the arrow) at the end of the tool E3 into hole (a) of adaptor (9), and pull out the injector by moving the weight of tool E3 up and down.
3. Adjust the valve clearance of the cylinder to be inspected. For details, see "Adjusting valve clearance". 4. Disconnect fuel high-pressure tube (5) and injector wiring harness (6).
30-16
D375A-6 (01)
DRAFT Engine and cooling system Measuring compression pressure
6. Install adapter E2 to the mounting hole on the injector and the compression gauge E1. a Fit the gasket to the injector end without fail a Fix the adapter with the injector holder. 3 Holder mounting bolt : 58.8 – 73.5 Nm {6 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.
7. Turn the starting switch to the ON position and switch the machine monitor to "Cylinder Cut-Out Operation" function display of the service mode. a For the operating method, see Special functions of machine monitor (EMMS). k Be sure to set all the injectors in the no-injection state so that the engine will not start.
8. Rotate the engine with the starting motor and test the compression pressure. a Read the pressure gauge pointer when it is stabilized. 9. After testing, remove measuring tools and reset the machine to its original status. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Install gasket (10) and O-rings (11) and (12). a Take care not to install O-ring (11) to the groove (b). 2 O-ring: Engine oil D375A-6 (03)
2) Fit adaptor (9) to injector (8), and press it in as a unit to the cylinder head by hand.
3) Install holder (7) and tighten bolt (13) and washer (14) temporarily. 2 Spherical surface of washer: Engine oil 4) Install the fuel high-pressure tube, and temporarily tighten sleeve nut (5). 5) Fully tighten bolt (13). 3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 6) Fully tighten sleeve nut (5). 3 Sleeve nut : 39.2 - 44.1 Nm {4 - 4.5 kgm}
a Install the injector wiring harness according to the following procedure 1) Assemble injector wiring harness (6) from the inside of rocker arm housing and fix the connector side with plate (15).
30-17 30-21
DRAFT Engine and cooling system Measuring compression pressure
2) Fit spacer (16) and fix it with bolt (17). 3) Alternately tighten nuts (18) on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Tighten the cylinder head cover mounting bolt with the following torque. 3 Cylinder head cover mounting bolt : {No. 1, 3, 4, 5, 6 cylinders} 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} {No.2 cylinder} 58.8 - 73.5 Nm {6 - 7.5 kgm}
30-18
D375A-6 (01)
DRAFT Engine and cooling system Testing blow-by pressure
2. Testing for VHMS specifications 1) Turn the starting switch to the ON position and switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
2) Test the blowby pressure when the torque converter is stalled at high idle speed. a For the torque converter stall procedure, see Step 3) and later in "6. Measuring torque converter stall speed (Inspection on Pm clinic screen)" of "Testing engine speed".
30-24 30-20
D375A-6 (03)
DRAFT Engine and cooling system Testing engine oil pressure
Testing engine oil pressure a Measuring tools for engine oil pressure Symbol 1 G
3 4
k
Part No. 799-101-5002 790-261-1204 799-401-2320 799-101-5230 6215-81-9720
2. Measuring with oil pressure gauge 1) Open the engine left cover. 2) Remove oil pressure test plug (1).
Part name Hydraulic tester Digital hydraulic tester Gauge Nipple O-ring
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
a A nipple (quick coupler) is installed into the hydraulic oil inspection port of the engine for the Pm clinic specification machine. a Measure the engine oil pressure under the following condition. q Engine oil temperature: Min. 70 °C q Engine coolant temperature: Within operating range q Working mode: P-mode q Gear shift mode: Manual 1. Checking with machine monitor (Pm clinic) 1) Turn the starting switch ON and set the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
2) Run the engine and measure the engine oil pressure at low idle and also at high idle.
D375A-6 (03)
3) Install nipple G3 and connect it to gauge G2.
4) Run the engine and measure the engine oil pressure at low idle and also at high idle.
5) After finishing measuring, remove all test tools in order to return the machine status as it was.
30-21 30-25
DRAFT Engine and cooling system Testing blow-by pressure
Testing blow-by pressure a Measuring tools for blow-by pressure Symbol F k
Part No. 799-201-1504
Part name Blow-by checker
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
3) Turn the starting switch to the ON position and switch the machine monitor to the "Adjustment" function display of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
a Measure the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: 45 – 55 °C q Working mode: P-mode q Gear shift mode: Manual 1. Testing with blowby kit 1) Open the engine left side cover and pull out blow-by hose (1). 2) Install nozzle [1] and hose [2] of blowby checker F to blowby hose (1) and connect them to gauge [3].
D375A-6 (03)
4) Run the engine at high idle and test the blow-by pressure when the torque converter stalls. a For the torque converter stall procedure, see "5. Measuring torque converter stall speed" of "Testing engine speed". a 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. 5) After finishing measuring, remove all test tools in order to return the machine status as it was.
30-19 30-23
Engine and cooling system Testing EGR valve drive oil pressure
Testing EGR valve drive oil pressure
30-25
a Measuring instruments for EGR valve drive pressure Symbol
Part No.
799-101-5002 790-261-1204 795T-690-1110 G 4 01435-00835 07000-E2012 1
k
Part name Hydraulic tester Digital hydraulic tester Block Bolt O-ring
Park the machine on a level ground and lower the work equipment and set firmly on the ground, then set the parking brake lever and work equipment lock lever to the LOCK position.
a Drive oil pressure for EGR valve will be checked under the following condition. q Engine oil temperature: 40 – 60 °C q Working mode: P-mode q Gear shift mode: Manual
5. Install the nipple (component part of G1) into measurement hole (a) (size: PT 1/8) of tool G4 and connect gauge [1] of hydraulic tester G1. Reference: The oil pressure to be measured will be a maximum of approximately 3 MPa {30 kg/cm2}.
1. Open the left side cover. 2. Remove flange mounting bolts (2) and clamp mounting bolt (3) of oil supply tube (1) that drives the EGR valve on the EGR valve side.
3. Install tool G4 on the oil supply portion of the EGR valve. 3 Mounting bolt (4) (component part of G4): 27 – 34 Nm {2.8 – 3.5 kgm} 4. Install oil supply tube (1) that drives the EGR valve on the top of tool G4 and tighten flange mounting bolts (2) on the EGR valve side. 3 Flange mounting bolt (2): 27 – 34 Nm {2.8 – 3.5 kgm}
30-22
D375A-6 (06)
DRAFT Engine and cooling system Testing EGR valve and bypass valve drive oil pressure
6. Start the engine and measure the oil pressure at low idle and high idle.
7. After testing, remove measuring tools and reset the machine to its original status. a Replace the flange O-ring on the EGR valve side with new one. 3 Flange mounting bolt (2): 27 - 34 Nm {2.8 - 3.5 kgm} 3 Clamp mounting bolt (3): 58.8 - 73.5 Nm {6 - 7.5 kgm}
D375A-6 (01)
30-23
DRAFT Engine and cooling system Handling of fuel system devices
Handling of fuel system devices a Precautions for checking and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Precautions for replacing fuel filter cartridge Be sure to use Komatsu genuine fuel filter cartridge. The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) are consisted of more precision parts than those used for the current pumps and nozzles. This system, therefore, employs a special filter with highly efficient filtering performance to prevent mixing of foreign substances. Thus, substituting it with a non-genuine filter could cause troubles in the fuel system. It is strictly prohibited to use such part.
30-24
D375A-6 (01)
DRAFT Engine and cooling system Releasing residual pressure from fuel system
Releasing residual pressure from fuel system a Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low pressure circuit: Feed pump – Fuel main filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly observe the following. k Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
D375A-6 (01)
30-25
DRAFT Engine and cooling system Testing fuel pressure
Testing fuel pressure
3. Install nipple H3 and connect it to gauge H2.
a Measuring tools for fuel pressure Symbol 1 H
2
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Gauge 799-101-5160 Nipple (R 1/8)
3
795-471-1450 Adapter (M8 x 1.25) 07005-00812 Gasket
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
a Test only the fuel pressure in the low-pressure circuit from the feed pump through the engine controller cooler and fuel filter to the supply pump. k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. a Test the fuel pressure under the following conditions. q Working mode: P-mode q Gear shift mode: Manual
4. Start the engine and inspect the fuel pressure with the engine running at high idle or at the equivalent of rated output speed (stall load). a If the fuel pressure is in the following range, it is normal. Engine speed At high idle or at the equivalent of rated output speed
Fuel pressure 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
1. Open the engine left cover. 2. Remove plug (1). 5. After finishing measuring, remove all test tools in order to return the machine status as it was.
30-30 30-26
D375A-6 (03)
DRAFT Engine and cooling system Handling of reduced cylinder mode operation
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
a Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows.
a No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. q When a machine or engine has been stored for a long time, implementing the no-injection cranking before starting the engine lubricates the engine parts and thus prevents its seizure. a Do not use the no injection cranking function for any purpose other than that mentioned above. a For the no injection cranking procedure, see "Special functions of machine monitor (EMMS)"section.
1. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). 2. When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. q Leakage through cylinder head gasket q Defective injection q Defective piston, piston ring, and cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system 3. Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the cylinder cut out mode operation easily with switches to find out a defective cylinder. a To implement reduced cylinder mode operation, see "Special functions of monitor panel (EMMS)". a Use the reduced cylinder mode for only the purpose of troubleshooting.
D375A-6 (03)
30-27 30-31
DRAFT Engine and cooling system Testing leakage from pressure limiter and return rate from injector
Testing leakage from pressure limiter and return rate from injector
a Testing instruments for fuel return rate and leakage Symbol 1 2 3 J
4 5 6
Part No. 6167-11-6640 6206-71-1770 Commercially available Commercially available Commercially available Commercially available
Part name Spacer Joint
a Test the fuel return rate and leakage under the following conditions. q Working mode: P-mode q Gear shift mode: Manual
Hose Hose Measuring cylinder Stopwatch
a Prepare an oil pan of about 20 l to receive the oil that will flow out during the testing process.. k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
30-28 30-32
D375A-6 (03)
DRAFT Engine and cooling system Testing leakage from pressure limiter and return rate from injector
1. Preparation work 1) Remove tube (3) between common rail (1) and block (2). 2) Insert spacer J1 on block (2) side and tighten the removed joint bolt again. 3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} a Fit the gaskets to both ends of the spacer.
3) Insert joint J2 to common rail (1) side and tighten the currently removed joint bolt again. 3 Joint bolt: 17.7 – 22.6 Nm {1.8 – 2.3 kgm} a Be sure to fit the gaskets to both ends of the joint. 4) Connect inspection hose J3 to the tip of joint J2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.
2. Testing leakage from pressure limiter 1) Route inspection hose J3 in such that it may be free from slack and then insert its end to the oil pan (saucer). 2) Turn the starting switch to the ON position and switch the machine monitor to "Adjustment" function display of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
3) Run the engine at high idle and stall the torque converter. After the engine speed is stabilized, measure the return rate in 1 minute with measuring cylinder J5. a For the torque converter stall procedure, see "5. Measuring torque converter stall speed" of "Testing engine speed". a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal. Engine speed (rpm) Equivalent to rated operation
D375A-6 (03)
Leakage (spill) (cc/min) Max. 10
30-29 30-33
DRAFT Engine and cooling system Testing leakage from pressure limiter and return rate from injector
a For the torque converter stall procedure, see "5. Measuring torque converter stall speed" of "Testing engine speed". a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal.
4) After finishing testing, stop the engine. 3. Testing return rate from injector 1) Remove the hose (4) at spill outlet and connect inspection hose J4 in stead. Then insert the hose end to the oil pan (saucer).
2) Turn the starting switch to the ON position and switch the machine monitor to "Adjustment" function display of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
Engine speed (Equivalent to rated output operation load) (rpm) 1,600 1,700 1,800 1,900 2,000
Return (Spill) limit (spill) (cc/min) 960 1,020 1,080 1,140 1,200
4) After finishing testing, stop the engine. 4. Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts.
3) Run the engine at high idle and stall the torque converter. After the engine speed is stabilized, measure the return rate in 1 minute with measuring cylinder J5.
30-34 30-30
D375A-6 (03)
DRAFT Engine and cooling system Bleeding air from fuel circuit
Bleeding air from fuel circuit k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Bleed air from the fuel circuit in the following cases according to this procedure. q When the fuel filter is replaced q When fuel is used up q When the engine is started for the first time after the fuel piping or supply pump is replaced a When the fuel filter is replaced, don't feed fuel to the filters, including both the main and pre-filter. k While the electric priming pump is in operation, pressure is applied to the fuel circuit. Do not loosen the air bleeding plug at this time, since the fuel may spout out. 1. Set the starting switch to OFF position.
3. Open the engine left cover. 4. Open air bleeding valve (2).
5. Set electric priming pump switch (3) inside the engine compartment to the "ON" position. a Lamp (4) will start flashing and operation of the electric priming pump will be started.
2. Check that supply valve (1) of the fuel tank is in the "OPEN" position.
D375A-6 (01)
30-31
DRAFT Engine and cooling system Bleeding air from fuel circuit
a The built-in timer of this switch automatically starts or stops operation of the electric priming pump. (See the figure below) a Operation of the electric priming pump is stopped as long as flashing of the lamp is continued. It is not an error. a Shifting the switch to “OFF” while the lamp is flashing turns off the lamp and stops the electric priming pump, too.
2) While the electric priming pump is operating, crank the engine with the starting motor. a If the engine does not start, wait for about 2 minutes and then repeat steps 1) and 2). a Do not rotate the starting motor for more than 20 seconds continuously. 3) If the engine starts, run it at low idle for 5 minutes to bleed all air from the fuel circuit.
6. After the specified time (about 7 minutes), lamp (4) goes off automatically and the electric priming pump stops. a When the fuel filter alone was replaced, above completes bleeding air.. 7. When fuel is not provided in the fuel circuit such as when run out of fuel occurred or when replacement of the fuel pipe or supply pump was done, set switch (3) to “ON” again after the electric priming pump is automatically stopped. 8. Bleeding air, in this case, completes as lamp (4) went off. 9. Close air bleeding valve (2). 10. Start the engine with the starting motor. a Do not rotate the starting motor for more than 20 seconds continuously. a The air in the high-pressure circuit is bled automatically if the engine is cranked. 11. If the engine starts, run it at low idle for 5 minutes to bleed all air from the fuel circuit. a If the engine does not start, the air may have not been bled from the low pressure circuit. In this case, try to start the engine again according to the following procedure. a Work with air bleeding valve (2) closed. a If you failed to start the engine, wait for about 2 minutes and then try to start again. 1) Set electric priming pump switch (3) to the "ON" position.
30-32
D375A-6 (01)
DRAFT Engine and cooling system Testing fuel circuit for leakage
Testing fuel circuit for leakage k
Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After checking the fuel system or removing its parts, check it for fuel leakage according to the following procedure. a Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage. 1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
8. Run the engine at high idle and load it. a Relieve by tilting the blade or raising the ripper. 9. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage. a If no fuel leakage is detected, check is completed.
2. Start the engine, keep its speed below 1,000 rpm, and stop it when its speed stabilizes. 3. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage. 4. Run the engine at low idle. 5. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage. 6. Run the engine at high idle. 7. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage.
D375A-6 (01)
30-33
DRAFT Engine and cooling system Replacing and adjusting alternator and air conditioner compressor belt
Replacing and adjusting alternator and air conditioner compressor belt k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
a The auto-tensioner is provided for the alternator and air conditioner compressor belt. Thus, testing and adjustment of the belt is usually not necessary. a Following describes the auto-tensioner adjustment procedure to be employed for the belt replacement. 1. Open the engine left side cover. 2. Loosen locknut (1), tighten push bolt (2) fully and then loose in tension pulley (4). 3. Replace belt (5). 4. After replacing the belt, loosen push bolt (2) until its installed length (a) is 90 mm.
5. Tighten locknut (1).
30-34
D375A-6 (01)
DRAFT Engine and cooling system Measuring fan speed
Measuring fan speed k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Measure the fan motor speed under the following condition. q Hydraulic oil temperature: 45 – 55 °C q Working mode: P-mode q Gear shift mode: Manual 1. Start the engine and set the machine monitor to Adjusting function of the service mode. q Adjustment ID: 1005 (Fan 100% mode) a For the operating method, see "Special functions of machine monitor (EMMS)". a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the state of the machine.
2. While running the engine at low idle and high idle, measure the fan speed 3. After finishing measurement, remove the measuring instruments and return the removed parts. a If the starting switch is turned to the OFF position, the fan 100% mode is reset.
D375A-6 (01)
30-35
DRAFT Engine and cooling system Testing fan circuit oil pressure
Testing fan circuit oil pressure a Testing instruments for fan circuit oil pressure Symbol 1 S
2 4 6
Part No. 799-101-5002 790-261-1204 790-301-1330 07372-21055 07000-13035
Part name Hydraulic tester Digital hydraulic tester q Flange Bolt O-ring
4. Install nipple [2] of hydraulic tester S1 and connect it to oil pressure gauge [1]. a For an analog oil pressure gauge, the pressure must be 40 MPa {400 kg/cm2}.
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Test the fan circuit oil pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C q Working mode: P-mode q Gear shift mode: Manual 1. Open the radiator mask. 2. Remove bolt (1) and disconnect tube (2).
5. Start the engine and switch the machine monitor to "Adjustment" function display of the service mode. q Adjustment ID: 1005 (Fan 100% mode) a For the operating method, see "Special functions of machine monitor (EMMS)". a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the state of the machine.
3. Install oil pressure testing flange S2 and then install tube (2) again with bolt S3. q The stem of oil pressure testing bolt S3 is 15 mm longer. 6. While running the engine at high idle, measure the fan circuit oil pressure. 7. After measuring, remove measuring tools and reset the machine to its original status.
30-36
D375A-6 (01)
DRAFT Engine and cooling system Bleeding air from fan pump
Bleeding air from fan pump a If the fan pump is removed and installed or its piping is disconnected and connected, bleed air from the pump case according to the following procedure. a Before bleeding air, check that the hydraulic oil level is proper. 1. Remove the floor mat. 2. Remove left footrest (1).
3. Loosen air bleeders (2) and (3), and leave them for 15 minutes.
4. After 15 minutes, run the engine at low idle. 5. When oil flows from air bleeders, tighten air bleeders (2) and (3).
D375A-6 (01)
30-37
DRAFT Engine and cooling system Adjusting fuel control dial and decelerator pedal
Adjusting fuel control dial and decelerator pedal
1. Outline of fuel control system q The following signals are inputted as rotation command signals to the engine controller. q Decelerator pedal potentiometer signal q 3rd throttle signal The engine controller controls the fuel control system of the engine (CRI system) according to the lowest engine speed signal among those input signals. q Adjust the deceleration slow speed by adjusting the decelerator pedal linkage.
30-42 30-38
[1] Fuel control dial (2nd throttle signal) [2] Engine controller [3] Power train controller [4] Decelerator pedal (1st throttle signal) [5] Decelerator potentiometer [6] Engine (CRI system) [7] Machine control signal (3rd throttle signal) [8] Rod 2. Preparation work a Set the working mode to P mode and set the gear shift mode to Manual. 1) Start the engine and switch the machine monitor to "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
D375A-6 (03)
DRAFT Engine and cooling system Adjusting fuel control dial and decelerator pedal
3. Adjusting the speed when using decelerator pedal With the fuel control dial in the high idle position, depress decelerator pedal (4) until it touches the stopper. Check that the engine speed is normal under this condition. q Engine speed: 900 ± 50 rpm a If the engine is not running at the correct speed, adjust installed dimension (a) of rod (8). q Standard installed dimension (a) of rod: 123 mm (reference) 4. Adjusting high idle speed Return the decelerator pedal, set the fuel control dial to the high idle position, and check that the engine is running at the correct high idle speed. q High idle speed: 1,900 (0/-50) rpm a If the high idle speed is abnormal, adjust it according to the following procedure. q If the engine speed is high: To remove the play of the decelerator pedal, use stopper bolt (9) to adjust the engine speed to less than 1,800 rpm, then adjust to the high idle speed. q If the engine speed is low: Use stopper bolt (9) to adjust to the high idle speed. 5. After finishing all adjustment, return the removed parts.
D375A-6 (03)
30-39 30-43
Power train Testing power train oil pressure
Power train
30-4
Testing power train oil pressure
30-4
a Testing tools for power train oil pressure Symbol K
1 3
Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Gauge
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Test the power train oil pressure under the following condition. q Power train oil temperature: Within operating range q Working mode: P mode q Gear shift mode: Manual a The power train oil pressure pickup ports (centralized oil pressure pickup ports) are located inside the inspection window cover on the left outside of the operator's cab.
No. Mark
14
RB
15
LUB
Oil pressure to check Right steering brake pressure Output pressure of sudden stop prevention valve Transmission lubricating oil pressure
Gauge (MPa {kg/cm2}) 6 {60}
1.0 {10}
a Table of pressure pick-up port positions and gauges to use No. Mark 1
IN
2
OUT
3
LU
4
SC
5
T/M
6
FWD
7
REV
8
1ST
9
2ND
10
3RD
11
LC
12
LB
13
RC
30-40
Oil pressure to check Torque converter inlet pressure Torque converter outlet pressure Torque converter lock-up clutch pressure Torque converter stator clutch pressure Transmission main relief pressure Transmission F clutch pressure Transmission R clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Left steering clutch pressure Left steering brake pressure Output pressure of sudden stop prevention valve Right steering clutch pressure
Gauge (MPa {kg/cm2}) 2.5 {25} 1.0 {10} 2.5 {25} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60}
6 {60}
6 {60}
D375A-6 (06)
Power train Testing power train oil pressure
1. Testring torque converter inlet pressure (IN) (Testing with oil pressure gauge) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (1). a When using an analogue oil pressure gauge, use one of 2.5 MPa {25 kg/cm2}.
2. Testing torque converter outlet pressure (OUT) (Testing with oil pressure gauge) 1) Connect gauge K2 to oil pressure test nipple (2).
2) Start the engine and set the PCCS lever in the fully neutral position. 3) Measure the torque converter inlet port pressure with the engine at low idle and high idle.
2) Start the engine and set the PCCS lever in the fully neutral position. 3) Measure the torque converter outlet port pressure with the engine at low idle and high idle.
4) After finishing testing, remove all test tools in order to return the machine status as it was.
4) After finishing testing, remove all test tools in order to return the machine status as it was.
D375A-6 (06)
30-41
DRAFT Power train Testing power train oil pressure
3. Measuring torque converter inlet pressure and outlet pressure [Checking with machine monitor (Pm clinic)] 1) Turn the starting switch to the ON position and switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
2) Start the engine and set the PCCS lever in the fully neutral position. a The test may be performed with the parking brake lever in the LOCK position. 3) While running the engine at low idle and high idle, measure the inlet pressure and outlet pressure of the torque converter.
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DRAFT Power train Testing power train oil pressure
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DRAFT Power train Testing power train oil pressure
4. Testing torque converter lock-up clutch pressure (LU) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (3). a For an analog oil pressure gauge, the pressure must be 2.5 MPa {25 kg/cm2}.
3) Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Automatic gear shift q Preset range: F2-R2 4) With the brake pedal depressed, set the PCCS lever to F and the gear speed to the 2nd. 5) Gradually release the brake pedal. 6) With the decelerator pedal depressed, set the fuel control dial to the MAX position. 7) Gradually release the decelerator pedal and raise the engine speed. 8) Test the torque converter lock-up clutch pressure when the engine speed reaches near the high idle. a The test cannot be made at a low engine speed. 9) After finishing measuring, remove all test tools in order to return the machine status as it was.
2) Start the engine, set the machine monitor to "Adjusting" function of the service mode, and disengage both steering clutches. q Adjustment ID: 5535 (Both steering clutch disengage mode) a For the operating method, see "Special functions of machine monitor (EMMS)" section.
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DRAFT Power train Testing power train oil pressure
5. Testing torque converter stator clutch pressure (SC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (4). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
2) Start the engine and set the PCCS lever in the fully neutral position. a The test may be performed with the parking brake lever in the LOCK position. 3) Test the torque converter stator clutch pressure with the engine at low idle and high idle.
4) After finishing measuring, remove all test tools in order to return the machine status as it was.
D375A-6 (03)
6. Testing transmission main relief pressure (T/M) [Testing using oil pressure gauge] 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (5). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
2) Start the engine and set the PCCS lever in the fully neutral position. a The test may be performed with the parking brake lever in the LOCK position. 3) Test the transmission main relief pressure with the engine at low idle and high idle.
4) After finishing measuring, remove all test tools in order to return the machine status as it was.
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DRAFT Power train Testing power train oil pressure
[Checking with machine monitor (for VHMS specification)] 1) Turn the starting switch to the ON position and switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)".
2) Start the engine and set the PCCS lever in the fully neutral position. a The test may be performed with the parking brake lever in the LOCK position. 3) Test the transmission main relief pressure with the engine at low idle and high idle.
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DRAFT Power train Testing power train oil pressure
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DRAFT Power train Testing power train oil pressure
7. Testing transmission F clutch pressure (FWD) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup plug (6). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
7) After finishing measuring, remove all test tools in order to return the machine status as it was.
2) Start the engine and set the parking brake lever in the FREE position. 3) Switch the machine monitor to the "Adjustment" function display of the service mode and disengage both steering clutches. q Adjustment ID: 5535 (Disengage mode for both steering clutches) a For the operating method, see "Special functions of machine monitor (EMMS)".
4) Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Manual gear shift q Preset range: F1-R1 5) While pressing the brake pedal, set the direction of PCCS lever in the forward position. a Keep the steering unit in neutral. a Check that [F1] is displayed in the gear speed display section. 6) Check the F clutch pressure with the engine at low and high idle. 30-52 30-44
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DRAFT Power train Testing power train oil pressure
8. Testing transmission R clutch pressure (REV) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to nipple (7) for checking oil pressure. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
6) Check the R clutch pressure with the engine at low and high idle.
7) After finishing measuring, remove all test tools in order to return the machine status as it was.
2) Start the engine and set the parking brake lever in the FREE position. 3) Switch the machine monitor to the "Adjustment" function display of the service mode and disengage both steering clutches. q Adjustment ID: 5535 (Disengage mode for both steering clutches) a For the operating method, see "Special functions of machine monitor (EMMS)".
4) Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Manual gear shift q Preset range: F1-R1 5) While pressing the brake pedal, set the PCCS lever in the backward position. a Keep the steering unit in neutral. a Check that [R1] is displayed in the gear speed display section.
D375A-6 (03)
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DRAFT Power train Testing power train oil pressure
9. Testing transmission 1st clutch pressure (1st) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to nipple (8) for checking oil pressure. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
6) Check the 1st clutch pressure with the engine at low and high idle.
7) After finishing measuring, remove all test tools in order to return the machine status as it was.
2) Start the engine and set the parking brake lever in the FREE position. 3) Switch the machine monitor to the "Adjustment" function display of the service mode and disengage both steering clutches. q Adjustment ID: 5535 (Disengage mode for both steering clutches) a For the operating method, see "Special functions of machine monitor (EMMS)".
4) Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Manual gear shift q Preset range: F1-R1 5) While pressing the brake pedal, set the direction of PCCS lever in the forward position. a Keep the steering unit in neutral. a Check that [F1] is displayed in the gear speed display section.
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DRAFT Power train Testing power train oil pressure
10. Testing transmission 2nd clutch pressure (2nd) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to nipple (9) for checking oil pressure. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
6) Check the 2nd clutch pressure with the engine at low and high idle.
7) After finishing measuring, remove all test tools in order to return the machine status as it was.
2) Start the engine and set the parking brake lever in the FREE position. 3) Switch the machine monitor to the "Adjustment" function display of the service mode and disengage both steering clutches. q Adjustment ID: 5535 (Disengage mode for both steering clutches) a For the operating method, see "Special functions of machine monitor (EMMS)".
4) Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Manual gear shift q Preset range: F1-R1 5) While pressing the brake pedal, set the direction of PCCS lever in the forward position and shift the gear to 2nd using the shiftup switch. a Keep the steering unit in neutral. a Check that [F2] is displayed in the gear speed display section. D375A-6 (03)
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DRAFT Power train Testing power train oil pressure
11. Testing transmission 3rd clutch pressure (3rd) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to nipple (10) for checking oil pressure. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
6) Check the 3rd clutch pressure with the engine at low and high idle.
7) After finishing measuring, remove all test tools in order to return the machine status as it was.
2) Start the engine and set the parking brake lever in the FREE position. 3) Switch the machine monitor to the "Adjustment" function display of the service mode and disengage both steering clutches. q Adjustment ID: 5535 (Disengage mode for both steering clutches) a For the operating method, see "Special functions of machine monitor (EMMS)".
4) Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Manual gear shift q Preset range: F1-R1 5) While pressing the brake pedal, set the direction of PCCS lever in the forward position and shift the gear to 3rd using the shiftup switch. a Keep the steering unit in neutral. a Check that [F3] is displayed in the gear speed display section. 30-56 30-48
D375A-6 (03)
DRAFT Power train Testing power train oil pressure
12. Testing left steering clutch pressure (LC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (11). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
13. Testing left steering brake pressure (LB) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (12). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
2) Start the engine and set the parking brake lever in the FREE position. 3) Operate the PCCS lever steering fully to the left. a Set the direction to the neutral position. 4) Test the left steering clutch pressure with the engine at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever steering is returned to neutral.
2) Start the engine and set the parking brake lever in the FREE position. 3) Test the left steering brake pressure with the engine at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever steering is operated fully to the left. a Check that the oil pressure becomes 0 when the brake pedal is depressed fully or the parking brake lever is operated to the LOCK position.
5) After finishing measuring, remove all test tools in order to return the machine status as it was.
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4) After finishing measuring, remove all test tools in order to return the machine status as it was.
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DRAFT Power train Testing power train oil pressure
14. Testing right steering clutch pressure (RC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (13). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
15. Testing right steering brake pressure (RB) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure test nipple (14). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
2) Start the engine and set the parking brake lever in the FREE position. 3) Operate the PCCS lever steering fully to the right. a Set the direction to the neutral position. 4) Test the right steering clutch pressure with the engine at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever steering is returned to neutral.
2) Start the engine and set the parking brake lever in the FREE position. 3) Test the right steering brake pressure with the engine at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever steering is operated fully to the right. a Check that the oil pressure becomes 0 when the brake pedal is depressed fully or the parking brake lever is operated to the LOCK position.
5) After finishing measuring, remove all test tools in order to return the machine status as it was.
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4) After finishing measuring, remove all test tools in order to return the machine status as it was.
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DRAFT Power train Testing power train oil pressure
16. Testing transmission lubrication pressure 1) Connect gauge K2 to oil pressure test nipple (15).
17. Testing of output pressure of sudden stop prevention valve (Sudden stop prevention valve operation mode) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipples (12) and (14). a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}. q (12): For steering left brake
2) Start the engine and test the transmission lubricating pressure with the engine at high idle.
q
(14): For steering right brake
3) After finishing measuring, remove all test tools in order to return the machine status as it was. 2) Start the engine, switch the machine monitor to "Adjusting" function of the service mode and deactivate the sudden stop prevention valve and right and left brake ECMV. q Adjustment ID: 9996 (Sudden stop prevention valve operation mode) a For the operating method, see "Special functions of machine monitor (EMMS)" section.
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DRAFT Power train Testing power train oil pressure
3) Set the parking brake lever in the FREE position and set the PCCS lever in the ALL NEUTRAL position. 4) Test the output pressure of the sudden stop prevention valve with the engine at low idle. a If the output pressure of the sudden stop prevention valve is as follows, it is normal. 2 q 1.13 – 1.57 MPa {11.5 – 16.0 kg/cm }
5) After finishing measuring, remove all test tools in order to return the machine status as it was.
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DRAFT Power train Testing power train oil pressure
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DRAFT Power train Adjusting transmission output speed sensor
Adjusting transmission output speed sensor k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
6. Hold sensor (2) and tighten locknut (4). a Take care that the speed sensor is not dragged. 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
1. Remove cover (1) under the fuel tank.
7. After finishing adjustment, return the removed parts. 2. Remove transmission output speed sensor (2). a Before adjusting, remove the sensor, and check that the tip of the sensor is not scratched and that there are no iron particles sticking to it.
8. Start the engine, set the machine monitor to "Adjusting" function of the service mode, and disengage both steering clutches. q Adjustment ID: 5535 (Disengage mode for both steering clutches) a For the operating method, see "Special functions of machine monitor (EMMS)". a Set the working mode to P mode and set the gear shift mode to Manual. 9. Operate the PCCS lever in the direction of forward or reverse position, and check the transmission speed is displayed normally.
3. Look through the sensor mounting hole and check that a tooth tip of gear (3) is at the center of the hole. a If the tooth tip is not at the center of the hole, adjust it by starting the engine and moving the machine forward or in reverse. 4. Screw in sensor (2) until its tip lightly touches the tooth tip of gear (3). 2 Threads of sensor: Gasket sealant (LG-5) 5. Return sensor (2) by 1/2 - 1 turn. a Clearance (a) between the sensor tip and gear tooth tip becomes 0.75 – 1.50 mm. 30-52
D375A-6 (01)
DRAFT Power train Simple test procedure for brake performance
Simple test procedure for brake performance k
k
Since the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Carry out the simple performance test of the brake under the following condition. q Power train oil temperature: Within operating range 1. Set the blade and ripper in the travel posture on a level place.
2. Start the engine and set the parking brake lever in the FREE position. 3. Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gear shift mode: Manual gear shift q Preset range: F2-R2 4. While pressing the brake pedal, set the direction of PCCS lever in the forward position. k If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. a Check that [F2] is displayed in the gear speed display section. a Keep the steering unit in neutral. 5. Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. 6. Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idle speed.
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DRAFT Power train Adjusting brake pedal and parking brake lever
Adjusting brake pedal and parking brake lever Adjusting brake pedal
Adjusting parking brake lever
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D375A-6 (01)
DRAFT Power train Adjusting brake pedal and parking brake lever
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. a When adjusting the travel of the brake pedal, disconnect the brake rod from the pedal. q Pedal stroke a: 75 mm q Stopper bolt installation dimension b: 42 mm 2. Adjusting installed length of brake rod 1) Keep the parking brake lever in the release position. 2) Install brake rod (3) and release brake pedal (1) (do not depress it). 3) 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. a The locknut of the turnbuckle has a left-handed thread (reverse thread) at the brake pedal end. q Stopper bolt installation dimension c: 32 mm q Stopper bolt installation dimension d: 14 mm 3 Locknut: 34.3 – 58.8 Nm {3.5 – 6.0 kgm} 4) Check that clearance x between yoke (12) and pin (13) is approximately 1 mm.
5. Checking brake oil pressure 1) Start the engine and switch the machine monitor to the "Adjustment" function display of the service mode. q Adjustment ID: 9995 (Control brake release mode) a For the operating method, see "Special functions of machine monitor (EMMS)". a The function of this mode is used to cancel electrical control of brake oil pressure and makes it possible to check the brake oil pressure mechanically. a Set the working mode to P mode and set the gear shift mode to Manual.
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. q Spool travel e: 19 – 23 mm 4. Adjusting brake potentiometer Turn the starting switch ON and set the machine monitor to Adjusting function of the service mode. q Adjustment ID: 0005 (Brake pedal potentiometer initial correction) a For the operating method, see "Special functions of machine monitor (EMMS)". a Set the working mode to P mode and set the gear shift mode to Manual.
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2) With the parking brake lever in the FREE position, depress the brake pedal fully and check that the brake oil pressure on both sides of left and right becomes 0.98 MPa {10 kg/cm2} or less. a For details of the method of testing the brake oil pressure, see "Testing power train oil pressure". a When the brake pedal is depressed, if the brake oil pressure does not drop below 0.98 MPa {10 kg/cm2}, adjust its linkage again.
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DRAFT Power train Adjusting brake pedal and parking brake lever
a If the linkage is adjusted normally, the brake pedal potentiometer may be adjusted wrongly or broken. (Adjust the potentiometer only when necessary.)
a Set the working mode to P mode and set the gear shift mode to Manual.
Adjusting parking brake lever side 1. Assembly and installation of lever assembly 1) Assemble lever assembly (7) and adjust the operation of limit switch (8). a When assembling the lever assembly, disconnect the parking cable from the lever. q Lever raised: OFF, lever lowered: ON q Operation stroke of limit switch: 3 mm 2) Install lever assembly (7). 2. Adjusting installed length of parking brake cable 1) Connect parking brake cable (9) to the lever and valve, then adjust installed dimensions f f and g. q Cable installation dimension (f): 112.8 mm q Cable installation dimension (g): 114.0 mm 2) Operate parking brake lever (10) between the free and lock positions, and adjust rod end (4) so that spool stroke h of brake valve (11) is normal. q Spool stroke (h): 23.0 mm 3) Check that clearance y between rod end (11) and pin (14) is approximately 0.5 mm. a When tightening the lock nuts of brake yoke (12) and rod end (11), exercise care so that the yoke and rod end will not interfere with pins (13) and (14). q The operating effort of the parking brake lever may increase.
2) Check that the limit switch signal is input normally when parking brake lever (10) is set in the FREE position and LOCK position. q FREE position: Travel lock NC OFF, Travel lock NO ON q LOCK position: Travel lock NC ON, Travel lock NO OFF
3. 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 testing the brake oil pressure, see "Testing power train oil pressure". 2 q LOCK position: 0 MPa {0 kg/cm }, FREE position: Specified pressure 4. Checking limit switch 1) Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. q Monitoring code: 40905 (P/T SW Input 3) a For the operating method, see "Special functions of machine monitor (EMMS)". 30-66 30-56
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Power train Adjusting position of pccs lever console
Adjusting position of pccs lever console
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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). a If it is not parallel, adjust installed dimension (a) of rod (3). q Standard installed dimension (a): 179 mm (Machine with operator's seat isolator: 178.5 mm) a The locknut at the rear of the turnbuckle has a left-handed thread (reverse thread)
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Power train Emergency escape method when there is failure in power train
Emergency escape method when there is failure in power train 30-67 a Tools for emergency escape Symbol L
Part No. 19M-06-32820 1 7824-66-6430 195-06-71220 2 790-190-1601
Part name Switch assembly Resistor Wiring harness Pump assembly
1. Emergency escape method using switch box (Use L1) a If the machine cannot be moved because of a trouble in the electrical system of the power train control unit (travel direction, gear range, steering), retreive the situation according to the following procedure. a 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 [1] and resistor [2] to wiring harness [3] of emergency escape device L1. k Resistor [2] controls the drive voltage of the solenoid, so connect it before connecting the wiring harness to the machine. k In order to prevent mistaken actuation, set all the gear speed switches of switch assembly [1] 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 [3] to PL1 connector (1) and PL2 connector (2). q PL1 connector (1): Connect to male and female ends
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PL2 connector (2): Connect to male end a The female end of connector PL2 remains disconnected, so cover it with vinyl. a Insert switch assembly [1] inside the cab through the cab window.
q
3) Disconnect the neutral safety relay (NSF) inside the fuse room, then connect pin [3] and pin [5] of the connector at the wiring harness end directly. k With this method, if the engine starts, the neutral safety relay function will not work, so before starting the engine, set the parking brake lever to the LOCK position and all the PCCS lever functions to the neutral position. k 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.
4) Start the engine and set the parking brake lever in the FREE position.
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Power train Emergency escape method when there is failure in power train
5) Operate switch assembly [1] and move the machine to a safe place. a The gear speed switch has an electric circuit that gives priority to operation of the low speed switch. k Take care that the L.H. and R.H. steering directions are opposite when reverse.
2. Emergency escape method with brake releasing device (Use L2) a If the engine cannot be started and the parking brake cannot be released, carry out the emergency escape according to the following procedure. 1) Assemble pump assembly L2.
2) Install volume pump [4] of pump assembly L2 to the outside of the operator’s cab.
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3) Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller solenoid valve.
4) Connect end hose of pump assembly L2 to the supply hose. (Use the nipple of face seal type.) a Block the solenoid valve side with plug. Plug: 02789-00315 5) Turn the starting switch ON and set the parking brake lever in the FREE position. 6) Operate the vacuum pump to raise the brake releasing oil pressure to the initial pressure. 2 q Initial pressure: 2.74 MPa {28 kg/cm } a Since an accumulator is installed in the circuit, the handle must be operated 30 50 times to raise the oil pressure. a If the oil pressure does not rise above a certain level, the relief valve may be set to low pressure. In this case, adjust the set pressure of the relief valve. 7) Tow the machine to a safe place. a The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again approximately one minute after. Therefore, work quickly. a When the brake release oil pressure drops to about 1.57 MPa {16 kg/cm2}, the brake is applied. In such a case, increase the brake release oil pressure to its initial level by operating the vacuum pump again.
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DRAFT Undercarriage and frame Inspecting wear of sprocket
Undercarriage and frame Inspecting wear of sprocket a Use the "Full-scale dimensions drawing of sprocket profile" in "Sprocket" in "maintenance standard" as a gauge for testing wear of the sprocket. a Make a copy of the "Full-scale dimensions drawing of sprocket profile" on a transparent paper or sheet and apply it directly to the sprocket to see if the sprocket can be used.
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D375A-6 (01)
DRAFT Undercarriage and frame Testing and adjusting track shoe tension
Testing and adjusting track shoe tension Testing 1. Drive the machine forward and stop on a horizontal surface. a Stop the machine without using the brake. 2. Put straight steel rod (1) on top of the track between the idler and front carrier roller, and test clearance (a) from the bottom of the steel rod to the track shoe grouser. q Standard clearance (a): 20 – 30 mm
2. If tension is too high: Loosen plug (3) and release some of the grease. k 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} 3. If tension is too low: Pump in grease through grease fitting (4). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly. a After finishing adjustment, check the tension again according to the above procedure.
Adjustment a If the track shoe tension is abnormal, adjust it according to the following procedure. 1. Remove cover (2).
D375A-6 (01)
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DRAFT Hydraulic system Measuring and adjusting work equipment oil pressure
Hydraulic system Measuring and adjusting work equipment oil pressure a Measuring and adjusting instruments for work equipment oil pressure Symbol 1 M 2
Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023
Part name Hydraulic tester Digital hydraulic tester Nipple (10 × 1.25 mm) O-ring
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Open the cover of the main control valve (both sides). Testing a Measure the work equipment oil pressure under the following condition. q Hydraulic oil temperature: 45 – 55°C q Working mode: P-mode q Gear shift mode: Manual a The unload pressure, work equipment oil pressure can be checked with the monitoring function of the service mode of the machine monitor (See 3).
3) Run the engine at high idle and set the blade control lever and ripper control lever in neutral and measure the unload pressure. a The work equipment lock lever may be set in the LOCK position. k Do not operate the work equipment when analog oil pressure gauge (6 MPa {60 kg/cm2}) is mounted. (This is required to protect the gauge from being damaged.)
1. Measuring unload pressure 1) Remove P oil pressure pickup plug (1) from the control valve.
4) After finishing measuring, remove all test tools in order to return the machine status as it was. 2. Measuring work equipment oil pressure 1) Remove P oil pressure pickup plug (1) and LS oil pressure pickup plug (2) from the control valve. 2) Mount nipple M2, and connect it to oil pressure gauge [1] of hydraulic tester M1. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
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DRAFT Hydraulic system Measuring and adjusting work equipment oil pressure
2) Mount nipple M2, and connect it to oil pressure gauge [1] of hydraulic tester M1. a When using analog oil pressure gauges, use ones of 40 MPa {400 kg/cm2}.
5) After finishing measuring, remove all test tools in order to return the machine status as it was. 3. Testing using machine monitor (Pm clinic) 1) Turn the starting switch to the ON position and switch the machine monitor to the "Pm clinic" function display of the service mode. a For the operating method, see "Special functions of machine monitor (EMMS)". a The VHMS specification is shown as an example in the figure.
3) Start the engine and set the work equipment lock lever in the free position. 4) Run the engine at high idle, operate the blade control lever and ripper control lever to relieve each cylinder at a stroke end, and measure the work equipment relief pressure and work equipment LS relief pressure. a The work equipment relief oil pressure is displayed at P stamp side (plug-1 side), but work equipment LS relief oil pressure is displayed at LS stamp side (plug-2 side).
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2) Start the engine and measure each oil pressure. a The measuring condition of each oil pressure is the same with 1 – 2 above. a Hydraulic pressure displayed at P stamp side of control valve can be measured, but hydraulic pressure at LS stamp side (work equipment LS relief pressure) cannot be measured.
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DRAFT Hydraulic system Measuring and adjusting work equipment oil pressure
Adjustment 1. Adjusting unload pressure a The unload pressure cannot be adjusted.
4) After finishing measurement, check the work equipment oil pressure according to the above measuring method.
2. Adjusting work equipment oil pressure a If the work equipment oil pressure is abnormal, adjust it with work equipment LS relief valve (3) according to the following procedure. a This figure shows a dual tilt model, 6-spool valve. (The single tilt model has a 5-spool valve.)
1) While fixing adjustment nut (4), loosen locknut (5). 2) Adjust the pressure by rotating adjustment nut (4). a If the adjustment nut is q rotated to the right, the pressure is heightened. q rotated to the left, the pressure is lowered. a Quantity of adjustment per turn of adjustment nut: Approx. 19.6 MPa {200 kg/cm2} 3) While fixing adjustment nut (4), tighten locknut (5). 3 Locknut: 39 – 49 Nm {4 – 5 kgm}
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DRAFT Hydraulic system Testing control circuit main pressure
Testing control circuit main pressure Tools for testing control circuit main pressure Symbol M
Part No. Part name 799 - 101 - 5002 Hydraulic tester 1 790 - 261 - 1204 Digital hydraulic tester
4. After finishing measurement, remove the measuring tools and return the removed parts. Adjusting a The self pressure reducing valve cannot be adjusted.
Testing k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
a Test the control circuit main pressure under the following conditions. q Hydraulic oil temperature: 45 – 55°C
1. Open the cover of the main control valve (both sides). 2. Connect oil pressure gauge [1] of hydraulic tester M1. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}. a Inspection nipple (1) is equipped.
3. Start the engine, run it at high idle, and test the oil pressure when the blade lever and ripper lever are placed at the HOLD position.
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DRAFT Hydraulic system Testing PPC valve output pressure
Testing PPC valve output pressure a Tools for testing PPC valve output pressure Symbol N k
1
Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
a Check that the control circuit oil pressure is correct before testing the PPC valve output pressure. a Test the PPC valve output pressure under the following conditions. q Hydraulic oil temperature: 45 – 55°C
4. Start the engine and set the work equipment lock lever in the Free position. 5. Run the engine at high idle, operate the control lever of the circuit to be tested, and test the oil pressure. a Operate the control lever fully when testing. a For blade LOWER, operate to the FLOAT position. 6. After finishing measurement, remove the measuring tools and return the removed parts.
1. Open the cover of the main control valve (both sides). 2. Remove the oil pressure switch (1) of the circuit to be tested. a For details of the position to be tested, see the drawing on the next page.
3. Fit nipple [1] (R1/8) of hydraulic tester N1, then connect to oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 6 MPa {60 kg/cm2}.
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DRAFT Hydraulic system Testing PPC valve output pressure
A. Blade RAISE B. Blade TILT (Right) C. Blade LOWER D. Blade TILT (Left)
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E. Ripper TILT (In) F. Ripper RAISE G. Ripper TILT (Back) H. Ripper LOWER
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DRAFT Hydraulic system Adjusting play of PPC valve
Adjusting play of PPC valve a If there is excessive play at the tip of the ripper lever and blade lever, adjust the PPC valve as follows. a The diagram shows the PPC valve for the ripper. q Standard play (a): 1 - 6 mm at the position 400 mm away from lever rotation center (both to front and rear, and to left and right) q Standard play (b): 0.03 – 0.30 mm (full stroke) a Exchange the joint (4) when lever end play is longer than 24 mm at neutral position must be joint may have damaged. 1. Remove boot (1). 2. Loosen locknut (2) and rotate disc (3) to adjust the amount of play. a Do not move the pistons at this time. 3. Secure disc (3) in position and tighten locknut (2). 3 Lock nut: 69 – 88 Nm {7 – 9 kgm} 4. Apply grease (G2-LI) to sliding area of joint (4) and to contact area of disc and piston. 2 Sliding area of the joint: G2-LI 2 Contact area of the disc and piston: G2-LI 5. Install boot (1).
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DRAFT Hydraulic system Testing output pressure of ripper pin-puller solenoid valve
Testing output pressure of ripper pin-puller solenoid valve a Tools for testing output pressure of ripper pin-puller solenoid valve Symbol 1 P 2
Part No. Part name 799 - 101 - 5002 Hydraulic tester 790 - 261 - 1204 Digital type hydraulic tester Oil pressure pickup adapter 799 - 401 - 3200 (03 size)
k
Stop the machine on level ground, lower the work equipment completely to the ground, then set the parking brake lever and work equipment lock lever to the LOCK position. a Test the output pressure of the ripper pin puller solenoid valve under the following conditions. q Power train oil temperature: Within operating range
4. Start the engine, run at high idle, and test the oil pressure when the ripper pin-puller switch is actuated.
1. Disconnect pin-puller cylinder hoses (1) and (2).
2. Fit adapter P2, then connect the hoses again.
5. After completing the test remove the testing equipment and set to the original condition.
3. Fit nipple P1 of hydraulic tester [1], then connect oil pressure gauge [2]. a Use a 6 MPa {60 kg/cm2} oil pressure gauge.
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DRAFT Hydraulic system Checking location of cause of hydraulic drift of blade and ripper
Checking location of cause of hydraulic drift of blade and ripper a 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. a The blade lift cylinder has a built-in piston valve, so do not operate the cylinder to the end of the stroke.
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.
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2. Operate the control lever in the direction to extend the cylinder rod, and check the movement of the cylinder. q If the downward movement becomes faster, the packing is defective. q If there is no change, the control valve is defective. a If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to charge the accumulator. [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.)
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DRAFT Hydraulic system Testing leakage inside work equipment cylinder
Testing leakage inside work equipment cylinder a Tools for testing leakage from work equipment cylinder Symbol L
Part No. Commercially available
Part name Measuring cylinder
a Test the oil leakage inside the hydraulic cylinder under the following conditions. q Hydraulic oil temperature: 45 – 55°C a The blade lift cylinder has a built-in piston valve, so the internal leakage cannot be tested.
3. Run the engine at high idle and apply the relief pressure to the bottom end of the cylinder. q Blade tilt cylinder: Extract the cylinder to be tested q Ripper lift cylinder: Lower ripper q Ripper tilt cylinder: Tilt ripper to front 4. Wait for 30 seconds, then test the amount of leakage over the next 1 minute. 5. After finishing measurement, return the removed parts.
1. Fully extend the cylinder to be tested, and set to the test posture. 1) Blade tilt cylinder Extract the cylinder to be tested to the stroke end. 2) Ripper lift cylinder Pull out the shank pin and lower the ripper to the end. 3) Ripper tilt cylinder Tilt the ripper fully to the front. 2. Disconnect hose on the cylinder head side and block the hose side with a plug. a Remove the hose cover of the blade tilt cylinder. k Take care not to disconnect the hose on the bottom side.
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DRAFT Hydraulic system Releasing remaining pressure in work equipment cylinders
Releasing remaining pressure in work equipment cylinders
Bleeding air from work equipment cylinders
a When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure in the circuit according to the following procedure.
a If the work equipment cylinder was removed and installed or its piping was disconnected and connected, bleed air from its circuit according to the following procedure.
1. Start the engine, and lower the blade and ripper to the ground.
1. Run the engine at low idle for about five minutes.
2. Stop the engine. 3. Loosen the hydraulic tank cap gradually to release the residual pressure in the tank. 4. Set the work equipment lock lever in the FREE position, and move the work equipment control lever (for blade and ripper) front, back, left and right. a After the levers are operated 2 – 3 times, the residual pressure in the accumulator is fully released.
2. Running the engine at low idle, extend and retract the cylinder to be bled 4 – 5 times. a Stop the piston rod about 100 mm before the end of the stroke. Never operate it to the relief position. 3. Running the engine at high idle and carry out the operation in 2. 4. Running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
5. Fully close the oil filler cap of hydraulic tank.
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DRAFT Hydraulic system Adjusting ripper lever position
Adjusting ripper lever position
a Use the following procedure to adjust the ripper lever to the optimum position. a 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. 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. 5) Loosen nut (3). 6) Turn knob (4) 180 °. 7) Tighten nut (3) to hold knob (4) in position.
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DRAFT Work equipment Adjusting work equipment lock lever
Work equipment Adjusting work equipment lock lever
k
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Tighten the locknut of the rod securely and bend the cotter pin securely. a Remove the control valve cover.
a For the operating method, see "Special functions of machine monitor (EMMS)". a Set the working mode to P mode and set the gear shift mode to Manual.
1. Set work equipment lock lever (1) in the LOCK position. 2. Set and install limit switch (2) to sliding surface (a) of lever (3). a Just set the roller of the limit switch to the sliding surface. Do not move it. 3. Set work equipment lock lever (1) in the FREE position and check that limit switch (2) operates normally. q Stroke of limit switch: 2.5 – 3 mm 4. Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. a Monitoring code: 70300 (Blade Sw Input)
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5. Check that the limit switch signal is input normally when work equipment lock lever (1) is set in the FREE position and LOCK position. q FREE position: Work equipment lock NC OFF, Work equipment lock NO ON q LOCK position: Work equipment lock NC ON, Work equipment lock NO OFF D375A-6 (03)
DRAFT Work equipment Adjusting blade
Adjusting blade
a 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) and (2). Adjustment location 1 2
Adjusted clearance
Standard clearance
Standard shim thickness
a b
See Note
4.5 mm
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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DRAFT Work equipment Adjusting blade
2) Use shims to adjust the clearance at trunnion portion (3). AdjustAdjusted ment locacleartion ance 3
c
Standard clearance
Standard shim thickness
1.56 ± 0.65 mm Total clearance
12 mm
2. Adjusting blade tilt (Only single tilt specification machine) 1) Adjust installation dimension (d) of brace (4) with the handle. q Dimension (d) of installed brace: 1,587 mm 2) Test left and right tilt (e1) and (e2). [Semi-U dozer] q Right tilt (e1): Approx. 770 mm q Left tilt (e2): Approx. 770 mm [Full-U dozer] q Right tilt (el): Approx. 840 mm q Left tilt (el): Approx. 840 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. q (e1) > (e2): Carry out fine adjustment to make installation dimension d longer q (e1) < (e2): Carry out fine adjustment to make installation dimension d shorter
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DRAFT Cab and its attachments Testing and adjusting operator's cab
Cab and its attachments Testing and adjusting operator's cab Check after installing cab assembly 1. Testing pressure in cab a Test the operator's cab according to the following conditions. q Engine speed: High idle q Blower speed: High (Hi) q Fresh/Recirculation switch: Fresh air position 1) Start the engine and switch the machine monitor to "Adjustment" function display of the service mode. q Adjustment code: 1005 (Fan 100% mode) a For the operating method, see "Special functions of machine monitor (EMMS)". a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the state of the machine.
a Secure the end of hose [1] to the operator's seat with tape.
6) Seal the mounting holes of lock lever (1) with tape (2). 2) Prepare a transparent vinyl hose. q Outside diameter: 10 mm, Length: 3000 mm 3) Secure the inside end of the hose to the top of the back seat with a tape. 4) Pour coolant in the hose up to about half. 5) Remove slide glass lever lock (1) and insert the other end of vinyl hose [1].
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DRAFT Cab and its attachments Testing and adjusting operator's cab
7) Set the coolant level in the vinyl hose out of the cab to that in the cab. 8) Run the engine at high idle and test coolant level difference (c). a [a] side: Inside of cab (Pressurized) [b] side: Out of cab (Atmospheric pressure) q Criteria Measuring value (c) X 8 mm {0.08 kPa {8 mmH2O}) a If the tested value is lower than the standard value, check the following. q Plug of control box q Clogging of air filters (recirculation and fresh air filters) in the air conditioner q Seals between the cab and the floor frame
2. Check of sealing performance 1) Close the all openings of the cab. 2) Throw water onto the area near the cab (hatched area) at a rate of about 19 l/min for 10 minutes. q At this time, it is not necessary to splash pressurized coolant. 3) Splash coolant horizontally from a hose over sealing surface (3). 4) Check around the dashboard carefully. a If coolant leaks, caulk the leaking part and check again.
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DRAFT Cab and its attachments Testing and adjusting operator's cab
3. Testing and adjusting door lock Close the door and check the relationship between the operator's cab and door. If there is any fault, repair it. 1) Check the installed height of damper rubber (4). (Check both sides, 4 pieces on each) q Stick adhesive tape [1] to the contact face of damper rubber (4), open and close the door 2 – 3 times. Then, check the contact face of adhesive tape [1] against the operator's cab. Normal: When the door is closed, the damper rubbers come in contact lightly. Abnormal: When the door is closed, the damper rubbers do not come in contact or come in contact so strongly that the adhesive tapes are removed.
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2) Check the relationship between the door latch and striker (on both sides). q Close door (5) and check the engaging condition of latch (6) and striker (7). q Normal: Deviation (a) is 0.5 mm or less. a Check deviation (a) between latch center (y) and striker center (x) from (A) direction.
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DRAFT Cab and its attachments Testing and adjusting operator's cab
3) Adjusting height of damper rubber q Loosen the mounting bolt of damper rubber (4). q The shim can be removed or installed without removing the mounting bolt. q Increase or decrease the number of shim (8) installed at the bottom of damper rubber (4) to properly adjust the height of damper rubber (4).
a Open the door and check the engaging condition of the open latch and striker. q Check that the claw of open latch (9) does not ride over the bent part of striker (10). q Check that the body of open latch (9) does not interfere with striker (10). 4) Adjusting height of latch and striker 1] Temporarily tighten the mounting bolt of striker (7), open and close the door 2 - 3 times to align latch (6) and striker (7) to each other. 2] Check the engaging condition of latch (6) and striker (7). 3] Securely tighten the mounting bolt of striker (7). 4] Open and close the door and check that it is locked and unlocked smoothly. If the door is not locked and unlocked smoothly (if the knob is heavy), perform the adjustment procedure from the first. a Operating effort of door unlock lever: 68.6 ± 19.6 N {7 ± 2 kg} 5) Apply grease (G2-LI) to latch (6). a If latch (6) is not sufficiently greased, the knob becomes heavy. 4. Testing open lock Lock the door open and check the relationship between the operator cab and door. If there is any fault, repair it. 1) Check of condition 1] Check the relationship between open lock latch (9) and striker (10) from the direction of (B).
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2] Check the installed height of the stopper rubbers. (Check both sides, 2 pieces on each.) q Lock the door open and shake it in the forward and reverse directions to see if it has any play. q Check that the operating effort of unlock lever is not heavy.
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DRAFT Cab and its attachments Testing and adjusting operator's cab
2) Adjusting 1] Adjusting latch and striker q Loosen the adjustment nut of striker (10) and adjust striker (10) so that it will not interfere with or ride over open latch (9), then tighten the nut. q If interference cannot be eliminated by adjusting striker (10), loosen the mounting bolt of open latch (9) and adjust open latch (9). q Push the door. If it moves until clearance (b) between striker (10) and open latch (9) is reduced to "0", loosen mounting nut (12) of stopper rubber (11) and extend stopper rubber (11) in the pushing direction to adjust.
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2] Adjusting installed height of stopper rubber 1] Loosen locknut (12) of stopper rubber (11). 2] If there is any play, adjust stopper rubber (11) until dimension (c) is as follows. a If the door is not locked easily or the unlock lever is heavy, return stopper rubber (11) in the range that the door does not have any play. q Dimension (c) of stopper rubber above cab: 35 ± 0.5 mm q Dimension (c) of stopper rubber under cab: 32 ± 0.5 mm q Operating effort of door unlock lever: 68.6 ± 19.6 Nm {7 ± 2 kgm} 3] After adjusting, tighten locknut (12).
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Cab and its attachments Testing and adjusting operator's seat isolator
Testing and adjusting operator's seat isolator a Machine with operator's seat isolator
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3) Stand backrest (4) of the operator's seat upright.
1. Breakage of rubber q Criterion: When the operator's seat is pressed with the hand, it must not touch the stopper of operator's seat isolator. a When the criterion is not satisfied. q Remove and disassemble the operator's seat isolator and check the rubber for breakage. q If the rubber is broken, replace the operator's seat isolator assembly. 1) Pull slide (1) and move the operator's seat to the forward end.
2) Pull turning lever (2) and rotate turntable (3) by 13 degrees. 4) Open window (5) on the left side of the operator's cab.
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Cab and its attachments Testing and adjusting operator's seat isolator
5) Press the seat surface through the window.
2. Oil leakage from damper q Criterion: No oil leakage from damper. a When the criterion is not satisfied. q Replace the operator's seat isolator assembly.
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1) Remove bolts (7) of front cover (6) of the operator's seat and remove the front cover.
2) Check damper (8) for oil leakage.
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Cab and its attachments Testing and adjusting operator's seat isolator
3. Breakage of stopper rubber q Criterion: The stopper must not come off. a When the criterion is not satisfied. q Replace the operator's seat isolator assembly. 1) Put your feet on foot rest (9) and brace your legs.
2) Check that stopper (10) touches stopper rubber (11) and does not the steel portion.
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Cab and its attachments Testing and adjusting operator's seat isolator
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Electrial system Special functions of machine monitor (EMMS)
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Upper section of machine monitor (Display section)
(a): Multi-display a The figure shows an example of display of symbols and gauges in the ordinary display mode (The contents of display depend on the condition of the machine and operating method). a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section)
[1]: Numeral 1 input switch/Operation mode selector switch [2]: Numeral 2 input switch/Gearshift mode selector switch [3]: Numeral 3 input switch/Customize switch [4]: Numeral 4 input switch/Buzzer cancel switch [5]: Numeral 5 input switch [6]: Numeral 6 input switch/Customize memory switch [7]: Numeral 7 input switch [8]: Numeral 8 input switch [9]: Numeral 9 input switch [0]: Numeral 0 input switch Switch having no numerals: Unused a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multi-display (a).
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DRAFT Electrial system Special functions of machine monitor (EMMS)
t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
A
Display of KOMATSU logo
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A
Display of check before starting
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A
Display of warning after check before starting
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A A A A B
Display of ending of maintenance interval Display of check of preset Display of ordinary screen Display of end screen Selection of operation mode
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B
Selection of gearshift mode
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B B B
Customizing operation Operation of customize memory Operation to cancel alarm buzzer Selection of dual tilt (Dual tilt specification)
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B B B B B C C
D D D
Operation to display camera mode (if camera is installed) Operation to display clock and service Check of maintenance information Setting and display of user mode Display of caution monitor Display function of action code and failure code O (Special operation) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing maintenance password
page 30-94 30-95
Service mode 01 Monitoring 02 Abnormality Record
Mechanical system "Abnormality Record"
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Electrical system "Abnormal30-101 ity Record"
03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit Setting of maintenance pass06 Default word Setting of camera Setting of ECO display 07 Adjustment
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08 PM clinic
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09 Cylinder Cut-Out
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10 No Injection 11 Fuel Consumption 12 Display of saved load 13 Setting of VHMS
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14 Snap shot (Machine equipped with VHMS)
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OSpecial operations
Operator mode (Outline)
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a Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch
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Electrical system Special functions of machine monitor (EMMS)
t Operator mode (Outline) 30-95 a Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see "the Structure, function and maintenance standard, or Operation and Maintenance Manual". a The following are the displays or functions of the operator mode explained in this section (including some items which need special operations).
30-95 Display of KOMATSU logo When starting switch is turned ON, KOMATSU logo is displayed for 2 seconds. After the KOMATSU logo is displayed for two seconds, the screen changes to "Password input (if password is set)" screen , or "Check before starting" screen.
Display pattern a b c d 1 1 1 1 2 2 2 2
Display of KOMATSU logo Display of check before starting Display of warning after check – – 3 – before starting Display of ending of maintenance – – – 3 interval Display of check of preset 3 3 4 4 Display of ordinary screen 4 4 5 5 Display of end screen Selection of operation mode Selection of gearshift mode Customizing operation Operation of customize memory Operation to cancel alarm buzzer Selection of dual tilt (Dual tilt specification) Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode Display of caution monitor Action code and failure code display function O (Special operation) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing maintenance password
Display of check before starting
When the screen changes to the check-before-starting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of preset". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.
a Display pattern of operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen depends on the setting and condition of the machine. a: When engine start lock is set effective b: When engine start lock is set ineffective c: When there is abnormal item in check-before-starting items d: When there is maintenance item which is not maintained after specified interval
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Display of warning after check before starting
Display of ending of maintenance interval
If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the radiator coolant level monitor (a) is warning of low radiator coolant level.
When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode.
Display of check of preset
If the check before starting is finished normally, the screen to check the preset (gear speed at start) is displayed for 2 seconds. a After display of check of preset is finished, the screen changes to "Display of ordinary screen".
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Display of ordinary screen
Selection of operation mode
If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a Power train oil temperature gauge (b) is displayed on the multi-gauge section (It is turned ON and OFF with the user mode function or [F2]). a ECO gauge (c) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).
While the ordinary screen is displayed, press the operation mode selector switch, and the operation mode monitor (a) changes. a Each time the switch is pressed, the operation mode changes between [P (Power)] and [E (Economy)].
Selection of gearshift mode
Display of end screen
When the starting switch is turned OFF, the end screen is displayed for 5 seconds.
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While the ordinary screen is displayed, press the gearshift mode selector switch, and the gearshift mode monitor (a) in the gear speed display section changes. a Each time the switch is pressed, the gearshift mode changes among [Automatic gearshift], [Manual gearshift] and [Shoe slip control] (Optional) in order. a If the automatic gearshift mode is selected, "AUTO" symbol (b) is displayed in the gear speed display section. If the manual gearshift mode or shoe slip control mode is selected, "MAN" symbol is displayed.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Customizing operation
Selection of dual tilt (Dual tilt specification)
While the ordinary screen is displayed, press the customize switch, and you can change the setting of the machine. a If the customize memory switch is operated while the above screen is displayed, up to 5 settings can be saved.
Select the blade dual tilt mode by changing the blade control lever knob switch while the ordinary screen is displayed. a If the dual tilt mode is turned ON, dual tilt mode monitor (a) is displayed. If the former is turned OFF, the latter is put out.
Operation of customize memory
Operation to display camera mode (if camera is installed)
While the ordinary screen is displayed, press the customize memory switch, and you can select the recorded setting of customization.
Operation to cancel alarm buzzer While the alarm buzzer is sounding, if the buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the buzzer cancel switch is pressed, the screen does not change.
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When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image. a Set the connection of the camera in the service mode.
a Up to 3 cameras can be connected. If the camera mode is selected, however, only the image of camera 1 is always displayed.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
a If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen. a When an error that there is a user code occurs in the camera mode, if the machine stops for 10 seconds, the screen changes to the ordinary screen and displays the error information. a When two or more cameras are connected, the image of one of them or the images of two of them can be displayed. a If 2-camera image display [F4] is selected, the image of camera 1 is displayed on the left side of the screen and the image of camera 2 is displayed on the right side. The image of camera 3 is displayed only singly. a If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1 second on the right and left screen. Operation to display clock and service meter
While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function. a Display of service meter
Check of maintenance information
While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.
a To reset the time left after finishing maintenance, more operations are necessary. (See "Maintenance history" section in service mode)
Setting and display of user mode
While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.
a Display of clock
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DRAFT Electrial system Special functions of machine monitor (EMMS)
a There are following items in the user menu. Utility screen select Multi gauge select Screen adjustment Time adjustment Language setting Reverse interlock selection mode Fan reverse mode Prelub skip
Display of action code and failure code
If an abnormality which displays an action code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a): Action code (3 digits) (b): Failure code (5 or 6 digits) (c): Telephone mark (d): Telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the fault history in the service mode, check the details in the service mode.
Display of caution monitor
If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor flashes at the left upper of the screen when the caution is generated.
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D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
a Remedies given by displayed action codes to operator to take are as follows (Excerpt from the Operation and Maintenance Manual). Action code
Method of indicating trouble
Examples of trouble
Remedy given to operator to take q
E01
q
Action code and failure code are displayed.
q q
Backup alarm does not sound. Fan speed is always at maximum.
q q
q q
E02 q
Action code and failure code are displayed. Alarm buzzer sounds.
q q
q q
E03
q q
Action code and failure code are displayed. Telephone No. is displayed (if set). Alarm buzzer sounds.
q q q q q
q
E04
q q
D375A-6 (03)
Action code and failure code are displayed. Telephone No. is displayed (if set). Alarm buzzer sounds.
q q q
Gear is not shifted up or down. Engine boost pressure is abnormal. Exhaust gas color is bad when temperature is low. Engine coolant temperature sensor is abnormal. Usable gear speeds are limited. Engine speed does not rise fully. Gear shift shock is large. Steering performance lowers. Braking shock is increased. Engine cannot be controlled. Machine cannot travel. Machine stops.
q
q q
q q
Although all or a part of automatic function stops, machine can be operated. Ask your Komatsu distributor for repair. If operator stops and restarts engine, machine can be operated without any functions being limited. However, operator has to pay attention. Ask your Komatsu distributor for repair.
Move machine to safe place. Ask your Komatsu distributor for repair.
Stop machine immediately. Ask your Komatsu distributor for repair.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Function of checking display of LCD (Liquid Crystal Display)
While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.
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Function of checking service meter
To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Function of changing maintenance password
When changing the maintenance password used for the maintenance setting function, follow these procedures.
q q
(If it has only 3 or less digits or has 7 or more digits, it is not accepted). [F5]: Delete input numeral/Return to ordinary screen [F6]: Confirm input numeral
1. While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4 ]+ [5]o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.
2. After the "Password" screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.
4. After the "New Password" screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.
5. If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully
3. After the New password input screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 – 6 digits D375A-6 (01)
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DRAFT Electrial system Special functions of machine monitor (EMMS)
t Service mode To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1. Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4]+[1]o[2]o[3] a This operation of the switches is accepted only while the ordinary screen is displayed.
a The items which can be selected in the service menu are as follows. 01 Monitoring Mechanical system "Abnormality Record" Electrical system "Abnormality Record" 03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Setting of unit Setting of maintenance pass06 Default word Setting of camera Setting of ECO display 07 Adjustment 08 PM clinic 09 Cylinder Cut-Out 10 No Injection 11 Fuel Consumption 12 Display of saved load 13 Setting of VHMS 14 Snap shot (Machine equipped with VHMS) 02 Abnormality Record
a Items with 2-digit codes are the menus displayed on the Service menu screen. The items on their right are the menus on the next hierarchy.
2. Selection of the service menu When the "Service Menu" screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].
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D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Monitoring
The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1. Selecting menu Select "01 Monitoring" on the "Service Menu" screen.
2. Selecting monitoring items After the "Monitoring selection menu screen" is displayed, select items to be monitored with the function switches or numeral input switches. q [F1]: Go to next page (screen) q [F2]: Go to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Delete input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.
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3. Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
4. Executing monitoring After the "Executing monitoring screen" is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be set to SI unit, metric unit, or inch unit with the Default function in the service mode.
6. Changing machine setting mode To change the setting of the "P/E Mode", "Fan Rev." mode, or "Working" mode during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to MPareturn to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished.
5. Holding monitoring information The monitoring information can be held and reset with the function switches. q [F3]: Reset holding q [F4]: Hold (displayed data) q [F5]: Return to monitoring selection menu screen
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Monitoring items list Code No. 50300 50301 50400 31619 31618 90600 90601 31628 32900 60100 60600 03001 03000
31521
50200 50201 31622 31616 31612 31613 31614 30100 31400 32601 32602 32603 32604 31642 90700 40001 60000 70200 31624 10000
40905
40906
31520
Monitoring item (displayed on screen) S/T Lever 1 Potentio S/T Lever 2 Potentio Brake Pedal Potentio Brake LH ECMV(F/B) Brake RH ECMV(F/B) S/T Clutch LH ECMV(F/B) S/T Clutch RH ECMV(F/B) S.S.P Solenoid Pitch Angle Pitch Angle Sensor BR Hold Relay Fuel Dial Throttle Fuel Dial Sensor S/T Clutch LH Fill Sw S/T Brake LH Fill Sw S/T Fill Sw Input S/T Clutch RH Fill Sw S/T Brake RH Fill Sw T/M Lever 1 Potentio T/M Lever 2 Potentio T/M Clutch F ECMV(F/B) T/M Clutch R ECMV(F/B) T/M Clutch 1st ECMV(F/B) T/M Clutch 2nd ECMV(F/B) T/M Clutch 3rd ECMV(F/B) T/C Oil Temperature T/M Out Speed T/C In Pressure T/C In Pressure Sensor T/C Out Pressure T/C Out Pressure Sensor L/U ECMV(F/B) S/C ECMV(F/B) Vehicle speed Traction T/M Out Speed Sensor Fan Pump Solenoid(F/B) Fan Speed SUNC SUNO SDNC P/T SW Input 3 SDNO PNC PNO F R T/M Fill Sw Input 1 1st 2nd 3rd L/U T/M Fill Sw Input 2 S/C
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Unit (Default: SI) SI
Metric
mV mV mV mA mA mA mA mA ° mV mV % mV
mV mV mV mA mA mA mA mA ° mV mV % mV ON • OFF ON • OFF ON • OFF ON • OFF mV mV mA mA mA mA mA C rpm
mV mV mA mA mA mA mA C r/min MPa mV MPa mV mA mA km/h W mV mA r/min
kg/cm2 mV kg/cm2 mV mA mA km/h W mV mA rpm ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF ON • OFF
Component Imperial in charge mV mV mV mA mA mA mA mA ° mV mV % mV
mV mV mA mA mA mA mA F rpm psi mV psi mV mA mA MPH W mV mA rpm
Remarks
P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T
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Electrical system Special functions of machine monitor (EMMS)
Code No.
40909
70700 70701 60200 60300 31200 43001 40910
70300
90802
31634 10007
40982
01501
40981
40983 37501 42610 42611 42612 42613 42801 20300 99003 20227 20402
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Monitoring item (displayed on screen) Back-up alarm N-safty P/T SW Output Pre-lub Motor Pre-heater Hydraulic Pump Pressure 1 Hydraulic Pressure Sensor 1 Acceleration Sensor Voltage SSC Command Speed Torque Converter Output Speed T/M Main Oil Pressure P/T SW Input 2 W/E Lock Switch (NO) W/E Lock SW (NC) W/E Knob Upper SW (NO) W/E Knob Upper SW Blade Sw Input (NC) W/E Knob Lower SW (NO) W/E Knob Lower SW (NC) Blade Lift Raise Blade Lift Lower Blade Lever Oil Press. Switch Blade Left Tilt Blade Right Tilt Fan Pump Solenoid 2 (F/B) Fan Speed Ripper Lift Raise Ripper Lift Lower Ripper Lever Oil Press. Switch Ripper Tilt in Ripper Tilt Out LS Solenoid (F/B) HYD. Oil Level ENG Low Idle W/E SW Input C-sig R-sig Acc ENG Hold W/E SW Output Fan Reverse Solenoid ENG Shut Down Ambient Temperature Exhaust Temperature, front Exhaust Temperature, rear Exhaust Temp. sensor, front Exhaust Temp. sensor, rear Blow-by Pressure VHMS LED Monitor Orbcomm Con. Power Orbcomm CommuSatellite Condition nication Status Data Transmission Monitor Ass'y P/N Monitor serial No
Unit (Default: SI) SI
Metric
Imperial
ON • OFF ON • OFF ON • OFF ON • OFF MPa mV mV r/min r/min MPa
mA r/min
kg/cm2 mV mV rpm rpm kg/cm2 ON • OFF ON • OFF ON • OFF
psi mV mV rpm rpm psi
W/E
ON • OFF
W/E
ON • OFF
W/E
ON • OFF
W/E
ON • OFF
W/E
mA rpm
mA rpm
C C C V V kPa
mA
W/E W/E
W/E
mA
W/E
ON • OFF
W/E
ON • OFF
W/E
C C C V V kg/cm2 —
Remarks
P/T P/T P/T P/T W/E W/E P/T P/T P/T VHMS P/T W/E W/E
ON • OFF
ON • OFF
mA
Component in charge
F F F V V psi
VHMS VHMS VHMS VHMS VHMS VHMS VHMS
ON • OFF
VHMS
— —
MON MON
D375A-6 (06)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Code No. 20228 20242 20404 20243 20244 20405 20245 04200 04300 04401 04402 18900 37200 00201 20216 20217 20400 01002 36700 31701 31703 17500 36400 36401 36200 36300 04107 04105 37400 37401
Monitoring item (displayed on screen) Monitor Prog P/N P/T Con Ass'y P/N P/T Con Serial No P/T Con Prog P/N W/E Con Ass'y P/N W/E Con Serial No W/E Con Prog P/N Fuel Level Sensor Volt Battery charge volt Hyd Oil Temperature Hyd Temp Sens Volt ECM Internal Temp Engine oil pressure Machine ID ECM Build Version ECM Calibration Data Ver ECM Serial No Engine Speed Engine Torque Ratio Decel Pedal Position Decel Pedal Pos Sens Volt Engine Power Mode Rail Pressure Rail Pressure Sens Volt Rail Press Command Injection Timing Command Coolant Temperature Coolant Temp Sens Volt Ambient Pressure Ambient Press Sens Volt
Unit (Default: SI) SI
V V C V C Mpa
r/min % % mV MPa V MPa CA C V Mpa V
Metric — — — — — — — V V C V C kg/cm2 — — — — rpm % % mV — kg/cm2 V kg/cm2 CA C V kg/cm2 V
Imperial
V V F V F psi
rpm % % mV psi V psi CA F V psi V
Component in charge MON P/T P/T P/T W/E W/E W/E MON MON MON MON ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG
36500 Charge Pressure-Abs
Mpa
kg/cm2
psi
ENG
36501 03203 37300 31706 18500 18501 18600 17201 18700 37201 14200 14201 42700 42701 17903 18001 18100 18101
V V l/h % C V mg/st CA Nm V C V C mV Mpa mV mm mV
V V l/h % C V mg/st CA kgm V C V C mV
V V gal/h % F V mg/st CA lbft V F V F mV psi mV mm mV
ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG
Charge Press Sens Volt Battery Power Supply Fuel Rate Final Throttle Position Charge Temperature Charge Temp Sens Volt Inject Fueling Command PCV Close Timing Engine Output Torque Eng Oil Press Sens Volt Fuel Temperature Fuel Temp Sens Volt ENG Oil Temperature ENG Oil Temp. sensor EGR Inlet Pressure-A EGR In Press Sens Volt EGR Valve Position EGR Valve Pos Sens Volt
D375A-6 (03)
kg/cm2 mV mm mV
Remarks
Indicated in absolute pressure (including ambient pressure)
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Electrical system Special functions of machine monitor (EMMS)
Code No.
Monitoring item (displayed on screen)
18200 BPS Valve Position 18201 BPS Valve Pos Sens Volt Acc 40912 P/T SW Input 1 R-sig C-sig
Unit (Default: SI) SI
Metric
Imperial
mm mV
mm mV ON • OFF ON • OFF ON • OFF
mm mV
Component in charge ENG ENG P/T P/T P/T
Remarks Not applicable for this machine
a Entry order of monitoring items in table The monitoring items are entered in the order of display on the "Monitoring" screen for item selection. a Unit The display unit can be set to SI, Metric, or Imperial unit freely (use "Unit" menu of "Default" in the service menu to select the unit.). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. a Component in charge MON: The machine monitor is in charge of detection of the monitoring information. ENG: The engine controller is in charge of detection of the monitoring information. P/T: The power train controller is in charge of detection of the monitoring information. W/E: The work equipment controller is in charge of detection of the monitoring information. VHMS: The VHMS controller is in charge of detection of the monitoring Information.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
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DRAFT Electrial system Special functions of machine monitor (EMMS)
"Abnormality Record" (Mechanical system "Abnormality Record")
The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical system abnormality or electrical system abnormality. To check the mechanical system abnormality record, perform the following procedures. 1. Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.
2. Selecting sub menu After the "Abnormality Record" screen is displayed, select "01 Mechanical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
3. Information displayed on "Abnormality Record" screen On the "Mechanical Systems" screen, the following information is displayed. (a): Sequential order from latest occurrence/Total number of records (b): Failure code (c): Contents of trouble (d): Occurrence number (e): Service meter reading at first occurrence (f): Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see Troubleshooting, "Failure codes table".
4. Deleting "Abnormality Record" The contents of the mechanical system "Abnormality Record" cannot be deleted.
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D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
"Abnormality Record" (Electrical system "Abnormality Record")
The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical system abnormality or electrical system abnormality. To check the electrical system abnormality record, perform the following procedures. 1. Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.
2. Selecting sub menu After the "Abnormality Record" screen is displayed, select "02 Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
3. Information displayed on "Abnormality Record" screen On the "Electrical Systems" screen, the following information is displayed. (a): Sequential order from latest occurrence/Total number of records (b): Failure code (c): Contents of trouble (d): Occurrence number (e): Service meter reading at first occurrence (f): Service meter reach at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record, see Troubleshooting, "Failure codes table".
4. Deleting "Abnormality Record" 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4]+[1]o[2]o[3] a Operate the switches similarly to the procedure for changing the ordinary display to the service mode.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
2) Check that the screen is set in the reset mode, and then reset the items one by one or together with the function switches. a If the screen is set in the reset mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Delete all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "Abnormality Record" screen q [F6]: Delete selected item a To delete items one by one: Select the item to be deleted with [F3] or [F4] and press [F6]. a To delete all items together: Press [F2], and all the items are deleted, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the deleting operation is accepted but the information is not deleted.
4) If the screen to notify completion of reset is displayed and then the "Electrical Systems" (reset mode) screen is displayed, the reset of the abnormality record is completed. a After a while, the screen returns to the "Electrical Sys. Error Reset" screen.
3) After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical Sys. Error Reset" screen (Delete mode) q [F6]: Execute deletion a The following figure shows the screen displayed when the items are reset one by one (which is a little different from the screen displayed when all the items are reset together). 30-102
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Maintenance Record
The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section. 1. Selecting menu Select "03 Maintenance Record" on the "Service Menu" screen.
a The following items can be selected in the maintenance record. 01 Engine Oil Change 02 Engine Oil Filter Change 03 Fuel Main Filter Change 41 Fuel Pre Filter Change 04 Hyd Oil Filter Change 06 Corrosion Resistor Change 07 Damper case service 08 Replacement interval of final drive case oil 10 Hydraulic oil change 19 Replacement of power train oil 20 Replacement of power train oil filter
2. Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Go to next page (screen) q [F2]: Go to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.
D375A-6 (03)
3. Items displayed on Maintenance Record screen. The following items are displayed. (a): Maintenance items (b): Number of times of change up to now (c): Service meter reading (SMR) at previous change
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Maintenance Mode Change
The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set replacement interval (by items) q Initialize all set change intervals
00 Maintenance Mode On/Off 01 Engine Oil Change Int 02 Eng Oil Filter Change Int 03 Fuel Main Filter Change Int 41 Fuel Pre Filter Change Int
1. Selecting menu Select "04 Maintenance Mode Change" on the Service menu screen.
04 Hyd Oil Filter Change Int 07 Check and replacement interval of damper case oil 08 Replacement interval of final drive case oil 10 Replacement interval of hydraulic oil 19 Replacement interval of power train oil 20 Replacement interval of power train oil filter 99 Use Default Value
2. Selecting sub menu After the "Maintenance Mode Change" screen is displayed, select an item to change the setting with the function switches or numeral input switches. q [F1]: Go to next page (screen) q [F2]: Go to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
a The following items can be selected on the Change of maintenance mode screen.
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3. Contents of setting of ON/OFF of maintenance mode After selecting "00 Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode screen q [F6]: Confirm selection and return to Maintenance mode screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.
4. Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Default: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). q Set: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 25 hours). q ON: Maintenance function of this item is set effective in operator mode. q OFF: Maintenance function of this item is set ineffective in operator mode. q [F3]: Select Reduce set value (Upper) or OFF (Lower). q [F4]: Select Increase set value (Upper) or ON (Lower). q [F5]: Cancel setting before confirmation and return to Maintenance Mode Change screen. q [F6]: Confirm setting of upper or lower line. a After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode change screen with [F5], the setting is effective. q
a If this operation is executed, the set values of all the maintenance items are set to default values. q [F5]: Return to Maintenance Mode Change screen q [F6]: Execute default setting a A while after [F6] is pressed, the initialization completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, initialization is completed.
Phone Number Entry
The telephone No. displayed when the user code/failure code is displayed in the operator mode can be input and changed according to the following procedure. If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode. 1. Selecting menu Select "05 Phone Number Entry" on the "Service Menu" screen. 5. Function of All Default Value After selecting "99 Use Default Value", if the screen is displayed, set with the function switches.
D375A-6 (01)
30-105
DRAFT Electrial system Special functions of machine monitor (EMMS)
2. Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the telephone No. q [F2]: Delete all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Delete input digit/Return to service menu q [F6]: Confirm input
a Up to 14 digits can be input from the left. Input nothing in the surplus positions. a If one of the input digits is wrong, move to that digit (and its background changes to orange) and overwrite it with the correct digit. a If [F6] is pressed without inputting a digit, there is not information of phone No. Accordingly, no phone No. is displayed in the operator mode.
30-106
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Default setting (Key-on Mode)
Check and change various settings related to the machine monitor and the machine with the "Default". The function of Key-on Mode is used to set the initial mode displayed on the machine monitor when the starting switch is turned ON. 1. Selecting menu Select "06 Default" on the "Service Menu" screen.
Default Value (ALL OFF): Default setting of all mode items (Power: P, other 3 items: OFF) is displayed when starting switch is turned ON q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to the "Default" screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, Mode at Previous key-off. q
2. Selecting sub menu After the "Default" screen is displayed, select "01 Key-on Mode" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. a This function sets the following 4 mode items (which are the items set with the customize switch in the operator mode). q Power: P/E q Reverse slow mode: ON/OFF q Work equipment fine control: ON/OF q Blade slow down: ON/OFF
3. Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Mode at previous key-OFF: Final mode in previous operation is displayed when starting switch is turned ON D375A-6 (01)
30-107
DRAFT Electrial system Special functions of machine monitor (EMMS)
Default setting (Setting of unit)
Check and change various settings related to the machine monitor and the machine with the "Default". The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1. Selecting menu Select "06 Default" on the "Service Menu" screen.
2. Selecting sub menu After the "Default" screen is displayed, select "02 Unit" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting unit After the "Unit" screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to the "Default" screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, the SI unit system is set.
30-108
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Default setting (Setting of maintenance password)
Check and change various settings related to the machine monitor and the machine with the "Default". The function of setting maintenance password is used to set the display of the password screen when the functions related to the maintenance are used in the operator mode. 1. Selecting menu Select "06 Default" on the "Service Menu" screen. 4. Displaying maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q The ordinary screen is changed to the maintenance mode (with [F5]) and then the "Maintenance table" screen is changed to the "Maintenance interval reset" screen.
2. Selecting sub menu After the "Default" screen is displayed, select "03 Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
5. Changing maintenance password The password can be changed by operating the switches specially in the operator mode. a See "Function of changing maintenance password" in the operator mode. a Default password: [000000] a If the password setting is changed from "Enable" to "Disable", the password is reset to the default. a When "Enable" is set again, be sure to set a new password. a The maintenance password is different from the engine start lock password.
3. Selecting Enable/Disable After the Maintenance Password screen is displayed, select the setting with the function switches. q Disable: Password screen is not displayed q Enable: Password screen is displayed q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to the "Default" screen q [F6]: Confirm selection and return to default screen
D375A-6 (01)
30-109
DRAFT Electrial system Special functions of machine monitor (EMMS)
Default setting (Setting of camera)
Check and change various settings related to the machine monitor and the machine with the "Default". The camera setting function is used to set default setting and removal of a camera. 1. Selecting menu Select "06 Default" on the "Service Menu" screen.
a After "Camera" screen is displayed, camera 1 can be always set. When 2 or more cameras are connected, if camera 1 is set, the screen changes to setting of camera 2 automatically. a After confirming the setting of each line with [F6], return to the "Default" screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a If 2 or more cameras are connected, be sure to set the use of them from camera 1 in order. a The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set. a When a camera is installed, check that the displayed image is not inverted horizontally in the operator mode.
2. Selecting sub menu After the "Default" screen is displayed, select "04 Camera" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting camera setting After the "Camera" setting screen is displayed, select the setting with the function switches. q OFF: Camera is not connected q Original image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to Default screen q [F6]: Confirm selection in each line 30-110
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Default setting (Setting of ECO display)
Check and change various settings related to the machine monitor and the machine with the "Default". The ECO display setting function is used to set the display of the ECO gauge. 1. Selecting menu Select "06 Default" on the "Service Menu" screen.
a Display of ECO gauge (a)
2. Selecting sub menu After the "Default" screen is displayed, select "05 ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON: Display ECO q OFF: Do not display ECO q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel selection and return to the "Default" screen q [F6]: Confirm selection and return to default screen a If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.
D375A-6 (01)
30-111
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjusting
The operator can adjust various items related to the machine with the machine monitor. When using an adjustment item, select it according to the following procedure. 1. Selecting menu Select "07 Adjustment" in the "Service menu" screen.
2. Selecting adjustment items After the "Adjustment" screen is displayed, input the 4-digit adjustment ID of the adjustment item to be used with the numeral input switches. q [F5]: Cancel adjustment and return to Service menu screen q [F6]: Confirm input adjustment ID and go to Adjustment screen a For the adjustment ID's and their adjustment items, see the adjustment items table.
3. Displaying adjustment screen After the "Adjustment" screen for the adjustment ID is displayed, you can start adjustment. a In the figure, adjustment ID [0002] is selected and displayed as an example. a "000", "00", and "0" on the left of the adjustment ID must be filled but they are not displayed on the adjustment screen. a The functions given to function switches [F3] – [F6] depend on the adjustment item. a For the method of operating each adjustment item, see the explanation of its adjustment ID.
a lf the input adjustment ID is incorrect, the message of "Not Available" is displayed and the ID input screen does not change (another ID can be input again with the numeral input switches while this screen is displayed).
30-112
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment items table Adjustment ID 0002 0004 0005 0007 0009 0010 0031 0036 0041
Adjustment item Power train controller initialization Work equipment specification setting Brake pedal potentiometer initial correction Engine decelerator cutting Pitch angle sensor initial correction Fan 70% mode Work equipment controller initialization Shoe slip control specification code setting Travel lever code setting
0530
Stall mode
1005 1012 1013 1014 1015 1016 2021 2022 5535 5537 5538 6001 6002 6003 7842 7843 7845 7847
Fan 100 % mode Steering lever neutral position adjustment Steering lever leftmost position adjustment Steering lever rightmost position adjustment Right brake oil pressure offset Left brake oil pressure offset Power train controller voltage check mode Work equipment controller voltage check mode Both steering clutch disengage mode Left steering clutch oil pressure offset Right steering clutch oil pressure offset R1 reverse slow set speed R2 reverse slow set speed R3 reverse slow set speed Transmission clutch IP and fill time automatic initial correction Transmission clutch IP manual initial correction Transmission clutch IP learning display Transmission clutch fill time manual initial correction
9995
Control brake release mode
9996 9997 9998
Sudden stop prevent valve operation mode High idle cut mode Max. gear speed setting mode
D375A-6 (03)
Remarks
Resetting auto-decelerating function
Setting and resetting uni-direction lever Recommended mode of torque converter stall
Fine adjustment of reverse slow mode Fine adjustment of reverse slow mode Fine adjustment of reverse slow mode
Control brake: Brake ECMV (Right and left)
30-113 30-125
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 0002 (Power train controller initialization)
Adjustment ID: 0004 (Work equipment specification setting)
This adjustment code is used to initialize the specification code recognized by the power train controller and the set values of the memory in the controller. a After the power train controller is replaced, be sure to carry out this adjustment once.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting
q
Functions of function switches [F3]: Increase specification value [CODE] [F4]: Decrease specification value [CODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting
q
Operating method: 1] Press [F6] and check that the alarm buzzer sounds. 2] Check that the displayed specification code [CODE] has changed from [1x1] to [111]. a If specification code [111] is not displayed, the controller unit may be defective. a Even if this adjustment code is turned off, the setting is effective.
q
Operating method: 1] Press [F3] or [F4] to select the specification value [CODE] of the work equipment concerned.
q
30-114
This adjustment code is used to make the work equipment controller recognize the type of the work equipment. a After the work equipment controller or the work equipment is replaced, be sure to carry out this adjustment once.
CODE Type of work equipment 0 Dual tiltdozer 1 Single tiltdozer
2] Press [F6] and check that the alarm buzzer sounds. k If the specification of the work equipment is different from the setting in the controller, the work equipment may move unexpectedly or an error may be made. Accordingly, be sure to match the controller to the work equipment. a Even if this adjustment code is turned off, the setting is effective.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 0005 (Brake pedal potentiometer initial correction)
Adjustment ID: 0007 (Engine decelerator cutting)
This adjustment code is used to stop the auto-deceleration function of the engine and check the high idle speed of the engine unit. a The engine can be operated and tested with only the auto-decelerator turned off with this adjustment code. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
This adjustment code is used to make the power train controller recognize the zero point of the brake pedal potentiometer. a After the power train controller or brake pedal potentiometer is replaced or the brake pedal linkage is disconnected and connected, be sure to carry out this adjustment once.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method: 1] Check that the brake pedal is in the neutral position (it is not pressed at all) and keep it in that position. 2] Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the correction is effective. a This adjustment code is used to make the controller recognize the zero point of the potentiometer. It is not used to adjust the braking force.
q
Operating method: When this adjustment code is displayed, its function is effective and the auto-deceleration function is stopped. a After this adjustment code is turned OFF, its function is ineffective.
D375A-6 (01)
30-115
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 0009 (Pitch angle sensor initial correction)
Adjustment ID: 0010 (Fan 70% mode)
This adjustment code is used to forcibly set the cooling fan speed to about 70%. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
This adjustment code is used to make the power train controller recognize the zero point of the pitch angle sensor and to correct the installation error. a After the power train controller is replaced or the pitch angle sensor is removed and installed or replaced, be sure to carry out this adjustment once.
q
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value Operating method: 1] Check that the machine is level. 2] Press [F6] and check that the alarm buzzer sounds. a If the adjustment is performed, displayed item [BODY PITCH ANGLE] changes to [0.0°] (No other displayed item changes). a Even if this adjustment code is turned off, the correction is effective.
30-116
q
Functions of function switches [F3]: Increase adjustment value [FAN 70 % SPEED MODE] [F4]: Decrease adjustment value [FAN 70 % SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method: The function is effective at the time when this adjustment is displayed and the cooling fan speed is controlled to about 70% of the maximum speed. a After this adjustment code is turned OFF, its function is ineffective.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 0031 (Work equipment controller initialization)
Adjustment ID: 0036 (Shoe slip control specification code setting)
This adjustment code is used to initialize the specification code recognized by the work equipment controller and the set values of the memory in the controller. a After the work equipment controller is replaced, be sure to carry out this adjustment once.
q
q
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting Operating method: 1] Press [F6] and check that the alarm buzzer sounds. 2] Check that the displayed specification code [CODE] has changed from [2x2] to [222]. a If specification code [222] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this adjustment code is turned off, the setting is effective.
D375A-6 (01)
This adjustment code is used to change the rocky terrain specification setting when the shoe slip control is used.
a When the shoe slip control operates, if shoe slip is not restrained even if the rocky terrain specification is set to "5", change the set value. q
Functions of function switches [F3]: Return [F4]: Go [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Confirm selection
q
Operating method: 1] Change the setting from [SSC SPEC H] to [SSC SPEC L] by pressing [F3] or [F4]. 2] Press [F6] to define the selection. a At this time, check that alarm buzzer sounds. a Even if this adjustment code is turned off, the setting is effective.
30-117
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 0041 (Travel lever code setting)
This adjustment code is used to correct the set value of the travel lever code recognized by the power train controller when it is different from the lever that is actually installed. a If the power train controller is replaced while a non-standard travel lever (for example, a uni-direction lever) is installed, be sure to perform this adjustment once. q Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting q
q
Operating method: 1] Perform adjustment ID "0002" (Initialization of power train controller) and "0031" (Initialization of work equipment controller). a After the above operation has been carried out, an error is displayed. 2] Enter adjustment ID "0041". 3] Press [F6] and check that the alarm buzzer sounds. 4] Check that the displayed specification code [CODE] has changed from [1x1] to [111]. a If specification code [111] is not displayed, the controller unit may be defective. a Even if this adjustment code is turned off, the setting is effective.
30-130 30-117-1
D375A-6 (03)
DRAFT Electrial system Special functions of machine monitor (EMMS)
D375A-6 (03)
30-117-2 30-131
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 0530 (Stall mode)
Adjustment ID: 1005 (Fan 100% mode)
This adjustment code is used to set the fan speed in the 100% mode automatically and make it possible to set the preset (gear speed at start) to [F3-R3] to stall the torque converter. a The preset (gear speed at start) can be set to [F3-R3] only while this adjustment code is selected. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary. q Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
q
Mode setting information within screen [P-AUTO SFT MODE]: Automatic Gearshift In P Mode [E-AUTO SFT MODE]: Automatic Gearshift In E Mode [P-MANUAL SFT MODE]: Manual Gearshift In P Mode [E-MANUAL SFT MODE]: Manual Gearshift In E Mode a When using this adjustment code, be sure to select "P-MANUAL SFT MODE". q Operating method: when this adjustment code is displayed, its function is effective and the preset (gear speed at start) is set to [F3-R3]. k This adjustment code does not stall the torque converter automatically. Accordingly, operate the levers and pedals securely when stalling the torque converter (For the procedure for stalling the torque converter, see Measuring engine speed). a When using this adjustment code, be sure to keep the hydraulic oil temperature above 45 °C.(If the hydraulic oil temperature drops below 40°C, the fan speed fluctuates) a After this adjustment code is turned OFF, its function is ineffective. q
30-132 30-118
This adjustment code is used to set the cooling fan speed to about 100% forcibly. It is also used to set the adjustment value of the maximum speed. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary. a Functions of function switches [F3]: Increase adjustment value [FAN 100 % SPEED MODE] [F4]: Decrease adjustment value [FAN 100 % SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: a When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 100% of the maximum speed. 1] increase Or decrease the adjustment value by pressing [F3] or [F4]. 2] when confirming the adjustment value, press [F6] and check that the alarm buzzer sounds. a When using this adjustment code, be sure to keep the hydraulic oil temperature above 45°C.(If the hydraulic oil temperature drops below 40°C, the fan speed fluctuates) a After this adjustment code is turned OFF, its function is ineffective but the set adjustment value is effective.
D375A-6 (03)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 1012 (Steering lever neutral position adjustment)
Adjustment ID: 1013 (Steering lever leftmost position adjustment)
This adjustment code is used to make the power train controller recognize the neutral position of the steering potentiometer of the PCCS lever. a After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: 1] Check that the PCCS lever is in the neutral position of the steering direction and keep it in that position. 2] Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the neutral position of the potentiometer. It is not used to adjust the steering force.
q
Operating method: 1] Operate the PCCS lever in the steering direction to the left stroke end and keep it there. 2] Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the leftmost position of the potentiometer. It is not used to adjust the steering force.
q
D375A-6 (01)
This adjustment code is used to make the power train controller recognize the leftmost position of the steering potentiometer of the PCCS lever. a After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
30-119
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 1014 (Steering lever rightmost position adjustment)
Adjustment ID: 1015 (Right brake oil pressure offset)
This adjustment code is used to make the power train controller recognize the rightmost position of the steering potentiometer of the PCCS lever. a After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
q
q
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Operating method: 1] Operate the PCCS lever in the steering direction to the right stroke end and keep it there. 2] Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the rightmost position of the potentiometer. It is not used to adjust the steering force.
30-134 30-120
This adjustment code is used to adjust the right brake oil pressure manually. a Use this adjustment code for work when necessary.
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.0098 MPa {0.1 kg/cm2} (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 MPa {0 kg/cm2}. a The adjustment range is -0.294 - 0.294 MPa {-3 - 3 kg/cm2}.
q
Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a If an adjustment has been performed, the adjustment value is displayed. It can be adjusted again within the allowable range. a It is not necessary to operate the brake during adjustment. After finishing adjustment, however, operate the brake and check that there is not a problem in the actual brake performance. a Even if this adjustment code is turned off, the adjustment is effective.
D375A-6 (03)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 1016 (Left brake oil pressure offset)
Adjustment ID: 2021 (Power train controller voltage check mode)
This adjustment code is used to adjust the left brake oil pressure manually. a Use this adjustment code for work when necessary.
q
q
q
q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.0098 MPa {0.1 kg/cm2} (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 MPa {0 kg/cm2}. a The adjustment range is -0.294 – 0.294 MPa {-3 – 3 kg/cm2}. Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a It is not necessary to operate the brake during adjustment. After finishing adjustment, however, operate the brake and check that there is not a problem in the actual brake performance. a If an adjustment has been performed, the adjustment value is displayed. It can be adjusted again within the allowable range. a Even if this adjustment code is turned off, the adjustment is effective.
D375A-6 (03)
This adjustment code is used to check the constant power supply voltage and switch power supply voltage applied to the power train controller. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Information displayed on screen [PT CONTROLLER UNSWITCH POWER]: Constant power supply voltage [PT CONTROLLER ACC POWER]: Switch power supply voltage
q
Operating method: When this adjustment code is displayed, its function is effective and the constant power supply voltage and switch power supply voltage are displayed simultaneously. a After this adjustment code is turned OFF, its function is ineffective.
30-121 30-135
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 2022 (Work equipment controller voltage check mode)
Adjustment ID: 5535 (Both steering clutch disengage mode)
This adjustment code is used to check the constant power supply voltage and switch power supply voltage applied to the work equipment controller. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
q
q
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused Information displayed on screen [WE CONTROLLER UNSWITCH POWER]: Constant power supply voltage [WE CONTROLLER ACC POWER]: Switch power supply voltage Operating method: When this adjustment code is displayed, its function is effective and the constant power supply voltage and switch power supply voltage are displayed simultaneously. a After this adjustment code is turned OFF, its function is ineffective.
30-122
This adjustment code is used to disengage both steering clutches with the parking brake ON.
a Used to check the torque converter lockup operation, lockup operating pressure and transmission clutch operating pressure. q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method: When this adjustment code is displayed, its function is effective and both steering clutches are disengaged. a After this adjustment code is turned OFF, its function is ineffective.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 5537 (Left steering clutch oil pressure offset)
a It is not necessary to steer the machine during adjustment. After finishing adjustment, however, steer the machine and check that there is no problem in the actual steering performance. a Even if this adjustment code is turned off, the adjustment is effective.
This adjustment code is used to manually adjust the pressure of the left steering clutch. q If a machine has been operated for a long period of time, the clutch oil pressure may be out of the standard pressure range because of wear of the clutch disc and the machine may not make a smooth gradual turn. In this case, this adjustment is effective to adjustment of oil pressure for smooth gradual turn. a Use this adjustment code for work when necessary. q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selection screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.0098 MPa {0.1 kg/cm2} (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 MPa {0 kg/cm2}. a The adjustment range is -0.294 – 0.294 MPa {-3 – 3 kg/cm2}.
q
Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a If an adjustment has been performed, the adjustment value is displayed. It can be adjusted again within the allowable range.
D375A-6 (03)
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 5538 (Right steering clutch oil pressure offset)
a It is not necessary to steer the machine during adjustment. After finishing adjustment, however, steer the machine and check that there is no problem in the actual steering performance. a Even if this adjustment code is turned off, the adjustment is effective.
This adjustment code is used to manually adjust the pressure of the left steering clutch. q If a machine has been operated for a long period of time, the clutch oil pressure may be out of the standard pressure range because of wear of the clutch disc and the machine may not make a smooth gradual turn. In this case, this adjustment is effective to adjustment of oil pressure for smooth gradual turn. a Use this adjustment code for work when necessary. q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selection screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The offset oil pressure is displayed and the adjustment value is increased or decreased by 0.0098 MPa {0.1 kg/cm2} (The value displayed on the screen is multiplied by 100). a The default adjustment value is 0 MPa {0 kg/cm2}. a The adjustment range is -0.294 – 0.294 MPa {-3 – 3 kg/cm2}.
q
Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a If an adjustment has been performed, the adjustment value is displayed. It can be adjusted again within the allowable range.
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D375A-6 (03)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 6001 (R1 reverse slow set speed)
Adjustment ID: 6002 (R2 reverse slow set speed)
This adjustment code is used to adjust the engine speed applied to travel at gear speed R1 with the reverse slow mode ON. a Use this adjustment code for work when necessary.
q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The lower speed (reduced from the high idle speed of 1,900 rpm) is displayed and the adjustment value is increased or decreased in 50 rpm units. a The adjustment value at shipment is 300 rpm. (Setting at shipment: 1,900 - 300 = 1,600 rpm)
q
Information displayed on screen The lower speed (reduced from the high idle speed of 1,900 rpm) is displayed and the adjustment value is increased or decreased in 50 rpm units. a The adjustment value at shipment is 300 rpm. (Setting at shipment: 1,900 - 300 = 1,600 rpm)
q
Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a If the set speed has been adjusted, the adjustment value is displayed. It can be adjusted again within the allowable range. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R1 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
q
Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a If the set speed has been adjusted, the adjustment value is displayed. It can be adjusted again within the allowable range. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R2 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
q
D375A-6 (01)
This adjustment code is used to adjust the engine speed applied to travel at gear speed R2 with the reverse slow mode ON. a Use this adjustment code for work when necessary.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 6003 (R3 reverse slow set speed)
Adjustment ID: 7842 (Transmission clutch IP and fill time automatic initial correction)
This adjustment code is used to adjust the engine speed applied to travel at gear speed R3 with the reverse slow mode ON. a Use this adjustment code for work when necessary.
q
q
q
q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The lower speed (reduced from the high idle speed of 1,900 rpm) is displayed and the adjustment value is increased or decreased in 50 rpm units. a The adjustment value at shipment is 300 rpm (Display: 30). (Setting at shipment: 1,900 - 300 = 1,600 rpm) Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a If the set speed has been adjusted, the adjustment value is displayed. It can be adjusted again within the allowable range. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R2 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
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This adjustment code is used to make the power train controller recognize the mechanical condition of the transmission. a After the power train controller or transmission is replaced, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Conditions for correction work 1] [ENGINE SPEED]: 1,700 – 1,950 rpm 2] [T/C TEMPERATURE]: 65 – 85°C 3] Parking brake lever: LOCK position 4] PCCS lever: Neutral position a When using this adjustment code, keep the above conditions (In particular, increase the power train oil temperature sufficiently before starting adjustment).
q
Operating method: 1] Stall the torque converter so that the torque converter oil temperature will be stabilized in the range of 65 – 85°C. 2] Fix the engine speed in the range of 1,700 – 1,900 rpm. 3] Set the PCCS lever in the neutral position and set the parking brake lever in the lock position. 4] Input adjustment ID [7842] directly with the numeral input switches and press [F6]. 5] Press [F6] again. a IP correction is started automatically. a Which clutch is being adjusted is displayed in section "a".
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
6] If [End of teaching. Press F6] is displayed in section "a", press [F6] again. a The buzzer sounds and the adjustment value is saved. a This work takes 3 - 5 minutes to complete.
Adjustment ID: 7843 (Transmission clutch IP manual initial correction)
This adjustment code is used to carry out correction manually when the correction is not carried out normally by the operation of IP automatic correction (Adjustment ID: 7842. a Use this adjustment code after the IP correction work, if necessary.
q
D375A-6 (01)
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value a If [F2] is pressed while [F1] is pressed, all the correction values are set to 0.
q
Functions of shift up/down switches You can select a clutch to be corrected manually with the shift-up and shift-down switches.
q
Conditions for correction work Same as the conditions for IP automatic correction (Adjustment ID: 7842).
q
Operating method: 1] Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2] Select a clutch to be corrected manually with the shift-up or shift-down switches. 3] Increase or decrease the adjustment value by pressing [F3] or [F4]. 4] Press [F6] and check that the alarm buzzer sounds. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the adjustment is effective.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 7845 (Transmission clutch IP learning display)
Adjustment ID: 7847 (Transmission clutch fill time manual initial correction)
This adjustment code is used to check the information of correction made by the operation of IP automatic correction (Adjustment ID: 7842) or IP manual correction (Adjustment ID: 7843). a Use this adjustment code for testing, adjusting, or troubleshooting when necessary. q Functions of function switches [F3]: Change display [F4]: Change display [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
q
q
Operating method: When this adjustment code is displayed, its function is effective and the correction information is displayed. a After this adjustment code is turned OFF, its function is ineffective.
This adjustment code is used to carry out correction manually when the correction is not carried out normally by the operation of fill time automatic correction (Adjustment ID: 7842). a Use this adjustment code after the fill time correction work, if necessary. q Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value a If [F2] is pressed while [F1] is pressed, all the correction values are set to 0. q Functions of shift up/down switches You can select a clutch to be corrected manually with the shift-up and shift-down switches. a The value displayed when the clutch is selected is correction information set automatically or manually before. q Conditions for correction work Same as the conditions for fill time automatic correction (Adjustment ID: 7842). q
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Operating method: 1] Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2] Select a clutch to be corrected manually with the shift-up or shift-down switches. 3] Increase or decrease the adjustment value by pressing [F3] or [F4]. 4] Press [F6] and check that the alarm buzzer sounds. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the adjustment is effective.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 9995 (Control brake release mode)
Adjustment ID: 9996 (Sudden stop prevent valve operation mode)
This adjustment code is used to release the control brake (right and left brake ECMV) to check the operation of the backup brake (brake pedal solenoid valve). a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method: When this adjustment code is displayed, its function is effective and the control brake (right and left brake ECMV) is kept released. a After this adjustment code is turned OFF, its function is ineffective.
q
Operating method: When this adjustment code is displayed, its function is effective and the sudden stop prevent solenoid valve and right and left brake ECMV are kept stopped. a After this adjustment code is turned OFF, its function is ineffective.
q
D375A-6 (01)
This adjustment code is used to stop the sudden stop prevent solenoid valve and right and left brake ECMV to check the operation of the sudden stop prevent valve. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Adjustment ID: 9997 (High idle cut mode)
This adjustment code is used to limit the high idle speed. a Use this adjustment code for work when necessary.
Adjustment ID: 9998 (Max. gear speed setting mode)
q
q
q
Functions of function switches [F3]: Increase adjustment value [HI IDLE RPM SET MODE] [F4]: Decrease adjustment value [HI IDLE RPM SET MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a To reset the high idle speed limit, set it to the original high idle speed (1,900 rpm) that was set at the time the machine was shipped. a The adjustment value is increased or decreased in 50 rpm units. a Even if this adjustment code is turned off, the setting is effective.
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This adjustment code is used to limit the maximum transmission gear speed. q The limited gear speed is applied in both automatic gearshift mode and manual gearshift mode. a Use this adjustment code for work when necessary. q
q
Functions of function switches [F3]: Increase adjustment value [MAX SHIFT] [F4]: Decrease adjustment value [MAX SHIFT] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: 1] Increase or decrease the adjustment value by pressing [F3] or [F4]. 2] Press [F6] and check that the alarm buzzer sounds. a When resetting the limitation of the maximum gear speed, set the adjustment value to the maximum gear speed (3RD) which is the initial setting at shipment. a Setting with this adjustment code becomes effective only after the starting switch is turned to OFF position and then to ON position again.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
PM clinic
q
3rd screen
q
4th screen (The figure shows VHMS installation specification)
q
5th screen
q
6th screen (The figure shows VHMS installation specification)
The machine monitor can check the condition of the machine without connecting testing tools to assist the Pm Clinic and other periodic inspections. 1) Selecting menu Select "08 PM CLINIC" on the Service menu screen.
2) Information displayed on Pm Clinic screen The Pm Clinic function displays the following information on 6 pages. q 1st screen
q
D375A-6 (01)
2nd screen (The figure shows VHMS installation specification)
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DRAFT Electrial system Special functions of machine monitor (EMMS)
q q q q q
[F1]: Change screen [F2]: Change screen [F3]: Reset holding [F4]: Hold (displayed data) [F5]: Return to service menu screen
3) Holding displayed information The displayed information can be held and released with [F3] and [F4].
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Cylinder Cut-Out operation
The operator can perform Cylinder Cut-Out operation with the machine monitor. Reduced cylinder mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1) Selecting menu Select "09 Cylinder Cut-Out" on the "Service Menu" screen.
2) Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be Cut-Out with the function switches. q [F1]: Move selection mark (R) to left q Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is disabled. a If the machine monitor disables a cylinder but the engine controller cannot disable that cylinder, the background of the cylinder No. becomes yellow. a One or more cylinders can be disabled.
D375A-6 (01)
3) Resetting disabled cylinder When changing a cylinder to be disabled or when reduced cylinder mode operation is finished, select a disabled cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes light blue, the cylinder is reset. a If the machine monitor rests a disabled cylinder but the engine controller cannot reset that disabled cylinder, the background of the cylinder No. becomes red. a The reduced cylinder mode operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the reduced cylinder mode operation is finished. 4) Function of holding displayed information If [F4] is pressed during the reduced cylinder mode operation, the displayed information is newly held (c) (The real-time information is kept displayed on the left side). a While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the reduced cylinder mode operation.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
[Reference] q
q
q
If a normally operating cylinder is disabled, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.
Display of No Injection
If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the no-injection cranking while the engine is stopped. 1) Selecting menu Select "10 No Injection" on the "Service Menu" screen.
2) Preparation for no injection cranking When the “No injection” screen is displayed, the machine monitor checks automatically if no injection cranking can be performed. If no injection cranking can be performed, the screen changes to the next screen automatically. a If no injection cranking cannot be performed because the engine is running or the communication is abnormal, the screen does not change from the following screen. In this case, depress [F5] to return to the "Service Menu" screen and solvethe problem.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
3) Display of confirmation screen The confirmation screen for no injection cranking is displayed. Select with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform
4) Starting no injection cranking If no injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Being prepared" is displayed. a Limit the cranking time to 20 seconds to protect the starting motor.
D375A-6 (01)
5) Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the "2. Preparation of No Injection cranking" screen automatically
6) Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message that the engine is running is displayed and the no injection cranking is not set effective. a Depress [F5] to return to the "Service Menu" screen, stop the engine, and select no injection cranking again.
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Display of Fuel Consumption
This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it. 1) Selecting menu Select "11 Fuel Consumption" on the "Service Menu" screen.
2) Starting measurement After the screen of "Fuel Consumption" is displayed, start measurement with the function switches. q [F1]: START q [F2]: CLEAR q [F5]: Return to service menu screen a When the screen of "Fuel Consumption" is displayed, if a data is indicated, it is the data of the previous measurement. This data is not an obstacle to new measurement and can be deleted by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and measurement starts. a The display unit of the fuel changes according to the unit set with the initialization (unit setting) function. SI and meter: l/h, inch: gal/h
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3) Display and function during measurement Clock mark (a) flashes during measurement. a While the fuel consumption is being measured, the operator can work with the operator mode and other functions. Measurement is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is measured only while the engine is running).
4) Finishing measurement Press [F1], and measurement is finished and the data are displayed on the finishing date and time side. 5) Displaying fuel consumption If the measurement is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.
D375A-6 (01)
DRAFT Electrial system Special functions of machine monitor (EMMS)
[F1]: Change screen [F2]: Change screen q [F5]: Return to service menu screen 2nd screen 1] F1 travel distance The cumulative travel distance in (theoretical value) is displayed. 2] F2 travel distance The cumulative travel distance in (theoretical value) is displayed 3] F3 travel distance The cumulative travel distance in (theoretical value) is displayed. 4] R1 travel distance The cumulative travel distance in (theoretical value) is displayed. 5] R2 travel distance The cumulative travel distance in (theoretical value) is displayed. 6] R3 travel distance The cumulative travel distance in (theoretical value) is displayed.
Display of saved load
q
This function displays the data accumulated since the machine started operation. (It displays the data saved in the controller.)
q
1) Selecting menu Select "12 Display of saved load" on the "Service Menu" screen.
2) Information displayed on Display of saved load screen The following Information is displayed 2 screens of the "Display of saved load" screen. q
q
F1
F2
F3
R1
R2
R3
1st screen 1] 1000 rpm service meter The number of cumulative operation hours at engine speed higher than 1,000 rpm is displayed. 2] Forward travel distance The cumulative forward travel distance (theoretical value) is displayed. 3] Reverse travel distance The cumulative reverse travel distance (theoretical value) is displayed.
D375A-6 (01)
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DRAFT Electrial system Special functions of machine monitor (EMMS)
Setting of VHMS This function is used to set installation of VHMS. If VHMS is installed when shipped, this setting has been completed. 1) Selecting menu Select "13 Setting of VHMS" on the "Service Menu" screen.
Snap shot (VHMS specification) This function sends a snap shot trigger command to the VHMS controller to execute the snap shot. VHMS specification has a manual snap shot function and an auto snap shot function. A manual snap shot can save the data for seven minutes and 30 seconds into the VHMS controller in order for them to be used for troubleshooting purposes. 1) Selecting menu Select "14 Snap shot" on the "Service Menu" screen.
2) Setting of installation of VHMS After the "Setting of VHMS" screen is displayed, select "ON" with the function switch. To reset the setting of VHMS, select "OFF". a Perform setting securely to prevent incorrect display and partial disability of the VHMS function.
q q q q
2) Operating method of manual snap shot After the "Snap shot" screen is displayed, start measuring data with the function switch. If [F1] is pressed to start measurement, display of [START] goes off. If measurement is finished, [START] is displayed again. a The elapsed measurement time is indicated in minute and second, and progress is indicated with a bar graph. a If [F5] is pressed during measurement, the screen returns to the service menu screen but measurement is continued.
[F3]: Select "ON" [F4]: Select "OFF" [F5]: Return to service menu screen [F6]: Confirm selection
q q
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[F1]: Start measurement [F5]: Return to service menu screen
D375A-6 (03)
DRAFT Electrial system Handling of voltage circuit of engine controller
Handling of voltage circuit of engine controller 1. Disconnecting or connecting operation of the connector between the engine controller and the engine shall be performed only when the starting switch is in the OFF position. k Before connecting the harness connector, be sure to completely remove sand, dust, water, etc., from inside of controller side connector. 2. Do not start the engine while the T adapter is inserted or connected to the connector between the engine controller and the engine for diagnosis. a The allowed starting switch position is either OFF or ON. It must not be set to START position.
D375A-6 (01)
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DRAFT Electrial system Adjustment method when controller has been replaced
Adjustment method when controller has been replaced a After machine is assembled or the power train controller or the work equipment controller is replaced, adjust the system according to the following procedure. k If the system is not adjusted, the machine may not operate normally but may move unexpectedly. Accordingly, be sure to adjust it. a Precautions for replacing a controller: If a controller is replaced, the memory of the oil and filter maintenance mode is reset. Accordingly, take a record of the next replacement periods of the oils and filters. a Precautions for replacing a controller: Stop the machine in a safe place and turn the starting switch to the OFF position. a Since the controller performs the finishing process for about 30 seconds after the starting switch is turned to the OFF position and the battery relay is turned OFF, do not remove the controller immediately. 1. Controller initial setting 1) Connect all the wiring harnesses and controllers. 2) Turn the starting switch to the ON position. a The buzzer sounds and the machine monitor indicates an error. 3) Turn the starting switch to the OFF position and wait for approx. 30 seconds. a It takes approx. 30 seconds to shut down the controller completely after the battery relay is turned OFF. 4) Turn the starting switch to the ON position again. a The machine monitor lights up, the buzzer sounds, and an error is indicated. 5) While pressing numeral input switch [4], press [1], [2] and [3] in order to set the machine monitor in the service mode.
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6) Select "07 Adjustment" in the "Service menu".
7) Input adjustment ID [0002] directly with the numeral input switches. (Initial setting of power train controller) 8) Press [F6]. a The buzzer sounds and the specification selection is saved. a Confirm that the displayed specification code has changed from [1 x 1] to [111].
D375A-6 (01)
DRAFT Electrial system Adjustment method when controller has been replaced
9) Press [F5] to return to the adjustment ID input screen. 10) Input adjustment ID [0031] directly with the numeral input switches. (Initial setting of work equipment controller) 11) Press [F6]. a The buzzer sounds and the specification selection is saved. a Ensure that the displayed specification code has changed from [2 x 2] to [222].
3) Press [F3] to select "ON" and press [F6] to settle the selection.
12) Press [F5] to return to the adjustment ID input screen. 13) Turn the starting switch to the OFF position and wait for approx. 30 seconds. a It takes approx. 30 seconds to shut down the controller completely after the battery relay is turned OFF. 14) Turn the starting switch to the ON position again. a The machine monitor lights up and displays normally. a The engine can be started now.
3. Shoe slip control setting a Set this item after the machine monitor was replaced, too. 1) Input "86" with the numeral input switches and press [F6] in the "Service menu" screen. 2) Press [F3] to select "ON" and press [F6] to settle the selection.
2. VHMS device setting (VHMS specification) a Set this item after the machine monitor was replaced, too. a Since the VHMS device is not installed in the default setting, be sure to set this item if the machine has the VHMS specification. 1) Set the machine monitor in the service mode. 2) Select "13 VHMS Setting" in the "Service menu" screen.
D375A-6 (01)
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DRAFT Electrial system Adjustment method when controller has been replaced
4. Prelube setting a Set this item after the machine monitor was replaced, too. 1) Input "87" with the numeral input switches and press [F6] in the "Service menu" screen. 2) Press [F3] to select "ON" and press [F6] to settle the selection.
4) Check to see if there is any failure code being indicated. If there is not any, delete all the recorded failure codes. a If any active failure codes exist, eliminate the cause of the incident by troubleshooting then carry out steps 5 and 6 again. 5. Turning power on again Turn the starting switch to the OFF position and turn it to the ON position again about 1 minute after (the battery relay is turned OFF). 6. Checking failure codes 1) Set the machine monitor in the service mode. 2) Select "02 Failure history" on the "Service menu" screen.
a Precautions after replacing controller: If any controller is replaced, the service meter in the oil and filter maintenance mode is reset to 0. As a result, the replacement period displayed on the monitor panel may be different from the actual operating hours. To solve this problem, determine the first replacement periods of the oils and filters after the replacement of the controller according to the replacement periods recorded before the replacement of the controller.
3) Press [F3] or [F4] to select "02 Electrical system failure history" and press [F6] to settle the selection.
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DRAFT Electrial system Adjustment method when controller has been replaced
7. Work equipment specification selection 1) Select "07 Adjustment" in the "Service menu" screen.
11. IP correction value check (Check of correction value of electric current) a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 7845 12. Trigger teaching value check a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 7847
2) Input adjustment ID [0004] directly with the numeral input switches and press [F6]. 3) Press [F3] or [F4] to select Dual tilt or Single tilt. 4) Press [F6] to settle the selection. a The buzzer sounds and the work equipment specification is saved.
13. Steering lever neutral position adjustment a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 1012 14. Steering lever leftmost position adjustment a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 1013 15. Steering lever rightmost position adjustment a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 1014 16. Shoe slip control specification setting a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 0036
8. Brake pedal potentiometer initial correction a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 0005
17. Travel lever code setting (For machines with non-standard travel lever only) a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 0041
9. Pitch angle sensor standard setting a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 0009 10. IP automatic correction and trigger automatic initial teaching a For details, see "Adjustment" function of "Special functions of machine monitor (EMMS)". q Adjustment ID: 7842 D375A-6 (03)
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DRAFT Electrial system Preparation work for troubleshooting of electrical system
Preparation work for troubleshooting of electrical system a When performing troubleshooting for an electrical circuit related to the machine monitor, engine controller, work equipment controller, power train controller, VHMS controller, or ORBCOMM terminal, expose the related connectors according to the following procedure.
3) Insert or connect test T-adapters into or to connectors CM01 and CM02 on the back side of the machine monitor.
1. Machine monitor 1) Remove cover (1).
2. Engine controller 1) Open covers (4) and (5) on the left side of the engine.
2) Remove 4 mounting bolts (2) and pull out machine monitor (3) toward this side.
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DRAFT Electrial system Preparation work for troubleshooting of electrical system
2) Remove engine controller covers (6) and (7).
3) Insert or connect the diagnostic T-adapter in or to the connector (ENG, EGC2, EGC3) of engine controller (8). a When disconnecting the connector, loosen its screw. a When returning the connector to the previous condition, tighten the screw to the following torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
k
In order to prevent malfunction and mistaken system error warning, be sure to completely remove foreign object (b) such as sand, dust, water, etc., from inside of controller side connector (a) with air blow etc., before connecting it to the harness connector.
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DRAFT Electrial system Preparation work for troubleshooting for electrical equipment system
3. Work equipment controller 1) Slide the operator's seat to the front end and fold the seat back forward. 2) Remove cover (9).
4. Power train controller 1) Slide the operator's seat to the front end and fold the seat back forward. 2) Remove cover (9).
3) Remove the mounting bolts of work equipment controller (10).
3) Remove the mounting bolts of power train controller (11).
4) Insert or connect test T-adapters into or to connectors WECN1, WECN2 and WECN3. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When returning the connector to the previous condition, tighten the screw to the following torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
4) Insert or connect test T-adapters into or to connectors PTCN1, PTCN2 and PTCN3. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When returning the connector to the previous condition, tighten the screw to the following torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
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Electrical system Preparation work for troubleshooting for electrical equipment system
5. VHMS controller (VHMS specification) 1) Open the cover on the left side of the floor and remove cover (12). 2) Insert or connect troubleshooting T-adapters into V1, V2A, V2B, V3A, V3B, V4A and V4B connectors of VHMS controller (13). a If it is difficult to remove and install the connectors, remove the controller for the ease of work.
6. ORBCOMM terminal 1) Remove seat belt buckle (14) and remove cover (15).
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2) Remove the mounting bolts of ORBCOMM terminal (16) and pull out the terminal.
3) Insert or connect test T-adapter into or to connector KOM1. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When returning the connector to the previous condition, tighten the screw to the following torque. 3 Screw:3 ± 1 Nm {0.3 ± 0.1 kgm}
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DRAFT Electrial system Inspection procedure of diode
Inspection procedure of diode a The direction of continuity of diode is marked on the surface of the diode.
1. When using digital tester 1) Set the tester in the diode range and read the indicated value. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Put the red probe (+) of the test lead to the anode (P) of and the black probe (–) to the cathode (N) of diode, and confirm the indicated value. 3) Evaluate the condition of the diode by the indicated value. q Indicated value remains unchanged: Conduction is absent (Failure) q The indicated value changes: The diode has conductivity (Normal) (See a below.) Note: In the case of silicon diode, the value between 460 – 600 mV is displayed. q Displayed value becomes 0 or near 0 : Short-circuiting of diode internal part (defect)
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2. When using analog tester 1) Set the tester in the resistance range. 2) Apply the leads of the tester as explainedbelow and check the movement of the pointer. 1] Set red (+) test lead to diode anode (P) side and black (–) test lead to cathode (N) side. 2] Set red (+) test lead to diode cathode (N) side and black (–) test lead to anode (P) side. 3) Evaluate the condition of the diode by the movement of the pointer. q Needle does not deflect with connection i) but deflects with connection ii): Normal. (However deflection range (resistance value) varies depending on the type of tester and testing range.) q Needle deflects with both connection i) and ii): Defective (internal short circuit) q Needle does not deflect with either connection 1] or 2]: Defective (internal disconnection)
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DRAFT Electrial system Handling of optional devices
Handling of optional devices a D375A-6 has connectors to install optional devices in its fuse box. When installing any optional device, receive the necessary signals and power through those connectors without modifying the wiring harness. a For the locations of the connectors, see Troubleshooting, "Connector list and three-dimensional layout". 1. Connecting the ACC signal of starting switch If the ACC signal (ON signal) of the starting switch is necessary for a optional device such as the turbocharger timer, connect it through the following connector pin. q Pin (B) of CN-ESD (3-pole heavy duty wire connector) a A 20A fuse is installed on the upstream side of this connector pin.
4. Connecting C signal of starting switch When starting switch signal C (starting signal) is necessary to an optional device such as prelube device, take it out of the following connector pin. q CN-PRS (2-pole heavy duty wire connector) a Remove the connector installed when the machine was delivered and connect pin (1) to the final starting signal output point of the prelube device and connect pin (2) to the input signal point from the starting switch. 5. Connecting external power source If an external power source is necessary, connect it through the following connectors. q CN-800 (Plug connector): Used for device in cab q CN-810 (Plug connector): Used for device out of cab a A 20A fuse is installed on the upstream side of these connectors.
2. Input of engine stop signal If the engine needs to be stopped with the starting switch in the ON position for an optional device such as the engine emergency stop system, use the circuit of the following connector pin. q Pin [A] of CN-ESD (3-pole heavy duty wire connector) a Before using this circuit, be sure to notify your Komatsu distributor. 3. Inputting engine low-idle command If it is required to keep the engine speed at low idle for an optional device such as the engine protector, use the circuit of the following connector pin. q Pin (C) of CN-ESD (3-pole heavy duty wire connector) a Before using this circuit, be sure to notify your Komatsu distributor.
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DRAFT Electrial system Request for opening ORBCOMM terminal
Request for opening ORBCOMM terminal a If the machine is equipped with ORBCOMM, fill in the "Request for opening VHMS ORBCOMM terminal" and send it by fax or mail to "KOMATSU KOMTRAX SUPPORT CENTER" before initializing the VHMS controller. a Initialize the VHMS controller after the opening notification is received from "KOMATSU KOMTRAX SUPPORT CENTER". a If the ORBCOMM antenna is installed and the starting switch is turned to the ON position before the opening notification is received, the ORBCOMM terminal transmits radio waves and ORBCOMM CO. LTD. sends out the stop signal automatically. In this case, complicated procedures and some time are required to open the ORBCOMM terminal service again.
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DRAFT Electrial system Request for opening ORBCOMM terminal
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DRAFT Electrial system Initialization procedures for VHMS controller
Initialization procedures for VHMS controller a Initialization tools for VHMS controller SymPart No. bol 1 799-608-3211 799-608-322 2 0 Z Commer3 cially available
Part name Discket Wiring harness Notebook type personal computer :Windows98/2000/Me/XP/VISTA (*) [With RS232C terminal]
*:VHMS setting tool Ver.3.06.00.03 or later, VHMS analysis tool Ver.3.05.00.00 or later. a Before starting full operation after completion of local assembly or before resuming operation after storage for a long period, initialize the VHMS controller according to the following procedure. a Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the initialization. a For the method of installing the VHMS Initialization Program to the personal computer, refer to the Operation and Maintenance Manual contained in the package of diskette Z1. a Since the service menu of the machine monitor will be used in the following procedure, read "Special functions of machine monitor (EMMS)" and understand the operating procedure in advance. a The initial setting procedure is described in the ORBCOM installation specification and the ORBCOM-less specification. When using the ORBCOM installation specification, implement the procedures needed for VHMS alone, bypassing those prepared only for ORBCOM installation specification. a During the initialization work, confirm each work according to the "VHMS Initialization Work Checklist".
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1. Check of machine information, engine information and controller information a This step is a work performed on the whole machine. Check and record the machine information, engine information, VHMS controller information and ORBCOMM terminal information. NO 1 2 3 4 5 6
Information to be checked Model name Machine serial No. Current service meter reading Engine serial No. Transmission serial No. VHMS controller serial No. ORBCOMM terminal serial No. 7 [Only for machines equipped with ORBCOM]
a VHMS controller (1) is in the control box on the left side of the floor and ORBCOMM terminal (2) is in the control box on the right side of the floor.
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DRAFT Electrial system Initialization procedures for VHMS controller
2. Connection of personal computer 1) Make sure that the starting switch is in the OFF position. k Be sure to turn off the starting switch before connecting or disconnecting the personal computer. 2) Connect personal computer Z3 and download connectors (VDW) and (DL1) by wiring harness Z2. a The download connectors are installed to the following places. q VDW: Under left rear of operator seat q DL1: Right rear of machine body (Side of backup lamp) a Connect the personal computer to the RS232C terminal.
3. Check of operation and satellite capturing condition of VHMS controller a This step is a work performed in the operator's cab. a Check of satellite capturing condition is necessary o only [ORBCOMM specification]. [Method of checking with monitoring function](Monitoring code: 99003) 1) Turn the starting switch to the ON position. 2) Set the machine monitor to display the service menu. a For the operating method, see "Special functions of machine monitor (EMMS)".
a Execute initialization of VHMS from the connector in the cab. a Use the ground download connector for only downloading.
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3) Select "01 Monitoring".
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DRAFT Electrial system Initialization procedures for VHMS controller
4) Input monitoring code 99003 directly with the numeral input switches. a The communication condition of the ORBCOMM terminal is displayed.
[Method of checking with monitoring function] (Monitoring code: 20300) 1) Input monitoring code 20300 directly with the numeral input switches. a The procedure up to inputting of the monitoring code is the same as the above section.
2) At least 3 minutes after the starting switch is turned to the ON position, check the communication condition of the ORBCOMM terminal by the display condition of the decimal point (indicated with the arrow) of the machine monitor.
Decimal point
Condition q
OFF
q q
ON
q q q
Blinking
q q
Power is not supplied to ORBCOMM controller. Communication line to VHMS controller is abnormal. Satellite is not captured. Power is supplied to ORBCOMM controller. Communication line to VHMS controller is normal. Power is supplied to ORBCOMM controller. Communication line to VHMS controller is normal. Satellite is captured.
[Method of checking with VHMS controller] 1) Turn the starting switch to the ON position. 2) The 7-segment LED (indicated with the arrow) of the VHMS controller flashes and rotates, and then counts up.
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DRAFT Electrial system Initialization procedures for VHMS controller
3) Confirm that the ORBCOMM terminal has captured the communication satellite by checking that the decimal point (indicated with the arrow) of the 7-segment LED is flashing. a The ORBCOMM terminal may take time to capture the satellite, depending on the strength of the signals from the satellite.
4. Startup of VHMS initialization tool a This step is a work performed in the operator's cab (on the personal computer). 1) Turn on the personal computer and start the OS. 2) Click the icon of [VHMS Initialization Tool] on the personal computer screen to start the VHMS initialization tool. Important a The setting screen varies with the version No. of the VHMS setting tool. a When using a tool before Ver. 3.5.2.1 (CD-ROM), set the VHMS in step 5. a When using an updated tool (Ver. 3.5.2.1 or after), set the VHMS in step 6. a It is recommended to download the latest VHMS setting tool from the WebCARE and update your tool. (Related material: Servicemate SMP-623) 3) Input the 10-digit service ID in [Service ID]. a Service ID: 7826147000 4) Select [Data clear and Set up] in the [Select Function] column. 5) Press the [OK] button to go to the setup screen.
5. Initialization of VHMS controller (Tool before Ver. 3.5.2.1) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR]. [Machine Information] 1) Open the [Machine information] tab. a The [Machine information] tab is displayed first in the [Data clear and Set up] menu. 2) Check all the data.
3) If information in the [Date/Time] box is not correct, change it according to the following procedures:
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DRAFT Electrial system Initialization procedures for VHMS controller
1] Press [Edit] button (1) on the right lower part of the [Date/Time] box to display the correction screen. 2] Correct the information and press the [OK] button.
4) If information in the [Machine information] box is not correct, change it according to the following procedures: 1] Press the [Edit] button (2) on the right lower part of the [Machine information] box to display the correction screen. 2] Correct the information and press the [OK] button.
5) After checking/changing all the data in [Machine information], press [Apply] button (3) to settle the setting. a Press the [Apply] button (3), and the screen for checking the setting will appear. Check the setting again and press the [OK] button if the setting is correct. a In case of the ORBCOMM Specification, execute [Communication Setting] first and then settle the setting.
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DRAFT Electrial system Initialization procedures for VHMS controller
[Communication Setting] (For ORBCOMM specification only) a Execute this setting after requesting for opening of the ORBCOM terminal and finishing the opening procedure. 6) Open the [Communication Setting] tab. 7) Check all the data.
8) To change the setting in [SHORT FAULT HISTRY], follow the procedure below: 1] Select [SHORT FAULT HISTRY] on the screen and press [Edit] button (5) on the left lower part of the [File Transfer Setting] block to display the setting screen. 2] Change the setting and then press the [OK] button. a At initialization, select [Occurrence] at [Timing] and set the function to [ON].
D375A-6 (01)
9) To change setting in [SHORT TREND ANALYSIS], follow the procedures below: 1] Select [SHORT TREND ANALYSIS] on the screen and press [Edit] button on the left lower part of the [File Transfer Setting] block to display the setting screen. 2] Change the setting and then press the [OK] button. a At initialization, input [20h] to [SMR] and set the function to [ON].
10)To change the setting of [Satellite Setting], follow the procedure below. 1] Press the [Edit] button in the [Satellite Setting] block to display the setting screen. 2] Set the GCC Code to the applicable area and then press the [OK] button.
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Electrical system Initialization procedures for VHMS controller
GCC Code 1
120
130
Area N.America (*1) C.S.Americas Faroe Islands Europe (*2) Middle East Asia (*3) Africa Oceania CIS Japan
Remarks *1: Except U.S. Territories in Micronesia and Midway Island
*2 Except Faroe Islands *3 Except Japan
a If the combination of the country name and code in the list box displayed by the setting tool is different from the above table, select the GCC code in the table or input the value through the keyboard. 11)After checking/changing all the data in [Communication Setting], press [Apply] button to enter the setting. a If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button if the setting is correct.
6. Initialization of VHMS controller (Ver. 3.5.2.1 or after) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR]. 1) Select [VHMS Setting] and press the "Next" button.
2) Select [Set up & All clear] and press the "Next" button. 12)After checking/changing the data of [Machine Information] and [Communication Setting], press the [Exit] button at the lower right portion of the screen to finish [VHMS Initial setting Tool].
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DRAFT Electrial system Initialization procedures for VHMS controller
3) Check the machine information. If it does not need to be corrected, press the "Next" button.
4) Select the time zone. 5) Input the local time. 6) If the DST (Daylight Saving Time) is used now, select it and press the "Next" button. a If the DST is selected, the clock is advanced 1 hour automatically, thus the time must be corrected again.
a If the VHMS was installed additionally, the information of [Serial No.] etc. must be input. 7) Set the GCC Code to the applicable area and then press the "Next" button. GCC Code 1
120
130
Area N.America (*1) C.S.Americas Faroe Islands Europe (*2) Middle East Asia (*3) Africa Oceania CIS Japan
Remarks *1: Except U.S. Territories in Micronesia and Midway Island
*2: Except Faroe Islands *3: Except Japan
a If the combination of the country name and code in the list box displayed by the setting tool is different from the above table, select the GCC code in the table or input the value through the keyboard.
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DRAFT Electrial system Initialization procedures for VHMS controller
8) The contents of the setting are displayed finally. If there is not a problem, press the "Apply" button.
9) The system asks you if you save the data before changing the setting. If you do not need to save, select "NO".
10)After finishing the work of changing the contents of initialization, press the "OK" button to finish the program.
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DRAFT Electrial system Initialization procedures for VHMS controller
7. Downloading of set data 1) Connect personal computer Z3 and download connectors (VDW) in the cab or ground download connector (DL1) by wiring harness Z2.
2) When using download connector (VDW) in the cab, set the starting switch in the ON position. 3) When using ground download connector (DL1), turn switch (3) ON. a The green LED lights up. 4) Operate the icon of [VHMS Technical Analysis Tool] on the personal computer to start the VHMS technical analysis tool.
a Download connector (VDW) in the cab is installed to the left rear lower part of the operator's seat.
a The ground download connector DL1 is installed to the side of the backup lamp at the rear right of the machine.
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a Input [User Name] and [Password]. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technical Analysis Tool.
5) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that downloading has completed before proceeding to the next step.
D375A-6 (03)
DRAFT Electrial system Initialization procedures for VHMS controller
8. Check of downloaded data a This step is a work performed in the operator's cab (on the personal computer). 1) Check the set data with the [View] function. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that the [MFA0] code at the time when the snapshot was operated is displayed in [Fault History]. a Make sure that the snap shot data is recorded.
3) If the data was downloaded in the cab, disconnect wiring harness Z2 from download connector (VDW).
4) If the data was downloaded on the ground, turn switch (3) OFF and disconnect wiring harness Z2 from download connector (DL1).
2) After checking the set data, terminate [VHMS Technical Analysis Tool]. 9. Disconnection of Personal Computer 1) Make sure that the starting switch is in the OFF position. k Be sure to turn off the starting switch before connecting or disconnecting the personal computer. 2) Finish the OS of the personal computer and then turn the personal computer OFF.
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DRAFT Electrial system Initialization procedures for VHMS controller
10. Report to Komatsu After completing steps 1 to 9 successfully, send the "VHMS/WebCARE setting notification form" to VHMS/WebCARE Support Center of Komatsu, Tokyo. a Since Komatsu has to set the receiving side of the satellite communication, be sure to inform Komatsu of the completion of the setting. a Send the VHMS data by Notes (LAN) or E-mail (WAN). a When using the KOMTRAX functions on the machine equipped with the ORBCOMM, complete the sign-up test on the machine side and enter the use of the KOMTRAX functions in the "VHMS/WebCARE setting notification form". Komatsu VHMS/WebCARE Support Center 2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) E-mail: [email protected]
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DRAFT Electrial system Initialization procedures for VHMS controller
[For storage] VHMS initial setting work check sheet Setting step
Date of setting: DB/branch name: Data entered by: Check item
Result
1
Check of nameplates of chassis and components
Model name Serial No. Engine serial No. Transmission controller serial No. VHMS controller serial No.
2
Connection of personal computer and VHMS controller
Is connection made securely?
yes
no
3 Check of operation VHMS controller
Is operation normal? (Decimal counting up must be displayed after rotation.)
yes
no
4 Starting of VHMS initialization Tool
Is setting tool set in "Data Clear and Set up" mode?
yes
no
Initialization of VHMS controller (Setting of machine information) 5 Set basic information of machine to VHMS controller in this step.
Is model name correct? Is machine serial No. input correctly? Is engine serial No. input correctly? Is today's date displayed? Does clock indicate present time? Is SMR input correctly?
yes yes yes yes yes yes
no no no no no no
6 Saving of set items
Is LED (7-segment) turned OFF?
yes
no
7 Check of VHMS function
Does LED operate normally?
yes
no
8 Execution of Quick Pm Clinic
Are service mode "SNAPSHOT" selected and is switch pressed?
yes
no
9 Saving operation of VHMS
Is LED (7-segment) turned OFF?
yes
no
10 Downloading
Does LED operate normally?
yes
no
Are all files downloaded? The time downloaded (Reference wrist watch) 11 Check of downloaded data
12 Saving operation of VHMS
D375A-6 (01)
yes no Hour, minute:
[Check of data] Is there MFA0 error in Fault History? Are SMR and time in Fault History matched to set values? Are all data of Snap Shot prepared?
yes yes yes
no no no
Is LED (7-segment) turned OFF?
yes
no
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DRAFT Electrial system Initialization procedures for VHMS controller
[For keeping] ORBCOMM Station Establishment Check Sheet Setting step
Date of setting: DB/branch name: Data entered by: Check item
1
Check of nameplates of chassis and components
Model name Serial No. Engine serial No. Transmission serial No. VHMS controller serial No. ORBCOMM controller serial No.
2
Connection of personal computer and VHMS controller
Is connection made securely?
3
Check of operation VHMS control- Is operation normal? ler (Counting up must be displayed after rotation.)
4 Starting of VHMS Initialization Tool Is setting tool set in "Set up" mode?
Initial setting of VHMS controller 1. Setting of communication (Machine information and PLM 5 have been set)
2. Setting of start of communication 6 Saving of set items 7
Enter set value of S.Fault History. Execution of communication Number of communication (Default: 8) Enter set value of S. Trend Analysis. Execution of communication Interval (Default: 20H) Enter set value of S. Payload data (If PLM is installed). Execution of communication Time to start collection Collection interval (Number of days)
yes
no
yes
no
yes
no
On hrs
Off
On hrs
Off
On
Off day
Is GCC code set? (130 for Japan)
yes
no
Is LED (7-segment) turned OFF after saving operation?
yes
no
yes
no
Check of operation of ORBCOMM How is display of decimal point on VHMS monitor (7-segment)? controller (Off, On, long/short flashing)
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Result
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DRAFT Electrial system Initialization procedures for VHMS controller
D375A-6 (01)
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Electrical system Using method of KOMTRAX functions of ORBCOMM terminal
Using method of KOMTRAX functions of ORBCOMM terminal a The ORBCOMM terminal equipped with the KOMTRAX function can display the machine on the control screen of the KOMTRAX system. a Whether the ORBCOMM terminal has the KOMTRAX functions can be checked by the part No. of the ORBCOMM terminal. a When using the KOMTRAX functions, perform the following procedure. 1. Make the request for opening the ORBCOMM terminal and receive the opening notification. a See "Request for opening ORBCOMM terminal". 2. Initialize the VHMS controller and set the GCC code of the machine location. a See "Initialization procedure for VHMS controller". 3. Perform the sign-up test on the machine side. a Perform the sign-up test in an open outdoor place. a If the sign-up test is performed in an indoor place where the satellite radio waves are blocked, it may not be completed. a It may take time to complete the sign-up test, depending on the condition of receiving signals from the ORBCOMM communication satellite and GPS satellite. 1) Check that the VHMS controller, ORBCOMM terminal, ORBCOMM antenna and GPS antenna are connected to the wiring harness of the machine. 2) Turn the starting switch to the ON position. 3) Wait until LED1 lights up. a LED1 keeps flashing until the sign-up test is completed.
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a The ORBCOMM terminal executes the sign-up test and judges the result by itself. The criterion is as follows. q The starting switch is in the ON position. q The VHMS controller can communicate with the ORBCOMM terminal (They are connected normally). q A valid GCC code is set to the VHMS controller. q The ORBCOMM terminal is receiving the signals from the ORBCOMM communication satellite. (The ORBCOMM antenna is connected.) q Positioning of the machine with the is completed (The GPS antenna is connected.) 4) Check that LED1 is lighting. a At this time, the sign-up test is completed. a Once the sign-up test is completed, the ORBCOMM terminal cannot be returned to the original state.
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Electrical system Using method of KOMTRAX functions of ORBCOMM terminal
[LED display] (1) LED-Green (2) LED-red
(3) LED – Yellow (4) LED – Green
[State] Waiting for server trigger: ON Normal operating state: OFF ORBCOMM satellite capture Satellite not captured: ON Satellite captured (No transmission data): Satellite captured (There is transmission Power OFF: OFF VHMS start recognition VHMS start recognized: ON VHMS stop recognized: OFF ORBCOMM MODEM power ON: ON KOMTRAX state
(5) LED – Red (6) LED – Red (7) 7 – segment
Unused Unused
(8) Dot
GPS satellite capture state
OFF: OFF Kept OFF Kept OFF Number of mails waiting to be sent (Max. of Satellite not captured: OFF Satellite captured: ON
* Flashing interval Quick flashing: Cycle of 1 sec (ON for 0.5 sec and OFF for 0.5 sec repeatedly) Slow flashing: Cycle of 4 sec (ON for 0.5 sec and OFF for 1.5 sec repeatedly)
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DRAFT Electrial system Using method of KOMTRAX functions of ORBCOMM terminal
4. Apply for starting to use. 1) Notify the VHMS/WebCARE operations administrator of the following information of the machine which has completed the station set-up check. q Model, model No. and serial No. of machine q Part No. and serial No. of ORBCOMM terminal q Reading of service meter when sign-up test was completed (0.1 h unit) 2) Fill in the "VHMS/WebCARE setting notification form" and enter "Use" in the column of "Use of KOMTRAX Service". 3) Send the "VHMS/WebCARE setting notification form" to VHMS/WebCARE Support Center in Komatsu Head Office. Komatsu VHMS/WebCARE Support Center 2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) E-mail: [email protected]
4) The KOMTRAX operations administrator registers the machine using the KOMTRAX client personal computer. a For the registration procedure, see the "Global KOMTRAX Web Reference Manual (For Key Person)".
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DRAFT Electrial system Precautions for replacing VHMS controller
Precautions for replacing VHMS controller a Tools for replacing VHMS controller SymPart No. Part name bol 1 799-608-3211 Discket 3 799-608-3220 Wiring harness Notebook type personal comZ Commercially puter 4 available :Windows98/2000/Me/XP/VIST A (*) [With RS232C terminal]
*:VHMS setting tool Ver.3.06.00.03 or later, VHMS analysis tool Ver.3.05.00.00 or later. a When the VHMS controller needs to be replaced, set it before removing it and the installed new VHMS controller according to the following procedure. a Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the initialization. a During the initialization work, confirm each work according to the "VHMS Initialization Work Checklist". [Work before replacing VHMS controller] 1. Downloading of remaining data a This step is a work performed in the operator's cab (on the personal computer). a Using the [Download] function, download the data currently recorded in the VHMS controller to the personal computer. a For the operating procedures, see Initialization procedures for VHMS controller, "8. Downloading of set data".
D375A-6 (01)
2. Check, saving and writing of information set in VHMS controller (Before Ver. 3.5.2.1) a This step is a work performed in the operator's cab (on the personal computer). a Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly installed VHMS controller. 2-1. Check and saving of information set in VHMS controller to be replaced. 1) Connect the personal computer and start the VHMS technical analysis tool. a See "Initialization procedures for VHMS controller". 2) Select "Save/Load" and press the "OK" button.
3) Check all the information before replacing the VHMS controller. 4) Select [Save] from [File] in the menu.
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DRAFT Electrial system Precautions for replacing VHMS controller
2-2. Writing of set information in new VHMS controller 1) Connect the personal computer again and start the VHMS technical analysis tool. a See "Initialization procedures for VHMS controller". 2) Select "Save/Load" and press the "OK" button. 5) Check the information again and press the "OK" button to save it.
3) Select [Load] from [File] in the menu. 6) Select [Exit] from [File] in the menu to finish the VHMS setting tool. 7) Disconnect the personal computer. a See Initialization procedures for VHMS controller, "9. Disconnection of Personal Computer". 8) Turn the personal computer OFF. 9) Replace the VHMS controller.
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DRAFT Electrial system Precautions for replacing VHMS controller
4) The saved information is displayed. Press the "OK" button.
7) After setting the time, press the "OK" button.
8) Press the [Apply] button, and the contents of the setting are displayed. Check the contents again and press the [OK] button if there is not a problem.
5) The saved information is displayed on another screen. 6) Press the [Edit] button to set the time.
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9) The system asks you if you will save the previous data. Press the "NO" button. a Usually, you do not need to save the previous data.
3. Check, saving and writing of information set in VHMS controller (Ver.3.5.2.1 or later) a This step is a work performed in the operator's cab (on the personal computer). a Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly installed VHMS controller. 3-1. Check and saving of information set in VHMS controller to be replaced. 1) Connect the personal computer and start the VHMS technical analysis tool. a See "Initialization procedures for VHMS controller". 2) Select [When VHMS needs to be replaced] and press the "Next" button.
10)Select [Exit] from [File] in the menu to finish the VHMS setting tool.
3) Select [Save Current Setting before replacement of VHMS controller] and press the "Next" button.
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DRAFT Electrial system Precautions for replacing VHMS controller
4) Check all the information before replacing the VHMS controller and press the "Save" button.
3) Select [Use Previous setting after replacement of VHMS controller] and press the "Next" button.
5) Select [Exit] from [File] in the menu to finish the VHMS setting tool. 6) Disconnect the personal computer. a See Initialization procedures for VHMS controller, "9. Disconnection of Personal Computer". 7) Turn the personal computer OFF. 8) Replace the VHMS controller.
4) The saved information is displayed. Press the "Next" button.
3-2. Writing of set information in new VHMS controller 1) Connect the personal computer again and start the VHMS technical analysis tool. a See "Initialization procedures for VHMS controller". 2) Select [When VHMS needs to be replaced] and press the "Next" button. 5) Set the time and press the "Apply" button.
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6) The system asks you if you will save the previous data. Press the "NO" button. a Usually, you do not need to save the previous data.
[Work after replacing VHMS controller] a After replacing the VHMS controller, carry out initialization according to the "Initialization Procedure for VHMS Controller". a Change the data to the information recorded before the VHMS controller was replaced. (Input the date and time when the VHMS controller was replaced.) a After completing the setting after the replacement, send the check sheet to VHMS/WebCARE Support Center of Komatsu, Tokyo. a Send the data downloaded before and after replacing the VHMS controller by Notes (LAN) or E-mail (WAN). Komatsu VHMS/WebCARE Support Center 2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan)
7) The above completes modification of the setting. Press [OK] button to end the VHMS initial setting tool.
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E-mail: [email protected]
D375A-6 (01)
DRAFT Pm Clinic service Pm Clinic service
Pm Clinic service Pm Clinic service Model D375A–6 #60001–
Serial No.
Service meter h
User name
Date of inspection / /
Serviceman
Specifications Blade □ Semi U blade □ U blade □
Blade tilt □ Single tilt blade □ Dual tilt blade
Attachment □ Multi–shank ripper □ Variable giant ripper □ Counter weight ( kg) □ Others
Shoe width □ 610 mm □ 710 mm □ 810 mm □ Others
Operating conditions Construction Type of soil (specific gravity) □ Construction, civil engineering □ Rock □ Roads □ Gravel □ Tunnels □ Sand □ □ Clay
Quarry, mine □ Coal □ Gold □ Limestone □
Type of work □ Dozing □ Side cutting □ Ripping □ Travel
% % % %
Existence of abnormalities Oil, coolant level check □ Engine coolant level □ Engine oil level □ Hydraulic oil level
When necessary □ Power train □ Final drive
□ Damper case □( )
Ambient temperature Max. Min.
Height above sea level
°C
m Operator's opinion Visual check results
[ Content: [ Content:
]
h
]
h
Failure code history [ Content: [ Content:
]
h
]
h
Operating mode q Working mode: P- or E-mode q Gear shift mode: Auto or Manual q Preset: F ,R Comment
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Pm Clinic measurement item or specification of the D375A–6 Measuring methods: Q: Measurement with machine monitor E: Measurement by gauge. (sensor or quick copuler) x: Need installation sensor or quick copuler Engine Specifications STD Pm clinic VHMS
Specifications STD Pm clinic VHMS
Engine speed
Engine oil pressure Exhaust temperature
Q Q Q
Q Q Q
Torque converter inlet pressure
Q Q Q
Torque converter outlet pressure
Q Q Q
Blow–by
Boost pressure
x x
Q Q Q
x
E Q
Power train oil circuit Torque converter stator L/U clutch pressure
E E E
Q
Steering pressure
Brake pressure
E E E
E E E
E E E
Power train oil circuit Transmission Specificamain relief tions pressure STD E Pm clinic E VHMS Q
1st
2nd
3rd
F
R
E E E
E E E
E E E
E E E
E E E
Work equipment circuit Specifications STD Pm clinic VHMS
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Transmission lubricating oil pressure
E E E
Fan circuit
Control source pressure
Pump pressure
Engine speed
E E E
E Q Q
Q Q Q
D375A-6 (06)
Pm Clinic Pm Clinic service
Testing points for Pm clinic (1/3)
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For the measurement procedures, see the following pages. *1. Engine speed: "Testing engine speed" *2. Blow–by pressure: "Testing blow–by pressure" *3. Engine oil pressure: "Testing engine oil pressure" *4. Boost pressure: "Testing intake air pressure (boost pressure)" *5. Exhaust gas temperature: "Testing exhaust temperature"
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Pm Clinic Pm Clinic service
Testing points for Pm clinic (2/3)
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For the measurement procedures, see the following pages. *6. Measurement related to torque converter: "Testing power train oil pressure" *7. Measurement related to transmission: "Testing power train oil pressure" *8. Measurement related to steering brake "Testing power train oil pressure"
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Pm Clinic Pm Clinic service
Testing points for Pm clinic (3/3)
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For the measurement procedures, see the following pages. *9. Hydraulic pressure of work equipment: "Measuring and ajusting work equipment oil pressure" *10. Source pressure of control circuit: "Testing of control circuit main pressure" *11. Fan speed: "Check of fan speed"
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Pm Clinic check sheet Work order No.
D375A–6
Date of inspection / /
Item
Service meter
Unit
Low idle
Engine speed
Deceleration pedal depressed
High idle
rpm
Engine
Torque converter stall (Adjustment ID: 0530) Torque converter stall + Work equipment relief (ripper raise) (Adjustment ID: 0530) Blowby pressure
SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH Oil temperature: Min. 70 °C
Low idle Engine oil pressure High idle Boost pressure
At torque converter stall
Exhaust temperature
Torque converter stall + Work equipment relief
Standard Service limit Test value for new OK NG Remarks value results machine 700 – 800
i
850 – 950
i
1,850 – 1,900
i
1,480– 1,580
1,450
1,450 – 1,550
1,400
Max. 3.43 {Max. 350}
Min. 9.41 {Min. 960}
Min. 117.68 {Min. 1.2}
Max. 78.45 {Max. 0.8}
Min. 392.27 {Min. 4.0}
Max. 235.36 {Max. 2.4}
kPa {mmHg}
Min. 155 {Min. 1,160}
Max. 141 {Max. 1.060}
°C
Max. 700
Min. 730
kPa {mmH2O}
At torque converter stall
Serviceman h
Test conditions
Decel
Serial No.
kPa {kg/cm2}
No. 1, 2 , 3 cylinder No. 4, 5, 6 cylinder
k For torque converter lockup clutch pressure, set both of the steering clutches to the disengage mode on the machine
monitor and check the pressure. Item
Test conditions
Unit
Inlet oil pressure
Torque converter
Outlet oil pressure Lockup clutch pressure Stator clutch pressure
Engine low idle
Transmission: Neutral
MPa {kg/cm2}
Inlet oil pressure Outlet oil pressure Lockup clutch pressure Stator clutch pressure Lockup clutch pressure
Engine high idle
Transmission: F2 (Adjustment ID: 5535)
Engine high idle
Standard Service limit Test value for new OK NG Remarks value results machine 0.03 – 0.25 {0.3 – 2.5} 0.03 – 0.20 {0.3 – 2.0} 0–0 {0 – 0} 2.25 – 2.87 {23.0 – 29.3} 0.69 – 1.05 {7.0– 10.7} 0.44 – 0.70 {4.5 – 7.0} 0–0 {0 – 0} 2.55 – 2.87 {26.0 – 29.3} 1.29 – 1.54 {13.2 – 15.7}
i i i i i i i i i i i i i i i i i i
k For each of the transmission clutch pressures, set both of the steering clutches to the disengage mode on the machine
monitor and check the pressures only in low idle for safety. Item
Test conditions
Unit
Engine low idle Main relief pressure
Transmission
Transmission: Neutral Lubricating oil pressure F clutch pressure R clutch pressure 1st clutch pressure 2nd clutch pressure 3rd clutch pressure
30-196 30-186
Engine high idle Engine high idle
Transmission: F1 (Adjustment ID: 5535) Transmission: R1 (Adjustment ID: 5535) Transmission: F1 (Adjustment ID: 5535) Transmission: F2 (Adjustment ID: 5535) Transmission: F3 (Adjustment ID: 5535)
Engine low idle Engine low idle Engine low idle Engine low idle Engine low idle
MPa {kg/cm2}
Standard Service limit Test OK NG Remarks value for new value results 2.48 – 2.87 {25.3 – 29.3} 2.68 – 2.87 {27.3 – 29.3} 0.08 – 0.25 {0.8 – 2.5} 2.25 – 2.84 {23.0 – 29.0} 2.25 – 2.84 {23.0 – 29.0} 2.06 – 2.35 {21.0 – 24.0} 2.25 – 2.84 {23.0 – 29.0} 2.25 – 2.84 {23.0 – 29.0}
2.38 – 3.07 {24.3 – 31.3} 2.58 – 3.07 {26.3 – 31.3} i i 2.06 – 3.13 {21.0 – 31.9} 2.06 – 3.13 {21.0 – 31.9} 1.86 – 2.55 {18.9 – 26.0} 2.06 – 3.13 {21.0 – 31.9} 2.06 – 3.13 {21.0 – 31.9}
D375A-6 (03)
DRAFT Pm Clinic service Pm Clinic service
Pm Clinic check sheet Work order No.
D375A–6
Date of inspection /
Item
Service meter
Test conditions
h
Unit
Engine low idle Steering clutch & brake
Left brake pressure Transmission: Neutral Left clutch pressure Engine high idle Left brake pressure
MPa {kg/cm2}
Right clutch pressure Engine low idle Right brake pressure Transmission: Neutral Right clutch pressure Engine high idle Right brake pressure Engine at high idle, F2, brake actuated
Hydraulic system
Item
Test conditions
Work equipment pump (Unload pressure)
Control lever in NEUEngine high idle TRAL position
Work equipment pump
Ripper lift relief or blade tilt relief
Control circuit source Control lever in NEUpressure TRAL position
Item Min. speed Fan
Engine low idle
Unit
MPa {kg/cm2}
Engine high idle
Test conditions
Unit
Engine low idle Fan 100 % mode
Max. speed
Item
Serviceman
/
Left clutch pressure
Brake performance
Serial No.
Standard value Service limit for new value machine
Test results
OK NG Remarks
Test results
OK NG Remarks
Test results
OK NG Remarks
Test results
OK NG Remarks
2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0} 2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0} 2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3} 2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3} 2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0} 2.25 – 2.84 2.2 – 3.04 {23.0 – 29.0} {22.4 – 31.0} 2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3} 2.55 – 2.87 2.4 – 3.07 {26.0 – 29.3} {24.4 – 31.3} Machine must not move
Standard value Service limit for new value machine 2.45 – 3.82 {25 – 39}
2.45 – 3.82 {25 – 39}
27.5 – 29.4 {280 – 300} 27.5 – 29.4 {280 – 300} 3.43 – 4.12 {35 – 42}
Min. 26.5 {Min. 270} Min. 26.5 {Min. 270} Min. 3.1 {Min. 32}
Standard value Service limit for new value machine 250 – 450
―
1,185 – 1,235
Max. 1,110
rpm Engine high idle
Test conditions
Unit
Standard value Service limit for new value machine
Engine low idle
7 – 13
20
Engine high idle
3.7 – 4.7
6
Engine low idle
2–4
6
Engine high idle
2.5 – 3.5
5
Engine low idle
4–6
7
2.5 – 3.5
5
Engine low idle
4–6
7
Engine high idle
2.5 – 3.5
5
Engine low idle
2–4
5
Engine high idle
2.5 – 3.5
5
Engine low idle
6 – 10
15
Engine high idle
2.8 – 3.8
6
Blade RAISE
Work equipment speed
Blade tilt (left and right tilt) [Single tilt model]
Blade tilt (left and right tilt) [Dual tilt model, Dual setting]
Engine high idle sec
Blade dump [Dual tilt specification]
Blade tilt (left and right tilt) [Dual tilt model, Single setting]
Ripper tilt (ino out)
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Pm Clinic Pm Clinic service
Pm Clinic check sheet Work order No.
D375A-6
Date of inspection /
Hydraulic drift
Item
Blade lift cylinder
Visual inspection of final drive drain plug Visual check of final drive drain plug
Service meter
Serviceman
/
h
Test conditions
Unit
Engine stopped Hydraulic oil temperature:
Standard value for new machine
Service limit value
Max. 65
i
Max. 25
i
Standard value for new machine
Service limit value
Test results
OK NG Remarks
Test results
OK NG Remarks
mm/5min. 45 to 55 °C
Ripper lift cylinder
Item
Serial No.
Test conditions
Unit
Engine speed – Engine stopped
There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts. Date
30-188
Service meter
Repair record
Date
Service meter
Repair record
D375A-6 (06)
DRAFT Pm Clinic service Pm Clinic service
D375A-6 (01)
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DRAFT Pm Clinic service Pm Clinic service
30-190
D375A-6 (01)
DRAFT Pm Clinic service Pm Clinic service
D375A-6 (01)
30-191
DRAFT Pm Clinic service Pm Clinic service
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D375A-6 (01)
DRAFT
D375A-6 SEN01868-02
BULLDOZER D375A-6 Shop Manual
Machine model D375A-6
Serial number 60001 and up
40 Troubleshooting
D375A-6 (01)
40-1
DRAFT Contents
Contents 40 Troubleshooting General Information on troubleshooting ........................................................................................................... Points to remember when troubleshooting ................................................................................................... Sequence of events in troubleshooting......................................................................................................... Checks before troubleshooting ..................................................................................................................... Classification and procedures for troubleshooting ........................................................................................ Failure codes table........................................................................................................................................ Phenomena and troubleshooting numbers ................................................................................................... Information in troubleshooting table.............................................................................................................. Troubleshooting method for disconnecting wiring harness of pressure sensor system................................ Connection table for connector pin numbers ................................................................................................ Connectors table and arrangement drawing................................................................................................. T-branch box and T-branch adapter table .................................................................................................... Fuse locations table ...................................................................................................................................... Troubleshooting by failure code ....................................................................................................................... Failure code [1380MW] Lock up clutch: Slip................................................................................................. Failure code [1500L0] Transmission clutch: Abnormal ................................................................................. Failure code [15E0MW] Transmission clutch: Slip........................................................................................ Failure code [15SAL1] Forward clutch: Fill high ........................................................................................... Failure code [15SALH] Forward clutch: Fill Low ........................................................................................... Failure code [15SBL1] Reverse clutch: Fill high ........................................................................................... Failure code [15SBLH] Reverse clutch: Fill Low........................................................................................... Failure code [15SEL1] Speed 1st clutch: Fill high ........................................................................................ Failure code [15SELH] Speed 1st clutch: Fill Low ........................................................................................ Failure code [15SFL1] Speed 2nd clutch: Fill high ....................................................................................... Failure code [15SFLH] Speed 2nd clutch: Fill Low ....................................................................................... Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................ Failure code [15SGLH] Speed 3rd clutch: Fill Low ....................................................................................... Failure code [15SJL1] L/U: Fill high .............................................................................................................. Failure code [15SJLH] L/U: Fill low............................................................................................................... Failure code [1800MW] P/T clutch: Slip........................................................................................................ Failure code [2201L1] Right clutch: Fill high ................................................................................................. Failure code [2201LH] Right clutch: Fill low.................................................................................................. Failure code [2202L1] Left clutch: Fill high ................................................................................................... Failure code [2202LH] Left clutch: Fill low .................................................................................................... Failure code [2300NR] Brake Themal Load Abnormality.............................................................................. Failure code [2301L1] Right brake: Fill high ................................................................................................. Failure code [2301LH] Right brake: Fill low .................................................................................................. Failure code [2301NR] Steering Brake RH Themal Load Abnormality ......................................................... Failure code [2302L1] Left brake: Fill high.................................................................................................... Failure code [2302LH] Left brake: Fill low..................................................................................................... Failure code [2302NR] Steering Brake LH Themal Load Abnormality.......................................................... Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection.................................................................. Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ..................................................................... Failure code [AA10NX] Air Cleaner Clogging ............................................................................................... Failure code [AB00MA] Battery Charge Abnormal ....................................................................................... Failure code [B@BAZG] Eng Oil Press Low................................................................................................. Failure code [B@BAZK] Eng Oil Level Low.................................................................................................. Failure code [B@BCNS] Eng Water Overheat ............................................................................................. Failure code [B@BCZK] Eng Water Level Low ............................................................................................ Failure code [B@CENS] T/C Oil Overheat ................................................................................................... Failure code [B@HANS] Hyd Oil Overheat................................................................................................... Failure code [B@HAZK] Hyd Oil Level Low.................................................................................................. Failure code [CA111] ECM Critical Internal Failure ...................................................................................... Failure code [CA115] Eng Ne and Bkup Speed Sens Error ......................................................................... Failure code [CA122] Chg Air Press Sensor High Error ...............................................................................
40-2
40 - 9 40 - 9 40 - 10 40 - 11 40 - 36 40 - 39 40 - 45 40 - 47 40 - 49 40 - 52 40 - 88 40 -102 40 -105 40 -109 40 -109 40 -110 40 -111 40 -112 40 -114 40 -116 40 -118 40 -120 40 -122 40 -124 40 -126 40 -128 40 -130 40 -132 40 -134 40 -136 40 -138 40 -140 40 -142 40 -144 40 -146 40 -148 40 -150 40 -152 40 -154 40 -156 40 -158 40 -160 40 -162 40 -164 40 -166 40 -166 40 -167 40 -168 40 -169 40 -170 40 -171 40 -172 40 -174 40 -176 40 -178
D375A-6 (01)
DRAFT Contents
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................ Failure code [CA131] Throttle Sensor High Error ......................................................................................... Failure code [CA132] Throttle Sensor Low Error .......................................................................................... Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................... Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ Failure code [CA144] Coolant Temp Sens High Error .................................................................................. Failure code [CA145] Coolant Temp Sens Low Error................................................................................... Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... Failure code [CA212] Eng Oil Temp Sensor High Error ............................................................................... Failure code [CA213] Eng Oil Temp Sensor Low Error ................................................................................ Failure code [CA221] Ambient Press Sens High Error ................................................................................. Failure code [CA222] Ambient Press Sens Low Error .................................................................................. Failure code [CA227] Sens Supply 2 Volt High Error ................................................................................... Failure code [CA234] Eng Overspeed .......................................................................................................... Failure code [CA238] Ne Speed Sens Supply Volt Error.............................................................................. Failure code [CA263] Fuel Temp Sensor High Error .................................................................................... Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................................... Failure code [CA271] IMV/PCV1 Short Error................................................................................................ Failure code [CA272] IMV/PCV1 Open Error................................................................................................ Failure code [CA273] PCV2 Short Error ....................................................................................................... Failure code [CA274] PCV2 Open Error ....................................................................................................... Failure code [CA322] Inj #1 (L#1) Open/Short Error..................................................................................... Failure code [CA323] Inj #5 (L#5) Open/Short Error..................................................................................... Failure code [CA324] Inj #3 (L#3) Open/Short Error..................................................................................... Failure code [CA325] Inj #6 (L#6) Open/Short Error..................................................................................... Failure code [CA331] Inj #2 (L#2) Open/Short Error..................................................................................... Failure code [CA332] Inj #4 (L#4) Open/Short Error..................................................................................... Failure code [CA342] Calibration Code Incompatibility................................................................................. Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................... Failure code [CA386] Sens Supply 1 Volt High Error ................................................................................... Failure code [CA441] Battery Voltage Low Error .......................................................................................... Failure code [CA442] Battery Voltage High Error ......................................................................................... Failure code [CA449] Rail Press Very High Error ......................................................................................... Failure code [CA451] Rail Press Sensor High Error ..................................................................................... Failure code [CA452] Rail Press Sensor Low Error...................................................................................... Failure code [CA553] Rail Press High Error ................................................................................................. Failure code [CA554] Rail Press Sensor In Range Error.............................................................................. Failure code [CA559] Rail Press Low Error .................................................................................................. Failure code [CA689] Eng Ne Speed Sensor Error ...................................................................................... Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................................... Failure code [CA757] All Continuous Data Lost Error................................................................................... Failure code [CA778] Eng Bkup Speed Sensor Error................................................................................... Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................................... Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................................... Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................. Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................................ Failure code [CA2249] Rail Press Very Low Error........................................................................................ Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................................. Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. Failure code [CA2351] EGR Valve Sol Current High Error........................................................................... Failure code [CA2352] EGR Valve Sol Current Low Error............................................................................ Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................ Failure code [D130KA] Neutral relay: Disconnection.................................................................................... Failure code [D130KB] Neutral relay: Short circuit .......................................................................................
D375A-6 (01)
40 -180 40 -182 40 -184 40 -186 40 -188 40 -190 40 -192 40 -194 40 -196 40 -198 40 -200 40 -202 40 -204 40 -206 40 -208 40 -209 40 -210 40 -212 40 -214 40 -216 40 -217 40 -218 40 -219 40 -220 40 -222 40 -224 40 -226 40 -228 40 -230 40 -232 40 -233 40 -234 40 -236 40 -237 40 -238 40 -239 40 -240 40 -242 40 -244 40 -245 40 -246 40 -250 40 -252 40 -253 40 -254 40 -256 40 -257 40 -258 40 -259 40 -260 40 -261 40 -262 40 -264 40 -266 40 -268 40 -270 40 -272 40 -274
40-3
DRAFT Contents
Failure code [D161KA] Back-up alarm releay: Disconnection ...................................................................... Failure code [D161KB] Back-up alarm releay: Short circuit.......................................................................... Failure code [D182KZ] Preheater Relay Abnormality ................................................................................... Failure code [D190KA] ACC signal relay: Disconnection ............................................................................. Failure code [D190KB] ACC signal relay: Short circuit ................................................................................. Failure code [D1EFKA] Pre lub. motor relay: Disconnection ........................................................................ Failure code [D1EFKB] Pre lub. motor relay: Short circuit............................................................................ Failure code [DAFRKR] Monitor: Can communication lost (PT) ................................................................... Failure code [dAFRKR] Monitor: CAN communication lost (WE) ................................................................. Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................ Failure code [DB2RKR] ENG cont.: Can communication lost (PT)............................................................... Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ...................................................... Failure code [DB90KT] WE controller: Abnormality in controller .................................................................. Failure code [DB91KK] WE controller: Source voltage reduction ................................................................. Failure code [DB92KK] WE controller: Output voltage reduction.................................................................. Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ............................................................ Failure code [DB99KQ] WE controller: Type select signal............................................................................ Failure code [DB9RKR] WE controller: Can communication lost (PT).......................................................... Failure code [DBB0KK] VHMS controller:Source voltage reduction ............................................................. Failure code [DBB0KQ] VHMS connector connection abnormality .............................................................. Failure code [DBB3KK] VHMS controller: Source voltage reduction ............................................................ Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction............................................................... Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction................................................................ Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction................................................................ Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) ........................................................... Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... Failure code [DBE1KK] PT controller: Source voltage reduction.................................................................. Failure code [DBE2KK] PT controller: Output voltage reduction .................................................................. Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction ............................................................. Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ................................................................ Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction ............................................................. Failure code [DBE9KQ] PT controller: Type select signal ............................................................................ Failure code [DBERKR] PT controller: Can communication lost (WE) ......................................................... Failure code [DD12KA] Shift up Sw: Disconnection ..................................................................................... Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... Failure code [DD13KA] Shift down Sw: Disconnection................................................................................. Failure code [DD13KB] Shift down Sw: Short circuit .................................................................................... Failure code [DD14KA] Parking lever Sw: Dissconnection........................................................................... Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ Failure code [DDB9L4] Reverse SW Signal disagreement........................................................................... Failure code [DDE2KA] Pre lub. oil press sw: Disconnection ....................................................................... Failure code [DDK3L4] Forward SW Signal disagreement........................................................................... Failure code [DDK5KA] Shift switch disconnection....................................................................................... Failure code [DDK5KB] Shift switch short circuit .......................................................................................... Failure code [DDN2LD] Blade tilt RH pressure SW abnormality .................................................................. Failure code [DDN3LD] Blade tilt LH pressure SW abnormality ................................................................... Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ................................................................... Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................... Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection........................................................................ Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ........................................................................... Failure code [DDNALD] Blade lift up pressure SW abnormality ................................................................... Failure code [DDNBLD] Ripper lift up pressure SW abnormality.................................................................. Failure code [DDNCLD] Ripper lift down pressure SW abnormality ............................................................. Failure code [DDNDLD] Ripper tilt in pressure SW abnormality ................................................................... Failure code [DDNELD] Ripper tilt back pressure SW abnormality .............................................................. Failure code [DDNFLD] Blade lift down pressure SW abnormality ............................................................... Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................. Failure code [DDNLKB] Weq lock Sw: Short circuit......................................................................................
40-4
40 -276 40 -278 40 -280 40 -282 40 -284 40 -286 40 -288 40 -290 40 -291 40 -292 40 -297 40 -300 40 -301 40 -302 40 -304 40 -306 40 -308 40 -309 40 -312 40 -314 40 -316 40 -318 40 -320 40 -322 40 -323 40 -323 40 -324 40 -326 40 -328 40 -330 40 -332 40 -334 40 -335 40 -338 40 -340 40 -342 40 -344 40 -346 40 -348 40 -350 40 -352 40 -354 40 -356 40 -358 40 -360 40 -362 40 -364 40 -366 40 -368 40 -370 40 -372 40 -374 40 -376 40 -378 40 -380 40 -382 40 -384 40 -386
D375A-6 (01)
DRAFT Contents
Failure code [DDT5KA] Neutral switch disconnection .................................................................................. Failure code [DDT5KB] Neutral switch short circuit ...................................................................................... Failure code [DDT5KQ] Lever SPEC selection signal disagreement ........................................................... Failure code [DDTSL1] S/C: Fill high ............................................................................................................ Failure code [DDTSLH] S/C: Fill low............................................................................................................. Failure code [DGE5KX] Ambient temp sensor abnormality .......................................................................... Failure code [DGS1KX] Hyd oil temp: signal abnormal ................................................................................ Failure code [DGT1KA] T/C oil temp sensor: Abnormal ............................................................................... Failure code [DGT1KX] T/C oil temp sensor: Abnormal ............................................................................... Failure code [DGT5KA] F exhaust temp sensor disconnection .................................................................... Failure code [DGT5KB] F exhaust temp sensor short circuit........................................................................ Failure code [DGT6KA] R exhaust temp sensor disconnection.................................................................... Failure code [DGT6KB] R exhaust temp sensor short circuit ....................................................................... Failure code [DH21KA] Weq pressure sensor: Disconnection ..................................................................... Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... Failure code [DHE5KB] ENG blow-by pressure sensor disconnection......................................................... Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ............................................................ Failure code [DHT3KX] T/M oil pressure sensor abnormality....................................................................... Failure code [DHT5KA] T/C in-pressure sensor: Disconnection................................................................... Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ...................................................................... Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................................................. Failure code [DHT7KB] T/C out-pressure sensor: Short circuit .................................................................... Failure code [DK10KA] Fuel control Dial: Disconnection.............................................................................. Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................. Failure code [DK30KA] ST lever 1: Disconnection ....................................................................................... Failure code [DK30KB] ST lever 1: Short circuit ........................................................................................... Failure code [DK30KX] ST lever: Out of normal range ................................................................................. Failure code [DK30KZ] ST lever: Disconnection or short circuit ................................................................... Failure code [DK30L8] ST lever: Signal mismatch ....................................................................................... Failure code [DK31KA] ST lever 2: Disconnection ....................................................................................... Failure code [DK31KB] ST lever 2: Short circuit ........................................................................................... Failure code [DK40KA] Brake potentiometer: Disconnection ....................................................................... Failure code [DK40KB] Brake potentiometer: Short circuit ........................................................................... Failure code [DK55KX] FR lever: Out of normal range................................................................................. Failure code [DK55KZ] FR lever: Disconnection or short circuit................................................................... Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................... Failure code [DK56KA] FR lever 1: Disconnection ....................................................................................... Failure code [DK56KB] FR lever 1: Short circuit........................................................................................... Failure code [DK57KA] FR lever 2: Disconnection ....................................................................................... Failure code [DK57KB] FR lever 2: Short circuit........................................................................................... Failure code [DK60KA] Acceleration sensor: Disconnection ........................................................................ Failure code [DK60KB] Acceleration sensor: Short circuit............................................................................ Failure code [DKH1KA] Pitch angle sensor: Disconnection.......................................................................... Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................. Failure code [DLF1KA] T/C out-speed sensor: Disconnection ..................................................................... Failure code [DLM3KA] Fan rev. sensor: Disconnection .............................................................................. Failure code [DLM3MB] Fan control: Decline ............................................................................................... Failure code [DLT3KA] T/M out-speed sensor: Disconnection ..................................................................... Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................ Failure code [DW59KA] Blade dual selector SOL disconnection.................................................................. Failure code [DW59KB] Blade dual selector SOL short circuit ..................................................................... Failure code [DW59KY] Blade dual selector SOL hot short.......................................................................... Failure code [DW5AKA] Blade pitch selector SOL disconnection ................................................................ Failure code [DW5AKB] Blade pitch selector SOL short circuit .................................................................... Failure code [DW5AKY] Blade pitch selector SOL Short circuit ................................................................... Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................. Failure code [DW7BKB] Fan rev EPC: Short circuit ..................................................................................... Failure code [DWN3KA] Ssp solenoid: Disconnection..................................................................................
D375A-6 (01)
40 -388 40 -390 40 -392 40 -394 40 -396 40 -398 40 -400 40 -402 40 -404 40 -406 40 -408 40 -410 40 -412 40 -414 40 -416 40 -418 40 -420 40 -422 40 -424 40 -426 40 -428 40 -430 40 -432 40 -434 40 -436 40 -438 40 -440 40 -440 40 -441 40 -442 40 -444 40 -446 40 -448 40 -450 40 -450 40 -451 40 -452 40 -454 40 -456 40 -458 40 -460 40 -462 40 -464 40 -466 40 -468 40 -469 40 -470 40 -471 40 -472 40 -473 40 -474 40 -475 40 -476 40 -477 40 -478 40 -479 40 -480 40 -481
40-5
DRAFT Contents
Failure code [DWN3KB] Ssp solenoid: Short circuit ..................................................................................... Failure code [DWN3KY] SSP solenoid: Short circuit .................................................................................... Failure code [DWN5KA] Fan pump solenoid 1: Disconnection..................................................................... Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ........................................................................ Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ........................................................................ Failure code [DWNCKA] Fan pump solenoid 2: Disconnection .................................................................... Failure code [DWNCKB] Fan pump solenoid 2: Short circuit........................................................................ Failure code [DWNCKY] Fan pump solenoid 2: Short circuit........................................................................ Failure code [DXH1KA] Lock-up ECMV: Disconnection ............................................................................... Failure code [DXH1KB] Lock-up ECMV: Short circuit................................................................................... Failure code [DXH1KY] Lock-up ECMV: Short circuit................................................................................... Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................. Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................ Failure code [DXH4KY] 1st clutch ECMV: Short circuit ................................................................................ Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ........................................................................... Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ............................................................................ Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................ Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................................................ Failure code [DXH7KA] R clutch ECMV: Disconnection............................................................................... Failure code [DXH7KB] R clutch ECMV: Short circuit .................................................................................. Failure code [DXH7KY] R clutch ECMV: Short circuit .................................................................................. Failure code [DXH8KA] F clutch ECMV: Disconnection ............................................................................... Failure code [DXH8KB] F clutch ECMV: Short circuit................................................................................... Failure code [DXH8KY] F clutch ECMV: Short circuit................................................................................... Failure code [DXH9KA] Right clutch ECMV: Disconnection ......................................................................... Failure code [DXH9KB] Right clutch ECMV: Short circuit............................................................................. Failure code [DXH9KY] Right clutch ECMV: Short circuit............................................................................. Failure code [DXHAKA] Left clutch ECMV: Disconnection ........................................................................... Failure code [DXHAKB] Left clutch ECMV: Short circuit............................................................................... Failure code [DXHAKY] Left clutch ECMV: Short circuit............................................................................... Failure code [DXHBKA] Right brake ECMV: Disconnection ......................................................................... Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................. Failure code [DXHBKY] Right brake ECMV: Short circuit............................................................................. Failure code [DXHCKA] Left brake ECMV: Disconnection ........................................................................... Failure code [DXHCKB] Left brake ECMV: Short circuit............................................................................... Failure code [DXHCKY] Left brake ECMV: Short circuit............................................................................... Failure code [DXJBKA] S/C ECMV: Disconnection ...................................................................................... Failure code [DXJBKB] S/C ECMV: Short circuit.......................................................................................... Failure code [DXJBKY] S/C ECMV: Short circuit.......................................................................................... Failure code [DY2HKA] Pre lub. motor: Disconnection................................................................................. Failure code [F@BBZL] ENG blow-by pressure high level ........................................................................... Failure code [F@BYNR] F exhaust temp high level (2) ................................................................................ Failure code [F@BYNS] F exhaust temp high level (1) ................................................................................ Failure code [F@BZNR] R exhaust temp high level (2)................................................................................ Failure code [F@BZNS] R exhaust temp high level (1) ................................................................................ Troubleshooting of electrical system (E-mode) ................................................................................................ Information contained in troubleshooting table ............................................................................................. E-1 Engine does not start (starting motor does not turn) .............................................................................. E-2 Preheater does not operate.................................................................................................................... E-3 When starting switch is turned ON, machine monitor displays nothing.................................................. E-4 When starting switch is turned ON (before starting engine), basic check item lights up........................ E-5 Precaution item lights up while engine is running .................................................................................. E-6 Emergency stop item lights up while engine is running.......................................................................... E-7 Engine coolant temperature gauge does not indicate normally ............................................................. E-8 Fuel gauge does not indicate properly ................................................................................................... E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................
40-6
40 -482 40 -484 40 -486 40 -487 40 -488 40 -490 40 -491 40 -492 40 -494 40 -495 40 -496 40 -498 40 -499 40 -500 40 -502 40 -503 40 -504 40 -506 40 -507 40 -508 40 -510 40 -511 40 -512 40 -514 40 -515 40 -516 40 -518 40 -519 40 -520 40 -522 40 -523 40 -524 40 -526 40 -527 40 -528 40 -530 40 -531 40 -532 40 -534 40 -535 40 -536 40 -538 40 -540 40 -541 40 -542 40 -543 40 -544 40 -545 40 -545 40 -547 40 -550 40 -554 40 -556 40 -558 40 -560 40 -561 40 -562 40 -564
D375A-6 (01)
Table of contents
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally..................... E-11 Contents of display by machine monitor are different from applicable machine ......... E-12 Machine monitor does not display some items ........................................................... E-13 Function switch does not work .................................................................................... E-14 Operation mode does not change............................................................................... E-15 Gearshift mode does not change ................................................................................ E-16 Customize function does not operate normally ........................................................... E-17 Customize memory function does not operate normally ............................................. E-18 Alarm buzzer does not sound or does not stop........................................................... E-19 When starting switch is turned OFF, service meter is not displayed........................... E-20 Machine monitor cannot be set in service mode......................................................... E-21 The ripper pin puller cylinder does not operate........................................................... E-22 Horn does not sound or does not stop ........................................................................ E-23 Back-up alarm does not sound or does not stop......................................................... E-24 Fan does not reverse .................................................................................................. E-25 The head lamp and rear lamp do not light up ............................................................. E-26 Windshield wiper does not operate ............................................................................. E-27 Window washer does not operate............................................................................... E-28 Electric priming pump does not operate or does not stop automatically..................... E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .................. E-30 Gear cannot be shifted................................................................................................ Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ Information in troubleshooting table..................................................................................... List of Failure Modes and Causes ....................................................................................... H-1 Machine lacks power(or drawbar pull) .......................................................................... H-2 Machine cannot travel (at 2nd or 3rd each speed) ....................................................... H-3 Machine cannot travel at any gear speeds ................................................................... H-4 Machine travels only in one direction, forward or reverse............................................. H-5 Large time lag at gear shifting or directional change .................................................... H-6 Machine connot turn ..................................................................................................... H-7 Machine turns only to one side ..................................................................................... H-8 Machine overruns at turnning ....................................................................................... H-9 Brake does not work ..................................................................................................... H-10 Torque converter does not lock up ............................................................................. H-11 Power train oil overheats ............................................................................................ H-12 All work equipment operates too slow or lacks power ................................................ H-13 All work equipment does not operate.......................................................................... H-14 Blade lift cylinder speed is too slow or lacks power .................................................... H-15 Blade tilt cylinder speed is too slow or lacks power .................................................... H-16 Ripper lift cylinder speed is too slow or lacks power................................................... H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... H-22 Blade pitch does not work (machine with dual tilt specification) ................................. H-23 Abnormal noise from around work equipment pump .................................................. H-24 Abnormal fan rotation (noise and/or vibration are abnormally large or engine overheats) H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator) ....................................................................... Troubleshooting of engine (S-mode) ...................................................................................... Method of using troubleshooting chart................................................................................. S-1 Engine does not start easily .......................................................................................... S-2 Engine does not start .................................................................................................... S-3 Engine does not rev up smoothly (response-up is poor)............................................... S-4 Engine stops during operation ...................................................................................... S-5 Engine does not rotate smoothly (hunting) ................................................................... S-6 Engine lacks power (or output shortage) ...................................................................... D375A-6 (07)
40- 565 40- 566 40- 566 40- 566 40- 567 40- 567 40- 568 40- 568 40- 569 40- 569 40- 569 40- 570 40- 572 40- 574 40- 576 40- 577 40- 584 40- 590 40- 596 40- 598 40- 600 40- 601 40- 601 40- 602 40- 604 40- 606 40- 607 40- 608 40- 609 40- 610 40- 611 40- 612 40- 612 40- 613 40- 614 40- 615 40- 616 40- 617 40- 617 40- 618 40- 618 40- 619 40- 619 40- 620 40- 620 40- 621 40- 621 40- 622 40- 622 40- 624 40- 624 40- 628 40- 630 40- 634 40- 636 40- 637 40- 638 40-7
Table of contents
S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 640 S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 642 S-9 Engine oil becomes contaminated quickly .................................................................... 40- 643 S-10 Fuel consumption is excessive.................................................................................... 40- 644 S-11 Oil mixes into coolant(coolant blows back or is reduced)............................................ 40- 645 S-12 Engine pressure monitor lights up (drop in engine oil pressure) ................................. 40- 646 S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 647 S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 649 S-15 Abnormal noise is heard.............................................................................................. 40- 650 S-16 Vibration is excessive.................................................................................................. 40- 651 S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls) ............................ 40- 652
40-8
D375A-6 (07)
DRAFT General Information on troubleshooting Points to remember when troubleshooting
General Information on troubleshooting Points to remember when troubleshooting k k k k k k
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 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot 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 preventreoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understandthe structure and function. However, a short cut to effective troubleshooting is to ask the operatorvarious 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 after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask the 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 the failure? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?
4) Check maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting table or troubleshooting flowchart to locate the position of the failure exactly. a The basic procedures 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.
3. Checks before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work. 3) Make checks of other items. D375A-6 (01)
40-9
DRAFT General Information on troubleshooting Sequence of events in troubleshooting
Sequence of events in troubleshooting (Rev. 2007. 12)
40-10
D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
Checks before troubleshooting
a. Engine, lubricating oil and coolant
No.
Item
Criterion
Remedy
1 Check for abnormal sounds and smells
―
Repair
2 Check for dirt around engine
―
Remove
3 Check for water leakage around engine
―
Repair
4 Check for oil leakage around engine
―
Repair
5 Check for leakage from fuel line
―
Repair
6 Check of radiator for clogging
―
Remove
7 Check of level and type of fuel
―
Refilling with oil
8 Check for foreign matter in fuel
―
Clean and drain
9 Check of fuel pre filter
―
Replace
10 Check of fuel filter
―
Replace
11 Check of level (in oil pan) and type of engine oil
Between H – L
Refilling with oil
12 Check of coolant level (in sub tank)
Between H – L Refilling with coolant No clogging indication on monitor
Clean or replace
1 Check for abnormal sounds and smells
―
Repair
2 Check for oil leakage
―
Repair
3 Check of hydraulic oil
Between H – L
Refilling with oil
4 Check of hydraulic oil strainer
―
Clean and drain
5 Check of hydraulic oil filter
―
Replace
6 Check of power train case oil level
Between H – L
Refilling with oil
7 Check of power train pump strainer
―
Clean and drain
8 Check of transmission oil filter and torque converter oil filter
―
Clean and drain
9 Check of damper case oil level
Between H – L
Refilling with oil
10 Check of final drive case oil level
Between H – L
Refilling with oil
―
Air bleeding
b. Hydraulic and mechanical equipment
13 Check of air cleaner for clogging
11 Execution of air bleeding operation
D375A-6 (01)
40-11
DRAFT General Information on troubleshooting Checks before troubleshooting
No.
Item
Criterion
Remedy
1 Check of battery terminals for looseness and corrosion
―
Retighten or replace
2 Check of alternator terminals for looseness and corrosion
―
Retighten or replace
3 Check of starting motor terminals for looseness and corrosion
―
Retighten or replace
20–30 V
Replace
Between H – L
Add or replace
―
Repair or replace
―
Repair
8 Check of grounding
―
Repair
9 Check for loose connector and damaged lock
―
Repair or replace
10 Check of connector pin for corrosion, bends and deformation
―
Repair or replace
11 Check for water and foreign matter in connector
―
Dry, clean or replace
12 Check of wiring harness for disconnection and short circuit
―
Repair or replace
13 Check of fuse for disconnection and corrosion
―
Replace
14 Check of circuit breaker
―
Push in reset button
4 Testing of battery voltage (with engine stopped) 5 Check of battery electrolyte level Check of wiring harness for discoloration, burnt areas and cover peeling Check for removal of wiring harness clamp and sagging of wiring har7 ness
c. Electrical equipment
6
e. Interior parts d. Exterior parts
After several minutes opera15 Check of alternator voltage (When engine speed is medium or higher) tion: 27.5 – 29.5 V Check of battery relay operation sound (When starting switch is 16 ― turned to ON or OFF position)
40-12
Replace
Replace
1 Check of undercarriage
―
Repair
2 Check of handrails and steps
―
Repair
3 Check of mirrors
―
Clean or repair
1 Check of gauges and monitors
―
Clean or replace
2 Check of seat belt
―
Repair
D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
Testing procedure before troubleshooting Walk-around check Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakage of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system. Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust. k
Accumulated combustibles around hot engine parts such as the engine muffler, turbocharger, etc. and leaking fuel and oil may cause a machine fire. Check thoroughly and repair any abnormalities without fail.
a1., b1. Check for abnormal sounds and smells Check for abnormal sounds and smells Some causes of abnormal sounds and smells can damage the machine if they are left as they are. Therefore, stop the machine immediately when you discover the cause. a2. Check around engine and dirt removal Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.) on hot engine parts such as the engine muffler, turbocharger, etc.. a3. Check for water leakage around engine a4. Check for oil leakage around engine Check any oil leaks from the engine and any water leaks from the coolant system. If any of them is abnormal, carry out a repair. a5. Check for leakage from fuel line Check any fuel leaks and damaged hoses and tubes. If any of them is abnormal, carry out a repair. a6. Check of radiator and dirt removal Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator. For removal of dirt from the radiator, see the Operation and maintenance manual, "Cleaning and testing of radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with the air conditioner)". b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that the clearance between them is within the normal range, and then repair any abnormalities.
D375A-6 (01)
b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage Check and repair any oil leaks. c1. Check around battery and dirt removal Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery. d1. Check of undercarriage (track, sprocket, idler and guard) for abnormalities, wear, loose bolts and oil leakage from roller Repair any abnormalities. d2. Check of handrails and steps for abnormalities and loose bolts Repair any abnormalities and retighten any loose bolts. d3. Check and cleaning of rear view mirrors Check and repair any abnormalities and breakage of the rear view mirrors. Clean the mirror surfaces and adjust their angles so that the operator can see the area behind him from the operator's seat. e1. Check of gauges and monitors for abnormalities Check the gauges and monitors inside the operator cab. If any of them is abnormal, replace it. Clean up the surfaces. e2. Check of seat belt and fittings Check any damaged hooks, locks and hook fittings. If any of them is abnormal, carry out a repair.
40-13
DRAFT General Information on troubleshooting Checks before troubleshooting
Testing according to testing procedure a. Engine, lubricating oil and coolant a7. Check of level and type of fuel Fuel is flammable and dangerous. Do not bring any open flame near fuel. k When adding fuel, take care not to let it overflow. k Wipe off any spilt fuel. If fuel has spilt over dirt and sand, remove the dirt and sand, too. 1. Turn the starting switch to the ON position and check the fuel level with fuel level gauge (G) in the monitor panel. After checking, return the switch to the OFF position. k
2. If the fuel level is low, open oil filler cap (F) of the fuel tank and add fuel through the oil filler port to the necessary level. q If the filter of breather (1) is clogged, the pressure in the tank decreases and fuel may not be supplied. To prevent this, clean the filter.
a8. Check for foreign matter in fuel 1. Open the cover on the rear side of the machine. 2. Put a container under drain hose (1) to receive the drained fuel. 3. Turn drain valve (2) to the "OPEN" position (O) to discharge the sediment and water in the bottom together with the fuel. 4. When only the clean fuel flows out, turn drain valve (2) to the "CLOSE" position (S). 5. Close the cover.
a9. Check for fuel pre-filter (water separator) k Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k High pressure is generated in the engine fuel piping system while the engine is running. Wait for at least 30 seconds after stopping the engine until the internal pressure decreases, and then replace the filter. k Do not bring any open flame near the filter. a Komatsu genuine fuel prefilter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine cartridges. a The common rail fuel injection system of this machine consists of parts that are more precise compared with the conventional injection pump and nozzle. If a fuel prefilter cartridge other than Komatsu genuine one is used, foreign matter may enter, which can cause a trouble in the injection system. Never use a substitute. a When testing and servicing the fuel system, be extremely careful that no foreign matter enters. If any dirt sticks, remove it completely by using fuel. q Prepare an oil receiving container. q Prepare the filter wrench.
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DRAFT General Information on troubleshooting Checks before troubleshooting
1. Turn supply valve (1) of the fuel tank to the "CLOSE" (S) position.
2. Open the engine hood. 3. Place the oil receiving container under prefilter cartridge (2). 4. Remove transparent cup (3) from pre-filter cartridge, and check it. If damaged, replace it with a new one. 5. Using the filter wrench, rotate filter cartridge (2) to the left to remove.
9. Clean the filter bracket and thinly apply oil to the packing surface of the filter cartridge. a Do not pour fuel into the filter cartridge. 10. Remove cap (A) at the center of the filter cartridge and install the cartridge in the filter bracket.
6. Clean transparent cup (3), and remove seal (4). 7. Coat seal with clean fuel or oil, and mount the seal. 8. Mount transparent cup (3) in pre-filter cartridge. 3 Tightening torque of transparent cup (3): 10 Nm {1.0 kgm} a Make sure that drain plug (5) at bottom of transparent cup (3) is secured. 3 Tightening torque of drain plug (5): 0.2 – 0.4 Nm {0.02 – 0.046 kgm}
D375A-6 (01)
11. Install the filter cartridge. a When installing the filter cartridge, tighten it by 3/4 turns after its O-ring has been securely placed on the sealing surface of the filter bracket. a If the prefilter cartridge has been over tightened, fuel will leak because the O-ring will have been damaged. If the filter cartridge is not tightened sufficiently, fuel will also leak through the clearance of the packing. Therefore, observe the tightening angle. 12. Then, proceed to "a10. Check of fuel filter".
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DRAFT General Information on troubleshooting Checks before troubleshooting
a10. Check of fuel filter Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k High pressure is generated in the engine fuel piping system while the engine is running. Wait for at least 30 seconds after stopping the engine until the internal pressure decreases, and then replace the filter. k Do not bring any open flame near the filter. a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine cartridges. k
a The common rail fuel injection system of this machine consists of parts that are more precise compared with the conventional injection pump and nozzle. If a fuel filter cartridge other than Komatsu genuine one is used, foreign matter may enter, which can cause a trouble in the injection system. Never use a substitute. a When testing and servicing the fuel system, be extremely careful that no foreign matter enters. If any dirt sticks, remove it completely by using fuel. q Prepare an oil receiving container. q Prepare the filter wrench. 1. Turn supply valve (1) of the fuel tank to the "CLOSE" (S) position.
4. Place the oil receiving container under filter cartridge (3). 5. Using the filter wrench, rotate filter cartridge (3) to the left to remove.
6. Clean the filter bracket and thinly apply oil to the packing surface of the filter cartridge. a Do not pour fuel into the filter cartridge. 7. Remove cap (A) at the center of the filter cartridge and install the cartridge in the filter bracket.
2. Open the engine hood. 3. Open air bleeding valve (2).
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D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
8. Install the filter cartridge. a When installing the filter cartridge, tighten it by 3/4 turns after its O-ring has been securely placed on the sealing surface of the filter bracket. a If the filter cartridge has been over tightened, fuel will leak because the O-ring will have been damaged. If the filter cartridge is not tightened sufficiently, fuel will also leak through the clearance of the packing. Therefore, observe the tightening angle. 9. Turn valve (1) at the fuel tank bottom to the "OPEN" (O) position. 10. Bleed air. For details, see Testing and adjusting, "Bleeding air from fuel circuit". 11. Close air bleeding valve (2). a11. Check of level (in oil pan) and type of engine oil k Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. a If the engine has been operated, wait for at least 15 minutes after stopping it, and check the oil level. a When checking, set the machine in a horizontal position. 1. Stop the engine. 2. Open the engine hood. 3. Remove oil level gauge (G) and wipe gauge oil off with a cloth. 4. Insert oil level gauge (G) fully and pull it out.
6. If the oil level is above H 1) Remove the cover from the machine bottom and place a waste oil container directly below it.
2) Remove drain plug (1). 3) Loosen drain valve (2) slowly so that the oil will not spurt over you, and drain the excessive oil. a Take care not to deform the stopper pin in drain valve (2) by overloosening it. Tightening torque of drain plug (1): 68.6 ± 9.81 Nm {7 ± 1 kgm} Tightening torque of drain valve (2): 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm}
5. Check the oil level on the "ENGINE STOPPED" stamp side of oil level gauge (G). If it is between the stamps of H and L, it is at the correct level. If the oil level is below L, add oil through oil filler port (F). 4) Check the oil level again. 7. If the oil is at the correct level, tighten the oil filler cap securely and close the engine hood.
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DRAFT General Information on troubleshooting Checks before troubleshooting
a12. Check of coolant level (in sub tank) The radiator cap does not need to be opened for the usual check.. Check the coolant level on the sub tank side while the engine is cold. k Immediately after the engine is stopped, the coolant will be hot and pressure will have accumulated in the radiator. If the cap is opened under these conditions, you may be scalded. When the radiator cap needs to be removed, wait until the temperature drops and rotate the cap slowly to release the pressure. Remove it fully, exercising care. 1. Open the door on the left side of the engine and check that coolant level (5) of reservoir tank (2) is between FULL and LOW. 2. If the reservoir tank is empty, coolant may be leaking. After checking, repair any abnormalities immediately. If there are no abnormalities, check the coolant level in the radiator and add coolant through coolant filler port (1) if necessary. At this time, check that the coolant level is above the bottom of strainer (4). 3. Add coolant to the reservoir tank up to the FULL level through coolant filler port (6). k
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D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
a13. Check of air cleaner for clogging k When using compressed air for cleaning, put on personal protective items such as safety glasses, cotton gloves, dust mask, etc. to protect yourself from dirt that will fly out. k It is dangerous to use excessive force to pull out the outer element from the air cleaner body. When working in an elevated or unstable location, take care that you do not fall due to the momentum created when you pull out the outer element. Testing If the internal yellow piston enters outer red zone (A) of dust indicator (1), clean the air cleaner element. After cleaning, press the reset button to reset.
Cleaning of outer element a Do not leave or store the element in direct sunlight before or after cleaning it. a Replace the outer element after cleaning it 6 times or after using it for 1 year. When replacing the outer element, replace the inner element, too. a If dust indicator (1) enters the red zone just after the outer element is cleaned, replace both outer and inner elements, even if the outer element has not been cleaned 6 times. 1. Open the door on the left side of the engine and unlock 6 hooks (2). Remove cover (3).
2. Hold and pull out outer element (4) while swinging it up, down and laterally and rotating element to the right and left. a Never remove inner element (5). If it is removed, dirt will enter and can lead to engine troubles. a Do not use a screwdriver or another tool. a After removing outer element (4), check that the inner element has not come off or slanted. If the inner element is slanting, push it in straight with the hand. 3. After removing outer element (4), cover the inner element (5) with a clean cloth or tape to prevent dirt from sticking to it. a Do not clean the element until the yellow piston of dust indicator (1) enters outer red zone (A). If the element is cleaned frequently before the yellow piston of dust indicator (1) enters outer red zone (A), the true performance of the air cleaner will not be realized and the cleaning effect will decrease. a If the outer element is checked or cleaned while the engine is running, the dirt sticking to it will fall into the inner element side more frequently and enter and damage the engine. Be sure to stop the engine before cleaning.
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DRAFT General Information on troubleshooting Checks before troubleshooting
4. Remove any dirt sticking to the inside of air cleaner body (6) and cover (3) with a clean cloth, brush, etc. a When cleaning the element, do not tap it or bump it against other objects.
6. Next, blow air along the outside pleats, and blow again along the inside pleats.
a After cleaning, light up the inside of the element to check it. If the element has a small hole or a thin component, replace it.
5. Blow dry compressed air (Max. 210 kPa {2 kg/cm2}) along the inside pleats of the outer element.
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7. Remove the cloth or tape covering inner element (6). 8. Check and remove any dirt, oil, etc. sticking to the sealing surface of the cleaned or new element. a If the element or O-ring used for more than 1 year is cleaned and reused, it can cause a trouble. Therefore, do not reuse it. a Do not use the element if its pleats, gasket or seal is damaged.
D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
9. Push the outer element straight into the air cleaner body while swinging it up, down and laterally. a Install the air cleaner elements so that their bottoms (ends with no holes) (B) and (C) will be on cover (3) side. If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged seriously.
10. Install cover (3) according to the following procedure. 1) Set cover (3) to the element.
2) Hitch the ends of hooks (2) to the projection of the air cleaner body to lock. a Hitch hooks (2) diagonally (top, bottom, right and left) to lock. a After installing cover (3), check for clearance between air cleaner body and cover (3). If there is any clearance, remove and install cover (3) correctly.
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DRAFT General Information on troubleshooting Checks before troubleshooting
Replacement of element 1. Remove outer element (4). For details, see "Cleaning of outer element". 2. Remove inner element (5) and install new inner element (5) quickly to air cleaner body (6). a Do not clean or reuse the inner element. When replacing the outer element, replace the inner element, too.
4. Replace O-ring (7) of cover (3) with a new one.
5. Install cover (3). For details, see "Cleaning of outer element". 6. Replace the seal of cover (3) with a new one.
a Install the air cleaner element so that its bottom (end with no hole) (B) will be on cover (3) side. If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged seriously. a If the outer element and cover are installed while the inner element is not installed securely, the outer element may be broken. Therefore, install the inner element securely.
3. Push the outer element straight into the air cleaner body while swinging it up, down and laterally. a Install the air cleaner element so that its bottom (end with no hole) (C) will be on cover (3) side. If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged seriously.
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DRAFT General Information on troubleshooting Checks before troubleshooting
b. Hydraulic and mechanical equipment b3. Check of hydraulic oil level k Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k If the oil filler cap is removed quickly, the oil may spurt out. Therefore rotate the oil filler cap slowly to release the internal pressure and remove it. 1. Lower the work equipment to the ground and stop the engine. Check the oil level and add new oil if necessary. 2. Turn the starting switch to the ON position within 15 seconds after stopping the engine and operate each control lever (work equipment and travel) to the stroke end in each direction to release the internal pressure. 3. Open the cover on the right side of the machine and check sight gauge (G). If the oil level is between lines H and L, it is at the correct level. a If the oil level is below line L, add oil through oil filter port (F). a Do not add oil to above line H. If too much is added, it may damage the hydraulic circuit and spurt out. a If the oil level is above line H, stop the engine and wait until the hydraulic oil cools down. Then, loosen drain valve (1) at the hydraulic tank bottom to drain excessive oil through drain plug (P) into a container.
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Since the oil level fluctuates according to the oil temperature, note the following when checking it. q Before operation (oil temperature: 10 - 30 ° C), the oil level should be at the center between lines H and L. q During operation (oil temperature: 50 - 80 ° C), the oil level should be near line H. b4. Check of hydraulic oil strainer Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k If the oil filler cap is removed quickly, the oil may spurt out. Therefore rotate the oil filler cap slowly to release the internal pressure and then remove it. 1. Stop the engine and remove oil filler cap (F) of the hydraulic tank to release the internal pressure. 2. Remove bolts (5) to remove cover (6). When removing the bolts, keep pressing down on cover (6) since it may be flung toward you by the internal spring. 3. Pull out the rod and remove the strainer. 4. Remove dirt from the strainer and clean using cleaning oil. If the strainer is broken, replace it with a new one. 5. Insert and set the strainer. 6. While pressing down the spring with the projection at the bottom of cover (1), install the bolts. 7. Tighten the mounting bolts. k
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DRAFT General Information on troubleshooting Checks before troubleshooting
b5. Check of hydraulic oil filter Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k If the oil filler cap is removed quickly, the oil may spurt out. Therefore rotate the oil filler cap slowly to release the internal pressure and then remove it. 1. On a level and firm surface, lower the work equipment to the ground and stop the engine. 2. Remove oil filler cap (F) of the hydraulic tank to release the internal pressure. k
7. Clean the inside of the case and the removed parts, and install the new element. 8. Set cover (1) and install it with the mounting bolts while pressing it with your hand. 9. Tighten the mounting bolts. 10. Install oil filler cap (F). 11. Run the engine at a low idling speed for 10 minutes to bleed air. 12. Stop the engine.
3. Prepare a container to receive the drained oil. 4. Remove drain plug (1) at the tank bottom and loosen drain valve (2) to drain the oil. a When loosening drain plug (1), take care that the oil does not splash over you.
5. After draining the oil, tighten drain plug (1) and drain valve (2). 6. Remove bolts (3), and then remove cover (4) and pull out the element out. a Check and remove dirt on the bottom of the filter case. At this time, take extreme care that dirt does not enter the hydraulic tank.
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DRAFT General Information on troubleshooting Checks before troubleshooting
b6. Check of power train case oil level k Since the undercover is heavy, do not open or close it from beneath. When removing bolts (5), stand on the rear side just under the cover so that you can move away quickly in case of an emergency. q When checking, set the machine in a horizontal position. q While the engine is stopped, the oil level cannot be accurately checked since the oil level increases. When checking while the engine is running or after the engine is started, check with the COLD side of gauge (G) in the idle state. 1. Start the engine, set the fuel control dial to low idle (MIN) position, and keep running the engine at a low idling speed for 3 - 5 minutes. q Perform the following procedure without stopping the engine. 2. Remove oil level gauge (G) and wipe gauge oil off with a cloth. 3. Insert oil level gauge (G) fully into the guide. 4. Pull out oil level gauge (G) and check the oil level. If the oil level is between (H) and (L) on the "COLD IDLE" stamp side of oil level gauge (G), it is the correct level. 5. If the oil level is below (L) on the "COLD IDLE" stamp side of oil level gauge (G), remove oil filter cap (F) and add oil. When adding oil, remove oil level gauge (G).
6. If the oil level is above H, open the undercover and drain the oil according to the following procedure. 1) Remove 2 bolts (4) on the front side of the machine. 2) Gradually remove 2 bolts (5) on the rear side of the machine, while holding cover (3). 3) Since the front of cover (3) is equipped with the hinge pin, lower cover (3) gradually.
(F): Front of machine
4) Remove hose (1) to change its position as (A) and loosen drain valve (2) to drain excessive oil. q When draining the oil, put a container under hose (1) to drain the oil into.
7. After checking the oil level and adding oil, install oil level gauge (G) and oil filler cap (F).
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DRAFT General Information on troubleshooting Checks before troubleshooting
b7. Check of power train pump strainer 1. Remove cover (1) at the rear of the left side cover and cover (2) on the left fender.
2. Loosen bolts (3) to remove case (4).
7. Add oil through oil filler port (F) up to the specified level. 8. After adding oil, check the oil level, referring to "Check of power train case oil level". 3. Remove strainer (5) and magnet (6). q If strainer (5) and magnet (6) are broken, replace with a new ones. 4. Loosen bolt (7) to separate strainer (5) and magnet (6). 5. Remove dirt from strainer (5) and clean in cleaning diesel oil. q Clean the inside of the case and plug, too. 6. Install strainer (5) again. 3 Tightening torque of bolt (7): 46 – 59 Nm {4.7 – 5.9 kgm}
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DRAFT General Information on troubleshooting Checks before troubleshooting
b8. Check of transmission oil filter and torque converter oil filter k If pressure remains in the filter, oil may spurt out. To prevent this, depress the brake pedal several times and lock it before opening the filter case. 1. Remove cover (A) on the right fender. (B): Transmission oil filter (C): Torque converter oil filter
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2. Remove bolts (1) of transmission oil filter (B) and torque converter oil filter (C). Pull up cover (2) and take out element (3). 3. Clean the inside of the case and the removed parts. 4. Install cover (A) on the right fender.
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DRAFT General Information on troubleshooting Checks before troubleshooting
b9. Check of damper case oil level Check the oil level while the engine is stopped. q When checking, set the machine in a horizontal position. 1. Pull out oil level gauge (G) and wipe off the oil with a cloth. 2. Insert oil level gauge (G) again fully into the oil level gauge pipe and pull it out. q
3. If the oil level is between stamps H and L of oil level gauge (G), it is at the correct level. If the oil level is below L, add oil through the oil level gauge holder.
4. If the oil level is above H, open the undercover, referring to step 6. of b.6 "Check of power train case oil level". 5. Prepare an oil pan, remove the drain plug to drain excessive oil, and check the oil level again.
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b10. Check of final drive case oil level k Since the oil may spurt out due to internal pressure, rotate the plug gradually from its side to release the internal pressure and then remove it carefully. 1. Park the machine on a level place. 2. Remove oil level plug (G) and check the oil level. If the oil level is near the plug hole bottom, it is at the correct level.
3. If the oil level is low, add power train oil through oil filler plug hole (F). a Remove all dirt and sand around oil filler plug (F) and take care that dirt and sand will not enter the plug hole when adding oil.
b11. Execution of air bleeding operation For the procedure for bleeding air from the fuel system, see Testing and adjusting, "Bleeding air from fuel circuit". q For the procedure for bleeding air from the hydraulic equipment, see Testing and adjusting, "Bleeding air from each part". q
D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
c. Electrical equipment c1. Check of battery terminals for looseness and corrosion Open cover (1) at the left front of the machine and check the terminals of battery (A) for looseness and corrosion.
c2. Check of alternator terminals for looseness and corrosion Open the engine hood and check alternator terminals B and R for disconnection, looseness and corrosion.
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c3. Check of starting motor terminals for looseness and corrosion Open the engine hood and check starting motor (ST-L) terminals B and C for disconnection, looseness and corrosion. Check starting motor (ST-U) similarly, too.
c4. Testing of battery voltage (with engine stopped) Using the battery tester, test the battery voltage while the engine is stopped.
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DRAFT General Information on troubleshooting Checks before troubleshooting
c5. Check of battery electrolyte level Check before operating the machine. k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that condition, its inside will deteriorate, its service life will be shortened and it may lead to an explosion. k Since the battery produces combustible gas that can explode, do not bring any open flame near it. k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or skin. If it does, wash it away with water and contact your doctor. a Do not add battery electrolyte to above the UPPER LEVEL mark. If too much is added, it can damage the painted surface and corrode the parts. a As refined water (Example: Commercially available battery fluid) added to the battery may freeze, add it before starting work for the day so that it will not freeze. q When checking the electrolyte level from the side of the battery 1. Clean around the electrolyte level lines with a cloth dampened with water and check that the electrolyte level is between UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) a Do not clean the battery with a dry cloth since static electricity may cause an explosion.
2. If the electrolyte level is below the center between the U.L. and L.L. lines, remove cap (2) and add refined water (Example: Commercially available battery fluid) to the U.L. line immediately. 3. After adding the refined water, tighten the cap securely.
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a If you have added refined water above the U.L. line, take some of it out using a syringe or similar tool. Neutralize the liquid that has been taken out with sodium bicarbonate or other suitable liquid, and wash it out with a large amount of water. q When electrolyte level cannot be checked from the side of the battery 1. Remove cap (2) on the top of the battery. (Described previously) 2. Look into electrolyte level opening (3) to check the electrolyte level. If the electrolyte level is below sleeve (4), be sure to add refined water (Example: Commercially available battery fluid) up to the sleeve bottom (U.L. line). q (A) Correct level: Since the electrolyte level is higher than the sleeve bottom, the shape of the electrode plates will appear distorted due to the surface tension. q (B) Low: Since the electrolyte level is below the sleeve bottom, the shape of the electrode plates will appear straight. 3. After adding the refined water, tighten cap (2).
a If you have added refined water above the U.L. line, take some of it out using a syringe or similar tool. Neutralize the liquid that has been taken out with sodium bicarbonate or other suitable liquid, and wash it out with a large amount of water.
D375A-6 (01)
DRAFT General Information on troubleshooting Checks before troubleshooting
c6. Check of wiring harness for discoloration, burnt areas and cover peeling q Check the wiring harness and cables for discoloration and burn. a Discoloration and burnt areas indicate the possibility of a short circuit or a circuit ground fault. q Check the wiring harnesses and cables for damage and peeling of the covers. q If any fault are discovered, repair or replace the wiring harness or cable.
c9. Check for loose connectors and damaged locks q Pull the male and female parts of the connector by the hand to check the condition of their connection. q If the connecting condition is abnormal, connect it securely.
c7. Check for removal of wiring harness clamps and sagging of the wiring harness q Check the wiring harnesses for sagging and play caused by removal of a clamp. a In particular, carefully check around the hot and movable parts. q If any part is off the clamp, resecure it with clamp.
q
q
Check the connector to see whether it is unlocked and check its lock portion and housing for cracks. Check lock screws (L) of controller (CNT) for looseness. a Use a 4-mm hexagonal wrench.
c8. Check of grounding a Check the ground terminal for looseness and rusting in particular. q Check the connection of ground strap (1) of engine controller (EC).
q
Open the cover at the front of the fuel tank on the left side of the machine and check the connection of the floor ground strap.
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DRAFT General Information on troubleshooting Checks before troubleshooting
c10. Check of connector pin for corrosion, bends and deformation q Disconnect the connector and check the pins for corrosion, bending and retraction. Check that the female pins have not expanded. q If any pin is found to be abnormal, repair or replace it. a If the pins are not shiny, apply contact restorer to them and connect and disconnect several times to shine them. (If the pins do not become shiny, connect and disconnect the connector 10 times)
q
Remove foreign matter in the connector using a cloth or other material, and blow compressed air against the inside of the connector.
c11. Check for water and foreign matter in the connector q Disconnect the connector and check whether there is water, dirt, sand, etc. in it.
a If there is sand or foreign matter in the connector, check the seal for damage. q If the seal is defective, repair or replace it. q Dry the moisture in the connector using a drier.
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DRAFT General Information on troubleshooting Checks before troubleshooting
c12. Check of wiring harness for disconnection and short circuiting q Check the connections (crimped parts) between each connector pin and wiring harness. q If any wire is disconnected as illustrated in (A), repair or replace the wiring harness or connector.
q
Open inspection cover (A), and fuse boxes (1) - (3) are seen.
Check whether any pins are touching any adjacent pins due to peeling of the wire cover, defective crimping of the pin, etc.
c13. Check of fuse for disconnection and corrosion a When replacing a fuse, be sure to turn off the power (turn the starting switch to the OFF position). q The fuse holders are installed to the left front lower part of operator's seat and to the overhead section. q If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder, replace the fuse. q Replace each fuse with another of the same capacity.
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Fuse box (4) is at the overhead section.
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DRAFT General Information on troubleshooting Checks before troubleshooting
c14. Check of circuit breaker Do not keep pressing the reset button of the circuit breaker. (Doing so can cause a fire.) q The circuit breaker breaks the electrical circuit to protect the electrical equipment and wiring when an overcurrent flows through it. It can be used repeatedly. k
Check of circuit breaker in each circuit If the circuit breaker is turned ON, reset button (1) comes out. q Check all the circuit breakers to see whether any of reset buttons (1) have come out. q To return the broken electrical circuit to normal condition, push in reset button (1) that has come out. a If reset button (1) comes out again soon after it is pushed in and the starting switch is turned to the ON position, the overcurrent is still flowing. Check the electrical circuit in this case.
Check of circuit breaker of main power supply 1. Turn the starting switch to the OFF position. 2. Open the inspection cover at the front of the fuel tank on the left side of the machine. Check circuit breakers (A) - (E).
q
q
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3. Push reset buttons (A) - (E) of the circuit breakers in order. a If the electrical circuit is broken, the operating effort of the reset button is heavier compared with the case when the circuit is operating normal. a The height of the reset button does not change when the circuit is broken or normal.
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DRAFT General Information on troubleshooting Checks before troubleshooting
c15. Check of alternator voltage (when engine speed is medium or higher) 1. Open the engine hood. 2. Connect the positive (+) line of the tester to alternator terminal (B) and connect the negative (-) line to the chassis ground. 3. Start and warm up the engine and measure the voltage while running the engine at a medium or a higher speed. q If the voltage is abnormal, repair or replace the alternator.
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c16. Check of battery relay operation sound 1. Open the battery cover. 2. Check whether the battery relay operation sound is heard when the starting switch is turned to the ON/OFF position. q If the operation sound is not heard, check the related circuits, referring to E-1 in the E mode. q If the related circuits are free from abnormalities, replace the battery relay.
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DRAFT General Information on troubleshooting Classification and procedures for troubleshooting
Classification and procedures for troubleshooting Classification of troubleshooting Mode
Contents
Display of code Troubleshooting by failure code E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for troubleshooting If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1. Procedure for troubleshooting when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the machine monitor, perform the troubleshooting for the corresponding "Display of code". a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order. Note down all the codes. 2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine monitor: Check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. (See [*1].) 1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code" according to the failure code. a If an electrical system failure code is dispayed after having noted down all the codes, delete all the codes and reproduce them, and then see if the trouble is still detected. (See [*2].) a A failure code of the mechanical system cannot be deleted. 2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon which is assumed to show a trouble again and select the same phenomenon from the list on the next page, and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode". 3. Action to take after trouble is eliminated Referring to the next page, clear all the failure codes in the electrical system abnormality record.
40-36
D375A-6 (01)
DRAFT General Information on troubleshooting Classification and procedures for troubleshooting
[*1], [*2] 1. While pressing numerical key [4] on the panel switch at the normal screen, press [1], [2] and [3] in order.
2. On the service menu screen, press [F3] switch (R) on the panel switch once to select "02 Abnormality Record". 3. Press [F6] switch ( ) on the panel switch to confirm and go to "Abnormality Record" screen.
D375A-6 (01)
4. Press [F6] switch ( ) on the panel switch to confirm and go to "Mechanical system" screen.
5. Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all the failure codes. a A mechanical system failure code cannot be cleared. 6. Press [F5] switch (Return) on the panel switch to return to the "Abnormality record" screen. 7. Enter the "Electrical system abnormality record" similarly to steps 2 and 3. 8. Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all of the failure codes. a "E" on the left of a failure code indicates that the failure code is "active" (the failure remains or restoration to normal has not been checked). A failure code having no "E" on its left is a "non-active" one. Since it disappears at the following clear step, be sure to note it down. 9. While pressing numerical key [4] on the panel switch, press [1], [2] and [3] in this order to enter the "Clear mode". (Same as 1) 10. Press [F2] switch(CLEAR) on the panel switch. 11. Press [F6] switch ( ) on the panel switch to clear all the failure codes temporarily. 12. Press [F5] switch (Return) on the panel switch to return to the "Electrical system abnormality record" screen. See if any failure code is still displayed and note down displayed ones.
40-37
DRAFT General Information on troubleshooting Classification and procedures for troubleshooting
13. Press [F5] switch (Return) on the panel switch to return to the "Abnormality record" screen.
40-38
D375A-6 (01)
DRAFT General Information on troubleshooting Failure codes table
Failure codes table Failure code 1380MW 1500L0 15E0MW 15SAL1 15SALH 15SBL1 15SBLH 15SEL1 15SELH 15SFL1 15SFLH 15SGL1 15SGLH 15SJL1 15SJLH 1800MW 2201L1 2201LH 2202L1 2202LH 2300NR 2301L1 2301LH 2301NR 2302L1 2302LH 2302NR 7RFAKA 7RFAKB AA10NX AB00MA B@BAZG B@BAZK B@BCNS B@BCZK B@CENS B@HANS B@HAZK CA111 CA115 CA122 CA123 CA131 CA132 CA135 CA141 CA144 CA145 CA153
D375A-6 (01)
Trouble (Displayed on screen) Lock up clutch:Slip Transmission clutch:Abnormal Transmission clutch:Slip Forward clutch:Fill high Forward clutch:Fill Low Reverse clutch:Fill high Reverse clutch:Fill Low Speed 1st clutch:Fill high Speed 1st clutch:Fill Low Speed 2nd clutch:Fill high Speed 2nd clutch:Fill Low Speed 3rd clutch:Fill high Speed 3rd clutch:Fill Low L/U :Fill high L/U :Fill low P/T clutch:Slip Right clutch:Fill high Right clutch:Fill low Left clutch:Fill high Left clutch:Fill low Brake Themal Load Abnormality Right brake:Fill high Right brake:Fill low Steering Brake RH Themal Load Abnormality Left brake:Fill high Left brake:Fill low Steering Brake LH Themal Load Abnormality ECM ACC CUT RELAY:Disconnection ECM ACC CUT RELAY:Short circuit Air Cleaner Clogging Battery Charge Abnormal Eng Oil Press Low Eng oil level low Eng Water Overheat Eng water level low T/C Oil Overheat Hyd Oil Overheat Hyd Oil Level Low ECM Critical Internal Failure Eng Ne and Bkup Speed Sens Error Chg Air Press Sensor High Error Chg Air Press Sensor Low Error Throttle Sensor High Error Throttle Sensor Low Error Eng Oil Press Sensor High Error Eng Oil Press Sensor Low Error Coolant Temp Sens High Error Coolant Temp Sens Low Error Chg Air Temp Sensor High Error
Component Reference Action code Category of record in charge document page P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T
– E03 – E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E02 E02 E02 E04 E04 E04 E04 – E04 E04
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system
40-109 40-110 40-111 40-112 40-114 40-116 40-118 40-120 40-122 40-124 40-126 40-128 40-130 40-132 40-134 40-136 40-138 40-140 40-142 40-144 40-146 40-148 40-150
P/T
–
Mechanical system
40-152
P/T P/T
E04 E04
Electrical system Electrical system
40-154 40-156
P/T
–
Mechanical system
40-158
W/E W/E MON MON ENG MON ENG MON P/T P/T W/E ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG
– – – – – – – – – – – E03 E03 E03 E03 E03 E03 E02 E01 E01 E01 E01
Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-160 40-162 40-164 40-166 40-166 40-167 40-168 40-169 40-170 40-171 40-172 40-174 40-176 40-178 40-180 40-182 40-184 40-186 40-188 40-190 40-192 40-194
40-39
DRAFT General Information on troubleshooting Failure codes table
Failure code CA154 CA187 CA212 CA213 CA221 CA222 CA227 CA234 CA238 CA263 CA265 CA271 CA272 CA273 CA274 CA322 CA323 CA324 CA325 CA331 CA332 CA342 CA351 CA352 CA386 CA441 CA442 CA449 CA451 CA452 CA453 CA554 CA559 CA689 CA731 CA757 CA778 CA1228 CA1625 CA1633 CA2185 CA2186 CA2249 CA2271 CA2272 CA2351 CA2352 D110KB D130KA D130KB D161KA D161KB
40-40
Trouble (Displayed on screen) Chg Air Temp Sensor Low Error Sens Supply 2 Volt Low Error Eng Oil Temp Sensor Low Error Eng Oil Temp Sensor Low Error Ambient Press Sens High Error Ambient Press Sens Low Error Sens Supply 2 Volt High Error Eng Overspeed Ne Speed Sens Supply Volt Error Fuel Temp Sensor High Error Fuel Temp Sensor Low Erro IMV/PCV1 Short Error IMV/PCV1 Open Error PCV2 Short Error PCV2 Open Error Inj #1(L#1) Open/Short Error Inj #5(L#5) Open/Short Error Inj #3(L#3) Open/Short Error Inj #6(L#6) Open/Short Error Inj #2(L#2) Open/Short Error Inj #4(L#4) Open/Short Error Calibration Code Incompatibility Injectors Drive Circuit Error Sens Supply 1 Volt Low Error Sens Supply 1 Volt High Error Battery Voltage Low Error Battery Voltage High Error Rail Press Very High Error Rail Press Sensor High Error Rail Press Sensor Low Error Rail Press High Error Rail Press Sensor In Range Error Rail Press Low Error Eng Ne Speed Sensor Error Eng Bkup Speed Sens Phase Error All Continuous Data Lost Error Eng Bkup Speed Sensor Error EGR Valve Servo Error 1 EGR Valve Servo Error 2 KOMNET Datalink Timeout Error Throt Sens Sup Volt High Error Throt Sens Sup Volt Low Error Rail Press Very Low Error EGR Valve Pos Sens High Error EGR Valve Pos Sens Low Error EGR Valve Sol Current High Error EGR Valve Sol Current Low Error Battery Relay:Drive Short Circuit Neutral relay:Disconnection Neutral relay:Short circuit Back-up alarm releay:Disconnection Back-up alarm releay:Short circuit
Component Reference Action code Category of record in charge document page ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG W/E P/T P/T P/T P/T
E01 E01 E01 E01 E01 E01 E03 E02 E03 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E04 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 – E02 E02 E01 E01
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-196 40-198 40-200 40-202 40-204 40-206 40-208 40-209 40-210 40-212 40-214 40-216 40-217 40-218 40-219 40-220 40-222 40-224 40-226 40-228 40-230 40-232 40-233 40-234 40-236 40-237 40-238 40-239 40-240 40-242 40-244 40-245 40-246 40-250 40-252 40-253 40-254 40-256 40-257 40-258 40-259 40-260 40-261 40-262 40-264 40-266 40-268 40-270 40-272 40-274 40-276 40-278
D375A-6 (01)
DRAFT General Information on troubleshooting Failure codes table
Failure code D182KZ D190KA D190KB D1EFKA D1EFKB DAFRKR dAFRKR DAFRMC DB2RKR dB2RKR DB90KT DB91KK DB92KK DB97KK DB99KQ DB9RKR DBB0KK DBB0KQ DBB3KK DBB5KP DBB6KP DBB7KP DBBQKR DBE0KT DBE1KK DBE2KK DBE5KK DBE6KK DBE7KK DBE9KQ DBERKR DD12KA DD12KB DD13KA DD13KB DD14KA DD14KB DDB9L4 DDE2KA DDK3L4 DDK5KA DDK5KB DDN2LD DDN3LD DDN7KA DDN7KB DDN9KA DDN9KB
D375A-6 (01)
Trouble (Displayed on screen) Preheater Relay Abnormality ACC signal relay:Disconnection ACC signal relay:Short circuit Pre lub. motor relay:Disconnection Pre lub. motor relay:Short circuit Monitor:Can communication lost(PT) Monitor:Can communication lost(WE) CAN Discon (Monitor Detected) ENG cont.:Can communication lost(PT) ENG controller:Can communication lost(WE) WE controller:Abnormality in controller WE controller:Source voltage reduction WE controller:Output voltage reduction WE cont.:Sensor voltage 5V (2) reduction WE controller:Type select signal WE controller:CAN communication error (PT) VHMS controller:Source voltage reduction VHMS Connector Connection Abnormality VHMS controller:Source voltage reduction VHMS:Output sensor1 voltage reduction VHMS:Output sensor2 voltage reduction VHMS:Output sensor3 voltage reduction PT controller:CAN communication lost (VHMS) PT controller:Abnormality in controller PT controller:Source voltage reduction PT controller:Output voltage reduction PT cont.:Sensor voltage5V (1) reduction PT cont.:Sensor voltage 24V reduction PT cont.:Sensor voltage 5V (2) reduction PT controller:Type select signal PT controller: CAN communication lost (WE) Shift up Sw:Disconnection Shift up Sw:Short circuit Shift down Sw:Disconnection Shift down Sw:Short circuit Parking lever Sw:Dissconnection Parking lever Sw:Short circuit Reverse SW Signal disagreement Pre lub. oil press sw:Disconnection Forward SW Signal disagreement Shift switch disconnection Shift switch short circuit Blade tilt RH pressure SW abnormality Blade tilt LH pressure SW abnormality WEQ Knob Sw(down):Disconnection WEQ Knob Sw(down):Short circuit WEQ Knob Sw(up):Disconnection WEQ Knob Sw(up):Short circuit
Component Reference Action code Category of record in charge document page P/T W/E W/E P/T P/T P/T W/E MON P/T
E01 – – E02 E02 E03 E03 E03 E03
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-280 40-282 40-284 40-286 40-288 40-290 40-291 40-292 40-297
W/E
E03
Electrical system
40-300
W/E W/E W/E W/E W/E
E01 E04 E04 – E04
Electrical system Electrical system Electrical system Electrical system Electrical system
40-301 40-302 40-304 40-306 40-308
P/T
E03
Electrical system
40-309
VHMS
–
Electrical system
40-312
VHMS
–
Electrical system
40-314
VHMS
–
Electrical system
40-316
VHMS VHMS VHMS
– – –
Electrical system Electrical system Electrical system
40-318 40-320 40-322
VHMS
–
Electrical system
40-323
P/T P/T P/T P/T P/T P/T P/T
E01 E04 E04 E03 E03 E01 E04
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-323 40-324 40-326 40-328 40-330 40-332 40-334
W/E
E03
Electrical system
40-335
P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T W/E W/E W/E W/E W/E W/E
E02 E02 E02 E02 E03 E03 E03 E02 E03 E02 E02 – – E02 E02 E01 E01
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-338 40-340 40-342 40-344 40-346 40-348 40-350 40-352 40-354 40-356 40-358 40-360 40-362 40-364 40-366 40-368 40-370
40-41
DRAFT General Information on troubleshooting Failure codes table
Failure code DDNALD DDNBLD DDNCLD DDNDLD DDNELD DDNFLD DDNLKA DDNLKB DDT5KA DDT5KB DDT5KQ DDTSL1 DDTSLH DGE5KX DGS1KX DGT1KA DGT1KX DGT5KA DGT5KB DGT6KA DGT6KB DH21KA DH21KB DHE5KB DHE5KY DHT3KX DHT5KA DHT5KB DHT7KA DHT7KB DK10KA DK10KB DK30KA DK30KB DK30KX DK30KZ DK30L8 DK31KA DK31KB DK40KA DK40KB DK55KX DK55KZ DK55L8 DK56KA DK56KB DK57KA DK57KB DK60KA DK60KB
40-42
Trouble (Displayed on screen) Blade lift up pressure SW abnormality Ripper lift up pressure SW abnormality Ripper lift down pressure SW abnormality Ripper tilt in pressure SW abnormality Ripper tilt back pressure SW abnormality Blade lift down pressure SW abnormality Weq lock Sw:Disconnection Weq lock Sw:Short circuit Neutral switch disconnection Neutral switch short circuit Lever SPEC selection signal disagreement S/C :Fill high S/C :Fill low Ambient temp sensor abnormality Hyd oil temp:signal abnormal T/C oil temp sensor:Abnormal T/C oil temp sensor:Abnormal F exhaust temp sensor disconnection F exhaust temp sensor short circuit R exhaust temp sensor disconnection R exhaust temp sensor short circuit Weq pressure sensor:Disconnection Weq pressure sensor:Short circuit ENG blow-by pressure sensor disconnection ENG blow-by pressure sensor short circuit T/M oil pressure sensor abnormality T/C in-pressure sensor:Disconnection T/C in-pressure sensor:Short circuit T/C out-pressure sensor:Disconnection T/C out-pressure sensor:Short circuit Fuel control Dial:Disconnection Fuel control Dial:Short circuit ST lever1:Disconnection ST lever1:Short circuit ST lever:Out of normal range ST lever:Disconnection or short circuit ST lever:Signal mismatch ST lever2:Disconnection ST lever2:Short circuit Brake potentiometer:Disconnection Brake potentiometer:Short circuit FR lever:Out of normal range FR lever:Disconnection or short circuit FR lever:Signal mismatch FR lever1:Disconnection FR lever1:Short circuit FR lever2:Disconnection FR lever2:Short circuit Acceleration sensor:Disconnection Acceleration sensor:Short circuit
Component Reference Action code Category of record in charge document page W/E W/E W/E W/E W/E W/E W/E W/E P/T P/T
– – – – – – E03 E03 E04 E04
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-372 40-374 40-376 40-378 40-380 40-382 40-384 40-386 40-388 40-390
P/T
E04
Electrical system
40-392
P/T P/T VHMS P/T W/E W/E VHMS VHMS VHMS VHMS W/E W/E
E02 E02 – E01 E01 E01 – – – – E01 E01
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-394 40-396 40-398 40-400 40-402 40-404 40-406 40-408 40-410 40-412 40-414 40-416
VHMS
–
Electrical system
40-418
VHMS
–
Electrical system
40-420
VHMS P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T
– E02 E02 E02 E02 E03 E03 E03 E03 E04 E04 E03 E03 E03 E03 E03 E04 E04 E03 E03 E03 E03 E03 E01 E01
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-422 40-424 40-426 40-428 40-430 40-432 40-434 40-436 40-438 40-440 40-440 40-441 40-442 40-444 40-446 40-448 40-450 40-450 40-451 40-452 40-454 40-456 40-458 40-460 40-462
D375A-6 (01)
DRAFT General Information on troubleshooting Failure codes table
Failure code DKH1KA DKH1KB DLF1KA DLM3KA DLM3MB DLT3KA DLT3KB DW59KA DW59KB DW59KY DW5AKA DW5AKB DW5AKY DW7BKA DW7BKB DWN3KA DWN3KB DWN3KY DWN5KA DWN5KB DWN5KY DWNCKA DWNCKB DWNCKY DXH1KA DXH1KB DXH1KY DXH4KA DXH4KB DXH4KY DXH5KA DXH5KB DXH5KY DXH6KA DXH6KB DXH6KY DXH7KA DXH7KB DXH7KY DXH8KA DXH8KB DXH8KY DXH9KA DXH9KB DXH9KY DXHAKA DXHAKB DXHAKY DXHBKA DXHBKB DXHBKY DXHCKA
D375A-6 (01)
Trouble (Displayed on screen) Pitch angle sensor:Disconnection Pitch angle sensor:Short circuit T/C out-speed sensor:Disconnection Fan rev. sensor:Disconnection Fan control:Decline T/M out-speed sensor:Disconnection T/M out-speed sensor:Abnormal Blade dual selector SOL disconnection Blade dual selector SOL short circuit Blade dual selector SOL short circuit Blade pitch selector SOL disconnection Blade pitch selector SOL short circuit Blade pitch selector SOL Short circuit Fan rev EPC:Disconnection Fan rev EPC:Short circuit Ssp solenoid:Disconnection Ssp solenoid:Short circuit SSP solenoid:Short circuit Fan pump solenoid 1:Disconnection Fan pump solenoid 1:Short circuit Fan pump solenoid 1:Short circuit Fan pump solenoid 2:Disconnection Fan pump solenoid 2:Short circuit Fan pump solenoid 2:Short circuit Lock-up ECMV:Disconnection Lock-up ECMV:Short circuit Lock-up ECMV:Short circuit 1st clutch ECMV:Disconnection 1st clutch ECMV:Short circuit 1st clutch ECMV:Short circuit 2nd clutch ECMV:Disconnection 2nd clutch ECMV:Short circuit 2nd clutch ECMV:Short circuit 3rd clutch ECMV:Disconnection 3rd clutch ECMV:Short circuit 3rd clutch ECMV:Short circuit R clutch ECMV:Disconnection R clutch ECMV:Short circuit R clutch ECMV:Short circuit F clutch ECMV:Disconnection F clutch ECMV:Short circuit F clutch ECMV:Short circuit Right clutch ECMV:Disconnection Right clutch ECMV:Short circuit Right clutch ECMV:Short circuit Left clutch ECMV:Disconnection Left clutch ECMV:Short circuit Left clutch ECMV:Short circuit Right brake ECMV:Disconnection Right brake ECMV:Short circuit Right brake ECMV:Short circuit Left brake ECMV:Disconnection
Component Reference Action code Category of record in charge document page P/T P/T P/T W/E W/E P/T P/T W/E W/E W/E W/E W/E W/E W/E W/E P/T P/T P/T W/E W/E W/E W/E W/E W/E P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T P/T
E03 E03 – E02 E02 E01 E01 E01 E01 E01 E02 E02 E02 E01 E01 E04 E04 E04 E01 E01 E02 E01 E01 E02 E02 E02 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E04 E03 E03 E04 E03 E03 E04 E03 E03 E04 E04 E04 E04 E04
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-464 40-466 40-468 40-469 40-470 40-471 40-472 40-473 40-474 40-475 40-476 40-477 40-478 40-479 40-480 40-481 40-482 40-484 40-486 40-487 40-488 40-490 40-491 40-492 40-494 40-495 40-496 40-498 40-499 40-500 40-502 40-503 40-504 40-506 40-507 40-508 40-510 40-511 40-512 40-514 40-515 40-516 40-518 40-519 40-520 40-522 40-523 40-524 40-526 40-527 40-528 40-530
40-43
DRAFT General Information on troubleshooting Failure codes table
Failure code DXHCKB DXHCKY DXJBKA DXJBKB DXJBKY DY2HKA F@BBZL F@BYNR F@BYNS F@BZNR F@BZNS
Trouble (Displayed on screen) Left brake ECMV:Short circuit Left brake ECMV:Short circuit S/C ECMV:Disconnection S/C ECMV:Short circuit S/C ECMV:Short circuit Pre lub. motor:Disconnection ENG blow-by pressure high level F exhaust temp high level (2) F exhaust temp high level (1) R exhaust temp high level (2) R exhaust temp high level (1)
Component Reference Action code Category of record in charge document page P/T P/T P/T P/T P/T P/T VHMS VHMS VHMS VHMS VHMS
E04 E04 E02 E02 E02 E02 – – – – –
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system
40-531 40-532 40-534 40-535 40-536 40-538 40-540 40-541 40-542 40-543 40-544
a The items in this table are arranged in the order of the failure codes. a A component in charge is a controller or the machine monitor in charge of the system check. MON : Monitor panel ENG : Engine controller P/T : Power train controller W/E : Work equipment controller VHMS : VHMS controller a The failure codes having no numbers in the action code column are not displayed on the ordinary screen when abnormality related to them occurs. They are simply recorded in the fault history of the service menu (Electrical equipment system or mechanical equipment system). a The history classification column shows in which system each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history. Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS controller, however, they are not recorded in the fault history The 4-letter codes in [ ] among the VHMS codes are the failure codes displayed on the 7-segment LED of the VHMS controller (They are divided into 2 2-letter codes). a Blinking and lighting of failure code q Blinking:The trouble has not been repaired. q Lighting:The trouble has been repaired.
40-44
D375A-6 (01)
DRAFT General Information on troubleshooting Phenomena and troubleshooting numbers
Phenomena and troubleshooting numbers Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.
Phenomena supposed to show troubles
Reference document page
Index
Action code and failure code The action code and failure code are displayed on the machine moni1 tor. When abnormality record is checked, failure code is shown in 2 Take actions by following the failure code. mechanical system abnormality record When abnormality record is checked, failure code is shown in electri3 cal system abnormality record Troubleshooting No.
Phenomena supposed to show troubles Index
Reference document page
Phenomena related to engine 4 Starting performance is poor 5 Engine does not start 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 43 44 45
S-1 E-1, S-2, -17
Engine does not pick up smoothly S-3 Engine stops during operations S-4 Engine does not rotate smoothly (such as hunting) S-5 Engine lack output (or lacks power) S-6 Exhaust smoke is black (incomplete combustion) S-7 Oil consumption is excessive (or exhaust smoke is blue) S-8 Oil contaminates quickly S-9 Fuel consumption is excessive S-10 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 Oil pressure drops S-12 Oil level rises (Entry of coolant/fuel) S-13 Coolant temperature becomes too high (overheating) S-14 Abnormal noise is heard S-15 Vibration is excessive S-16 The preheater does not operate. E-2 Electric priming pump does not operate or does not stop automatically. E-28 Phenomena related to power train Power is low (Insufficient drawbar pull) H-1 The machine does not travel (at 2nd or 3rd) H-2 The machine does not start at all gear speeds H-3 The machine can travel in forward or reverse only H-4 Large time lag at gear speed shifting or forward-reverse shifting H-5 Steering does not turn H-6 Steering turns only in one direction (left or right) H-7 The machine oversteered H-8 Brake does not work. H-9 Torque converter lockup is not turned on H-10 The torque converter oil temperature is heated abnormally high H-11 Phenomena related to work equipment All work equipment operates slowly or lacks power. H-12 All work equipment does not operate. H-13 Blade lift is slow to raise, or lifting force is not enough H-14 Blade tilt is slow to raise, or tilting force is not enough H-15 Ripper lift is slow to raise, or lifting force is not enough H-16 Ripper tilt is slow to raise, or tilting force is not enough H-17 Excessive hydraulic drift of blade lift. H-18 Excessive hydraulic drift of blade tilt. H-19 Excessive hydraulic drift of ripper lift. H-20 The ripper pin puller cylinder does not work. E-21, H-21 The blade pitch does not work. H-22 Abnormal noise is heard from around the work equipment pump H-23 Fan speed is abnormal (such as excessive noise or vibration of fan, or H-24 overheating)
D375A-6 (01)
40-628 40-547, 40-630, 40-652 40-634 40-636 40-637 40-638 40-640 40-642 40-643 40-644 40-645 40-646 40-648 40-649 40-650 40-651 40-550 40-596 40-604 40-606 40-607 40-608 40-609 40-610 40-611 40-612 40-612 40-613 40-614 40-615 40-616 40-617 40-617 40-618 40-618 40-619 40-619 40-620 40-570, 40-620 40-621 40-621 40-622
40-45
DRAFT General Information on troubleshooting Phenomena and troubleshooting numbers
Troubleshooting No.
Phenomena supposed to show troubles
Phenomena related to machine monitor 46 When starting switch turned ON, machine monitor displays nothing When starting switch is turned to ON position (with engine stopped), 47 basic check item (radiator coolant level) lamp lights. 48 Precaution lights up while engine is running 49 Emergency stop item lights up while engine is running 50 Engine coolant temperature gauge does not indicate normally 51 Fuel gauge does not operate normally Power train oil temperature gauge (multi-gauge) does not indicate nor52 mally Hydraulic oil temperature gauge (multi-gauge) does not operate nor53 mally Contents of display by machine monitor are different from applicable 54 machine 55 Machine monitor does not display some items 56 Function switch does not work 57 Operation mode does not change 58 Gear shift mode does not change 59 Customize function does not operate normally 60 Customize memory function does not operate normally 61 Alarm buzzer cannot be stopped 62 When starting switch is turned OFF, service meter is not displayed. 63 Machine monitor cannot be set in service mode 64 Horn does not sound or stop sounding. 65 Backup alarm does not sound or does not stop from sounding 66 Fan does not rotate in reverse. 67 Headlamp, back-up lamp, and/or ripper point lamp does not light 68 Windshield wiper does not operate. 69 Window washer does not operate. The ORBCOMM terminal does not operate normally (Data are not 70 transmitted). 71 Gear cannot be shifted
40-46
Index
Reference document page
E-3
40-554
E-4
40-556
E-5 E-6 E-7 E-8
40-558 40-560 40-561 40-562
E-9
40-564
E-10
40-565
E-11
40-566
E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-22 E-23 E-24 E-25 E-26 E-27
40-566 40-566 40-567 40-567 40-568 40-568 40-569 40-569 40-569 40-572 40-574 40-576 40-577 40-584 40-590
E-29
40-598
E-30
40-600
D375A-6 (01)
DRAFT General Information on troubleshooting Information in troubleshooting table
Information in troubleshooting table a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. User code Display on machine monitor Failure description Action of controller Indication of problem on machine Related information
Failure code Display on machine monitor
Trouble
Description of problem that appears on machine monitor as: abnormality record
Description of the failure detected by the machine monitor or controller Action taken by machine monitor or controller to protect system or devices when machine monitor or controller detects failure Problem that appears on machine as result of action taken by machine monitor or controller (shown above) Information related to detected failure or troubleshooting
Cause
Procedure, measuring location, standard (value) and remarks q Procedure q Measuring location Probable causes a "Between A - B" means "Measure voltage or resistance and so on between A and B". q Standard value in normal condition to evalute assumed cause if it is good condition or not. q Remarks required to evaluate the cause is correct 1 - Defective q Perform troubleshoot in following procedure in numerical order. q If the testing result shows abnormality, the cause described on the left column conforms. q If it shows normal, and unless otherwise specified particularly, proceed to the next step (cause). Disconnection in wiring harq Check that the failure is fixed after a failure was found and repaired. ness 2 (Disconnection or defective q Disconnection in wiring contact in connector) The connector connection is defective or the wiring harness is disconnected. q Ground fault A harness not connected to ground (earth) circuit contacts the ground (earth) or machine. Ground fault of wiring harness q Hot short circuit 3 (Contact with ground circuit) A harness not connected to the power (24 V) circuit contacts the power (24 V) circuit. q Short circuit An independent wire in the harness abnormally contacts another wire. (Poor insulation at connector and others) Hot short 4 (Short circuit with 24 V circuit) (1) How to indicate connector number and handle T-branch For troubleshooting, insert or connect T-branch adapter as follows unless especially specified. q When "male" or "female" is not indicated with a connector number, disconnect the connector, and insert T-branch adapter in both male and female. q When "male" or "female" is indicated with a connector number, disconnect 5 Short circuit in wiring harness the connector, and connect T-branch adapter only to either male or femae end. (2) Description sequence of pin number and handling of tester lead Connect positive (+) lead and negative (-) lead of tester as explained below for troubleshooting, unless otherwise specified. qConnect positive (+) lead to pin No. or wiring harness entered on front side. 6 Defective controller q Connect the minus (-) lead to a pin or harness indicated in the rear.
D375A-6 (01)
40-47
DRAFT General Information on troubleshooting Information in troubleshooting table
Related circuit diagram
This drawing is a part of the circuit diagram related to troubleshooting. q Connector No.: Indicates (Model - Number of pins) and (Color). q "Connector No. and pin No." from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. q Arrow (io): Roughly shows the location on the machine. q NO: Normally Open q NC: Normally Closed
40-48
D375A-6 (01)
DRAFT General Information on troubleshooting Troubleshooting method for disconnecting wiring harness of pressure sensor system
Troubleshooting method for disconnecting wiring harness of pressure sensor system a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may have the deferences among the registances measured and its own polarities. So troubleshoting must be performed carefully. Failure codes applicable to this diagnosis q CA123: Charge air pressure sensor low error q CA222: Ambient pressure sensor low error Procedure 1. Measure and record resistance of pressure sensor unit. 1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor. 2) Measure resistances R1 and R2 between pins. a If tester probes polarities to apply are reversed, measured values may change. Therefore, when measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and 2. a If measured value is infinite, take measurements with tester probes polarities exchanged each other and record the finite value obtained as a measured value. a Since measured values may be diferent from each other, take several measurements. Cause of the diferences appears to be that the sensor may be charged by the tester. Take several measurement in both steps 1 and 2. Take the fact into consideration this diferences when determining whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller connected 1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor connectors first.(*) 2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and connect T-adapter (4) to wiring harness side. 3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'. 3. Judging disconnection If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, "wiring harness is disconnected". D375A-6 (01)
40-49
DRAFT General Information on troubleshooting Troubleshooting method for disconnecting wiring harness of pressure sensor system
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values Sensor Charge pressure sensor
Ambient pressure sensor
R2: Between (1) and (3) R1: Between (2) and (3)
Internal resistance of measured sensor (Reference value) Approx. 2.9kΩ Approx. 4.3kΩ
R2: Between (1) and (3)
Approx. 3.2kΩ
Sensor pin measuring location
R1: Between (2) (+) and (1) (-) R1: Between (1) (+) and (2) (-)
Approx. 4.6kΩ Approx. 2.9kΩ
Remarks Sensor is common to engine models 125, 170 and 12V140 Sensor is common to engine models 95, 125, 170 and 12V140 If polarities are reversed, resistance value changes.
*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code) When measuring R2' of charge pressure sensor (CA123) Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, G sensor, EGR lift sensor and bypass valve lift sensor q When measuring R2' of ambient pressure sensor (CA222) Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, G sensor, EGR lift sensor and bypass valve lift sensor q
40-50
D375A-6 (01)
DRAFT General Information on troubleshooting Troubleshooting method for disconnecting wiring harness of pressure sensor system
Measurement record (For measuring locations, see circuit diagram related to each code) Sensor
Charge pressure sensor
Sensor unit (Measuring location on sensor pin side) R2: Between (1) and (3) R1: Between (2) and (3) R2: Between (1) and (3)
Ambient pressure sensor
D375A-6 (01)
R1: Between (2) (+) and (1) (-) R1: Between (1) (+) and (2) (-)
Measured value
Sensor + Wiring harness (Measuring location on wiring harness side of engine controller) R1: Between (1) (+) and (2) (-) R1': Between (44) and (47) R2': Between (37) and (38) (*) R1': Between (3) (+) and (38) (-) R1': Between (38) (+) and (3) (-)
Measured value
40-51
DRAFT General Information on troubleshooting Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2009. 04) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
40-52
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-53
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40-54
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-55
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40-56
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-57
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40-58
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-59
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-60
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-61
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40-62
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-63
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40-64
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-65
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-66
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-67
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-68
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-69
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-70
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-71
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-72
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-73
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-74
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-75
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-76
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-77
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-78
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-79
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-80
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-81
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-82
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-83
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-84
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-85
DRAFT General Information on troubleshooting Connection table for connector pin numbers
40-86
D375A-6 (01)
DRAFT General Information on troubleshooting Connection table for connector pin numbers
D375A-6 (01)
40-87
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connectors table and arrangement drawing Connec- Connector Number tor No. type of pins 19
DT
4
20
DTHD
1
21
DTHD
1
241
DT
6
241
DT
6
250
Terminal
1
255
Terminal
1
256
Terminal
1
260
Terminal
1
270
Terminal
1
280
Terminal
1
453
DT
2
Location Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Starting switch B terminal Starting switch R1 terminal Starting switch R2 terminal Starting switch BR Starting switch ACC terminal Starting switchC terminal Power train oil temperature sensor Standby electric power supply Standby electric power supply
Address F-1
ADH2
Relay
5
ADHA
DT
4
-
AF1
DT
2
N-2
AL/B
Terminal
1
N-1
AL/R
Terminal
1
N-1
ASUS
DT
2
N-1
AT11
-
1
N-2
B105L
Terminal
1
N-2
B105S
Terminal
1
B30L
Terminal
1
B30S
Terminal
1
U-8
B7L
Terminal
1
X-9
B7S
Terminal
1
BH1L
Terminal
1
BH2S
Terminal
1
BKA
Relay
5
BKAL
DT
2
BLD
DT
2
BLU
DT
2
BP
DT
2
Bypass valve
AF-2
BRB
Terminal
1
Battery relay 1
J-2
BRB
Terminal
1
Battery relay 2
L-3
BRC
Terminal
1
Battery relay 1
K-3
X-8 X-8 B-7
AB-3
810
Plug
1
12S1
YAZAKI
2
12 V socket 1
U-5
12S2
YAZAKI
2
12 V socket 2
U-5
12VS
DT
3
AC1
MIC
17 16
AC3
AMP
12
ACS
DT
2
ACT
Relay
5
ADH
40-88
SWP
6
Additional power supply 1 relay Additional power supply 2 relay Intermediate connector Air cleaner clogging switch Alternator B terminal Alternator R terminal Air suspension seat (optional)
5
1
AMP
Address
Relay
Plug
AC2
Location
ADH1
800
Intermediate connector Air conditioner unit Air conditioner control panel Air conditioner control panel Diode (surge-killer) ACC cutout relay Additional heater switch (optional)
Connec- Connector Number tor No. type of pins
X-9 N-4 N-5
N-5 AH-1 V-6
W-7
W-7 U-4 C-1 AG-1 AG-1 U-6
GPS antenna
-
Circuit breaker (105A) Circuit breaker (105A) Circuit breaker (30A) Circuit breaker (30A) Circuit breaker (30A) Circuit breaker (30A) Circuit breaker (105A) Circuit breaker (105A) Backup alarm relay
L-5 L-4 K-5 K-4 K-5 J-4 K-5 K-4 U-7
Backup alarm
J-8
Blade lift lower oil pressure switch Blade lift raise oil pressure switch
P-9
P-9
O-6
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number tor No. type of pins
Location
Address
Connec- Connector Number tor No. type of pins
Location 12 V power supply 12 V power supply Right wiper switch Rear wiper switch Rear lamp switch (optional) Right door wiper motor Left door wiper motor Washer system harness
Address
BRC
Terminal
1
Battery relay 2
L-3
CN-12V
-
3
BRE
Terminal
1
Battery relay 1
J-1
CN-12V S
-
3
BRE
Terminal
1
Battery relay 2
L-1
CN-13
-
6
BRK
DT
3
Q-1
CN-14
-
6
CN-15
-
2
BSW
DT
3
CN-17
-
4
W-6
CN-18
-
4
L-4
CN-19
-
4
W-5
CN2
DT
2
W-5
CN-2
-
1
K-4
CN-20
-
1
W-5
CN-21
-
1
-
CN-22
-
2
CN-23
-
2
CN-25
-
2
CN-26
-
2
CN3
DT
2
CN-3
-
1
CN-34
-
4
CN4
DT
2
Injector #4
CN-4
-
4
Rear window wiper motor
C-9
CN5
DT
2
Injector #5
AI-5
CN-5
-
1
Rear speaker (left)
C-8
CN6
DT
2
Injector #6
AI-5
CN-6
-
1
Rear speaker (left)
C-8
Brake potentiometer Intermediate connector (one-way type model) (optional) Circuit breaker (20A) Circuit breaker (105A) Circuit breaker (20A) Circuit breaker (20A) Circuit breaker (30A) Circuit breaker (20A) Circuit breaker (40A) (optional) Circuit breaker (20A) Circuit breaker (20A) Circuit breaker (30A) Circuit breaker (105A) Machine monitor Machine monitor Machine monitor Machine monitor Machine monitor
-
CB1
-
1
CB105
-
1
CB2
-
1
CB3
-
1
CB30
-
1
CB4
-
1
CB40
-
1
CB5
-
1
CB6
-
1
CB7
-
1
CBH1
-
1
CM01
070
18
CM02
070
12
CM03
070
18
CM04
070
12
CM05
MITSUMI
8
CN1
DT
2
Injector #1
B-9 G-9
CN-1
-
1
Additional light (optional)
CN-10
-
9
Radio
CN-11
-
6
CN-12
-
6
D375A-6 (01)
Left wiper switch Front wiper switch
W-5 W-5 J-4 K-5 N-6 N-5 AF-4
A-9
Injector #2 Rear speaker (right) ACC power supply Battery power supply Cigarette lighter power port Front lamp switch (optional) Rotary lamp (If equipped) Revolving warning lamp switch (optional) Injector #3 Rear speaker (right) Heated wire glass relay
X-9 A-9 A-9 B-9 E-9 F-9 F-1 AF-4 C-9 X-8 X-8 I-9
B-9 B-9
B-9
AG-5 C-9 AH-5
A-9
40-89
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number of pins type tor No. CN-6_1
-
1
CN-6_2
-
1
CN-81
-
2
CN-9
-
6
CN-AL1
-
2
CN-AL2
-
2
CN-AL3
-
2
CN-AL4
-
2
CN-AL5
-
2
CN-AL6
-
2
CN-SM1
-
5
CONV
DT
6
CT2
DT
3
CTV
DT
3
DEC
DT
3
DIAL
H
3
DL1
BENDIX
5
DLSW
Terminal
4
DLT
DT
2
DPNL
-
2
DS1
DT-B
12
DS2
DT-C
12
DS3
DT-A
12
DS4
DT-D
12
DS5
DT-B
12
E
40-90
Terminal
1
Location Heated wire glass relay (EU model) Heated wire glass relay (EU model) Room lamp Front wiper motor Headlamp (left) Headlamp (right) Headlamp (left rear) Headlamp (right rear) Back-up lamp (left) Back-up lamp (right)
Address -
CAN terminating resistor CAN terminating resistor Deceleration potentiometer Fuel control dial VHMS download connector Download switch VHMS download light Emergency evacuation system circuit (C/B model) Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Alternator E terminal
E22
DT-A
12
EFP
DT
2
EG1
DTP04-2P
2
EG2
DT-B
12
EG3
DT
4
EG4
DT-A
12
EG5
DT
4
EG6
DT
6
EGC2
DRC26-50S 04
50
EGC3
DTP06-4S
4
EGR
DT
2
EHL
Relay
5
ENBP
DT
3
ENG
DRC-60
60
EPP
DT
6
ES2
DT
2
ESD
DT
3
EXAF
DT
3
EXAR
DT
3
EXHF
DT
2
EXHR
DT
2
EXTF
DT
2
EXTR
DT
2
E-9 D-8 -
Converter
Connec- Connector Number of pins tor No. type
S-1 AJ-2 W-2 Q-1 S-8 K-9 K-8 K-9
AC-1
N-4 N-3 N-4 N-3 N-3 AG-1
Location Intermediate connector Electric priming pump Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Engine controller Engine controller EGR valve Engine holding relay Blow-by pressure sensor Engine controller (Spare) Intermediate connector (male) Service connector Exhaust gas temperature sensor, front amp Exhaust gas temperature sensor, rear amp Exhaust gas temperature sensor (front) Exhaust gas temperature sensor (rear) Exhaust gas temperature sensor, front amp Exhaust gas temperature sensor, rear amp
Address AJ-2 AI-1 AJ-3 AJ-3 AJ-3 C-7 C-8 C-7 AJ-3 AJ-2 AF-3 W-7 AI-1 AJ-2 C-1 E-9 T-2
X-3
V-3
AF-9
AE-8
X-3
V-2
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number of pins tor No. type F1T
DT
2
F2T
DT
2
F3T
DT
2
F40
DTHD
1
FA1
DT
2
FA2
DT
2
FAR2
DT
2
FD1
24-31
31
FD1
24-31
31
FD2
DT-A
12
FD5
DT-B
12
FEN
DT
2
FFT
DT
2
FGS
DT
2
FLB
DT
2
FLC
DT
2
FLSW
SWP
6
FLUC
DT
2
FRB
DT
2
FRC
DT
2
FRT FRTS
D375A-6 (01)
DT Terminal
2 6
Location 1st clutch ECMV (fill switch) 2nd clutch ECMV (fill switch) 3rd clutch ECMV (fill switch) Intermediate connector (optional) Fan pump (LPV90) solenoid valve Fan pump (LPV30) solenoid valve Fan reverse solenoid valve Intermediate connector Intermediate connector Intermediate connector Intermediate connector Air conditioner compressor Forward clutch ECMV (fill switch) Fuel level gauge Left steering brake ECMV (fill switch) Left steering clutch ECMV (fill switch) Front lamp switch Torque converter lockup clutch right ECMV (fill switch) Right steering brake ECMV (fill switch) Right steering clutch ECMV (fill switch) Reverse clutch ECMV (fill switch) FR lever (optional)
Address
Connec- Connector Number tor No. type of pins
Location Fan reverse sensor Fuse box (inlet) Fuse box (outlet) Fuse box (inlet) Fuse box (outlet) Fuse box (inlet) Fuse box (outlet) Intermediate connector Torque converter stator clutch left ECMV (fill switch) Intermediate connector (optional) Engine Bkup speed (G) sensor
Address
FRV
DT
2
FS11
-
5
FS12
-
5
FS21
-
5
FS22
-
5
FS31
-
5
FS32
-
5
FSB
24-31
31
FSTC
DT
2
FTS
-
3
G
DT
3
GND
-
1
Ground
E-1
GND01
-
1
Ground
N-7
GND02
-
1
Ground
N-7
K-6
GND03
-
1
Ground
N-7
AD-5
GND05
Terminal
1
Ground (fender)
H-2
GND06
Terminal
1
Ground (floor)
S-1
GND07
Terminal
1
Ground
A-5
GND0A
Terminal
1
Ground (lamp)
A-6
GND0B
Terminal
1
Ground (fender)
H-2
GND1
Terminal
1
Ground (cab)
B-8
GND11
Terminal
1
Ground (engine)
AJ-2
GND2
Terminal
1
Ground (cab)
B-8
H01
-
1
H02
-
1
Z-9
Y-8
Y-8
-
Y-5
AA-7 A-3 J-5 K-7 T-2 AH-1
A-3 V-9 V-9 V-9 V-9 W-9 W-9 M-8
Y-5
R-1
AJ-4
AA-9
AB-8 O-7
Y-4
AD-6
AB-7
Z-9
Additional heater PW1 Additional heater PW2
R-8 R-8
-
40-91
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number tor No. type of pins HDT
DT
2
HHP
DT
3
HLS
DT
2
HLS
DT
2
HNSW
DT
HRN
-
2
HT
Terminal
1
HT/A
Terminal
1
HT/B
Terminal
1
HTD
DT
2
INJ
DT
12
INT
DT
2
J1939
DT
3
Location Hydraulic oil temperature sensor Hydraulic oil pump pressure sensor Intermediate connector (female) Hydraulic oil level sensor (optional)
Address AA-7
LHDR1
DT
2
LMD1
DT
2
LMD2
DT
2
LMFL
Relay
5
LMFR
Relay
5
LMRE
Relay
5
LMW
Relay
5
LREL
DT
2
LRER
DT
2
LRP
DT
2
LRR
DT
3
LWKL
DT
2
LWKR
DT
2
M26
DT
6
MMS
DT-C
12
D-8
E-9
C-2
Horn switch
Q-8
Horn
A-3
Preheater relay Preheater relay Preheater relay Diode (surge-killer) Intermediate connector Intake temperature sensor Service connector (engine) Junction connector Junction connector
Connec- Connector Number tor No. type of pins
C-8 E-1 E-1 I-3 AJ-5 B-2 AG-5
JB1
-
8
JB2
-
11
JM01
-
KEY
DT
6
Starting switch
N-6
KOM1
DRC-40A
40
Communication terminal
P-7
NE
FRAMATONE
3
KOM2
-
1
GPS antenna
Q-8
NSF
Relay
5
KOM3
-
1
NSW
DT
3
OBC
DT-A
12
LHD
DT
4
LHDL
DT
2
OLV
DT
2
OPSW
SWP
6
OPT
Relay
5
P03
DT
6
LHDL1
LHDR
40-92
DT
DT
Junction box
2
2
Communication terminal antenna Intermediate connector Left headlamp Left headlamp (additional headlamp model) (optional) Right headlamp
AF-4 AG-5 -
Q-8 A-3 A-2
-
A-5
Location Right headlamp (additional headlamp model) (optional) Diode (surge-killer) Diode (surge-killer) Left headlamp relay Right headlamp relay Back-up lamp relay Working lamp relay Left back-up lamp (70W) Right back-up lamp (70W) Ripper point lamp (70W) (optional) Intermediate connector Left working lamp (70W) Right working lamp (70W) Air conditioner controller (cab model) Intermediate connector (MMS device (optional)) Engine Ne speed sensor Neutral safety relay Parking brake lever switch Intermediate connector Engine oil level switch (optional) Option switch (optional) Engine compartment lamp relay (optional) Intermediate connector
Address
-
O-1 O-1 U-8 V-6 W-6 X-8 K-6 F-9 H-9 F-1 A-6
P-1
W-4
AJ-3 X-8 T-2 R-8 AI-1 O-6
W-7
P-7
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number tor No. type of pins PAMB
AMP
3
PCV1
SUMITOMO
2
PCV2
SUMITOMO
2
PFUEL
AMP
3
PHR
Relay
5
PIM
SUMITOMO
3
PL1
24-23
23
PL1F
24-23
23
PL1M
24-23
23
PL2
24-31
31
PL2
24-31
31
PL3
24-31
31
PLB
DT
2
PLS
DT
2
PLSW
DT
2
PLUB
Relay
5
PM1
Terminal
1
PNL
24-31
31
POIL
FRAMATONE
3
POP
Terminal
1
PPL
DT
2
D375A-6 (01)
Location Ambient pressure sensor Supply pump #1 Supply pump #2 Common rail pressure sensor Preheater relay Boost pressure sensor Intermediate connector Emergency evacuation system circuit (C/B model) Emergency evacuation system circuit (C/B model) Intermediate connector Emergency evacuation system circuit (C/B model) Intermediate connector Intermediate connector (pre-lubrication system) Diode (surge-killer) Pin puller switch Pre-lubrication relay Pre-lubrication motor (optional) Emergency evacuation system circuit (C/B model) Engine oil pressure sensor Pre-lubrication oil pressure switch (optional) Pin puller solenoid valve
Address AJ-3
Connec- Connector Number of pins type tor No. PR1
Terminal
1
PR2
Terminal
1
PR3
Terminal
1
X-7
PR4
Terminal
1
AJ-4
PRE
DT
2
AD-6
PRT1
DT-A
12
PRT2
DT
4
PRT3
DT
2
PT1
DT
3
AJ-4 AJ-4 AH-5
AD-1
AD-1
PTCN1 DRC26-24A
24
PTCN2 DRC26-40A
40
PTCN3 DRC26-40B
40
AD-7
AD-1
PWR
DTHD
1
RB1
DT
6
RDG
DT-B
12
I-3
RES
DT
2
Q-8
RLSW
SWP
6
U-7
RPD
DT
2
RPNL
-
2
RPU
DT
2
RSD
DT
2
RTB
DT
2
RTI
DT
2
RTS
-
3
A-6
C-1
-
AB-3
AI-1
-
I-9
Location Pre-lubrication relay (optional) Pre-lubrication relay (optional) Pre-lubrication relay (optional) Pre-lubrication relay (optional) Pre-lubrication connector Intermediate connector Intermediate connector Intermediate connector Pitch angle sensor Power train controller Power train controller Power train controller Intermediate connector Intermediate connector Intermediate connector Resistor Rear lamp switch Ripper lower oil pressure switch Emergency evacuation system circuit (C/B model) Ripper raise oil pressure switch Diode (BR hold (backup)) Ripper tilt back oil pressure switch Ripper tilt in oil pressure switch Intermediate connector (optional)
Address -
-
-
D-8 M-2 D-1 M-2 D-1 U-6 U-6 T-7 U-3 D-8 A-5 AI-1 O-7 O-8
AD-3
P-8 J-4 P-8
P-8
R-1
40-93
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number tor No. type of pins S1T
DT
2
S2T
DT
2
S3T
DT
2
SBP
DT
4
SEGR
DT
4
SFT
DT
2
SFTD
-
3
SFTU
-
3
SLB
DT
2
SLC
DT
2
SLUC
DT
2
SNC
DT
6
SOL1
DT
2
SOL2
DT
2
SRB
SRC
DT
DT
2
2
SRT
DT
2
SRV
DT-A
12
40-94
Location 1st clutch ECMV (solenoid valve) 2nd clutch ECMV (solenoid valve) 3rd clutch ECMV (solenoid valve) Bypass valve position sensor EGR valve position sensor Forward clutch ECMV (solenoid valve) Shift down switch Shift down switch Left steering brake ECMV (solenoid valve) Left steering clutch ECMV (solenoid valve) Torque converter lockup clutch right ECMV (solenoid valve) BG shift switch (one-way type model) (optional) Pitching solenoid valve Dual-tilt system solenoid valve Right steering brake ECMV (solenoid valve) Right steering clutch ECMV (solenoid valve) Reverse clutch ECMV (solenoid valve) KOMNET service connector
Address Y-9
Connec- Connector Number tor No. type of pins
Location
Address
Acceleration sensor (dedicate SSC model option) Torque converter stator clutch left ECMV (solenoid valve) Starting motor A Starting motor B Starting motor A (top) Starting motor B (bottom) Sudden stop prevention solenoid valve Data writing connector (S/T controller)
SSA
DT
4
SSTC
DT
2
ST/B1
Terminal
1
ST/B2
Terminal
1
ST1
DT
2
Z-7
ST2
DT
2
R-1
STB
DT
2
STF
X
4
SW
Terminal
1
Battery relay 1
K-1
SW
Terminal
1
Battery relay 2
L-1
SX-8
Terminal
1
TC1
DT
2
TFUEL
PACKARD
2
TIM
PACKARD
2
TIP
DT
3
TL1
24-31
31
TL2
DT-B
8
TL3
DT
6
TL3
DT
6
TLS
DT
2
TM1
DT
2
Y-7
Y-8
AF-2
AF-3
R-1
AD-5
AB-8
Y-4
S-7
D-8 D-8
AD-5
AB-8
Y-8
P-1
E-1
Y-5
AE-6 AE-5 AG-5 AG-5 AC-8
T-7
Ground F-1 (fender) Torque converter output AC-7 speed sensor Fuel temperaAG-1 ture sensor Boost temperAI-5 ature sensor Torque converter inlet Y-6 pressure sensor Intermediate M-9,U-5 connector Intermediate T-7 connector Intermediate T-7 connector (one-way type model) T-7 (optional) Blade tilt left oil pressure P-9 switch Transmission outlet shaft speed sensor AD-7 (VHMS installation model only)
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
Connec- Connector Number of pins type tor No.
TMF
TMMD
X
DT
4
3
TMV
24-23
23
TOIL
PACKARD
2
TOP
DT
3
TR1L
-
1
TR1S
-
1
TR2L
-
1
TR2L
-
1
TR2S
-
1
TRS
DT
2
TWTR
PACKARD
2
USB
DTHD
1
V1
070
20
V2A
070
18
V2B
070
12
V3A
070
18
V3B
070
12
V4A
070
14
V4B
070
10
VDA
DT-D
12
VDB
DT-B
12
VDC
DT-D
12
D375A-6 (01)
Location Data writing connector (work equipment controller) Transmission main oil pressure sensor (VHMS installation model only) Intermediate connector Engine oil temperature sensor Torque converter outlet pressure sensor Main power terminal Main power terminal Main power terminal 2 Main power terminal Main power terminal 2 Blade tilt right oil pressure switch Coolant temperature sensor Intermediate connector VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller Intermediate connector Intermediate connector Intermediate connector
Address
Connec- Connector Number tor No. type of pins VDW
BENDIX
5
VED
DT-C
12
VEG
DT-C
12
VF1
DT-B
12
VF2
24-31
31
T-7
Z-7
AA-7
WECN1 DRC26-24A
24
WECN2 DRC26-40A
40
WECN3 DRC26-40B
40
AJ-2
AB-3
K-3
WELK
DT
3
K-3
WLD
DT
2
-
WSFR
YAZAKI
2
K-3
WSLH
YAZAKI
2
-
WSRH
YAZAKI
2
WSRR
YAZAKI
2
P-9
TAJIMI AH-5
Location
Address
VHMS downS-2 load connector Intermediate K-6 connector Intermediate AJ-3 connector Intermediate V-3 connector Intermediate U-4,V-2 connector Work equipment controlT-7 ler Work equipment controlS-8 ler Work equipment controlS-8 ler WE lock P-7 switch Coolant level A-3 sensor Washer tank J-5 (front) Washer tank J-5 (left) Washer tank J-4 (right) Washer tank J-5 (rear) Rear view camera (optional)
U-3 V-2 W-2 X-2 W-2 W-2 X-2 W-2 L-9 K-7 I-3
40-95
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
40-96
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
D375A-6 (01)
40-97
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
40-98
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
D375A-6 (01)
40-99
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
40-100
D375A-6 (01)
DRAFT General Information on troubleshooting Connectors table and arrangement drawing
D375A-6 (01)
40-101
DRAFT General Information on troubleshooting T-branch box and T-branch adapter table
T-branch box and T-branch adapter table
799-601-2600 799-601-3100 799-601-3200 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 799-601-4350 799-601-4360 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
40-102
T-box(for ECONO) T-box(for MS) T-box(for MS) • Plate for MS (14-pin) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for DLI Adapter for DLI Adapter for DLI Extension cable (ECONO type) Case T-box(for DRC 60, ECONO) Case Adapter for X (T-adapter) Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M Adapter for S (White)
24 24 17 17 5 10 5 17 19 14
q q q q
q q q q q q
q q q q q q q q q q
q q q q q q q q q
q q q q q q q q q
Out of kit
q q q
q
60
X2P X3P X4P SW6P SW8P SW12P SW14P SW16P M2P M3P M4P M6P M8P S8P S10P
799-601-4201
799-601-9300
799-601-9200
799-601-4101
q q q q q q q q q q q q q q
MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5S MS-17P MS-19P MS-14P
5 MIC-5P 13 MIC-13P 17 MIC-17P 21 MIC-21P 9 MIC-9P 2 ECONO2P 3 ECONO3P 4 ECONO4P 8 ECONO8P 12 ECONO12P 8 DLI-8P 12 DLI-12P 16 DLI-16P 12 ECONO12P
1 2 3 4 6 8 12 14 16 1 2 3 4 6 8 8 10
799-601-9100
q
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
q
799-601-7000
q
21 37 37
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part number
Number of pins
(Rev. 2009. 03) a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q q q q q q
q q q q
q
q
q q q q q
q q q q q
q q q q q q
q q
q q q q q
q q q q
q q q q q
q q q q
q q
q q
q
D375A-6 (01)
DRAFT General Information on troubleshooting T-branch box and T-branch adapter table
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*
Adapter for S (Blue) Adapter for S (Blue) Adapter for S (White) Adapter for S (White) Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Short connector for X Case Case Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for relay Adapter for relay Adapter for JFC Adapter for DTM Adapter for DT Adapter for DT Adapter for DT Adapter for DT Adapter for DT (Gray) Adapter for DT (Black) Adapter for DT (Green) Adapter for DT (Brown) Adapter for DT (Gray) Adapter for DT (Black) Adapter for DT (Green) Adapter for DT (Brown) Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Plate for HD30 (24-pin) T-box(for ECONO) Case Case Adapter for DRC Adapter for DRC Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor Socket for engine (CRI-T2) 799-601-9430* Socket for engine(CRI-T3) PCV 799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2)
D375A-6 (01)
24
q q q q q q q q q q q q q q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
q q q q q q
799-601-7500
799-601-7400
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31
799-601-7100
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31
799-601-7000
S12P S16P S16PW S12PW A8P A12P A16P A20P -
799-601-2800
12 16 16 12 8 12 16 20 2
799-601-2700
Identification symbol
799-601-2500
Part name
Number of pins
Part number
T-adapter kit
q
q q q q q q q q q
q q q q q q q q q q q q q q q q q q q q q q q q q
q q q q q q q q q q q q
q q q
q q q q q q q q q q q q q
q q q q
q q q q
40 24 2
DRC-40 DRC-24 G
3
A3
q q
2
P
q q
3 2
1,2,3 S
q
q q
40-103
DRAFT
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) 2 Temperature sensor Socket for engine (HPI-T2) 795-799-5540* 2 Socket for engine(CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 3 795-799-5470 Cable for engine (HPI-T2) 3 795-799-5480 Cable for engine (HPI-T2) 3 799-601-4110 Adapter for engine (140-T3) PIM 4 799-601-4130 Adapter for engine (CRI-T3) NE,CAM 3 Adapter for engine (CRI-T3) 799-601-4140 3 Atomosphere pressure 799-601-4150 Adapter for engine (CRI-T3) POIL 3 Adapter for engine (CRI-T3) 799-601-4160 2 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA 3 Socket for engine (CRI-T3) 799-601-4190* 3 Common rail pressure Socket for engine (CRI-T3) 799-601-4230* 4 Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 3 799-601-4250* Socket for engine (CRI-T3) PIM 3 799-601-4330* Socket for engine (CRI-T3) G 3 Socket for engine (CRI-T3) 799-601-4340* 2 Pump actuator Socket for engine (CRI-T3)(95) 799-601-4380* 4 Air intake pressure/temperature 799-601-4260 Adapter for controller (ENG) 4 799-601-4211 Adapter for controller (ENG) 50 799-601-4220 Adapter for controller (ENG) 60 799-601-4390* Socket for controller (95 ENG) 60 799-601-4280* Box for controller (PUMP) 121 799-601-9720 Adapter for controller (HST) 16 799-601-9710 Adapter for controller (HST) 16 799-601-9730 Adapter for controller (HST) 26 2, 799-601-9890 Multi-adapter for DT2 – 4 andDTM2 3, 4
C
q q
A
q q
ITT3N FCIN
q q q q
FCIG
q q
FCIB
q q
4160
q q
4180
q q
1,2,3L
q q
1,2,3,4C
q q
1,2,3A 1,2,3B 1,2,3,G
q q q q q q
2,PA
q q
-
q q q
q
1,2,3,4T DTP4 DRC50 DRC60 HST16A HST16B HST26A
Out of kit
799-601-4201
799-601-4101
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
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part number
Number of pins
General Information on troubleshooting T-branch box and T-branch adapter table
q q q q
q q q q q q
"*" Shows not T-adapter but socket.
40-104
D375A-6 (01)
DRAFT General Information on troubleshooting Fuse locations table
Fuse locations table Connection table of circuit breakers and fuse boxes a This connection table shows the devices to which each power supply of the circuit breakers and fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally. Mounting location of circuit breakers (1) - (4)
Mounting location of circuit breakers (5) - (10)
D375A-6 (01)
40-105
DRAFT General Information on troubleshooting Fuse locations table
Circuit breakers CB1–CB7, CB30, CB105 and CBH1
1 2 3
Power breaker (Power supply type) (Main power supply) (Constant power supply) (Main power supply)
4
(Constant power supply)
5 6
CB105 (Main power supply) Starting switch (ACC)
Capacity (A) 105 30 105 30
Circuit Destination of power breaker No. CB105 Main power supply CB30 Constant power supply CBH1 Preheater relay Engine controller constant power source CB7 Power supply of electric priming pump timer
20
CB1
Power train controller
20
CB2
Machine monitor (ACC)
7 8 9
CB105 (Main power supply)
20 20 20
CB3 CB4 CB5
Work equipment controller Air conditioner Headlamp
10
CB30 (Constant power supply)
20
CB6
Constant power supply of starting switch
a Resetting circuit breakers (1) – (4) Turn starting switch to OFF position, and press RESET button 5 - 10 minutes after power-off. If electrical circuit is open, the RESET button is heavy to operate when compared with normal operation. The RESET button has the same height when electrical circuit is open and when breakers are reset. Therefore, you can determine the condition by checking the return force. Do not hold down the RESET button too long. a Resetting circuit breakers (5) – (10) Turn starting switch to OFF position, and press protruded RESET button (11). If RESET button is protruded again, perform troubleshooting and repair defect.
40-106
D375A-6 (01)
DRAFT General Information on troubleshooting Fuse locations table
Mounting location of fuse boxes FS11 – FS31
Mounting location of fuse box (Cab top end)
D375A-6 (01)
40-107
DRAFT General Information on troubleshooting Fuse locations table
Fuse box FS11
1 2 3 4 5
Power breaker Fuse capacity Destination of power (Power supply type) (A) CB105 (Main power supply) 20 VHMS controller power supply Constant power supply of VHMS, power train, and work equip20 CB30 (Constant power supment controllers ply) 20 Constant power supply of cab 10 12V converter constant power supply CB105 (Main power supply) 20 12V converter power supply
Fuse box FS21 Power breaker (Power supply type)
1 2 3 4 5
Fuse capacity (A) 5 20 CB105 (Main power supply) 20 20 20
Destination of power Backup alarm Pin puller, preheater, air suspension seats Additional heater Working lamp Rear lamp
Fuse box FS31
1 2 3 4 5
Power breaker (Power supply type) Starting switch (ACC)
Fuse capacity (A) 5 5 CB105 (Main power supply) 20 20 Starting switch (ACC) 20
Destination of power ACC for engine controller Horn Spare power supply (1) Spare power supply (2) Spare ACC signal
Fuse box (Cab top end) Power breaker (Power supply type)
1 2 3 4 5 6 7 8 9 10
40-108
Fuse capacity (A) 10 10 15 10 15 CB105 (Main power supply) 20 20 20 CB30 (Constant power sup10 ply)
Destination of power Radio, cigarette lighter, room lamp Rear wiper Rear wiper Front wiper Left wiper Additional back-up lamp Additional headlamp, revolving warning lamp Glass with heating wire Spare Radio memory
D375A-6 (01)
Troubleshooting by failurecode Failure code [1380MW] Lock up clutch: Slip
Troubleshooting by failurecode
40-109
Failure code [1380MW] Lock up clutch: Slip
40-109
Action code
Failure code Failure
-
1380MW
Detail of failure Action of controller Problem on machine
q
When torque converter is locked up, sensed engine speed does not match with sensed torque converter output speed.
q
None in particular.
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None in particular.
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Engine speed and torque converter speed can be checked with monitoring function. (Code 01002: Engine speed) (Code 31200: Transmission input speed (Torque converter output speed)) Method of reproducing failure code: Start engine, turn lockup clutch ON and drive machine.
Related information q
Cause Lockup clutch slip(When system is normal) Defective engine speed sen2 sor system Defective torque converter 3 speed sensor Defective power train con4 troller 1
D375A-6 (06)
Lockup clutch slip (Power train controller system)
Procedure, measuring location, criteria and remarks Check for cause of lockup clutch slip and damage of machine. If failure code[CA689] or [CA778] is displayed, carry out troubleshooting for it. If failure code [DLF1KA] is displayed, carry out troubleshooting for it. Since failure is in it, troubleshooting cannot be carried out.
40-109
DRAFT Troubleshooting by failure code Failure code [1500L0] Transmission clutch: Abnormal
Failure code [1500L0] Transmission clutch: Abnormal Action code E03
Failure code Transmission clutch: Abnormal Failure 1500L0 (Power train controller system) q Among failure codes related to transmission clutch, following codes occurred at the same time (Gear speed limit). (1) Either of [DXH4KA] and [DXH4KB] and either of [DXH5KA] and [DXH5KB]. q Among failure codes related to transmission clutch, following codes occurred at the same time (Travel trouble). (2) Either of [DXH8KA] and [DXH8KB] and either of [DXH7KA] and [DXH7KB]. (3) Either of [DXH6KA] and [DXH6KB] and either of [DXH5KA] and [DXH5KB] and either of [DXH4KA] Detail of failand [DXH4KB] ure (4)[15SALH] and [15SBLH] (5) Either of [15SAL1] and [DXH8KY] and either of [15SBL1] and [DXH7KY] (6)[15SELH] and [15SFLH] and [15SGLH] (7) Either of [15SEL1] and [DXH4KY], and either of [15SFL1] and [DXH5KY] (8) Either of [15SEL1] and [DXH4KY], and either of [15SGL1] and [DXH6KY] (9) Either of [15SFL1] and [DXH5KY], and either of [15SGL1] and [DXH6KY] Action of conq Limits operation of engine and transmission. troller Problem that q The auto shift down function does not start. appears on q Once machine is stopped, engine speed is limited to medium (half). machine q Once machine is stopped, it can travel only by the minimum gear which can operate. Related inforq Method of reproducing failure code: Engine start + Run mation Cause Procedure, measuring location, criteria and remarks Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes. [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH] [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA], [DXH8KB], [DXH4KY], [DXH5KY], [DXH6KY], [DXH7KY], [DXH8KY]
40-110
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15E0MW] Transmission clutch: Slip
Failure code [15E0MW] Transmission clutch: Slip Action code ― Detail of failure Action of controller Problem on machine
q q
None in particular.
q
None in particular.
q
Torque converter speed and transmission speed can be checked with monitoring function. (Code 31200: Transmission input speed (Torque converter output speed)) (Code 31400: Transmission output speed) Method of reproducing failure code: Start engine and drive machine.
Related information q
1 2 3 4
Failure code Transmission clutch slip Failure 15E0MW (Power train controller system) Sensed torque converter output speed does not match with sensed transmission output speed.
Cause Transmission clutch slip (When system is normal) Defective torque converter speed sensor Defective transmission speed sensor Defective power train controller
D375A-6 (01)
Procedure, measuring location, criteria and remarks Check for cause of transmission clutch slip and damage of machine. Check if failure code [DLF1KA] is displayed Carry out troubleshooting for it. Check if failure code [DLT3KA], [DLT3KB] is displayed Carry out troubleshooting for it. Since failure is in it, troubleshooting cannot be carried out.
40-111
DRAFT Troubleshooting by failure code Failure code [15SAL1] Forward clutch: Fill high
Failure code [15SAL1] Forward clutch: Fill high Action code E03
Failure code Forward clutch fill dwitch signal is ON. Failure 15SAL1 (Power train controller system) q Nevertheless controller does not output command current to transmission F clutch ECMV solenoid Detail of failure circuit, fill switch signal is ON. q Sets transmission to neutral when operator sets it to reverse position (Prevention of double engageAction of conment). troller q Limits operation of engine and transmission. q Once machine is stopped, engine speed is limited to medium (half). Problem on q Once machine is stopped, travel is limited to F1. machine q The automatic gearshift system does not operate. q State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) q Method of reproducing failure code: Start engine and set PCCS lever in neutral position. Related inforq Remove seat (approx. 50 kg) and cover under seat. mation q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective F clutch ECMV fill 2. Disconnect connector FFT and connect T-adapter to male side. 1 switch (Internal short cirBetween FFT (female) (1) and ground cuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FFT. Ground fault of wiring har3. Start engine 2 ness or defective power If failure code [15SAL1] is still displayed, there is ground fault of wiring harness or train controller power train controller is defective. (If failure code [15SAL1] is not displayed, F clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and FFT, and connect T-adapter to female side of 3 (Contact with ground cireither of them. cuit) Between PTCN2 (female) (5) or FFT (female) (1) and Resistance Min. 1 MΩ ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train con- 3. Start engine 4 troller a Keep PCCS lever in N position. Between PTCN2 (5) and ground Voltage 7 – 11 V 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (5) and ground F1/F2/F3 Voltage Max.1 V
40-112
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SAL1] Forward clutch: Fill high
Circuit diagram related to forward clutch ECMV
D375A-6 (01)
40-113
DRAFT Troubleshooting by failure code Failure code [15SALH] Forward clutch: Fill Low
Failure code [15SALH] Forward clutch: Fill Low Action code E03 Detail of failure Action of controller Problem on machine
Related information
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Failure code Forward clutch fill switch signal is OFF. Failure 15SALH (Power train controller system) Nevertheless controller outputs command current to transmission F clutch ECMV solenoid circuit, fill switch signal is turned OFF. Sets transmission to neutral when operator sets it to forward position (Prevention of defective engagement). 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 R1. The automatic gearshift system does not operate. State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) Method of reproducing failure code: Start engine and set PCCS lever in forward position. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
Cause
1
Defective F clutch ECMV fill switch (It does not turn ON)
2
Disconnection in wiring harness (Disconnection or defective contact)
3
Defective power train controller
40-114
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FFT and connect T-adapter to male side. 3. Start engine a Keep PCCS lever in N position. Between FFT (male) (1) and ground Resistance Min. 1 MΩ 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between FFT (male) (1) and ground F1/F2/F3 Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to female side of them. Between PTCN2 (female) (5) and FFT (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine a Keep PCCS lever in N position. Between PTCN2 (5) and ground Voltage 7–11 V 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (5) and ground F1/F2/F3 Voltage Max. 1 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SALH] Forward clutch: Fill Low
Circuit diagram related to forward clutch ECMV
D375A-6 (01)
40-115
DRAFT Troubleshooting by failure code Failure code [15SBL1] Reverse clutch: Fill high
Failure code [15SBL1] Reverse clutch: Fill high Action code E03
Failure code Reverse clutch fill switch signal is ON. Failure 15SBL1 (Power train controller system) q Nevertheless controller does not output command current to transmission R clutch ECMV solenoid Detail of failure circuit, fill switch signal is turned ON. q Sets transmission to neutral when operator sets it to forward position (Prevention of double engageAction of conment). troller q Limits operation of engine and transmission. q Once machine is stopped, engine speed is limited to medium (half). Problem on q Once machine is stopped, travel is limited to R1. machine q The automatic gearshift system does not operate. q State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) q Method of reproducing failure code: Start engine and set PCCS lever in neutral position. Related inforq Remove seat (approx. 50 kg) and cover under seat. mation q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective R clutch ECMV fill 2. Disconnect connector FRT and connect T-adapter to male side. 1 switch (Internal short cirBetween FRT(female) (1) and ground cuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FRT. Ground fault of wiring har3. Start engine 2 ness or defective power If failure code [15SBL1] is still displayed, there is ground fault of wiring harness or train controller power train controller is defective. (If failure code [15SBL1] is not displayed, R clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN2 and FRT and connect T-adapter to female side of 3 ness either of them. (Contact with ground circuit) Between PTCN2 (female) (36) or FRT (female) (1) Resistance Min. 1 MΩ and ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train con- 3. Start engine 4 troller a Keep PCCS lever in N position. Between PTCN2 (36) and ground Voltage 7 –11 V 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (36) and ground R1/R2/R3 Voltage Max. 1 V
40-116
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SBL1] Reverse clutch: Fill high
Circuit diagram related to reverse clutch ECMV
D375A-6 (01)
40-117
DRAFT Troubleshooting by failure code Failure code [15SBLH] Reverse clutch: Fill Low
Failure code [15SBLH] Reverse clutch: Fill Low Action code E03 Detail of failure Action of controller Problem on machine
Related information
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Failure code Reverse clutch fill switch signal is OFF. Failure 15SBLH (Power train controller system) Nevertheless controller outputs command current to transmission R clutch ECMV solenoid circuit, fill switch signal is turned OFF. Sets transmission to neutral when operator sets it to reverse position (Prevention of defective engagement). 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. The automatic gearshift system does not operate. State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) Method of reproducing failure code: Start engine and set PCCS lever in reverse position. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FRT and connect T-adapter to male side. 3. Start engine Defective R clutch ECMV fill a Keep PCCS lever in N position. 1 Resistance Min. 1 MΩ switch (It does not turn ON) Between FRT (male) (1) and ground 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between FRT (male) (1) and ground R1/R2/R3 Resistance Max. 1 Ω Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and FRT, and connect T-adapters to female side 2 (Disconnection or defective of them. contact) Between PTCN2 (female) (36) and FRT (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine a Keep PCCS lever in N position. Defective power train con3 Between PTCN2 (36) and ground Voltage 7 – 11 V troller 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (36) and ground R1/R2/R3 Voltage Max. 1V
40-118
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SBLH] Reverse clutch: Fill Low
Circuit diagram related to reverse clutch ECMV
D375A-6 (01)
40-119
DRAFT Troubleshooting by failure code Failure code [15SEL1] Speed 1st clutch: Fill high
Failure code [15SEL1] Speed 1st clutch: Fill high Action code E03
Failure code Speed 1st clutch: fill switch signal is ON. Failure 15SEL1 (Power train controller system) q Nevertheless controller does not output command current to transmission 1st clutch ECMV solenoid Detail of failure circuit, fill switch signal is turned ON. Action of conq Limits operation of engine and transmission. troller q Once machine is stopped, engine speed is limited to medium (half). Problem on q Once machine is stopped, travel is limited to F1 and R1. machine q The automatic gearshift system does not operate. q State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) q Method of reproducing failure code: Start engine and set PCCS lever in neutral position. Related inforq Remove seat (approx. 50 kg) and cover under seat. mation q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause Defective 1st clutch ECMV 1 fill switch (Internal short circuit)
Ground fault of wiring har2 ness or defective power train controller
Ground fault of wiring harness 3 (Contact with ground circuit)
4
Defective power train controller
40-120
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector F1T and connect T-adapter to male side. Between F1T (female) (1) and ground Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector F1T. 3. Start engine If failure code [15SEL1] is still displayed, there is ground fault of wiring harness or power train controller is defective. (If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and F1T and connect T-adapter to female side of either of them. Between PTCN2 (female) (35) or F1T (female) (1) and Resistance Min. 1 MΩ ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine a Keep PCCS lever in N position. Between PTCN2 (35) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (35) and ground F1/R1 Voltage Max. 1 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SEL1] Speed 1st clutch: Fill high
Circuit diagram related to 1st clutch ECMV
D375A-6 (01)
40-121
DRAFT Troubleshooting by failure code Failure code [15SELH] Speed 1st clutch: Fill Low
Failure code [15SELH] Speed 1st clutch: Fill Low Action code E03 Detail of failure Action of controller Problem on machine
q
q
Limits operation of engine and transmission.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F2 and R2. The automatic gearshift system does not operate. State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) Method of reproducing failure code: Start engine and set PCCS lever in F1 or R1 position. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q q q
Related information
Failure code Speed 1st clutch fill switch signal is OFF. Failure 15SELH (Power train controller system) Nevertheless controller outputs command current to transmission 1st clutch ECMV solenoid circuit, fill switch signal is turned OFF.
q q q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine a Keep PCCS lever in N position. Defective 1st clutch ECMV fill Between F1T (male) (1) and ground Resistance Min. 1 MΩ 1 switch (It does not turn ON) 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between F1T (male) (1) and F1/R1 Resistance Max. 1 Ω ground Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and F1T, and connect T-adapters to female side 2 (Disconnection or defective of them. contact) Between PTCN2 (female) (35) and F1T (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine Defective power train control- a Keep PCCS lever in N position. 3 Between PTCN2 (35) and ground Voltage 7 – 11 V ler 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (35) and ground F1/R1 Voltage Max. 1V
40-122
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SELH] Speed 1st clutch: Fill Low
Circuit diagram related to 1st clutch ECMV
D375A-6 (01)
40-123
DRAFT Troubleshooting by failure code Failure code [15SFL1] Speed 2nd clutch: Fill high
Failure code [15SFL1] Speed 2nd clutch: Fill high Action code E03
Failure code Speed 2nd clutch fill switch is ON. Failure 15SFL1 (Power train controller system) q Nevertheless controller does not output command current to transmission 2nd clutch ECMV soleDetail of failure noid circuit, fill switch signal is turned ON. Action of conq Limits operation of engine and transmission. troller q Once machine is stopped, engine speed is limited to medium (half). Problem on q Once machine is stopped, travel is limited to F2 and R2. machine q The automatic gearshift system does not operate. q State (ON/OFF) of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) q Method of reproducing failure code: Start engine and set PCCS lever in neutral position. Related inforq Remove seat (approx. 50 kg) and cover under seat. mation q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 2nd clutch ECMV fill switch (Internal short cir- 2. Disconnect connector F2T and connect T-adapter to male side. Between F2T (female) (1) and ground cuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector F2T. Ground fault of wiring har3. Start engine ness or defective power If failure code [15SFL1] is still displayed, there is ground fault of wiring harness or train controller power train controller is defective. (If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN2 and F2T, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN2 (female) (25) or F2T (female) (1) Resistance Min. 1 MΩ and ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train con- 3. Start engine troller a Keep PCCS lever in N position. Between PTCN2 (25) and ground Voltage 7 – 11 V 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (25) and ground F2/R2 Voltage Max. 1 V
40-124
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SFL1] Speed 2nd clutch: Fill high
Circuit diagram related to 2st clutch ECMV
D375A-6 (01)
40-125
Troubleshooting by failurecode Failure code [15SFLH] Speed 2nd clutch: Fill Low
Failure code [15SFLH] Speed 2nd clutch: Fill Low Action code
Failure code Failure
E03
15SFLH
Detail of failure Action of controller Problem on machine
2nd clutch oil pressure 2 (Power train controller system)
q
Nevertheless controller outputs command current to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is turned OFF.
q
Limits operation of engine and transmission.
q
Once machine is stopped, engine speed is limited to medium (half) speed. Once machine is stopped, travel is limited to F1 and R1. The automatic gearshift system does not operate. The condition (ON/OFF) of the 2nd clutch ECMV fill switch signal can be checked with the monitoring function. (Code: 40906 T/M Fill Sw Input 1) Method of reproducing failure code: Start engine and PCCS lever in F2 or R2 position. Remove seat (approx. 50 kg) and cover under seat. First, check power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
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Related information
40-126
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Cause
Procedure, measuring location, criteria and remarks 1. 2. 3. a
Turn starting switch to OFF position. Disconnect connector F2Tand connect T-adapter to male side. Start engine. Keep PCCS lever in N position.
Defective 2nd clutch ECMV Between F2T (male) (1) and ground Resistance Min. 1 Mz 1 fill switch (It does not turn Descriptions for 1 to 3 are the same as above. ON) 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between F2T (male) (1) and F2/R2 Resistance Max. 1 z ground 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors PTCN2 and F2T and connect T-adapters to each female ness 2 side. (Open circuit in wiring or defective contact)
Between PTCN2 (female) (25) and F2T (female) (1) 1. 2. 3. a
3
Defective power train controller
Between PTCN2 (25) and ground
Max. 1 z
Voltage
7 – 11 V
Descriptions for 1 to 3 are the same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (25) and ground
40-126
Resistance
Turn starting switch to OFF position. Insert T-adapter into connector PTCN2. Start engine. Keep PCCS lever in N position.
F2/R2
Voltage
Max. 1 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [15SFLH] Speed 2nd clutch: Fill Low
Circuit diagram related to 2st clutch ECMV
D375A-6 (01)
40-127
DRAFT Troubleshooting by failure code Failure code [15SGL1] Speed 3rd clutch: Fill high
Failure code [15SGL1] Speed 3rd clutch: Fill high Action code E03
Failure code Speed 3rd clutch fill switch signal is ON. Failure 15SGL1 (Power train controller system) q Nevertheless controller does not output command current to transmission 3rd clutch ECMV solenoid Detail of failure circuit, fill switch signal is turned ON. Action of conq Limits operation of engine and transmission. troller q Once machine is stopped, engine speed is limited to medium (half). Problem on q Once machine is stopped, travel is limited to F3 and R3. machine q The automatic gearshift system does not operate. q State (ON/OFF) of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) q Method of reproducing failure code: Start engine and set PCCS lever in neutral position. Related inforq Remove seat (approx. 50 kg) and cover under seat. mation q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 3rd clutch ECMV fill switch (Internal short cir- 2. Disconnect connector F3T and connect T-adapter to male side. Between F3T (female) (1) and ground cuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector F3T. Ground fault of wiring har3. Start engine ness or defective power If failure code[15SGL1] is still displayed, there is ground fault of wiring harness or train controller power train controller is defective. (If failure code[15SGL1] is not displayed, 3rd clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and F3T, and connect T-adapter to female side of (Contact with ground cireither of them. cuit) Between PTCN2 (female) (15) or F3T (female) (1) Resistance Min. 1 MΩ and ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train con- 3. Start engine troller a Keep PCCS lever in N position. Between PTCN2 (15) and ground Voltage 7 – 11 V 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (15) and ground F3/R3 Voltage Max. 1 V
40-128
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SGL1] Speed 3rd clutch: Fill high
Circuit diagram related to 3st clutch ECMV
D375A-6 (01)
40-129
DRAFT Troubleshooting by failure code Failure code [15SGLH] Speed 3rd clutch: Fill Low
Failure code [15SGLH] Speed 3rd clutch: Fill Low Action code E03 Detail of failure Action of controller Problem on machine
q
Failure code Speed 3rd clutch fill switch signal is OFF. Failure 15SGLH (Power train controller system) Nevertheless controller outputs command current to transmission 3rd clutch ECMV solenoid circuit, fill switch signal is turned OFF.
q
Limits operation of engine and transmission.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. The automatic gearshift system does not operate. State (ON/OFF) of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) Method of reproducing failure code: Start engine and PCCS lever in F3 or R3 position. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
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Related information
q q q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector F3T and connect T-adapter to male side. 3. Start engine Defective 3rd clutch ECMV a Keep PCCS lever in N position. Between F3T (male) (1) and ground Resistance Min. 1 MΩ 1 fill switch (It does not turn 1 – 3 are same as above. ON) 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between F3T (male) (1) and F3/R3 Resistance Max. 1 Ω ground 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors PTCN2 and F3T and, connect T-adapters to female side ness 2 of them. (Disconnection or defective Between PTCN2 (female) (15) and F3T (female) contact) Resistance Max. 1 Ω (1) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine Defective power train control- a Keep PCCS lever in N position. 3 Between PTCN2 (15) and ground Voltage 7 – 11 V ler 1 – 3 are same as above. 4. While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between PTCN2 (15) and ground F3/R3 Voltage Max. 1 V
40-130
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [15SGLH] Speed 3rd clutch: Fill Low
Circuit diagram related to 3st clutch ECMV
D375A-6 (01)
40-131
Troubleshooting by failurecode Failure code [15SJL1] L/U: Fill high
Failure code [15SJL1] L/U: Fill high Action code
Failure code Failure
E02
15SJL1
Detail of failure Action of controller Problem on machine
Lockup clutch fill switch signal is ON. (Power train controller system)
q
Nevertheless controller does not output command current to torque converter lockup clutch ECMV solenoid circuit, fill switch signal is turned ON.
q
Prohibits lockup.
q
Engine may stall during travel.
q
State of lockup clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31520 T/M Fill Sw Input 2) Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in automatic gearshift mode). Remove seat (approx. 50 kg) and cover under seat. First, check power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q
Related information
40-132
q q q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Disconnect connector FLUC and connect T-adapter to male side. Between FLUC (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FLUC. Ground fault in wiring har- 3. Start engine. 2 ness or defective power a Keep PCCS lever in N position. If failure code [15SJL1] is still displayed, there is ground fault in wiring harness or train controller power train controller is defective. (If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors PTCN2 and FLUC, and connect T-adapters to either 3 ness female side. (Contact with ground circuit) Between PTCN2 (female) (38) or FLUC (female) (1) and Resistance Min. 1 Mz ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine. a Keep PCCS lever in N position. Defective power train con- Between PTCN2 (38) and ground Voltage 7 – 11 V 4 troller Descriptions for 1 to 3 are the same as above. 4. Raise tracks off the ground. 5. Travel in R1 (Reverse) (Automatic gear shift mode) and troubleshoot with clutch locked up. a See Testing and adjusting, "Testing power train oil pressure", "4) Testing torque converter lockup clutch pressure (LU)". Defective lockup clutch 1 ECMV fill switch (Internal short circuit)
Between PTCN2 (38) and ground
40-132
R1
Voltage
Max. 1 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [15SJL1] L/U: Fill high
Circuit diagram related to lockup clutch ECMV
D375A-6 (01)
40-133
Troubleshooting by failurecode Failure code [15SJLH] L/U: Fill low
Failure code [15SJLH] L/U: Fill low Action code
Failure code Failure
E02 Detail of failure Action of controller Problem on machine
15SJLH
Lockup clutch fill switch is OFF. (Power train controller system)
q
Nevertheless controller outputs command current to torque converter lockup clutch ECMV solenoid circuit, fill switch signal is turned OFF.
q
Prohibits lockup.
q
It is impossible to lockup.
q
State of lockup clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31520 T/M Fill Sw Input 2) Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in automatic gearshift mode). Remove seat (approx. 50 kg) and cover under seat. First, check power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q
Related information
40-134
q q q
Procedure, measuring location, criteria and remarks 1. 2. 3. 4. 5.
Turn starting switch to OFF position. Disconnect connector FLUC, and connect T-adapter to male side. Start engine. Raise tracks off the ground. Defective lockup clutch Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in 1 ECMV fill switch (It does not operation. turn ON) a See Testing and adjusting, “Testing power train oil pressure”, 4) Testing torque converter lockup clutch pressure (LU)”. Between FLUC (female) (1) and ground Resistance Max. 1 z (Fill switch ON) 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors PTCN2 and FLUC and connect T-adapters to each female ness 2 side. (Open circuit in wiring or Between PTCN2 (female) (38) and FLUC (female) (1) Resistance Max. 1 z defective contact) If no abnormality is found by the above checks, power train controller is defective. Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine. a Keep PCCS lever in N position. q
3
Defective power train controller
Between PTCN2 (38) and ground
7 – 11 V
Descriptions for 1 to 3 are the same as above. 4. Raise tracks off the ground. 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in operation. a See Testing and adjusting, "Testing power train oil pressure", "4) Testing torque converter lockup clutch pressure (LU)". Between PTCN2 (38) and ground
40-134
Voltage
R1
Voltage
Max. 1 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [15SJLH] L/U: Fill low
Circuit diagram related to lockup clutch ECMV
D375A-6 (01)
40-135
DRAFT Troubleshooting by failure code Failure code [1800MW] P/T clutch: Slip
Failure code [1800MW] P/T clutch: Slip Action code Failure code Power train clutch slip Failure E02 1800MW (Power train controller system) Detail of failure q When torque converter is locked up, engine speed does not match sensed transmission output. Action of conq None in particular. troller Problem on machine q Engine state (speed) and torque converter state (speed) can be checked with monitoring funtion. Related infor(Code 01002: Engine speed, Code 31200: Transmission input speed (Torque converter speed)) mation q Method of reproducing failure code: Engine start + Turn lockup clutch ON + Drive machine.
1 2 3 4
Cause Power train clutch slip (When the system is normal) Defective engine rotation sensor Defective transmission speed sensor Defective power train controller
40-136
Procedure, measuring location, criteria and remarks a Clutch slip was detected; check the cause and machine damage state, then repair the machine. Check whether failure codes [CA689] and [CA778] are displayed. If they are displayed, carry out the troubleshooting. Check whether failure codes [DLT3KA] or [DLT3KB] is displayed. If it is displayed, carry out the troubleshooting. Internally trouble; troubleshooting is impossible.
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [1800MW] P/T clutch: Slip
D375A-6 (01)
40-137
DRAFT Troubleshooting by failure code Failure code [2201L1] Right clutch: Fill high
Failure code [2201L1] Right clutch: Fill high Action code E04 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Right clutch fill switch signal is ON. Failure 2201L1 (power train controller system) Nevertheless controller does not output command current to right steering clutch ECMV solenoid circuit, fill switch signal is turned ON.
q
Limits operation of engine, transmission, and brake.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel. State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input ) Method of reproducing failure code: Start engine. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q q
q q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective right steering clutch ECMV fill switch (Internal short 2. Disconnect connector FRC and connect T-adapter to male side. Between FRC (female) (1) and ground circuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FRC. Ground fault of wiring harness 3. Start engine or defective power train conIf failure code [2201L1] is still displayed, there is ground fault of wiring harness or troller power train controller is defective. (If failure code [2201L1] is not displayed, right steering clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiringharness 2. Disconnect connectors PTCN2 and FRC and connect T-adapter to female side (Contact with ground circuit) of either of them. Between PTCN2 (female) (16) or FRC (female) (1) Min. 1 MΩ Resistance and ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train controller 3. Start engine a Keep PCCS lever in N position. Between PTCN2 (16) and ground Voltage 7 – 11 V 1 – 3 are same as above. 4.While depressing brake pedal, operate PCCS lever (to select steering) and perform troubleshooting. Between PTCN2 (16) and ground Left Max. Voltage Max. 1 V
40-138
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2201L1] Right clutch: Fill high
Circuit diagram related to right clutch ECMV
D375A-6 (01)
40-139
DRAFT Troubleshooting by failure code Failure code [2201LH] Right clutch: Fill low
Failure code [2201LH] Right clutch: Fill low Action code E04 Detail of failure Action of controller Indication of problem on machine
q
q
Limits operation of engine, transmission, and brake.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel.
q q
Related information
Failure code Right steering clutch fill switch signal is OFF. Failure 2201LH (power train controller system) Nevertheless controller outputs command current to right steering clutch ECMV solenoid circuit, fill switch signal is turned OFF.
q q q q
State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Method of reproducing failure code: Start engine and release parking brake lever and operate PCCS lever (right steering). Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
Cause
1
2
3
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FRC and connect T-adapter to male side. 3. Start engine Defective right steering clutch a Keep PCCS lever in N position. Resistance Min. 1 MΩ ECMV fill switch (It does not Between FRC (male) (1) and ground 1 – 3 are same as above. turn ON) 4.While depressing brake pedal, operate PCCS lever (to select gear speed) and perform troubleshooting. Between FRC (male) (1) and Left Max. Resistance Max. 1 Ω ground 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors PTCN2 and FRC, and connect T-adapters to female ness side of them. (Disconnection or defective Between PTCN2 (female) (16) and FRC (female) contact) Resistance Max. 1 Ω (1) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine a Keep PCCS lever in N position. Defective power train control- Between PTCN2 (16) and ground Voltage 7 – 11 V ler 1. – 3. are same as above. 4.While depressing brake pedal, operate PCCS lever (to select steering) and perform troubleshooting. Between PTCN2 (16) and Left Max. Voltage Max. 1 V ground
40-140
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2201LH] Right clutch: Fill low
Circuit diagram related to right clutch ECMV
D375A-6 (01)
40-141
DRAFT Troubleshooting by failure code Failure code [2202L1] Left clutch: Fill high
Failure code [2202L1] Left clutch: Fill high Action code E04 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Speed Left clutch fill switch signal is ON. Failure 2202L1 (Power train controller system) Nevertheless controller does not output command current to left steering ECMV solenoid circuit, fill switch signal is turned ON.
q
Limits operation of engine, transmission, and brake.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel. State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Method of reproducing failure code: Start engine. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q q q q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective left steering ECMV 2. Disconnect connector FLC and connect T-adapter to male side. fill switch (Internal short cirBetween FLC (female) (1) and ground cuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FLC. Ground fault of wiring harness or defective power train con- 3. Start engine If failure code [2202L1] is still displayed, there is ground fault of wiring harness or troller power train controller is defective. (If failure code [2202L1] is not displayed, left steering fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring harness 2. Disconnect connectors PTCN2 and FLC, and connect T-adapter to female side (Contact with ground circuit) of either of them. Between PTCN2 (female) (26) or FLC (female) (1) Resistance Min. 1 MΩ and ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train control- 3. Start engine ler a Keep PCCS lever in N position. Between PTCN2 (26) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4.While depressing brake pedal, operate PCCS lever (to select steering) and perform troubleshooting. Between PTCN2 (26) and ground Left Max. Voltage Max. 1 V
40-142
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2202L1] Left clutch: Fill high
Circuit diagram related to left clutch ECMV
D375A-6 (01)
40-143
DRAFT Troubleshooting by failure code Failure code [2202LH] Left clutch: Fill low
Failure code [2202LH] Left clutch: Fill low Action code E04 Detail of failure Action of controller Problem on machine
q
q
Limits operation of engine, transmission, and brake.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel. State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Method of reproducing failure code: Engine start and release parking brake lever and operate PCCS lever. (left steering). Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q q q
Related information
Failure code Left cluth fill switch is OFF. Failure 2202LH (Power train controller system) Nevertheless controller outputs command current to left steering ECMV solenoid circuit, fill switch signal is turned OFF.
q q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FLC and connect T-adapter to male side. 3. Start engine a Keep PCCS lever in N position. Defective left steering ECMV Between FLC (male) (1) and ground Resistance Min. 1 MΩ 1 fill switch (It does not turn ON) 1 – 2 are same as above. 4.While depressing brake pedal, operate PCCS lever (to select steering) and perform troubleshooting. Between FLC (male) (1) and Left Max. Resistance Max. 1 Ω ground 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors PTCN2 and FLC and connect T-adapters to female side ness 2 of them. (Disconnection or defective Between PTCN2 (female) (26) and FLC (female) contact) Resistance Max. 1 Ω (1) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine a Keep PCCS lever in N position. Defective power train control- Between PTCN2 (26) and ground Voltage 7 – 11 V 3 ler 1. – 3. are same as above. 4.While depressing brake pedal, operate PCCS lever (to select steering) and perform troubleshooting. Between PTCN2 (26) and Left Max. Voltage Max.1 V ground
40-144
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2202LH] Left clutch: Fill low
Circuit diagram related to left clutch ECMV
D375A-6 (01)
40-145
DRAFT Troubleshooting by failure code Failure code [2300NR] Brake Themal Load Abnormality
Failure code [2300NR] Brake Themal Load Abnormality Action code – Detail of failure Action of controller Problem on machine Related information
Failure code Brake thermal load abnormality Failure 2300NR (Power train controller system) q The power train controller judged from the angle of inclination, travel speed, continuous operating time of the brake pedal, etc. that the brake was heating abnormally. q
None in particular. – –
Cause Procedure, measuring location, criteria and remarks 1 Improper braking during downhill travel (Machine traveled down a slope with brake pedal pressed) Defective power train con2 When the operation in cause 1 is not performed troller
40-146
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2300NR] Brake Themal Load Abnormality
D375A-6 (01)
40-147
DRAFT Troubleshooting by failure code Failure code [2301L1] Right brake: Fill high
Failure code [2301L1] Right brake: Fill high Action code E04 Detail of failure Action of controller Indication of problem on machine
q
Failure code Speed right brake fill switch signal is ON. Failure 2301L1 (power train controller system) Nevertheless controller does not output command current to right steering brake ECMV solenoid circuit, fill switch signal is turned ON.
q
Limits operation of engine, transmission, and brake.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel.
q q
Related information
q q q q
State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Method of reproducing failure code: Start engine. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective right steering brake ECMV fill switch (Inter- 2. Disconnect connector FRB and connect T-adapter to male side. Between FRB(female) (1) and ground nal short circuit) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FRB. Ground fault of wiring harness or defective power train 3. Start engine If failure code [2301L1] is still displayed, there is ground fault of wiring harness or controller power train controller is defective. (If failure code [2301L1] is not displayed, right steering brake fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN2 and FRB, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN2(female )(37) or FRB (female) (1) Resistance Min. 1 MΩ and ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train con3. Start engine troller 4. Release the parking brake. a Keep PCCS lever in N position. Between PTCN2 (37) and ground Voltage Max. 1 V 1 – 4 are same as above. 5. While depressing the brake and carry out troubleshooting. Between PTCN2 (37) and ground Voltage 7 – 11 V
40-148
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2301L1] Right brake: Fill high
Circuit diagram related to right brake ECMV
D375A-6 (01)
40-149
DRAFT Troubleshooting by failure code Failure code [2301LH] Right brake: Fill low
Failure code [2301LH] Right brake: Fill low Action code E04 Detail of failure Action of controller Indication of problem on machine
q
Failure code Right brake fill switch signal is OFF. Failure 2301LH (power train controller system) Nevertheless controller outputs command current to right steering brake ECMV solenoid circuit, fill switch signal is turned OFF.
q
Limits operation of engine, transmission, and brake.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel.
q q
Related information
q q q q
State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Method of reproducing failure code:Start engine and release the parking brake. Remove seat (approx. 50 kg) and cover under seat. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
Cause
Defective right steering brake 1 ECMV fill switch (It does not turn ON)
Disconnection in wiring harness 2 (Disconnection or defective contact)
3
Defective power train controller
40-150
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FRB and connect T-adapter to male side. Between FRB (male) (1) and ground Resistance Min. 1 MΩ 1 – 2 are same as above. 3. Start engine. a Keep PCCS lever in N position. 4. Release the parking brake and carry out troubleshooting. Between FRB (male) (1) and ground Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and FRB, and connect T-adapters to female side of them. Between PTCN2 (female) (37) and FRB (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine 4. Release the parking brake. a Keep PCCS lever in N position. Between PTCN2 (37) and ground Voltage Max. 1 V 1 – 4 are same as above. 5. While depressing the brake and carry out troubleshooting. Between PTCN2 (37) and ground Voltage 7 – 11 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2301LH] Right brake: Fill low
Circuit diagram related to right brake ECMV
D375A-6 (01)
40-151
DRAFT Troubleshooting by failure code Failure code [2301NR] Steering Brake RH Themal Load Abnormality
Failure code [2301NR] Steering Brake RH Themal Load Abnormality Action code – Detail of failure Action of controller Problem on machine Related information
q
q
Failure code Right steering brake thermal load abnormality Failure 2301NR (Power train controller system) The power train controller judged from the angle of inclination and continuous operating time of the right steering that the steering brake was heating abnormally. None in particular. – –
Cause Procedure, measuring location, criteria and remarks 1 Improper steering during downhill travel (Machine traveled down a slope and was steered to right continuously) Defective power train con2 When the operation in cause 1 is not performed troller
40-152
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2301NR] Steering Brake RH Themal Load Abnormality
D375A-6 (01)
40-153
DRAFT Troubleshooting by failure code Failure code [2302L1] Left brake: Fill high
Failure code [2302L1] Left brake: Fill high Action code E04
Failure code Left brake fill switch signal is ON. Failure 2302L1 (power train controller system) q Nevertheless controller does not output command current to left steering brake clutch ECMV solenoid Detail of failure circuit, fill switch signal is turned ON. Action of conq Limits operation of engine, transmission, and brake. troller Problem on q Once machine is stopped, engine speed is limited to medium (half). machine q Once machine is stopped, it becomes impossible to travel. q State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Related infor- q Method of reproducing failure code: Start engine. q Remove seat (approx. 50 kg) and cover under seat. mation q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective left steering brake 2. Disconnect connector FLB and connect T-adapter to male side. 1 clutch ECMV fill switch Between FLB(female) (1) and ground (Internal short circuit)) Resistance Min. 1 MΩ (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FLB. Ground fault of wiring har- 3. Start engine 2 ness or defective power If failure code [2302L1] is still displayed, there is ground fault of wiring harness or train controller power train controller is defective. (If failure code [2302L1] is not displayed, left steering brake clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and FLB and connect T-adapter to female side of 3 (Contact with ground cireither of them. cuit) Between PTCN2(female) (6) or FLB(female) (1) and Resistance Min. 1 MΩ ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train con- 3. Start engine 4 troller 4. Release the parking brake. a Keep PCCS lever in N position. Between PTCN2 (6) and ground Voltage Max. 1 V 1 – 4 are same as above. 5. While depressing the brake and carry out troubleshooting. Between PTCN2 (6) and ground Voltage 7 – 11 V
40-154
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2302L1] Left brake: Fill high
Circuit diagram related to left brake ECMV
D375A-6 (01)
40-155
DRAFT Troubleshooting by failure code Failure code [2302LH] Left brake: Fill low
Failure code [2302LH] Left brake: Fill low Action code E04
Failure code Left brake fill switch signal is OFF. Failure 2302LH (power train controller system) q Nevertheless controller outputs command current to left steering brake clutch ECMV solenoid circuit, Detail of failure fill switch signal is turned OFF. Action of conq Limits operation of engine, transmission, and brake. troller Indication of q Once machine is stopped, engine speed is limited to medium (half). problem on q Once machine is stopped, it becomes impossible to travel. machine q State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring function. (Code: 31521 Steering Fill Sw Input) Related infor- q Method of reproducing failure code: Engine start and release parking bake lever. mation q Remove seat (approx. 50 kg) and cover under seat. q First, check the power train oil filter for clogging etc. q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure". Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FLB and connect T-adapter to male side. Resistance Min. 1 MΩ Defective left steering brake Between FLB(male) (1) and ground 1 – 2 are same as above. 1 clutch ECMV fill switch (It 3. Start engine. does not turn ON) a Keep PCCS lever in N position. 4. Release the parking brake and carry out troubleshooting. Between FLB (male) (1) and ground Resistance Max. 1 Ω Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and FLB, and connect T-adapters to female side of 2 (Disconnection or defective them. contact) Between PTCN2 (female) (6) and FLB(female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Start engine Defective power train con- 4. Release the parking brake. 3 a Keep PCCS lever in N position. troller Between PTCN2 (6) and ground Voltage Max. 1 V 1 – 4 are same as above. 5. While depressing the brake and carry out troubleshooting. Between PTCN2 (6) and ground Voltage 7 – 11 V
40-156
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2302LH] Left brake: Fill low
Circuit diagram related to left brake ECMV
D375A-6 (01)
40-157
DRAFT Troubleshooting by failure code Failure code [2302NR] Steering Brake LH Themal Load Abnormality
Failure code [2302NR] Steering Brake LH Themal Load Abnormality Action code – Detail of failure Action of controller Indication of problem on machine Related information
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Failure code Left steering brake thermal load abnormality Failure 2302NR (Power train controller system) Power train controller judged from the angle of inclination, travel speed and continuous operating time of the left steering that the steering brake was heating abnormally. None in particular. – –
Cause Procedure, measuring location, criteria and remarks 1 Improper steering during downhill travel (Machine traveled down a slope and was steered to left continuously) Defective power train control2 When the operation in cause 1 is not performed ler
40-158
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [2302NR] Steering Brake LH Themal Load Abnormality
D375A-6 (01)
40-159
DRAFT Troubleshooting by failure code Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection Action code ― Detail of failure Action of controller Problem on machine
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Failure code Engine controller ACC cut relay disconnection Failure 7RFAKA (Work equipment controller system) No voltage is applied to engine controller ACC cut relay primary (coil side) circuit when no grounding.
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Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
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Engine does not start. If engine ACC cutoff mechanism is mounted, the engine cannot be stopped by ACC cutoff. (The engine cannot be stopped by engine ACC cutoff mechanism.) Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring function (Code: 40983 W/E controller SW output). Method of reproducing failure code: Turn the starting switch to ON position This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but not on secondary side (contact side). If pin WECN2 (8) has ground fault, engine cannot be started.
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Related information
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Cause Procedure, measuring location, criteria and remarks Defective engine con- 1. Turn starting switch to OFF position. troller ACC cut relay 2. Disconnect connector ACT and connect T-adapter to male side. 1 (Internal disconnection Between ACT (male) (1) and (2) Resistance 200 – 400 Ω or short circuit) 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of Disconnection or short them. 2 circuit in wiring harness a If resistance is 1 MΩ or above, wiring harness has disconnection. If resistance is 1 Ω or below, wiring harness has short circuit. Between KEY (female) (1) and WECN2 (female) (8) Resistance 200 – 400 Ω a If cause 2 is not the cause for the trouble, this check is not required. Disconnection in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connectors WECN2, ACT and KEY, and connect T-adapters to female side 3 (Disconnection or of them. defective contact) Between WECN2 (female) (8) and ACT (female) (2) Resistance Max. 1 Ω Between KEY (female) (1) and ACT (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors WECN2 and ACT, and connect T-adapters to female side of harness 4 them. (Contact with ground Between ACT (female) (2) or WECN2 (female) (8) and circuit) Resistance Min. 1 MΩ ground If cause is not found by the above checks, work equipment controller is defective. q Reference: The following are criteria in normal condition. 1. Turn starting switch to OFF position. Defective work equip5 ment controller 2. Insert T-adapter into connector WECN2. 3. Turn starting switch to ON position. Between WECN2 (8) and ground Voltage Max. 1 V
40-160
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection
Circuit diagram related to engine controller shut down
D375A-6 (01)
40-161
DRAFT Troubleshooting by failure code Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit Action code ― Detail of failure Action of controller Problem on machine Related information
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Failure code Engine controller ACC cut relay disconnection Failure 7RFAKB (Work equipment controller system) Abnormal current flows when grounding to engine controller ACC cut relay primary (coil side) circuit .
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Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
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Engine does not start.
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Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring function (Code: 40983 W/E controller SW output). Method of reproducing failure code: Turn the starting switch ON. This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but not on secondary side (contact side).
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Cause Procedure, measuring location, criteria and remarks Defective engine con- 1. Turn starting switch to OFF position. troller ACC cut relay 2. Disconnect connector ACT and connect T-adapter to male side. 1 (Internal disconnection Between ACT (male) (1) and (2) Resistance 200 - 400 Ω or short circuit) 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and KEY and connect T-adapters to female side of Disconnection or short them. 2 circuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below 1 Ω, wiring harness has short circuit. Between KEY (female) (1) and WECN2 (female) (8) Resistance 200 - 400 Ω 1. Turn starting switch to OFF position. Short circuit with power 2. Disconnect connectors WECN2 and ACT, and connect T-adapter to female side of supply in wiring harness 3 WECN2. (Contact with 24 V cir3. Turn starting switch to ON position. cuit) Between WECN2 (female) (8) and ground Voltage Max. 1 V If cause is not found by the above checks, work equipment controller is defective. q Reference: the followings are criteria in normal condition. Defective work equip- 1. Turn starting switch to OFF position. 4 ment controller 2. Insert T-adapter into connector WECN2. 3. Turn starting switch to ON position. Between WECN2 (8) and ground Voltage Max. 1 V
40-162
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit
Circuit diagram related to engine controller shut down
D375A-6 (01)
40-163
Troubleshooting by failurecode Failure code [AA10NX] Air Cleaner Clogging
Failure code [AA10NX] Air Cleaner Clogging Action code
Failure code Failure
–
AA10NX
Detail of failure Action of controller Problem on machine Related information
40-164
Air cleaner clogging (Machine monitor system)
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Air cleaner clogging switch signal voltage was not 1 V or less while engine was running, and machine monitor detected clogging of air cleaner (open of switch contacts).
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None in particular
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If the machine is operated under such a condition, engine may be damaged.
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Method of reproducing failure code: Start engine.
Cause
Procedure, measuring location, criteria and remarks
Air cleaner may be clogged. Check it for clogging and then clean or replace if clogged. 1. Turn starting switch to OFF position. 2. Disconnect connector AF1 and connect T-adapter to male side. Defective air cleaner clog- 3. Start engine. 2 ging switch (Internal disconWhen air cleaner is Resistance Max. 1 z nection) normal *1 Between AF1 (male) (1) and (2) When air cleaner is Resistance Min. 1 Mz clogged *2 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors CM01, CM02 and AF1, and connect T-adapters to each ness female side. 3 (Open circuit in wiring or Between CM02 (female) (4) and AF1 (female) (1) Resistance Max. 1 z defective contact in connector) Between CM01 (female) (7) and AF1 (female) (2) Resistance Max. 1 z 1
4
Air cleaner clogging (When system is normal)
Defective power train controller
1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Start engine. When air cleaner is normal Between CM02 (4) and CM01 (7) Air cleaner is clogged
Voltage
Max. 1 V
Voltage
7 – 11 V
Air cleaner suction resistance *1: Max. -3,430 Pa {-350 mmH2O} *2: -7,470 ± 490 Pa {-762 ± 50 mmH2O} q
40-164
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [AA10NX] Air Cleaner Clogging
Circuit diagram related to air cleaner
D375A-6 (01)
40-165
DRAFT Troubleshooting by failure code Failure code [AB00MA] Battery Charge Abnormal
Failure code [AB00MA] Battery Charge Abnormal Action code –
Failure code Battery Charge Abnormal Trouble AB00MA (Machine monitor system) q While engine was running, voltage from alternator lowered, and machine monitor detected that batDetail of failure tery charge voltage was low. Action of conq Displays charge level monitor red on machine monitor. troller Problem on q If machine is used as it is, battery may not be charged. machine q Battery voltage can be checked with monitoring function. Related infor(Code: 04300 Charge voltage) mation q Method of reproducing failure code: Start engine. Cause Defective charge by alter1 nator (When system is normal) Defective charge level 2 monitor system
Procedure, measuring location,criteria and remarks It is suspected that problem causing defective battery charge is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. If cause 1 is not detected, charge level monitor system may be defective. Perform “E-5 Caution item lights up while engine is running” in E mode.
Failure code [B@BAZG] Eng Oil Press Low Action code –
Failure code Eng Oil Press Low Failure B@BAZG (Engine controller system) q While engine was running, signal voltage from engine oil pressure sensor dropped, and engine conDetail of failure troller detected engine oil pressure too low. Action of conq Displays engine oil pressure monitor red on machine monitor. troller Problem on q If machine is used as it is, engine may be seized. machine q Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system. Related inforq Engine oil pressure can be checked with monitoring function. mation (Code: 37200 Engine Oil Pressure) q Method of reproducing failure code: Start engine. Cause Lowering of engine oil 1 pressure (When system is normal) 2
Procedure, measuring location, criteria and remarks Engine oil pressure may be low. Check it and remove cause if it is low.
Defective engine oil pres- If cause 1 is not the cause for the trouble, engine oil pressure sensor system may be sure caution lamp circuit defective. Perform troubleshooting for failure codes [CA135] and [CA141].
40-166
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BAZK] Eng Oil Level Low Action code – Detail of failure Action of controller Problem on machine Related information
Failure code Eng oil level low Failure B@BAZK (Machine monitor system) q While engine was running, signal voltage from engine oil level switch was not 1 V or less, machine monitor detected that engine oil level was low (oil level switch was open). q
Displays radiator coolant level monitor red on machine monitor.
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If machine is used as it is, engine may be seized.
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Method of reproducing failure code: Start engine.
Cause Procedure, measuring location, criteria and remarks Engine oil level low 1 Check engine oil level. If it is low, remove cause. (When system is normal) 1. Turn starting switch to OFF position. Defective engine oil level 2. Disconnect connector OLV. 2 sensor (Internal defect) 3. Turn starting switch to ON position. Between OLV (male) (1) and ground Resistance Disconnection in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connector CM02 and connect T-adapter to female side. 3 (Disconnection or defecBetween CM02 (female) (2) and OLV(female) (1) Resistance tive contact in connector) If cause is not found by above checks, machine monitor is defective. q Reference: the followings are criteria in normal condition. Defective machine moni- 1. Turn starting switch to OFF position. 4 tor 2. Insert T-adapter into connector CM02. 3. Turn starting switch to ON position. Between CM02 (female) (2) and ground Voltage
Max. 1 Ω
Max. 1 Ω
Max. 1 V
Circuit diagram related to engine oil level
D375A-6 (01)
40-167
DRAFT Troubleshooting by failure code Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCNS] Eng Water Overheat Action code – Detail of failure Action of controller Problem on machine Related information
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Failure code Eng Coolant Overheat Failure B@BCNS (Engine controller system) While engine was running, voltage from engine coolant temperature sensor dropped, and engine controller detected that engine coolant was overheated.
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Displays engine coolant temperature monitor red on machine monitor.
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If machine is used as it is, engine may be seized.
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Engine controller inputs voltage of engine coolant temperature sensor signal and then transmits the data to machine monitor through CAN communication system. Engine coolant temperature can be checked with monitoring function (Code: 04107 Coolant Temperature) Method of reproducing failure code: Start engine.
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Cause Procedure, measuring location, criteria and remarks Overheated engine coolant 1 Check engine coolant for overheating. If it is overheated, remove cause. (when system is normal) Defective engine coolant If cause 1 is not detected, engine coolant temperature sensor may be defective. Per2 temperature sensor system form troubleshooting for failure codes [CA144] and [CA145].
40-168
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [B@BCZK] Eng Water Level Low
Failure code [B@BCZK] Eng Water Level Low Action code –
Failure code Eng coolant level low Failure B@BCZK (Machine monitor system) q While starting switch was ON (and engine was stopped) or engine was running, radiator coolant level Detail of failswitch signal was not 1 V or less, machine monitor detected that radiator coolant level was low (senure sor contact was open). Action of conq Displays radiator coolant level monitor red on machine monitor. troller Problem on q If machine is used as it is, engine may be overheated. machine Related inforq Method of reproducing failure code: Start engine. mation
1 2
Cause Procedure, measuring location, criteria and remarks Coolant level low Check radiator sub tank for lowering of coolant level. If coolant level is low, add cool(When system is normal) ant. If cause 1 is not detected, radiator coolant level monitor may be defective. Carry out Defective radiator cool"E-4 Caution item lights up while starting switch is ON (and engine is stopped)" in E ant level monitor system mode.
D375A-6 (01)
40-169
DRAFT Troubleshooting by failure code Failure code [B@CENS] T/C Oil Overheat
Failure code [B@CENS] T/C Oil Overheat Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Torque converter overheating Failure B@CENS (Power train controller system) q While engine was running, voltage from torque converter oil temperature sensor dropped, and power train controller detected that power train oil was overheated. q
Displays power train oil temperature monitor red on machine monitor.
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If machine is used as it is, power train components may be damaged.
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Work equipment controller inputs the signal voltage of torque converter oil temperature sensor, and transmits this information to the machine monitor through power train controller on CAN communication system. Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Method of reproducing failure code: Start engine.
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Cause Procedure, measuring location, criteria and remarks Overheating of torque con1 verter oil (When system is Torque converter oil may be overheated. If it is overheated, remove cause. normal) Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor system may be 2 oil temperature sensor sysdefective. Perform troubleshooting for failure code [DGT1KA] or [DGT1KX] . tem
40-170
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [B@HANS] Hyd Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat Action code ― Detail fo failure Action of controller Problem on machine Related information
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Failure code Hydraulic Oil overheating Failure B@HANS (Power train controller system) While engine was running, hydraulic oil temperature sensor voltage dropped, and power train controller detected hydraulic oil overheat by data sent from machine monitor by CAN communication.
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Displays hydraulic oil temperature monitor red on machine monitor.
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If machine is operated as it is, work equipment circuit units may be damaged.
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Signal voltage of hydraulic oil temperature sensor is input in machine monitor, and then the data is transmitted to power train controller through CAN communication system. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hyd Oil Temperature) Method of reproducing failure code: Start engine.
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Cause Hyd Oil Overheat 1 (When system is normal) 2
Procedure, measuring location, criteria and remarks Hydraulic oil may be overheating. Check it and remove cause if it is overheating.
If cause 1 is not the cause for the trouble, hydraulic oil temperature gauge system may Defective hydraulic oil tembe defective. Perform troubleshooting for failure code [DGS1KX] or "E-10 Hydraulic oil perature gauge system temperature gauge (Multi-gauge) does not display normally" in E-mode.
D375A-6 (01)
40-171
Troubleshooting by failurecode Failure code [B@HAZK] Hyd Oil Level Low
Failure code [B@HAZK] Hyd Oil Level Low Action code
Failure code Failure
–
B@HAZK
Related information
Low Hydraulic Oil Level (Work equipment controller system)
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Signal voltage from or hydraulic oil lever switch open oil level switch was not 1 V or less while engine was running, and work equipment controller detected low hydraulic oil level or oil lever switch open..
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None in particular.
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If machine is operated as it is, work equipment circuit units may be damaged.
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Signal of hydraulic oil level switch is input to work equipment controller and then the data is transmitted to machine monitor through CAN communication system. Hydraulic oil level switch can be checked with monitoring function. (Code: 40981 W/E controller SW input) Method of reproducing failure code: Start engine.
Detail of failure Action of controller Problem on machine
40-173
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Cause Hydraulic oil level low (dur1 ing normal system operation)
Procedure, measuring location, criteria and remarks Hydraulic oil may be low. Check it and add oil if necessary.
1. Turn starting switch to OFF position. Defective hydraulic oil level 2. Disconnect connector HLS and connect T-adapter to male side. 2 3. Turn starting switch to ON position. switch (Internal defect) Between HLS (male) (1) and (2) Resistance
Max. 1 z
1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to each ness 3 female side. (wire breakage or defective Between WECN2 (female) (28) and WECN1 (female) Resistance Max. 1 z contact of connector) (4) If cause is not found by above checks, work equipment controller is defective. q Reference: the followings are criteria in normal condition. Defective work equipment 1. Turn starting switch to OFF position. 4 2. Insert T-adapter into connectors WECN1 and WECN2. controller 3. Turn starting switch to ON position. Between WECN2 (28) and WECN1 (4)
Circuit diagram related to hydraulic oil level
40-172
Voltage
Max. 1 V
40-173
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [B@HAZK] Hyd Oil Level Low
D375A-6 (01)
40-173
Troubleshooting by failurecode Failure code [CA111] ECM Critical Internal Failure
Failure code [CA111] ECM Critical Internal Failure Action code
Failure code Failure
E03
CA111
Detail of failure Action of controller Problem on machine Related information
40-174
Abnormality in engine controller (Engine controller system)
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Trouble occurred in engine controller.
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None in particular
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Machine continues operation normally but may stop suddenly or may not able to start again once it stops. Power supply voltage of engine controller can be checked with moniitoring funtion. (Code: 03203 Power supply voltage) Method of reproducing failure code: turn engine starting switch to ON position.
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Cause
Procedure, measuring location, criteria and remarks
1
Looseness or corrosion of battery terminal
2
Loosened terminal or partial 1. Turn starting switch to OFF position. disconnection at terminal Check terminals of alternator, battery relay, ground (GND11) etc. for looseness.
3
Defective wiring harness connector
4 Improper battery voltage
5 Defective alternator
6 Defective engine controller
40-174
The battery terminal may be loose or corroded. Inspect the terminal itself.
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position, then carry out troubleshooting. 2. Perform troubleshooting when engine is cranked. Between battery terminal Voltage 20 – 30V (+) and (-). 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female side of connector E22. 3. Start engine (Engine speed: Middle or faster). Between E22 (3) and Voltage 26 – 30.5V ground If no abnormality is found by the above checks, the engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) q Reference: The followings are standard values in normal condition. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Insert T-adapter between male and female sides of EGC3. 3. Connect the ground cable. 4. Measure voltage with starting switch at OFF position and when starting engine. Between EGC3 (3) and (1)
Voltage
20 – 30V
Between EGC3 (4) and (2)
Voltage
20 – 30V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA111] ECM Critical Internal Failure
Circuit diagram related to engine controller power supply
D375A-6 (01)
40-175
DRAFT Troubleshooting by failure code Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA115] Eng Ne and Bkup Speed Sens Error Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Abnormality in engine Ne/Bkup speed sensor Failure CA115 (Engine controller system) Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
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Stops the engine.
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The engine does not start. (if engine has been stopped.) Engine stops. (if engine has been running.)
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Method of reproducing failure code: Start engine.
1 2
Cause Defective Ne speed sensor system Defective Bkup speed sensor system
3
Defective engine controller
40-176
Procedure, measuring location, criteria and remarks Carry out troubleshooting for failure code [CA689]. Carry out troubleshooting for failure code [CA778]. If cause is not found by above checks,, engine controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA115] Eng Ne and Bkup Speed Sens Error
D375A-6 (01)
40-177
DRAFT Troubleshooting by failure code Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA122] Chg Air Press Sensor High Error Action code E03 Detail of failure Action of controller Problem on machine
Related information
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Failure code Charge pressure sensor too high Failure CA122 (Engine controller system) High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit. Sets charge pressure (boost pressure) to fixed value (400kPa {4.1 kg/cm2}), and continues operation.
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Engine does not accelerate smoothly.
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The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: 36501 (V)). Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be checked with monitoring function (Code: 36500 (kPa)). Method of reproducing failure code: Turn the starting switch to ON position. If sensor connector is disconnected, code [CA123] "Low Error" is displayed, even in normal condition.
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Cause
1 2
3
4
5
6
Procedure, measuring location, criteria and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on troubleconnector shooting" section, and check them directly. Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time, carry out troublesupply system shooting for that first. 1. Turn starting switch to OFF position. 2. Disconnect connector PIM. Defective charge pressure 3. Turn starting switch ON position. (boost pressure) sensor If failure code changes from [CA122] to [CA123], charge pressure (boost pressure) sensor is defective. 1. Turn starting switch to OFF position, then carry out troubleshooting. Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side of ness ENG. Between ENG (female) (37) - (44) Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Short circuit with power supply in wiring harness 2. Disconnect connector PIM, and insert T-adapter into connector ENG. (Short circuit with 24 V cir- 3. Turn starting switch to ON position (with connector PIM disconnected). cuit) Between ENG (44) and (47) Voltage Max. 1V If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the failure is in it, troubleshooting cannot be performed.)
40-178
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA122] Chg Air Press Sensor High Error
Circuit diagram related to charge pressure sensor
D375A-6 (01)
40-179
Troubleshooting by failurecode Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA123] Chg Air Press Sensor Low Error Action code
Failure code Failure
E03
CA123
40-180
Charge pressure sensor too low (Engine controller system)
Detail of failure
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Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of controller Problem on machine
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Sets charge pressure (boost pressure) to fixed value (400kPa {4.1 kg/cm2}), and continues operation.
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Engine does not accelerate smoothly.
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The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: 36501 (V)). Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be checked with monitoring function (Code: 36500 (kPa)). Method of reproducing failure code: Turn starting switch to ON position. Since T-adapter of sensor connector is "socket", voltage at sensor connector cannot be checked. If sensor connector is disconnected, this code is displayed.
Related information
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Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
Defective power supply sys2 tem of charge pressure sen- If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first. sor (boost pressure sensor) 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and PIM. Short circuit in wiring har3 3. Connect T-adapter to female side of ENG. ness Between ENG (female) Resistance Min. 1 Mz (44) and (47) 1. Turn starting switch to OFF position, then carry out troubleshooting. Ground fault in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side of 4 ness ENG. (Contact with ground circuit) Between ENG (female) Resistance Min. 1 Mz (44) and ground Open circuit in wiring harIf cause is not found by the above checks, there may be open circuit in wiring har5 ness ness. (*) a If causes 1 - 5 are not the cause for the trouble and check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. Defective charge pressure 2. Connect T-adapter to connector ENG. (boost pressure) sensor 3. Turn starting switch to ON position. 6 Between (Improper input voltage of ENG engine controller) Sensor out(female) Voltage 0.3–4.7V put (44) and (47) Defective If no abnormality is found by the above checks, the engine controller is defective. 7 engine (Since this is an internal failure, troubleshooting cannot be performed.) controller
*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related troubleshooting information".
40-180
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA123] Chg Air Press Sensor Low Error
Circuit diagram related to charge pressure sensor
D375A-6 (01)
40-181
Troubleshooting by failurecode Failure code [CA131] Throttle Sensor High Error
Failure code [CA131] Throttle Sensor High Error Action code
Failure code Failure
E03
CA131
Detail of failure Action of controller Problem on machine Related information
40-182
Throttle sensor too high (Engine controller system)
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High voltage occurred in decelerator pedal potentiometer signal circuit.
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Operate the decelerator pedal at a fixed value.
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The engine does not reach full throttle.
q
Signal of decelerator potentiometer voltage can be checked with monitoring function (Code: 31703). Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring function (Code: 31701). Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
2
Defective throttle sensor power supply system
If failure code [CA2185] is displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector DEC and connect T-adapter to male side.
3
Defective decelerator pedal Between DEC (male) (B) and (C) (throttle sensor) Between DEC (male) (A) and (C)
Resistance
4.0–6.0 kz
Resistance
0.2–5.0 kz
Between DEC (male) (B) and (A)
Resistance
0.2–5.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connector EGC2 and connect T-adapter to female side.
4
Open or short circuit in wirBetween EGC2 (female) (22) and (23) ing harness Between EGC2 (female) (9) and (23)
5
Short circuit in wiring harness
Hot short circuit in wiring 6 harness (Contact with 24 V circuit)
7 Defective engine controller
40-182
Resistance
4.0–6.0 kz
Resistance
0.2–5.0 kz
a If no abnormality is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors EGC2 and DEC, and connect T-adapters to either female side. Between EGC2 (female) (9) and (22), or between DEC Resistance Min. 1 Mz (female) (A) and (B) 1. Turn starting switch to OFF position. 2. Disconnect connector DEC and connect T-adapter to female side. 3. Turn starting switch to ON position. Between DEC (female) (B) and ground
Voltage
Max. 1 V
If no abnormality is found by the above checks, the engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of EGC2. 3. Turn starting switch to ON position. 4. Operate decelerator pedal, and troubleshoot. Between EGC2 (22) Power supply Voltage 4.75 – 5.25 V and (23) Approx. 4.7 Between Depress decelerator pedal. Voltage V EGC2 (9) Approx. 0.4 Release decelerator pedal. Voltage and (23) V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA131] Throttle Sensor High Error
Circuit diagram related to decelerator pedal
D375A-6 (01)
40-183
DRAFT Troubleshooting by failure code Failure code [CA132] Throttle Sensor Low Error
Failure code [CA132] Throttle Sensor Low Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Throttle sensor too low Failure CA132 (Engine controller system) q Decelerator potentiometer signal circuit of throttle sensor detected abnormally low voltage. q
Operate the decelerator pedal at a fixed value.
q
The engine does not reach full speed.
q
Signal of decelerator potentiometer voltage can be checked with monitoring function (Code: 31703). Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring function (Code: 31701). Method of reproducing failure code: Turn the starting switch to ON position
q q
Cause 1
Defective wiring harness connector
2
Defective throttle sensor power supply system
3
4
5
6
7
8
Procedure, measuring location, criteria and remarks Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Testing before troubleshooting" of "Related troubleshooting information". If failure code [CA2186] is also indicated, perform troubleshooting for it first.
1. Turn starting switch to OFF position. 2. Disconnect connector DEC and connect T-adapter to male side. Defective decelerator Between DEC (female)(B) and (C) Resistance 4.0–6.0 kΩ pedal (throttle sensor) Between DEC (female)(A) and (C) Resistance 0.2 - 5.0 kΩ Between DEC (female)(B) and (A) Resistance 0.2 - 5.0 kΩ 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector EGC2 and connect T-adapter to female side. cuit in wiring harness Between EGC2 (female) (22) and (23) Resistance 4.0–6.0 kΩ Between EGC2 (female) (9) and (23) Resistance 0.2 - 5.0 kΩ a If no abnormality is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connector EGC2 and DEC and connect T-adapter to each female harness side. (Disconnection or defecBetween EGC2 (female) (22) and DEC (female)(A) Resistance Max. 1 Ω tive contact in connector) Between EGC2 (female) (9) and DEC (female)(B) Resistance Max. 1 Ω Between EGC2 (female) (23) and DEC (female)(C) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of ness either of them. Between EGC2 (female) (9) and (23) or between Resistance Min. 1 MΩ DEC (female) (B) and (C) 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of ness either of them. (Contact with ground cirBetween EGC2 (female) (9) or DEC (female) (B) cuit) Resistance Min. 1 MΩ and ground If no abnormality is found by the above checks, the engine controller is defective. (Since the failure is it, troubleshooting cannot be performed.) q Reference: The following are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of EGC2. 3. Turn starting switch to ON position. Defective engine controller 4. Operate decelerator pedal, and troubleshoot. EGC2 Between (22) and Power supply Voltage 4.75–5.25V (23) Depress decelerator Voltage Approx.4.7V pedal. EGC2 Between (9) and (23) Release decelerator Voltage Approx.0.4V pedal.
40-184
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA132] Throttle Sensor Low Error
Circuit diagram related to decelerator pedal
D375A-6 (01)
40-185
Troubleshooting by failurecode Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA135] Eng Oil Press Sensor High Error Action code
Failure code Failure
E03
CA135
Detail of failure Action of controller Problem on machine Related information
Engine oil pressure sensor signal voltage is too high (Engine controller system)
q
High voltage was detected in engine oil pressure sensor signal circuit.
q
Sets engine oil pressure to default (250kPa {2.5 kg/cm2}), and allows for operation.
q
Signal voltage from engine oil pressure sensor can be checked with monitoring function (Code: 37201 (V)). Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code: 37200 (kPa)). Method of reproducing failure code: Turn starting switch to ON position.
q q
1
40-186
Cause
Procedure, measuring location, criteria and remarks
Defective wiring harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting".
Defective power supply time 2 of engine oil pressure sen- If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it first. sor 1. Turn starting switch to OFF position. 2. Disconnect connector POIL. Defective engine oil pres3 3. Turn starting switch to ON position. sure sensor If failure code changes from [CA135] to [CA141], sensor is defective.
4
Short circuit in wiring harness
Hot short circuit in wiring 5 harness (Contact with 24 V circuit)
6 Defective engine controller
40-186
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL, and connect T-adapters to either female side. Between ENG (female)(13) and (37), or between POIL Resistance Min. 1 Mz (female)(1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector POIL. 3. Connect T-adapter to female side of connector POIL or connect T-adapter to connector ENG. 4. Turn starting switch to ON position (with connector POIL disconnected). BetweenENG(13) and (47) , or between POIL (female) Voltage Max. 1V (3) and (2) If no abnormality is found by above checks, the engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA135] Eng Oil Press Sensor High Error
Circuit diagram related to engine oil pressure sensor
D375A-6 (01)
40-187
Troubleshooting by failurecode Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA141] Eng Oil Press Sensor Low Error Action code
Failure code Failure
E01
CA141
Detail of failure Action of controller Problem on machine Related information
Engine oil pressure sensor signal voltage is too low. (Engine controller system)
q
Low voltage was detected in engine oil pressure sensor signal circuit.
q
Sets engine oil pressure to default (250kPa {2.5 kg/cm2}), and continues operation.
q
Signal voltage from the engine oil pressure sensor can be checked with the monitoring function (Code: 37201 (V)). Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code: 37200 (kPa)). Method of reproducing failure code: Turn starting switch to ON position.
q q
1
40-18
Cause
Procedure, measuring location, criteria and remarks
Defective wiring harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting". If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it first
Defective power supply sys- 1. Turn starting switch to OFF position. 2 tem of engine oil pressure 2. Disconnect connector POIL and connect T-adapter to each female side of them. sensor 3. Turn starting switch to ON position. Between POIL(female)(1) and (2)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
Ground fault in wiring har4 ness (Contact with ground circuit)
5
Short circuit in wiring harness
Defective engine oil pressure sensor (Improper input 6 voltage to engine controller)
Between ENG (13) and (47) 7 Defective engine controller
40-188
Power supply input
Voltage
4.75 – 5.25V
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL and connect T-adapters to each female side. a If power input in checks on cause 2 is normal, this check is not required. Resistance Max. 1 z Between ENG (female) (37) and POIL(female)(1) a If power input in checks on cause 2 is normal, this check is not required. Resistance Max. 1 z Between ENG (female) (47) and POIL(female)(2) Between ENG (female) (3) and POIL (female)(3) (SenResistance Max. 1 z sor output) 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL, and connect T-adapters to either female side. Between ENG(female)(13) and ground, or between Resistance Min. 1 Mz POIL(female)(3) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and POIL, and connect T-adapters to either female side. Between ENG (female)(13) and (47), or between POIL Resistance Min. 1 Mz (female) (2) and (3) a If causes 1 – 5 are not the cause for failure and check result of cause 6 is abnormal, sensor may be defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of connector ENG 3. Turn starting switch to ON position. Sensor output
Voltage
0.3 – 4.7 V
If no abnormality is found by above checks, the engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA141] Eng Oil Press Sensor Low Error
Circuit diagram related to engine oil pressure sensor
D375A-6 (01)
40-189
Troubleshooting by failurecode Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA144] Coolant Temp Sens High Error Action code
Failure code Failure
E01
CA144
Detail of failure Action of controller Problem on machine
Coolant temperature sensor signal valtage is too high. (Engine controller system)
q
High voltage was detected in engine coolant temperature sensor signal circuit.
q
Sets coolant temperature to fised temperature (90 °C) ,and allows for operation.
q
Engine does not start easily at low temperature. Overheat prevention function does not work. Signal voltage from engine coolant temperature sensor can be checked with monitoring function (Code: 04105 (V)). Temperature sensed by engine coolant temperature sensor can be checked with monitoring function (Code: 04107 (°C)). Method of reproducing failure code: Turn starting switch to ON position. If temperature sensor connector is disconnected, this failure code is displayed. Since T-adapter for sensor connector is "socket" type , T-adapter cannot be connected to wiring harness.
q q q
Related information
40-190
q q q
Cause
Procedure, measuring location, criteria and remarks
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting". 1. Turn starting switch to OFF position. 2. Disconnect connector TWTR and connect socket to male side of connector. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C , regard coolant temperature sensor as normal. Between 0 °C Resistance 30 - 37 kz TWTR 25 °C Resistance 9.3 - 10.7 kz (male) (A) Defective coolant temperaand (B) 2 50 °C Resistance 3.2 - 3.8 kz ture sensor a Coolant 80 °C Resistance 1.0 - 1.3 kz temperature -Resistaure 95 °C Resistance 700 - 800 z characteristics 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Open or short circuit in wir- Between ENG (female) (15) and (38) (Coolant tempera3 ture: Min. 0 °C) 700 z ing harness Resistance a Use” coolant temperature -Resistance characteris37 kz tics ” table shown above as resistance criteria. If no abnormality is found by the above checks, engine controller is defective. (Since 4 Defective engine controller this is an internal failure, troubleshooting cannot be performed.) 1
Defective wiring harness connector
40-190
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA144] Coolant Temp Sens High Error
Circuit diagram related to coolant temperature sensor
D375A-6 (01)
40-191
Troubleshooting by failurecode Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA145] Coolant Temp Sens Low Error Action code
Failure code Failure
E01
CA145
Detail of failure Action of controller Problem on machine
Low voltage was detected in engine coolant temperature sensor signal circuit.
q
Sets coolant temperature to fixed temperature (90 °C),and allows for operation.
q
Engine does not start easily at low temperature. Overheat prevention function does not work. Signal voltage from engine coolant temperature sensor can be checked with monitoring function (Code: 04105 (V)). Temperature sensed by engine coolant temperature sensor can be checked with monitoring function (Code: 04107 (°C)). Method of reproducing failure code: Turn starting switch to ON position. If temperature sensor connector is disconnected, this failure code is not displayed but failure code for High Error is displayed.
q
q q q
Cause 1
2
Coolant temperature sensor signal valtage is too low (Engine controller system)
q
q
Related information
40-192
Defective wiring harness connector
Defective coolant temperature sensor
Procedure, measuring location, criteria and remarks Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting". 1. Turn starting switch to OFF position. 2. Disconnect connector TWTR and connect socket to male side of connector. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal.
Between TWTR (male) (A) and (B) a Coolant temperature-Resistaure characteristics
0 °C
Resistance
30 - 37 kz
25 °C
Resistance
9.3 - 10.7 kz
50 °C
Resistance
3.2 - 3.8 kz
80 °C
Resistance
1.0 - 1.3 kz
95 °C
Resistance
700 - 800 z
All coolant temperature Resistance Min. 1 Mz range 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female)(15) and (38) (Coolant temperature: Min. 0 °C) 700 z Resistance a Use” coolant temperature -Resistance characteristics ” 37 kz table shown above as resistance criteria. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female side of ENG.
Between (B) and ground
3
Short circuit in wiring harness
Ground fault in wiring har4 ness (Contact with ground circuit) 5 Defective engine controller
40-192
Between ENG (female) (15) and ground
Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA145] Coolant Temp Sens Low Error
Circuit diagram related to coolant temperature sensor
D375A-6 (01)
40-193
DRAFT Troubleshooting by failure code Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA153] Chg Air Temp Sensor High Error Action code E01 Detail of failure Action of controller Problem on machine
Failure code CA153
Charge (Boost) temperature sensor signal voltage is too high. (Engine controller system)
q
High voltage was detected in charge (boost) temperature sensor signal circuit.
q
Sets charge temperature to fixed temperature (70 °C) ,and allows for operation.
q
Engine does not start easily at low temperature.
q
Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18501 (V)). Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18500 (°C)). Method of reproducing failure code: Turn the starting switch to ON position. Since T-adapter for sensor connector is "socket" type , T-adapter cannot be connected to wiring harness. If temperature sensor connector is disconnected, this failure code is displayed.
q
Related information
Failure
q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks See descriptions of related to wiring harness and connectors in "c: Electrical equipment" Defective wiring harness in "Checks before troubleshooting" of "General information on troubleshooting" , and connector check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector TIM and connect socket to male side of connector. a If charge temperature sensor resistance is 280 Ω - 382 kΩ, regard charge temperature sensor as normal. -40 °C Resistance 291 kΩ – 382 kΩ Defective charge temperBetween TIM (male) -20 °C Resistance 85 kΩ – 109 kΩ ature sensor (A) and (B) 0 °C Resistance 29 kΩ – 36 kΩ a Charge tempera30 °C Resistance 7.3 kΩ – 8.8 kΩ 60 °C Resistance 2.3 kΩ –2.7 kΩ ture -Resistance 90 °C Resistance 860 – 970 Ω chariacteristic 130 °C Resistance 280 – 320 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (23) and (47) cuit in wiring harness a Use "charge temperature-Resistance characteris- Resistance 280 Ω - 382 kΩ tics" table shown above as resistance criteria. Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure ler is in it, troubleshooting cannot be performed.)
40-194
D375A-6 (01)
Troubleshooting by failurecode Failure code [CA153] Chg Air Temp Sensor High Error
Circuit diagram related to charge temperature sensor
D375A-6 (06)
40-195
40-195
DRAFT Troubleshooting by failure code Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA154] Chg Air Temp Sensor Low Error Action code E01 Detail of failure Action of controller Problem on machine
Related information
q
Failure Charge (Boost) temperature sensor signal volatge too low Failure code (Engine controller system) CA154 Low voltage was detected in charge (boost) temperature sensor signal circuit.
q
Set charge temperature to fixed temperature (70 °C) ,and allow for operation.
q
Engine does not start easily at low temperature.
q
Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18501 (V)). Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18500 (°C)). Method of reproducing failure code: Turn the starting switch to ON position. If temperature sensor connector or harness is disconnected,this failure code is not displayed but failure code for High Error is displayed.
q q q
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks Defective wiring harness before troubleshooting" of "General information on troubleshooting" , and check them connector directly. 1. Turn starting switch to OFF position. 2. Disconnect connector TIM and connect socket to male side of connector. a If temperature sensor has resistance of 280 Ω - 382 kΩ, regard charge temperature sensor as normal. -40 °C Resistance 291 kΩ – 382 kΩ Defective charge temper-20 °C Resistance 85 kΩ – 109 kΩ ature sensor TIM (male) (A) and (B) 0 °C Resistance 29 kΩ – 36 kΩ a Charge temperature 30 °C Resistance 7.3 kΩ – 8.8 kΩ -Resistance chari60 °C Resistance 2.3 kΩ – 2.7 kΩ acteristic 90 °C Resistance 860 – 970 Ω 130 °C Resistance 280 – 382 Ω 1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) and (47) ness a Use "charge temperature-Resistance characteris- Resistance 280 Ω – 382 kΩ tics" table shown above as resistance criteria. Ground fault of wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connectors ENG and TIM and connect T-adapter to female side of ENG. (Contact with GND cirBetween ENG (female) (23) and ground Resistance Min. 1 MΩ cuit) Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure is ler in it, troubleshooting cannot be performed.)
40-196
D375A-6 (01)
Troubleshooting by failurecode Failure code [CA154] Chg Air Temp Sensor Low Error
Circuit diagram related to charge temperature sensor
D375A-6 (06)
40-197
40-197
Troubleshooting by failurecode Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error Action code
Failure code Failure
E03
CA187
Detail of failure
Sensor power supply 2 (5 V) circuit voltage is too low.
q
Engine controller ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals. Engine controller ignores signals from engine oil pressure sensor, sets engine oil pressure to default value (500 kPa {2.5 kg/cm2}),and allows engine to run. Engine controller ignores signals from ambient pressure sensor ,sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}),and allows engine to run. Engine controller ignores signals from boost pressure sensor, sets boost pressure to default value (400 kPa {4.1 kg/cm2}),and allows engine to run. Engine controller ignores signals from EGR valve lift sensor , limits engine output and closes EGR valve.
q q q
Problem on machine Related information
q
Engine output drops.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Sensor power source 2 too low (Engine controller system)
q
q
Action of controller
40-198
Defective wiring harness connector
2 Defective sensor or harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After troubleshooting of each connector, turn starting switch to OFF position. If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective. a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [CA187]. Sensor or harness
Connector
Bkup speed sensor system
G connector
Engine oil pressure sensor
POIL connector
Charge (boost) pressure sensor
PIM connector
Ambient pressure sensor
PAMB connector
EGR valve lift sensor
SEGR connector
Engine wiring harness
ENG connector
3 Defective related system
If another failure code is displayed, perform troubleshooting for it.
4 Defective engine controller
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to male side. 3. Turn starting switch to ON position with engine wiring harness disconnected. Between ENG (male) (37) and (47)
40-198
Voltage
4.75 – 5.25 V
D375A-6 (06)
Troubleshooting by failurecode Failure code [CA187] Sens Supply 2 Volt Low Error
Circuit diagram related to sensor power supply 2
D375A-6 (06)
40-19
40-199
DRAFT Troubleshooting by failure code Failure code [CA212] Eng Oil Temp Sensor High Error
Failure code [CA212] Eng Oil Temp Sensor High Error Action code E01 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Engine oil temperature sensor signal voltage is too high. Failure CA212 (Engine controller system) High voltage was detected engine oil temperature sensor signal circuit
q
Sets engine oil temperature to fixed value (100 °C), and allows engine to run.
q
Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code: 42701 (V)). Temperature sensed by engine oil temperature sensor can be checked with monitoring function (Code: 42700 (°C)). Method of reproducing failure code: Turn starting switch to ON position. This failure code is displayed if temperature sensor connector or harness is disconnected. Since T-adapter for sensor connector is “socket” type, it cannot be connected to wiring harness.
q q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in Defective wiring harness "Checks before troubleshooting" of "General information on troubleshooting" , and connector check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector TOIL and connect socket to male side of connector. a If coolant temperature sensor resistance is 700 Ω – 37 kΩ with coolant temperature above 0 °C, regard coolant temperature sensor as normal. Defective oil temperature 0 °C Resistance 30 - 37 kΩ sensor TOIL(male) between (A) 25 °C Resistance 9.3 - 10.7 kΩ and (B) 50 °C Resistance 3.2 - 3.8 kΩ a Oil temperature -Resis80 °C Resistance 1.0 - 1.3 kΩ tance characteristic 95 °C Resistance 700 - 800 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side of connector. Disconnection or short circuit Between ENG (female) (17) and (47) (with oil temperain wiring harness ture above 0 °C) Resistance 700 Ω - 37 kΩ a Use”Oil temperature -Resistance charactenis” table shown above as resistance criteria. If no abnormality is found by above checks, engine controller is defective. (Since failDefective engine controller ure is in it, troubleshooting cannot be performed.)
40-200
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA212] Eng Oil Temp Sensor High Error
Circuit diagram related to engine oil temperature sensor
D375A-6 (01)
40-201
DRAFT Troubleshooting by failure code Failure code [CA213] Eng Oil Temp Sensor Low Error
Failure code [CA213] Eng Oil Temp Sensor Low Error Action code E01 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Engine oil temperature sensor signal voltage is too low. Failure CA213 (Engine controller system) Low voltage was detected in engine oil temperature sensor signal circuit.
q
Sets engine oil temperature to fixed value (100 °C), and allows engine to run.l
q
Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code: 42701 (V)). Temperature sensed by engine oil temperature sensor can be checked with monitoring function (Code: 42700 (°C)). Method of reproducing failure code: Turn the starting switch to ON position. If temperature sensor connector is disconnected, this failure code is not displayed but failure code for High Error is displayed.
q q q
Cause 1
Defective wiring harness connector
2
Defective oil temperature sensor
3
Short circuit in wiring harness
Ground fault of wiring har4 ness (Contact with GND circuit)
5 Defective engine controller
40-202
Procedure, measuring location, criteria and remarks See the descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connectors TOIL and connect socket to male side of connector. a If oil temperature sensor resistance is 700 Ω - 37 kΩ with oil temperature is above0 °C, regard oil temperature sensor as normal. 0 °C Resistance 30 - 37 kΩ Between TOIL (male) (A) 25 °C Resistance 9.3 - 10.7 kΩ and (B) 50 °C Resistance 3.2 - 3.8 kΩ a Oil temperature -Resis80 °C Resistance 1.0 - 1.3 kΩ tance characteristics 95 °C Resistance 700 - 800 Ω All oil temBetween (B) and ground perature Resistance Min. 1 MΩ range 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (17) and (47) (Oil temperature: Min. 0 °C) Resistance 700 - 37 kΩ a Use”Oil temperature -Resistance charactenis” table shown above as resistance criteria. 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and TOIL, and connect T-adapter to female side of ENG. Between ENG (female) (17) and ground Resistance Min. 1 MΩ If no abnormality is found by above checks, engine controller is defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA213] Eng Oil Temp Sensor Low Error
Circuit diagram related to engine oil temperature sensor
D375A-6 (01)
40-203
DRAFT Troubleshooting by failure code Failure code [CA221] Ambient Press Sens High Error
Failure code [CA221] Ambient Press Sens High Error Action code Failure code Ambient pressure sensor signal voltage is too high. Trouble E01 CA221 (Engine controller system) Detail of failure q High voltage was detected in ambient pressure sensor signal circuit . Action of con2 q Sets ambient pressure value to default value (50.99kPa {0.52 kg/cm }),and allow engine to run. troller Problem on q Engine output drops. machine q Signal voltage from ambient pressure sensor can be checked with the monitoring function (Code: 37401 (V)). Related inforq Ambient pressure by the ambient pressure sensor can be checked with the monitoring function mation (Code: 37400 (kPa)). q Method of reproducing failure code: Turn the starting switch to ON position. Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
Defective power supply 2 line of ambient presIf failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first. sure sensor 1. Turn starting switch to OFF position. Defective ambient pres- 2. Disconnect connector PAMB. 3 sure sensor 3. Turn starting switch to ON position. If failure code changes from [CA221] to [CA222] ,sensor is defective. 1. Turn starting switch to OFF position. Short circuit in wiring 4 2. Disconnect connector ENG and PAMB, and connect T-adapter to female side of ENG. harness Between ENG (female) (37) and (3) Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring har2. Disconnect connector PAMB. ness 5 (Short circuit to 24 V cir- 3. Insert T-adapter into connector ENG. 4. Turn starting switch to ON position (with connector PAMB disconnected). cuit) Between ENG(3) – (38) Voltage Min. 1 V Defective engine con- If no abnormality is found by the above checks, the engine controller is defective. (Since 6 troller failure is in it, troubleshooting cannot be performed.)
40-204
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA221] Ambient Press Sens High Error
Circuit diagram related to atmospheric pressure sensor
D375A-6 (01)
40-205
DRAFT Troubleshooting by failure code Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA222] Ambient Press Sens Low Error Action code Failure code Ambient pressure sensor value too low. Failure E01 CA222 (Engine controller system) Detail of failure q Low voltage was detected ambient pressure sensor signal circuit . Action of con2 q Sets ambient pressure value to default value(52.44 kPa {0.53 kg/cm }),and allows engine to run. troller Problem on q Engine output drops. machine q Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37401 (V)). q Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function (Code: 37400 (kPa)). Related inforq Method of reproducing failure code: Turn starting switch to ON position. mation q Since T-adapter of sensor connector is "socket" type, voltage at sensor connector cannot be checked. q If sensor connector is disconnected, this code is displayed. Cause
1
2
3
4
5
6
7
Procedure, measuring location, criteria and remarks See descriptions of wire harness and connectors in "c. Electrical equipment" in "Checks Defective wiring harness before troubleshooting" of "Gemeral information on troubleshooting ,and check them connector directly". Defective power supply line of ambient pressure If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first. sensor 1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connectors PAMB and ENG. ness 3. Connect T-adapter to female side of ENG. Between ENG (female) (3) and (38) Resistance Min. 1 MΩ Ground fault of wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connectors PAMB and ENG and connect T-adapter to female side of (Contact with ground cirENG. cuit) Between ENG(female)(3) and ground Resistance Min. 1 MΩ Disconnection in wiring If cause is not found by the above checks, wiring harness may be disconnected. (*) harness a If causes 1 - 5 are not the cause for failure and check result of cause 6 is abnormal, sensor is defective. Defective ambient pres1. Turn starting switch to OFF position. sure sensor 2. Insert T-adapter into connector ENG. (Improper input voltage 3. Turn starting switch to ON position. from engine controller) Sensor Approx. 0.3 - 4.7 ENG Between (3) and (38) Voltage output V Defective engine control- If no abnormality is found by above checks, the engine controller is defective. (Since ler failure is in it, troubleshooting cannot be performed.)
*: Refer to "Troubleshooting method for disconnecting wiring harness of pressure sensor system" of "General information on troubleshooting".
40-206
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA222] Ambient Press Sens Low Error
Circuit diagram related to ambient pressure sensor
D375A-6 (01)
40-207
Troubleshooting by failurecode Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA227] Sens Supply 2 Volt High Error Action code
Failure code Failure
E03
CA227
Detail of failure
High voltage in engine controller sensor power supply 2 (5 V) circuit was detected.
q
q
Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals. Ignores signals from engine oil pressure sensor,sets engine oil pressure to default value (250 kPa {2.5 kg/cm2}),and allows engine to run. Ignores signals from ambient pressure sensor, sets ambient pressure to default value (52.44 kPa {0.53 kg/cm2}),and allows engine to run. Ignores signals from boost pressure sensor, sets boost pressure to default value (400 kPa {4.1 kg/cm2}),and allows engine to run. Ignores signals from EGR valve lift sensor, limits engine output and closes EGR valve.
q
Engine output drops.
q
Method of reproducing failure code: Turn the starting switch to ON position .
q q
Problem on machine Related information
Sensor power supply circuit valtage is too high (Engine controller system)
q q
Action of controller
40-208
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA187].
40-208
D375A-6 (06)
Troubleshooting by failurecode Failure code [CA234] Eng Overspeed
Failure code [CA234] Eng Overspeed Action code
Failure code Failure
E02
CA234
Detail of failure Action of controller Problem on machine Related information
Engine overspeed (Engine controller defective)
q
Engine speed exceeded operating range.
q
Reduce fuel injection rate until engine speed lowers in operating range.
q
Engine speed fluctuates.
q
Engine speed can be checked by monitoring function (Code: 01002 (rpm)). Method of reproducing failure code: Start engine and keep it running at high idle.
q
Cause
Procedure, measuring location, criteria and remarks
1 Use of improper fuel
Improper fuel may be used. Check it directly.
2 Defect in related system
If another failure code is displayed, perform troubleshooting for it.
3 Usage is improper 4 Defective engine controller
D375A-6 (06)
40-209
The method of using machine may be improper, so instruct the operator on how to use machine properly. If causes 1 and 2 are not cause of failure, engine controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-209
DRAFT Troubleshooting by failure code Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA238] Ne Speed Sens Supply Volt Error Action code Failure code Ne speed sensor power supply voltage error Failure E03 CA238 (Engine controller system) Detail of failure q Abmormality was detected rror occurred in Ne speed sensor power supply (5 V) circuit. Action of con- q Controls engine by using signals from Bkup speed sensor. q Limits engine output and allows engine to run. troller q Engine output drops. Problem on q Engine stops during operation (when Bkup speed sensor is also defective) machine q Engine cannot start during stop (when Bkup speed sensor is also defective) Related inforq Method of reproducing failure code: Turn starting switch to ON position. mation Cause
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks Defective wiring harness 1 before troubleshooting" of "General information on troubleshooting" , and check them connector directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, turn starting switch to OFF position. Defective sensor or wir- If this failure code is not displayed when a sensor is disconnected, sensor or engine wiring 2 harness is defective. ing harness a Other failure code (s) is (are) also displayed. This is because sensor connector is disconnected. Therefore, ignore code(s) other than failure code [CA238]. Sensor or harness Connector Ne speed sensor NE Engine harness ENG 1. Turn starting switch to OFF position. Defective engine con2. Disconnect connector ENG and connect T-adapter to male side of connector. 3 troller 3. Turn starting switch to ON position with engine wiring harness disconnected. Between ENG(male)(16) and (48) Voltage 4.75 – 5.25V
Circuit diagram related to Ne speed sensor
40-210
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA238] Ne Speed Sens Supply Volt Error
D375A-6 (01)
40-211
DRAFT Troubleshooting by failure code Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA263] Fuel Temp Sensor High Error Action code E01 Detail of failure Action of controller
Failure code CA263
Failure
Fuel temperature sensor signal voltage is too high (Engine controller system)
q
High voltage was detected in fuel temperature sensor signal circuit .
q
Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel temperature. Sets fuel temperature value to fixed value (95 °C) and allows engine to run.
q
Problem on machine q q
Related information
q q q
Signal voltage from the fuel temperature sensor can be checked with the monitoring function (Code: 14201 (V)). Temperature sensed by fuel temperature sensor can be checked with the monitoring function (Code: 14200 (°C)). Method of reproducing failure code: Turn the starting switch to ON position. This failure code is displayed if temperature sensor connector is disconnected. Because that T-adapter for sensor connector is “socket” type, it cannot be connected to wiring harness.
Cause 1
Defective wiring harness connector
2
Defective fuel temperature sensor
3
Disconnection or short circuit in wiring harness
4 Defective engine controller
40-212
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector TFUEL and connect socket to male side of connector. a If coolant temperature sensor resistance is 700 Ω – 37 kΩ with coolant temperature is above 0 °C, regard coolant temperature sensor as normal. TFUEL(male) 0 °C Resistance 30 - 37 kΩ 25 °C Resistance 9.3 - 10.7 kΩ between 50 °C Resistance 3.2 - 3.8 kΩ (A) and (B) 80 °C Resistance 1.0 - 1.3 kΩ a Fuel temperature -Resis95 °C Resistance 700 - 800 Ω t a n c e characteristic 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (30) and (47) (Fuel temperature : above 0 °C) a Use “Fuel temperature - Resistance Resistance 700 Ω - 37 kΩ characteristics” table shown above as resistance critaeria. If no abnormality is found by above checks, engine controller is defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA263] Fuel Temp Sensor High Error
Circuit diagram related to fuel temperature sensor
D375A-6 (01)
40-213
DRAFT Troubleshooting by failure code Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA265] Fuel Temp Sensor Low Error Action code E01 Detail of failure Action of controller
Failure code CA265
Failure
Fuel temperature sensor signal voltage is to low (Engine controller system)
q
Low voltage was detected in fuel temperature sensor signal circuit.
q
Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel temperature. (Sets to fixed value (95 °C) and ,and allows engine to run)
q
Signal voltage from fuel temperature sensor can be checked with monitoring function (Code: 14201 (V)). Temperature sensed by fuel temperature sensor can be checked with monitoring function (Code: 04204 (°C)). Method of reproducing failure code: Turn the starting switch to ON position. This code is not displayed but failure code for “High Error” is displayed, if sensor connector is disconnected.
Problem on machine
Related information
q q q
Cause
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in Defective wiring harness 1 "Checks before troubleshooting" of "General information on troubleshooting" section, connector and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector TFUEL and connect socket to male side. a If coolant temperature sensor resistance is 700 Ω – 37 kΩ with coolant temperature is above0 °C, regard coolant temperature sensor as normal. 0 °C Resistance 30 - 37 kΩ Defective fuel tempera- TFUEL(male) between 2 25 °C Resistance 9.3 - 10.7 kΩ (A) and (B) ture sensor 50 °C Resistance 3.2 - 3.8 kΩ a Fuel temperature 80 °C Resistance 1.0 - 1.3 kΩ Resistance charac95 °C Resistance 700 - 800 Ω teristic Between (B) and All fuel temResistance Min. 1 MΩ ground perature range 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (15) and (38) (Fuel temperaShort circuit in wiring 3 ture : above 0 °C) harness a Use”Fuel temperature Resistance Resistance 700 Ω - 37 kΩ characteristics ” table shown above as resistance criteria. Ground fault of wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connector TFUEL, and connect T-adapter to female side of ENG. 4 (Contact with GND cirBetween ENG (female) (30) and ground Resistance Min. 1 MΩ cuit) Defective engine control- If no abnormality is found by the above checks, engine controller is defective. (Since fail5 ler ure is in it, troubleshooting cannot be performed.)
40-214
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA265] Fuel Temp Sensor Low Error
Circuit diagram related to fuel temperature sensor
D375A-6 (01)
40-215
Troubleshooting by failurecode Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA271] IMV/PCV1 Short Error Action code
Failure code
E03
CA271
Detail of failure Action of controller Problem on machine Related information
40-216
Fail- IMV/PCV1 short circuit error ure (Engine controller system)
q
Short circuit was detected in supply pump PCV1 circuit.
q
Pulse voltage of approx. 24V is normally applied to PCV1 (1) while engine is running, but it cannot be measured with circuit tester .
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in Defective wiring harness 1 "Checks before troubleshooting" of "General information on troubleshooting", and connector check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector PCV1. Defective supply pump 2 PCV1 (Internal short circuit) 3. Turn starting switch to ON position. If failure code changes from [CA271] to [CA272], supply pump PCV1 is defective.
3
Short circuit in wiring harness
Ground fault in wiring har4 ness (Contact with ground circuit)
5
Hot short in wiring harness (Contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side of connector . Between ENG (female) (4) and (5) (PCV1 resistance)
Resistance
2.3 – 5.3 z
Between ENG(female)(4) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and PCV1, and connect Tadapter to female side of ENG. Between ENG(female)(4) and ground 1. 2. 3. 4.
Voltage
Max. 3 V
If no abnormality is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to PCV1
40-216
Min. 1 Mz
Turn starting switch to OFF position. Disconnect connector PCV1. Insert T-adapter into connector ENG. Turn starting switch to ON position (with connector PCV1 disconnected).
ENG Between (4) and (5) 6 Defective engine controller
Resistance
40-216
D375A-6 (06)
Troubleshooting by failurecode Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error Action code
Failure code
E03 Failure description Action of controller Problem on machine
CA272
Related information
Failure
IMV/PCV1 disconnection (Engine controller system)
q
Disconnection was detected in supply pump PCV1 circuit.
q
Method of reproducing failure code: Turn starting switch to ON position. While engine is running normally, Pulse voltage of approx. 24 V is normally applied to PCV (1) while engine is running ,but it cannot be measured with circuit tester since it is pulse voltage. Since T-adapter for PCV connector is "socket" type , T-adapter cannot be connected to wiring harness.
q q
Cause 1
40-217
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connectors PCV1 and connect socket to male side.
Defective supply pump PCV1 2 (Internal open circuit in wirBetween PCV1 (male) (1) and (2) Resistance ing) 1. Turn starting switch to OFF position. Open or short circuit in wir- 2. Disconnect connector ENG and connect T-adapter to female side. 3 ing harness Between ENG (female) (4) and (5) (PCV1 resistance) Resistance Ground fault in wiring har4 ness (Contact with ground circuit) 5 Defective engine controller
2.3 - 5.3 z
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and PCV1. 3. Connect T-adapter to female side of connector ENG. Between ENG (4) and (5)
Resistance
Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to PCV1
D375A-6 (06)
2.3 - 5.3 z
40-217
40-217
Troubleshooting by failurecode Failure code [CA273] PCV2 Short Error
Failure code [CA273] PCV2 Short Error Action code
Failure code
E03
CA273
Detail of failure Action of controller Problem on machine Related information
Fail- PCV2 short circuit error ure (Engine controller system)
q
Short circuit was detected in supply pump PCV2 circuit.
q
Engine output drops.
q
Method of reproducing failure code: Turn starting switch to ON position. While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But it is pulse voltage and cannot be measured by using multimeter.
q
Cause 1
Defective wiring harness connector
Defective supply pump 2 PCV2 (Internal short)
3
Short circuit in wiring harness
Ground fault in wiring har4 ness (Contact with ground circuit)
Hot short circuit in wiring 5 harness (Contact with 24 V circuit)
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector PCV2. 3. Turn starting switch to ON position. If failure code changes from [CA273] to [CA274], supply pump PCV2 is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (9) and (10) (PCV2 resistance)
6 Defective engine controller
Resistance
2.3 – 5.3 z
1. Turn starting switch to OFF position. 2. Disconnect connector ENG and PCV2, and connect Tadapter to female side of ENG. Between ENG (female) (9) and ground 1. 2. 3. 4.
Resistance
Min. 1 Mz
Turn starting switch to OFF position. Disconnect connector PCV2. Insert T-adapter into connector ENG. Turn starting switch to ON position (with connector PCV2 disconnected).
Between ENG (9) and (10)
Voltage
Max. 3 V
If no abnormality is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to PCV2
40-218
40-218
40-218
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA274] PCV2 Open Error
Failure code [CA274] PCV2 Open Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code PCV2 disconnection Failure CA274 (Engine controller system) q Disconnection was detected in supply pump PCV2 circuit.
q q
Method of reproducing failure code: Turn the starting switch ON. , Pulse voltage of approx. 24 V is normally applied to PCV2 (1) while engine is running, but it cannot be measured with circuit tester.
Cause
1
2
3
4
5
Procedure, measuring location, standard (value) and remarks See the descriptions of wiring harness and connectors in "c: Electrical equipment" in Defective wiring harness "Checks before troubleshooting" of "General information on troubleshooting" , and connector check them directly. Defective supply pump 1. Turn starting switch to OFF position. PCV2 2. Disconnect connector PCV2 and connect socket to male side. (Internal disconnection) Between PCV2 (male) (1) and (2) Resistance 2.3 - 5.3 Ω 1. Turn starting switch to OFF position. Disconnection or short cir2. Disconnect connector ENG and connect T-adapter to female side. cuit in wiring harness Between ENG (female) (9) and (10) (PCV2 resist) Resistance 2.3 - 5.3 Ω 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connector ENG and PCV2. ness (Contact with GND circuit) 3. Connect T-adapter to female side of connector ENG. Between ENG (female) (9) and (10) Resistance Min. 1 MΩ If no abnormality is found by above checks, engine controller is defective. (Since the Defective engine controller failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to PCV2
D375A-6 (01)
40-219
DRAFT Troubleshooting by failure code Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Injector #1(L#1) open/short circuit error Failure CA322 (Engine controller system) q Disconnection or short circuit was detected in injector #1 circuit.
q q q q
Engine output drops. Engien speed does not stabilize Method of reproducing failure code: Start engine. Pulse voltage of about 65 V is applied noromally supplied to injector (+) side while engine is running but it cannot be measured with circuit tester .
Cause 1
Defective wiring harness connector
2 Defective injector #1
3
Disconnection in, or ground fault of wiring harness
Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)
Ground fault of wiring har5 ness (Contact with ground circuit)
6
Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-220
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CN1 and connect T-adapter to male side. Between CN1 (male) (1) and (2) Resistance 0.4 - 1.1 Ω Between CN1 (male) (1) – ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (45) – (53) Resistance 0.4 - 1.1 Ω Between ENG(female)(45) and ground Resistance Min. 1 MΩ a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN1, and connect T-adapters to each female side. Between ENG (female) (45) and CN1 (female) (1) Resistance Max. 1 Ω Between ENG (female) (53) and CN1 (female) (2) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN1, and connect T-adapter to female side of either one of them. Between ENG (female) (45) or CN1 (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN1, and connect T-adapter to female side of ENG. a Check with circuit tester in continuity mode. Between ENG (female) (45) and each pin other than No continuity (45) pin. (No sound is heard) Between ENG (female) (53) and each pin other than No continuity (53) pin. (No sound is heard) If the failure codes for other injectors are displayed, perform troubleshooting of them, too. If no abnormality is found by above checks, engine controller is defective. (Since failure is in it , troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA322] Inj #1 (L#1) Open/Short Error
Circuit diagram related to injector #1
D375A-6 (01)
40-221
DRAFT Troubleshooting by failure code Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Injector #5(L#5) open/short circuit error Trouble CA323 (Engine controller system) q Disconnection or short circuit was detected in injector #5 circuit.
q q q q
Engine output drops. Engine speed does not stabilize. Method of reproducing failure code: Start engine. Pulse voltage of about 65V is normally supplied to injector (+) side while engine is running, but it cannot be measured with circuit tester .
Cause 1
Defective wiring harness connector
2 Defective injector #5
Disconnection in, or 3 ground fault of wiring harness Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector) Ground fault of wiring har5 ness (Contact with GND circuit)
6
Short circuit in wiring harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CN5 and connect T-adapter to male side. Between CN5 (male) (1) and (2) Resistance 0.4 - 1.1 Ω Between CN5 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (46) – (60) Resistance 0.4 - 1.1 Ω Between ENG(female)(46) and ground Resistance Min. 1 MΩ a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN5, and connect T-adapters to each female side. Between ENG (female) (46) and CN5 (female) (1) Resistance Max. 1 Ω Between ENG (female) (60) and CN5 (female) (2) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN5, and connect T-adapter to female side of either one of them. Between ENG (female) (46) or CN5 (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN5, and connect T-adapter to female side of ENG. a Check with circuit tester in continuity mode. Between ENG (female) (46) and each pin other than No continuity pin (46) pin. (No sound is heard) Between ENG (female) (60) and each pin other than No continuity pin (60) pin. (No sound is heard)
Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting for them, too. injectors or wiring harness Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure 8 ler is in it, troubleshooting cannot be performed.) 7
40-222
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA323] Inj #5 (L#5) Open/Short Error
Circuit diagram related to injector #5
D375A-6 (01)
40-223
DRAFT Troubleshooting by failure code Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Injector #3(L#3) open /short circuit error Failure CA324 (Engine controller system) q Disconnection or short circuit was detected in injector #3 circuit.
q q q q
Engine output drops. Engine speed does not stabilize. Method of reproducing failure code: Start engine. Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running, but it cannot be measured with circuit tester.
Cause 1
Defective wiring harness connector
2 Defective injector #3
3
Disconnection in, or ground fault of wiring harness
Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)
Ground fault of wiring har5 ness (Contact with GND circuit)
6
Short circuit in wiring harness
Procedure, measuring location, standard (value) and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CN3 and connect T-adapter to male side. Between CN3 (male) (1) and (2) Resistance 0.4 - 1.1 Ω Between CN3 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (55) – (52) Resistance 0.4 - 1.1 Ω Between ENG(female)(55) and ground Resistance Min. 1 MΩ a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN3, and connect T-adapters to each female side. Between ENG (female) (55) and CN3 (female) (1) Resistance Max. 1 Ω Between ENG (female) (52) and CN3 (female) (2) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN3, and connect T-adapter to female side of either one of them. Between ENG (female) (55) or CN3 (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN3, and connect T-adapter to female side of ENG. a Check with circuit tester in continuity mode. Between ENG (female) (55) and each pin other than No continuity pin (55) pin. (No sound is heard) Between ENG (female) (52) and each pin other than No continuity pin (52) pin. (No sound is heard)
Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting for them, too. injectors or wiring harness If no abnormality is found by above checks, engine controller is defective. (Since fail8 Defective engine controller ure is in it, troubleshooting cannot be performed.) 7
40-224
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA324] Inj #3 (L#3) Open/Short Error
Circuit diagram related to injector #3
D375A-6 (01)
40-225
DRAFT Troubleshooting by failure code Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Injector #6 (L#6) open / short circuit error Trouble CA325 (Engine controller system) q Opening or short circuit was detected in drive circuit of No. 6 injector.
q q q q
Engine output drops. Engine speed does not stabilize. Method of reproducing failure code: Start engine. Pulse voltage of approx. 65 V is normally supplied to injector (+) side while engine is running normally but it cannot be measured with circuit tester .
Cause 1
Defective wiring harness connector
2 Defective injector #6
Disconnection in, or 3 ground fault of wiring harness Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector) Ground fault of wiring har5 ness (Contact with GND circuit)
6
Short circuit in wiring harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CN6 and connect T-adapter to male side. Between CN6 (male) (1) and (2) Resistance 0.4 - 1.1 Ω Between CN6 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (57) – (59) Resistance 0.4 - 1.1 Ω Between ENG(female)(57) and ground Resistance Min. 1 MΩ a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN6, and connect T-adapters to each female side. Between ENG (female) (57) and CN6 (female) (1) Resistance Max. 1 Ω Between ENG (female) (59) and CN6 (female) (2) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN6, and connect T-adapter to female side of either one of them. Between ENG (female) (57) or CN6 (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN6, and connect T-adapter to female side of ENG. a Check with circuit tester in continuity mode. Between ENG (female) (57) and each pin other than No continuity pin (57) pin. (No sound is heard) Between ENG (female) (59) and each pin other than No continuity pin (59) pin. (No sound is heard)
Defective injector or wiring If the failure codes for other injectors are displayed, perform troubleshooting for them, 7 harness of another cylintoo. der If no abnormality is found by above checks, engine controller is defective. (Since failure 8 Defective engine controller is in it, troubleshooting cannot be performed.)
40-226
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA325] Inj #6 (L#6) Open/Short Error
Circuit diagram related to injector #6
D375A-6 (01)
40-227
DRAFT Troubleshooting by failure code Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error Action code E03 Detail of failure Action of controller Problem on machine Related information
q
Failure code Injector #2 Open/Short circuit error Failure CA331 (Engine controller system) Disconnection or short circuit was detected in injector #2 circuit.
q q q q
Engine output drops. Engine speed does not stabilize. Method of reproducing failure code: Start engine. Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running, but it cannot be measured with circuit tester .
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in Defective wiring harness "Checks before troubleshooting" of "General information on troubleshooting", and connector check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CN2 and connect T-adapter to male side. Defective injector #2 Between CN2 (male) (1) and (2) Resistance 0.4 - 1.1 Ω Between CN2 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ENG and connect T-adapter to female side. fault of wiring harness Between ENG (female) (54) – (51) Resistance 0.4 - 1.1 Ω Between ENG (female) (54) and ground Resistance Min. 1 MΩ a If no abnormality is found in checks on cause 3, this check is not required. Disconnection in wiring har1. Turn starting switch to OFF position. ness (Disconnection in wiring or 2. Disconnect connectors ENG and CN2, and connect T-adapters to each female side. defective contact in connecBetween ENG (female) (54) and CN2 (female) (1) Resistance Max. 1 Ω tor) Between ENG (female) (51) and CN2 (female) (2) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors ENG and CN2, and connect T-adapter to female side of ness either one of them. (Contact with GND circuit) Between ENG (female) (54) or CN2 (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN, and connect T-adapter to female side of ENG. Short circuit in wiring hara Check with circuit tester in continuity mode. ness Between ENG (female) (54) and each pin other than pin No continuity (54) pin. (No sound is heard) Between ENG (female) (51) and each pin other than pin No continuity (51) pin. (No sound is heard) Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting for them, injectors or wiring harness too. If no abnormality is found by above checks, engine controller is defective. (Since failDefective engine controller ure is in it, troubleshooting cannot be performed.)
40-228
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA331] Inj #2 (L#2) Open/Short Error
Circuit diagram related to injector #2
D375A-6 (01)
40-229
DRAFT Troubleshooting by failure code Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Injector #4 (L#4) open / short circuit error Failure CA332 (Engine controller system) q Disconnection or short circuit was detected in injector #4 circuit.
q q q q
Engine output drops. Engine speed does not stabilize. Method of reproducing failure code: Start engine. Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running but it cannot be measured with circuit tester.
Cause 1
Defective wiring harness connector
2 Defective injector #4
3
Disconnection in, or ground fault of wiring harness
Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)
Ground fault of wiring har5 ness (Contact with GND circuit)
6
Short circuit in wiring harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CN4 and connect T-adapter to male side. Between CN4 (male) (1) and (2) Resistance 0.4 - 1.1 Ω Between CN4 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. Between ENG (female) (56) – (58) Resistance 0.4 - 1.1 Ω Between ENG (female) (56) and ground Resistance Min. 1 MΩ a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN4, and connect T-adapters to each female side. Between ENG (female) (56) and CN4 (female) (1) Resistance Max. 1 Ω Between ENG (female) (58) and CN4 (female) (2) Resistance Max. 1 Ω a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN4, and connect T-adapter to female side of either one of them. Between ENG (female) (56) or CN4 (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and CN4, and connect T-adapter to female side of ENG. a Check with circuit tester in continuity mode. Between ENG (female) (56) and each pin other than No continuity pin (56) . (No sound is heard) Between ENG (female) (58) and each pin other than No continuity pin (58) . (No sound is heard)
Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting for them, too. injectors or wiring harness If no abnormality is found by above checks, engine controller is defective. (Since fail8 Defective engine controller ure is in it, troubleshooting cannot be performed.) 7
40-230
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA332] Inj #4 (L#4) Open/Short Error
Circuit diagram related to injector #4
D375A-6 (01)
40-231
DRAFT Troubleshooting by failure code Failure code [CA342] Calibration Code Incompatibility
Failure code [CA342] Calibration Code Incompatibility Action code E03 Detail of failure Action of controller Problem on machine Related information
q
q
Engine continues running ordinarily, but it may stop during operation or may not restart once it is stopped.
q
Method of reproducing failure code: Turn the starting switch to ON position.
Cause
40-232
Failure Engine controller data inconsistency Failure code (Engine controller system) CA342 Data inconsistency occurres in engine controller.
Procedure, measuring location, criteria and remarks Preform troubleshooting for failure code [CA111].
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA351] Injectors Drive Circuit Error Action code Failure code Injectors drive circuit error Failure E03 CA351 (Engine controller system) Detail of failure q Abnormality has occurred in injector drive circuit. Action of conq Limits engine output for travel (Limits common rail pressure) and allows engine to run troller Problem on q Engine output drops. machine Related inforq Method of reproducing failure code: Start engine. mation Cause 1 Defect in related system
D375A-6 (01)
Procedure, measuring location, standard (value) and remarks Check whether other failure code (failure code related to injector system ) are displayed together. If another code is displayed, perform troubleshooting for it. Perform troubleshooting for failure code [ CA111]
40-233
DRAFT Troubleshooting by failure code Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error Action code E03 Detail of failure Action of controller Problem on machine Related information
q
Failure Sensor power supply 1voltage is too low Failure code (Engine controller system) CA352 Low voltage was detected in sensor power supply 1 (5 V) circuit.
q
Limits engine output (limits common rail pressure) and allows engine to run.
q
Engine output drops.
q
Method of reproducing failure code: Turn the starting switch to ON position.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks Defective wiring harbefore troubleshooting" of "General information on troubleshooting", and check them ness connector directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, turn starting swith to OFF position. Defective sensor or wir- If this failure code is not displayed when sensor is disconnected, the sensor or engine wiring harness ing harness is defective. a Other failure code(s) is(are) displayed at the same time. This is because the sensor connector is disconnected. Therefore, ignore failure codes other than [CA352]. Sensor, harness Connector Common rail pressure sensor PFUEL Engine harness ENG Defect in related sysIf another failure code is displayed, perform troubleshooting for it. tem 1. Turn starting switch to OFF position. Defective engine con- 2. Disconnect connector ENG and connect T-adapter to male side. troller 3. Turn starting switch to ON position with engine wiring harness disconnected. Between ENG (male) (33) and (47) Voltage 4.75 – 5.25 V
40-234
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA352] Sens Supply 1 Volt Low Error
Circuit diagram related to sensor power supply 1
D375A-6 (01)
40-235
DRAFT Troubleshooting by failure code Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA386] Sens Supply 1 Volt High Error Action code E03 Detail of failure Action of controller Problem on machine Related information
q q
Limits engine output (limits common rail pressure) and allows engine to run
q
Engine output drops.
q
Method of reproducing failure code: Turn the starting switch to ON position.
Cause
40-236
Failure Sensor power supply 1 voltage is too high Failure code (Engine controller system) CA386 High voltage was detected in sensor power supply 1 (5 V) circuit.
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code[CA352]
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error Action code Failure code Battery power circuit voltage is to low Trouble E04 CA441 (Engine controller system) Contents of q Low voltage was detected in battery power supply circuit. trouble Action of controller Problem that q Engine contionues running ordinarily, but it may stop during operation or may not restart once it is appears on stopped. machine Related inforq Method of reproducing failure code: Turn the starting switch to ON position. mation Cause
D375A-6 (01)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA111].
40-237
Troubleshooting by failurecode Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error Action code
Failure code Failure
E03
CA442
Detail of failure Action of controller Problem on machine Related information
40-238
Battery power supply circuit voltage is too high (Engine controller system)
q
High voltage (36V) was detected in battery power supply circuit.
q
Engine continues running ordinarily, but it may stop during operation or may not restart once it is stoped. Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage of engine controller can be checked with monitoring function (Code: 03203 (V)).
q q
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA111].
40-238
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error Action code E03
Failure code Common rail pressure is abmormally high Failure CA449 (Engine controller system) q Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set Detail of failure maximum level). Action of conq Limits engine output (limits common rail pressure) ,and allows engine to run. troller Problem on q Engine output drops. machine q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code: 36401 (V)). Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring mation function (Code: 36400 (MPa)). q Method of reproducing failure code: Turn the starting switch to ON position. Cause
D375A-6 (01)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA553].
40-239
Troubleshooting by failurecode Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error Action code
Failure code Failure
E03
CA451
Detail of failure Action of controller Problem on machine
Related information
40-240
Common rail pressure sensor signal voltage is too high. (Engine controller system)
q
High voltage was detected in signal circuit of common rail pressure sensor.
q
Limits engine output (limits common rail pressure) and allows engine to run
q
Engine output is drops.
q
Signal voltage from common rail pressure sensor can be checked with monitoring function (Code: 36401 (V)). Common rail pressure sensed by common rail pressure sensor can be checked with monitoring function (Code: 36400 (MPa)). This failure code is displayed if common rail pressure sensor connector is disconnected. Method of reproducing failure code: Turn the starting switch to ON position.
q q q
Cause
Procedure, measuring location, criteria and remarks
Directly check wire harness and connectors by referring to "c. Electrical equipment" Defective wiring harness 1 described in "Check before troubleshooting" of "General information on troubleshootconnector ing". a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is displayed, perform troubleshooting for it first. Defective common rail pres- 1. Turn starting switch to OFF position. 2 sure sensor power supply 2. Disconnect connector PFUEL and connect T-adapter to female side. line 3. Turn starting switch to ON position. Power supply Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V input 1. Turn starting switch to OFF position. 2. Disconnect connectors PFUEL and ENG and connect T-adapters to each female side. a If power supply input in checks on cause 2 is normal, Open circuit in wiring harthis check is not required. Resistance Max. 1 z ness 3 Between ENG(female) (33) and PFUEL(female) (1) (wire breakage or defective a If power supply input in checks on cause 2 is normal, contact of connector) this check is not required. Resistance Max. 1 z Between ENG (female) (47) and PFUEL (female) (3) Between ENG (female) (25) and PFUEL (female) (2) Resistance Max. 1 z (Sensor output) 1. Turn starting switch to OFF position. 2. Disconnect connectors PFUEL and ENG Short circuit in wiring har4 3. Connect T-adapter to female side of ECM. ness Between ENG (female) (25) and (33) Resistance Min. 1 Mz
5
Hot short in wiring harness (Contact with 24 V circuit)
1. 2. 3. a
Turn starting switch to OFF position. Disconnect connectors PFUEL and insert T-adapter into connector ECM. Turn starting switch to ON position (with connector PFUEL disconnected). ENG (25) pin is connected to 5V source through resistor in engine controller.
Between ENG (25) and (47)
Voltage
Approx. 5V
a If causes 1 – 5 are not cause of failure and check result of cause 6 is abnormal, sensor is defective. Defective common rail pres1. Turn starting switch to OFF position. sure sensor 6 2. Insert T-adapter into connector ENG (Improper input voltage to 3. Turn starting switch to ON position. engine controller) Between ENG (25) and (47) 7 Defective engine controller
40-240
Sensor output
Voltage
0.2 – 4.6V
If no abnormality is found by the above checks, the engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA451] Rail Press Sensor High Error
Circuit diagram related to common rail pressure
D375A-6 (01)
40-241
Troubleshooting by failurecode Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error Action code
Failure code Failure
E03
CA452
Detail of failure Action of controller Problem on machine
Related information
Common rail pressure sensor signal voltage is to low (Engine controller system)
q
Low voltage was detected in signal circuit of common rail pressure sensor.
q
Limits engine output (limits common rail pressure),and allows engine to run.
q
Engine output is drops.
q
Signal voltage from the common rail pressure sensor can be checked with monitoring function (Code: 36401 (V)). Common rail pressure sensed by common rail pressure sensor can be checked with monitoring function (Code: 36400 (MPa)). Method of reproducing failure code: Turn starting switch to ON position. This failure code is not displayed but failure code, position [CA451] for “High Error ” is displayed when sensor connector is disconnected even if it is normal.
q q q
1
40-242
Cause
Procedure, measuring location, criteria and remarks
Defective wiring harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting". a If failure code [CA352]or [CA386] is displayed, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position. 2. Disconnect connector PFUEL and connect T-adapter to female side. 2 sure sensor power supply 3. Turn starting switch to ON position. line Power supply Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V input 1. Turn starting switch to OFF position. Defective common rail pres- 2. Disconnect connector PFUEL 3 3. Turn starting switch to ON position. sure sensor If failure code changes from [CA452] to [CA451] , sensor is defective. 1. Turn starting switch to OFF position. Ground fault in wiring har- 2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female side 4 ness of ENG (Contact with ground circuit) Between ENG (female) (25) and ground Resistance Min. 1 Mz
5
Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female side of ENG Between ENG (25) and (47)
6 Defective engine controller
40-242
Resistance
Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA452] Rail Press Sensor Low Error
Circuit diagram related to common rail pressure
D375A-6 (01)
40-243
DRAFT Troubleshooting by failure code Failure code [CA553] Rail Press High Error
Failure code [CA553] Rail Press High Error Action code E03
Failure code Common rail pressure is high Failure CA553 (Engine controller system) q Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the signal Detail of failure circuit of common rail pressure sensor. Action of controller Problem on machine q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code: 36401 (V)). Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring funcmation tion (Code: 36400 (MPa)). q Method of reproducing failure code: Start engine. Cause 1 Defect in related system 2 Use of improper fuel Defective electrical system 3 of common rail pressure sensor Defective mechanical sys4 tem of common rail pressure sensor 5 Defective overflow valve 6 Clogging of overflow piping 7 Defective pressure limiter
40-244
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Check fuel used directly (for high viscosity). Electrical system of common rail pressure sensor may be defective. Perform troubleshooting for failure codes [CA451] and [CA452]. Check mechanical system of common rail pressure sensor directly. Check overflow valve directly for broken spring, worn seat, and stuck ball. Check overflow piping directly for clogging. Check pressure limiter directly for mechanical defect.
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA554] Rail Press Sensor In Range Error Action code Failure code Common rail pressure sensor signal voltage is beyond input range Failure E03 CA554 (Engine controller system) Detail of failure q Signal voltage of common rail pressure sensor is beyond input range. Action of conq Limits engine output (limits common rail pressure) and allows engine to run. troller Problem on q Engine output drops. machine q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code: 36401 (V)). Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring funcmation tion (Code: 36400 (MPa)). q Method of reproducing failure code: Turn starting switch to ON position. Cause
D375A-6 (01)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA451], [CA452]
40-245
DRAFT Troubleshooting by failure code Failure code [CA559] Rail Press Low Error
Failure code [CA559] Rail Press Low Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Supply pump does not pressure feed fuel Failure CA559 (Engine controller system) q Supply pump does not pressure feed fuel (level1). q
Limits common rail pressure.
q
Engine output drops.
q
Common rail pressure sensed by common rail pressure sensor can be checked with monitoring function (Code: 36400 (MPa)). Method of reproducing failure code: Start engine.
q
Cause 1 Defect in related system 2 Use of improper fuel
3
4 5 6
7
8
9
Procedure, measuring location,criteria and remarks If another failure code is displayed, perform troubleshooting for it first. Fuel used may be improper. Check it directly. a For more information on troubleshooting, see Note 1. For check of fuel pressure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure". Defect in low pressure cirFuel pressure in low-pressure circuit 0.15 – 0.3 MPa cuit parts (At high idle or under load equivalent to rated {1.5 – 3.0 kg/cm2} output operation) Clogged fuel filter,or a For more information on troubleshooting, see Note 2. strainer Defective electrical sysElectrical system of supply pump PCV may be defective. Perform troubleshooting for tem of supply pump PCV failure code [CA271], [CA272], [CA273], or [CA274]. Defective common rail Common rail pressure sensor may be defective. Check wiring harness for damage. pressure sensor a For check of leakage from pressure limiter, see Testing and adjusting, “Checking fuel return rate and leakage”. Leakage from pressure limiter Defective pressure limiter (Rated output operation or equiralent (load at Max. 10 cc/min stalling)) a For check of limit return rate (spill) from injector, see Testing and adjusting, “Checking fuel return rate and leakage”. Engine speed during rated output operation Injector return or equivalent (spill) limit (load at stalling) Defective injector 1,600 rpm 960 cc/min 1,700 rpm 1,020 cc/min 1,800 rpm 1,080 cc/min 1,900 rpm 1,140 cc/min 2,000 rpm 1,200 cc/min Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
Perform the above troubleshooting and use the attached "Check sheet for no-pressure feed",to note the check resuets.
40-246
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA559] Rail Press Low Error
Note 1: Check the low-pressure circuit parts for the following items. 1) Fuel level 2) Clogging of fuel tank breather 3) Locking and wear of feed pump,clogging of filters 4) Leaking or clogging of fuel low-pressure piping 5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.) 6) Clogged fuel filter 7) Fuel in oil pan (Fuel leakage inside head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2) , and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2) : Spring is seen through hole on nut side. q Fuel inlet joint(3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check. If clogged, clean. 2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 3) Fuel filter: If the problem is not solved by performing 1) and 2) above, replace the fuel filter.
D375A-6 (01)
40-247
Troubleshooting by failurecode Failure code [CA559] Rail Press Low Error
Model Machine serial No. Engine Engine serial No.
# #
Check sheet for no-pressure feed D375A-6 Work No. Date of check SAA6D170E-5 Service meter reading Worker's name
A. Visual check 1 Fuel leakage to outside 2 Clogging of fuel tank breather
/
/
h
Good NG
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode Good NG operation 3 Checking failure code / / / / Check of monitoring information Standard Measured Code Display item Condition for check unit value(Refeenc Good NG value e value) Low idle r/min 700 – 800 01003 Engine speed High idle r/min 1,850 – 1,900 At torque converter stalling r/min 1,490 – 1,580 Low idle % 0 Decelerator 31701 Pedal Position High idle % 100 Inject Fueling 18600 At torque converter stall mg/st Command 4 Rail Press Com36200 At torque converter stall MPa mand Common rail 36400 At torque converter stall MPa pressure Low idle CA Injection timing 36300 High idle CA command At torque converter stall CA Charge Pres36500 At torque converter stall kPa sure-ABS Coolant Temper04107 Low idle °C ature 14200 Fuel Temperature Low idle °C Cylinder cut out mode operation (Engine speed) Standard Measured Good NG Function Cut out cylinder Condition for check unit value(Refervalue ence value) No. 1 cylinder Low idle r/min 5 No. 2 cylinder Low idle r/min Low idle r/min Set by No. 3 cylinder cylinder No. 4 cylinder Low idle r/min No. 5 cylinder Low idle r/min No. 6 cylinder Low idle r/min -
C.Check of fuel circuit pressure
6
Fuel low-pressure circuit pressure
Condition for check
High idling or under load equivaMPa lent to rated output operation(stall{kg/cm2} ing)
D.Check of strainers and filters 7 Visual inspection of strainer 8 Visual inspection of gauze filter 9 Visual check of fuel filter 10 Visual inspection of bypass valve
40-248
Unit
Standard value(Reference value)
Measured Good NG value
0.15 – 0.3 {1.5 – 3.0} Good NG
D375A-6 (06)
Troubleshooting by failurecode Failure code [CA559] Rail Press Low Error
E.Checking leakage and fuel return rate 11
Unit
Standard value(Reference value)
cc/min
Max. 10
Torque converter stall 1,600 rpm
cc/min
960
Torque converter stall 1,700 rpm
cc/min
1,020
Torque converter stall 1,800 rpm
cc/min
1,080
Torque converter stall 1,900 rpm
cc/min
1,140
Torque converter stall 2,000 rpm
cc/min
1,200
Condition for check
Leakage from pressure lim- Under load equivalent to rated iter output operation (stalling)
12 Return rate from injector
D375A-6 (06)
Measured Good NG value
Speed:
Return rate:
40-249
Troubleshooting by failurecode Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA689] Eng Ne Speed Sensor Error Action code
Failure code Failure
E03
CA689
Detail of failure Action of controller Problem on machine
Engine Ne speed sensor signal is abnormal (Engine controller system)
q
Abnormal signal appear in engine Ne speed sensor circuit.
q
Controls engine by using signals from engine Bkup speed sensor.
q
Engine stops during operation (When engine Bkup speed sensor is also defective). Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective) Method of reproducing failure code: Start engine. Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with circuit tester. Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester. Speed sensor calculates engine speed by detecting holes made in the flywheel.
q q
Related information
40-250
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting".
2
Defective Ne speed sensor If failure code [CA238] is also displayed, perform troubleshooting for it first. power supply line
Breakage or improper instalEngine Ne speed sensor may be damaged or improperly installed (loose). Check 3 lation (looseness) of engine sensor directly. Ne speed sensor 1. Turn starting switch to OFF position. 2. Disconnect connector NE and connect T-adapter to female side. 4 Defective Ne speed sensor 3. Turn starting switch to ON position. power supply input Power supply Between NE (female) (1) and (2) Voltage 4.75 – 5.25 V input 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and NE. 3. Turn starting switch to ON position. If no abnormality is found in checks on cause 4, this Open circuit in wiring harcheck is not required. Resistance Max. 1 z ness 5 (wire breakage or defective Between ENG (female) (16) and NE (female) (1) If no abnormality is found in checks on cause 4, this contact of connector) check is not required. Resistance Max. 1 z Between ENG (female) (48) and NE (female) (2) Between ENG (female) (27) and NE (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and NE. Short circuit in wiring harBetween ENG (female) (16) and (27), or between NE 6 ness (female) (1) and (3) Between ENG (female) (27) and (48), or between NE (female) (2) and (3) 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors ENG and NE. 7 ness Between ENG (female) (27) or NE (female) (3) and (Contact with ground circuit) ground 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector NE. 8 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between NE (female) (3) and ground
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1V
Defective engine Ne speed If failure is not found by above checks, engine Ne speed sensor may be defective. sensor (Since failure is in it, troubleshooting cannot be performed.) If failure is not found by above checks, engine controller may be defective. (Since 10 Defective engine controller failure is in it, troubleshooting cannot be performed.) 9
40-250
D375A-6 (06)
Troubleshooting by failurecode Failure code [CA689] Eng Ne Speed Sensor Error
Circuit diagrams related to engine Ne speed sensor
q
40-251
Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of flywheal, and the engine controller calculates the engine speed and phase.
D375A-6 (06)
40-251
Troubleshooting by failurecode Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error Action code
Failure code Failure
E03
CA731
Detail of failure Action of controller Problem on machine
40-252
Engine Bkup speed sensor phase error (Engine controller system)
q
Engine Bkup speed sensor circuit detects phase error. (Bkup speed sensor signal and Ne speed sensor signal are out of phase.)
q
Controls the engine by using signals from engine Ne speed sensor.
q
Engine stops during operation (When engine Ne speed sensor is also defective) Engine cannot be started if it is stopped. (When engine Ne speed sensor is also defective). q Method of reproducing failure code: Start engine. Related infora If Bkup speed sensor needs to be replaced, fuel supply pump must be replaced. (See "Disassembly mation and assembly", "Removal and installation of fuel supply pump assembly".) q
Cause
Procedure, measuring location, criteria and remarks
Defective engine Ne speed 1 sensor system Defective engine Bkup 2 speed sensor system
Engine Ne speed sensor may be defective. Perform troubleshooting for failure code [CA689] Engine Bkup speed sensor may be defective. Perform troubleshooting for failure code [CA778]
40-252
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA757] All Continuous Data Lost Error
Failure code [CA757] All Continuous Data Lost Error Action code Failure code All engine controller data lost error Failure E04 CA757 (Engine controller system) Detail of failq All data in engine controller are lost. ure Action of controller Problem on q Engine continues running, but it may stop during operations or may not restart once it is in stopped. machine Related q Method of reproducing failure code: Turn starting switch ON. information Cause
D375A-6 (01)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA111].
40-253
Troubleshooting by failurecode Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA778] Eng Bkup Speed Sensor Error Action code
Failure code Failure
E03
CA778
40-254
Eng Bkup Speed Sensor Error (Engine controller system)
Detail of failure
q
Abnormality has occurred in engine Bkup speed sensor circuit.
Action of controller
q
Controls engine by using Ne speed sensor signal. Limits engine output and allows engine to run. Engine stops during operation (when Ne speed sensor is also defective at the same time). Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same time). Method of reproducing failure code: Start engine. a If engine Bkup speed sensor is replaced, fuel supply pump must be replaced. (See "Disassembly and assembly", "Removal and installation of fuel supply pump assembly".) Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with circuit tester. Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.
Problem on machine
q q q q
Related information
q q
1
Cause
Procedure, measuring location, criteria and remarks
Defective wiring harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting".
Defective sensor power supIf failure code [CA187] or [CA227] is also displayed, troubleshoot it first. ply line Damage or improper instalEngine Bkup speed (G) sensor may be damaged or improperly installed (loose). 3 lation (loose) of engine Bkup Check sensor directly. speed (G) sensor 1. Turn starting switch to OFF position. 2. Disconnect connector RES and connect T-adapter to male side. 4 Defective resistor (RES)
2
Between RES (male) (1) and (2)
Resistance
620 z
1. Turn starting switch to OFF position. Defective engine Bkup 2. Disconnect connector G and connect T-adapter to female side. 5 speed sensor power supply 3. Turn starting switch to ON position. Power supply input Between G (female) (A) and (B) Voltage 4.75 – 5.25 V input Open or short circuit in wir- 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and G, and connect T-adapter to female side of ENG. 6 ing harness Between ENG (female) (37) and (26) Resistance 620 z (Resistor RES line) 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG, G and RES, and connect T-adapters to each female side. a If power supply voltage in checks on cause 5 is norOpen circuit in wiring harmal, this check is not required. Resistance Max. 1 z ness 7 (wire breakage or defective Between ENG (female) (37) and G (female) (A) a If power supply voltage in checks on cause 5 is norcontact of connector) mal, this check is not required. Resistance Max. 1 z Between ENG (female) (47) and G (female) (B) Between ENG (female) (26) and G (female) (C)
40-254
Resistance
Max. 1 z
D375A-6 (06)
Troubleshooting by failurecode Failure code [CA778] Eng Bkup Speed Sensor Error
Cause
8
Short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG, G and RES, and connect T-adapter to female side of ENG or G. Between ENG (female) (26) and (37), or between G Resistance Min. 1 Mz (female) (A) and (C) Between ENG (female) (26) and (47), or between G (female) (B) and (C)
Ground fault in wiring har9 ness (contact with ground circuit)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and G and connect T-adapters to either female side. Between ENG (female) (26) or G (female) (C) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Hot short circuit in wiring 2. Disconnect connectors G and RES, and connect T-adapter to female side. 10 harness (Contact with 24 V 3. Turn starting switch to ON position. circuit) Between G (female) (C) and ground Voltage Max. 1 V 11
Defective engine Ne speed If engine failure is not found by above checks, engine Bkup speed sensor may be sensor defective. (Since this is an internal failure, troubleshooting cannot be performed.)
12 Defective engine controller
If failure is not found by above checks, engine controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
D375A-6 (06)
40-25
40-255
DRAFT Troubleshooting by failure code Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1228] EGR Valve Servo Error 1 Action code E03
Failure code Abnormal EGR valve servo 1 Failure CA1228 (Engine controller system) q An abnormality has occurred in EGR valve servo (level 1). Detail of failure (Response from EGR lift sensor differs for EGR valve opening command value.) Action of conq Stops current to EGR valve (closes EGR valve). troller Problem on machine q EGR valve position can be checked with monitoring function (Code: 18100 EGR valve position Related infor(mm)). mation q Method of reproducing failure code: Turn the starting switch to ON position. 1
2
3
4 5 6 7 8 9
Cause Defect in related system
Procedure, measuring location, criteria and remarks If another failure code is indicated, carry out troubleshooting for it. a For measurement of EGR valve drive pressure, see Testing and adjusting, “ Measuring EGR valve and bypass valve drive pressure” . Engine speed EGR valve drive pressure Improper EGR valve drive Low idle Min. 1.18 MPa {12 kg/cm2} pressure High idle Min. 1.43 MPa {14.6 kg/cm2} If EGR valve drive pressure is not normal, check items 3 and 4. a For check of engine oil pressure, see Testing and adjusting, "Testing engine oil pressure". Engine Engine oil pressure Defective engine hydraulic Low idle Min. 0.08 MPa {0.8 kg/cm2} system (main circuit) High idle Min. 0.21 MPa {2.1 kg/cm2} If engine oil pressure is not normal, preform troubleshooting (S mode) for mechanical system. (S-12 Oil pressure lowers.) Defective oil pipe for EGR Oil pump relief valve for the EGR valve circuit may be defective, directly check it. valve Defective oil pipe for EGR Oil pipe for the EGR valve circuit may be defective, directly check it. valve Defective oil return pipe for Oil return pipe for the EGR valve circuit may be defective, directly check it. EGR valve Defective EGR valve EGR valve may be defective, directly check it. Defective EGR valve lift Perform troubleshooting for failure code [CA2271]. sensor If causes 1 – 8 are not cause of faillure, engine controller may be defective. (Since Defective engine controller failure is in it, troubleshooting cannot be performed.)
40-256
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1625] EGR Valve Servo Error 2 Action code E03
Failure code Abnormal EGR valve servo 2 Failure CA1625 (Engine controller system) q An abnormality has occurred in EGR valve servo (level 2). Detail of failure (Response from EGR lift sensor differs for EGR valve opening command value.) Action of con- q Limits engine output and allows engine to run. troller q Stops current to EGR valve (closes EGR valve). Problem on q Engine output drops. machine q EGR valve position can be checked with the monitoring function (Code: 18100 EGR valve position Related infor(mm)). mation q Method of reproducing failure code: Turn the starting switch to ON position. Cause
D375A-6 (01)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA1228].
40-257
DRAFT Troubleshooting by failure code Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1633] KOMNET Datalink Timeout Error Action code Failure code CAN (KOMNET) communication disconnection Failure E03 CA1633 (Engine controller system) Detail of fail- q Engine controller detected communication error in CAN (KOMNET) communication circuit between ure engine controller and power train controller ,work equipment controller or machine monitor. Action of con- q Controls engine in default mode, and holds state at the time of abnormally. troller q If cause of failure disappears, system resets itself. q Information may not be transmitted normally through CAN (KOMNET) communication and machine Problem on may not operate normally. machine (Trouble phenomenon depends on failed section.) Related inforq Method of reproducing failure code: Start engine. mation Cause
40-258
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DB2RKR].
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2185] Throt Sens Sup Volt High Error Action code E03 Detail of failure Action of controller Problem on machine Related information
q
Failure code Throttle sensor power supply voltage is too high Failure CA2185 (Engine controller system) High voltage (approx. 5.25 V) was detected in throttle sensor power supply circuit.
q
Controls engine with decelerator pedal position at fixed value.
q
Engine speed cannot be controlled with decelerator pedal.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective throttle sensor (decelerator pedal)
3
Short circuit in wiring harness
Hot short in wiring harness 4 (Short circuit to 24 V circuit) 5
Defective engine controller
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector DEC and turn starting switch to ON position. If this failure code is not displayed, throttle sensor is defective. a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [CA2185]. 1. Turn starting switch to OFF position. 2. Disconnect connectors EGC2, EGC3 and DEC, and connect T-adapters to female side of EGC2 and EGC3. Between EGC2 (female) (22) and each pin other than Resistance Min. 1 MΩ EGC2 (female) (22) pin Between EGC2 (female) (22) and EGC3 (female)(3) Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector DEC and connect T-adapter to female side. 3. Turn starting switch to ON position. Between DEC(female)(A) and ground Voltage 4.75–5.25V 1. Turn starting switch to OFF position. 2. Disconnect connector EGC2 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between EGC2 (female) (22) and (23) Voltage 4.75–5.25V
Circuit diagram related to decelerator pedal
D375A-6 (01)
40-259
Troubleshooting by failurecode Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error Action code
Failure code Failure
E03 Detail of failure Action of controller Problem on machine Related information
CA2186
Throttle sensor power supply voltage is too low (Engine controller system)
q
Low voltage was detected in throttle sensor power supply circuit.
q
Controls engine with decelerator pedal postion at fixed value.
q
Engine speed cannot be controlled with decelerator pedal.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
40-260
Procedure, measuring location, criteria and remarks
Defective wiring 1 harness connector
2
3
4
5
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting". 1. Turn starting switch to OFF position. Defective throttle 2. Disconnect connector DEC and turn starting switch to ON position. sensor (decelerator If this failure code is not displayed, throttle sensor is defective. a Other failure code is displayed together. This is because that the sensor connector is dispedal) connected. Ignored except the failure code other than [CA2186]. Ground fault of wir- 1. Turn starting switch to OFF position. ing harness 2. Disconnect connectors EGC2 and DEC and connect T-adapters to either female side. (Contact with Between EGC2 (female) (22) or DEC (female) (A) and ground Resistance Min. 1 Mz ground circuit) 1. Turn starting switch to OFF position. 2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of EGC2. Short circuit in wir3. Turn starting switch to ON position. ing harness Between EGC2 (female) (22) and each pin other than EGC2 Resistance Min. 1 Mz (female) (22) pin 1. Turn starting switch to OFF position. 2. Disconnect connector EGC2 and connect T-adapter to male side. Defective engine 3. Turn starting switch to ON position with connecting engine wiring harness disconnected. controller Between EGC2 (female) (22) and (23)
Circuit diagram related to decelerator pedal
40-260
Voltage
4.75–5.25V
40-260
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error Failure Supply pump no-pressure feed error 2 Failure code (Engine controller system) E03 CA2249 Detail of failure q No-pressure feed error (level 2) in supply pump was detected. Action of conq Limits common rail pressure. troller Problem on q Engine output drops. machine q The signal voltage from the common rail pressure sensor can be checked with the monitoring function (Code: 36401 (V)). Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring mation function (Code: 36400 (MPa)). q Method of reproducing failure code: Start engine. Action code
Cause
D375A-6 (01)
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA559] .
40-261
Troubleshooting by failurecode Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2271] EGR Valve Pos Sens High Error Action code
Failure code Failure
E03
CA2271
40-262
EGR valve lift sensor signal voltage is too high. (Engine controller system)
Detail of failure
q
High voltage was detected in EGR valve lift sensor signal circuit.
Action of controller Problem on machine
q q
Limits engine output and continues operation. Closes the EGR valve.
q
Engine output drops.
q
Signal voltage from EGR valve lift sensor can be checked with monitoring function (Code: 18101 (V)). Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code: 18100 (mm). Method of reproducing failure code: Start engine.
Related information
q q
Cause
Procedure, measuring location, criteria and remarks
Defective wiring 1 harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described in "Check before troubleshooting" of "General information on troubleshooting".
Defective sensor 2 power supply system
If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
Defective EGR 3 valve lift sensor (internal defect) Short circuit in wir4 ing harness Hot short in wiring 5 harness (contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector SEGR. 3. Turn starting switch to ON position (with connector SEGR disconnected). If failure code changes from [CA2271] to [CA2272], sensor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and SEGR, and connect T-adapters to either female side. Between ENG (female) (37) and (19), between SEGR (female) Resistance Min. 1 Mz (1) and (3), or between SEGR (female) (1) and (4) 1. Turn starting switch to OFF position. 2. Disconnect connector SEGR and connect T-adapter to female side. 3. Turn starting switch to ON position (with connector SEGR disconnected). Between SEGR (female) (3) or (4) and (2)
Voltage
Max. 1 V
If cause is not found by the above checks, engine controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.) 6
Defective engine controller
q Reference; the following is standard value in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ENG. 3. Turn starting switch to ON position.
Between ENG(19) and (47)
40-262
Voltage
1.0 – 4.0 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [CA2271] EGR Valve Pos Sens High Error
Circuit diagram related to EGR valve
D375A-6 (01)
40-263
DRAFT Troubleshooting by failure code Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2272] EGR Valve Pos Sens Low Error Action code E03 Detail of failure Action of controller Problem that appears on machine Related information
q
Failure code EGR valve lift sensor signal voltage is too low. Failure CA2272 (Engine controller system) The signal of EGR valve lift sensor circuit is abnormally low. Limits engine output and continues operation. Closes the EGR valve.
q
Engine output drops.
q
The signal (voltage) from the EGR valve lift sensor can be checked with the monitoring function (Code: 18101 (V)). Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code: 18100 (mm)). Method of reproducing failure code: Start engine.
q q
q q
Cause
1
2
3
4
5
6
7
Procedure, measuring location, criteria and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on troubleconnector shooting" section, and check them directly. If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. Defective sensor power 2. Disconnect connector SEGR and connect T-adapter to female side. supply system 3. Turn starting switch to ON position. Power supBetween SEGR (female) (1) and (2) Voltage 4.75 – 5.25 V ply 1. Turn starting switch to OFF position. 2. Disconnect connector SEGR and ENG, and connect T-adapters to each female side. a If power supply voltage in check on cause 2 is norDisconnection in wiring harmal, this check is not required. Resistance Max. 1 Ω ness Between ENG (female) (37) and SEGR (female) (1) (Disconnection in wiring or a If power supply voltage in check on cause 2 is nordefective contact in connecmal, this check is not required. Resistance Max. 1 Ω tor) Between ENG (female) (47) and SEGR (female) (2) Between ENG (female) (19) and SEGR (female) (3) and, between ENG (female) (19) and SEGR (female) Resistance Max. 1 Ω (4), (Sensor output) 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of ness either of them. (Contact with GND circuit) Between ENG (female) (19) and ground, or between Resistance Min. 1 MΩ SEGR (female) (3) and ground 1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of either of them. ness Between ENG (female) (19) and (47), or between Resistance Min. 1 MΩ SEGR (female) (2) and (3) a If cause items 1 - 5 are not the cause for the trouble and check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. Defective EGR valve lift 2. Insert T-adapter into connector ENG or SEGR. sensor 3. Turn starting switch to ON position. Between ENG(19) and (47), or between SEGR (3) and Voltage 0.5 – 4.5 V (2) If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the failure is in it, troubleshooting cannot be performed.)
40-264
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA2272] EGR Valve Pos Sens Low Error
Circuit diagram related to EGR valve
D375A-6 (01)
40-265
DRAFT Troubleshooting by failure code Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2351] EGR Valve Sol Current High Error Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q
Failure code Short circuit in power supply line to EGR valve solenoid Failure CA2351 (Engine controller system) Short circuit was detected in the power supply line to EGR valve solenoid. Limits engine output and continues operation. Closes the EGR valve.
q
Engine output drops.
q
Method of reproducing failure code: Turn the starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective EGR valve solenoid (internal disconnection)
3
Disconnection or short circuit in wiring harness
4 Short circuit in wiring harness
5
Hot short (Short circuit with 24 V circuit) in wiring harness
6 Defective engine controller
40-266
Procedure, measuring location, criteria and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector EGR and connect T-adapter to male side. Between EGR (male) (1) and (2) Resistance 10 - 21 Ω Between EGR (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to male side. a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring harness has short circuit. Between ENG (male) (22) and (11) Resistance 10 - 21 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and EGR, and connect T-adapter to female side of either of them. Between ENG (female) (22) and (11), or Resistance Min. 1 MΩ between EGR (female) (1) and (2) 1. Turn starting switch to OFF position. 2. Disconnect connector EGR and connect T-adapter to male side. 3. Turn starting switch to ON position (with connector EGR disconnected). Between EGR (female) (1) and (2) Voltage Max. 1 V If cause is not found by the above checks, engine controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA2351] EGR Valve Sol Current High Error
Circuit diagram related to EGR valve
D375A-6 (01)
40-267
DRAFT Troubleshooting by failure code Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2352] EGR Valve Sol Current Low Error Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code CA2352
Disconnection error was detected in power supply line to EGR valve solenoid.
q q
Limits engine output and continues operation. Closes the EGR valve.
q
Engine output drops.
q
Method of reproducing failure code: Turn the starting switch to ON position.
Defective wiring harness connector
Defective EGR valve sole2 noid (Internal disconnection)
3
Disconnection or short circuit in wiring harness
Disconnection in wiring harness (Disconnection or 4 defective contact in connector)
5 Defective engine controller
40-268
Disconnection in power supply line to EGR valve solenoid drive system (Engine controller system)
q
Cause 1
Failure
Procedure, measuring location, criteria and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector EGR and connect T-adapter to male side. Between EGR (male) (1) and (2) Resistance 10 - 21 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector ENG and connect T-adapter to female side. a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring harness has short circuit. Between ENG (female) (22) and (11) Resistance 10 - 21 Ω a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENG and EGR, and connect T-adapters to female side of them. ResisBetween ENG (female) (22) and EGR (female) (1) Max. 1 Ω tance ResisBetween ENG (female) (11) and EGR (female) (2) Max. 1 Ω tance If no abnormality is found by the above checks, engine controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [CA2352] EGR Valve Sol Current Low Error
Circuit diagram related to EGR valve
D375A-6 (01)
40-269
DRAFT Troubleshooting by failure code Failure code [D110KB] Battery Relay: Drive Short Circuit
Failure code [D110KB] Battery Relay: Drive Short Circuit Action code – Detail of failure Action of controller Problem on machine
q
Failure code Short circuit in battery relay drive circuit Failure D110KB (Work equipment controller system) Abnormal current flowed when outputting 24 V to battery relay primary circuit (coil side).
q
Stops 24 V output to battery relay primary circuit (coil side).
q
Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
q
Output condition (voltage) to battery relay primary circuit (coil side) can be checked with monitoring function. (Code 60600: Battery relay drive voltage) Method of reproducing failure code: Turn starting switch from ON to OFF.
Related information q
Cause Defective battery relay 1 (Internal short circuit) Ground fault of wiring har2 ness (Contact with GND circuit)
3
Defective work equipment controller
40-270
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Between terminals SW and BRE Continuity 1. Turn starting switch to OFF position. 2. Disconnect negative battery cable (in order not to make short circuit). 3. Disconnect cable from terminal BRE and disconnect connector WECN3. Between terminal SW and ground Resistance Min. 1 MΩ If cause is not found by the above checks, work equipment controller is defective. q Reference: the following is standard value in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN3. 3. Turn starting switch to ON position. Between WECN3 (4) and ground Voltage 20 – 30 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D110KB] Battery Relay: Drive Short Circuit
Circuit diagram related to battery relay
D375A-6 (01)
40-271
DRAFT Troubleshooting by failure code Failure code [D130KA] Neutral relay: Disconnection
Failure code [D130KA] Neutral relay: Disconnection Action code E02 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Open cricuit in neutral safety relay Failure D130KA (Power train controller system) No voltage is applied to neutral safety relay primary circuit (coil side) when controller stopped grounding.
q
Stops grounding to neutral safety relay primary circuit (coil side).
q
Engine does not start.
q
Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW output) Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever to Free position. This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side). If PTCN2 (8) has ground fault, engine can start even if PCCS lever is not set to Neutral position.
q q q
Cause Defective neutral safety relay 1 (Internal disconnection or short circuit)
2
3
4
5
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector NSF and connect T-adapter to male side. Between NSF (male) (1) and (2)
Resistance
200 – 400 Ω
1. Turn starting switch to OFF position. Disconnection or short 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of them. circuit in wiring hara If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring ness harness has short circuit. Between KEY (female) (1) and PTCN2 (female) (8) Resistance 200 – 400 Ω a If cause 2 is not the cause for the trouble, this check is not required. Disconnection in wir- 1. Turn starting switch to OFF position. ing harness 2. Disconnect connectors PTCN2, NSF and KEY, and connect T-adapters to female side (Disconnection or of them. defective contact) Between PTCN2 (female) (8) and NSF (female) (2) Resistance Max. 1 Ω Between KEY (female) (1) and NSF (female) (1) Resistance Max. 1 Ω Ground fault of wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to female side of (Contact with ground them. circuit) Between NSF (female) (2) or PTCN2 (female) (8) and ground Resistance Min. 1 MΩ If cause is not found by the above checks, power train controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train 2. Insert T-adapter into connector PTCN2. controller 3. Turn starting switch to ON position. 4. Operate parking brake lever and troubleshoot. Lever: FREE Voltage 20 – 30 V Between PTCN2 (8) and ground Lever: LOCK Voltage Max. 1 V
40-272
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D130KA] Neutral relay: Disconnection
Circuit diagram related to neutral safety relay
D375A-6 (01)
40-273
DRAFT Troubleshooting by failure code Failure code [D130KB] Neutral relay: Short circuit
Failure code [D130KB] Neutral relay: Short circuit Action code E02 Detail of failure Action of controller Indication of problem on machine
Related information
q
Failure code Short circuit in neutral safety relay Failure D130KB (Power train controller system) Abnormal current flowed in neutral safety relay primary circuit (coil side) when controller grounded neutral safety relay.
q
Stops grounding to neutral safety relay primary circuit (coil side).
q
Engine does not start.
q
Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW output) Method of reproducing failure code: Turn the starting switch to ON position and operate parking brake lever to LOCK position. This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side).
q q
Cause Defective neutral safety relay 1 (Internal disconnection or short circuit)
2
Disconnection or short circuit in wiring harness
Hot short in wiring harness 3 (Short circuit with 24 V circuit)
4
Defective power train controller
40-274
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector NSF and connect T-adapter to male side. Between NSF (male) (1) and (2)
Resistance
200 - 400 Ω
1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of them. a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring harness has short circuit. Between KEY (female) (1) and PTCN2 (female) (8) Resistance 200 - 400 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and NSF, and connect T-adapter to female side of PTCN2. 3. Turn starting switch to ON position. Between PTCN2 (female) (8) and ground Voltage Max. 1 V If cause is not found by the above checks, power train controller is defective. q Reference: the following are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. 3. Turn starting switch to ON position. 4. Operate parking brake lever and troubleshoot. Lever: FREE Voltage 20 – 30 V Between PTCN2 (8) and ground Lever: LOCK Voltage Max. 1 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D130KB] Neutral relay: Short circuit
Circuit diagram related to neutral safety relay
D375A-6 (01)
40-275
DRAFT Troubleshooting by failure code Failure code [D161KA] Back-up alarm releay: Disconnection
Failure code [D161KA] Back-up alarm releay: Disconnection Action code E01 Failure description Action of controller Indication of problem on machine
Related information
q
Failure code Disconnection in Backup alarm relay Trouble D161KA (Power train controller system) No voltage is applied to backup alarm relay primary circuit (coil side) when controller stopped grounding.
q
Stops grounding to backup alarm relay primary circuit (coil side).
q
Backup alarm does not sound.
q
Output condition to backup alarm relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW output) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever to neutral. This failure code detects failure on primary side (coil side) of backup alarm relay, but not in secondary side (contact side). If pin PTCN2(18) has ground fault, backup alarm keeps sounding.
q q q
Cause 1 Defective fuse FS22-5 Defective backup alarm relay 2 (Internal disconnection or short circuit)
3
4
5
6
Procedure, measuring location, criteria and remarks If fuse FS22-5 is blown out, circuit probably has ground fault. In this case, perform troubleshooting for cause 5 first. 1. Turn starting switch to OFF position. 2. Disconnect connector BKA and connect T-adapter to male side. Between BKA (female)(1) and (2)
Resistance
200 – 400 Ω
Turn starting switch to OFF position. Remove fuse FS22-5. Disconnection or short cirDisconnect connector PTCN2 and connect T-adapter to female side. cuit in wiring harness If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring harness has short circuit. Between PTCN2 (female) (18) and FS22-5 Resistance 200 – 400 Ω a If cause 3 is not the cause for the trouble, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and BKA and connect T-adapters to each female (Disconnection or defective side. contact) Between PTCN2 (female) (18) and BKA (female) (2) Resistance Max. 1 Ω Between FS22-5 and BKA (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Remove fuse FS22-5. 3. Disconnect connector PTCN2 and connect T-adapter to female side. ness Resistance Min. 1 MΩ (Contact with ground circuit) Between BKA(female) (1) and ground Between BKA (female) (2) or PTCN2 (female) (18) and Resistance Min. 1 MΩ ground If cause is not found by the above checks, power train controller is defective. q Reference: the following is standard value in normal condition. 1. Turn starting switch to OFF position. Defective power train con- 2. Insert T-adapter in connector PTCN2. troller 3. Turn starting switch to ON position. 4. Operate PCCS lever and perform troubleshooting. Between PTCN2(18) and N Voltage 20 – 30 V R(Reverse) Voltage Max. 1 V chassis ground
40-276
1. 2. 3. a
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D161KA] Back-up alarm releay: Disconnection
Circuit diagram related to back-up alarm relay
D375A-6 (01)
40-277
DRAFT Troubleshooting by failure code Failure code [D161KB] Back-up alarm releay: Short circuit
Failure code [D161KB] Back-up alarm releay: Short circuit Action code E01 Detail of failure Action of controller Indication of problem on machine
Related information
Failure code Short circuit in backup alarm relay Failure D161KB (Power train controller system) q Abnormal current flowed in backup alarm relay circuit when controller grounded backup alarm relay. q
Stops grounding to backup alarm relay primary circuit.
q
Backup alarm does not sound.
q
Output condition to backup alarm relay can be checked by monitoring function. (Code 40909: P/T control SW output) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever to reverse. This failure code detects failure on primary side (coil side) of backup alarm relay, but not on secondary side (contact side).
q q
Cause Defective backup alarm relay 1 (Internal disconnection or short circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector BKA and connect T-adapter to male side. Between BKA (male) (1) and (2)
Resistance
300 - 600 Ω
1. 2. 3. a
Turn starting switch to OFF position. Disconnect fuse FS22-5. Disconnection or short cirDisconnect connector PTCN2 and connect T-adapter to female side. 2 cuit in wiring harness If resistance is above1 MΩ, wiring harness is broken. If resistance is below1 Ω, wiring harness has short circuit. Between PTCN2 (female) (18) and FS22-5 Resistance 300 - 600 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and BKA and connect T-adapter to female side of Hot short in wiring harness 3 PTCN2. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between PTCN2 (female) (18) and ground Voltage Max. 1 V If cause is not found by the above checks, power train controller is defective. q Reference: the following are standard values in normal condition. 1. Turn starting switch to OFF position. Defective transmission 2. Insert T-adapter in connector PTCN2. 4 controller 3. Turn starting switch to ON position. 4. Operate PCCS lever and perform troubleshooting. N Voltage 20 – 30 V Between PTCN2(18) and ground R(Reverse) Voltage Max. 1 V
40-278
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D161KB] Back-up alarm releay: Short circuit
Circuit diagram related to back-up alarm relay
D375A-6 (01)
40-279
DRAFT Troubleshooting by failure code Failure code [D182KZ] Preheater Relay Abnormality
Failure code [D182KZ] Preheater Relay Abnormality Action code E01 Detail of failure Action of controller Indication of problem on machine
q
q
Stops grounding to preheater relay primary circuit (coil side).
q
Auto preheater does not operate (or continues to preheat). Preheater operates when it is turned ON manually.
q q
Related information
Failure code Preheater relay open or short circuit Failure D182KZ (Power train controller system) Abnormal current flowed when preheater relay primary is grounded circuit (coil side) or no voltage is applied when it is not grounded.
q q
Output to preheater relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW output) Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever to free position. This failure code detects failure on primary side (coil side) of preheater relay, but not on secondary side (contact side).
Cause Defective preheater relay 1 (Internal disconnection or short circuit)
2
3
4
5
6
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector PHR and connect T-adapter to male side. Between PHR (male) (1) and (2)
Resistance
200 – 400 Ω
1. Turn starting switch to OFF position. Disconnection or short 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of them. circuit in wiring hara If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring ness harness has short circuit. Between KEY (female) (1) and PTCN2 (female) (19) Resistance 200 – 400 Ω a If cause 2 is not the cause for the trouble, this check is not required. Disconnection in wir- 1. Turn starting switch to OFF position. ing harness 2. Disconnect connectors PTCN2, PHR and KEY, and connect T-adapters to female side (Disconnection or of them. defective contact) Between PTCN2 (female) (19) and PHR (female) (2) Resistance Max. 1 Ω Between KEY (female) (1) and PHR (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors PTCN2 and PHR, and connect T-adapters to female side of harness them. (Contact with ground Between PHR (female) (2) or PTCN2 (female) (19) and circuit) Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. Hot short in wiring har2. Disconnect connectors PTCN2 and PHR, and connect T-adapter to PTCN2 female ness connector. (Contact with 24 V cir3. Turn starting switch to ON position. cuit) Between PTCN2 (female) (19) and ground Voltage Max. 1 V If cause is not found by the above checks, power train controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train 2. Insert T-adapter into connector PTCN2. 3. Turn starting switch to ON position. controller Auto preheater Voltage 20 – 30 V not operated Between PTCN2 (19) and ground Auto preheater Voltage Max. 1 V operated
40-280
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D182KZ] Preheater Relay Abnormality
Circuit diagram related to preheater relay
D375A-6 (01)
40-281
DRAFT Troubleshooting by failure code Failure code [D190KA] ACC signal relay: Disconnection
Failure code [D190KA] ACC signal relay: Disconnection Action code E00 Detail of failure Action of controller Problem on machine
Related information
q
Failure code ACC signal drive relay disconnection Failure D190KA (Work equipment controller system) No voltage is applied to engine holding relay (EHL) primary circuit (coil side) when no grounding.
q
Stops grounding to engine holding relay (EHL) primary circuit (coil side).
q
Turbocharger timer does not function (if the turbocharger timer is installed). Machine is not affected (if turbocharger timer is not installed). Output to engine holding relay (EHL) primary circuit (coil side) can be checked with monitoring function. (Code: 40983 W/E controller SW output) Method of reproducing failure code: Turn the starting switch to ON position This failure code detects failure on primary side (coil side) of engine holding relay (EHL), but not on secondary side (contact side). If WECN2 (18) has ground fault, engine keeps running even if starting switch is turned to OFF position.
q q q q q
Cause Procedure, measuring location, criteria and remarks Defective engine hold- 1. Turn starting switch to OFF position. ing relay (Internal dis- 2. Disconnect connector EHL and connect T-adapter to male side. 1 connection or short Between EHL (male) (1) and (2) Resistance 200 – 400 Ω circuit) 1. Turn starting switch to OFF position. Disconnection or short 2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of them. 2 circuit in wiring hara If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below ness 1 Ω, wiring harness has short circuit. Between KEY (female) (1) and WECN2 (female) (18) Resistance 200 – 400 Ω a If cause 2 is not the cause for the trouble, this check is not required. Disconnection in wir- 1. Turn starting switch to OFF position. ing harness 2. Disconnect connectors WECN2, EHL and KEY, and connect T-adapters to female side 3 (Disconnection or of them. defective contact) Between WECN2 (female) (8) and EHL (female) (2) Resistance Max. 1 Ω Between KEY (female) (1) and EHL (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors WECN2 and EHL, and connect T-adapters to female side of harness 4 them. (Contact with ground Between EHL (female) (2) or WECN2 (female) (18) and circuit) Resistance Min. 1 MΩ ground Defective work equip5 If cause is not found by the above checks, work equipment controller is defective. ment controller
40-282
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D190KA] ACC signal relay: Disconnection
Circuit diagram related to ACC signal drive relay
D375A-6 (01)
40-283
DRAFT Troubleshooting by failure code Failure code [D190KB] ACC signal relay: Short circuit
Failure code [D190KB] ACC signal relay: Short circuit Action code E00 Detail of failure Action of controller Problem on machine
Related information
q
Failure code ACC signal drive relay short circuit Failure D190KB (Work equipment controller system) No current flows when grounding to engine holding relay (EHL) primary circuit (coil side) or no voltage is applied when no grounding.
q
Stops grounding to engine holding relay (EHL) primary circuit (coil side).
q
Turbocharger timer does not function (if the turbocharger timer is installed). Machine is not affected (if turbocharger timer is not installed). Output to engine shutoff delay relay (EHL) primary circuit (coil side) can be checked by monitoring function. (Code: 40983 W/E controller SW output) Method of reproducing failure code: Turn the starting switch to ON position This failure code detects failure on primary side (coil side) of engine shutoff delay relay (EHL), but not on secondary side (contact side).
q q
q q
Cause Procedure, measuring location, criteria and remarks Defective engine hold- 1. Turn starting switch to OFF position. ing relay (Internal dis- 2. Disconnect connector EHL and connect T-adapter to male side. 1 connection or short Between EHL (male) (1) and (2) Resistance 200 – 400 Ω circuit) 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of Disconnection or short them. 2 circuit in wiring harness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring harness has short circuit. Between KEY (female) (1) and WECN2 (female) (18) Resistance 200 – 400 Ω 1. Turn starting switch to OFF position. Hot short in wiring har2. Disconnect connectors WECN2 and EHL, and connect T-adapter to female side of ness 3 WECN2. (Contact with 24 V cir3. Turn starting switch to ON position. cuit) Between WECN2 (female) (18) and ground Voltage Max. 1 V Defective work equip4 If cause is not found by the above checks, work equipment controller is defective. ment controller
40-284
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D190KB] ACC signal relay: Short circuit
Circuit diagram related to ACC signal drive relay
D375A-6 (01)
40-285
Troubleshooting by failurecode Failure code [D1EFKA] Pre lub. motor relay: Disconnection
Failure code [D1EFKA] Pre lub. motor relay: Disconnection Action code
Failure code Failure
E02 Detail of failure Action of controller Problem on machine
D1EFKA
No voltage is applied to pre-lubricating motor relay primary (coil side) circuit when grounding is cut off.
q
Stops grounding to pre-lubricating motor relay primary circuit (coil side).
q
The pre-lubricating motor does not operate. The engine does not start (engine starts if pre-lubrication is skipped). Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW Output) Method of reproducing failure code: Turn starting switch to ON position. This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on secondary side (contact side). If pin PTCN2 (9) has ground fault, pre-lubricating motor keeps running.
q
q q q
Cause
Pre-lubricating motor relay open circuit (Power train controller system)
q
q
Related information
40-286
Procedure, measuring location, criteria and remarks
Defective pre-lubri- 1. Turn starting switch to OFF position. cating motor relay 2. Disconnect connector PLUB and connect T-adapter to male side. 1 (internal open cirBetween PLUB (male) (1) and (2) Resistance 200 – 400 z cuit or short circuit) 1. Turn starting switch to OFF position. Open or short cir- 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to each female side. a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring har2 cuit in wiring harness has short circuit. ness Between KEY (female) (1) and PTCN2 (female) (9)
Resistance
200 – 400 z
a If cause item 2 is not the cause for the trouble, this check is not required. Open circuit in wir- 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2, PLUB and KEY, and connect T-adapters to each female ing harness side. 3 (Wire breakage or defective contact of Between PTCN2 (female) (9) and PLUB (female) (2) Resistance Max. 1 z connector) Between KEY (female) (1) and PLUB (female) (1) Resistance Max. 1 z Ground fault in wir- 1. Turn starting switch to OFF position. ing harness 2. Disconnect connectors PTCN2 and PLUB, and connect T-adapters to each female side. 4 (Contact with Between PLUB (female) (2) or PTCN2 (female) (9) and ground Resistance Min. 1 Mz ground circuit) If cause is not found by the above checks, power train controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power 3. Turn starting switch to ON position. 5 When pre-lubricatrain controller tion has been comVoltage 20 – 30 V Between PTCN2 (9) and ground pleted Pre-lubrication is in Voltage Max. 1 V operation.
40-286
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [D1EFKA] Pre lub. motor relay: Disconnection
Circuit diagram related to pre-lubricating motor relay
D375A-6 (01)
40-287
DRAFT Troubleshooting by failure code Failure code [D1EFKB] Pre lub. motor relay: Short circuit
Failure code [D1EFKB] Pre lub. motor relay: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
q
Failure code Pre-lubricating motor relay disconnection Failure D1EFKB (Power train controller system) No current flows when grounding to pre-lubricating motor relay primary (coil side) circuit or no voltage is applied when no grounding.
q
Stops grounding to pre-lubricating motor relay primary circuit (coil side).
q
Pre-lubricating motor does not operate. Engine does not start (engine starts if pre-lubrication is skipped). Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW output) Method of reproducing failure code: Turn the starting switch to ON position This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on secondary side (contact side).
q q q q
Cause Procedure, measuring location, criteria and remarks Defective pre-lubricat- 1. Turn starting switch to OFF position. ing motor relay 2. Disconnect connector PLUB and connect T-adapter to male side. 1 (Internal disconnection Between PLUB (male) (1) and (2) Resistance 200 – 400 Ω or short circuit) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of Disconnection or short them. 2 circuit in wiring harness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring harness has short circuit. Between KEY (female) (1) and PTCN2 (female) (9) Resistance 200 – 400 Ω 1. Turn starting switch to OFF position. Hot short in wiring har2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of ness 3 PTCN2. (Contact with 24 V cir3. Turn starting switch to ON position. cuit) Between PTCN2 (female) (9) and ground Voltage Max. 1 V If cause is not found by the above checks, power train controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Defective power train 3. Turn starting switch to ON position. 4 controller When pre-lubrication has been Voltage 20 – 30 V Between PTCN2 (9) and ground completed During pre-lubriVoltage Max. 1 V cation
40-288
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [D1EFKB] Pre lub. motor relay: Short circuit
Circuit diagram related to pre-lubricating motor relay
D375A-6 (01)
40-289
DRAFT Troubleshooting by failure code Failure code [DAFRKR] Monitor: Can communication lost (PT)
Failure code [DAFRKR] Monitor: Can communication lost (PT) Action code
Failure code
q
CAN communication with machine monitor is impossible (detected by power train controller) DAFRKR (Power train controller system) Power train controller cannot recognize machine monitor with CAN communication circuit.
q
Limits operation of engine and transmission.
q
System may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN communication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it can be observed only through KOMTRAX system. Since each controller and machine monitor receive power from battery directly, they are kept ON even while starting switch is OFF. Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.
Failure
E03 Detail of failure Action of controller Problem on machine
q q q q q
Related information q q
Cause Procedure, measuring location, criteria and remarks Defective power supply 1 Perform troubleshooting for E mode, "E-3". to machine monitor Defective CAN commu2 Perform troubleshooting for failure code [DAFRMC], cause 10 and after. nication
40-290
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [dAFRKR] Monitor: CAN communication lost (WE)
Failure code [dAFRKR] Monitor: CAN communication lost (WE) Action code
Failure code
q
CAN communication with machine monitor is impossible (detected by work equipment controller) dAFRKR (Work equipment controller system) Work equipment controller cannot recognize machine monitor with CAN communication circuit.
q
Limits operation of engine and transmission.
q
System may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN communication of machine monitor fails, code [dAFRKR] is not displayed on machine monitor and it can be observed only through KOMTRAX system. Since each controller and machine monitor receive power from battery directly, they are kept ON even while starting switch is OFF. Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.
Failure
E03 Detail of failure Action of controller Problem on machine
q q q q q
Related information q q
Cause Procedure, measuring location, criteria and remarks Defective power supply 1 Perform troubleshooting for E mode, "E-3". to machine monitor Defective CAN commu2 Perform troubleshooting for failure code [DAFRMC], cause 10 and after. nication
D375A-6 (01)
40-291
Troubleshooting by failurecode Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DAFRMC] CAN Discon (Monitor Detected) Action code
Failure code Failure
E03 Detail of failure Action of controller Problem on machine
DAFRMC q q q q q q q q q
Related information
q q q
40-293
CAN communication is impossible (Machine monitor Detected) (Machine monitor system)
Machine monitor cannot recognize power train controller, work equipment controller or VHMS controller in CAN communication. Limits operation of engine and transmission. If cause of failure disappears, machine monitor returns to normal status. System may not operate properly. Once machine is stopped, engine speed is limited to medium (half) speed. Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is sent to machine monitor by CAN communication. Accordingly, if other CAN-related failure code such as [DB2RKR] is displayed on machine monitor, there can not be ground fault, short circuit and hot short circuit in wiring harness (CAN communication line). If failurecode [DB2RKR] is also displayed, problem with engine controller, cause items 1 to 6, will be the most probable cause of the failure. Since each controller and machine monitor receive power from battery directly, they are kept ON even while starting switch is OFF. The CAN communication line signal in operation is pulse voltage, so it cannot be measured by using multimeter.
Cause Defective engine 1 controller circuit breaker (CB7) Defective engine 2 controller (Internal short circuit)
Procedure, measuring location, criteria and remarks If circuit breaker trips, controller probably has short circuit in it. a 1. 2. a a
If circuit breaker does not trip, this check is not required. Turn starting switch to OFF position. Disconnect connectors EGC3 and connect T-adapter to male side. Measured value: approx. 9 – 20 kz If measured value is below 10 z, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1)
Defective power 3 supply to engine controller
1. 2. 3. a
Resistance
Max. 10 z
Turn starting switch to OFF position. Disconnect connectors EGC3 and connect T-adapter to female side. If circuit breaker has tripped, reset it. If result is abnormal, perform troubleshooting for [CA111].
Between EGC3 (female) (3) and (1) or ground
Voltage
20 – 30 V
Between EGC3 (female) (4) and (2) or ground
Voltage
20 – 30 V
1. Turn starting switch to OFF position. Broken engine con- 2. Remove the fuse in fuse box FS32-5. 4 troller ACC fuse If fuse has blown out, the circuit probably has ground fault. In this case, perform troubleshooting for cause 14 first. Defective ACC cut5 out relay drive (for If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it first. engine controller)
40-292
D375A-6 (06)
Troubleshooting by failurecode Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause
6
7
8
9
10
Defective ACC cutout relay (for engine controller) (Internal disconnection or short circuit) Defective power supply to power train controller Defective power supply to work equipment controller Defective power supply to VHMS controller Defective CAN terminating resistor (Internal open or short circuit in wiring)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay; connector BKA, etc.) 3. Turn starting switch to ON position. If this failure code goes off, original ACC cutout relay (for engine controller) is defective. If failure code [DBERKR] or [DBBQKR] is also displayed, perform troubleshooting for failure code [DBE1KK] or [DBE2KK] first. If failure code [DB9RKR] is also displayed, perform troubleshooting for failure code [DB91KK] and [DB92KK] first.
Perform troubleshooting for failure codes [DBB0KK] and [DBB3KK]. 1. Turn starting switch to OFF position. 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them. Between CT2 (male) (A) and (B)
Resistance
120 ± 12 z
Between CM02 (male) (8) and (10)
Resistance
120 ± 12 z
q
a
1. 2. a Open or short cir11 cuit in wiring harness
CAN communication line There is 120 z CAN terminating resistor inside machine monitor, too. Since120 z resistor is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, there is no open circuit in writing harness. Turn starting switch to OFF position and disconnect ground cable. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapter to female side of that connector. If connector has short circuit (Resistance between terminals is1 z or less), disconnect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short circuit between wiring harnesses or in controller.
Between EGC2 (female) (46) and (47)
Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22)
Resistance Approx. 60 z
Between WECN2 (female) (32) and (22)
Resistance Approx. 60 z
Between V4A (female) (12) and (4)
Resistance Approx. 60 z
Between CT2 (female) (A) and (B)
Resistance
Between CM02 (female) (9) and (10)
Resistance
Approx. 120 z Approx. 120 z
a If check result of cause item 11 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapters to female side of them. Between PTCN2 (female) (32) and CM02 (female) (9)/(8)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and CM02 (female) (10)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between PTCN2 (female) (32) and V4A (female) (4)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and V4A (female) (12)
Resistance
Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A)
Resistance
Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B)
Resistance
Max. 1 z
Open circuit in wir- Between PTCN2 (female) (32) and EGC2 (female) (46) ing harness 12 (wire breakage or Between PTCN2 (female) (22) and EGC2 (female) (47) defective contact of Between PTCN2 (female) (32) and WECN2 (female) (32) connector) Between PTCN2 (female) (22) and WECN2 (female) (22)
D375A-6 (06)
40-293
Troubleshooting by failurecode Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause
Procedure, measuring location, criteria and remarks q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2. 3. Connect the ground cable and turn the starting switch to ON position.
Open circuit in wir- Between PTCN3 (14) or (24) and (31) ing harness 13 (wire breakage or Between WECN3 (14) or (24) and (31) defective contact of Between V1 (17) and (19) connector) Between CM01 (14) and (3)
Voltage
20 – 30 V
Voltage
20 – 30 V
Voltage
20 – 30 V
Voltage
20 – 30 V
Between ACT(1), (3) and ground
Voltage
20 – 30 V
Between EGC2 (39) and ground
Voltage
20 – 30 V
q CAN communication line a If another failure code related to CAN communication such as [DB2RKR] is displayed on machine monitor, this check is not required. a If check result of cause item 11 is normal (there is open cricuit), measure at only 1 place. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors PTCN2, WECN2, V4A, CM02 and EGC2, and connect T-adapters to either female side. Between PTCN2 (female) (32), WECN2 (female) (32), V4A (female) (4), CM02 (female) (8), (9) or EGC2 (female) (46) and Resistance Min. 1 Mz ground
Ground fault in wiring harness (Con- Between PTCN2 (female) (22) , WECN2 (female) (22), V4A 14 (female) (12), CM02 (female) (10) or EGC2 (female) (47) and Resistance Min. 1 Mz tact with ground ground circuit) q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapters to either female side. 3. Disconnect connectors EGC2 and connect T-adapter to female side.
Short circuit or hot short circuit in wir15 ing harness (Contact with 24 V circuit)
Between PTCN3 (female) (14), (24), WECN3 (female) (14), (24), V1 (female) (17) or CM01 (female) (14) and ground
Resistance
Min. 1 Mz
Between EGC2 (female) (39) and ground
Resistance
Min. 1 Mz
a If another failure code related to CAN communication such as [DB2RKR] is displayed on machine monitor, this check is not required. a If check result of cause item 11 is normal (there is no disconnection), measure at only 1 place each. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Insert T-adapter into connector PTCN2, WECN2, V4A, CM02 or EGC2. 3. Connect ground strap. 4. Turn starting switch to ON position. a Since voltages of CAN H and CAN L are 2.5 ± 1 V even while communication is continued, they are judged to be normal if they are 1 - 4 V. Between PTCN2 (32), WECN2 (32), V4A (4), CM02 (8), (9) or Voltage 1–4V EGC2(46) and ground Between PTCN2 (22), WECN2 (22), V4A(12), CM02( 10), or EGC2 (47) and ground
40-294
Voltage
1–4V
D375A-6 (06)
Troubleshooting by failurecode Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause
Procedure, measuring location, criteria and remarks
If cause is not found by above checks and another failure code related to CAN communication such as [DB2RKR] is not displayed, identify which controller is defective according to following procedure. q Step 1 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect engine controller (connector EGC2). 3. Connect the ground cable and turn the starting switch to ON position. Defective NO power train controller Is failure code [DB2RKR] displayed? Defective YES engine controller Defective work equipNO ment controlDefective engine Is failure code [dB2RKR] displayed? ler controller, power Defective train controller, work YES engine con16 equipment controltroller ler or VHMS conq Step 2 troller 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect power train controller (connector PTCN2). 3. Connect the ground cable and turn the starting switch to ON position. Defective work equipNO ment controlIs failure code [DBERKR] displayed? ler Defective YES power train controller Defective NO VHMS controller Is failure code [DBBQKR] displayed? Defective YES power train controller Defective machine If Failure is not found by above checks, machine monitor is defective. 17 monitor (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
40-295
DRAFT Troubleshooting by failure code Failure code [DAFRMC] CAN Discon (Monitor Detected)
Circuit diagram related to CAN
40-296
D375A-6 (01)
Troubleshooting by failurecode Failure code [DB2RKR] ENG cont.: Can communication lost (PT)
Failure code [DB2RKR] ENG cont.: Can communication lost (PT) Action code
Failure code Failure
E03
DB2RKR
40-298
CAN communication with engine controller is impossible. (detected by power train controller) (Power train controller system)
Detail of failure
q
Power train controller cannot recognize engine controller in CAN communication.
Action of controller
q
Limits operation of engine and transmission.
q
System may not operate properly. Once machine stops, engine speed is limited to half of full speed. Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [DB2RKR] is displayed on the machine monitor, CAN communication between power train controller and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short circuit in CAN communication line. If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller problem in cause1 and 2. Since each controller and machine monitor receive power from battery directly, they have power even while starting switch is OFF. Since CAN communication line signal is pulse voltage, it cannot be measured with multimeter.
Problem on machine
q q q q q
Related information
q q q
Cause Defective engine controller 1 circuit breaker (CB7)
2
Defective engine controller (Internal short circuit)
Procedure, measuring location, criteria and remarks If circuit breaker is turned OFF, controller probably has short circuit in it. a 1. 2. a a
If circuit breaker has tripped, this check is not required. Turn starting switch to OFF position. Disconnect connectors EGC3 and connect T-adapter to male side. Measured value: approximately 9-20 kz If measured value is below 10 z, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1)
3
Defective power supply to engine controller
4
Broken engine controller ACC fuse
5
Defective ACC cutout relay (for engine controller) drive
Defective ACC cutout relay (for engine controller) 6 (internal open circuit or short circuit)
Defective CAN terminating 7 resistor (Internal open or short circuit)
D375A-6 (06)
1. 2. 3. a
Resistance
Max. 10 z
Turn starting switch to OFF position. Disconnect connectors EGC3 and connect T-adapter to female side. If circuit breaker has tripped, reset it. If result is abnormal, perform troubleshooting for [CA111].
Between EGC3 (female) (3) and (1) or ground
Voltage
20 – 30 V
Between EGC3 (female) (4) and (2) or ground
Voltage
20 – 30 V
1. Turn starting switch to OFF position. 2. Remove the fuse in fuse box FS32-5. If fuse has blown out, the circuit probably has ground fault. In this case, perform troubleshooting for cause item 11 first. If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay; connector BKA, etc.) 3. Turn starting switch to ON position . If this failure code goes off, original ACC cutout relay (for engine controller) is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them. Between CT2 (male) (A) and (B)
Resistance
120 ± 12 z
Between CM02 (male) (8) and (10)
Resistance
120 ± 12 z
40-297
Troubleshooting by failurecode Failure code [DB2RKR] ENG cont.: Can communication lost (PT)
Cause
Open or short cir8 cuit in wiring harness
Procedure, measuring location, criteria and remarks q CAN communication line a There is 120 z CAN terminating resistor inside machine monitor, too. Since 120 z resistor is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, there is no open circuit in writing harness. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapter to female side of that connector. a If connector has short circuit (Resistance between terminals is1 z or less), disconnect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short circuit between wiring harnesses or in controller. Between EGC2 (female) (46) and (47) Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22)
Resistance
Approx. 60 z
Between WECN2 (female) (32) and (22)
Resistance
Approx. 60 z
Between V4A (female) (12) and (4)
Resistance
Approx. 60 z
Between CT2 (female) (A) and (B)
Resistance
Approx. 120 z
Between CM02 (female) (9) and (10) Resistance Approx. 120 z a If check result of cause item 8 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapters to female side of them. Between PTCN2 (female) (32) and CM02 (female) (9)/(8) Resistance Max. 1 z Identifying open circuit in wiring harness (Wire 9 breakage or defective contact of connector)
Between PTCN2 (female) (22) and CM02 (female) (10)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and EGC2 (female) (46)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and EGC2 (female) (47)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and WECN2 (female) (32)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and WECN2 (female) (22)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and V4A (female) (4)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and V4A (female) (12)
Resistance
Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A)
Resistance
Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B) Resistance Max. 1 z q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2. Open circuit in wir- 3. Connect the ground cable and turn the starting switch to ON position. Between PTCN3 (14) or (24) and (31) Voltage 20 – 30 V ing harness 10 (wire breakage or Between WECN3 (14) or (24) and (31) defective contact of Between V1 (17) and (19) connector) Between CM01 (14) and (3) Between ACT(1), (3) and ground
Voltage
20 – 30 V
Voltage
20 – 30 V
Voltage
20 – 30 V
Voltage
20 – 30 V
Between EGC2 (39) and ground Voltage 20 – 30 V q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. Ground fault in wir- 2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapters to either female side. ing harness (Con11 3. Disconnect connectors EGC2 and connect T-adapter to female side. tact with ground Between PTCN3 (female) (14), (24), WECN3 (female) (14), circuit) Resistance Min. 1 Mz (24), V1 (female) (17) or CM01 (female) (14) and ground Between EGC2 (female) (39) and ground 12
Defective engine controller
13
Defective power train controller
40-298
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) If cause is not found by the above checks, power train controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DB2RKR] ENG cont.: Can communication lost (PT)
Circuit diagram related to CAN
D375A-6 (01)
40-299
DRAFT Troubleshooting by failure code Failure code [dB2RKR] ENG controller: CAN communication lost (WE)
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) Action code
Failure code
E03 Detail of failure Action of controller Problem on machine
q q
Limits operation of engine, transmission, and fan.
q
System may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn starting switch ON. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [dB2RKR] is displayed on machine monitor, CAN communication between work equipment controller and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN communication line. If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller problem. Since each controller and machine monitor receive power from battery directly, they are kept ON even while starting switch is OFF. Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.
q q q q q
Related information
q q q
Cause
40-300
CAN communication with engine controller is impossible (detected by work equipment controller) dB2RKR (Work equipment controller system) Work equipment controller cannot recognize engine controller in CAN communication circuit. Failure
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DB2RKR].
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DB90KT] WE controller: Abnormality in controller
Failure code [DB90KT] WE controller: Abnormality in controller Action code Failure code Data recorded in work equipment controller are abnormal Failure E01 DB90KT (Work equipment controller system) Detail of failure q Information in ROM (non-volatile memory) in work equipment controller is abnormal. Action of conq Reset internal adjustment values to default values. troller Appears on q Operating feel of work equipment may become bad. machine q Adjusting function by machine monitor may not operate properly. Related inforq Method of reproducing failure code: Turn starting switch ON. mation Cause
Procedure, measuring location, criteria and remarks Use Adjustment function in service mode, and perform operation of reproducing trouble. Defective adjustment of 1 If "E" of failure code disappears at this time, system is normal. work equipment controller q Adjustment code: 0031 (Initialization of work equipment controller) Defective work equipment Troubleshooting cannot be carried out since defect is in work equipment controller. (If 2 controller there is no visible trouble in machine, controller may be used as it is.)
D375A-6 (01)
40-301
DRAFT Troubleshooting by failure code Failure code [DB91KK] WE controller: Source voltage reduction
Failure code [DB91KK] WE controller: Source voltage reduction Action code E04 Detail of failure Action of controller Problem on machine
q
Failure code Battery direct voltage drop of work equipment controller Failure DB91KK (Work equipment controller system) The battery direct power supply voltage for work equipment controller is below 17 V.
q
Limits operation of engine, transmission, brake and work equipment.
q
Machine monitor may not display properly. Relay and solenoid may not be actuated and therefore, system may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, it becomes impossible to travel. Main power source voltage for work equipment controller can be checked in adjusting function. (Code 2022: Work equipment controller voltage check mode) Method of reproducing failure code: Turn starting switch ON.
q q q
Related information
q q
Cause Trip of circuit breaker 1 (CB30)
Procedure, measuring location, criteria and remarks If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first. If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trouble2 Defective fuse FS12-4 shooting for cause 7 first. Loose terminal or dis- 1. Turn starting switch to OFF position. 3 connection at terminal Check terminals of battery, battery relay, etc. Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine. 4 age Between battery (+) and (-) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Disconnection in, or 3. Disconnect connector WECN3 and connect T-adapter to female side. 5 ground fault of wiring 4. Connect ground strap. harness a If voltage is 0 V, wiring harness has open cricuit or ground fault. Between WECN3 (female) (1) and (21)/(31) Voltage 20 – 30 V Between WECN3 (female) (11) and (32)/(33) Voltage 20 – 30 V a If cause item 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Disconnection in wir- 3. If fuse has blown out, replace it. ing harness 4. If circuit breaker has tripped, reset it. 6 (Disconnection or 5. Disconnect connector WECN3 and connect T-adapter to female side. defective contact) Between WECN3 (female) (21), (31), (32) or (33) and Resistance Max. 1 Ω ground a Check terminal GND01 for looseness and rust. Between WECN3 (female) (1) or (11) and battery (+) Resistance Max. 1 Ω a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect ground strap. harness 3. If fuse has blown out, replace it. 7 (Contact with ground 4. If circuit breaker has tripped, reset it. circuit) 5. Disconnect connector WECN3 and connect T-adapter to female side. Between WECN3 (female) (1) and (21)/(31) Resistance Min. 1 MΩ Between WECN3 (female) (11) and (32)/(33) Resistance Min. 1 MΩ If cause is not found by above checks, work equipment controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective work equip- 2. Disconnect ground strap. 8 ment controller 3. Insert T-adapter into connector WECN3. 4. Connect ground strap. Between WECN3 (1) and (21)/(31) Voltage 20 – 30 V Between WECN3 (11) and (32)/(33) Voltage 20 – 30 V
40-302
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DB91KK] WE controller: Source voltage reduction
Circuit diagram related to power supply for work equipment controller
D375A-6 (01)
40-303
DRAFT Troubleshooting by failure code Failure code [DB92KK] WE controller: Output voltage reduction
Failure code [DB92KK] WE controller: Output voltage reduction Action code
Failure code
E04 Detail of failure Action of controller Indication of problem on machine Related information
Voltage drop in power supply for work equipment controller-related actuators DB92KK (Work equipment controller system) Power supply (battery relay output) voltage for the actuators related to work equipment controller (relay, solenoid or others) is below 17 V. Failure
q
q
Limits operation of engine, transmission, brake and work equipment.
q
Relay and solenoid may not be actuated and therefore, system may not operate properly. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel. Power source voltage of work equipment controller can be checked in adjusting function. (Code 2022: Work equipment controller voltage check mode) Method of reproducing failure code: Turn the starting switch to ON position.
q q q q
Cause Trip of circuit breaker 1 CB3 or CB105 Loose terminal or dis2 connection at terminal Improper battery volt3 age
4
5
6
7
Procedure, measuring location, criteria and remarks If CB3 or CB105 circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc. 1. Perform troubleshooting with starting switch at OFF and when starting engine. Between battery (+) and (-) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Insert T-adapter into connector WECN3. Defective wiring har4. Connect ground strap. ness or power train 5. Turn starting switch to ON position. controller Between WECN3 (2) and (21) Voltage 20 – 30 V Between WECN3 (12) and (31) Voltage 20 – 30 V Between WECN3 (22) and (32) Voltage 20 – 30 V a If cause item 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wir- 2. Disconnect ground strap (in order not to make short circuit). 3. Disconnect connector WECN3 and connect T-adapter to female side. ing harness Between ground and WECN3 (female) (21)/(31)/(32)/ (Disconnection or (33) respectively Resistance Max. 1 Ω defective contact) a Check terminal GND01 for looseness and rust. Between terminal BRC and WECN3 (female) Resistance Max. 1 Ω (2)/(12)/(22) respectively a If cause 4 is not the cause for the trouble, this check is not required. Ground fault of wiring 1. Turn starting switch to OFF position. harness 2. Disconnect ground strap (in orde not to make short circuit). (Contact with GND cir- 3. If circuit breaker has tripped, reset it. cuit) 4. Disconnect connector WECN3. Between terminal BRC and ground Resistance Min. 1 MΩ Defective work equipIf cause is not found by above checks, work equipment controller is defective. ment controller
40-304
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DB92KK] WE controller: Output voltage reduction
Circuit diagram related to power supply for work equipment controller
D375A-6 (01)
40-305
DRAFT Troubleshooting by failure code Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction Action code ―
Failure code Work equipment sensor 5 V power supply abnormality Failure DB97KK (Work equipment controller system) q Voltage of 5 V power supply circuit for work equipment controller sensor is below 4.5 V or above 5.5 Detail of failure V. q Abnormal current flowed in 5 V power supply circuit for work equipment controller sensor. Action of conq Stops output to 5 V power supply circuit if abnormal voltage flows. troller Problem on q Hydraulic pressure of work equipment pump cannot be monitored correctly (but machine operations are not affected). machine Related inforq Method of reproducing failure code: Turn the starting switch to ON position mation Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector HHP. Defective hydraulic pump 3. Turn starting switch to ON position. pressure sensor (Internal q If this code is not displayed when hydraulic pump pressure sensor is disconnected, defect) that sensor is defective. a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DB97KK]. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors WECN3 and HHP, and connect T-adapter to female side of ness either one of them. (Contact with ground cirBetween WECN3 (female) (34) or HHP (female) (B) and Resiscuit) Min. 1 MΩ ground tance 1. Turn starting switch to OFF position. Short circuit in wiring har- 2. Disconnect connector HHP and connect T-adapter to female side. ness 3. Turn starting switch to ON position. Between HHP (female) (B) and (A) Voltage 4.5 – 5.5 V If cause is not found by the above checks, work equipment controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. Defective work equipment 2. Insert T-adapters into connectors WECN1 and WECN3. controller 3. Turn starting switch to ON position. a Since 24 V power is supplied to connector WECN3, 5 V output cannot be checked with connector WECN3 disconnected. Between WECN3(34) and WECN1(21) Voltage 4.5 – 5.5 V
40-306
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction
Circuit diagram related to work equipment controller sensors 5 V power supply
D375A-6 (01)
40-307
DRAFT Troubleshooting by failure code Failure code [DB99KQ] WE controller: Type select signal
Failure code [DB99KQ] WE controller: Type select signal Action code E04
Failure code Machine model selection error on work equipment Failure DB99KQ (Work equipment controller system) q Specification setting in work equipment controller does not match specification setting memory (Initial Detail of failure setting of work equipment controller has not yet been performed). Action of con- q Turns all outputs from work equipment controller OFF. troller q Limits operation of engine, transmission, brake and work equipment. q Machine does not move at all. Problem on q Once machine is stopped, engine speed is limited to half of full speed. machine q Once machine stops, it cannot travel at all. Related inforq Method of reproducing failure code: Turn the starting switch to ON position. mation Causes 1
Defective adjustment of work equipment controller
40-308
Procedure, measuring location, criteria and remarks Use adjustment function in service mode, and perform operation of reproducing trouble. If “E” of failure code disappears at this time, system function is proper. q Adjustment code: 0031 (Initial setting of work equipment controller)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DB9RKR] WE controller: Can communication lost (PT)
Failure code [DB9RKR] WE controller: Can communication lost (PT) Action code
Failure code
q
CAN communication with work equipment controller (detected power train controller) DB9RKR (Power train controller system) Power train controller cannot recognize work equipment controller in CAN communication circuit.
q
Limits operation of engine and transmission.
q
System may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn the starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [DB9RKR] is displayed on the machine monitor, CAN communication between power train controller and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN communication line. Since each controller and machine monitor receive power from battery directly, they are kept ON even while starting switch is OFF. Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.
Failure
E03 Detail of failure Action of controller Problem on machine
q q q q q
Related information q q
Cause Defective power supply to 1 work equipment controller
Procedure, measuring location, criteria and remarks If failure code [DAFRMC] is also displayed, perform troubleshooting for failure code [DB91KK] and [DB92KK] first. 1. Turn starting switch to OFF position. Defective CAN terminating 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of resistor 2 them. (Internal disconnection or Between CT2 (male) (A) and (B) Resistance 120 ± 12 short circuit) Between CM02 (male) (8) and (10) Resistance 120 ± 12 q CAN communication line a There is 120 Ω CAN terminating resistor inside machine monitor, too. Since 120 Ω resistor is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 Ω which is combined resistance, wiring harness is not open cricuited. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapter to female side of that connector. Disconnection or short cir3 a If connector has short circuit (Resistance between terminals is1 Ω or less), disconcuit in wiring harness nect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short circuit between wiring harnesses or in controller. Between EGC2 (female) (46) and (47) Resistance Approx. 60 Ω Between PTCN2 (female) (32) and (22) Resistance Approx. 60 Ω Between WECN2 (female) (32) and (22) Resistance Approx. 60 Ω Between V4A (female) (12) and (4) Resistance Approx. 60 Ω Between CT2 (female) (A) and (B) Resistance Approx. 120 Ω Between CM02 (female ) (9) and (10) Resistance Approx. 120 Ω
D375A-6 (01)
40-309
Troubleshooting by failurecode Failure code [DB9RKR] WE controller: Can communication lost (PT)
Cause
Procedure, measuring location, criteria and remarks a If check result of cause 3 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapters to female side of them. Between PTCN2 (female) (32) and CM02 (female) Resistance Max. 1 z (9)/(8) Between PTCN2 (female) (22) and CM02 (female) (10)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and EGC2 (female) (46) Open circuit in wiring harBetween PTCN2 (female) (22) and EGC2 (female) (47) ness 4 (wire breakage or defective Between PTCN2 (female) (32) and WECN2 (female) contact of connector) (32) Between PTCN2 (female) (22) and WECN2 (female) (22)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between PTCN2 (female) (32) and V4A (female) (4)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and V4A (female) (12)
Resistance
Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A)
Resistance
Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B)
Resistance
Max. 1 z
q
ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2. 3. Connect the ground cable and turn the starting switch to ON position. Between PTCN3 (14) or (24) and (31) Open circuit in wiring harness Between WECN3 (14) or (24) and (31) 5 (wire breakage or defective Between V1 (17) and (19) contact of connector)
Voltage
20 – 30 V
Voltage
20 – 30 V
Voltage
20 – 30 V
Between CM01 (14) and (3)
Voltage
20 – 30 V
Between ACT(1), (3) and ground
Voltage
20 – 30 V
Between EGC2 (39) and ground
Voltage
20 – 30 V
q
ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapters to either female side. Ground fault in wiring har3. Disconnect connectors EGC2 and connect T-adapter to female side. 6 ness (Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3 (female) (14), (24), V1 (female) (17) or CM01 (female) (14) and Resistance Min. 1 Mz ground Between EGC2 (female) (39) and ground 7
Defective work equipment controller
8
Defective power train controller
40-310
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, work equipment controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) If cause is not found by the above checks, power train controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DB9RKR] WE controller: Can communication lost (PT)
Circuit diagram related to CAN
D375A-6 (01)
40-311
DRAFT Troubleshooting by failure code Failure code [DBB0KK] VHMS controller:Source voltage reduction
Failure code [DBB0KK] VHMS controller:Source voltage reduction Action code ―
Failure code Voltage drop in power supply to VHMS controller Failure DBB0KK ( VHMS contron system) q When engine was running, the switch power voltage from battery relay to VHMS controller dropped Detail of failure below 19.5 V. Action of conq None in particular. troller Problem on q System may not operate properly. machine Related inforq VHMS controller LED displays "n9" o "C01". mation Cause Trip of circuit breaker 1 (CB105) 2 3 4
5
6
7
8
Procedure, measuring location, criteria and remarks If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. If fuse FS12-5 is blown out, circuit probably has ground fault. In this case, perform Defective fuse FS12-5 troubleshooting for cause 7 first. Loose terminal or discon- 1. Turn starting switch to OFF position. nection at terminal Check terminals of battery, battery relay, TR1S, TR2L, etc. 1. Turn starting switch to OFF position. Improper battery voltage 2. Perform troubleshooting when engine is cranked. Between battery (+) and (-) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector V1 and connect T-adapter to female side. 4. If fuse has blown out, replace it. Disconnection in, or ground 5. If circuit breaker has tripped, reset it. fault of wiring harness 6. Connect ground strap. 7. Turn starting switch to ON position. a If voltage is 0 V, wiring harness is open-cricuited or ground fault. Between Vl (female) (8) and (11)/(12) Voltage 20 – 30 V Between Vl (female) (9) and (19)/(20) Voltage 20 – 30 V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Disconnection in wiring 3. If fuse has blown out, replace it. harness 4. If circuit breaker has tripped, reset it. (Disconnection or defec5. Disconnect connector V1 and connect T-adapter to female side. tive contact) Between V1 (female) (11)/(12)/(19)/(20) and ground ResisMax. 1 Ω a Check terminal GND01 for looseness and rusting. tance ResisBetween V1 (female) (8)/(9) and battery relay BRC terminal Max. 1 Ω tance a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Ground fault of wiring har- 3. If fuse is blown out, replace it. ness 4. If circuit breaker has tripped, reset it. (Contact with ground cir5. Disconnect connector V1 and connect T-adapter to female side. cuit) ResisBetween V1 (female) (8) and (11)/(20) Min. 1 MΩ tance ResisBetween V1(female)(9) and ground Min. 1 MΩ tance If cause is not found by the above checks, power train controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Defective VHMS controller 3. Insert T-adapter in connector V1. 4. Connect ground strap. 5. Turn starting switch to ON position. Between V1(8) and (11)/(12) Voltage 20 – 30 V Between V1(9) and (19)/(20) Voltage 20 – 30 V
40-312
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBB0KK] VHMS controller:Source voltage reduction
Circuit diagram related to power supply for VHMS controller
D375A-6 (01)
40-313
DRAFT Troubleshooting by failure code Failure code [DBB0KQ] VHMS connector connection abnormality
Failure code [DBB0KQ] VHMS connector connection abnormality Action code ― Detail of failure Action of controller Problem on machine Related information
Failure code VHMS connector connection abnormality Failure DBB0KQ (VHMS controller system) q Incorrect connection of connector V2A, V2B, V3A or V3B of VHMS controller q
None in particular.
q
Sensor signal value may not be indicated properly.
q
VHMS controller LED displays "n9" o "05".
Cause Wrong connector connec1 tion
40-314
Procedure, measuring location, criteria and remarks Check if connectors "V2A" and "V3A" as well as connectors "V2B" and "V3B" of VHMS controller are connected incorrectly.
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBB0KQ] VHMS connector connection abnormality
D375A-6 (01)
40-315
DRAFT Troubleshooting by failure code Failure code [DBB3KK] VHMS controller: Source voltage reduction
Failure code [DBB3KK] VHMS controller: Source voltage reduction Action code – Detail of failure Action of controller Problem on machine Related information
Failure code Voltage drop in unswithed power supply to VHMS controller Failure DBB3KK (VHMS controller system) q 24 V power supply voltage from battery to VHMS controller is below 12.5 V. q
None in particular.
q
VHMS does not operate.
q
VHMS controller LED displays "n9" o "05".
Cause Trip of circuit breaker 1 (CB30) 2 Defective fuse FS12-4 Loose terminal 3 or disconnection at terminal 4 Improper battery voltage
Procedure, measuring location, criteria and remarks If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc. 1. Turn starting switch OFF, then carry out troubleshooting. 2. When starting engine. Between battery (+) and (-)
Voltage
20 – 30 V
1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector V1 and connect T-adapter to female side. 4. If fuse has blown out, replace it. Disconnection in, or ground 5. If circuit breaker has tripped, reset it. 5 fault of wiring harness 6. Connect ground strap. a If voltage is 0 V, wiring harness is open-cricuited or ground fault. Between V1 (female) (6) and (11)/(12) Voltage
20 – 30 V
Between V1 (female) (7) and (19)/(20) Voltage 20 – 30 V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Disconnection in wiring 3. If fuse is blown out, replace it. harness 4. If circuit breaker has tripped, reset it. 6 (Disconnection or defec5. Disconnect connector V1 and connect T-adapter to female side. tive contact) Between V1 (female) (11)/(12)/(19)/(20) and ground Resistance Max. 1 Ω a Check terminal GND0I for looseness and rust. Between V1 (female) (6), (7) and battery (+) Resistance Max. 1 Ω a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect ground strap. 3. If fuse is broken, replace it. ness 7 (Contact with ground cir4. If circuit breaker is turned OFF, reset it. cuit) 5. Disconnect connector V1 and connect T-adapter to female side. Between V1 (female) (6) and (11)/(20) Voltage Min. 1 MΩ Between V1(female)(7) and ground Voltage Min. 1 MΩ If cause is not found by the above checks, power train controller is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 8 Defective VHMS controller 3. Insert T-adapter in connector V1. 4. Connect ground strap. Between V1(6) and (11)/(12) Voltage 20 – 30 V Between V1(7) and (19)/(20) Voltage 20 – 30 V
40-316
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBB3KK] VHMS controller: Source voltage reduction
Circuit diagram related to power supply for VHMS controller
D375A-6 (01)
40-317
DRAFT Troubleshooting by failure code Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction Action code E00
Failure code VHMS sensor 5 V power supply abnormality Failure DBB5KP ( VHMS contron system) q Voltage of 5 V power supply circuit from VHMS controller to sensors is below 4.5 V or above 5.5 V. Detail of failure q Abnormal current flowed in 5 V power supply circuit for VHMS controller sensor. Action of conq None in particular. troller Problem on q A part of VHMS does not operate. machine Related inforq VHMS controller LED displays "N9" o "04". mation Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Disconnect connector ENBP. Defective blowby pressure 3. Turn starting switch to ON position. 1 sensor (Internal defect) q If this code is not displayed, blowby pressure sensor is defective. a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBB5KP]. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors V1 and ENBP, and connect T-adapter to female side of ness 2 either one of them. (Contact with ground cirResiscuit) Between V1 (female) (4) or ENBP (female) (B) and ground Min. 1 MΩ tance 1. Turn starting switch to OFF position. 2. Disconnect connector ENBP and connect T-adapter to female side. Hot short in wiring harness 3 (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between ENBP (female) (B) and (A)
Voltage
4.5 – 5.5 V
If cause is not found by the above checks, VHMS controller is defective. Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector V1 and V2A. 3. Turn starting switch to ON position. a Since 24 V power is supplied to connector V1, 5 V output cannot be checked with 4 Defective VHMS controller connector V1 disconnected. q
40-318
Between V1(4) and V2A(12)
Voltage
4.5 – 5.5 V
Between V1(4) and V2A(12)
Voltage
4.5 – 5.5 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction
Circuit diagram related to power supply for VHMS controller sensors 5V
D375A-6 (01)
40-319
DRAFT Troubleshooting by failure code Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction Action code ―
q
Failure code VHMS sensor 24 V power supply abnormality Failure DBB6KP (VHMS controller system) 24 V power supply circuit voltage from VHMS controller to sensors is above normal range (20 V - 30 V). Abnormal current flowed in 24 V sensor power supply circuit to VHMS controller.
q
None in particular.
q
Sensor input value to controller may not be obtained correctly.
q
VHMS controller LED displays "n9" o "02".
q
Detail of failure Action of controller Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective transmission main oil pressure 2. Disconnect following connectors one by one and turn starting switch to ON position each time. sensor, front (cylinder 3. After troubleshooting, return to 1. Nos. 1 - 3) exhaust q If this code is not displayed when a sensor or a device is disconnected, that sensor or temperature sensor, device is defective. rear (cylinder Nos. 4 a Other failure codes are displayed, too. This is because the connector is disconnected. 1 6) exhaust temperaIgnore failure codes other than [DBB6KP]. ture sensor, front Device or sensor Connector exhaust temperature TMMD sensor amplifier or rear Transmission main oil pressure sensor Front (cylinder Nos. 1 3) exhaust temperature sensor EXHF exhaust temperature Rear (cylinder No. 4 6) exhaust temperature sensor EXHR sensor amplifier (InterFront exhaust temperature sensor amplifier EXAF nal defect) Rear exhaust temperature sensor amplifier EXAR 1. Turn starting switch to OFF position. 2. Disconnect connectors EXHF, EXHR, EXTF, EXTR, EXAF, EXAR, TMMD, V1 and V2A, and connect T-adapter to female side of them or to male side of EXTF. Between EXHF (female) (1) or EXTF (male) (1) and Resistance Min. 1 MΩ Ground fault of wiring ground Between EXHF (female) (1) and (2), or between EXTF harness Resistance Min. 1 MΩ 2 (Contact with ground (male) (1) and (2) Between EXHR (female) (1) or EXTR (male) (1) and circuit) Resistance Min. 1 MΩ ground Between EXHR (female) (1) and (2), or between EXTR Resistance Min. 1 MΩ (male) (1) and (2) Between V1 (female) (2) and ground Resistance Min. 1 MΩ Between V1 (female) (2) and V2A (female) (12)/(13) Resistance Min. 1 MΩ If cause is not found by the above checks, VHMS controller is defective. q Reference; The following are standard values in normal condition. 1. Turn starting switch to OFF position. Defective VHMS con- 2. Insert T-adapter into connectors V1 and V2A. 3 troller 3. Turn starting switch to ON position. a Since 24 V power is supplied to connector V1, 24 V output cannot be checked with connector V1 disconnected. Between V1 (2) and V2A (12)/(13) Voltage 20 – 30 V
40-320
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction
Circuit diagram related to VHMS controller sensor 24V power supply
D375A-6 (01)
40-321
DRAFT Troubleshooting by failure code Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction Action code ―
Failure code VHMS sensor 12 V power supply abnormality Failure DBB7KP ( VHMS contron system) q Voltage of 12 V power supply circuit from VHMS controller to sensors is below 11.5 V or above 12.5 Detail of failure V. q Abnormal current flowed in 12 V sensor power supply circuit to VHMS controller. Action of conq None in particular. troller Problem on q When downloading from VHMS controller, LED (Download light) does not light up. machine Related inforq VHMS controller LED displays "N9" o "03". mation Cause
1
Defective download LED (Internal defect)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector DLT. 3. Turn starting switch to ON position. q If this code is not displayed, download LED is defective. a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBB7KP].
1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors V1 and DLT, and connect T-adapter to female side of either ness 2 one of them. (Contact with ground cirResiscuit) Between V1 (female) (3) or DLT (female) (1) and ground Min. 1 MΩ tance 1. Turn starting switch to OFF position. 2. Disconnect connector DLT and connect T-adapter to female side. Hot short in wiring harness 3 (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between DLT (female) (1) and (2)
Voltage 11.5 – 12.5 V
If cause is not found by the above checks, VHMS controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector V1. 4 Defective VHMS controller 3. Turn starting switch to ON position. a Since 24 V power is supplied to connector V1, 12 V output cannot be checked with connector V1 disconnected. V1 Between (3) and (12)
Voltage 11.5 – 12.5 V
Circuit diagram related to VHMS controller sensor 24 V power supply
40-322
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) Action code
Failure code
CAN communication with power train controller is impossible (detected by VHMS controller) DBBQKR (VHMS controller system) VHMS controller cannot recognize engine controller, power train controller, work equipment controller, and machine monitor in CAN communication. Failure
E00 Detail of failure Action of controller Problem on machine Related information
q
q
None in particular.
q
VHMS function to collect information from other controllers does not work.
q
VHMS controller LED panel displays "n8" o "02".
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DBERKR].
Failure code [DBE0KT] PT controller: Abnormality in controller Action code Failure code Data recorded in power train controller are abnormal Failure E01 DBE0KT (Power train controller system) Detail of failure q Information in ROM (non-volatile memory) in power train controller is abnormal. Action of conq Resets internal adjustment values to default values. troller Problem on q Transmission gear shift feel may become bad. machine q Adjusting function by power train controller may not operate properly. Related inforq Method of reproducing failure code: Turn starting switch to ON position. mation Cause
Procedure, measuring location, criteria and remarks Use adjustment function in service mode, and perform operation of reproducing trouble. Defective adjustment of 1 If "E" of failure code disappears at this time, system function is proper. power train controller q Adjustment code: 0002 (initial setting of power train controller) Defective power train con- Troubleshooting cannot be performed since defect is in power train controller. (If there is 2 troller no any visible trouble in machine, controller may be used as it is.)
D375A-6 (01)
40-323
DRAFT Troubleshooting by failure code Failure code [DBE1KK] PT controller: Source voltage reduction
Failure code [DBE1KK] PT controller: Source voltage reduction Action code E04 Detail of failure Action of controller Problem on machine
q
Failure code Battery direct power supply voltage drop for power train controller Failure DBE1KK (Power train controller system) The voltage of battery direct power supply to power train controller is below 17 V.
q
Limits operation of engine, transmission, and brake.
q
Machine monitor may not display correctly. Relay and solenoid may not be actuated and therefore, system may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, it becomes impossible to travel. Power source voltage of power train controller can be checked by adjusting function. (Code 2021: Power train controller voltage check mode) Method of reproducing failure code: Turn starting switch ON.
q q q
Related information
q q
Cause Trip of circuit breaker 1 (CB30) 2 3 4
5
6
7
8
Procedure, measuring location, criteria and remarks If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first. If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform troubleDefective fuse FS12-4 shooting for cause 7 first. Loose terminal, 1. Turn starting switch to OFF position. or disconnection at terCheck terminals of battery, battery relay, etc. minal Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine. age Between battery (+) and (-) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Disconnection in, or 3. Disconnect connector PTCN3 and connect T-adapter to female side. ground fault of wiring 4. Connect ground strap. harness a If voltage is 0 V, wiring harness is open-cricuited or ground fault. Between PTCN3 (female) (1) and (21), (31) Voltage 20 – 30 V Between PTCN3 (female) (11) and (32), (33) Voltage 20 – 30 V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Disconnection in wir- 3. If fuse has blown out, replace it. ing harness 4. If circuit breaker has tripped, reset it. (Disconnection or 5. Disconnect connector PTCN3 and connect T-adapter to female side. defective contact) Between PTCN3 (female) (21)/(31)/(32)/(33) and ground Resistance Max. 1 Ω a Check terminal GND01 for looseness and rust. Between PTCN3 (female) (1)/(11) and battery (+) Resistance Max. 1 Ω a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect ground strap. harness 3. If fuse is blown out, replace it. (Contact with ground 4. If circuit breaker has tripped, reset it. circuit) 5. Disconnect connector PTCN3 and connect T-adapter to female side. Between PTCN3 (female) (1) and (21)/(31) Resistance Min. 1 MΩ Between PTCN3 (female) (11) and (32)/(33) Resistance Min. 1 MΩ If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train 2. Disconnect ground strap. controller 3. Insert T-adapter into connector PTCN3. 4. Connect ground strap. Between PTCN3 (1) and (21)/(31) Voltage 20 – 30 V Between PTCN3 (11) and (32)/(33) Voltage 20 – 30 V
40-324
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBE1KK] PT controller: Source voltage reduction
Circuit diagram related to power train controller power supply
D375A-6 (01)
40-325
DRAFT Troubleshooting by failure code Failure code [DBE2KK] PT controller: Output voltage reduction
Failure code [DBE2KK] PT controller: Output voltage reduction Action code
Failure code
E04 Detail of failure Action of controller Problem on machine Related information
Voltage drop in power supply for power train controller-related actuators DBE2KK (Power train controller system) Power supply (battery relay output) voltage for the actuators related to power train controller (relay, solenoid or others) is below 17 V. Failure
q
q
Limits operation of engine, transmission and brake.
q
Relay and solenoid may not drive be actuated and therefore, system may not operate properly. Once machine is stopped, engine speed is limited to half of full speed. Once machine is stopped, it becomes impossible to travel. Main power source voltage of power train controller can be checked by adjusting function. (Code 2021: Power train controller voltage check mode) If battery relay is not turned ON, see E-mode, E-1. Method of reproducing failure code: Turn starting switch to ON position.
q q q q q
Cause Trip of circuit breaker 1 CB1 or CB105 Loose terminal, 2 or disconnection at terminal Improper battery volt3 age
Procedure, measuring location, criteria and remarks If CB1 or CB105 circuit breaker has tripped circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc.
1. Perform troubleshooting with starting switch at OFF and when starting engine. Between battery (+) and (-) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Defective wiring har- 3. Insert T-adapter into connector PTCN3. 4. Connect ground strap. 4 ness or power train 5. Turn starting switch to ON position. controller Between PTCN3 (2) and (21) Voltage 20 – 30 V Between PTCN3 (12) and (31) Voltage 20 – 30 V Between PTCN3 (22) and (32) Voltage 20 – 30 V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect ground strap (in order not to make short circuit). harness 3. Disconnect connector PTCN3 and connect T-adapter to female side. 5 (Disconnection or Between PTCN3 (female) (21)/(31)/(32)/(33) and defective contact) ground Resistance Max. 1 Ω a Check terminal GND01 for looseness and rust. Between PTCN3 (female) (2), (12) or (22) and BRC Resistance Max. 1 Ω a If cause 4 is not the cause for the trouble, this check is not required. Ground fault of wiring 1. Turn starting switch to OFF position. harness 2. Disconnect ground strap (in order not to make short circuit). 6 (Contact with ground 3. If circuit breaker has tripped, reset it. circuit) 4. Disconnect connector PTCN3. Between terminal BRC and ground Resistance Min. 1 MΩ Defective power train 7 If cause is not found by the above checks, power train controller is defective. controller
40-326
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBE2KK] PT controller: Output voltage reduction
Circuit diagram related to power train controller power supply
D375A-6 (01)
40-327
DRAFT Troubleshooting by failure code Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction Action code E03
Failure code Power train controller 5 V power supply (1) abnormality Failure DBE5KK (Power train controller system) q Voltage of 5 V power supply (1) circuit from power train controller to sensors is below 4.5 V or above Detail of failure 5.5 V. q Abnormal current flowed in 5 V power supply (1) circuit for power train controller sensors. Action of con- q Stops output to 5 V power supply (1) circuit, if abnormal current flows. q Limits operation of engine and transmission. troller q System may not operate properly. Problem on q Once machine is stopped, engine speed is limited to half of full speed. machine q Once machine is stopped, travel is limited to F1 and R1. Related inforq Method of reproducing failure code: Turn the starting switch to ON position. mation Causes
1
Defective fuel control dial, brake pedal or PCCS lever (Internal defect)
2
Defective transmission controller
3
Ground fault of wiring harness (Contact with GND circuit)
4
Hot short in wiring harness (Contact with 24 V circuit)
40-328
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After troubleshooting, return to 1. q If this code is not displayed when a sensor is disconnected, that sensor is defective. a Other failure codes are displayed at the same time. This is because the connector is disconnected. Ignore failure codes other than [DBE5KK]. Device Connector Fuel control dial DIAL PCCS lever TL2 Brake pedal BRK 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between ground and any one of PTCN1 (female) (22) Voltage 4.5 – 5.5 V and (21) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, DIAL and TL2, and connect T-adapter to female side of any one of them. Between ground and any one of PTCN1 (female) (22), ResisMin. 1 MΩ TL2 (female) (4)/(5), BRK (C) or DIAL (female) (1) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors DIAL, TL2 and BRK, and connect T-adapter to female side of any one of them. 3. Turn starting switch ON. Between TL2 (female) (4) and (1), or between TL2 (female) (5) and (8), between BRK (C) and (A), or Voltage 4.5 – 5.5 V between DIAL (female) (1) and (3)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction
Circuit diagram related to power train controller sensors 5 V (1) power supply
D375A-6 (01)
40-329
DRAFT Troubleshooting by failure code Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction Action code E03
Failure code Power train controller sensor 24 V power supply abnormality Failure DBE6KK (Power train controller system) q Voltage of 24 V power supply circuit from power train controller to sensors is below 17 V or above Detail of failure 30 V. q Abnormal current flowed in 24 V power supply circuit for power train controller sensors. Action of con- q Stops output to 24 V power source circuit if abnormal voltage flows. q Limits operation of engine and transmission. troller q System may not operate properly. Problem on q Once machine is stopped, engine speed is limited to half of full speed. machine q Once machine stops, travel is limited to F1 and R1. Related inforq Method of reproducing failure code: Turn starting switch ON. mation Causes
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. Defective inclination angle 3. After troubleshooting, return to 1). sensor, torque converter q If this code is not displayed when a sensor is disconnected, that sensor is defective. inlet pressure sensor or a Other failure codes are displayed, too. This is because the connector is disconnecttorque converter outlet ed. Ignore failure codes other than [DBE6KK]. pressure sensor (Internal Sensor Connector defect) Inclination angle sensor PT1 Torque converter inlet pressure sensor TIP Torque converter outlet pressure sensor TOP 1. Turn starting switch to OFF position. Defective power train con- 2. Disconnect connector PTCN1 and connect T-adapter to female side. troller 3. Turn starting switch to ON position. Between PTCN1 (female) (16) and (21) Voltage 20 – 30V 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN1, PT1, TIP and TOP, and connect T-adapter to ness female side of any one of them. (Contact with ground cirBetween ground and any one of PTCN1 (female) (16), cuit) Resistance Min. 1 MΩ TIP(B), TOP(B) or PT1 (female) (C) 1. Turn starting switch to OFF position. 2. Disconnect connectors PT1, TIP and TOP, and connect T-adapter to female side Short circuit in wiring harof any one of them. ness 3. Turn starting switch to ON position. Between TIP(B) and (A), between TOP(B) and (A), or Voltage 20 – 30V between PT1 (female) (C) and (A)
40-330
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction
Circuit diagram related to power train controller sensor 24 V power supply
D375A-6 (01)
40-331
DRAFT Troubleshooting by failure code Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction Action code E01
Failure code Power train controller sensor 5 V power supply (2) abnormality Failure DBE7KK (Power train controller system) q Voltage of 5 V power supply (2) circuit from power train controller to sensors is below 4.5 V or above Detail of failure 5.5 V. q Abnormal current flowed in 5 V power supply (2) circuit for power train controller sensors. Action of conq Stops output to 5 V power supply (2) circuit, if abnormal current flows. troller Problem on q Shoe slip control function may not operate properly (only for machine with shoe slip control). machine Related inforq Method of reproducing failure code: Turn the starting switch to ON position mation Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SSA. Defective acceleration sen3. Turn starting switch to ON position. sor q If this code is not displayed, acceleration sensor is defective. (Internal defect) a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBE7KK]. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN3 and SSA, and connect T-adapter to female side of ness either one of them. (Contact with ground cirResisBetween PTCN3 (female) (34) or SSA (female) (1) and cuit) Min. 1 MΩ ground tance 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SSA (female) (1) and (3) Voltage 4.5 – 5.5 V If cause is not found by the above checks, power train controller is defective. q Reference: The following are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con- 2. Insert T-adapter in connector PTCN3. troller 3. Turn starting switch to ON position. a Since 24 V power is supplied to connector PTCN3, 5 V output cannot be checked with connector PTCN3 disconnected. Between PTCN3(34) and ground Voltage 4.5 – 5.5 V
40-332
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction
Circuit diagram related to power train controller sensor 5 V (2) power supply
D375A-6 (01)
40-333
DRAFT Troubleshooting by failure code Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DBE9KQ] PT controller: Type select signal Action code E04
Failure code Power train controller: Type select signal Failure DBE9KQ (Power train controller system) q Specification setting in power train controller does not match specification setting memory (InitializaDetail of failure tion of power train controller is not performed). Action of con- q Turns all outputs of power train controller to OFF position. troller q Limits operation of engine and transmission. q Machine does not move at all. Problem on q Once machine is stopped, engine speed is limited to medium (half). machine q Once machine stops, it cannot travel at all. Related inforq Method of reproducing failure code: Turn starting switch to ON position. mation Causes 1
Defective adjustment of power train controller
40-334
Procedure, measuring location, criteria and remarks Display adjustment function in service mode and perform operation of reproducing trouble. If “E” of failure code disappears at this time, system is normal. q Adjustment code: 0002 (Initialization of power train controller)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DBERKR] PT controller: Can communication lost (WE)
Failure code [DBERKR] PT controller: Can communication lost (WE) Action code
Failure code
q
CAN communication with power train controller is impossible. (detected by work equipment controller ) DBERKR (Work equipment controller system) Work equipment controller cannot recognize power train controller in CAN communication.
q
Limits operation of engine and transmission.
q
System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Method of reproducing failure code: Turn the starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal of starting switch. Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [DBERKR] is displayed on the machine monitor, CAN communication between work equipment controller and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN communication line. Since each controller and machine monitor receive power from battery directly, they are kept ON even while starting switch is OFF. Since CAN communication line signal in operation is pulse voltage, it cannot be measured with multimeter.
Failure
E03 Detail of failure Action of controller Problem on machine
q q q q q
Related information q q
Cause Defective power supply to 1 power train controller Defective CAN terminal resistor 2 (Internal disconnection or short circuit)
3
Disconnection or short circuit in wiring harness
D375A-6 (01)
Procedure, measuring location, criteria and remarks If failure code [DBBQKR] is also displayed, perform troubleshooting for failure code [DBE1KK] and [DBE2KK] first. 1. Turn starting switch to OFF position. 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them. Between CT2 (male) (A) and (B) Resistance 120 ± 12 Between CM02 (male) (8) and (10) Resistance 120 ± 12 q CAN communication line a There is 120 Ω CAN terminal resistor inside machine monitor, too. Since 120 Ω resistor is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 Ω which is combined resistance, there is not open circuit in wiring harness. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapter to female side of that connector. a If connector has short circuit (Resistance between terminals is 1 Ω or less), disconnect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short circuit between wiring harnesses or in controller. Between EGC2 (female) (46) and (47) Resistance Approx. 60 Ω Between PTCN2 (female) (32) and (22) Resistance Approx. 60 Ω Between WECN2 (female) (32) and (22) Resistance Approx. 60 Ω Between V4A (female) (12) and (4) Resistance Approx. 60 Ω Between CT2 (female) (A) and (B) Approx. Resistance 120 Ω Between CM02 (female) (9) and (10) Approx. Resistance 120 Ω
40-335
Troubleshooting by failurecode Failure code [DBERKR] PT controller: Can communication lost (WE)
Cause
Procedure, measuring location, criteria and remarks a If check result of cause 3 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect T-adapters to female side of them. Between PTCN2 (female) (32) and CM02 (female) Resistance Max. 1 z (9)/(8) Between PTCN2 (female) (22) and CM02 (female) (10)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and EGC2 (female) (46) Open circuit in wiring harBetween PTCN2 (female) (22) and EGC2 (female) (47) ness 4 (wire breakage or defective Between PTCN2 (female) (32) and WECN2 (female) contact of connector) (32) Between PTCN2 (female) (22) and WECN2 (female) (22)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between PTCN2 (female) (32) and V4A (female) (4)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and V4A (female) (12)
Resistance
Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A)
Resistance
Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B)
Resistance
Max. 1 z
q
ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2. 3. Connect the ground cable and turn the starting switch to ON position. Between PTCN3 (14) or (24) and (31) Open circuit in wiring harness Between WECN3 (14) or (24) and (31) 5 (wire breakage or defective Between V1 (17) and (19) contact of connector)
Voltage
20 – 30 V
Voltage
20 – 30 V
Voltage
20 – 30 V
Between CM01 (14) and (3)
Voltage
20 – 30 V
Between ACT(1), (3) and ground
Voltage
20 – 30 V
Between EGC2 (39) and ground
Voltage
20 – 30 V
q
ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground strap. 2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapters to either female side. Ground fault in wiring har3. Disconnect connectors EGC2 and connect T-adapter to female side. 6 ness (Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3 (female) (14), (24), V1 (female) (17) or CM01 (female) (14) and Resistance Min. 1 Mz ground Between EGC2 (female) (39) and ground 7
Defective power train controller
8
Defective work equipment controller
40-336
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, power train controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) If cause is not found by above checks, work equipment controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DBERKR] PT controller: Can communication lost (WE)
Circuit diagram related to CAN
D375A-6 (01)
40-337
DRAFT Troubleshooting by failure code Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [DD12KA] Shift up Sw: Disconnection Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code Shift up switch: Disconnection Failure DD12KA (Power train controller system) q Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time. q
Recognizes that the shift up switch is not pressed.
q
Transmission gear cannot be shifted up.
q
"NO*" line is used for sensing operation and "NC*" line is used for detecting error. Condition of shift up switch signal can be checked with monitoring function. (Code: 40905 Power train control switch Input 3) Method of reproducing failure code: Turning on the starting switch and operating the shift up switch Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.
q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFTU. 3. Turn shift up switch to ON or OFF position and troubleshoot. Defective shift up switch a "Switch OFF": Release, "Switch ON": Press (Internal disconnection) Between SFTU (male) (3) and Switch: OFF Resistance Max. 1 Ω Switch: ON Resistance Min. 1 MΩ (2) Between SFTU (male) (1) and Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω (2) 1. Turn starting switch to OFF position. 2. Disconnect connector SFTU. 3. Insert T-adapter into connector TL3. 4. Turn starting switch ON position. Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it in wiring harness shows hot short in wiring harness. a Voltage of approx. 9 V is applied to signal lines of "NO" and "NC" through resistor in power train controller. Between TL3(1) and (2) Voltage 7 – 11V Between TL3(3) and (2) Voltage 7 – 11V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and PTCN3 and connect T-adapters to each female Disconnection in wiring side. harness 3. Turn shift up switch to ON or OFF position and troubleshoot. (Disconnection or defec- Between PTCN3 (female) (29) and PTCN1 Switch: OFF Resistance Max. 1 Ω tive contact) (female) (10). Between PTCN3 (female) (39) and PTCN1 Switch: ON Resistance Max. 1 Ω (female) (10). If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 and PTCN3. 3. Turn starting switch ON position. Defective transmission 4. Turn shift up switch to ON or OFF position and troubleshoot. controller a Voltage of apporx. 9 V is applied to PTCN3 pin (29) and PTCN3 pin (39) through resistor in power train controller. Between PTCN3(29) and Switch: OFF Voltage Max. 1V 7 – 11V Switch: ON Voltage PTCN1(10) Between PTCN3(39) and Switch: OFF Voltage 7 – 11V Max. 1V Switch: ON Voltage PTCN1(10)
*NO: Normally Open *NC: Normally Closed
40-338
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DD12KA] Shift up Sw: Disconnection
Circuit diagram related to shift up switch
D375A-6 (01)
40-339
DRAFT Troubleshooting by failure code Failure code [DD12KB] Shift up Sw: Short circuit
Failure code [DD12KB] Shift up Sw: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code Shift up switch: Short circuit Failure DD12KB (Power train controller system) q Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time. q
Recognizes that the shift up switch is not pressed.
q
Transmission gear cannot be shifted up.
q
"NO*" line is used for sensing operation and "NC*" line is used for detecting error. Condition of shift up switch signal can be checked with monitoring function. (Code: 40905 Power train controller input 3) Method of reproducing failure code: Turn starting switch to ON position (and operate shift up switch). Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.
q q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFTU. 3. Turn shift switch to ON or OFF position and troubleshoot. Defective shift up switch a "Switch OFF": Release, "Switch ON": Press 1 (Internal disconnection) Between SFTU (male) (3) and Switch: OFF Resistance Max. 1 Ω Switch: ON Resistance Min. 1 MΩ (2) Between SFTU (male) (1) and Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω (2) 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN3 and SFTU, and connect T-adapter to female side of ness 2 PTCN3. (Contact with ground cirBetween PTCN3 (female) (39) and ground Resistance Min. 1 MΩ cuit) Between PTCN3 (female) (29) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SFTU, and connect T-adapter to female side of PTCN3. Short circuit in wiring har- a Check with multimeter in continuity mode. 3 ness No continuity Between PTCN3 (female) (29) and each pin other than (29) (No sound is heard) No continuity Between PTCN3 (female) (39) and each pin other than (39) (No sound is heard) If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 and PTCN3. 3. Turn starting switch to ON position. Defective power train con- 4. Turn shift switch to ON or OFF position and troubleshoot. 4 troller a Voltage of apporx.9 V is applied to PTCN3 pin (29) and PTCN3 pin (39) through resistor in power train controller. Between PTCN3(29) and Switch: OFF Voltage Max. 1 V 7 – 11 V Switch: ON Voltage PTCN1(10) Between PTCN3(39) and Switch: OFF Voltage 7 – 11 V Max. 1 V Switch: ON Voltage PTCN1(10)
*NO: Normally Open *NC: Normally Closed
40-340
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DD12KB] Shift up Sw: Short circuit
Circuit diagram related to shift up switch
D375A-6 (01)
40-341
DRAFT Troubleshooting by failure code Failure code [DD13KA] Shift down Sw: Disconnection
Failure code [DD13KA] Shift down Sw: Disconnection Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code Shift-down switch Disconnection Failure DD13KA (Power train controller system) q Both linens of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time. q
Recognizes that the shift up switch is not pressed.
q
Shift down is not possible.
q
“NO*” line is used for sensing operation and “NC*” line is used for detecting error. Condition of shift up switch signal can be checked with moniitoring function. (Code: 40905 Power train control Input 3) Method of reproducing failure code: Turn starting switch ON (and operate shift up switch) ConnectorSFTD has no T-adapters, don't carry out troubleshooting in female side.
q q q
Cause
Procedure, measuring location, criteria and remarks Turn starting switch to OFF position. Disconnect connector SFTD. Insert T-adapter into connector TL3. Turn starting switch ON position. If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24 V, it shows hot short in wiring harness. a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between TL3(4) and (5) Voltage 7 – 11V Between TL3(6) and (5) Voltage 7 – 11V 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors PTCN1, PTCN3 and SFTD, and connect T-adapter to each harness female side 2 (Disconnection or defec- Between PTCN3 (female) (19) and SFTD (male) (1) Resistance Max. 1 Ω tive contact) Between PTCN1 (female) (10) and SFTD (male) (2) Resistance Max. 1 Ω Between PTCN3 (female) (9) and SFTD (male) (3) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector TL3 and connect T-adapter to male side. 3. Turn shift up switch to ON or OFF position and troubleshoot. Defective shift down switch a “Switch OFF”: Release, “Switch ON”: Press 3 (Internal disconnection) Switch: OFF Resistance Max. 1 Ω Between TL3 (male) (5) and (6) Switch: ON. Resistance Min. 1 MΩ Switch: OFF Resistance Min. 1 MΩ Between TL3 (male) (4) and (5) Switch:ON Resistance Max. 1 Ω If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 and PTCN3. 3. Turn starting switch ON position. Defective transmission 4. Turn shift down switch to ON or OFF position and troubleshoot. 4 controller a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through resistor in power train controller. Between PTCN3 (19) and Switch: OFF Voltage 7 – 11 V Max. 1 V Switch: ON Voltage PTCN1 (10) Between PTCN3 (9) and Switch: OFF Voltage Max. 1 V 7 – 11 V Switch: ON Voltage PTCN1 (10) 1. 2. 3. 4. Disconnection or hot short a 1 in wiring harness
*NO: Normally Open *NC: Normally Closed
40-342
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DD13KA] Shift down Sw: Disconnection
Circuit diagram related to shift up switch
D375A-6 (01)
40-343
DRAFT Troubleshooting by failure code Failure code [DD13KB] Shift down Sw: Short circuit
Failure code [DD13KB] Shift down Sw: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code Shiftdown switch: short circuit Failure DD13KB (Power train controller system) q Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time. q
Recognizes that the shift up switch is not pressed.
q
Shift down is not possible.
q
“NO*” line is used for sensing operation and “NC*” line is used for detecting error. Condition of shift up switch signal can be checked with moniitoring function. (Code: 40905 Power train control Input 3) Method of reproducing failure code: Turn starting switch ON (and operate shift down switch). Connector SFTD has no T-adapters, don't carry out troubleshooting in female side.
q q q
Cause
1
2
3
4
Procedure, measuring location, cirteria and remarks 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female side of ness PTCN3. (Contact with GND circuit) Between PTCN3 (female) (9) and ground Resistance Min. 1 MΩ Between PTCN3 (female) (19) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female side of PTCN3. Short circuit in wiring har- a Check with multimeter in continuity mode. ness No continuity Between PTCN3 (female) (9) and each pin other than (9) (No sound is heard) No continuity Between PTCN3 (female) (19) and each pin other than (19) (No sound is heard) 1. Turn starting switch to OFF position. 2. Disconnect connector TL3 and connect T-adapter to male side. 3. Turn shift down switch to ON or OFF position and troubleshoot. Defective shift down switch a “Switch OFF”: Release, “Switch ON”: Press (Internal disconnection) Switch: OFF Resistance Max. 1 Ω Between TL3 (male) (5) and (6) Switch: ON Resistance Min. 1 MΩ Switch: OFF Resistance Min. 1 MΩ Between TL3 (male) (4) and (5) Switch: ON Resistance Max. 1 Ω If cause is not found by the above checks, power train controller is defective. q Reference; the followings are cirteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 and PTCN3. 3. Turn starting switch to ON position. Defective transmission 4. Turn shift down switch to ONor OFF position and troubleshoot. controller a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through resistor in power train controller. Between PTCN3 (19) and Switch: OFF Voltage 7 – 11 V Max. 1 V Switch: ON Voltage PTCN1 (10) Between PTCN3 (9) and Switch: OFF Voltage Max. 1 V 7 – 11 V Switch: ON Voltage PTCN1 (10)
*NO: Normally Open *NC: Normally Closed
40-344
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DD13KB] Shift down Sw: Short circuit
Circuit diagram related to shift down switch
D375A-6 (01)
40-345
DRAFT Troubleshooting by failure code Failure code [DD14KA] Parking lever Sw: Dissconnection
Failure code [DD14KA] Parking lever Sw: Dissconnection Action code E03
Failure code Parking lever switch: Disconnection Failure DD14KA (Power train controller system) q Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the same Detail of failure time. Action of con- q Recognizes parking brake lever is in Free position. troller q Limits operation of engine and transmission. q Once machine stops, engine speed is limited to medium (half). Problem on q Once machine stops, travel is limited to F1 and R1. machine q Engine cannot start. q NC* line is used for sensing operation and NO* line is used for detecting error. q Condition of parking brake lever switch signal can be checked with monitoring function. Related infor(Code: 40905 Power train control Input 3) mation q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever. q When parking brake lever is in free position, parking brake lever switch is turned to ON position. Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector NSW and connect T-adapter to male side. Defective parking brake 3. Operate parking brake lever and troubleshoot. lever switch (Internal dis- Between NSW (male) (A) Lever: LOCK Resistance Min. 1 MΩ connection) Lever: FREE Resistance Max. 1 Ω and (B) Between NSW (male) (A) Lever: LOCK Resistance Max. 1 Ω Lever: FREE Resistance Min. 1 MΩ and (C) 1. Turn starting switch to OFF position. 2. Disconnect connector NSW and connect T-adapter to female side. 3. Turn starting switch to ON position. Disconnection or hot short a If voltage is 0 V, it shows short circuit in wiring harness, and if voltage is 24 V, it shows hot short in wiring harness. in wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between NSW (female) (B) and (A) Voltage 7 – 11 V Between NSW (female) (C) and (A) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors PTCN1 and NSW and connect T-adapters to each female harness side. (Open circuit or defective Between PTCN1 (female) (12) and NSW (female) (C) Resistance Max. 1 Ω contact) Between PTCN1 (female) (18) and NSW (female) (B) Resistance Max. 1 Ω Between NSW(female)(A) and ground Resistance Max. 1 Ω If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. Defective power train con- 4. Operate parking brake lever and troubleshoot. troller a Voltage of about 9 V is applied to PTCN1 pin (12) and pin (18) through resistor in power train controller. Between PTCN1(18) and Lever: LOCK Voltage 7 – 11 V Max. 1 V Lever: FREE Voltage ground Between PTCN1(12) and Lever: LOCK Voltage Max. 1 V 7 – 11 V Lever: FREE Voltage ground
*NO: Normally Open *NC: Normally Closed
40-346
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DD14KA] Parking lever Sw: Dissconnection
Circuit diagram related to parking brake lever switch
D375A-6 (01)
40-347
DRAFT Troubleshooting by failure code Failure code [DD14KB] Parking lever Sw: Short circuit
Failure code [DD14KB] Parking lever Sw: Short circuit Action code E03
Failure code Parking lever switch: Short circuit Failure DD14KB (Power train controller system) q Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same Detail of failure time. Action of con- q Recognizes parking brake lever is in FREE position. troller q Limits operation of engine and transmission. q Once machine stops, engine speed is limited to medium (half). Problem on q Once machine stops, travel is limited to F1 and R1. machine q Engine cannot start. q “NC*” line is used for sensing opration and “NO*” line is used for detecting error. q Condition of parking brake lever switch signal can be checked with monitoring function. Related infor(Code: 40905 Power train control Input 3) mation q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever. q When parking brake lever is FREE, parking brake lever switch becomes “ON”. Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector NSW and connect T-adapter to male side. Defective parking brake 3. Operate parking brake lever and troubleshoot. lever switch (Internal dis- Between NSW (male) (A) Lever: LOCK Resistance Min. 1 MΩ connection) Lever: FREE Resistance Max. 1 Ω and (B) Between NSW (male) (A) Lever: LOCK Resistance Max. 1 Ω Lever: FREE Resistance Min. 1 MΩ and (C) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female side of Ground fault of wiring harone of them. ness Between NSW (female) (B) and ground or between Min. 1 MΩ Resistance (Contact with GND circuit) PTCN1 (female) (18) and ground Between NSW (female) (C) and ground or between Min. 1 MΩ Resistance PTCN1 (female) (12) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectorsPTCN1, NSW and connect T-adapter to female side of PTCN1. Short circuit in wiring har- a Check with multimeter continuity mode. ness Between PTCN1 (female) (12) and each pin other than No continuity (12) (No sound is heard) Between PTCN1 (female) (18) and each pin other than No continuity (18) (No sound is heard) If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. Defective power train con- 4. Operate shiftup switch and troubleshoot. troller a Voltage of about 9 V is applied to PTCN1 pin (12) and pin (18) through resistor in power train controller. Between PTCN1(18) and Lever: LOCK Voltage 7 – 11V Lever: FREE Max. 1V Voltage chassis ground Between PTCN1(12) and Lever: LOCK Voltage Max. 1V Lever: FREE 7 – 11V Voltage chassis ground
*NO: Normally Open *NC: Normally Closed
40-348
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DD14KB] Parking lever Sw: Short circuit
Circuit diagram related to parking brake lever switch
D375A-6 (01)
40-349
DRAFT Troubleshooting by failure code Failure code [DDB9L4] Reverse SW Signal disagreement
Failure code [DDB9L4] Reverse SW Signal disagreement Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Inconsistent reverse switch signal Failure DDB9L4 (Power train controller system) q There is inconsistency in line 2 of NO* for reverse switch circuit. q
Recognizes that reverser switch is not pressed.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1. Condition of reverse switch signal can be checked with monitoring function. (Code: 40905 Power train control input 3) Method of reproducing failure code: Turn starting switch to ON position (and operate reverse switch). Since T-adapter is not prepared for connector RTS, female side check is not required.
q q q q
Cause Wrong selection of travel 1 lever type
Procedure, measuring location, standard (value) and remarks If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
1. 2. 3. 4. Disconnection or hot short a 2 in wiring harness
Turn starting switch to OFF position. Disconnect connector RTS. Insert T-adapter into connector TL3. Turn starting switch to ON position. If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it shows hot short in wiring harness. a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between TL3(4) and (2) Voltage 7 – 11 V Between TL3(6) and (5) Voltage 7 – 11 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, PTCN3, TL3 and RTS, and connect T-adapters to Disconnection in wiring female side of PTCN1, PTCN3 and PL3. harness 3 Resistance Max. 1 Ω (Disconnection or defec- Between PTCN3 (female) (19) and RTS (male) (1) Between PTCN1 (female) (10) and TL3 (female) (2) Resistance Max. 1 Ω tive contact) Between PTCN1 (female) (10) and RTS (male) (2) Resistance Max. 1 Ω Between PTCN3 (female) (9) and RTS (male) (3) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female side of ness 4 PTCN3. (Contact with ground cirBetween PTCN3 (female) (9) and ground Resistance Min. 1 MΩ cuit) Between PTCN3 (female) (19) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female side of PTCN3. Short circuit in wiring har- a Check with multimeter in continuity mode. 5 ness No continuity Between PTCN3 (female) (9) and each pin other than (9) (No sound is heard) No continuity Between PTCN3 (female) (19) and each pin other than (19) (No sound is heard) 1. Turn starting switch to OFF position. 2. Disconnect connector TL3 and connect T-adapter to male side. 3. Disconnect connector FTS. 4. Turn reverse switch to ON or OFF position and troubleshoot. Defective reverse switch 6 a "Switch OFF": Release, "Switch ON": Press (Internal disconnection) Switch: OFF Resistance Min. 1 MΩ Between TL3 (male) (5) and (6) Switch: ON Resistance Max. 1 Ω Between TL3 (male) (4) and Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω FTS (female) (2)
40-350
D375A-6 (01)
Troubleshooting by failurecode Failure code [DDB9L4] Reverse SW Signal disagreement
Cause
6
7
Defective reverse switch (Internal disconnection)
Defective power train controller
Procedure, measuring location, criteria and remarks 1. 2. 3. 4. a
Turn starting switch to OFF position. Disconnect connectors TL3 and connect T-adapters to female side. Disconnect connector FTS. Turn reverse switch ON/OFF, and troubleshoot. “Switch OFF”: Release, “Switch ON”: Press
Between TL3 (male) (5) and (6)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
Between TL3 (male) (4) and FTS (female) (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors PTCN1 and PTCN3. 3. Turn starting switch to ON position. 4. Turn reverse switch ON/OFF, and troubleshoot. a Voltage of approximately 9 V is applied to PTCN3 pin (19) and pin (9) through resistor in power train controller. Between PTCN3 (19) and PTCN1 (10)
Switch: OFF
Voltage
7 – 11 V
Switch: ON
Voltage
Max. 1 V
Between PTCN3 (9) and PTCN1 (10)
Switch: OFF
Voltage
7 – 11 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open Circuit diagram related to reverse switch
40-35
a Exclusive for single-direction lever
D375A-6 (06)
40-351
DRAFT Troubleshooting by failure code Failure code [DDE2KA] Pre lub. oil press sw: Disconnection
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection Action code E02
Failure code Pre-lubricating oil pressure switch disconnection Failure DDE2KA (Power train controller) q Power train controller has started pre-lubrication, pre-lubricating motor is operating, and voltage is Detail of failure detected at pre-lubricating motor. However, pre-lubricating oil pressure switch is not turned to OFF position. Action of conq None in particular troller Problem on q Engine does not run (It runs in skip mode, however). machine q Pre-lubricating oil pressure switch is turned to ON position when oil pressure is not applied. q Whether pre-lubricating oil pressure switch is turned to ON position can be checked with monitoring Related inforfunction. mation (Code: 40910 PT controller SW input 2) q Whether pre-lubricating motor is in operation can be checked with monitoring function. (Code: 40909 P/T controller SW output) Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect terminal POP. Defective pre-lubricating oil 3. Turn starting switch to ON position. pressure switch a During pre-lubrication Between terminal POP (on pre-lubricating oil pressure Not conductive switch side) and ground Disconnection in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connector PTCN2 and connect T-adapter to female side. (Disconnection or defecBetween PTCN2 (female) (13) and ground Resistance Max. 1 Ω tive contact)tive contact) Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connector PTCN2 and connect T-adapter to female side. (Contact with ground cir3. Disconnect terminal POP. cuit) Between PTCN2 (female) (13) and ground Resistance Min. 1 MΩ If cause is not found by above checks, power train controller is defective. q Reference: Following shows criteria in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN2. troller 3. Turn starting switch to ON position. a During pre-lubrication Voltage 7 – 11 V Between PTCN2 (13) and (29)
Circuit diagram related to pre-lubricating oil pressure switch
40-352
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDE2KA] Pre lub. oil press sw: Disconnection
D375A-6 (01)
40-353
DRAFT Troubleshooting by failure code Failure code [DDK3L4] Forward SW Signal disagreement
Failure code [DDK3L4] Forward SW Signal disagreement Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code Inconsistent forward switch signal Failure DDK3L4 (Power train controller system) q There is inconsistency in line 2 of NO* for forward switch circuit. q
Recognizes that forward switch is not pressed.
q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to R1. Condition of forward switch signal can be checked with monitoring function. (Code: 40905 Power train control input 3) Method of reproducing failure code: Turn starting switch to ON position (and operate forward switch).
q q q
Cause Wrong selection of travel 1 lever type
2
3
4
5
6
Procedure, measuring location, criteria and remarks If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
1. Turn starting switch to OFF position. 2. Disconnect connector FTS. 3. Disconnect connectors TL3 and connect T-adapters to female side. 4. Turn shift up switch to ON or OFF position and troubleshoot. Defective forward switch a "Switch OFF": Release, "Switch ON": Press (Internal disconnection) Between FTS (male) (3) and Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω TL3 (male) (5) Switch: OFF Resistance Min. 1 MΩ Between FTS (male) (1) and (2) Switch: ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector FTS. 3. Insert T-adapter into connector TL3. 4. Turn starting switch to ON position. Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it in wiring harness shows hot short in wiring harness. a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between TL3(1) and (2) Voltage 7 – 11 V Between TL3(3) and (5) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, PTCN3 and TL3, and connect T-adapters to female Disconnection in wiring side of them. harness 3. Disconnect connector RTS. (Disconnection or defecBetween PTCN3 (female) (39) and TL3 (female) (1) Resistance Max. 1 Ω tive contact) Between PTCN1 (female) (10) and TL3 (female) (2) Resistance Max. 1 Ω Between PTCN3 (female) (29) and TL3 (female) (3) Resistance Max. 1 Ω Between PTCN1 (female) (10) and RTS (male) (2) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of ness PTCN3. (Contact with ground cirBetween PTCN3 (female) (39) and ground Resistance Min. 1 MΩ cuit) Between PTCN3 (female) (29) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of PTCN3. Short circuit in wiring har- a Check with multimeter in continuity mode. ness No continuity Between PTCN3 (female) (29) and each pin other than (29) (No sound is heard) NO continuity Between PTCN3 (female) (39) and each pin other than (39) (No sound is heard)
40-354
D375A-6 (01)
Troubleshooting by failurecode Failure code [DDK3L4] Forward SW Signal disagreement
Cause
6
7
Short circuit in wiring harness
Defective power train controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of PTCN3. a Check with multimeter in continuity mode. Between PTCN3 (female) (29) and each pin other than No continuity (29) (No sound is heard) Between PTCN3 (female) (39) and each pin other than No continuity (39) (No sound is heard) If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors PTCN1 and PTCN3. 3. Turn starting switch to ON position. 4. Turn shift up switch to ON or OFF position and troubleshoot. a The voltage of approximately 9 V is applied to PTCN3 pin (29) and pin (39) through the resistor in power train controller. Between PTCN3 (29) and PTCN1 (10)
Switch: OFF
Voltage
7 – 11 V
Switch: ON
Voltage
Max. 1 V
Between PTCN3 (39) and PTCN1 (10)
Switch: OFF
Voltage
7 – 11 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open Circuit diagram related to forward switch
40-359
a Exclusive for single-direction lever
D375A-6 (06)
40-355
DRAFT Troubleshooting by failure code Failure code [DDK5KA] Shift switch disconnection
Failure code [DDK5KA] Shift switch disconnection Action code E02
Failure code Shift switch disconnection Failure DDK5KA (Transmission controller system) q Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are OPEN Detail of failure (switch: OFF) at the same time. Action of conq Recognizes that switch is not pressed. troller Problem on q Gear cannot be shifted up and down (1st io 2nd). machine q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for detecting error. Related inforq Condition of shift up switch signal can be checked with monitoring function. mation (Code: 40905 Power train control Input 3) q Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch. Cause Wrong selection of travel 1 lever type
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
Turn starting switch to OFF position. Disconnect connector SNC and connect T-adapter to male side. Turn shift switch to ON or OFF position and troubleshoot. Defective shift switch "Switch OFF": Release, "Switch ON": Press (Internal disconnection) Switch: OFF Resistance Max. 1 Ω Between SNC (male) (1) and (3) Switch: ON Resistance Min. 1 MΩ Switch: OFF Resistance Min. 1 MΩ Between SNC (male) (1) and (2) Switch: ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector SNC and connect T-adapter to female side. 3. Turn starting switch to ON position. Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it shows hot short in wiring harness. in wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between SNC (female) (2) and (1) Voltage 7–11 V Between SNC (female) (3) and (1) Voltage 7–11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter to ness female side of them. (Disconnection or defective Between PTCN1 (female) (10) and SNC (female) (1) Resistance Max. 1 Ω contact) Between PTCN2 (female) (7) and SNC (female) (2) Resistance Max. 1 Ω Between PTCN1 (female) (6) and SNC (female) (3) Resistance Max. 1 Ω If cause is not found by the above checks, power train controller is defective. q Reference: the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-connector into connectors PTCN1 and PTCN2. 3. Turn starting switch to ON position. Defective power train con- 4. Turn shift switch to ON or OFF position and troubleshoot. troller a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through resistor in power train controller. Switch: OFF Voltage 7–11 V Between PTCN2 (7) and PTCN1 (10) Switch: ON Voltage Max. 1 V Switch: OFF Voltage Max. 1 V Between PTCN1 (6) and PTCN1 (10) Switch: ON Voltage 7–11 V
40-356
1. 2. 3. a
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDK5KA] Shift switch disconnection
Circuit diagram related to shift switch
a Exclusive for single-direction lever
D375A-6 (01)
40-357
DRAFT Troubleshooting by failure code Failure code [DDK5KB] Shift switch short circuit
Failure code [DDK5KB] Shift switch short circuit Action code E02
Failure code Shift switch short circuit Failure DDK5KB (Power train controller system) q Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are 0 V (switch: Detail of failure ON) at the same time. Action of conq Recognizes that switch is not pressed. troller Problem on q Gear cannot be shifted up and down (1stio2nd). machine q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for detecting error. Related infor- q Condition of shift up switch signal can be checked with monitoring function. mation (Code: 40905 Power train control Input 3) q Method of reproducing failure code: Turn the starting switch to ON position and operate the shift up switch Cause Wrong selection of travel 1 lever type
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
Turn starting switch to OFF position. Disconnect connector SNC and connect T-adapter to male side. Turn shift up switch to ON or OFF position and troubleshoot. Defective shift up switch “Switch OFF”: Release, “Switch ON”: Press (Internal disconnection) Switch: OFF Resistance Max. 1 Ω Between SNC (male) (1) and (3) Switch: ON Resistance Min. 1 MΩ Switch:OFF Resistance Min. 1 MΩ Between SNC (male) (1) and (2) Switch: ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1, STC3 and SNC and connect T-adapter to female side of one of them. Ground fault of wiring har3. Turn starting switch to ON position. ness Resistance Min. 1 MΩ (Contact with rround circuit) Between SNC (female) (2) and ground , or between PTCN2(female) (7) and ground Between SNC (female) (3) and ground , or between Resistance Min. 1 MΩ PTCN1 (female) (6) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters to female side of PTCN1 and PTCN2. Short circuit in wiring hara Check with multimeter in continuity mode. ness No continuity (No sound is Between PTCN1 (female) (6) and each pin other than (6) heard) Between PTCN2 (female) (7) and each pin other than No continuity (No sound is (7) heard) If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors PTCN1 and PTCN2. 3. Turn starting switch to ON position. Defective power train con- 4. Turn shift up switch to ON or OFF position and troubleshoot. troller a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through resistor in power train controller. Switch: OFF Voltage 7–11 V Between PTCN2 (7) and PTCN1(10) Switch: ON Voltage Max. 1 V Switch: OFF Voltage Max. 1 V Between PTCN1 (6) and PTCN1(10) Switch: ON Voltage 7–11 V
40-358
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D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDK5KB] Shift switch short circuit
Circuit diagram related to shift switch
D375A-6 (01)
40-359
DRAFT Troubleshooting by failure code Failure code [DDN2LD] Blade tilt RH pressure SW abnormality
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Blade tilt right hand oil pressure switch is pressed for long time Failure DDN2LD (Work equipment controller system) q The signal of the blade tilt left oil pressure switch circuit is kept turned O V (ON) for 60 seconds. q
Recognizes that the oil pressure switch is turned to OFF position.
q
Data communication of VHMS may be abnormal
q
The input state (ON/OFF) from the blade tilt right hand oil pressure switch can be checked moniitoring funtion. (Code 90802: Blade oil pressure switch input state) Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after 60 seconds). First, check the power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
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Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incorrect shift 1 (When electrical system is lever operation might be made. normal) 1. Turn starting switch to OFF position. Defective blade tilt right 2. Disconnect connector TRS and connect T-adapter to male side. 2 hand oil pressure switch Between TRS (female)(1) and (2) Resis(Internal short circuit) Min. 1 MΩ (Oil pressure switch is OFF position.) tance 1. Turn starting switch to OFF position. 2. Disconnect connector TRS. Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDN2LD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDN2LD] is not displayed, blade tilt right oil pressure switch is defective.) a If cause 3 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors WECN2 and TRS, and connect T-adapter to female side of 4 (Contact with ground cireither one of them. cuit) Between WECN2 (female) (7) and ground, or betweenTRS ResisMin. 1 MΩ (female) (1) and ground. tance If “check result of cause 3 is abnormal” and “check result of cause 4 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep PCCS lever in N position. Between WECN2(7) and WECN1(4) Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate blade lever and perform troubleshooting. Between WECN2(7) and R.H. tilt Voltage Max. 1 V WECN1(4)
40-360
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDN2LD] Blade tilt RH pressure SW abnormality
Circuit diagram related to Blade tilt right hand oil pressure switch
D375A-6 (01)
40-361
DRAFT Troubleshooting by failure code Failure code [DDN3LD] Blade tilt LH pressure SW abnormality
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality Action code ― Detail of failure Action of controller Problem s on machine
Related information
Failure code Blade tilt left hand oil pressure switch is pressing for long time Failure DDN3LD (Work equipment controller system) q The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds. q
Recognizes that the oil pressure switch is turned to OFF position.
q
Data communication of VHMS may be abnormal.
q
The input state (ON/OFF) from the blade tilt left hand oil pressure switch can be checked moniitoring funtion. (Code 90802: Blade oil pressure switch input state) Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after 60 seconds). First, check the power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
q q q
Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If the error code lamp still lights up (resetting is still urged) after the resetting operation 1 (When electrical system is is performed, it is suspected that the lever was operated to cause an error. normal) 1. Turn starting switch to OFF position. Defective blade tilt left 2. Disconnect connector TLS and connect T-adapter to male side. 2 hand oil pressure switch Between TLS (female)(1) and (2) Resis(Internal short circuit) Min. 1 MΩ (Oil pressure switch is OFF position) tance 1. Turn starting switch to OFF position. 2. Disconnect connector TLS. Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.) 3 ness or defective work If failure code [DDN3LD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDN3LD] is not displayed, blade tilt left oil pressure switch is defective.) a If cause 3 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors WECN2 and TLS, and connect T-adapter to female side of 4 (Contact with ground cireither one of them. cuit) Between WECN2 (female) (17) and ground, or between TLS ResisMin. 1 MΩ (female) (1) and ground. tance If “check result of cause 3 is abnormal” and “check result of cause 4 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep PCCS lever in N position. Between WECN2(17) and WECN1(4) Voltage 7 – 11 V 1. – 3. are same as above. 4.While depressing brake pedal, operate blade lever and perform troubleshooting. Between WECN2(17) and Max. 1 V L.H. tilt Voltage WECN1(4)
40-362
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDN3LD] Blade tilt LH pressure SW abnormality
Circuit diagram related to blade tilt left hand oil pressure switch
D375A-6 (01)
40-363
DRAFT Troubleshooting by failure code Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection Action code E02
Failure code Work equipment knob switch (lower): Disconnection Failure DDN7KA (Work equipment controller system) q Both lines of NO: Normally Open and NC: Normally Closed for blade knob lower switch circuit are Detail of failure OPEN (switch: OFF) at the same time. Action of conq Recognizes that blade knob switch lower is not pressed. troller Problem on q Blade knob switch lower does not work. machine q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for detecting error. q Condition of blade knob switch lower signal can be checked with monitoring function. Related infor(Code: 70300 Blade Sw Input) mation q Method of reproducing failure code: Turn the starting switch ON position and (operate blade pitch switch). q Since T-adapter is not prepared for connector WNBL, female side check is not required. Cause
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Procedure, measuring location, standard (value) and remarks Turn starting switch to OFF position. Disconnect connector WNBL. Insert T-adapter into connector P03. Turn starting switch to ON position. Disconnection or hot If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it short in wiring harness shows hot short in wiring harness. a Voltage of approx.9 V is applied to signal lines of “NO” and “NC” through resistor in work equipment controller. Between P03 (2) and (1) Voltage 7 – 11 V Between P03 (5) and (1) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors WECN1, WECN2 and WNBL, and connect T-adapter to each harness female side (Disconnection or defecBetween WECN2 (female) (26) and WNBL (female) (1) Resistance Max. 1 Ω tive contact) Between WECN1 (female) (4) and WNBL (female) (2) Resistance Max. 1 Ω Between WECN2 (female) (36) and WNBL (female) (3) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector P03 and connect T-adapter to male side. 3. Turn blade knob lower switch to ON or OFF position and troubleshoot. Defective blade knob lower switch(Internal dis- a “Switch OFF”: Release, “Switch ON”: Press Between P03(male) (2) and Switch: OFF Resistance Max. 1 Ω connection) Switch: ON Resistance Min. 1 MΩ (1) Between P03(male) (1) and Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω (2) If cause is not found by the above checks, work equipment controller is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. 3. Turn starting switch to ON position. Defective work equip4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot. ment controller a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through resistor in work equipment controller. Between WECN2(36) and Switch: OFF Voltage Max. 1 V 7 – 11 V Switch: ON Voltage WECN1(4) Between WECN2(26) and Switch: OFF Voltage 7 – 11 V Max. 1 V Switch: ON Voltage WECN1(4)
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D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
Circuit diagram related to work equipment knob switch
D375A-6 (01)
40-365
DRAFT Troubleshooting by failure code Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit Action code E02
Failure code Work equipment knob switch (Lower): Short circuit Failure DDN7KB (Work equipment controller system) q Both lines of NO: Normally Open and NC: Normally Closed for blade knob switch lower circuit are 0 Detail of failure V (switch: ON) at the same time. Action of conq Recognizes that blade knob lower switch is not pressed. troller Problem on q Blade knob switch (lower) does not work. machine q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for detecting error. q Condition of blade knob switch lower signal can be checked with monitoring function. Related infor(Code: 70300 Blade Sw Input) mation q Method of reproducing failure code: Turn the starting switch to ON position and (operate blade pitch switch). q Since T-adapter is not prepared for connector WNBL female side check is not required. Cause
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Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and WNBL and connect T-adapter to female side Ground fault of wiring harof WECN2. ness ResisMin. 1 MΩ (Contact with GND circuit) Between WECN2 (female) (26) and ground tance ResisBetween WECN2 (female) (36) and ground Min. 1 MΩ tance 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and WNBL and connect T-adapters to female side of WECN2. Short circuit in wiring har- a Check with tester in continuity mode. ness No continuity Between WECN2 (female) (26) and each pin other than (26) (No sound is heard) No continuity Between WECN2 (female) (36) and each pin other than (36) (No sound is heard) 1. Turn starting switch to OFF position. 2. Disconnect connector P03 and connect T-adapter to male side. 3. Turn blade knob switch (lower) to ON or OFF position and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press ResisDefective blade knob Switch: OFF Max. 1 Ω Between P03 (male) (5) and tance switch lower (Internal disResis(1) connection) Switch: ON Min. 1 MΩ tance ResisSwitch: OFF Min. 1 MΩ Between P03 (male) (1) and tance Resis(2) Switch: ON Max. 1 Ω tance If cause is not found by the above checks, work equipment controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. 3. Turn starting switch to ON position. Defective work equipment 4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot. controller a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through resistor in work equipment controller. Between WECN (36) and Switch: OFF Voltage Max. 1 V Switch: ON 7 – 11 V Voltage WECN (4) Between WECN (26) and Switch: OFF Voltage 7 – 11 V Switch: ON Max. 1 V Voltage WECN (4)
40-366
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
Circuit diagram related to work equipment knob switch
D375A-6 (01)
40-367
DRAFT Troubleshooting by failure code Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection Action code E01
Failure code Work equipment knob switch (raise): Disconnection Failure DDN9KA (Work equipment controller system) q Both lines of NO: Normally Open and NC : Normally Closed for blade knob upper switch circuit are Detail of failure OPEN (switch: OFF) at the same time. Action of conq Recognizes that blade knob upper switch is not pressed. troller Problem on q Blade knob switch (raise) does not work. machine q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for detecting error. q Condition of blade knob switch signal can be checked with monitoring function. Related infor(Code: 70300 Blade Sw Input) mation q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob switch (raise). q Since T-adapter is not prepared for connector WNBU female side check is not required. Cause
Procedure, measuring location, criteria and remarks Turn starting switch to OFF position. Disconnect connector WNBU. Turn blade upper knob switch (raise) to ON or OFF position and troubleshoot. “Switch OFF”: Release, “Switch ON”: Press ResisDefective blade knob Switch: OFF Max. 1 Ω tance switch raise (Internal dis- Between WNBU (male) (3) and Resis(2) connection) Switch: ON Min. 1 MΩ tance ResisSwitch: OFF Min. 1 MΩ Between WNBU (male) (1) and tance Resis(2) Switch:ON Max. 1 Ω tance 1. Turn starting switch to OFF position. 2. Disconnect connector WNBU. 3. Insert T-adapter into connector P03. 4. Turn starting switch to ON position. Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it in wiring harness shows hot short in wiring harness. a Voltage of apporx.9 V is applied to signal lines of “NO” and “NC” through resistor in work equipment controller. Between P03 (female) (4) and (3) Voltage 7 – 11 V Between P03 (female) (6) and (3) Voltage 7 – 11 V 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1 and WECN2 and connect T-adapters to each Disconnection in wiring female side. harness 3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot. (Disconnection or defec- Between WECN2 (female) (15) and WECN1 ResisSwitch: OFF Max. 1 Ω tive contact) (female) (4) tance Between WECN2 (female) (5) and WECN1 ResisSwitch: ON Max. 1 Ω (female) (4) tance If cause is not found by the above checks, work equipment controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. 3. Turn starting switch to ON position. Defective work equipment 4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot. controller a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through resistor in work equipment controller. Between WECN2 (5) and Switch: OFF Voltage 7 – 11 V Switch: ON Voltage Max. 1 V WECN1 (4) Between WECN2 (15) and Switch: OFF Voltage Max. 1 V Switch: ON Voltage 7 – 11 V WECN1 (4) 1. 2. 3. a
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40-368
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection
Circuit diagram related to work equipment knob switch
D375A-6 (01)
40-369
DRAFT Troubleshooting by failure code Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit Action code E01
Failure code Work equipment knob switch (raise): Disconnection Failure DDN9KB (Work equipment controller system) q Both lines of NO: Normally Open and NC : Normally Closed for blade knob switch raise circuit are 0 Detail of failure V (switch: ON) at the same time. Action of conq Recognizes that blade knob upper switch is not pressed. troller Problem on q Blade knob switch (raise) does not work. machine q NO: Normally Open line is used for sensing operation and NC: line is used for detecting error. q Condition of blade knob switch signal can be checked with monitoring function. Related infor(Code: 70300 Blade Sw Input) q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob mation switch (raise). q Since T-adapter is not prepared for connector WNBU female side check is not required. Cause
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Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector WNBU and connect T-adapter to male side. Defective blade knob switch 3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press raise (Internal disconnecBetween WNBU (male) (3) and Switch: OFF Resistance Max. 1 Ω tion) Switch: ON Resistance Min. 1 MΩ (2) Between WNBU (male) (1) and Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω (2) 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors WECN1, WECN2 and WNBU and connect T-adapter to ness female side of either one of them. (Contact with groung circuit) Between WECN1 (female) (5) and ground Resistance Min. 1 MΩ Between WECN1 (female) (15) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and WNBU and connect T-adapter to female side of WECN2. Short circuit in wiring hara Check with multimeter in continuity mode. ness Between WECN2 (female) (5) and each pin other than No continuity (5) (No sound is heard) Between WECN2 (female) (15) and each pin other than No continuity (15) (No sound is heard) If cause is not found by the above checks, work equipment controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. 3. Turn starting switch to ON position. Defective work equipment 4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot. controller a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through resistor in work equipment controller. Between WECN2 (5) and Switch: OFF Voltage 7 – 11 V Switch: ON Max. 1 V Voltage WECN1 (4) Between WECN2 (15) and Switch: OFF Voltage Max. 1 V Switch: ON 7 – 11 V Voltage WECN1 (4)
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D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit
Circuit diagram related to work equipment knob switch
D375A-6 (01)
40-371
DRAFT Troubleshooting by failure code Failure code [DDNALD] Blade lift up pressure SW abnormality
Failure code [DDNALD] Blade lift up pressure SW abnormality Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Blade lift raise oil pressure switch is pressed for long time Failure DDNALD (Work equipment controller system) q The signal of blade lift raise (full stroke) oil pressure switch circuit is kept turned to ON position for 60 seconds. q
Recognizes that the oil pressure switch is turned OFF.
q
Data of the VHMS may become abnormal.
q
Input state (ON/OFF) from blade raise (full stroke) oil pressure switch can be checked monitoring function. (Code 90802: Blade oil pressure switch input) Method of reproducing failure code: Turn starting switch to ON position (Error is reproduced after 60 seconds). First, check power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
q q q
Cause Procedure, measuring location, cirteria and remarks Wrong operation of lever If failure code lamp still lights up (resetting is still urged) after the resetting operation is 1 (When electrical system is performed, it is suspected that lever was operated to cause an error. normal) 1. Turn starting switch to OFF position. Defective blade raise oil 2 pressure switch (Internal 2. Disconnect connector BLU and connect T-adapter to male side. Between BLU (female) (1) and (2) short circuit) Resistance Min. 1 MΩ (Oil pressure switch: OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector BLU. Ground fault of wiring har3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDNALD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDNALD] is not displayed, blade raise oil pressure switch is defective.) a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors WECN2 and BLU, and connect T-adapter to female side of 4 ness either one of them. (Contact with GND circuit) Between WECN2 (female) (16) and ground or betweenBLU Resistance Min. 1 MΩ (female) (1) and ground. If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equip3. Start engine. 5 ment controller a Keep blade lever in neutral position. Between WECN2 (16) and WECN1 (4) Voltage 7 – 11 V 1. – 3. are same as above. 4. Operate blade lever and troubleshoot. Between WECN2 (16) and Blade lever: Raise Voltage Max. 1 V WECN1 (4)
40-372
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNALD] Blade lift up pressure SW abnormality
Circuit diagram related to blade raise oil pressure switch
D375A-6 (01)
40-373
DRAFT Troubleshooting by failure code Failure code [DDNBLD] Ripper lift up pressure SW abnormality
Failure code [DDNBLD] Ripper lift up pressure SW abnormality Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Ripper lift raise oil pressure switch is pressed for long time Failure DDNBLD (Work equipment controller system) q The signal of the ripper raise oil pressure switch circuit is kept turned to ON position for 60 seconds. q
Recognizes that oil pressure switch is turned to OFF position.
q
Shoe slip control (SSC) function does not activate normally. VHMS data may become abnormal. Input state (ON/OFF) from the ripper raise oil pressure switch can be checked moniitoring funtion.(Code 40982: Ripper oil pressure switch input ) Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after 60 seconds). First, check power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
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Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If failure code lamp still lights up (resetting is still urged) after the resetting operation is 1 (When electrical system is performed, it is suspected that the lever was operated to cause an error. normal) 1. Turn starting switch to OFF position. Defective ripper raise oil 2 pressure switch (Internal 2. Disconnect connector RPU and connect T-adapter to male side. Between RPU (female) (1) and (2) Resisshort circuit) Min. 1 MΩ (Oil pressure switch: OFF) tance 1. Turn starting switch to OFF position. 2. Disconnect connector RPU. Ground fault of wiring har3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDNBLD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDNBLD] is not displayed, ripper raise oil pressure switch is defective) a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors WECN2 and RPU, and connect T-adapter to female side of 4 ness either one of them. (Contact with GND circuit) Between WECN2 (female) (13) and ground, or betweenRPU ResisMin. 1 MΩ (female) (1) and ground. tance If “check result of cause 3 is abnormal” and “check result of cause 4 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep ripper lever in neutral position. Between WECN2 (13) and WECN1 (4) Voltage 7 – 11 V 1. – 3. are same as above. 4.Operate ripper lever and perform troubleshooting. Between WECN2 (13) and Ripper lever: Raise Voltage Max. 1 V WECN1 (4)
40-374
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNBLD] Ripper lift up pressure SW abnormality
Circuit diagram related to ripper raise oil pressure switch
D375A-6 (01)
40-375
DRAFT Troubleshooting by failure code Failure code [DDNCLD] Ripper lift down pressure SW abnormality
Failure code [DDNCLD] Ripper lift down pressure SW abnormality Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Ripper lower oil pressure switch is pressed for long time Failure DDNCLD (Work equipment controller system) q Signal of ripper lift lower oil pressure switch circuit is kept turned to ON position for 60 seconds. q
Recognizes that oil pressure switch is turned OFF.
q
Shoe slip control (SSC) function does not activate normally. VHMS data may become abnormal. Input state (ON/OFF) from ripper lower oil pressure switch can be checked in the real-time moniitoring mode. (Code 40982: Ripper oil pressure switch input signal) Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after 60 seconds). First, check power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
q q q q q
Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If failure code lamp still lights up (resetting is still urged) after the resetting operation is 1 (When electrical system is performed, it is suspected that the lever was operated to cause an error. normal) 1. Turn starting switch to OFF position. Defective ripper lower oil 2 pressure switch (Internal 2. Disconnect connector RPD and connect T-adapter to male side. Between RPD (female) (1) and (2) Resisshort circuit) Min. 1 MΩ (Oil pressure switch : OFF) tance 1. Turn starting switch to OFF position. 2. Disconnect connector RPD. Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDNCLD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDNCLD] is not displayed, ripper lift lower oil pressure switch is defective) a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors WECN2 and RPD, and connect T-adapter to female side of 4 ness either one of them. (Contact with GND circuit) Between WECN2 (female) (3) and ground or betweenRPD ResisMin. 1 MΩ (female) (1) and ground. tance If “check result of cause 3 is abnormal” and “check result of cause 4 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep ripper lever in neutral position. Between WECN2 (3) and WECN1 (4) Voltage 7 – 11 V 1. – 3. are same as above. 4.Operate ripper lever and perform troubleshooting. Between WECN2 (3) and Ripper lever: Lower Voltage Max. 1 V WECN1 (4)
40-376
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNCLD] Ripper lift down pressure SW abnormality
Circuit diagram related to ripper lower oil pressure switch
D375A-6 (01)
40-377
DRAFT Troubleshooting by failure code Failure code [DDNDLD] Ripper tilt in pressure SW abnormality
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Ripper tilt in oil pressure switch is pressed for long time Failure DDNDLD (Work equipment controller system) q Signal of ripper tilt in oil pressure switch circuit is kept turned to ON position for 60 seconds. q
Recognizes that oil pressure switch is turned to OFF position.
q
Shoe slip control (SSC) function does not operate normally. VHMS data may become abnormal. Input state (ON/OFF) from ripper tilt in oil pressure switch can be checked with monitoring function. (Code 40982: Ripper oil pressure switch input state) Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after 60 seconds). First, check the power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
q q q q q
Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incorrect lever 1 (When electrical system is operation might be made. normal) 1. Turn starting switch to OFF position. Defective ripper tilt in oil 2. Disconnect connector RTI and connect T-adapter to male side. 2 pressure switch (Internal Between RTI (female)(1) and (2) Resisshort circuit) Min. 1 MΩ (Turn oil pressure switch: OFF.) tance 1. Turn starting switch to OFF position. 2. Disconnect connector RTI. Ground fault of wiring har3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDNDLD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDNDLD] is not displayed, ripper tilt in oil pressure switch is defective.) a If cause 3 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors WECN2 and RTI, and connect T-adapter to female side of 4 (Contact with ground cireither one of them. cuit) Between WECN2 (female) (2) and ground or between RTI ResisMin. 1 MΩ (female) (1) and ground. tance If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep ripper lever in neutral position. Between WECN2(2) and WECN1(4) Voltage 7 – 11 V 1. – 3. are same as above. 4. Operate ripper lever and troubleshoot. Between WECN2(2) and Ripper lever: Tilt in Voltage Max. 1 V WECN1(4)
40-378
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNDLD] Ripper tilt in pressure SW abnormality
Circuit diagram related to ripper tilt in oil pressure switch
D375A-6 (01)
40-379
DRAFT Troubleshooting by failure code Failure code [DDNELD] Ripper tilt back pressure SW abnormality
Failure code [DDNELD] Ripper tilt back pressure SW abnormality Action code ― Detail of failure Action of controller Problem on machine
Related information
Failure code Ripper tilt back oil pressure switch is pressed for long time Failure DDNELD (Work equipment controller system) q Signal of the ripper tilt back oil pressure switch circuit is kept turned to ON position for 60 seconds. q
Recognizes that the oil pressure switch is turned OFF.
q
Shoe slip control (SSC) function does not activate normally. VHMS data may become abnormal. Input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked moniitoring funtion. (Code 40982: Ripper oil pressure switch input ) Method of reproducing failure code: Turn starting switch to ON position (Error is reproduced after 60 seconds). First, check the power train oil filter for clogging etc. Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
q q q q q
Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If failure code lamp still lights up (resetting is still urged) after the resetting operation is 1 (When electrical system is performed, it is suspected that lever was operated to cause an error. normal) 1. Turn starting switch to OFF position. Defective ripper tilt back oil 2 pressure switch (Internal 2. Disconnect connector RTB and connect T-adapter to male side. Between RTB (female)(1) and (2) Resisshort circuit) Min. 1 MΩ (Oil pressure switch: OFF) tance 1. Turn starting switch to OFF position. 2. Disconnect connector RTB. Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDNELD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDNELD] is not displayed, ripper tilt back oil pressure switch is defective) a If cause 3 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors WECN2 and RTB, and connect T-adapter to female side of 4 (Contact with ground cireither one of them. cuit) Between WECN2 (female) (38) and ground or betweenRTB ResisMin. 1 MΩ (female) (1) and ground. tance If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep ripper lever in neutral position. Between WECN2 (38) and WECN1 (4) Voltage 7 – 11 V 1. – 3. are same as above. 4.Operate ripper lever and perform troubleshooting. Between WECN2 (38) and Ripper lever: Tilt back Voltage Max. 1 V WECN1 (4)
40-380
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNELD] Ripper tilt back pressure SW abnormality
Circuit diagram related to ripper tilt back oil pressure switch
D375A-6 (01)
40-381
DRAFT Troubleshooting by failure code Failure code [DDNFLD] Blade lift down pressure SW abnormality
Failure code [DDNFLD] Blade lift down pressure SW abnormality Action code ―
Failure code Blade lift lower oil pressure switch is pressed for long time Failure DDNFLD (Work equipment controller system) q Signal of blade lower (full stroke) oil pressure switch circuit is kept turned to ON position for 60 secDetail of failure onds. Action of conq Recognizes that oil pressure switch is turned to OFF position. troller Indication of problem on q VHMS data may become abnormal. machine q Input state (ON/OFF) from blade lower (full stroke) oil pressure switch can be checked with monitoring function. (Code 90802: Blade oil pressure switch input state) q Method of reproducing failure code: Turn starting switch to ON position (and wait for longer than 180 Related inforsec.). mation q First, check power train oil filter for clogging etc. q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure". Cause Procedure, measuring location, criteria and remarks Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incorrect lever 1 (When electrical system is operation might be made. normal) 1. Turn starting switch to OFF position. Defective blade lower oil 2. Disconnect connector BLD and connect T-adapter to male side. 2 pressure switch (Internal Between BLD (female)(1) and (2) Resisshort circuit) Min. 1 MΩ (Oil pressure switch: OFF.) tance 1. Turn starting switch to OFF position. 2. Disconnect connector BLD. Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.). 3 ness or defective work If failure code [DDNFLD] is still displayed, there is ground fault of wiring harness or equipment controller work equipment controller is defective. (If failure code [DDNFLD] is not displayed, blade lower oil pressure switch is defective.) a If cause 3 is not the cause for the trouble, this check is not required. Ground fault of wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors WECN2 and BLD, and connect T-adapter to female side of 4 (Contact with ground cireither one of them. cuit) Between WECN2 (female) (6) and ground or betweenBLD ResisMin. 1 MΩ (female) (1) and ground tance If “check result of cause 3 is abnormal” and “check result of cause 4 is normal”, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. Defective work equipment 3. Start engine. 5 controller a Keep blade lever in neutral position. Between WECN2(6) and WECN1(4) Voltage 7 – 11 V 1. – 3. are same as above. 4. Operate lever and troubleshoot. Between WECN2(6) and Blade lever: Lower Voltage Max. 1 V WECN1(4)
40-382
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNFLD] Blade lift down pressure SW abnormality
Circuit diagram related to blade lower oil pressure switch
D375A-6 (01)
40-383
DRAFT Troubleshooting by failure code Failure code [DDNLKA] Weq lock Sw: Disconnection
Failure code [DDNLKA] Weq lock Sw: Disconnection Action code E03
Failure code Work equipment lock switch: Disconnection Failure DDNLKA (Work equipment controller system) q Both lines of NO* and NC* for work equipment lock lever switch circuit are OPEN (switch: OFF) at Detail of failure the same time. Action of con- q Recognizes that work equipment lock lever is in LOCk position. troller q Limits operation of engine and transmission. q Once machine is stopped, engine speed is limited to medium (half). Problem on q Once machine stops, travel is limited to F1 and R1. machine q Work equipment operation is impossible. q Engine does not run. q "NO*" line is used for sensing operation and "NC*" line is used for detecting error. q Condition of work equipment lock lever switch signal can be checked with monitoring function. (Code: 70300 Blade Sw Input) Related inforq Method of reproducing failure code: Turn starting switch to ON position and operate work eqiupment mation lock lever. q When work equipment lock lever is free, work equipment lock lever switch becomes "ON". (Lever is locked in illustration.) Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector WELK and connect T-adapter to male side. Defective work equipment 3. Operate work equipment lock lever and troubleshoot. 1 lock lever switch (Internal Between WELK (male) (A) and Lever: FREE Resistance Min. 1 MΩ disconnection) Lever: LOCK Resistance Max. 1 Ω (B) Between WELK (male) (A) and Lever: FREE Resistance Max. 1 Ω Lever: LOCK Resistance Min. 1 MΩ (C) 1. Turn starting switch to OFF position. 2. Disconnect connector WELK and connect T-adapter to female side. 3. Turn starting switch to ON position. Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it 2 shows hot short in wiring harness. in wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between WELK (female) (A) and (B) Voltage 7 – 11 V Between WELK (female) (A) and (C) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors WECN1, WECN2 and WELK, and connect T-adapters to harness 3 female side . (Disconnection or defecBetween WECN1 (female) (10) and WELK (female) (A) Resistance Max. 1 Ω tive contact) Between WECN2 (female) (35) and WELK (female) (B) Resistance Max. 1 Ω Between WECN2 (female) (25) and WELK (female) (C) Resistance Max. 1 Ω If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. 3. Turn starting switch to ON position. Defective work equipment 4. Operate work equipment lock lever switch and troubleshoot. 4 controller a Voltage of apporx.9 V is applied to WECN2 pin (25) and pin (35) through resistor in power train controller. Between WECN2(25) and Lever: FREE Voltage 7 – 11 V Max. 1 V Lever: LOCk Voltage WECN1(10) Between WECN2(35) and Lever: FREE Voltage Max. 1 V 7 – 11 V Lever: LOCk Voltage WECN1(10)
*NO: Normally Open *NC: Normally Closed
40-384
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNLKA] Weq lock Sw: Disconnection
Circuit diagram related to equipment lock switch
D375A-6 (01)
40-385
DRAFT Troubleshooting by failure code Failure code [DDNLKB] Weq lock Sw: Short circuit
Failure code [DDNLKB] Weq lock Sw: Short circuit Action code E03
Failure code Work equipment lock switch: Short circuit Failure DDNLKB (Power train controller systerm) q Both lines of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch: ON) at the Detail of failure same time. Action of con- q Recognizes that work equipment lock lever is in Lock position. troller q Limits operation of engine and transmission. q Once machine stops, engine speed is limited to medium (half). Problem on q Once machine stops, travel is limited to F1 and R1. machine q Work equipment operation is impossible. q Engine does not run. q “NO*” line is used for sensing operation and “NC” line is used for detecting error. q Condition of work equipment lock lever switch signal can be checked with monitoring function. (Code: 70300 Blade Sw Input) Related inforq Method of reproducing failure code: Turn starting switch to ON position and operate work equipment mation lock lever. q When work equipment lock lever is free, work equipment lock lever switch becomes "ON". (Lever is locked in illustration.) Cause
Defective work equipment 1 lock lever switch (Internal disconnection)
Ground fault of wiring har2 ness (Contact with GND circuit)
3
Short circuit in wiring harness
4
Defective power train controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector WELK and connect T-adapter to male side. 3. Operate work equipment lock lever and troubleshoot. Between WELK (male) (A) and Lever: FREE Resistance Min. 1 MΩ Lever: LOCK Resistance Max. 1 Ω (B) Between WELK (male) (A) and Lever: FREE Resistance Max. 1 Ω Lever: LOCK Resistance Min. 1 MΩ (C) 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1, WECN2 and WELK and connect T-adapter to female side of one of them. Between WELK (female) (B) and ground or between Resistance Min. 1 MΩ WECN2 (female) (35) and ground. Between WELK (female) (C) and ground or between Resistance Min. 1 MΩ WECN2 (female) (25) and ground. 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN2 and WELKand connect T-adapters to female side of WECN2. a Check with multimeter in continuity mode. Between WECN2 (female) (25) and each pin other than No continuity (25) (No sound is heard) Between WECN2 (female) (35) and each pin other than No continuity (35) (No sound is heard) If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 and WECN2. 3. Turn starting switch to ON position. 4. Operate work equipment lock lever switch and troubleshoot. a Voltage of approx.9 V is applied to WECN2 pin (25) and pin (35) through resistor in power train controller. Between WECN2 (25) and Lever: FREE Voltage 7 – 11 V Max. 1 V Lever: LOCK Voltage WECN1 (10) Between WECN2 (35) and Lever: FREE Voltage Max. 1 V 7 – 11 V Lever: LOCK Voltage WECN1 (10)
*NO: Normally Open *NC: Normally Closed
40-386
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDNLKB] Weq lock Sw: Short circuit
Circuit diagram related to work equipment lock switch
D375A-6 (01)
40-387
DRAFT Troubleshooting by failure code Failure code [DDT5KA] Neutral switch disconnection
Failure code [DDT5KA] Neutral switch disconnection Action code E04
Failure code Neutral switch disconnection Failure DDT5KA (Power train controller system) q Both lines of NO: Normally Open and NC: Normally Closed for neutral switch circuit are OPEN Detail of failure (switch: OFF) at the same time. Action of conq Recognizes that neutral switch is not pressed. troller Problem on q Once machine is stopped, engine speed is limited to medium (half). machine q Once machine is stopped, it cannot travel any more. q Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch. Related infor- q First, check the power train oil filter for clogging etc. mation q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure". Cause Wrong selection of travel 1 lever type
2
3
4
5
Procedure, measuring location, standard (value) and remarks If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
1. Turn starting switch to OFF position. 2. Disconnect connector SNC and connect T-adapter to male side. 3. Turn neutral switch to ON or OFF position and troubleshoot. Defective neutral switch a “Switch OFF”: Release, “Switch ON”: Press (Internal disconnection) Between SNC (male) (4) Switch: OFF Resistance Max. 1 Ω Switch: ON Resistance Min. 1 MΩ and (6) Between SNC (male) (4) Switch: OFF Resistance Min. 1 MΩ Switch: ON Resistance Max. 1 Ω and (5) 1. Turn starting switch to OFF position. 2. Disconnect connector SNC and connect T-adapter to female side. 3. Turn starting switch ON position. Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it shows hot short in wiring harness. in wiring harness a Voltage of apporx.9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between SNC (female) (5) and (4) Voltage 7–11 V Between SNC (female) (6) and (4) Voltage 7–11 V a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter to each harness female side (Disconnection or defecBetweenPTCN1 (femail)(10) and SNC (femail)(4) Resistance Max. 1 Ω tive contact) BetweenPTCN2(femail)(17) andSNC (femail)(5) Resistance Max. 1 Ω BetweenPTCN2(femail)(27) andSNC (femail)(6) Resistance Max. 1 Ω If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 and PTCN2. 3. Turn starting switch ON position. Defective power train con- 4. Turn neutral switch to ON or OFF position and troubleshoot. troller a Voltage of apporx.9 V is applied to PTCN2 pin (17) and PTCN2 pin (27) through resistor in power train controller. Between PTCN2(27) and Switch: OFF Voltage Max. 1 V Switch: ON Voltage 7–11 V PTCN1(10) Between PTCN2(17) and Switch: OFF Voltage 7–11 V Switch: ON Max. 1 V Voltage PTCN1(10)
40-388
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDT5KA] Neutral switch disconnection
Circuit diagram related to neutral switch
D375A-6 (01)
40-389
DRAFT Troubleshooting by failure code Failure code [DDT5KB] Neutral switch short circuit
Failure code [DDT5KB] Neutral switch short circuit Action code E04 Detail of failure Action of controller Problem on machine Related information
1
2
3
4
5
q
Failure code Neutral switch short circuit Failure DDT5KB (Power train controller systerm) Both lines of NO: Normally Open and NC : Normally Closed for neutral switch circuit are 0 V(switch: ON) at the same time.
q
Recognizes that neutral switch is not pressed.
q q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
q
Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
Cause Procedure, measuring location, standard (value) and remarks Wrong selection of travel lever If failure code [DDT5KQ] is displayed, carry out troubleshooting for it. type 1. Turn starting switch to OFF position. 2. Disconnect connector SNC and connect T-adapter to male side. 3. Turn neutral switch to ON or OFF position and troubleshoot. Defective neutral switch a “Switch OFF”: Release, “Switch ON”: Press (Internal disconnection) Between SNC (male) Switch: OFF Resistance Max. 1 Ω Resistance Min. 1 MΩ Switch: ON (4) and (6) Between SNC (male) Switch: OFF Resistance Min. 1 MΩ Resistance Max. 1 Ω Switch: ON (4) and (5) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters to female side of them. Ground fault of wiring harness Between SNC (female) (5) or PTCN2 (female) (Contact with ground circuit) Resistance Min. 1 MΩ (17) and ground Between SNC (female) (6) and PTCN2 (female) Resistance Min. 1 MΩ (27) and groud 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters to female side of PTCN2. Short circuit in wiring harness a Check with tester in continuity mode. Between PTCN2 (female) (17) and each pin No continuity other than (17) (No sound is heard) Between PTCN2 (female) (27) and each pin No continuity other than (27) (No sound is heard) If cause is not found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors PTCN1 and PTCN2. 3. Turn starting switch ON position. Defective power train control- 4. Turn shift up switch to ON or OFF position and troubleshoot. ler a Voltage of apporx.9 V is applied to PTCN2 pin (27) and PTCN2 pin (17) through resistor in power train controller. Between PTCN2 (27) Switch: OFF Voltage Max. 1 V Switch: ON Voltage 7–11 V and PTCN1 (10) Between PTCN2 (17) Switch: OFF Voltage 7–11 V Switch: ON Voltage Max.1 V and PTCN1 (10)
40-390
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDT5KB] Neutral switch short circuit
Circuit diagram related to meutral switch
D375A-6 (01)
40-391
Troubleshooting by failurecode Failure code [DDT5KQ] Lever SPEC selection signal disagreement
Failure code [DDT5KQ] Lever SPEC selection signal disagreement Action code
Failure code Failure
E04
DDT5KQ
Detail of failure Action of controller Problem on machine Related information
Lever specification selection signal disagreement (Power train controller systerm)
q
While optional travel lever is installed, optional travel lever device is not set.
q q
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
40-396
Procedure, measuring location, criteria and remarks
Check type of travel lever in Select optional travel lever. adjustment mode: 0041. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and SNC and connect T-adapters to each female Ground fault in wiring harside. 2 ness Between PTCN2 (female)(17) and ground or between Resistance Min. 1 Mz (Contact with ground circuit) SNC (female) (5) and ground Between PTCN2 (female)(27) and ground or between Resistance Min. 1 Mz SNC (female) (6) and ground Defective power train con- If causes 1 and 2 are not detected, power train controller may be defective. (Since 3 troller this is an internal failure, troubleshooting cannot be performed..)
1
Wrong selection of travel lever
Circuit diagram related to lever specification selection
40-392
40-396
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DDT5KQ] Lever SPEC selection signal disagreement
D375A-6 (01)
40-393
DRAFT Troubleshooting by failure code Failure code [DDTSL1] S/C: Fill high
Failure code [DDTSL1] S/C: Fill high Action code E02 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Stator clutch oil pressure 1 Failure DDTSL1 (Power train controller system) Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill switch signal is turned to ON position.
q
None in particular
q
Sufficient traveling torque may not be obtained
q
ON/OFF of stator clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31520 T/M fill SW input 2) Method of reproducing failure code: Start engine. Remove seat (approx. 50 kg) and seat bottom cover. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective stator clutch 2. Disconnect connector FSTC and connect T-adapter to male side. ECMV fill switch (Internal Between FSTC (female) (1) and ground short circuit) Resistance Min. 1 MΩ (Fill switch: OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector FSTC. Ground fault of wiring har3. Start engine. ness or defective power train a Keep PPC lever in N position. controller If failure code [DDTSL1] is still displayed, there is ground fault of wiring harness or power train controller is defective. (If failure code [DDTSL1] is not displayed, stator clutch fill switch is defective.) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PTCN2 and FSTC, and connect T-adapter to female side ness of either of them. (Contact with ground circuit) Between PTCN2 (female) (2) and ground or between Resistance Min. 1 MΩ FSTC (female) (1) and ground If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN2. troller Between PTCN2 (2) and ground Voltage 7 – 11 V 1. – 2. are same as above. 3. Start engine. a Keep PCCS lever in N position. Between PTCN2 (2) and ground Voltage Max. 1 V
40-394
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDTSL1] S/C: Fill high
Circuit diagram related to stator clutch oil pressure
D375A-6 (01)
40-395
DRAFT Troubleshooting by failure code Failure code [DDTSLH] S/C: Fill low
Failure code [DDTSLH] S/C: Fill low Action code E02 Detail of failure Action of controller Problem on machine
Related information
q
Failure code Stator clutch oil pressure 2 Failure DDTSLH (Power train controller system) Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill switch signal is turned OFF.
q
None in particular
q
Sufficient traveling torque may not be obtained
q
ON/OFF of stator clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31520 T/M fill SW input 2) Method of reproducing failure code: Start engine. Remove seat (approx. 50 kg) and seat bottom cover. First, check the power train oil filter for clogging etc. Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train oil pressure".
q q q q
Cause Defective stator clutch 1 ECMV fill switch (Fill switchdose not turn to ON position) Disconnection in wiring harness 2 (Disconnection or defective contact)
3
Defective power train controller
40-396
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FSTC and connect T-adapter to male side. 3. Start engine. Between FSTC (female) (1) and ground Resistance Max. 1 Ω (Fill switch: ON) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN2 and FSTC and connect T-adapter to female side of either of them. Between PTCN2 (female) (2) and FSTC (female) (1) Resistance Max. 1 Ω If no abnormality is found by the above checks, power train controller is defective. q Reference; the followings are criteria in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN2. Between PTCN2 (2) and ground Voltage 7 – 11 V 1–2 are same as above. 3. Start engine. a Keep PCCS lever in N position. Between PTCN2 (2) and ground Voltage Max. 1 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DDTSLH] S/C: Fill low
Circuit diagram related to stator clutch oil pressure
D375A-6 (01)
40-397
Troubleshooting by failurecode Failure code [DGE5KX] Ambient temp sensor abnormality
Failure code [DGE5KX] Ambient temp sensor abnormality Action code
Failure code Failure
–
DGE5KX
Detail of failure Action of controller Problem on machine Related information
40-402
Atmospheric temperature sensor:Abnormality (VHMS controller system)
q
Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or less.
q
None in particular
q
Monitoring function fails to monitor the atmospheric temperature.
q
The LED of the VHMS controller displays "n4"o"01". If the machine is normal, the input state (temperature) from the atmospheric temperature sensor can be checked with the monitoring function (Code: 37501 ATR TEMP). Method of reproducing failure code: Turn the starting switch to ON position.
q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector INT and connect T-adapter to male side. a If ambient temperature sensor resistance is 2.2 – 34 kz, regard ambient temperature sensor as normal.
1
Defective atmospheric temperature sensor
INT (male)
Between (1) and (2)
Atmospheric temperature
Resistance
-20 °C
27 - 34 kz
0 °C
10 - 13 kz
25 °C
3.8 - 4.6 kz
40 °C
2.2 - 2.6 kz
1. Turn starting switch to OFF position. 2. Disconnect connector V2A and connect T-adapter to female side. Open or short circuit in wir- Between V2A (female) (10) and (12) 2 a Resistance accords with ambient temperature - reing harness Resistance 2.2 - 34 kz sistance characteristics table of ambient temperature sensor in cause 2. a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors V2A and INT and connect T-adapters to each female side. ness 3 (wire breakage or defective Between V2A (female) (10) and INT (female) (1) Resistance Max. 1 z contact of connector) Between V2A (female) (12) and INT (female) (2) Resistance Max. 1 z 1. Turn starting switch to OFF position. Ground fault in wiring har- 2. Disconnect connectors INT and V2A and connect T-adapters to either female 4 ness side. (Contact with ground circuit) Between INT (female) (1) and ground or between V2A Resistance Min. 1 Mz (female) ( 10) and ground 1. Turn starting switch to OFF position. Hot short circuit or short cir- 2. Disconnect connectors INT and connect T-adapter to female side. 5 3. Turn starting switch to ON position. cuit in wiring harness Between INT (female) (1) and (2) 6 Defective VHMS controller
40-398
Voltage
Approx. 5 V
If cause is not found by above checks, the VHMS controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DGE5KX] Ambient temp sensor abnormality
Circuit diagram related to ambient temperature sensor
D375A-6 (01)
40-399
DRAFT Troubleshootingbyfailurecode Failurecode[DGS1KX] Hydoil temp: signal abnormal
Failure code [DGS1KX] Hyd oil temp: signal abnormal Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DGS1KX
Failure
Hydraulic oil temperature sensor: Abnormal (Mechane monitor power train control system)
q
Hydraulic oil temperature sensor signal is out of normal range.
q
None in particular.
q
Hydraulic oil temperature on monitor panel is not displayed normally. Fan speed is limited to half. Hydraulic oil temperature can be checked in monitoring mode. (Code: 04401 Hydraulic oil temperature) Method of reproducing failure code: Turn starting switch to ON position or start engine.
q q q
Cause
Procedure, measuring location, crit and remarks 1. Turn starting switch to OFF position. Defective hydraulic oil temper- 2. Disconnect connector HDT and connect T-adapter to male side. ature sensor 10 °C Resistance Approx. 90 kΩ 1 Between HDT (male) (1) and (2) (Internal disconnection or 30 °C Resistance Approx. 35 kΩ a Temperature characteristics short circuit) 80 °C Resistance Approx. 6.5 kΩ of oil temperature sensor 100 °C Resistance Approx. 3.5 kΩ 1. Turn starting switch to OFF position. 2. Disconnect connector HDT and connect T-adapter to female side. Disconnection, short circuit or 3. Turn starting switch ON position. 2 hot short in or ground fault of a If voltage is 0 V, wiring harness has disconnection, ground fault or short circuit, and if voltage is 24 V, wiring harness has hot short. wiring harness a Voltage of 5 V is applied to temperature sensor signal lines through resistor in power train controller. Between HDT (female) (1) and (2) Voltage Approx. 5 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CM01 and connect T-adapter to female side. Disconnection or short circuit a Resistance accords with temperature characteristics table in cause 1. 3 in wiring harness a If resistance is above1 MΩ, wiring harness has disconnection. If resistance is below 1 Ω, wiring harness has short circuit. Approx.3.5 – Between CM01 (female) (8) and (12) Resistance 90 kΩ a If neither of causes 2 and 3 is the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors CM01 and HDT, and connect T-adapters to female side ness 4 of them. (Disconnection or defective Between CM01 (female) (8) and HDT (female) Resistance contact) Max. 1 Ω (1) Between CM01 (female) (12) and HDT (female) Resistance Max. 1 Ω (2) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring harness 2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side 5 (Contact with ground circuit) of either of them. Between CM01 (female) (8) and (3), or between Resistance Min. 1 MΩ HDT (female) (1) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side of CM01. 6 Short circuit in wiring harness a Check with multimeter in continuity mode. Between CM01 (female) (8) and each pin other No continuity (No sound is heard) than (8) 7 Defective machine monitor If no failure is detected by the above checks, machine monitor is defective.
40-400
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DGS1KX] Hyd oil temp: signal abnormal
Circuit diagram related to hydraulic oil temperature sensor
D375A-6 (01)
40-401
DRAFT Troubleshooting by failure code Failure code [DGT1KA] T/C oil temp sensor: Abnormal
Failure code [DGT1KA] T/C oil temp sensor: Abnormal Action code E01 Detail of failure Action of controller Problem on machine Related information
q
Failure code Torque converter oil temperature sensor: Disconnection Failure DGT1KA (Work equipment controller system) Torque converter oil temperature sensor signal is out of normal range.
q
None in particular.
q
Power train oil temperature gauge may not indicate normally. Fan speed is limited to half speed. Gear shift shock of transmission increases. Torque converter oil temperature is considered to be power train oil temperature. Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Method of reproducing failure code: Turn starting switch to ON position or start engine.
q q q q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective torque con2. Disconnect connector 453 and connect T-adapter to male side. verter oil temperature 25 °C Resistance Approx. 42 kΩ 1 sensor Between 453 (male) (1) and (2) 30 °C Resistance Approx. 35 kΩ (Internal disconnection a Temperature characteristics of oil 80 °C Resistance Approx. 6.5 kΩ or short circuit) temperature sensor 100 °C Resistance Approx. 3.5 kΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors 453 and connect T-adapter to female side. Disconnection, short cir- 3. Turn starting switch ON position. cuit or hot short in or a If voltage is 0 V, wiring harness has disconnection, ground fault or short circuit, and if 2 ground fault of wiring voltage is 24 V, wiring harness has hot short. harness a Voltage of apporx.5 V is applied to temperature sensor signal lines through resistor in power train controller. Between 453 (female) (1) and (2) Voltage Approx. 5 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1 and connect T-adapter to female side. Disconnection or short a Resistance accords with temperature characteristics table in cause 1. 3 circuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below 1 Ω, wiring harness has short circuit. Approx. 3.5 – Between WECN1 (female) (20) and (21) Resistance 90 kΩ a If neither of causes 2 and 3 is the cause for the trouble, this check is not required. Disconnection in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connectors WECN1 and 453, and connect T-adapters to female side of 4 (Disconnection or them. defective contact) Between (female) (20) and 453 (female) (1) Resistance Max. 1 Ω Between WECN1 (female) (21) and 453 (female) (2) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of Short circuit in wiring WECN1. 5 harness a Check with multimeter in continuity mode. Between WECN1 (female) (20) and each pin other No continuity (No sound is than (20) heard.) Defective work equip6 If cause is not found by above checks, work equipment controller is defective. ment controller
40-402
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DGT1KA] T/C oil temp sensor: Abnormal
Circuit diagram related to torque converter oil temperature sensor
D375A-6 (01)
40-403
DRAFT Troubleshooting by failure code Failure code [DGT1KX] T/C oil temp sensor: Abnormal
Failure code [DGT1KX] T/C oil temp sensor: Abnormal Action code E01 Detail of failure Action of controller Problem on machine Related information
q
Failure code Torque converter oil temperature sensor: Short circuit Failure DGT1KX (Work equipment controller system) Torque converter oil temperature sensor signal is out of normal range.
q
No particular action
q
Power train oil temperature gauge may not indicate normally. Fan speed is limited to half speed. Shock at gear shift is hard. Torque converter oil temperature is considered to be power train oil temperature. For temperature characteristics table of oil temperature sensor, see [DGT1KA]. If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DGT1KA] is displayde.
q q q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective torque con2. Disconnect connector 453. verter oil temperature 3. Turn starting switch ON position. sensor If failure code[DGT1KX] goes off and disconnection code [DGT1KA] is displayed, torque (Internal disconnection converter oil temperature sensor is defective. or short circuit) (If failure code [DGT1KX] is still displayed, it shows that wiring harness or power train controller is defective.) 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of harness either of them. (Contact with ground cirBetween WECN1 (female) (20) and ground or cuit) Resistance Min. 1 MΩ between 453 (female) (1) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of Short circuit in wiring WECN1. harness a Check with multimeter in continuity mode. Between WECN1 (female) (20) and each pin other No continuity (No sound is heard) than (20) Defective work equipIf no failure is detected by the above checks, work equipment controller is defective. ment controller
40-404
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DGT1KX] T/C oil temp sensor: Abnormal
Circuit diagram related to torque converter oil temperature sensor
D375A-6 (01)
40-405
Troubleshooting by failurecode Failure code [DGT5KA] F exhaust temp sensor disconnection
Failure code [DGT5KA] F exhaust temp sensor disconnection Action code
Failure code Failure
–
DGT5KA
Detail of failure Action of controller Problem on machine Related information
40-410
Front exhaust temp sensor disconnection: Disconnection (VHMS controller system)
q
Input signal voltage from the exhaust gas temperature sensor on the engine front side is below 0.5 V.
q
None in particular
q
Monitoring function fails to monitor the exhaust gas temperature on the engine front side
q
The LED of the VHMS controller displays “n3" o "12". If the machine is normal, the input state (temperature) from the front exhaust gas temperature sensor can be checked with the monitoring function (Code: 42610 EXHAUST TEMP FRONT). Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DBB6KP] is displayed, troubleshoot it first.
1. Turn starting switch to OFF position. Defective sensor power sup- 2. Disconnect connector EXAF and connect T-adapter to female side. 1 ply system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 4 or after. Between EXAF (A) and (C)
Power supply
Voltage
20 – 30 V
a Check that failure code [DGT6KA] is not displayed. 1. Turn starting switch to OFF position. Defective front (cylinder 2. Replace connector EXHF with EXHR. 2 Nos. 1 - 3) exhaust tempera3. Turn starting switch to ON position. ture sensor If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1 - 3) exhaust temperature sensor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors EXTF, EXHF, V1 and V2A, and connect T-adapters to each female side or male side of EXTF. a If cause 1 is not the cause for the failure, this check is not required. Resistance Max. 1 z Open circuit in wiring harBetween V1 (female) (2) and EXAF (female) (A) ness Between V2A (female) (7) and EXAF (female) (B) Resistance Max. 1 z 3 (wire breakage or defective a If cause 1 is not the cause for the failure, this check contact of connector) is not required. Resistance Max. 1 z Between V2A (female) (13) and EXAF (female) (C) Between EXHF (female) (1) and EXTF (male) (1)
Resistance
Max. 1 z
Between EXHF (female) (2) and EXTF (male) (2)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors EXHF, EXTF,EXAF, V1 and V2A, and connect T-adapters to each female side or male side of EXTF. Between EXHF (female) (1) or EXTF (male) (1) and Resistance Min. 1 Mz Ground fault in wiring harground 4 ness Between EXHF (female) (1) and (2) ,or EXTF (male) (1) Resistance Min. 1 Mz (Contact with ground circuit) and (2)
40-406
Between V2A (female) (7) and ground
Resistance
Min. 1 Mz
Between V2A (female) (7) and (13)
Resistance
Min. 1 Mz
D375A-6 (06)
Troubleshooting by failurecode Failure code [DGT5KA] F exhaust temp sensor disconnection
Cause
Procedure, measuring location, criteria and remarks
a Check that failure code [DGT6KA] is not displayed. 1. Turn starting switch to OFF position. Defective front (cylinder 2. Replace connector EXAF with EXAR. 5 Nos. 1 - 3) exhaust tempera- 3. Turn starting switch to ON position. ture sensor amplifier If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1 - 3) exhaust temperature sensor amplifier is defective. If cause is not found by above checks, VHMS controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.) q Reference: The following shows standard values in the normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors V1 and V2A. 3. Turn starting switch to ON position.
100 °C - 200 °C
Voltage
1.4 – 1.8 V
200 °C - 300 °C
Voltage
1.8 – 2.2 V
300 °C - 400 °C Between V2A(7) and (13) a Exhaust temperature characteris- 400 °C - 500 °C tics 500 °C - 600 °C
Voltage
2.2 – 2.6 V
Voltage
2.6 – 3.0 V
Voltage
3.0 – 3.4 V
600 °C - 700 °C
Voltage
3.4 – 3.9 V
700 °C - 800 °C
Voltage
3.9 – 4.3 V
6 Defective VHMS controller
Circuit diagram related to exhaust temperature sensor
D375A-6 (06)
40-41
40-407
Troubleshooting by failurecode Failure code [DGT5KB] F exhaust temp sensor short circuit
Failure code [DGT5KB] F exhaust temp sensor short circuit Action code
Failure code Failure
-
DGT5KB
Detail of failure Action of controller Problem on machine
Related information
40-412
Front exhaust temp sensor disconnection:Short circuit (VHMS controller system)
q
Input signal voltage from the exhaust gas temperature sensor on the engine front side is above 4.9 V.
q
None in particular
q
Monitoring function fails to monitor the exhaust gas temperature on the engine front side
q
The machine monitor does not display any failure code (the relevant failure code can be checked by downloading data stored in the VHMS controller). The LED of the VHMS controller displays “n3" o "11". If the machine is normal, the input state (temperature) from the front exhaust gas temperature sensor can be checked with the monitoring function (Code: 42610 EXHAUST TEMP FRONT). Method of reproducing failure code: Turn the starting switch to ON position.
q q q
Cause
Procedure, measuring location, criteria and remarks
Defective sensor power sup1 If failure code [DBB6KP] is displayed, troubleshoot it first. ply system a Check that failure code [DGT6KB] is not displayed. 1. Turn starting switch to OFF position. Defective front (cylinder 2. Replace connector EXHF with EXHR. 2 Nos. 1 - 3) exhaust tempera3. Turn starting switch to ON position. ture sensor If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1 - 3) exhaust temperature sensor is defective. 1. Turn starting switch to OFF position. Hot short circuit in wiring 2. Disconnect all connectors EXAF and connect T-adapter to female side. 3 harness 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between EXAF (female) (B) and (C) Voltage Max. 1 V a Check that failure code [DGT6KB] is not displayed. 1. Turn starting switch to OFF position. Defective front (cylinder 2. Replace connector EXAF with EXAR. 4 Nos. 1 - 3) exhaust tempera3. Turn starting switch to ON position. ture sensor amplifier If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1 - 3) exhaust temperature sensor amplifier is defective. If cause is not found by above checks, VHMS controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.) q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors V1 and V2A. 3. Turn starting switch to ON position.
5 Defective VHMS controller Between V2A (7) and (13) a Exhaust temperature characteristics
40-408
100 °C - 200 °C
Voltage
1.4 – 1.8 V
200 °C - 300 °C
Voltage
1.8 – 2.2 V
300 °C - 400 °C
Voltage
2.2 – 2.6 V
400 °C - 500 °C
Voltage
2.6 – 3.0 V
500 °C - 600 °C
Voltage
3.0 – 3.4 V
600 °C - 700 °C
Voltage
3.4 – 3.9 V
700 °C - 800 °C
Voltage
3.9 – 4.3 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DGT5KB] F exhaust temp sensor short circuit
Circuit diagram related to exhaust temperature sensor
D375A-6 (01)
40-409
Troubleshooting by failurecode Failure code [DGT6KA] R exhaust temp sensor disconnection
Failure code [DGT6KA] R exhaust temp sensor disconnection Action code
Failure code Failure
-
DGT6KA
Detail of failure Action of controller Problem on machine Related information
40-414
Rear exhaust temp sensor disconnection: Disconnection (VHMS controller system)
q
Input signal voltage from the exhaust gas temperature sensor on the engine rear side is below 0.5 V.
q
None in particular
q
Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
q
The LED of the VHMS controller displays “n3” o ”22”. If the machine is normal, the input state (temperature) from the rear exhaust gas temperature sensor can be checked with the monitoring function (Code: 42611 EXHAUST TEMP REAR). Method of reproducing failure code: Turn the starting switch to ON position.
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DBB6KP] is displayed, troubleshoot it first.
1. Turn starting switch to OFF position. Defective sensor power sup- 2. Disconnect connector EXAR and connect T-adapter to female side. 1 ply system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 4 or after. Between EXAR (A) and (C)
Power supply
Voltage
20 – 30 V
a Check that failure code [DGT5KA ]is not displayed. 1. Turn starting switch to OFF position. Defective rear (cylinder Nos. 2. Replace connector EXHF with EXHR. 2 4 - 6) exhaust temperature 3. Turn starting switch to ON position. sensor If failure code [DGT5KA] changes to [DGT6KA], original rear (cylinder Nos, 4-6) exhaust temperature sensor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors EXTR, EXHR, V1 and V2A, and connect T-adapters to each female side or male side of EXTR. a If cause 1 is not the cause for the trouble, this check is not required. Resistance Max. 1 z Open circuit in wiring harBetween V1 (female) (2) and EXAR (female) (A) ness Between V2A (female) (5) and EXAR (female) (B) Resistance Max. 1 z 3 (wire breakage or defective a If cause 1 is not the cause for the trouble, this check contact of connector) is not required. Resistance Max. 1 z Between V2A (female) (13) and EXAR (male) (C) Between EXHR (female) (1) and EXTR (male) (1)
Resistance
Max. 1 z
Between EXHR (female) (2) and EXTR (male) (2)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors EXHR, EXTR, EXAR, V1 and V2A, and connect T-adapters to each female side or male side of EXTR. Between EXHR (female) (1) or EXTR (male) (1) and Resistance Min. 1 Mz Ground fault in wiring harground 4 ness Between EXHR (female) (1) and (2) or EXTR (male) (1) Resistance Min. 1 Mz (Contact with ground circuit) and (2)
40-410
V2A (female) (5) and ground
Resistance
Min. 1 Mz
V2A (female) (5) and (13)
Resistance
Min. 1 Mz
D375A-6 (06)
Troubleshooting by failurecode Failure code [DGT6KA] R exhaust temp sensor disconnection
Cause
Procedure, measuring location, criteria and remarks
a Check that failure code [DGT5KA ]is not displayed. 1. Turn starting switch to OFF position. Defective rear (cylinder Nos. 2. Replace connector EXAF with EXAR. 5 4 - 6) exhaust temperature 3. Turn starting switch to ON position. sensor amplifier If failure code [DGT6KA] changes to [DGT5KA], original rear (cylinder Nos. 4 - 6) exhaust temperature sensor amplifier is defective. If cause is not found by above checks, VHMS controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.) q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors V1 and V2A. 3. Turn starting switch to ON position.
6 Defective VHMS controller Between V2A(5) and (13) a Exhaust temperature characteristics
Circuit diagram related to exhaust temperature sensor
D375A-6 (06)
100 °C – 200 °C
Voltage
1.4 – 1.8 V
200 °C – 300 °C
Voltage
1.8 – 2.2 V
300 °C – 400 °C
Voltage
2.2 – 2.6 V
400 °C – 500 °C
Voltage
2.6 – 3.0 V
500 °C – 600 °C
Voltage
3.0 – 3.4 V
600 °C – 700 °C
Voltage
3.4 – 3.9 V
700 °C – 800 °C
Voltage
3.9 – 4.3 V
40-415
40-411
Troubleshooting by failurecode Failure code [DGT6KB] R exhaust temp sensor short circuit
Failure code [DGT6KB] R exhaust temp sensor short circuit Action code
Failure code Failure
-
DGT6KB
Detail of failure Action of controller Problem on machine Related information
40-416
Rear exhaust gas temperature sensor (R): Short circuit (VHMS controller system)
q
Input signal voltage from the exhaust gas temperature sensor on the engine rear side is above 4.9 V.
q
None in particular
q
Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
q
The LED of the VHMS controller displays "n3 o "21". If the machine is normal, the input state (temperature) from the rear exhaust gas temperature sensor can be checked with the monitoring function (Code: 42611 EXHAUST TEMP REAR). Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause
Procedure, measuring location, criteria and remarks
Defective sensor power supIf failure code [DBB6KP] is displayed, troubleshoot it first. ply system a Check that failure code [DGT5KB] is not displayed. 1. Turn starting switch to OFF position. Defective rear (cylinder Nos. 2. Replace connector EXHF with EXHR. 2 4 - 6) exhaust temperature 3. Turn starting switch to ON position. sensor If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 - 6) exhaust temperature sensor is defective. 1. Turn starting switch to OFF position. Hot short circuit in wiring 2. Disconnect connector EXAR and connect T-adapter to female side. 3 harness 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between EXAR (female) (B) and (C) Voltage Max. 1 V
1
a Check that failure code [DGT5KB] is not displayed. 1. Turn starting switch to OFF position. Defective rear (cylinder Nos. 2. Replace connector EXAF with EXAR. 4 4 - 6) exhaust temperature 3. Turn starting switch to ON position. sensor amplifier If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 - 6) exhaust temperature sensor amplifier is defective. If cause is not found by above checks, VHMS controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.) q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector V1 and V2A. 3. Turn starting switch to ON position.
5 Defective VHMS controller Between V2A (5) and (13) a Exhaust temperature characteristics
40-412
100 °C - 200 °C
Voltage
1.4 – 1.8 V
200 °C - 300 °C
Voltage
1.8 – 2.2 V
300 °C - 400 °C
Voltage
2.2 – 2.6 V
400 °C - 500 °C
Voltage
2.6 – 3.0 V
500 °C - 600 °C
Voltage
3.0 to 3.4 V
600 °C - 700 °C
Voltage
3.4 to 3.9 V
700 °C - 800 °C
Voltage
3.9 to 4.3 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DGT6KB] R exhaust temp sensor short circuit
Circuit diagram related to exhaust temperature sensor
D375A-6 (01)
40-413
DRAFT Troubleshooting by failure code Failure code [DH21KA] Weq pressure sensor: Disconnection
Failure code [DH21KA] Weq pressure sensor: Disconnection Action code E01 Detail of failure Action of controller Problem on machine Related information
q
Failure code Work equipment pump oil pressure sensor : Disconnection Failure DH21KA (Work equipment controller system) Signal voltage of work equipment pump oil pressure sensor is below 0.2 V.
q
None in particular.
q
Oil pressure of work equipment pump cannot be monitored.
q
Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring function. (Code: 70701 Hydraulic Pressure Sensor 1) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
1
Defective sensor 5 V power suplly system
2
Defective work equipment pump oil pressure sensor (Internal disconnection) or ground fault
3
Disconnection in wiring harness (Disconnection or defective contact in connector)
4
Ground fault of wiring harness (Contact with ground circuit)
5
Defective work equipment controller
40-414
Procedure, measuring location, criteria and remarks If failure code [DB97KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector HHP and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Power Between HHP (female) (B) and (A) Voltage 4.5 – 5.5 V supply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector HHP. 3. Turn starting switch to ON position. a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5 V), internal disconnection and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, work equipment pump oil pressure sensor is defective. Sensor Between HHP (female) (C) and (A) Voltage 0.5 – 4.5 V output 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1, WECN3 and HHP, and connect T-adapters to female side of them.) a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 Ω Between WECN1 (female) (21) and HHP (female) (A) a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 Ω Between WECN3 (female) (34) and HHP (female) (B) Between WECN1 (female) (9) and HHP Resistance Max. 1 Ω (female) (C) a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1 and HHP, and connect T-adapter to female side of either of them. Between WECN1 (female) (9) and (21), or Resistance Min. 1 MΩ between HHP (female) (C) and (A) Between WECN1 (female) (9) and ground, or Resistance Min. 1 MΩ between HHP (female) (C) and ground If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WECN1 3. Turn starting switch to ON position. Between WECN1 (9) and (21) Voltage 0.5 – 4.5 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DH21KA] Weq pressure sensor: Disconnection
Circuit diagram related to work equipment pump oil pressure
D375A-6 (01)
40-415
DRAFT Troubleshooting by failure code Failure code [DH21KB] Weq pressure sensor: Short circuit
Failure code [DH21KB] Weq pressure sensor: Short circuit Action code E01 Detail of failure Action of controller Problem on machine Related information
q
Failure code Work equipment pump oil pressure sensor: Disconnection Failure DH21KB (Work equipment controller system) Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
q
None in particular.
q
Oil pressure of work equipment pump cannot be monitored.
q
Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring function. (Code: 70701 Hydraulic Pressure Sensor 1) Method of reproducing failure code: Turn starting switch to ON position. If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DH21KA] is displayed.
q q
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DB97KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector HHP and connect T-adapter to female side. Defective sensor 5 V power 3. Turn starting switch ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Power Between HHP (female) (B) and (A) Voltage 4.5 – 5.5 V supply 1. Turn starting switch to OFF position. 2. Disconnect connector HHP Defective work equipment 3. Turn starting switch to ON position. pump oil pressure sensor If failure code [DH21KB] is not displayed but [DH21KA] of disconnection is dis(Internal disconnection) or played, work equipment pump oil pressure sensor is defective. (If failure code ground fault [DH21KB] is still displayed, it shows that wiring harness or power train controller is defective.) 1. Turn starting switch to OFF position. Hot short in wiring harnesss 2. Disconnect connector HHP and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch ON position. Between HHP (female) (C) and(A) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN1 and HHP, and connect T-adapter to female side of WECN1. Short circuit in wiring harness a Check with tester in continuity mode. Between WECN1 (female) (9) and each pin No continuity (No sound is heard) other than (9) If cause is not found by the above checks, work equipment controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective work equipment controller 2. Insert T-adapter into connector WECN1 3. Turn starting switch to ON position. Between WECN1 (9) and (21) Voltage 0.5 – 4.5 V
40-416
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DH21KB] Weq pressure sensor: Short circuit
Circuit diagram related to work equipment pump oil pressure
D375A-6 (01)
40-417
DRAFT Troubleshooting by failure code Failure code [DHE5KB] ENG blow-by pressure sensor disconnection
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection Action code – Detail of failure Action of controller Problem on machine Related information
q
Failure code Engine blow-by pressure sensor: Disconnection Failure DHE5KB (VHMS controller system) Input signal voltage from the blow-by pressure sensor is below 0.1 V.
q
None in particular.
q
Monitoring function fails to monitor the blow-by pressure
q
The LED of the VHMS controller displays "n3"o"32". The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring function (Code: 42801 BLOWBY PRESSURE). Method of reproducing failure code: Start engine and performs troubleshooting
q q
Cause
1
Defective sensor 5 V power supply system
2
Ground fault of wiring harness (Contact with ground circuit)
3
Defective blow-by pressure sensor (Internal defect)
4
5
Disconnection in wiring harness (Disconnection or defective contact in connector)
Defective VHMS controller
40-418
Procedure, measuring location, criteria and remarks If failure code [DBB5KP] is displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 4 or after. Between ENBP (B) and (A) Power supply Voltage 4.85 –5.15 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP, V1 and V2A, and connect T-adapters to female side of one of them. Between ENBP (female) (C) and (A), or Resistance Min. 1 MΩ between V2A (female) (18) and (12) Between ENBP (female) (C) or V2A (female) Resistance Min. 1 MΩ (18) and ground 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ENBP. 3. Turn starting switch to ON position, start engine, and then perform troubleshooting. Between ENBP (C) Sensor output (Normal) Voltage 0.5 – 4.5 V Sensor output (High idle) Voltage 0.5 – 0.9 V and (A) 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP and connect T-adapter to male side. Between ENBP (female) (A), (B), (C) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP, V1 and V2A and connect T-adapters to female side of them. a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between V1 , V2A (female) (12) and ENBP (female) (A) a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between V1 (female) (4) and ENBP (female) (B) Between V2A (female) (18) and ENBP (female) Resistance Max. 1 Ω (C) If cause is not found by above checks, VHMS controller may be defective. (Since failure is in it, troubleshooting cannot be performed.) q Reference: The following shows standard values in the normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector V1 and V2A. 3. Turn starting switch to ON position, start engine, and then perform troubleshooting. Between V1 (4) and V2A (12) Power supply Voltage 4.85 – 5.15 V Between V2A (18) Sensor output (Normal) Voltage 0.5 – 4.7 V Sensor output (High idle) Voltage 0.5 – 0.9 V and (12)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DHE5KB] ENG blow-by pressure sensor disconnection
Circuit diagram related to engine blow-by pressure sensor
D375A-6 (01)
40-419
DRAFT Troubleshooting by failure code Failure code [DHE5KY] ENG blow-by pressure sensor short circuit
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit Action code – Detail of failure Action of controller Problem on machine Related information
q
Failure code Engine blow-by pressure sensor: Short circuit Failure DHE5KY (VHMS controller system) Input signal voltage from the blow-by pressure sensor is above 4.7 V.
q
None in particular.
q
Monitoring function fails to monitor the blow-by pressure
q
The LED of the VHMS controller displays "n3" o "31". The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring function (Code: 42801 BLOWBY PRESS). Method of reproducing failure code: Start engine and performs troubleshooting
q q
Cause
1
Defective sensor 5 V power supply system
2
Hot short in wiring harness (Contact with 24V circuit)
3
Defective blow-by pressure sensor (Internal defect)
4
Defective VHMS controller
40-420
Procedure, measuring location, criteria and remarks If failure code [DBB5KP] is displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP and connect T-adapter to female side. 3. Turn starting switch ON position. Between ENBP (B) and (A) Power supply Voltage 4.85 – 5.15 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP, V1 and V2A and connect T-adapter to female side of one of them. Between ENBP (female) (C) and (A) , or Voltage Max. 1 V between V2A (female) (18) and (12) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ENBP. 3. Turn starting switch to ON position, start engine, and then perform troubleshooting. Between ENBP (C) Sensor output (Normal) Voltage 0.5 – 4.5 V Sensor output (High idle) Voltage 0.5 – 0.9 V and (A) 1. Turn starting switch to OFF position. 2. Disconnect connectors ENBP and connect T-adapter to male side. Between ENBP (male) (A), (B),( C) and ground Resistance Min. 1 MΩ If cause is not found by above checks, VHMS controller may be defective. (Since failure is in it, troubleshooting cannot be performed.) q Reference: The following shows standard values in the normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector V1 and V2A. 3. Turn starting switch to ON position, start engine, and then perform troubleshooting. Between V1 (4) and V2A (12) Power supply Voltage 4.85 – 5.15 V Between V2A (18) Sensor output (Normal) Voltage 0.5 – 4.7 V Sensor output (High idle) Voltage 0.5 – 0.9 V and (12)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DHE5KY] ENG blow-by pressure sensor short circuit
Circuit diagram related to engine blow-by pressure sensor
D375A-6 (01)
40-421
DRAFT Troubleshooting by failure code Failure code [DHT3KX] T/M oil pressure sensor abnormality
Failure code [DHT3KX] T/M oil pressure sensor abnormality Action code – Detail of failure Action of controller Problem on machine Related information
Failure code DHT3KX
Failure
Transmission oil pressure sensor input signal out of range
q
Signal voltage of transmission oil pressure sensor is abnormal (below 0.3 V or above 4.9 V).
q
None in particular.
q
System may not operate normally.
q
LED displays "n6" o "14".
Cause
1
2
3
4
5
6
Procedure, measuring location, criteria and remarks If failure code [DBB6KP] is displayed, troubleshoot it first. 1. Turn starting switch to OFF position. Defective sensor power supply 2. Disconnect connectors TMMD and connect T-adapter to female side. system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between TMMD (B) and (C) Power supply Voltage 20 – 30 V 1. Turn starting switch to OFF position. Defective transmission main oil 2. Disconnect connectors TMMD and connect T-adapter to female side. pressure sensor 3. Turn starting switch to ON position. Between TMMD (A) and (C) Voltage 1–5V 1. Turn starting switch to OFF position. 2. Disconnect connectors TMMD,V1 and V2A and connect T-adapters to female side of them. a If cause 1 is not the cause for the failure, this Disconnection in wiring harness check is not required. Resistance Max. 1 Ω (Disconnection or defective con- Between V1 (female) (2) and TMMD (female) (B) tact in connector) a If cause 1 is not the cause for the failure, this check is not required. Resistance Max. 1 Ω Between V2A (female) (12) and TMMD (female) (C) Between V2A (female) (15) and TMMD (female) Resistance Max. 1 Ω (A) 1. Turn starting switch to OFF position. 2. Disconnect connectors TMMD,V1 and V2A and connect T-adapter to female side of one of them. Ground fault of wiring harness Between V2A (female) (15) or TMMD (female) (A) (Contact with ground circuit) Resistance Min. 1 MΩ and ground Between V2A (female) (15) and (12) , or between Resistance Min. 1 MΩ TMMD (female) (A) and (C) 1. Turn starting switch to OFF position. Hot short or short circuit in wiring 2. Disconnect connectors TMMD and connect T-adapter to female side. harness 3. Turn starting switch to ON position. Between TMMD (female) (A) and (C) Voltage Max. 1 V If cause is not found by above checks, VHMS controller is defective. q Reference: Following shows standard values in normal condition. 1. Turn starting switch to OFF position. Defective VHMS controller 2. Insert T-adapter into connector V2A. 3. Turn starting switch to ON position. Between V2A (15) and (12) Voltage 1–5V
40-422
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DHT3KX] T/M oil pressure sensor abnormality
Circuit diagram related to transmission oil pressure sensor
D375A-6 (01)
40-423
Troubleshooting by failurecode Failure code [DHT5KA] T/C in-pressure sensor: Disconnection
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection Action code
Failure code Failure
E02
DHT5KA
Detail of failure Action of controller Problem on machine Related information
40-428
Torque converter inlet pressure sensor: Disconnection (Power train controller system)
q
Signal voltage of torque converter inlet pressure sensor is below 0.2 V.
q
None in particular
q
No hydraulic pressure can be monitored at torque converter inlet. Gear shift shock of transmission increases. Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function. (Code 32602: Torque converter inlet pressure sensor voltage) Method of reproducing failure code: Turn starting switch to ON position.
q q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DBE6KK] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position. Defective 5 V power supply 2. Disconnect connector TIP and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between TIP (female) (B) and (A)
Defective torque converter 2 inlet pressure sensor (internal failure) or ground fault
1. 2. 3. a
Power supply
Voltage
20 – 30 V
Turn starting switch to OFF position. Insert T-adapter into connector TIP. Turn starting switch ON position. If power supply voltage is normal and sensor output voltage is abnormal (below 0.5 V), internal disconnection and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, torque converter inlet pressure sensor is defective.
Between TIP (female) (C) and (A)
Sensor output
Voltage
0.5 – 6.0 V
1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to each female side. Open circuit in wiring hara If power supply voltage in checks on cause 1 is norness mal, this check is not required. Resistance Max. 1 z 3 (wire breakage or defective Between PTCN1 (female) (16) and TIP (female) (B) contact of connector) a If power supply voltage in checks on cause 1 is normal, this check is not required. Resistance Max. 1 z Between PTCN1 (female) (21) and TIP (female) (A) Between PTCN1 (female) (13) and TIP (female) (C)
Resistance
Max. 1 z
a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to either female Ground fault in wiring harside. 4 ness Between PTCN1 (female) (13) and (21), or between TIP (Contact with ground circuit) Resistance Min. 1 Mz (female) (C) and (A) Between PTCN1 (female) (13) and ground, or between Resistance Min. 1 Mz TIP (female) (C) and ground If cause is not found by above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. Defective power train con- 1. Turn starting switch to OFF position. 5 2. Insert T-adapter into connector PTCN1 troller 3. Turn starting switch ON position. Between PTCN1 (13) and (21)
40-424
Voltage
0.5 – 6.0 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DHT5KA] T/C in-pressure sensor: Disconnection
Circuit diagram related to torque converter inlet pressure sensor
D375A-6 (01)
40-425
Troubleshooting by failurecode Failure code [DHT5KB] T/C in-pressure sensor: Short circuit
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit Action code
Failure code Failure
E02
DHT5KB
Detail of failure Action of controller Problem on machine
Torque converter inlet pressure sensor: short circuit (Power train controller system)
q
Signal voltage of torque converter inlet pressure sensor is above 4.7 V.
q
None in particular
q
No hydraulic pressure can be monitored at torque converter inlet. Gear shift shock of transmission increases. Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function. (Code: 32602 Torque converter inlet pressure sensor voltage) Method of reproducing failure code: Turn starting switch to ON position.. If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DHT5KA] is displayed.
q q
Related information
40-430
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DBE6KK] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position. Defective sensor 5 V power 2. Disconnect connector TIP and connect T-adapter to female side. 1 supply system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between TIP (female) (B) and (A)
Power supply
Voltage
20 – 30 V
1. Turn starting switch to OFF position. 2. Disconnect connector TIP. Defective torque converter 3. Turn starting switch to ON position. 2 inlet pressure sensor (interIf failure code [DHT5KB] is not displayed, torque converter inlet pressure sensor is nal failure) or ground fault defective. (If failure code [DHT5KB] is still displayed, it shows that wiring harness or power train controller is defective.) 1. Turn starting switch to OFF position. Hot short circuit in wiring 2. Disconnect connector TIP and connect T-adapter to female side. harness 3 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between TIP (female) (C) and (A) or ground Voltage Max. 1 V
4
Short circuit in wiring harness
5
Defective power train controller
1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female side of PTCN1. a Check with circuit tester in continuity mode. Between PTCN1 (female ) (13) and each pin other than No continuity (No sound is (13) heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 3. Turn starting switch to ON position. Between PTCN1 (13) and (21)
40-426
Voltage
0.5 – 6.0 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DHT5KB] T/C in-pressure sensor: Short circuit
Circuit diagram related to torque converter inlet pressure sensor
D375A-6 (01)
40-427
DRAFT Troubleshooting by failure code Failure code [DHT7KA] T/C out-pressure sensor: Disconnection
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection Action code E02 Detail of failure Action of controller Problem on machine Related information
q
Failure code Torque converter outlet pressure sensor: Disconnection Failure DHT7KA (Power train controller system) Signal voltage of torque converter outlet pressure sensor is below 0.2 V.
q
None in particular.
q
No hydraulic pressure can be monitored at torque converter outlet. Gear shift shock of transmission increases. Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function. (Code 32604: Torque converter outlet pressure sensor voltage) Method of reproducing failure code: Turn starting switch to ON position.
q q q
Cause
1
Defective power supply system
2
Defective torque converter outlet pressure sensor (internal failure) or ground fault
3
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
4
Ground fault of wiring harness (Contact with ground circuit)
5
Defective power train controller
40-428
Procedure, measuring location, criteria and remarks If failure code [DBE6KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector TOP and connect T-adapter to female side. 3. Turn starting switch ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between TOP (female) (B) and (A) Power supply Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector TOP. 3. Turn starting switch ON position. a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5 V), internal disconnection and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, torque converter outlet pressure sensor is defective. Between TOP (female) (C) and (A) Sensor output Voltage 0.5 – 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TOP, and connect T-adapters to female side of them. a If power supply voltage in checks on cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (16) and TOP (female) (B) a If power supply voltage in checks on cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (21) and TOP (female) (A) Between PTCN1 (female) (7) and TOP (female) Resistance Max. 1 Ω (C) a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female side of either of them. Between PTCN1 (female) (7) and (21), or between Resistance Min. 1 MΩ TOP (female) (C) and (A) Between PTCN1 (female) (7) and ground, or Resistance Min. 1 MΩ between TOP (female) (C) and ground If cause is not found by above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 3. Turn starting switch ON position. Between PTCN1 (7) and (21) Voltage 0.5 – 6.0 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DHT7KA] T/C out-pressure sensor: Disconnection
Circuit diagram related to torque converter outlet pressure sensor
D375A-6 (01)
40-429
DRAFT Troubleshooting by failure code Failure code [DHT7KB] T/C out-pressure sensor: Short circuit
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code DHT7KB
Failure
Torque converter outlet pressure sensor: short circuit (Power train controller system)
q
Signal voltage of torque converter outlet pressure sensor is above 4.7 V.
q
None in particular.
q
No hydraulic pressure can be monitored at torque converter outlet. Gear shift shock of transmission increases. Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function. (Code 32604: Torque converter outlet pressure sensor voltage) Method of reproducing failure code: Turn starting switch to ON position. If the sensor connector is disconnected in the normal condition and turn starting switch to ON position,failure code [DHT7KA ] is displayed.
q q q q
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBE6KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. Defective sensor power sup- 2. Disconnect connector TOP and connect T-adapter to female side. ply system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between TOP (female) (B) and (A) Power supply Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect connector TOP. Defective torque converter outlet pressure sensor (inter- 3. Turn starting switch to ON position. If failure code [DHT7KB] is not displayed, torque converter outlet pressure sensor nal failure) or ground fault is defective.(If failure code [DHT7KB] is still displayed, it shows that wiring harness or power train controller is defective.) 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector TOP and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between TOP (female) (C) and (A) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female side of PTCN1. Short circuit in wiring harness a Check with tester in continuity mode. Between PTCN 1 (female) (7) and each pin other No continuity (No sound is than (7) heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. Defective power train control- 1. Turn starting switch to OFF position. ler 2. Insert T-adapter into connector PTCN1 3. Turn starting switch to ON position. Between PTCN1 (7) and (21) Voltage 0.5 – 6.0 V
40-430
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DHT7KB] T/C out-pressure sensor: Short circuit
Circuit diagram related to torque converter outlet pressure sensor
D375A-6 (01)
40-431
DRAFT Troubleshooting by failure code Failure code [DK10KA] Fuel control Dial: Disconnection
Failure code [DK10KA] Fuel control Dial: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q q q q q
Failure code Fuel control Dial: Disconnection Failure DK10KA (Power train controller system) Signal voltage of fuel control dial is below 0.5 V. Continues control with signal of decelerator pedal potentiometer. Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of fuel control dial signal can be checked with monitoring function. (Code: 03000 Fuel Dial Sensor) Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBE5KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector DIAL and connect T-adapter to female side. Defective sensor 5 V power 3. Turn starting switch to ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Between DIAL (female) (1) and Power supply Voltage 4.5 – 5.5 V (3) 1. Turn starting switch to OFF position. 2. Disconnect connector DIAL and connect T-adapter to male side. 3. Turn starting switch to ON position. Defective fuel dial (Internal disconnection or 4. Rotate fuel control dial and troubleshoot. Between DIAL (male) (1) and (3) Resistance Approx. 5 Ω ground fault) Between DIAL (male) (2) and (3) Resistance 0.5 - 4.5 kΩ Between DIAL (male) (1) and (2) Resistance 0.5 - 4.5 kΩ Between DIAL(male) (2) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1, TL1 and BRK, and connect T-adapter to female side of PTCN1 Disconnection or short cir- a Resistance is same as table in cause 2. cuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below 1 Ω, wiring harness has short circuit. Between PTCN1 (female) (22) and (21) Resistance Approx. 5 Ω Between PTCN1 (female) (8) and (21) Resistance 0.5 - 4.5 kΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and DIAL, and connect T-adapters to female side of them. a If power supply voltage in cause 1 or check result of cause 3 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (22) and DIAL(female) Disconnection in wiring har(1) ness a If power supply voltage in cause 1 or check re(Disconnection or defecsult of cause 3 is normal, this check is not retive contact in connector) quired. Resistance Max. 1 Ω Between PTCN1 (female) (21) and DIAL (female) (3) a If check result of cause 3 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (8) and DIAL (female) (2) a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female side of ness either of them. (Contact with ground cirPTCN1 (female) (8) and (21), or between DIAL Resistance Min. 1 MΩ cuit) (female) (2) and (3) PTCN1 (female) (8) and ground , or between Resistance Min. 1 MΩ DIAL (female) (2) and ground
40-432
D375A-6 (01)
Troubleshooting by failurecode Failure code [DK10KA] Fuel control Dial: Disconnection
Cause
6
Defective power train controller
Procedure, measuring location, criteria and remarks If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. 4. Rotate fuel control dial and troubleshoot. PTCN1 (8) and (21)
Circuit diagram related to fuel control dial
D375A-6 (06)
Voltage
0.5 – 4.5 V
40-437
40-433
DRAFT Troubleshooting by failure code Failure code [DK10KB] Fuel control Dial: Short circuit
Failure code [DK10KB] Fuel control Dial: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q q q q q
Failure code Fuel control Dial: Short circuit Failure DK10KB (Power train controller system) Signal voltage of fuel control dial is above 4.5 V. Continues control with signal of decelerator pedal potentiometer.. Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of fuel control dial signal can be checked with monitoring function. (Code: 03000 Fuel Dial Sensor) Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBE5KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. Defective sensor 5 V power 2. Disconnect connector DIAL and connect T-adapter to female side. supply system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between DIAL (female) (1) and (3) Power supply Voltage 4.5 – 5.5 V 1. Turn starting switch to OFF position. 2. Disconnect connector DIAL and connect T-adapter to male side. Defective fuel dial 3. Turn starting switch to ON position. (Internal disconnection or 4. Rotate fuel control dial and troubleshoot. short circuit) Between DIAL (male) (1) and (3) Resistance Approx. 5 Ω Between DIAL (male) (2) and (3) Resistance 0.5 - 4.5 kΩ Between DIAL (male) (1) and (2) Resistance 0.5 - 4.5 kΩ 1. Turn starting switch to OFF position. Hot short circuit in wiring 2. Disconnect connector DIAL and connect T-adapter to male side. harness (Contact with 24 V 3. Turn starting switch to ON position. circuit) Between DIAL (female) (2) and (3) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female side of Short circuit in wiring harPTCN1. ness a Check with tester in continuity mode. Between PTCN1 (female) (8) and each pin other No continuity (No sound is than (8) heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1. troller 3. Turn starting switch to ON position. 4. Rotate fuel control dial and troubleshoot. PTCN1 (8) and (21) Voltage 0.5 – 4.5 V
40-434
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK10KB] Fuel control Dial: Short circuit
Circuit diagram related to fuel control dial
D375A-6 (01)
40-435
DRAFT Troubleshooting by failure code Failure code [DK30KA] ST lever 1: Disconnection
Failure code [DK30KA] ST lever 1: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q q q q q
Failure code Steering potentiometer 1: Disconnection Failure DK30KA (Power train controller system) Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT ) is below 0.5 V. Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) Method of reproducing failure code: Turn starting switch to ON position and Operate PCCS lever (in steering direction))
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBE5KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector TL2 and connect T-adapter to female side. Defective sensor 5 V power 3. Turn starting switch to ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Between TL2 (female) (5) and (8) Power supVoltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector TL2. 3. Turn starting switch ON position. 4. Operate PCCS lever (steering) and troubleshoot. Defective PCCS lever a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or steering potentiometer 1 below), internal disconnection and ground fault cannot be identified. In this case, (Internal disconnection) or go to cause 4. ground fault If check result of cause 4 is normal, PCCS lever steering potentiometer 1 is defective. Sensor outBetween TL2 (female) (7) and (8) Voltage 0.96 – 4.04 V put 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female side of them. Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this ness check is not required. Resistance Max. 1 Ω (Disconnection or defec- Between PTCN1 (female) (22) and TL2 (female) (5) tive contact in connector) a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (21) and TL2 (female) (8) Between PTCN1 (female) (2) and TL2 (female) (7) Resistance Max. 1 Ω a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of ness either of them. (Contact with ground cirBetween PTCN1 (female) (2) and (21), or between Resistance Min. 1 MΩ cuit) TL2 (female) (7) ground (8) Between PTCN1 (female) (2) and ground, or Resistance Min. 1 MΩ between TL2 (female) (7) and ground If cause is not found by the above checks, power train controller is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1. troller 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and troubleshoot. Between PTCN1 (2) and (21) Voltage 0.96 – 4.04 V
40-436
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK30KA] ST lever 1: Disconnection
Circuit diagram related to steering potentiometer
D375A-6 (01)
40-437
DRAFT Troubleshooting by failure code Failure code [DK30KB] ST lever 1: Short circuit
Failure code [DK30KB] ST lever 1: Short circuit Action code E03 Detail of failure Action of controller problem on machine Related information
1
2
3
4
5
q q q q q q q
Failure code Steering potentiometer 1: Short circuit Failure DK30KB (Power train controller system) Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT) is above 4.5 V. Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in steering direction).
Cause Procedure, measuring location, criteria and remarks Defective sensor 5 V power If failure code [DBE5KK] is also displayed, troubleshoot it first. supply system 1. Turn starting switch to OFF position. 2. Disconnect connector TL2. Defective PCCS lever 3. Turn starting switch to ON position. steering potentiometer 1 4. Operate PCCS lever (steering) and troubleshoot. (Internal disconnection) or If failure code [DK30KB] is not displayed, PCCS lever steering potentiometer is defecground fault tive. (If failure code [DK30KB] is still displayed, wiring harness or power train controller is defective.) a Since connector TL2is disconnected, many failure codes are displayed. Ignore all displayed failure codes other than [DK30KB]. 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector TL2 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between TL2 (female) (7) and (8) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of Short circuit in wiring harPTCN1. ness a Check with tester in continuity mode. Between PTCN1 (female) (2) and each pin other No continuity (No sound is heard) than (2) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1. troller 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and troubleshoot. Between PTCN1 (2) and (21) Voltage 0.96 – 4.04 V
40-438
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK30KB] ST lever 1: Short circuit
Circuit diagram related to steering potentiometer
D375A-6 (01)
40-439
DRAFT Troubleshooting by failure code Failure code [DK30KX] ST lever: Out of normal range
Failure code [DK30KX] ST lever: Out of normal range Action code E04 Detail of failure Action of controller Problem on machine
q
Failure code Steering potentiometers 1 and 2: Out of normal range Failure DK30KX (Power train controller system) In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), either of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at the same time.
q
Limits operation of engine and transmission.
q
Once machine stops, engine speed is limited to medium (half). Once machine stops, it cannot travel at all. Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in steering direction).
q q
Related information q
Cause Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
Failure code [DK30KZ] ST lever: Disconnection or short circuit Action code E04 q
Failure code Steering potentiometer: Abnormal at key ON Failure DK30KZ (Power train controller system) In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), when starting switch is turned ON, only either side is abnormal and then either of failure codes[DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at the same time.
q
Limits operation of engine and transmission.
q
Once machine stops, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in steering direction).
Detail of failure Action of controller Problem on machine
q q
Related information q
Cause Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA]and [DK31KB].
40-440
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK30L8] ST lever: Signal mismatch Action code E03 Detail of failure Action of controller Problem on machine
q q q q q q
Related information
q
Failure code Steering potentiometer: Signal mismatch Failure DK30L8 (Power train controller system) In PCCS lever steering potentiometer 1 (ST lever POT)and 2 (ST lever POT 2), total of both signal voltages is below 4.41 V or above 5.59 V. Continues control with signal of normal one of PCCS lever steering potentiometer 1 (ST lever POT)or 2 (ST lever POT 2). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever steering potentiometer can be checked with monitoring function. (Code: 50300 S/T Lever 1 Potentio) (Code: 50301 S/T Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in steering direction).
Cause Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
D375A-6 (01)
40-441
DRAFT Troubleshooting by failure code Failure code [DK31KA] ST lever 2: Disconnection
Failure code [DK31KA] ST lever 2: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q q q q q
Failure code Steering potentiometer 2: Disconnection Failure DK31KA (Power train controller system) Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is below 0.5 V. Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever steering potentiometer 2 can be checked with monitoring function. (Code: 50301 S/T Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in steering direction).
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBE5KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector TL2 and connect T-adapter to female side. Defective sensor 5 V power 3. Turn starting switch to ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Power supBetween TL2 (female) (5) and (8) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and troubleshoot. Defective PCCS lever a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5 steering potentiometer 2 V), internal disconnection and ground fault cannot be identified. In this case, go to (Internal disconnection) or cause 4. ground fault If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective. Sensor outBetween TL2 (female) (6) and (8) Voltage 0.96 – 4.04 V put 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female side of them. Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this check ness is not required. Resistance Max. 1 Ω (Disconnection or defec- Between PTCN1 (female) (22) and TL2 (female) (5) tive contact in connector) a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (21) and TL2 (female)(8) Between PTCN1 (female) (19) and TL2 (female) (6) Resistance Max. 1 Ω a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN1 andTL2, and connect T-adapter to female side of ness either of them. (Contact with ground cirBetween PTCN1 (female) (19) and (21) , or between TL2 Resistance Min. 1 MΩ cuit) (female) (6) and (8) Between PTCN1 (female) (19) and ground , or between Resistance Min. 1 MΩ TL2 (female) (6) and ground If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1 troller 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and troubleshoot. Between PTCN1(19) and (21) Voltage 0.96 – 4.04 V
40-442
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK31KA] ST lever 2: Disconnection
Circuit diagram related to steering potentiometer
D375A-6 (01)
40-443
DRAFT Troubleshooting by failure code Failure code [DK31KB] ST lever 2: Short circuit
Failure code [DK31KB] ST lever 2: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
1
2
3
4
5
q q q q q q q
Failure code Steering potentiometer 2: Short circuit Failure DK31KB (Power train controller system) Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is above 4.5 V. Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever steering potentiometer 2 can be checked with monitoring function. (Code: 50301 S/T Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in steering direction).
Cause Procedure, measuring location, criteria and remarks Defective sensor 5 V power If failure code [DBE5KK] is also displayed, troubleshoot it first. supply system 1. Turn starting switch to OFF position. 2. Disconnect connector TL2. 3. Turn starting switch to ON position. Defective PCCS lever 4. Operate PCCS lever (steering) and troubleshoot. steering potentiometer 2 (Internal disconnection) or If failure code [DK31KB] is not displayed, PCCS lever steering potentiometer is defective.( If failure code [DK31KB] is still displayed, wiring harness or power train controller ground fault is defective.) a Since connector TL2 is disconnected, many failure codes are displayed.Ignore all displayed failure codes other than [DK31KB] 1. Turn starting switch to OFF position. Hot short of wiring harness 2. Disconnect connectors TL2 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between TL2 (female) (6) and (8) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of Short circuit in wiring harPTCN1. ness a Check with tester in continuity mode. Between PTCN1 (female) (19) and each pin other No continuity (No sound is heard) than (19) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1 troller 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and troubleshoot. Between PTCN1 (19) and (21) Voltage 0.96 – 4.04 V
40-444
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK31KB] ST lever 2: Short circuit
Circuit diagram related to steering potentiometer
D375A-6 (01)
40-445
DRAFT Troubleshooting by failure code Failure code [DK40KA] Brake potentiometer: Disconnection
Failure code [DK40KA] Brake potentiometer: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
q
Failure code Brake potentiometer: Disconnection Failure DK40KA (Power train controller system) Signal voltage of brake pedal potentiometer is below 0.5 V.
q
Limits operation of engine and transmission.
q
travel is limited to F1 and R1. Once machine stops, engine speed is limited to medium (half). Signal voltage of brake pedal potentiometer can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.
q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks If failure code [DBE5KK]is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector BRK and connect T-adapter to female side. Defective sensor 5 V 3. Turn starting switch to ON position. power supply system a If power supply voltage is abnormal, go to cause 3 or after. Power Between BRK (female) (C) and (A) Voltage 4.5 – 5.5 V supply 1. Turn starting switch to OFF position. 2. Disconnect connector BRK and connect T-adapter to male side. Defective brake pedal 3. Turn starting switch to ON position. potentiometer 4. Depress brake pedal and troubleshoot. (Internal disconnection or Between BRK (male) (C) and (A) Resistance Approx. 5 kΩ ground fault) Between BRK (male) (A) and (B) Resistance 0.25 - 7.0 kΩ Between BRK (male) (B) and (C) Resistance 0.25 - 7.0 kΩ Between BRK (male) B)and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PCTN1 and TL1, and connect T-adapters to female side of them PTCN1. Disconnection or short cir- a Resistance is same as table in cause 2. cuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below 1 Ω, wiring harness has short circuit. Between PTCN1 (female) (22) and (21) Resistance Approx. 2 kΩ Between PTCN1 (female) (3) and (21) Resistance 0.2 - 1.8 kΩ 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and BRK, and connect T-adapters to female side of them. a If power supply voltage in cause 1 or check result of cause 3 is normal, this check is not required. Resistance Max. 1 Ω Disconnection in wiring Between PTCN1 (female) (21) and BRK (female) harness (A) (Disconnection or defec- a If power supply voltage in cause 1 or check retive contact in connector) sult of cause 3 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (22) and BRK (female) (C) a If check result of cause 3 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (3) and BRK (female) (B)
40-446
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK40KA] Brake potentiometer: Disconnection
Circuit diagram related to brake potentiometer
D375A-6 (01)
40-447
DRAFT Troubleshooting by failure code Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DK40KB] Brake potentiometer: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code DK40KB
Failure
Brake potentiometer: Short circuit (Power train controller system)
q
Signal voltage of brake pedal potentiometer is above 4.8 V.
q
Limits operation of engine and transmission.
q
travel is limited to F1 and R1. Once machine stops, engine speed is limited to medium (half). Signal voltage of brake pedal potentiometer can be checked with monitoring function. (Code: 50400 Brake Pedal Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.
q q q
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBE5KK]is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector BRK and connect T-adapter to female side. Defective sensor 5 V power 3. Turn starting switch to ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Between BRK (female) (C) and Power supply Voltage 4.5 – 5.5 V (A) 1. Turn starting switch to OFF position. 2. Disconnect connector BRK and connect T-adapter to male side. Defective brake pedal 3. Turn starting switch to ON position. potentiometer (Internal disconnection or 4. Depress brake pedal and troubleshoot. Between BRK (female) (C) and (A) Resistance Approx. 5 kΩ short circuit) Between BRK (female) (A) and (B) Resistance 0.25 - 7.0 kΩ Between BRK (female) (B) and (C) Resistance 0.25 - 7.0 kΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector BRK and connect T-adapter to male side. (Contact with 24 V circuit) 3. Turn starting switch ON position. Between BRK (female) (B) and (A) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1 and BRK , and connect T-adapter to female side of Short circuit in wiring harPTCN1. ness a Check with tester in continuity mode. Between PTCN1 (female) (3) and each pin other No continuity (No sound is heard) than (3) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1. troller 3. Turn starting switch to ON position. 4. Depress brake pedal and troubleshoot. Between PTCN1(3) and (21) Voltage 0.5 – 4.5 V
40-448
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK40KB] Brake potentiometer: Short circuit
Circuit diagram related to brake potentiometer
D375A-6 (01)
40-449
DRAFT Troubleshooting by failure code Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KX] FR lever: Out of normal range Action code E04 Detail of failure Action of controller Problem on machine Related information
q
Failure code Front/Rear potentiometers 1 and 2: Out of normal range Failure DK55KX (Power train controller system) In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB]occurred at the same time.
q
Limits operation of engine and transmission.
q
Once machine stops, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in F-R direction)
q q
q
Cause Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA] and [DK57KB].
Failure code [DK55KZ] FR lever: Disconnection or short circuit Action code E04 Detail of failure Action of controller Problem on machine
q
Failure code Front/Rear potentiometer: Abnormal at key ON Failure DK55KZ (Power train controller system) In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), when starting switch is turned to ON position, only either side is abnormal and then either of failure codes [DK56KA] and [DK56KB]and either of failure codes [DK57KA] and [DK57KB] occurred at the same time.
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Limits operation of engine and transmission.
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Once machine stops, engine speed is limited to medium (half). Once machine stops, it cannot travel at all. Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in F-R direction)
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Related information
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Cause Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA] and [DK57KB].
40-450
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK55L8] FR lever: Signal mismatch Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Front/Rear potentiometer: Signal mismatch Failure DK55L8 (Power train controller system) In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), total of both signal voltages is below 4.41 V or above 5.59 V. Continues control with signal of normal one of PCCS lever F-R potentiometer 1 or 2. Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) (Code: 50201 T/M Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in F-R direction)
Cause Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DK56KA], [DK56KB],[DK57KA] and [DK57KB].
D375A-6 (01)
40-451
Troubleshooting by failurecode Failure code [DK56KA] FR lever 1: Disconnection
Failure code [DK56KA] FR lever 1: Disconnection Action code
Failure code Failure
E03
DK56KA
40-460
Front/Rear potentiometer 1: Disconnection (Power train controller system)
Detail of failure
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Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is below 0.5 V
Action of controller Problem on machine
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Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in F-R direction).
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Related information
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Cause
Procedure, measuring location, criteria and remarks If failure code [DBE5KK] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position. Defective sensor 5 V power 2. Disconnect connector TL2 and connect T-adapter to female side. 1 3. Turn starting switch to ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Between TL2 (female) (4) and Power supply Voltage 4.5 – 5.5 V (1) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector TL2. Defective PCCS lever F-R 3. Turn starting switch ON position. 4. Operate PCCS lever (F-R) and troubleshoot. potentiometer 1 (Internal a If power supply voltage is normal and sensor output voltage is abnormal (below 2 disconnection) or ground 0.5 V), internal disconnection and ground fault cannot be identified. In this case, fault go to cause 4. If check result of cause 4 is normal, PCCS lever F-R potentiometer 1 is defective. Between TL2 (3) and (1)
Sensor output
Voltage
1.39–3.61 V
1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to each female side. a If power supply voltage in cause 1 is normal, this Disconnection in wiring harcheck is not required. Resistance Max. 1 z ness 3 Between PTCN1 (female) (22) and TL2 (female) (4) (open circuit or defective a If power supply voltage in cause 1 is normal, this contact) check is not required. Resistance Max. 1 z Between PTCN1 (female) (21) and TL2 (female) (1) Between PTCN1 (female) (20) and TL2 (female) (3)
Resistance
Max. 1 z
a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to either female Ground fault of wiring harside. 4 ness Between PTCN1 (female) (20) and (21), or between (Contact with ground circuit) Resistance Min. 1 Mz TL2(female)(3) and (1) Between PTCN1 (female) (20) and ground, or Resistance Min. 1 Mz between TL2 (female) (3) and ground If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con- 2. Insert T-adapter into connector PTCN1. 5 troller 3. Turn starting switch to ON position. 4. Operate PCCS lever (F-R) and troubleshoot. Between PTCN1 (20) and (21)
40-452
Voltage
1.39 – 3.61 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DK56KA] FR lever 1: Disconnection
Circuit diagram related to Front/Rear potentiometer
D375A-6 (01)
40-453
Troubleshooting by failurecode Failure code [DK56KB] FR lever 1: Short circuit
Failure code [DK56KB] FR lever 1: Short circuit Action code
Failure code Failure
E03
DK56KB
40-462
Front/Rear potentiometer 1: Short circuit (Power train controller system)
Detail of failure
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Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is above 4.5 V.
Action of controller
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Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4). Limits operation of engine and transmission.
Problem on machine
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Related information
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Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function. (Code: 50200 T/M Lever 1 Potentio) Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in F-R direction).
Cause
Procedure, measuring location, criteria and remarks
Defective sensor 5 V power If failure code [DBE5KK] is also displayed, troubleshoot it first. supply system 1. Turn starting switch to OFF position. 2. Disconnect connectors TL2. 3. Turn starting switch to ON position. Defective PCCS lever F-R 4. Operate PCCS lever (F-R) and troubleshoot. potentiometer 1 If failure code [DK56KB] is not displayed, PCCS lever steering potentiometer is 2 (Internal disconnection) or defective. (This failure code is still displayed, wiring harness or power train controller ground fault is defective.) a Since connector TL2 is disconnected, many failure codes are displayed. Ignore all displayed failure codes other than [DK56KB]. 1. Turn starting switch to OFF position. Hot short of wiring harness 2. Disconnect connectors TL2, and connect T-adapter to female side. 3 3. Turn starting switch ON position. (Contact with 24 V circuit)
1
Between TL2 (female) (3) and (1) or ground
4
Short circuit in wiring harness
5
Defective power train controller
Between PTCN1 (20) and (21)
40-454
Voltage
Max. 1 V
1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of PTCN1. a Check with tester in continuity mode. Between PTCN1 (female) (20) and each pin other than No continuity (No sound is (20) heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. 4. Operate PCCS lever (F-R) and troubleshoot. Voltage
1.39 – 3.61 V
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DK56KB] FR lever 1: Short circuit
Circuit diagram related to Front/Rear potentiometer
D375A-6 (01)
40-455
DRAFT Troubleshooting by failure code Failure code [DK57KA] FR lever 2: Disconnection
Failure code [DK57KA] FR lever 2: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Front/Rear potentiometer 2: Disconnection Failure DK57KA (Power train controller system) Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is below 0.5 V. Continues control with signal of PCCS lever F-R potentiometer 1 (F/R lever 3). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever F-R potentiometer 2 can be checked with monitoring function. (Code: 50201 T/M Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in F-R direction).
Cause
1
2
Defective sensor 5 V power supply system
Defective PCCS lever F-R potentiometer 2 (Internal disconnection) or ground fault
3
Disconnection in wiring harness (Disconnection or defective contact in connector)
4
Ground fault of wiring harness (Contact with ground circuit)
5
Defective power train controller
40-456
Procedure, measuring location, criteria and remarks If failure code [DBE5KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector TL2 and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between TL2 (female) (4) and (1) Power supply Voltage 4.5 – 5.5 V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector TL2. 3. Turn starting switch ON position. 4. Operate PCCS lever (F-R) and troubleshoot. a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5 V), internal disconnection and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, PCCS lever F-R potentiometer 2 is defective. Between TL2 (2) and (1) Sensor output Voltage 1.39 – 3.61 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female side of them. a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1 (female) (22) and TL2 (female) (4) a If power supply voltage on cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1(female) (21) and TL2 (female) (1) Between PTCN1(female) (14) and TL2 (female) (2) Resistance Max. 1 Ω a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of either of them. Between PTCN1 (female) (14) and (21), or between Resistance Min. 1 MΩ TL2 (female) (2) and (1) Between (female) (14) and ground , or between TL2 Resistance Min. 1 MΩ (female) (2) and ground If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 3. Turn starting switch to ON position. 4. Operate PCCS lever (F-R) and troubleshoot. Between PTCN1 (14) and (21) Voltage 1.39 – 3.61 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK57KA] FR lever 2: Disconnection
Circuit diagram related to Front/Rear potentiometer
D375A-6 (01)
40-457
DRAFT Troubleshooting by failure code Failure code [DK57KB] FR lever 2: Short circuit
Failure code [DK57KB] FR lever 2: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
1
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Failure code Front/Rear potentiometer 2: Short circuit Failure DK57KB (Power train controller system) Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is above 4.5 V. Continues control with signal of PCCS lever F-R potentiometer 1 (F/R lever 3). Limits operation of engine and transmission. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. Signal voltage of PCCS lever F-R potentiometer 2 can be checked with monitoring function. (Code: 50201 T/M Lever 2 Potentio) Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in F-R direction).
Cause Procedure, measuring location, criteria and remarks Defective sensor 5 V power If failure code [DBE5KK] is also displayed, troubleshoot it first. supply system 1. Turn starting switch to OFF position. 2. Disconnect connector TL2. Defective PCCS lever F-R 3. Turn starting switch to ON position. potentiometer 2 (Internal 4. Operate PCCS lever (F-R) and troubleshoot. disconnection) or ground If failure code [DK57KB]is not displayed, PCCS lever F-R potentiometer is defective. fault (If failure code [DK57KB] is still displayed, wiring harness or power train controller is defective.) a Since connector TL2 is disconnected, many failure codes are displayed. Ignore all displayed failure codes other than [DK57KB]. 1. Turn starting switch to OFF position. Hot short of wiring harness 2. Disconnect connector TL2 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between TL2 (female) (2) and (1) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of Short circuit in wiring harPTCN1. ness a Check with tester in continuity mode. Between PTCN1 (female) (14) and each pin other No continuity (No sound is than (14) heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train con2. Insert T-adapter into connector PTCN1. troller 3. Turn starting switch to ON position. 4. Operate PCCS lever (F-R) and troubleshoot. Between PTCN1 (14) and (21) Voltage 1.39 – 3.61 V
40-458
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK57KB] FR lever 2: Short circuit
Circuit diagram related to Front/Rear potentiometer
D375A-6 (01)
40-459
DRAFT Troubleshooting by failure code Failure code [DK60KA] Acceleration sensor: Disconnection
Failure code [DK60KA] Acceleration sensor: Disconnection Action code E01 Detail of failure Action of controller Problem on machine Related information
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Failure code Acceleration sensor: Disconnection Failure DK60KA (Power train controller system) Signal voltage of acceleration sensor is below 0.5 V.
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Turns shoe slip control(SSC) function OFF.
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Even if shoe slips, engine speed does not change.
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Input (voltage) from acceleration sensor can be checked in moniitoring function. (Code 60200 : Voltage of acceleration sensor) Method of reproducing failure code: Turn starting switch to ON position.
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Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBB7KP] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector SSA and connect T-adapter to female side. Defective 5 V power supply 3. Turn starting switch to ON position. system a If power supply voltage is abnormal, go to cause 3 or after. Power supBetween SSA(female)(1) and (3) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectorSSA. 3. Turn starting switch to ON position. Defective acceleration sen- a If power supply voltage is normal and sensor output voltage is abnormal (below sor sensor (Internal discon0.5 V), internal disconnection and ground fault cannot be identified. In this case, nection) or ground fault go to cause 4. If check result of cause 4 is normal, acceleration sensor sensor is defective. Sensor outBetween SSA (female) (2) and (3) Voltage 0.75 – 4.25 V put 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1, PTCN3 and SSA, and connect T-adapters to female side of them. Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this ness check is not required. Resistance Max. 1 Ω (Disconnection or defective Between PTCN3 (female) (34) and SSA (female) (1) contact in connector) a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN 1(female) (21) and SSA (female) (3) Between PTCN1 (female) (1) and SSA (female) (2) Resistance Max. 1 Ω a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1, SSA, and connect T-adapter to female side of Ground fault of wiring hareither of them. ness (Contact with ground circuit) Between PTCN1 (female) (1) and (21), or between Resistance Max. 1 MΩ SSA (female) (2) and (3) Between PTCN1 (female) (1) and ground, or Resistance Max. 1 MΩ between SSA (female) (2) and ground If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. Defective power train control- 1. Turn starting switch to OFF position. ler 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. Between PTCN1 (1) and (21) Voltage 0.75 – 4.25 V
40-460
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK60KA] Acceleration sensor: Disconnection
Circuit diagram related to acceleration sensor
D375A-6 (01)
40-461
DRAFT Troubleshooting by failure code Failure code [DK60KB] Acceleration sensor: Short circuit
Failure code [DK60KB] Acceleration sensor: Short circuit Action code E01 Detail of failure Action of controller Problem on machine Related information
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Failure code Acceleration sensor: Short circuit Failure DK60KB (Power train controller system) Signal voltage of acceleration sensor is above 4.5 V.
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Turns shoe slip control(SSC) function OFF.
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Even if shoe slips, engine speed does not change.
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Input (voltage) from acceleration sensor can be checked in moniitoring function. (Code 60200 : Voltage of acceleration sensor) Method of reproducing failure code: Turn starting switch to ON position.
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Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks If failure code [DBB7KP] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector SSA and connect T-adapter to female side. Defective sensor 5 V power 3. Turn starting switch to ON position. supply system a If power supply voltage is abnormal, go to cause 3 or after. Power supBetween SSA (female) (1) and (3) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Disconnect connector SSA. Defective acceleration sensor sensor (Internal discon- 3. Turn starting switch to ON position. If failure code [DK60KB] is not displayed , acceleration sensor is defective. (If failure nection) or ground fault code [DK60KB] is still displayed, it shows that wiring harness or power train controller is defective.) 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SSA (female) (2) and (3) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1 and SSA, and connect T-adapter to female side of PTCN1. Short circuit in wiring harness a Check with tester in continuity mode. Between PTCN1 (female) (1) and (1) and each pin No continuity(No sound is other than heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. Defective power train control- 1. Turn starting switch to OFF position. ler 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. Between PTCN1 (1) and (21) Voltage 0.75 – 4.25 V
40-462
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DK60KB] Acceleration sensor: Short circuit
Circuit diagram related to acceleration sensor
D375A-6 (01)
40-463
DRAFT Troubleshooting by failure code Failure code [DKH1KA] Pitch angle sensor: Disconnection
Failure code [DKH1KA] Pitch angle sensor: Disconnection Action code E03 Detail of failure Action of controller Problem on machine
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Related information
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Failure code Pitch angle sensor: Disconnection Failure DKH1KA (Power train controller system) Signal voltage of pitch angle sensor is below 0.15 V. Cannot sense pitch angle of machine. Limits operation of engine and transmission. Gearshift shock is made on slope or steering shock is made on level ground. Once machine is stopped, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. State of pitch angle sensor signal can be checked with monitoring function. (Code: 60100 Pitch Angle Sensor) Method of reproducing failure code: Turn the starting switch to ON position. If sensor connector is disconnected in normal condition, this code is displayed.
Cause
1
Defective 24 V power supply system
Defective pitch angle sensor 2 (Internal defect) or ground fault
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Ground fault of wiring har4 ness (Contact with ground circuit)
5
Defective power train controller
40-464
Procedure, measuring location, criteria and remarks If failure code [DBE6KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector PT1 and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Between PT1 (female) (C) and (A) Power supply Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PT1. 3. Turn starting switch to ON position. a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5 V), internal disconnection and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, pitch angle sensor is defective. Between PT1 (female) (B) and (A) Sensor output Voltage 0.24 – 4.76 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female side of them. a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN3 (female) (16) and PT1 (female) (C) a If power supply voltage in cause 1 is normal, this check is not required. Resistance Max. 1 Ω Between PTCN1(female) (21) and PT1 (female) (A) Between PTCN1 (female) (9) and PT1 (female) (B) Resistance Max. 1 Ω a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female side of either of them. Between PTCN1 (female) (9) and (21), or between Resistance Max. 1 MΩ PT1 (female) (B) and (A) Between PTCN1 (female) (9) and ground, or between Resistance Max. 1 MΩ PT1 (female) (B) and ground If cause is not found by above checks, power train controller is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1 3. Turn starting switch to ON position. Between PTCN1 (9) and (21) Voltage 0.24 – 4.76 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DKH1KA] Pitch angle sensor: Disconnection
Circuit diagram related to pitch angle sensor
D375A-6 (01)
40-465
DRAFT Troubleshooting by failure code Failure code [DKH1KB] Pitch angle sensor: Short circuit
Failure code [DKH1KB] Pitch angle sensor: Short circuit Action code E03 Detail of failure Action of controller Problem on machine
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Related information
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Failure code Pitch angle sensor: Short circuit Failure DKH1KB (Power train controller system) Signal voltage of pitch angle sensor is above 4.85 V. Cannot sense pitch angle of machine. Limits operation of engine and transmission. Gearshift shock is made on slope or steering shock is made on level ground. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1. State of pitch angle sensor signal can be checked with monitoring function. (Code: 60100 Pitch Angle Sensor) Method of reproducing failure code: Turn the starting switch to ON position. If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DHT5KA] is displayed.
Cause
1
Defective sensor 24 V power supply system
2
Defective pitch angle sensor (Internal defect)
3
Hot short in wiring harness (Contact with 24 V circuit)
4 Short circuit in wiring harness
5
Defective power train controller
40-466
Procedure, measuring location, criteria and remarks If failure code [DBE6KK] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector PT1 and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to cause 3 or after. Power supBetween PT1 (female) (C) and (A) Voltage 20 – 30 V ply 1. Turn starting switch to OFF position. 2. Disconnect connector PT1. 3. Turn starting switch to ON position. If failure code [DKH1KB] is not displayed but [DKH1KA] of disconnection is displayed, pitch angle sensor is defective. (If failure code [DKH1KB] is still displayed, it shows that wiring harness or power train controller is defective.) 1. Turn starting switch to OFF position. 2. Disconnect connector PT1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between PT1 (female) (B) and (A) or ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1 and PT1, and connect T-adapter to female side of a Check with tester in continuity mode. No continuity (No sound is Between PTCN1 (female ) (9) and each pin other than (9) heard) If cause is not found by the above checks, power train controller is defective. q Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. Between PTCN1 (9) and (21) Voltage 0.24 – 4.76 V
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DKH1KB] Pitch angle sensor: Short circuit
Circuit diagram related to pitch angle sensor
D375A-6 (01)
40-467
DRAFT Troubleshooting by failure code Failure code [DLF1KA] T/C out-speed sensor: Disconnection
Failure code [DLF1KA] T/C out-speed sensor: Disconnection Action code – Detail of failure Action of controller Problem on machine Related information
Failure code DLF1KA
Failure
Torque converter oil temperature sensor disconnection (Power train controller system)
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No signal is input from torque converter output speed sensor.
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Recognizes that torque converter output speed is 0 rpm .
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Torque converter output speed cannot be monitored
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Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine or run tracks in the air with machine body put on the stands).
Cause Defective torque converter output speed sensor (Inter1 nal disconnection or short circuit)
2
3
4
5
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector C1 and connect T-adapter to male side. Between TC1 (male) (1) and (2) Resistance Approx. 560 Ω Between TC1 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN2 and connect T-adapter to female side. a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN2 (female) (29) and (20) Resistance Approx. 560 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN2 and TC1, and connect T-adapters to female side of (Disconnection or defective them. contact in connector) Between PTCN2 (female) (29) and TC1 (female) (2) Resistance Max. 1 Ω Between PTCN2 (female) (20) and TC1 (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector TC1 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between TC1 (female) (1) and (2) Voltage 3–4V Defective power train conIf cause is not found by above checks, power train controller may be defective. (Since troller failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to torque converter output speed sensor
40-468
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DLM3KA] Fan rev. sensor: Disconnection
Failure code [DLM3KA] Fan rev. sensor: Disconnection Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code DLM3KA
Failure
Fan speed sensor: Disconnection (Work equipment controller system)
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No signal is input from fan speed sensor.
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Recognizes that fan speed is 0 rpm.
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Fan speed cannot be monitored. Fan PID control cannot be started. Fan speed can be checked with monitoring function. (Code: 10007 Fan speed) Method of reproducing failure code: Turn the starting switch to ON position
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Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective fan speed sensor 2. Disconnect connector FRV and connect T-adapter to male side. (Internal disconnection or Between FRV (male) (1) and (2) Resistance Approx. 2 kΩ short circuit) Between FRV (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector WECN2 and connect T-adapter to female side. a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between WECN2 (female) (40) and (39) Resistance Approx. 2 kΩ a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors WECN2 and FRV, and connect T-adapters to female side (Disconnection or defective of them. contact in connector) Between WECN2 (female) (39) and FRV (female) (2) Resistance Max. 1 Ω Between WECN2 (female) (40) and FRV (female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector FRV and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between FRV (female) (1) and (2) Voltage 3–4V Defective work equipment If cause is not found by above checks, work equipment controller may be defective. controller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan speed sensor
D375A-6 (01)
40-469
DRAFT Troubleshooting by failure code Failure code [DLM3MB] Fan control: Decline
Failure code [DLM3MB] Fan control: Decline Action code E02 Detail of failure Action of controller Problem on machine
Related information
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Failure code Fan speed control function low Failure DLM3MB (Work equipment controller system) Difference between fan speed set value with work equipment controller and actual speed sensed by fan speed sensor exceeds 100 rpm.
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Work equipment controller does not perform PID control on fan.
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Fan speed set value with work equipment controller can be checked with monitoring function. (Code: 10000 Fan speed command) Fan speed sensed by fan speed sensor can be checked with monitoring function. (Code: 10007 Fan speed) This code is conditioned that fan solenoid is normal and fan speed sensor is also normal (it means normal electrically).
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Cause 1 Defective hydraulic system
40-470
Procedure, measuring location, criteria and remarks Perform Testing and adjusting, "Testing fan hydraulic circuit".
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KA] T/M out-speed sensor: Disconnection Action code E01 Detail of failure Action of controller Problem on machine
Failure code DLT3KA
Transmission output speed sensor: Disconnection (Power train controller system)
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No signal is input from transmission output speed sensor.
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Recognizes that transmission output speed is 0 rpm.
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Transmission output speed cannot be monitored. Traction force cannot be calculated. Automatic shift down function does not operate. Once machine stops, gear shift mode is limited to manual gear shift mode. Transmission output speed can be checked with monitoring function. (Code: 31400 T/M Out Speed) Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine or run tracks in the air with machine body put on the stands).
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Related information
Trouble
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Cause Defective transmission bevel gear (output) speed sensor 1 (Internal disconnection or short circuit)
2
3
4
6
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector TM1 and connect T-adapter to male side. Between TM1 (male) (1) and (2) Resistance About 560 Ω Between TM1 (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN2 and connect T-adapter to female side. a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN2 (female) (39) and (30) Resistance About 560 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connector PTCN2 and TM1, and connect T-adapters to female side of (Disconnection or defective them. contact in connector) Between PTCN2 (female) (39) and TM1 (female) (2) Resistance Max. 1 Ω Between PTCN2 (female) (30) and TM1(female) (1) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector TM1 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between TM1 (female) (1) and (2) Voltage 3–4V Defective power train conIf cause is not found by above checks, power train controller may be defective. (Since troller failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to transmission output speed sensor
D375A-6 (01)
40-471
DRAFT Troubleshooting by failure code Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DLT3KB] T/M out-speed sensor: Abnormal Action code E01 Detail of failure Action of controller Problem on machine
Failure code DLT3KB
Transmission output speed sensor: Disconnection (Power train controller system)
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No signal is input from transmission output speed sensor
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Recognizes that transmission output speed is 0 rpm.
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Transmission output speed cannot be monitored Traction force cannot be calculated. Automatic shift down function may not operate correctly. Once machine stops, gear shift mode is limited to manual gear shift mode. Transmission output speed sensor can be checked with moniitoring function. (Code: 31400 T/M Out Speed) Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine or run tracks in the air with machine body put on the stands).
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Related information
Failure
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Cause Defective transmission bevel gear (output) speed sensor 1 (Internal disconnection or short circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector TM1 and connect T-adapter to male side. Between TM1 (male) (1) and (2) Resistance Approx. 560 Ω Between TM1 (male)(1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN2 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN2 (female) (39) and (30) Resistance Approx. 560 Ω 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connector PTCN2 and TM1, and connect T-adapter to female side of 3 ness either of them. (Contact with ground circuit) Between PTCN2 (female) (30) or TM1 (female) (1) Resistance Min. 1 MΩ and ground Defective power train conIf cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to transmission output speed sensor
40-472
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DW59KA] Blade dual selector SOL disconnection
Failure code [DW59KA] Blade dual selector SOL disconnection Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DW59KA
Failure
Dual tilt selector solenoid: Disconnection (Work equipment controller system)
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Any current does not flow when power is output to the dual tilt selector solenoid circuit.
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Stops output to dual tilt selector solenoid circuit.
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Dual tilt cannot be selector.
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Method of reproducing failure code: Turn starting switch to ON position and operate dual tilt selector switch.
Cause Procedure, measuring location, criteria and remarks Defective dual tilt selector 1. Turn starting switch to OFF position. 1 solenoid (Internal disconnec- 2. Disconnect connector SOL2 and connect T-adapter to male side. tion) SOL2 (male) (1) and (2) Resistance 10 – 40 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector WECN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between WECN3 (female) (7) and (23) Resistance 10 – 40 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side 3 (Disconnection in wiring or of them. defective contact in connec- Between WECN3 (female) (7) and SOL2 (female) (1) Resistance Max. 1 Ω tor) Between WECN3 (female) (23) and SOL2 (female) Resistance Max. 1 Ω (2) Defective work equipment If cause is not found by the above checks, work equipmet controller may be defec4 controller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to dual tilt selector solenoid
D375A-6 (01)
40-473
DRAFT Troubleshooting by failure code Failure code [DW59KB] Blade dual selector SOL short circuit
Failure code [DW59KB] Blade dual selector SOL short circuit Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DW59KB
Failure
Dual tilt selector solenoid: Short circuit (Work equipment controller system)
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Abnormal current flowed when power is output to dual tilt selector solenoid circuit.
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Stops output to dual tilt selector solenoid circuit.
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Dual tilt cannot be selector.
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Method of reproducing failure code: Turn starting switch to ON position and operate dual tilt selector switch.
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective dual tilt selector solenoid (Internal short cir- 2. Disconnect connector OL2 and connect T-adapter to male side. Between SOL2 (male) (1) and (2) Resistance 10 – 40 Ω cuit) Between SOL2 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side ness of them. (Contact with ground circuit) Between WECN3 (female) (7) or SOL2 (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side Short circuit in wiring harof either of them. ness Between WECN3 (female) (7) and (23) or between Resistance Min. 1 MΩ SOL2 (female) (1) and (2) Defective work equipment If cause is not found by the above checks, work equipment controller may be defeccontroller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to dual tilt selector solenoid
40-474
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DW59KY] Blade dual selector SOL hot short
Failure code [DW59KY] Blade dual selector SOL hot short Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DW59KY
Failure
Dual tilt selector solenoid: Short circuit (Work equipment controller system)
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Current flows constantly to dual tilt selector solenoid circuit.
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Stops output to dual tilt selector solenoid circuit.
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Only tilt can be operated and dual tilt cannot be operated. Blade single tilt does not operate . Method of reproducing failure code: Turn starting switch to ON position and operate dual tilt selector switch.
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Cause Defective dual tilt selector 1 solenoid (Internal short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Short circuit in wiring harness
4
Defective work equipment controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SOL2 and connect T-adapter to male side. Between SOL2 (male) (1) and (2) Resistance 10 – 40 Ω Between SOL2 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector SOL2 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between SOL2 (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN3 and SOL2, and connect T-adapter to female side of WECN3. a Check with tester in continuity mode. Between WECN3 (female) (7) and each pin other No continuity (No sound is than (7) heard.) 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN3, RB1 and SOL2, and connect T-adapter to female side and male side of RB1 in 2 times. a Check with tester in continuity mode. No continuity (No sound is Between RB1 (female) (3) and each pin other than (3) heard.) No continuity (No sound is Between RB1 (male) (3) and each pin other than (3) heard.) If cause is not found by above checks, work equipment controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to dual tilt selector solenoid
D375A-6 (01)
40-475
Troubleshooting by failurecode Failure code [DW5AKA] Blade pitch selector SOL disconnection
Failure code [DW5AKA] Blade pitch selector SOL disconnection Action code
Failure code Failure
E02
DW5AKA
Detail of failure Action of controller Problem on machine Related information
Work equipment pitch select solenoid: Disconnection (Work equipment controller system)
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No current flows when power is output to the work equipment pitch select solenoid circuit.
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Stops output to pitch select solenoid circuit.
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Blade pitch cannot be changed.
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Method of reproducing failure code: Turn starting switch to ON position and operate pitch select switch.
Cause
Procedure, measuring location, criteria and remarks
Defective work equipment 1. Turn starting switch to OFF position. 1 pitch select solenoid (Inter- 2. Disconnect connector SOL1 and connect T-adapter to male side. Between SOL1 (male) (1) and (2) Resistance nal disconnection)
2
40-48
Disconnection or short circuit in wiring harness
10 – 40 z
1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and connect T-adapter to female side. a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below 1 z, wiring harness has short circuit. Between WECN3 (female) (17) and (23)
Resistance
10 – 40 z
a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors WECN3 and SOL1, and connect T-adapters to each ness female side. 3 (wire breakage or defective Between WECN3 (female) (17) and SOL1 (female) (1) Resistance Max. 1 z contact of connector) Between WECN3 (female) (23) and SOL1 (female) (2) Defective work equipment 4 controller
Circuit diagram related to work equipment pitch select solenoid
40-476
Resistance
Max. 1 z
If cause is not found by the above checks, work equipment controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-48
D375A-6 (06)
Troubleshooting by failurecode Failure code [DW5AKB] Blade pitch selector SOL short circuit
Failure code [DW5AKB] Blade pitch selector SOL short circuit Action code
Failure code Failure
E02
DW5AKB
Detail of failure Action of controller Problem on machine Related information
40-489
Work equipment pitch select solenoid: Short circuit (Work equipment controller system)
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Abnormal current flowed when power was output to work equipment pitch select solenoid circuit.
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Stops output to pitch select solenoid circuit.
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Blade pitch cannot be changed.
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Method of reproducing failure code: Turn starting switch to ON position and operate pitch select switch.
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SOL1 and connect T-adapter to male side.
Defective work equipment 1 pitch select solenoid (Inter- Between SOL1 (male) (1) and (2) nal short circuit) Between SOL1 (male) (1) and ground
Resistance
10 – 40 z
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female side 2 ness of either of them. (Contact with ground circuit) WECN3 (female) (17) or SOL1 (female) (1) and ground Resistance Min. 1 Mz
3
Short circuit in wiring harness
4
Defective work equipment controller
1. Turn starting switch to OFF position. 2. Disconnect connectors WECN3 and SOL1, and connect T-adapters to either female side. Between WECN3 (female) (17) and (23) or between Resistance Min. 1 Mz SOL1 (female) (1) and (2) If cause is not found by the above checks, work equipment controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to work equipment pitch select solenoid
D375A-6 (06)
40-489
40-477
Troubleshooting by failurecode Failure code [DW5AKY] Blade pitch selector SOL Short circuit
Failure code [DW5AKY] Blade pitch selector SOL Short circuit Action code
Failure code Failure
E02
DW5AKY
Detail of failure Action of controller Problem on machine Related information
40-490
Work equipment pitch select solenoid: Short circuit (Work equipment controller system)
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Current flows constantly to work equipment pitch select solenoid circuit.
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Stops output to pitch select solenoid circuit.
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Only pitch operation can be changed and tilt operation cannot be changed.
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Method of reproducing failure code: Turn starting switch to ON position and operate pitch select switch.
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SOL1 and connect T-adapter to male side.
Defective work equipment 1 pitch select solenoid (Inter- Between SOL1 (male) (1) and (2) nal short circuit) Between SOL1 (female) (1) and ground Hot short in wiring harness 2 (Contact with 24 V circuit)
Short circuit in wiring harness
4
Defective work equipment controller
Resistance
Min. 1 Mz
Voltage
Max. 1 V
1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and SOL1 and connect T-adapter to female side of WECN3. a Check with tester in continuity mode. Between WECN3 (female) (17) and each pin other than No continuity(No sound is (17) heard) 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN3, RB1 and SOL1, and connect T-adapter to female side and male side of RB1 separately in 2 times a Check with tester in continuity mode. No continuity(No sound is Between RB1 (female) (1) and each pin other than (1) heard) No continuity(No sound is Between RB1 (male) (1) and each pin of (1) heard) If cause is not found by the above checks, work equipment controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to work equipment pitch select solenoid
40-478
10 – 40 z
1. Turn starting switch to OFF position. 2. Disconnect connector SOL1 and connect T-adapter to female side. 3. Turn starting switch ON position. Between SOL1 (female) (1) and ground
3
Resistance
40-491
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKA] Fan rev EPC: Disconnection Action code E01 Detail of failure Action of controller Problem on machine Related information
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Failure code Fan reverse solenoid: Disconnection Failure DW7BKA (Work equipment controller system) When power is output to fan reverse solenoid circuit, no current flows.
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Stops output to fan reverse solenoid circuit.
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Fan reverse function cannot be used.
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Output condition to fan reverse solenoid can be checked with monitoring function. (Code: 40983 W/E control SW output) Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.
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Cause Defective fan reverse sole1 noid (Internal disconnection)
2
3
4
5
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FAR2 and connect T-adapter to male side. Between FAR2 (male) (1) and (2) Resistance 34 – 44 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector WECN3 and connect T-adapter to female side. a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between WECN3 (female) (18) amd (13) Resistance 34 – 44 Ω a If cause 2 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring har- 2. Disconnect connector WECN3 and FAR2, and connect T-adapters to their female ness sides. (Disconnection or defective Between WECN3 (female) (18) and FAR2 (female) Resistance Max. 1 Ω contact in connector) (1) Between WECN3 (female) (13) and FAR2 (female) Resistance Max. 1 Ω (2) 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector FAR2 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch ON position. Between FAR2 (female) (1) and ground Voltage Max. 1 V Defective work equipment If cause is not found by the above checks, work equipment controller may be defeccontroller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan reverse EPC
D375A-6 (01)
40-479
DRAFT Troubleshooting by failure code Failure code [DW7BKB] Fan rev EPC: Short circuit
Failure code [DW7BKB] Fan rev EPC: Short circuit Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DW7BKB
Fan reverse solenoid: Short circuit (Work equipment controller system)
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When power was output to fan reverse solenoid circuit, abnormal current flowed.
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Stops output to fan reverse solenoid circuit.
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Fan reverse function cannot be used.
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Output condition of fan reverse solenoid can be checked with monitoring function. (Code: 40983 W/E control SW output) Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.
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Cause 1
Failure
Defective fan reverse solenoid (Internal short circuit)
Ground fault of wiring har2 ness (Contact with GND circuit)
3
Short circuit in wiring harness
4
Defective work equipment controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FAR2 and connect T-adapter to male side. Between FAR2 (male) (1) and (2) Resistance 34 – 44 Ω Between FAR2 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female side of either of them. Between WECN3 (female) (18) or FAR2 (female) (1) Resistance Min. 1 MΩ or ground 1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female side of either of them. Between WECN3 (female) (18) and (13) or betwen Resistance Min. 1 MΩ FAR2 (female) (1) and (2) If cause is not found by the above checks, work equipment controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan reverse EPC
40-480
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWN3KA] Ssp solenoid: Disconnection
Failure code [DWN3KA] Ssp solenoid: Disconnection Action code E04 Detail of failure Action of controller Problem on machine Related information
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Failure code Sudden stop prevention solenoid disconnection Failure DWN3KA (Power train controller system) When power is output to sudden stop prevention solenoid circuit, no current flows. Stops output to sudden stop prevention solenoid circuit. Restricts operations of engine, transmission, and brake. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it becomes impossible to travel. Output condition to sudden stop prevention solenoid can be checked with monitoring function. (Code: 31628 Sudden stop prevention valve current (F/B)) Method of reproducing failure code: Turn the starting switch to ON position.
Cause Defective sudden stop pre1 vention solenoid (Internal disconnection)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector STB and connect T-adapter to male side. Between STB (male) (1) and (2) Resistance 5 – 15 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (7) and (13) Resistance 5 – 15 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and STB, and connect T-adapters to their female 3 (Disconnection in wiring or sides. defective contact in connecBetween PTCN3 (female) (7) and STB (female) (1) Resistance Max. 1 Ω tor) Between PTCN3 (female) (13) and STB (female) (2) Resistance Max. 1 Ω Defective power train control- If cause is not found by above checks, power train controller may be defective. 4 ler (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to sudden stop prevention solenoid
D375A-6 (01)
40-481
DRAFT Troubleshooting by failure code Failure code [DWN3KB] Ssp solenoid: Short circuit
Failure code [DWN3KB] Ssp solenoid: Short circuit Action code E04 Detail of failure Action of controller Problem on machine Related information
Failure code DWN3KB
Failure
Sudden stop prevention solenoid short circuit (Power train controller system)
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When power is output to sudden stop prevention solenoid circuit, abnormal current flowed.
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Stops output to sudden stop prevention solenoid circuit. Restricts operations of engine, transmission, and brake. Once machine stops, engine speed is restricted to medium (half). Once machine is stopped, it becomes impossible to travel. Output condition to sudden stop prevention solenoid can be checked with monitoring function. (Code: 31628 Sudden stop prevention valve current (F/B)) Method of reproducing failure code: Turn starting switch tp ON position.
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Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective sudden stop pre2. Disconnect connector STB and connect T-adapter to male side. vention solenoid Between STB (male) (1) and (2) Resistance 5 – 15 Ω (Internal short circuit) Between STB (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (7) or STB (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of Short circuit in wiring harness either of them. Between PTCN3 (female) (7) and (13) ro between Resistance Min. 1 MΩ STB (female) (1) and (2) Defective power train control- If cause is not found by the above checks, work equipment controller may be defecler tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to sudden stop prevention solenoid
40-482
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWN3KB] Ssp solenoid: Short circuit
D375A-6 (01)
40-483
DRAFT Troubleshooting by failure code Failure code [DWN3KY] SSP solenoid: Short circuit
Failure code [DWN3KY] SSP solenoid: Short circuit Action code E04 Detail of failure Action of controller
Failure code DWN3KY
When power is output to sudden stop prevention solenoid circuit, current flows.
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Stops output to sudden stop prevention solenoid circuit. Restricts operations of engine, transmission, and brake. Emergency sudden stop prevention function does not work. Once machine stops, engine speed is restricted to medium (half). Once machine stops, machine does not travel. Output to sudden stop prevention solenoid can be checked with monitoring function (Code: 31628 Sudden stop prevention valve current (F/B)) Method of reproducing failure code: Turn the starting switch to ON position.
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Related information
Sudden stop prevention solenoid short circuit (Power train controller system)
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Problem on machine
Failure
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Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective sudden stop pre2. Disconnect connector STB and connect T-adapter to male side. vention solenoid Between STB (male) (1) and (2) Resistance 5 – 15 Ω (Internal defect) Between STB (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector STB and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between STB (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (7) and each pin other than No continuity (No sound is (7) heard) 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors PTCN3, STB, PL2 and PL2, and connect T-adapter to female side and male side of RB1 separately in 2 times a Check with tester in continuity mode. Between PL2 (female) (23) and each pin other than No continuity (No sound is (23) heard) Between PL2 (male) (23) and each pin other than No continuity (No sound is (23) heard) Defective power train control- If cause is not found by the above checks, power train controller may be defective. ler (Since failure is in it, troubleshooting cannot be performed.)
40-484
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWN3KY] SSP solenoid: Short circuit
Circuit diagram related to sudden stop prevention solenoid
D375A-6 (01)
40-485
DRAFT Troubleshooting by failure code Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DWN5KA
Failure
Fan pump solenoid 1: Disconnection (Work equipment controller system)
q
When power is output to fan pump EPC solenoid 1 circuit (LPV90), no current flows.
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Stops output to fan pump EPC solenoid 1 circuit(LPV90).
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The output of fan pump(LPV90) is always at maximum speed.
q
Output to fan pump EPC solenoid 1 can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B)) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause Procedure, measuring location, criteria and remarks Defective fan pump solenoid 1. Turn starting switch to OFF position. 1 1 2. Disconnect connector FA1 and connect T-adapter to male side. (Internal disconnection) Between FA1 (male) (1) and (2) Resistance 2 – 12 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector WECN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between WECN3 (female) (36) and (23) Resistance 2 – 12 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connector WECN3 and FA1, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between WECN3 (female) (36) and FA1 (female) (1) Resistance Max. 1 Ω Between WECN3 (female) (23) and FA1 (female) (2) Resistance Max. 1 Ω Defective work equipment If cause is not found by the above checks, work equipment controller may be defec4 controller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan pump solenoid 1
40-486
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWN5KB] Fan pump solenoid 1: Short circuit
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DWN5KB
Failure
Fan pump solenoid 1: Short circuit (Work equipment controller system)
q
When power was output to fan pump control solenoid 1 (LPV90)circuit, abnormal current flowed.
q
Stops output to fan pump control solenoid 1 (LPV90) circuit.
q
Output of fan pump solenoid 1 (LPV90) is always at maximum speed.
q
Output condition to fan pump control solenoid 1 can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B)) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective fan pump control 2. Disconnect connector FA1 and connect T-adapter to male side. solenoid 1 Between FA1 (male) (1) and (2) Resistance 2 – 12 Ω (Internal disconnection) Between FA1 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between WECN3 (female) (36) or FA1 (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of Short circuit in wiring harness either of them. Between WECN3 (female) (36) and (23) or between Resistance Min. 1 MΩ FA1 (female) (1) and (2) Defective work equipment If cause is not found by the above checks, work equipment controller may be defeccontroller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan pump solenoid 1
D375A-6 (01)
40-487
DRAFT Troubleshooting by failure code Failure code [DWN5KY] Fan pump solenoid 1: Short circuit
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code DWN5KY
Failure
Fan pump control solenoid 1: Short circuit (Work equipment controller system)
q
Current flows constantly to fan pump EPC solenoid 1 (LPV90)circuit.
q
Stops output to fan pump EPC solenoid 1 circuit.
q
The output of fan pump (LPV90) is always at minimum speed. Machine may be overheat. Output condition to fan pump EPC solenoid 1 can be checked with monitoring function. (Code: 31624 Fan pump Solenoid (F/B)) Method of reproducing failure code: Turn starting switch to ON position.
q q q
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective fan pump control 2. Disconnect connector FA1 and connect T-adapter to male side. solenoid 1 Between FA1 (male) (1 and (2) Resistance 2–12 Ω (Internal short circuit) Between FA1 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector FA1 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between FA1 (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of WECN3. a Check with tester in continuity mode. Between WECN3 (female) (36) and each pin other No continuity (No sound is than (36) heard) 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors WECN3, FA1 and PL3, and connect T-adapter to female side and male side of PL3 separately in 2 times a Check with tester in continuity mode. Between PL3 (female) (21) and each pin other than No continuity (No sound is (21) heard) Between PL3 (male) (21) and each pin other than No continuity (No sound is (21) heard) If cause is not found by the above checks, work equipment controller may be defecDefective work equipment controller tive. (Since failure is in it, troubleshooting cannot be performed.)
40-488
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWN5KY] Fan pump solenoid 1: Short circuit
Circuit diagram related to fan pump solenoid 1
D375A-6 (01)
40-489
DRAFT Troubleshooting by failure code Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DWNCKA
Failure
Fan pump solenoid 2: Disconnection (Work equipment controller system)
q
When power is output to fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
q
Stops output to fan pump EPC solenoid 2 circuit.
q
Fan pump solenoid 2 (LPV30) is always at maximum speed.
q
Output condition to fan pump EPC solenoid 2 can be checked with monitoring function. (Code: 31634 Fan pump Solenoid 2 (F/B)) Method of reproducing failure code: Turn the starting switch to ON position.
q
Cause Defective fan pump EPC 1 solenoid 2 (Internal disconnection)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FA2 and connect T-adapter to male side. Between FA2 (male) (1) and (2) Resistance 2 – 12 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector WECN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between WECN3 (female) (26) and (23) Resistance 2 – 12 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connector WECN3 and FA2, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between WECN3 (female) (26) and FA2 (female) (1) Resistance Max. 1 Ω Between WECN3 (female) (23) and FA2 (female) (2) Resistance Max. 1 Ω Defective work equipment If cause is not found by the above checks, work equipment controller may be defec4 controller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan pump solenoid 2
40-490
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit Action code E01 Detail of failure Action of controller Problem on machine Related information
Failure code DWNCKB
Failure
Fan pump solenoid 2: Short circuit (Work equipment controller system)
q
When power is output to fan pump EPC solenoid 2 (LPV30) circuit, abnormal current flows.
q
Stops output to fan pump EPC solenoid 2 circuit.
q
Outputto fan pump solenoid 2 (LPV30) is kept at maximum.
q
Output condition to fan pump EPC solenoid 2 can be checked with monitoring function. (Code: 31634 Fan pump Solenoid 2 (F/B)) Method of reproducing failure code: Turn the starting switch to ON position.
q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective fan pump EPC 2. Disconnect connector FA2 and connect T-adapter to male side. solenoid 2 Between FA2 (male) (1) and (2) Resistance 2 – 12 Ω (Internal disconnection) Between FA2 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connector WECN3 and FA2, and connect T-adapter to female side of ness either of them. (Contact with GND circuit) Between WECN3 (female) (26) or FA2 (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connector WECN3 and FA2, and connect T-adapter to female side of Short circuit in wiring harness either of them. Between WECN3 (female) (26) and (23) or between Resistance Min. 1 MΩ FA2 (female) (1) and (2) Defective work equipment If cause is not found by the above checks, work equipment controller may be defeccontroller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to fan pump solenoid 2
D375A-6 (01)
40-491
DRAFT Troubleshooting by failure code Failure code [DWNCKY] Fan pump solenoid 2: Short circuit
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code DWNCKY
Failure
Fan pump solenoid 2: Short circuit (Work equipment controller system)
q
Current flows always in fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
q
Stops output to fan pump EPC solenoid 2 circuit.
q
Fan pump (LPV30) output is always at minimum speed. Fan speed does not increase. Output condition to fan pump EPC solenoid 2 can be checked with monitoring function. (Code: 31634 Fan pump Solenoid 2 (F/B)) Method of reproducing failure code: Turn the starting switch to ON position.
q q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective fan pump EPC 2. Disconnect connector FA2 and connect T-adapter to male side. solenoid 2 Between FA2 (male) (1) and (2) Resistance 2 – 12 Ω (Internal short circuit) Between FA2 (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector FA2 and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between FA2 (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors WECN3 and FA2, and connect T-adapter to female side of WECN3. a Check with tester in continuity mode. Between WECN3 (female) (26) and each pin other No continuity (No sound is than (26) heard.) 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors WECN3, PL3 and FA2, and connect T-adapter to female side and male side of PL3 separately in 2 times. a Check with tester in continuity mode. Between PL3 (female) (24) and each pin other than No continuity (No sound is (24) heard.) Between PL3 (male) (24) and each pin other than No continuity (No sound is (24) heard.) If cause is not found by above checks, work equipment controller may be defective. Defective work equipment controller (Since failure is in it, troubleshooting cannot be performed.)
40-492
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DWNCKY] Fan pump solenoid 2: Short circuit
Circuit diagram related to fan pump solenoid 2
D375A-6 (01)
40-493
DRAFT Troubleshooting by failure code Failure code [DXH1KA] Lock-up ECMV: Disconnection
Failure code [DXH1KA] Lock-up ECMV: Disconnection Action code E02 Detail of failure Action of controller Problem on machine
Failure code DXH1KA
Failure
Lock-up solenoid: Disconnection (Power train controller system)
q
When power is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
q
Stops output to torque converter lockup clutch ECMV solenoid circuit.
q
Torque converter lockup function does not operate.
q
Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31642 L/U ECMV (F/B)) Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).
Related information q
Cause Procedure, measuring location, criteria and remarks Defective lockup clutch 1. Turn starting switch to OFF position. 1 ECMV solenoid (Internal dis- 2. Disconnect connector SLUC and connect T-adapter to male side. connection) Between SLUC (male) (1) and (2) Resistance 3 – 13 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (16) and (23) Resistance 3 – 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connector PTCN3 and SLUC, and connect T-adapters to their female 3 (Disconnection in wiring or sides. defective contact in connecBetween PTCN3 (female) (16) and SLUC (female) (1) Resistance Max. 1 Ω tor) Between PTCN3 (female) (23) and SLUC (female) (2) Resistance Max. 1 Ω Defective power train control- If cause is not found by the above checks, power train controller may be defective. 4 ler (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to lock-up ECMV
40-494
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH1KB] Lock-up ECMV: Short circuit
Failure code [DXH1KB] Lock-up ECMV: Short circuit Action code E02 Detail of failure Action of controller Problem on machine
q
Failure code Lock-up solenoid: Short circuit Failure DXH1KB (Power train controller system) When power is output to torque converter lockup clutch ECMV solenoid circuit, abnormal current flows.
q
Stops output to torque converter lockup clutch ECMV solenoid circuit.
q
Torque converter lockup function does not operate.
q
Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31642 L/U ECMV (F/B)) Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).
Related information q
Cause Defective lockup clutch 1 ECMV solenoid (Internal disconnection) Ground fault of wiring har2 ness (Contact with ground circuit)
3 Short circuit in wiring harness
4
Defective power train controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SLUC and connect T-adapter to male side. Between SLUC (male) (1) and (2) Resistance 3 – 13 Ω Between SLUC (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side of either of them. Between PTCN3 (female) (16) or SLUC (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side of either of them. Between PTCN3 (female) (16) and (23)or between Resistance Min. 1 MΩ SLUC (female) (1) and (2) If cause is not found by the above checks, work equipment controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to lock-up solenoid
D375A-6 (01)
40-495
DRAFT Troubleshooting by failure code Failure code [DXH1KY] Lock-up ECMV: Short circuit
Failure code [DXH1KY] Lock-up ECMV: Short circuit Action code E03 Detail of failure Action of controller
Failure code DXH1KY
Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.
q
Stops output to torque converter lockup clutch ECMV solenoid circuit. Limits operation of engine and transmission. Torque converter lockup function operates constantly. Engine may stall during travel. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1 and R1. Output condition to lockup clutch ECMV solenoid can be checked with monitoring function. (Code: 31642 L/U ECMV (F/B)) Method of reproducing failure code: Start engine and travel in auto gearshift mode (while lockup is in operation).
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Related information
Lock-up solenoid: Short circuit (Power train controller system)
q
q
Problem on machine
Failure
q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective lockup clutch ECMV solenoid (Internal dis- 2. Disconnect connector SLUC and connect T-adapter to male side. Between SLUC (male) (1) and (2) Resistance 3 – 13 Ω connection) Between SLUC (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SLUC and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SLUC (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (16) and each pin other No continuity (No sound is than (16) heard) Short circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connector PTCN1 to 3 and SLUC, and connect T-adapter to female side of PTCN1 to 3. a Check with tester in continuity mode. Between PTCN3 (female) (16) and each pin of No continuity (No sound is PTCN1 (female) heard) Between PTCN3 (female) (16) and each pin of No continuity (No sound is PTCN2 (female) heard) Defective power train conIf cause is not found by the above checks, work equipment controller may be defectroller tive. (Since failure is in it, troubleshooting cannot be performed.)
40-496
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH1KY] Lock-up ECMV: Short circuit
Circuit diagram related to lock-up solenoid
D375A-6 (01)
40-497
DRAFT Troubleshooting by failure code Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KA] 1st clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 1st clutch ECMV: Disconnection Failure DXH4KA (Power train controller system) When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows. Stops output to transmission 1st clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Automatic gear shifting function does not operate. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is limited to F2 and R2. Output condition to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31612 T/M Clutch 1st ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F1 or R1.
Cause Defective 1st clutch ECMV 1 solenoid (Internal disconnection)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S1T and connect T-adapter to male side. Between S1T (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection.If resistance is becuit in wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (37) and (23) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and S1T, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (37) and S1T (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (23) and S1T (female) (2) Resistance Max. 1 Ω Defective power train con- If cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to 1st clutch ECMV
40-498
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KB] 1st clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q q q q q q
Failure code 1st clutch ECMV: Short circuit Failure DXH4KB (Power train controller system) When power was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed. Stops output to transmission 1st clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Automatic gear shifting function does not operate. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F2 and R2. Output condition to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31612 T/M Clutch 1st ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F1 or R1.
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 1st clutch ECMV solenoid (Internal short cir- 2. Disconnect connector S1T and connect T-adapter to male side. Between S1T (male) (1) and (2) Resistance 3 – 13 Ω cuit) Between S1T (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (37) or S1T (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (37) and (23), or between Resistance Min. 1 MΩ S1T (female) (1) and (2) Defective power train con- If cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to 1st clutch ECMV
D375A-6 (01)
40-499
DRAFT Troubleshooting by failure code Failure code [DXH4KY] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 1st clutch ECMV: Short circuit Failure DXH4KY (Power train controller system) Current flows constantly to transmission 1st clutch ECMV solenoid circuit. Stops output to transmission 1st clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Automatic gear shifting function does not operate. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1 and R1. Output condition to 1st clutch ECMV solenoid can be checked with monitoring function. (Code: 31612 T/M Clutch 1st ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F1 or R1.
Cause Defective 1st clutch ECMV 1 solenoid (Internal short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Short circuit in wiring harness
4
Defective power train controller
40-500
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S1T and connect T-adapter to male side. Between S1T (male) (1) and (2) Resistance 3 - 13 Ω Between S1T (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector S1T and connect T-adapter to female side. 3. Turn starting switch ON position. Between S1T (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (37) and each pin other than No continuity (No sound is (37) heard) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 to PTCN3 and S1T, and connect T-adapters to female sides of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (6) and each pin of PTCN1 No continuity (No sound is (female) heard) Between PTCN3 (female) (6) and each pin of PTCN2 No continuity (No sound is (female) heard) If cause is not found by the above checks, power train controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH4KY] 1st clutch ECMV: Short circuit
Circuit diagram related to 1st clutch ECMV
D375A-6 (01)
40-501
DRAFT Troubleshooting by failure code Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 2nd clutch ECMV: Disconnection Failure DXH5KA (Power train controller system) When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows. Stops output to transmission 2nd clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Automatic gear shifting function does not operate. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1 and R1. Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31613 T/M Clutch 2nd ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F2 or R2.
Cause Procedure, measuring location, criteria and remarks Defective 2nd clutch ECMV 1. Turn starting switch to OFF position. 1 solenoid (Internal discon2. Disconnect connector S2T and connect T-adapter to male side. nection)) Between S2T (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is becuit in wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (28) and (3) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and S2T, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (28) and S2T (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (3) and S2T (female) (2) Resistance Max. 1 Ω Defective power train con- If cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to 2nd clutch ECMV
40-502
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 2nd clutch ECMV: Short circuit Failure DXH5KB (Power train controller system) When power was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed. Stops output to transmission 2nd clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Automatic gearshift system function does not operate. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1 and R1. Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31613 T/M Clutch 2nd ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F2 or R2.
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 2nd clutch ECMV 1 solenoid (Internal short cir- 2. Disconnect connector S2T and connect T-adapter to male side. Between S2T (male) (1) and (2) Resistance 3 - 13 Ω cuit) Between S2T (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female side of 2 ness either of them. (Contact with ground circuit) Between PTCN3 (female) (28) or S2T (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female side of Short circuit in wiring har3 either of them. ness Between PTCN3 (female) (28) and (3), or between Resistance Min. 1 MΩ S2T (female) (1) and (2) Defective power train con- If cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to 2nd clutch ECMV
D375A-6 (01)
40-503
DRAFT Troubleshooting by failure code Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 2nd clutch ECMV: Short circuit Failure DXH5KY (Power train controller system) Current flows constantly to transmission 2nd clutch ECMV solenoid circuit. Stops output to transmission 2nd clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Automatic gearshift system function does not operate. Once machine stops, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F2 and R2. Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function. (Code: 31613 T/M Clutch 1st ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F2 or R2.
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 2nd clutch ECMV solenoid (Internal short cir- 2. Disconnect connector S2T and connect T-adapter to male side. Between S2T (male) (1) and (2) Resistance 3 - 13 Ω cuit) Between S2T (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector S2T and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between S2T (female) (1) and ground Voltage Max. 1V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (28) and each pin other No continuity (No sound is than (28) heard) Short circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN1 to PTCN3 and S2T, and connect T-adapters to female side of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (28) and each pin of No continuity (No sound is PTCN1 (female) heard) Between PTCN3 (female) (28) and each pin of No continuity (No sound is PTCN2 (female) heard) Defective power train con- If cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
40-504
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
Circuit diagram related to 2nd clutch ECMV
D375A-6 (01)
40-505
DRAFT Troubleshooting by failure code Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 3rd clutch ECMV: Disconnection Failure DXH6KA (Power train controller system) When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows. Stops output to transmission 3rd clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1 and R1. Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31614 T/M Clutch 3rd ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F3 or R3.
Cause Procedure, measuring location, criteria and remarks Defective 3rd clutch ECMV 1. Turn starting switch to OFF position. 1 solenoid (Internal discon2. Disconnect connector S3T and connect T-adapter to male side. nection) Between S3T (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above1 MΩ, wiring harness has disconnection. If resistance is cuit in wiring harness below1 Ω, wiring harness has short circuit. Between PTCN3 (female) (38) and (13) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and S3T, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (38) and S3T (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (13) and S3T (female) (2) Resistance Max. 1 Ω Defective power train con- If cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to 3rd clutch ECMV
40-506
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code 3rd clutch ECMV: Short circuit Failure DXH6KB (Power train controller system) When power was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed. Stops output to transmission 3rd clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1 and R1. Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31614 T/M Clutch 3rd ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F3 or R3.
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 3rd clutch ECMV solenoid (Internal short cir- 2. Disconnect connector S3T and connect T-adapter to male side. Between S3T (male) (1) and (2) Resistance 3 - 13 Ω cuit) Between S3T (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S3T, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (38) or S3T (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and S3T and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (38) and (13), or between Resistance Min. 1 MΩ S3T (female) (1) and (2) Defective power train con- If cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to 3rd clutch ECMV
D375A-6 (01)
40-507
DRAFT Troubleshooting by failure code Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
Failure code DXH6KY
Failure
3rd clutch ECMV: Short circuit (Power train controller system)
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Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.
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Stops output to transmission 3rd clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F3 and R3. Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function. (Code: 31614 T/M Clutch 3rd ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F3 or R3.
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Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective 3rd clutch ECMV solenoid (Internal 2. Disconnect connector S3T and connect T-adapter to male side. Between S3T (male) (1) and (2) Resistance 3 - 13 Ω short circuit) Between S3T (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring har2. Disconnect connector S3T and connect T-adapter to female side. ness (Contact with 24 V circuit) 3. Turn starting switch ON position. Between S3T (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and S3T and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (38) and each pin other No continuity (No sound is heard) than (38) Short circuit in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN1 to PTCN3 and S3T, and connect T-adapters to female sides of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (38) and each pin of No continuity (No sound is heard) PTCN1 (female) Between PTCN3 (female) (38) and each pin of No continuity (No sound is heard) PTCN2 (female) If cause is not found by the above checks, power train controller may be defective. Defective power train controller (Since failure is in it, troubleshooting cannot be performed.)
40-508
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
Circuit diagram related to 3rd clutch ECMV
D375A-6 (01)
40-509
DRAFT Troubleshooting by failure code Failure code [DXH7KA] R clutch ECMV: Disconnection
Failure code [DXH7KA] R clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Reverse clutch ECMV: Disconnection Failure DXH7KA (Power train controller system) When power is output to transmission R clutch ECMV solenoid circuit, no current flows. Stops output to transmission R clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to F1. Output condition to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to R (Reverse).
Cause Defective R clutch ECMV 1 solenoid (Internal disconnection)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SRT and connect T-adapter to male side. Between SRT (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is becuit in wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (27) and (3) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and SRT, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (27) and SRT (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (3) and SRT (female) (2) Resistance Max. 1 Ω Defective power train con- If cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to reverse clutch ECMV
40-510
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KB] R clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Reverse clutch ECMV: Short circuit Failure DXH7KB (Power train controller system) When power was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed. Stops output to transmission R clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F1. Output condition to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to R (Reverse).
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective R clutch ECMV solenoid (Internal short cir- 2. Disconnect connector SRT and connect T-adapter to male side. Between SRT (male) (1) and (2) Resistance 3 - 13 Ω cuit) Between SRT (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (27) or SRT (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (27) and (3), or between Resistance Min. 1 MΩ SRT (female) (1) and (2) Defective power train con- If cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to reverse clutch ECMV
D375A-6 (01)
40-511
DRAFT Troubleshooting by failure code Failure code [DXH7KY] R clutch ECMV: Short circuit
Failure code [DXH7KY] R clutch ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine Related information
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Failure code Reverse clutch ECMV: Short circuit Failure DXH7KY (Power train controller system) Current flows constantly to transmission R clutch ECMV solenoid circuit. Stops output to transmission R clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine stops, machine does not travel at all. Output condition to R clutch ECMV solenoid can be checked with monitoring function. (Code: 31616 T/M Clutch R ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to R (Reverse).
Cause Defective R clutch ECMV 1 solenoid (Internal short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Short circuit in wiring harness
4
Defective power train controller
40-512
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SRT and connect T-adapter to male side. Between SRT (male) (1) and (2) Resistance 3 - 13 Ω Between SRT (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector SRT and connect T-adapter to female side. 3. Turn starting switch to ON position. Between SRT (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (27) and each pin other No continuity (No sound is than (27) heard) 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN1 to PTCN3 and SRT, and connect T-adapters to female side of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (27) and each pin of No continuity (No sound is PTCN1 (female) heard) Between PTCN3 (female) (27) and each pin of No continuity (No sound is PTCN2 (female) heard) If cause is not found by the above checks, power train controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH7KY] R clutch ECMV: Short circuit
Circuit diagram related to reverse clutch ECMV
D375A-6 (01)
40-513
DRAFT Troubleshooting by failure code Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KA] F clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Forward clutch ECMV: Disconnection Failure DXH8KA (Power train controller system) When power is output to transmission F clutch ECMV solenoid circuit, no current flows. Stops output to transmission F clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine stops, travel is restricted to R1. Output condition to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F (Forward).
Cause Defective F clutch ECMV 1 solenoid (Internal disconnection)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFT and connect T-adapter to male side. Between SFT (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is becuit in wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (17) and (13) Resistance 3 - 13 Ω a If cause 2 is not the cause for the trouble, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and SFT, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (17) and SFT (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (13) and SFT (female) (2) Resistance Max. 1 Ω Defective power train con- If cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to forward clutch ECMV
40-514
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH8KB] F clutch ECMV: Short circuit
Failure code [DXH8KB] F clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Forward clutch ECMV: Short circuit Failure DXH8KB (Power train controller system) When power was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed. Stops output to transmission F clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to R1. Output condition to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F (Forward).
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective F clutch ECMV solenoid (Internal short cir- 2. Disconnect connector SFT and connect T-adapter to male side. Between SFT (male) (1) and (2) Resistance 3 - 13 Ω cuit) Between SFT (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (17) or SFT (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and F SET and connect T-adapter to female side Short circuit in wiring harof either of them. ness Between PTCN3 (female) (17) and (13), or between Resistance Min. 1 MΩ SFT (female) (1) and (2) Defective power train con- If cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to forward clutch ECMV
D375A-6 (01)
40-515
DRAFT Troubleshooting by failure code Failure code [DXH8KY] F clutch ECMV: Short circuit
Failure code [DXH8KY] F clutch ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine Related information
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Failure code Forward clutch ECMV: Short circuit Failure DXH8KY (Power train controller system) Current flows constantly to transmission F clutch ECMV solenoid circuit. Stops output to transmission F clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Once machine stops, engine speed is restricted to medium (half). Once machine stops, machine does not travel at all. Output condition to F clutch ECMV solenoid can be checked with monitoring function. (Code: 31622 T/M Clutch F ECMV (F/B)) Method of reproducing failure code: Start engine and set gear to F (Forward).
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective F clutch ECMV solenoid (Internal short cir- 2. Disconnect connector SFT and connect T-adapter to male side. Between SFT (male) (1) and (2) Resistance 3 - 13 Ω cuit) Between SFT (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harnesss 2. Disconnect connector SFT and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch ON position. Between SFT (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (17) and each pin other No continuity (No sound is heard) than (17) Short circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN1 to PTCN3 and SFT, and connect T-adapters to female sides of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (17) and each pin of No continuity (No sound is heard) PTCN1 (female) Between PTCN3 (female) (17) and each pin of No continuity (No sound is heard) PTCN2 (female) Defective power train con- If cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
40-516
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH8KY] F clutch ECMV: Short circuit
Circuit diagram related to forward clutch ECMV
D375A-6 (01)
40-517
DRAFT Troubleshooting by failure code Failure code [DXH9KA] Right clutch ECMV: Disconnection
Failure code [DXH9KA] Right clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Right steering clutch ECMV disconnection Failure DXH9KA (Power train controller system) When power is output to right steering clutch ECMV solenoid circuit, current does not flow. Stops outputting to right steering clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Machine cannot be steered to right. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F1 and R1. Output condition (current) to right steering clutch ECMV solenoid can be checked with moniitoring funtion. (Code: 90601 Right steering clutch ECMV output current(F/B)) Method of reproducing failure code: Turn starting switch to ON position, release parking brake lever and operate PCCS lever (to steer to right).
Cause Procedure, measuring location, criteria and remarks Defective right steering 1. Turn starting switch to OFF position. 1 clutch ECMV solenoid (Inter- 2. Disconnect connector SRC and connect T-adapter to male side. nal short circuit) Between SRC (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between SRC (female) (35) and (23) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har1. Turn starting switch to OFF position. ness 3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and SRC , and connect T-adapters to their female sides. defective contact in connecBetween PTCN3 (female) (35) and SRC (female) (1) Resistance Max. 1 Ω tor) Between PTCN3 (female) (23) and SRC (female) (2) Resistance Max. 1 Ω Defective power train conIf cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to right steering clutch ECMV
40-518
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH9KB] Right clutch ECMV: Short circuit
Failure code [DXH9KB] Right clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Right steering clutch ECMV short circuit Failure DXH9KB (Power train controller system) When power was output to right steering clutch solenoid circuit, abnormal current flowed. Stops output to right steering clutch solenoid circuit. Restricts operation of engine and transmission. Machine cannot be steered to right. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F1 and R1. Output condition (current) to right steering clutch solenoid can be checked with moniitoring funtion. (Code: 90601 Right steering clutch ECMV output current (F/B)) Method of reproducing failure code: Turn starting switch to ON position, release parking brake lever and operate PCCS lever (to steer to right).
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective rihht steering clutch ECMV solenoid (Inter- 2. Disconnect connector SRC and connect T-adapter to male side. Between SRC (male) (1) and (2) Resistance 3 - 13 Ω nal short circuit) Between SRC (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (35) or SRC (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (35) and (23), or between Resistance Min. 1 MΩ SRC (female) (1) and (2) Defective power train conIf cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to right steering clutch ECMV
D375A-6 (01)
40-519
DRAFT Troubleshooting by failure code Failure code [DXH9KY] Right clutch ECMV: Short circuit
Failure code [DXH9KY] Right clutch ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine Related information
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Failure code Right steering clutch ECMV short circuit Failure DXH9KY (Power train controller system) Current flows constantly to right steering clutch ECMV solenoid circuit. Stops outputting to right steering clutch solenoid circuit. Restricts operation of engine and transmission. Right clutch cannot be engaged (machine cannot travel straight). Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output (current) condition to right steering clutch ECMV solenoid can be checked with monitoring function. (Code: 90601 Right steering clutch ECMV output current (F/B)) Method of reproducing failure code: Turn starting switch to ON position and release parking brake lever.
Cause
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2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective right steering clutch ECMV solenoid (Inter- 2. Disconnect connector SRC and connect T-adapter to male side. Between SRC (male) (1) and (2) Resistance 3–13 Ω nal short circuit) Between SRC (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SRC (female) (1) and ground Voltage Max. 1V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SRC, and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (35) and each pin other than No continuity (No sound is (35) heard.) Short circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN1 to 3 and SRC, and connect T-adapter to female sides of PTCN1 to 3. a Check with tester in continuity mode. Between PTCN3 (female) (35) and each pin of PTCN1 No continuity (No sound is (female) heard.) Between PTCN3 (female) (35) and each pin of PTCN2 No continuity (No sound is (female) heard.) Defective power train conIf cause is not found by above checks, power train controller may be defective. (Since troller failure is in it, troubleshooting cannot be performed.)
40-520
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXH9KY] Right clutch ECMV: Short circuit
Circuit diagram related to right steering clutch ECMV
D375A-6 (01)
40-521
DRAFT Troubleshooting by failure code Failure code [DXHAKA] Left clutch ECMV: Disconnection
Failure code [DXHAKA] Left clutch ECMV: Disconnection Action code E03 Detail of failure Action of controller Problem on machine Related information
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Failure code Left steering clutch ECMV disconnection Failure DXHAKA (Power train controller system) When power is output to left steering clutch solenoid circuit, current does not flow. Stops output to left steering clutch solenoid circuit. Restricts operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F1 and R1. Output condition (current) to left steering clutch ECMV solenoid can be checked with moniitoring funtion. (Code: 90600 Left steering clutch ECMV output current (F/B)) Method of reproducing failure code: Turn starting switch to ON position, release parking brake lever and operate PCCS lever (to steer to left).
Cause Procedure, measuring location, criteria and remarks Defective left steering clutch 1. Turn starting switch to OFF position. 1 ECMV solenoid (Internal dis- 2. Disconnect connector SLC and connect T-adapter to male side. connection) Between SLC (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (25) and (23) Resistance 3 - 13 Ω a If cause 2 is not the cause for the trouble, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and SLC, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (25) and SLC (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (23) and SLC (female) (2) Resistance Max. 1 Ω Defective power train conIf cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to left steering clutch ECMV
40-522
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXHAKB] Left clutch ECMV: Short circuit
Failure code [DXHAKB] Left clutch ECMV: Short circuit Action code E03 Detail of failure Action of controller Problem on machine Related information
q q q q q q q q
Failure code Left steering clutch ECMV short circuit Failure DXHAKB (Power train controller system) When signal was output to left steering clutch ECMV solenoid circuit, abnormal current flowed. Stops outputting to left steering clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, travel is restricted to F1 and R1. Output condition (current) to left steering clutch ECMV solenoid can be checked with moniitoring funtion. (Code: 90600 Left steering clutch ECMV output current (F/B)) Method of reproducing failure code: Turn starting switch to ON position, release parking brake lever and operate PCCS lever (to steer to left).
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective left steering clutch 2. Disconnect connector SLC and connect T-adapter to male side. ECMV solenoid (Internal Between SLC (male) (1) and (2) Resistance 3 - 13 Ω short circuit) Between SLC (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors PTCN3 and SLC, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (25) or SLC (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (25) and (23), or between Resistance Min. 1 MΩ SLC (female) (1) and (2) Defective power train conIf cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to left steering clutch ECMV
D375A-6 (01)
40-523
DRAFT Troubleshooting by failure code Failure code [DXHAKY] Left clutch ECMV: Short circuit
Failure code [DXHAKY] Left clutch ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine Related information
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Failure code Left steering clutch ECMV circuit short Failure DXHAKY (Power train controller system) Current flows constantly to left steering clutch ECMV solenoid circuit. Stops outputting to left steering clutch ECMV solenoid circuit. Restricts operation of engine and transmission. Left clutch cannot be engaged (machine cannot travel straight). Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to left steering clutch solenoid can be checked with moniitoring funtion. (Code: 90600 Left steering clutch ECMV output current (F/B)) Method of reproducing failure code: Turn starting switch to ON position and release parking brake lever.
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective left steering clutch 2. Disconnect connector SRC and connect T-adapter to male side. ECMV solenoid (Internal Between SLC (male) (1) and (2) Resistance 3 – 13 Ω short circuit) Between SLC (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SLC (female) (1) and ground Voltage Max. 1V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (25) and each pin other than No continuity (No sound is (25) heard.) Short circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN1 to PTCN3 and SLC, and connect T-adapters to female side of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (25) and each pin of PTCN1 No continuity (No sound is (female) heard.) Between PTCN3 (female) (25) and each pin of PTCN2 No continuity (No sound is (female) heard.) Defective power train conIf cause is not found by above checks, power train controller may be defective. (Since troller failure is in it, troubleshooting cannot be performed.)
40-524
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXHAKY] Left clutch ECMV: Short circuit
Circuit diagram related to left steering clutch ECMV
D375A-6 (01)
40-525
DRAFT Troubleshooting by failure code Failure code [DXHBKA] Right brake ECMV: Disconnection
Failure code [DXHBKA] Right brake ECMV: Disconnection Action code E04 Detail of failure Action of controller Problem on machine
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Related information
q
Failure code Right brake ECMV disconnection Failure DXHBKA (Power train controller system) When signal is output to right steering brake solenoid circuit, no current flows. Stops outputting to right steering brake ECMV solenoid circuit. Restricts operation of engine, transmission and brake. Operates sudden stop prevention valve. Right brake keeps applied. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to right steering brake solenoid can be checked with moniitoring funtion. (Code: 31618 output current (F/B) of right steering brake ECMV) Method of reproducing failure code: Turn starting switch to ON position and release parking brake lever.
Cause Procedure, measuring location, criteria and remarks Defective right steering 1. Turn starting switch to OFF position. 1 brake ECMV solenoid (Inter- 2. Disconnect connector SRB and connect T-adapter to male side. nal disconnection) Between SRB (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (15) and (13) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and SRB, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (15) and SRB (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (13) and SRB (female) (2) Resistance Max. 1 Ω Defective power train conIf cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to right brake ECMV
40-526
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXHBKB] Right brake ECMV: Short circuit
Failure code [DXHBKB] Right brake ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine
q q q q q q q q
Related information
q
Failure code Right brake ECMV short circuit Failure DXHBKB (Power train controller system) When power was output to right steering brake ECMV solenoid circuit, abnormal current flowed. Stops outputting to right steering brake ECMV solenoid circuit. Restricts operation of engine, transmission, and brake. Operates sudden stop prevention valve. Right brake keeps applied. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring funtion. (Code: 31618 output current (F/B) of right steering brake ECMV) Method of reproducing failure code: Turn starting switch to ON position and release parking brake
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective right steering brake ECMV solenoid (Inter- 2. Disconnect connector SRB and connect T-adapter to male side. Between SRB (male) (1) and (2) Resistance 3 - 13 Ω nal short circuit) Between SRB (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (15) or SRB (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (15) and (13), or between Resistance Min. 1 MΩ SRB (female) (1) and (2) Defective power train conIf cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to right brake ECMV
D375A-6 (01)
40-527
DRAFT Troubleshooting by failure code Failure code [DXHBKY] Right brake ECMV: Short circuit
Failure code [DXHBKY] Right brake ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem that appears on machine
q q q q q q q q
Related information
q
Failure code Right brake ECMV hot short Failure DXHBKY (Power train controller system) When power is output to right steering brake ECMV solenoid circuit, no current flows. Stops outputting to right steering brake ECMV solenoid circuit. Restricts operation of engine, transmission and brake. Operates sudden stop prevention valve. Right brake does not operate. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring funtion. (Code: 31618 output current (F/B) of right steering brake ECMV) Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever (Lock).
Cause
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective right steering 1 brake clutch ECMV solenoid 2. Disconnect connector SRB and connect T-adapter to male side. Between SRB (male) (1) and (2) Resistance 3 - 13 Ω (Internal short circuit) Between SRB (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SRB and connect T-adapter to female side. 2 (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SRB (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SRB and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (15) and each pin other No continuity (No sound is than (15) heard) Short circuit in wiring har1. Turn starting switch to OFF position. 3 ness 2. Disconnect connectors PTCN1 to PTCN3 and SRB, and connect T-adapters to female sides of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (15) and each pin of No continuity (No sound is PTCN1 (female) heard) Between PTCN3 (female) (15) and each pin of No continuity (No sound is PTCN2 (female) heard) Defective power train conIf cause is not found by the above checks, power train controller may be defective. 4 troller (Since falure is in it, troubleshooting cannot be performed.)
40-528
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXHBKY] Right brake ECMV: Short circuit
Circuit diagram related to right brake ECMV
D375A-6 (01)
40-529
DRAFT Troubleshooting by failure code Failure code [DXHCKA] Left brake ECMV: Disconnection
Failure code [DXHCKA] Left brake ECMV: Disconnection Action code E04 Detail of failure Action of controller Problem that appears on machine
q q q q q q q q
Related information
q
Failure code Left brake ECMV disconnection Failure DXHCKA (Power train controller system) When signal is output to left steering brake solenoid circuit, any current does not flow. Stops outputting to left steering brake ECMV solenoid circuit. Restricts operation of engine, transmission and brake. Operates sudden stop prevention valve. Left brake keeps applied. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to left steering brake ECMV solenoid can be checked with moniitoring funtion. (Code: 31619 output current (F/B)of left steering brake ECMV) Method of reproducing failure code: Turn starting switch to ON position and release parking brake
Cause Procedure, measuring location, standard (value) and remarks Defective left steering brake 1. Turn starting switch to OFF position. 1 ECMV solenoid (Internal dis- 2. Disconnect connector SLB and connect T-adapter to male side. connection) Between SLB (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is bein wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (5) and (13) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN3 and SLB, and connect T-adapters to their female 3 (Disconnection or defective sides. contact in connector) Between PTCN3 (female) (5) and SLB (female) (1) Resistance Max. 1 Ω Between PTCN3 (female) (13) and SLB (female) (2) Resistance Max. 1 Ω Defective power train conIf cause is not found by the above checks, power train controller may be defective. 4 troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to left brake ECMV
40-530
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXHCKB] Left brake ECMV: Short circuit
Failure code [DXHCKB] Left brake ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine
q q q q q q q q
Related information
q
Failure code Left brake ECMV short circuit Failure DXHCKB (Power train controller system) When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed. Stops output to left steering brake solenoid circuit. Restricts operation of engine, transmission, and brake. Operates sudden stop prevention valve. Left brake keeps applied. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to left steering brake solenoid can be checked with moniitoring funtion. (Code: 31619 output current (F/B) of left steering brake ECMV) Method of reproducing failure code: Turn starting switch to ON position and release parking brake lever.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective left steering brake 2. Disconnect connector SLB and connect T-adapter to male side. ECMV solenoid (Internal Between SLB (male) (1) and (2) Resistance 3 - 13 Ω short circuit) Between SLB (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female side of ness either of them. (Contact with ground circuit) Between PTCN3 (female) (5) or SLB (female) (1) and Resistance Min. 1 MΩ ground 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female side of Short circuit in wiring hareither of them. ness Between PTCN3 (female) (5) and (13), or between SLB Resistance Min. 1 MΩ (female) (1) and (2) Defective power train conIf cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to left brake ECMV
D375A-6 (01)
40-531
DRAFT Troubleshooting by failure code Failure code [DXHCKY] Left brake ECMV: Short circuit
Failure code [DXHCKY] Left brake ECMV: Short circuit Action code E04 Detail of failure Action of controller Problem on machine
q q q q q q q q
Related information
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Failure code Left brake ECMV hot short Failure DXHCKY (Power train controller system) When power is output left steering brake solenoid circuit,current flows. Stops output to left steering brake ECMV solenoid circuit. Restricts operation of engine, transmission and brake. Operates sudden stop prevention valve. Left brake does not operate. Once machine is stopped, engine speed is restricted to medium (half). Once machine is stopped, it cannot travel at all. Output condition (current) to left steering brake ECMV solenoid can be checked with moniitoring funtion. (Code: 31619 Left brake ECMV output current(F/B)) Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever (Lock).
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Defective left steering brake ECMV solenoid (Internal dis- 2. Disconnect connector SLB and connect T-adapter to male side. Between SLB (male) (1) and (2) Resistance 3 - 13 Ω connection) Between SLB (male) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector SLB and connect T-adapter to female side. (Contact with 24 V circuit) 3. Turn starting switch to ON position. Between SLB (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (5) and each pin other No continuity (No sound is than (5) heard) Short circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors PTCN1 to PTCN3 and SLB, and connect T-adapters to female sides of PTCN1 to PTCN3. a Check with tester in continuity mode. Between PTCN3 (female) (5) and each pin of No continuity (No sound is PTCN1 (female) heard) Between PTCN3 (female) (5) and each pin of No continuity (No sound is PTCN2 (female) heard) Defective power train conIf cause is not found by the above checks, power train controller may be defective. troller (Since failure is in it, troubleshooting cannot be performed.)
40-532
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXHCKY] Left brake ECMV: Short circuit
Circuit diagram related to left brake ECMV
D375A-6 (01)
40-533
DRAFT Troubleshooting by failure code Failure code [DXJBKA] S/C ECMV: Disconnection
Failure code [DXJBKA] S/C ECMV: Disconnection Action code E02 Detail of failure Action of controller Problem on machine Related information
q q q
Failure code Stator clutch ECMV: Disconnection Failure DXJBKA (Power train controller system) When power is output to transmission stator clutch ECMV solenoid circuit, no current flows. Stops output to transmission stator clutch ECMV solenoid circuit. Restritcs operation of engine and transmission.
q
Engine speed may not be transmitted normally.
q
Output condition to stator clutch ECMV solenoid can be checked with monitoring function. (Code: 90700 S/C ECMV output current (F/B)) Method of reproducing failure code: Start engine and travel.
q
Cause Procedure, measuring location, criteria and remarks Defective stator clutch 1. Turn starting switch to OFF position. 1 ECMV solenoid (Internal dis- 2. Disconnect connector SSTC and connect T-adapter to male side. connection) Between SSTC (male) (1) and (2) Resistance 3 - 13 Ω 1. Turn starting switch to OFF position. Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side. 2 a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is becuit in wiring harness low 1 Ω, wiring harness has short circuit. Between PTCN3 (female) (6) and (3) Resistance 3 - 13 Ω a If cause 2 is not the cause for the failure, this check is not required. Disconnection in wiring har1. Turn starting switch to OFF position. ness 3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and SSTC, and connect T-adapters to their female sides. defective contact in connecBetween PTCN3 (female) (6) and SSTC (female) (1) Resistance Max. 1 Ω tor) Between PTCN3 (female) (3) and SSTC (female) (2) Resistance Max. 1 Ω Defective transmission con- If cause is not found by above checks, power train controller may be defective. (Since 4 troller fialure is in it, troubleshooting cannot be performed.)
Circuit diagram related to stator clutch ECMV
40-534
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXJBKB] S/C ECMV: Short circuit
Failure code [DXJBKB] S/C ECMV: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
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Failure code Stator clutch ECMV: Short circuit Failure DXJBKB (Power train controller system) When power is output to stator clutch ECMV solenoid circuit, abnormal current flow. Stops output to transmission stator clutch ECMV solenoid circuit. Restricts operation of engine and transmission.
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Engine speed may not be transmitted normally.
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Output condition to stator clutch ECMV solenoid can be checked with monitoring function. (Code: 90700 S/C ECMV output current (F/B)) Method of reproducing failure code: Start engine and travel.
q
Cause Defective stator clutch 1 ECMV solenoid (Internal short circuit) Ground fault of wiring har2 ness (Contact with GND circuit)
3
Short circuit in wiring harness
4
Defective power train controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SSTC and connect T-adapter to male side. Between SSTC (male) (1) and (2) Resistance 3 – 13 Ω Between SSTC (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side of either of them. Between PTCN3 (female) (6) or SSTC (female) (1) Resistance Min. 1 MΩ and ground 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side of either of them. Between PTCN 3(female) (6) and (3) or between Resistance Min. 1 MΩ SSTC (female) (1) and (2) If cause is not found by the above checks, work equipment controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to stator clutch ECMV
D375A-6 (01)
40-535
DRAFT Troubleshooting by failure code Failure code [DXJBKY] S/C ECMV: Short circuit
Failure code [DXJBKY] S/C ECMV: Short circuit Action code E02 Detail of failure Action of controller Problem on machine Related information
q q q
Failure code Stator clutch ECMV: Short circuit Failure DXJBKY (Power train controller system) When power is output to transmission 1st clutch ECMV solenoid circuit, current flows constantly. Stops output to transmission 1st clutch ECMV solenoid circuit. Restricts operation of engine and transmission.
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Engine speed may not be transmitted normally.
q
Output condition to stator clutch ECMV solenoid can be checked with monitoring function. (Code: 90700 S/C ECMV output current (F/B)) Method of reproducing failure code: Start engine and set gear to F1 or R1.
q
Cause Defective stator clutch 1 ECMV solenoid (Internal short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Short circuit in wiring harness
4
Defective power train controller
40-536
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SSTC and connect T-adapter to male side. Between SSTC (male) (1) and (2) Resistance 3 – 13 Ω Between SSTC (female) (1) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. 2. Disconnect connector SSTC and connect T-adapter to female side. 3. Turn starting switch to ON position. Between SSTC (female) (1) and ground Voltage Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side of PTCN3. a Check with tester in continuity mode. No continuity (No sound is Between PTCN3 (female) (6) and each pin other than (6) heard) 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1 to 3 and SSTC , and connect T-adapters to female sides of PTCN1 to 3. a Check with tester in continuity mode. Between PTCN3 (female) (6) and each pin of PTCN1 No continuity (No sound is (female) heard) Between PTCN3 (female) (6) and each pin of PTCN2 No continuity (No sound is (female) heard) If cause is not found by the above checks, work equipment controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DXJBKY] S/C ECMV: Short circuit
Circuit diagram related to stator clutch ECMV
D375A-6 (01)
40-537
DRAFT Troubleshooting by failure code Failure code [DY2HKA] Pre lub. motor: Disconnection
Failure code [DY2HKA] Pre lub. motor: Disconnection Action code E02 Detail of failure Action of controller Problem on machine Related information
Failure code DY2HKA
Failure
Pre-lubricating motor disconnection (Power train controller system)
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After power train controller starts pre-lubrication, power is not supplied to pre-lubricating motor.
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No particular action
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Engine does not operate (It operates in skip mode, however).
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Whether pre-lubricating motor is operating can be checked with monitoring function. (Code: 40910 PT controller SW input 2) Primary side of pre-lubricating relay is checked with failure codes [D1EFKA] and [D1EFKB].
q
Cause Defective circuit breaker 1 (CBH1) 2
3
4
5
6
7
8
9
Procedure, measuring location, criteria and remarks If circuit breaker is operating, the circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Loose terminal or disconnecCheck terminals of battery relay, preheater relay, pre-lubricating relay, pre-lubricating tion at terminal motor, etc. 1. Turn starting switch to OFF position. 2. Replace relay (PLUB) with another relay (e.g. backup alarm relay BKA). Defective relay (PLUB) 3. Turn starting switch to ON position. If pre-lubrication is completed, original relay (PLUB) is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector PLS. Defective diode (PLS) 3. Turn starting switch to ON position. If pre-lubrication is completed, diode (PLS) is defective. 1. Turn starting switch to OFF position. Defective pre-lubricating 2. Disconnect terminal PM1. motor Between terminal PM1 (on pre-lubricating motor side) Continuity and ground 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector PLUB. 3. If circuit breaker is turned OFF, reset it. 4. Turn starting switch to ON position. a If voltage is 0 V, wiring harness has disconnection or ground fault (If voltage is abDisconnection in, or ground normal and check result of cause 8 is normal, wiring harness has disconnection). fault in wiring harness Between PLUB (3) and ground Voltage 20 – 30 V Between PLUB (5) and ground Voltage 20 – 30 V Between PR1 and ground Voltage 20 – 30 V Between PR2 and ground Voltage 20 – 30 V Between PR3 and ground Voltage 20 – 30 V Between PM1 and ground Voltage 20 – 30 V Defective pre-lubricating If voltages at terminals PR1 and PR3 are normal and voltage at terminal PR2 is relay abnormal as check result of cause 6, pre-lubricating relay is defective. a If cause 6 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN1 and connect T-adapter to female side. Ground fault in wiring har3. Disconnect terminal PR3. ness 4. If circuit breaker is turned OFF, reset it. (Contact with ground circuit) Between PTCN1 (female) (23) and ground Resistance Min. 1 MΩ Between terminal PR1 and ground Resistance Min. 1 MΩ Between terminal PR3 (on wiring harness side) and Resistance Min. 1 MΩ ground If cause is not found by above checks, power train controller is defective. q Reference: Following shows standard values in normal condition. 1. Turn starting switch to OFF position. Defective power train controller 2. Insert T-adapter into connector PTCN1. 3. Turn starting switch to ON position. Between PTCN1 (23) and (10) Voltage 20 – 30 V
40-538
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [DY2HKA] Pre lub. motor: Disconnection
Circuit diagram related to pre-lubricating motor
D375A-6 (01)
40-539
Troubleshooting by failurecode Failure code [F@BBZL] ENG blow-by pressure high level
Failure code [F@BBZL] ENG blow-by pressure high level Action code
Failure code
–
F@BBZL
Failure Detail of failure Action of controller Problem on machine Related information
Engine blow-by pressure abnormally high level
q
Engine blowby pressure is higher than threshold value of 900 mmH2O {8.83 kPa}.
q
None in particular
q
If machine is used as it is, engine may be broken.
q
Blowby pressure can be checked with monitoring code 42801(kPa). The LED of the VHMS controller displays "n3" and "38" alternately and repeatedly.
q
Cause Abnormal increase of engine blow-by pressure Defective engine blow-by 2 pressure sensor 1
40-576
Procedure, measuring location, criteria and remarks q q
Check engine and then repair if necessary. Check the breather hose outlet for clogging, bend, or break. If any, repair it.
Troubleshooting for failure codes [DHE5KB] and [DHE5KY].
3 Defective VHMS controller
40-540
D375A-6 (06)
DRAFT Troubleshooting by failure code Failure code [F@BYNR] F exhaust temp high level (2)
Failure code [F@BYNR] F exhaust temp high level (2) Action code –
Failure code Front exhaust temperature abnormal increase (2) Failure F@BYNR (VHMS controller system) q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side) increased and VHMS controller detected temperature higher than exhaust temperature sensor limit line 2 for more than 10 seconds. Detail of failure (Exhaust gas temperature limit line 2: Straight line between 750 °C at rated output speed at minimum and 800 °C at max. torque speed) Action of conq None in particular. troller Problem on q If machine is used as it is, engine may be broken. machine Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 (°C). mation q The LED of the VHMS controller displays "n3" and "62" alternately and repeatedly. Cause Procedure, measuring location, standard (value) and remarks Abnormal increase of front exhaust tempera1 Check the engine for abnormality. Correct, if any. ture (When system is normal) Front exhaust tempera2 ture sensor system Troubleshooting for failure codes "DGT5KA" and "DGT5KB". defective Defective VHMS control3 ler
D375A-6 (01)
40-541
DRAFT Troubleshooting by failure code Failure code [F@BYNS] F exhaust temp high level (1)
Failure code [F@BYNS] F exhaust temp high level (1) Action code –
Failure code Front exhaust temperature abnormal increase (1) Failure F@BYNS (VHMS controller system) q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side)increased and VHMS controller detected temperature higher than exhaust temperature sensor limit line 1 for more Detail of failthan 20 seconds. ure (Exhaust temperature limit line 1: Straight line between 700 °C at rated output speed and 750 °C at maximum torque speed) Action of conq Flashes warning lamp and turns on caution buzzer. (Function of monitor panel) troller Problem on q If machine is used as it is, engine may be broken. machine Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 (°C). mation q VHMS controller LED indicates "n3" and "61" alternately and repeatedly. Cause Procedure, measuring location, criteria and remarks Abnormal increase of front 1 exhaust temperature Check the engine for abnormality, Correct, if any. (When system is normal) Front exhaust tempera2 ture sensor system defecTroubleshooting for failure codes "DGT5KA" and "DGT5KB". tive Defective VHMS control3 ler
40-542
D375A-6 (01)
DRAFT Troubleshooting by failure code Failure code [F@BZNR] R exhaust temp high level (2)
Failure code [F@BZNR] R exhaust temp high level (2) Action code –
Failure code Rear exhaust temperature abnormal increase (2) Failure F@BZNR (VHMS controller system) q Signal voltage of exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increased and VHMS controller detected temperature higher than exhaust temperature sensor limit line 2 for more than 10 seconds. Detail of fialure (Exhaust gas temperature limit line 2: Straight line between 750 °C at rated output speed at minimum and 800 °C at max. torque speed) Action of conq None in particular. troller Problem on q If machine is used as it is, engine may be broken. machine Related infor- q Rear exhaust temperature can be checked with monitoring code: 42611 (°C). mation q The LED of the VHMS controller displays "n3" and "82" alternately and repeatedly. Cause Procedure, measuring location, criteria and remarks Abnormal increase of 1 rear exhaust temperature Check the engine for abnormality. Correct, if any. (When system is normal) Rear exhaust tempera2 ture sensor system Troubleshooting for failure codess "DGT6KA" and "DGT6KB". defective Defective VHMS control3 ler
D375A-6 (01)
40-543
DRAFT Troubleshooting by failure code Failure code [F@BZNS] R exhaust temp high level (1)
Failure code [F@BZNS] R exhaust temp high level (1) Action code –
Failure code Rear exhaust temperature abnormal increase (1) Failure F@BZNS (VHMS controller system) q Signal voltage of exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increased and VHMS controller detected temperature higher than exhaust temperature sensor limit line 1 for more Detail of failthan 20 seconds. ure (Exhaust gas temperature limit line 1: Straight line between 700 °C at rated output speed at minimum and 750 °C at max. torque speed) Action of conq None in particular. troller Problem on q If machine is used as it is, engine may be broken. machine Related infor- q Rear exhaust temperature can be checked with monitoring code: 42611 (°C). mation q The LED of the VHMS controller displays "n3" and "38" alternately and repeatedly. Cause Procedure, measuring location, criteria and remarks Abnormal increase of rear 1 exhaust temperature Check the engine for abnormality. Correct, if any. (When system is normal) Rear exhaust temperature 2 sensor system defective Troubleshooting for failure codes "DGT6KA" and "DGT6KB". Defective VHMS control3 ler
40-544
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table
Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table a Troubleshooting Table and Circuit Diagram Related collectively include the following information. Perform troubleshooting work after fully grasping their contents. Trouble Trouble which occurred in the machine Related inforInformation related to detected trouble or troubleshooting mation Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks q Procedure q Measuring location Possible causes a "Between A and B" means the measurement of voltage, resistance or others between terminals A and B. q Standard value in normal state to judge possible causes q Remarks on judgment q Perform troubleshoot in following procedure in numerical order. - defective q If the testing result shows abnormality, the cause described on the left column conforms. q If it shows normal, and unless otherwise specified particularly, proceed to the next step (cause). q After correction of a single failure, check to see that this problem has been solved. Disconnection in wiring harThen, start the next troubleshooting. ness (Disconnection or defective q Disconnection contact in connector) Connector is connected imperfectly or wiring harness is broken. q Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Ground fault of wiring harq Hot short ness Wiring harness which is not connected to power source (24 V) circuit is in contact (Contact with ground circuit) with power source (24 V) circuit. q Short circuit Independent wiring harnesses are in contact with each other abnormally. (Poor insulation of connector or others) Hot short (Short circuit with 24 V cir(1) Method of indicating connector No. and handling of Tadapter cuit) Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. q If connector No. has no marks of “male” and “female”, disconnect connector and insert T-adapters in both male side and female side. q If connector No. has marks of “male” and “female”, disconnect connector Short circuit in wiring harand connect T-adapter to only male side or female side. ness (2) Entry 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. qConnect positive (+) lead to pin No. or wiring harness entered on front side. qConnect negative (-) lead to pin No. or harness entered on rear side. Defective controller
D375A-6 (01)
40-545
DRAFT Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table
Related circuit diagram This is the excerpted circuit diagram related to troubleshooting q The circuit diagram includes connector numbers and pin numbers related to the trouble. q Indication of "Connector No. & Pin No." from branched or jointed position: The destination branching position or source jointed position in the same wiring harness is shown. q Arrow (io): Roughly shows the location on the machine. q NO: Normally Open q NC: Normally Closed
40-546
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-1 Engine does not start (starting motor does not turn)
E-1 Engine does not start (starting motor does not turn) Trouble
q q
q
Related information q q
The starting motor does not turn and accordingly the engine does not start. Since the engine start circuit has the neutral safety function, the engine does not start unless the work equipment lock lever and parking brake lever are in the lock position and the travel lever is in the neutral position. Before carrying out troubleshooting, check that no related failure code is displayed. (If the failure code [D110KB][D130KA][D130KB][D190KA][D190KB][D1EFKA][D1EFKB][DD14KA][DD14KB] [7RFAKA][7RFAKB][DDE2KA][DY2HKA] is displayed, troubleshoot them first.) In the case of "the battery relay does not make operating sound" when turning the starting switch ON, perform E-1 also. If engine does not stop, replace engine holding relay.
Cause Procedure, measuring location, standard (value) and remarks Defective circuit breaker CB30 If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault. In 1 or CB6 this case, perform troubleshooting for cause 16 first. If fuse FS31-5 is broken, circuit probably has ground fault. In this case, trouble2 Defective fuse FS31-5 shoot cause 16 first. 1. Turn starting switch to OFF position. Loose terminal or disconnec3 Check terminals of battery relay, alternator, starting motor, ground, ground 01, tion at terminal ground 11 etc. Battery voltage Min. 24V 4 Insufficient battery capacity Electrolyte specific gravity Min. 1.26 1. Turn starting switch ON position. Defective parking lever switch 2. Operate parking brake lever and troubleshoot. 5 (internal defect or defective Display of "P" on Free position Other than “P” is displayed. adjustment) Lock position “P” is displayed. monitor panel 1. Turn starting switch ON position. Defective work equipment lock 2. Operate work equipment lock lever switch and troubleshoot. lever switch Display of "Lock 6 Free position Symbol OFF (internal defect or defective work equipment" adjustment) symbol on monitor Lock position Symbol ON panel 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector KEY. 4. Turn starting switch to ON, OFF and START positions and troubleshoot. Defective starting switch OFF Resistance Min. 1 MΩ 7 Between terminals 250 and 260 (Internal disconnection) ON Resistance Max. 1 Ω OFF Resistance Min. 1 MΩ Between terminals 250 and 270 ON Resistance Max. 1 Ω OFF Resistance Min. 1 MΩ Between terminals 250 and 280 START Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Replace neutral safety relay (NSF) with another relay (such as BKA). 8 Defective neutral safety relay 3. Start engine If engine starts, original neutral safety relay (NSF) is defective. 1. Turn starting switch to OFF position. Defective engine ACC cutout 2. Replace engine ACC cutout relay (ACT) with another relay (such as BKA). 9 relay 3. Start engine If engine starts, original engine ACC cutout relay (ACT) is defective. a If the engine does not stop 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 10 Defective engine holding relay 3. Replace engine holding relay (EHL) with another relay (such as BKA). 4. Connect ground strap. If engine stops, original engine holding relay (EHL) is defective. 1. Turn starting switch to OFF position. Defective diode RSD 2. Remove connector RSD and connect T-adapter to diode. 11 (Internal disconnection or a Measure in diode range of tester. short circuit) Between RSD (male) (1) (+) and (2) (-) No continuity Between RSD (male) (2) (+) and (1) (-) Continuity
D375A-6 (01)
40-547
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (starting motor does not turn)
Cause 12
Defective alternator (Internal short circuit)
Detective starting motor 13 (internal defect)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to ON position. Between terminal AL/R and ground 1. Turn starting switch to OFF position. 2. Start the engine for troubleshooting. Power supply: Between terminal B and chassis ground Between charge terminal R and ground
Voltage
Max. 12 V
Voltage
20 – 30 V
Voltage
Max. 12 V
Between starting motor terminal C and Voltage 20 – 30 V ground When voltages of power supply, charging and starting circuits are normal but starting motor does not rotate, starting motor is defective. q Battery relay 1. Turn starting switch to OFF position. Between terminal BRE and ground
Resistance
Max. 1 z
q
Battery relay 1. Turn starting switch to OFF position. 2. Turn starting switch to START position. a Check to where 24 V is supplied to identify disconnected place. Between terminal 260 and ground
Voltage
20 – 30 V
Between terminal SW and ground
Voltage
20 – 30 V
Between terminal BRB and ground
Voltage
20 – 30 V
Between terminal BRC and ground
Voltage
20 – 30 V
q
Open circuit in wiring har14 ness
Defective battery relay 15 (Does not turn ON)
1. 2. 3. 4. 5. a
Alternator and starting motor Turn starting switch to OFF position. Disconnect ground strap. Insert T-adapters into connectors NSF, ST1 and ST2. Connect ground strap. Turn starting switch to START position and troubleshoot. Check to where 24 V is supplied to identify disconnected place.
Between terminal 280 and ground
Voltage
20 – 30 V
Between NSF (1) and ground
Voltage
20 – 30 V
Between NSF (3) and ground
Voltage
20 – 30 V
Between NSF (5) and ground
Voltage
20 – 30 V
Between ST1 (1) and ground
Voltage
20 – 30 V
Between ST2 (1) and ground
Voltage
20 – 30 V
Between terminal AL/B and ground
Voltage
20 – 30 V
Between terminal ST/B and ground
Voltage
20 – 30 V
If only terminal BRC voltage is abnormal during battery relay check for cause 14, battery relay is defective. a If cause 14 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connectors NSF, PTCN1, WECN1, CM01 and ST.
Ground fault in wiring har16 ness Between terminal 250 and ground (Contact with ground circuit) Between terminal 280 or NSF (3) and ground
Between NSF (5), ST2 (1) or ST1 (1) and ground Hot short circuit in wiring harness 17 (Short circuit with 24 V circuit)
40-548
1. Turn starting switch to OFF position. 2. Disconnect terminal AL/R. 3. Turn starting switch to ON position. Between terminal AL/R (Wiring harness side) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
D375A-6 (06)
DRAFT Troubleshooting of electrical system (E-mode) E-1 Engine does not start (starting motor does not turn)
Circuit diagram related to starting of engine
D375A-6 (01)
40-549
DRAFT Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
E-2 Preheater does not operate Trouble
1)Manual preheater does not operate. a This troubleshooting describes the procedures to be followed when the automatic and manual preheating does not function to heat the electrical intake air heater mounting section. q For preheating, both the “Automatic preheating function” and “Manual preheating function” are available. When either function is performed, the preheating lamp lights up. (When only the preheating does not light up, troubleshoot "3) While the preheater is operating, the Related informapreheating monitor does not light up") q If "the machine monitor does not light up" or "the battery relay does not make operating sound" tion when turning the starting switch ON, the main electric power supply system is supposed to be defective. So, troubleshoot E-3 and E-1. q Before carrying out troubleshooting, check that no related failure code is displayed. (If the failure code [CA153], [CA154], [D110KB] or [D182KZ] is displayed, firstly perform these troubleshooting.) Cause Defective circuit breaker 1 CBH1 Loose terminal or disconnec2 tion at terminal
3
4
5
6
7
8
Procedure, measuring location, standard (value) and remarks If CBH1 circuit breaker is turned ON, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first. 1. Turn starting switch to OFF position. Check terminals of heater relay, battery relay, etc. 1. Turn starting switch to OFF position. Defective diode HTD 2. Remove connector HTD and connect T-adapter to diode. (Internal disconnection or a Measure in diode range of tester. short circuit) Between HTD (male) (1) (+) and (2) (-) No continuity Between HTD (male) (2) (+) and (1) (-) Continuity Defective electrical intake air 1. Turn starting switch to OFF position. heater 2. Disconnect terminal HT/B. (Internal disconnection) Between terminal HT/B and ground There is continuity 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector KEY and connect T-adapter to male side. Defective starting switch 4. Turn starting switch to OFF/HEAT position and troubleshoot. OFF Resistance Min. 1 MΩ Between terminals 250 and 255 HEAT Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector CM01. Between terminal 255 and ground There is continuity 1. Turn starting switch to OFF position. 2. Turn starting switch ON position. Disconnection in, or ground Between terminal HT/A and ground Voltage 20 – 30 V fault of wiring harness 1. Turn starting switch to OFF position. 2. Disconnect terminal HT/B. 3. Turn starting switch to HEAT position (Connect R1). a Disconnect so that current will not flow in heater when starting switch is turned to HEAT position. Between terminal HT and ground Voltage 20 – 30 V a If cause 6 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors KEY and CM01 and terminals HT and BRC. ness Between terminal HT/A and ground Resistance Min. 1 MΩ (Contact with GND circuit) Between terminal HT (on wiring harness side) and Resistance Min. 1 MΩ ground Defective preheater relay If cause 6 is not the cause for the trouble and preheater relay operation sound is not (Does not turn ON) (Terminal heard, preheater relay is defective. HT/B)
40-550
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Circuit diagram related to preheating of engine
D375A-6 (01)
40-551
DRAFT Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Trouble
2) Automatic preheater does not operate. q Automatic preheater operates when engine coolant temperature is below -5 °C. Related informa(Monitoring code Engine coolant temperature: 04107) q If automatic preheater does not operate, check if manual preheater operates. tion q Engine controller troubleshoots primary (coil) side of preheater relay by failure code [D182KZ]. Cause
1
2
3
4
5
Procedure, measuring location, standard (value) and remarks If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform trouDefective fuse FS22-4 bleshooting for cause 5 first. 1. Turn starting switch to OFF position. 2. Replace preheater relay (connector: PHR) with backup alarm relay (connector: Defective preheater relay BKA). (Internal disconnection or 3. Turn starting switch ON position. short circuit) If automatic preheater operates when engine coolant temperature is below -5 °C, original preheater relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector PTCN2 and connect T-adapter to female side. Disconnection in, or ground a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is befault of wiring harness low 1 Ω, wiring harness has short circuit. a Preheater relay coil resistance Between PTCN2 (female) (19) and ground Resistance 200 – 400 Ω 1. Turn starting switch to OFF position. Disconnection in wiring har- 2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of ness PHR. (Disconnection or defective 3. Remove fuse FS22-4. contact) Between PHR (female) (3) and ground Continuity Between PHR (female) (5) and FS22-4 Resistance Max. 1 Ω If fuse is not broken, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PHR, FSB and ASUS, and connect T-adapter to female ness side of PHR. (Contact with GND circuit) 3. Remove fuse FS22-4. Between PHR (female) (5) and ground Resistance Min. 1 MΩ
Trouble 3) While preheater is operating, the preheating monitor does not light up. Related informa- q There are "Automatic preheater" and "Manual preheater" installed. When either function is opertion ated, the preheating lamp lights up. Cause
1
2
3
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Disconnection in wiring har2. Disconnect connectors PHR and CM01, and connect T-adapters to female side ness of them. (Disconnection or defective Between PHR (female) (3) and CM01 (female) (16) Resistance Max. 1 Ω contact) Between terminal 255 and CM01 (female) (16) Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors PHR, CM01 and terminal HT, and connect T-adapter to ness female side of CM01. (Contact with GND circuit) Between CM01 (female) (16) and ground Resistance Min. 1 MΩ If cause is not found by above checks, machine monitor is defective. q Reference (the followings are standard values in normal condition) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. Defective machine monitor 3. Disconnect terminal HT. a Disconnect so that current will not flow in heater when starting switch is turned to HEAT position. 4. Turn starting switch to HEAT position. Between CM01 (16) and (3) Resistance 20 – 30 V
40-552
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Circuit diagram related to preheating of engine
D375A-6 (01)
40-553
DRAFT Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned ON, machine monitor displays nothing
E-3 When starting switch is turned ON, machine monitor displays nothing Trouble
q q
q
Related information
q
When starting switch turned ON, machine monitor displays nothing When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password (if set), screen of check before starting, screen to check setting of preset, and ordinary screen in order. When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. In the case of "the battery relay does not make operating sound" when turning the starting switch ON, perform E-1.
Cause Defective circuit breaker CB30 or 1 CB6 Loose terminal or disconnection at 2 terminal 3
4
5
6
7
Standard value in normal state/Remarks on troubleshooting If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault. In this case, perform troubleshooting for cause 8 first. 1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc. 1. Turn starting switch to OFF position. Insufficient battery capacity Battery voltage (2pieces) Min. 24V Electrolyte specific gravity Min. 1.26 a If machine monitor has not been replaced, this check is not required. Misalignment of wiring harness 1. Turn starting switch to OFF position. (Numbers of pins of CM01 and 2. Remove machine monitor. CM03 are same) Check that connectors CM01 (white) and CM03 (green) are matched to connector colors of machine monitor unit. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector CM01 and connect T-adapter to female side. Disconnection in or ground fault of 4. Connect ground strap. wiring harness or defective start- a If voltage is 0 V, wiring harness has disconnection or ground fault. Between CM01 (female) (1) and (3) Voltage 20 – 30 V ing switch Between CM01 (female) (2) and (4) Voltage 20 – 30 V 1 - 4 are same as above. 5. Turn starting switch to ON position (Connect ACC). Between CM01 (female) (14) and (4) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector KEY. 4. Turn starting switch to ON/OFF position and troubleshoot. Defective starting switch When the travel steerResistance Min. 1 MΩ Between terminals 250 and 270 ing signal is OFF ON Resistance Max. 1 Ω a If cause 5 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. If circuit breaker is turned ON, reset it. 4. Disconnect connector CM01 and connect T-adapter to female side. Disconnection in wiring harness (Disconnection or defective con- Between CM01 (female) (3), (4) and ground Resistance Max. 1 Ω a Check terminal GND01 for looseness and rust. tact) Between CM01 (female) (1), (2) and battery (+) Resistance Max. 1 Ω 1 - 4 are same as above. 5. Turn starting switch to ON position (Connect ACC with ground strap disconnected). Between CM01 (female) (14) and battery (+) Resistance Max. 1 Ω
40-554
D375A-6 (01)
Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned ON, machine monitor displays nothing
Cause
Standard value in normal condition/Remarks on troubleshooting
a 1. 2. Ground fault in wiring har- 3. 8 ness 4. (Contact with ground circuit) a
If cause 5 is not the cause for the trouble, this check is not required. Turn starting switch to OFF position. Disconnect ground strap. If circuit breaker is turned ON, reset it. Disconnect connector CM01 and connect T-adapter to female side. Check that condition is normal when starting switch is turned to ON position (Connect ACC with ground strap disconnected).
Between CM01 (female) (1) and ground 9 Defective machine monitor
Min. 1 Mz
If cause is not found by above checks, machine monitor is defective.
Circuit diagram related to machine monitor
D375A-6 (06)
Resistance
40-595
40-555
DRAFT Troubleshooting of electrical system (E-mode) E-4 When starting switch is turned ON (before starting engine), basic check item lights up
E-4 When starting switch is turned ON (before starting engine), basic check item lights up 1) When starting switch is turned to ON position (with engine stopped), engine oil pressure monitor lights up. q Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring funcRelated information. tion (Code: 37200 Engine Oil Pressure) Trouble
Cause Procedure, measuring location, standard (value) and remarks Defective engine oil pressure 1 caution lamp circuit Perform troubleshooting for failure codes [CA135], [CA141]. (Engine controller circuit) If cause 1 is not detected, machine monitor may be defective. 2 Defective machine monitor (Since trouble is in system, troubleshooting cannot be carried out.) Trouble Related information
2) When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up. q
Engine oil level monitor (oil level switch) is optional.
Cause Procedure, measuring location, standard (value) and remarks Defective engine oil level 1 switch system (machine mon- Perform troubleshooting for failure code [B@BAZK]. itor system) If cause 1 is not detected, machine monitor may be defective. 2 Defective machine monitor (Since trouble is in system, troubleshooting cannot be carried out.) Trouble 3) Radiator coolant level monitor lights. Related information Cause Radiator coolant level 1 decrease (When system is normal)
Procedure, measuring location, standard (value) and remarks The coolant level monitor may be insufficient. Check coolant level and add coolant if necessary.
1. Turn starting switch to OFF position. Defective coolant level sensor 2. Disconnect connector WLD and connect T-adapter to male side. 2 Between FULL and LOW Resistance (Internal defect) Between WLD (male) (1) Value when coolant level Resistance and (2) is low Disconnection in wiring har- 1. Turn starting switch to OFF position. ness 2. Disconnect connector CM02 and connect T-adapter to female side. 3 (Disconnection or defective a Add coolant. contact) Between CM02 (female) (3) and WLD (female) (1) Resistance If cause is not found by above checks, machine monitor is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM02. 4 Defective machine monitor 3. Turn starting switch ON position. Between FULL and LOW Voltage Between CM02 (female) (3) Value when coolant level Voltage and ground is low
40-556
Max. 1 Ω Min. 1 MΩ
Max. 1 Ω
Max. 1V Min. 7V
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-4 When starting switch is turned ON (before starting engine), basic check item lights up
Circuit diagram related to radiator coolant level
D375A-6 (01)
40-557
DRAFT Troubleshooting of electrical system (E-mode) E-5 Precaution item lights up while engine is running
E-5 Precaution item lights up while engine is running Trouble Related information
q q q
Precaution item lights up while engine is running. Check item is charge level monitor. State of generation signal of alternator can be checked with monitoring function. (Code 04300: Battery Charge Volt.)
Cause Loose terminal or discon1 nection at terminal Defective alternator 2 (insufficient power generation) Defective diode RSD 3 (Internal disconnection or short circuit)
Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)
Ground fault of wiring har5 ness (Contact with GND circuit)
6
Defective machine monitor panel
40-558
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Check terminals of alternator etc. 1. Turn starting switch to OFF position. 2. Start engine and troubleshoot while running engine at medium speed or higher. Between terminal AL/R and ground Voltage 20 – 30V 1. Turn starting switch to OFF position. 2. Remove connector RSD and connect T-adapter to diode. a Measure in diode range of tester. Between RSD (male) (1) (+) and (2) (-) No continuity Between RSD (male) (2) (+) and (1) (-) Continuity 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connectors CM01 and RSD, and connect T-adapter to female side of CM01. 4. Disconnect terminal AL/R. Between CM01 (female) (11) and AL/R Resistance Max. 1 Ω Between alternator terminal E and ground Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connectors CM01, RSD, PTCN1, WECN1, ST1 and ST2, and connect T-adapter to female side of CM01. 4. Disconnect terminal AL/R. Between CM01 (female) (11) and ground Resistance Min. 1 MΩ If cause is not found by above checks, machine monitor is defective. q Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Insert T-adapter into connector CM01. 4. Connect ground strap. 5. Start engine and troubleshoot while running engine at medium speed or higher. Between CM01 (11) and (3) Voltage 20 – 30V
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-5 Precaution item lights up while engine is running
Circuit diagram related to charge level
D375A-6 (01)
40-559
DRAFT Troubleshooting of electrical system (E-mode) E-6 Emergency stop item lights up while engine is running
E-6 Emergency stop item lights up while engine is running Trouble
1)Engine coolant temperature monitor lights up. q Signal voltage of engine coolant temperature sensor is input to engine controller and then the Related informadata is transmitted to machine monitor through CAN communication system. tion q Engine coolant temperature can be checked with monitoring function (Code: 04107 Coolant Temperature) Cause Overheating of engine cool1 ant (when system is normal) Defective coolant tempera2 ture sensor system 3 Defective machine monitor
Procedure, measuring location, standard (value) and remarks Engine coolant may be overheated. If it is overheated, remove cause. If cause 1 is not detected, engine coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145]. If causes 1 – 2 are not detected, machine monitor may be defective (Since trouble is in system, troubleshooting cannot be carried out.)
Trouble
2) Engine oil pressure monitor lights up. q Signal of engine oil pressure sensor is input to engine controller and then the data is transmitted Related informato machine monitor through CAN communication system. q Engine oil pressure can be checked with monitoring function. tion q (Code: 37200 Engine Oil Pressure) Cause Procedure, measuring location, standard (value) and remarks Reduction of engine oil presCheck the engine oil pressure as the drop of engine oil pressure is detected. 1 sure q Perform troubleshooting "S-12 (Oil pressure drop)". (When system is normal) Defective engine oil pressure If cause 1 is not the cause for the trouble, engine oil pressure switch system may be 2 system defective. Perform troubleshooting for failure codes [CA135] and [CA141]. If causes 1 – 2 are not detected, machine monitor may be defective 3 Defective machine monitor (Since trouble is in system, troubleshooting cannot be carried out.) Trouble
3) Torque converter oil temperature monitor lights up. q Signal voltage of torque converter oil temperature sensor is input to power train controller and Related informathen the data is transmitted to machine monitor through CAN communication system. tion q Torque converter oil temperature can be checked with monitoring function. q (Code: 30100 T/C oil temperature) Cause Procedure, measuring location, standard (value) and remarks Overheating of torque con1 verter oil (When system is nor- Torque converter oil may be overheated. If it is overheated, remove cause. mal) If cause 1 is not the cause for the trouble, torque converter oil temperature sensor Defective torque converter oil 2 system may be defective. Perform troubleshooting for failure codes [DGT1KA] and temperature sensor system [DGT1KX]. If causes 1 – 2 are not detected, machine monitor may be defective 3 Defective machine monitor (Since trouble is in system, troubleshooting cannot be carried out.) Trouble 4) Hydraulic oil temperature monitor lights up. Related informa- q Hydraulic oil temperature can be checked with monitoring function q (Code: 04401 Hyd Oil Temperature) tion Cause Overheating of hydraulic oil 1 (When system is normal) Defective hydraulic oil temper2 ature gauge system or machine monitor
40-560
Procedure, measuring location, standard (value) and remarks Hydraulic oil may be overheating. Check it and remove cause if it is overheating. If cause 1 is not the cause for the trouble, hydraulic oil temperature sensor system or machine monitor may be defective. Perform troubleshooting for failure code [DGS1KX].
D375A-6 (01)
Troubleshooting of electrical system (E-mode) E-7 Engine coolant temperature gauge does not indicate normally
E-7 Engine coolant temperature gauge does not indicate normally
40-601
1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C). Trouble 2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H). q Signal voltage of engine coolant temperature sensor is input to engine controller and then the Related informadata is transmitted to machine monitor through CAN communication system. q Engine coolant temperature can be checked with monitoring function tion (Code: 04107 Coolant Temperature) Cause
Procedure, measuring location, standard (value) and remarks
Defective coolant tempera- Engine coolant temperature sensor system may be defective. Perform troubleshootture sensor system ing for failure codes [CA144] and [CA145]. If cause 1 is not detected, machine monitor may be defective. 2 Defective machine monitor (Since this is an internal failure, troubleshooting cannot be performed.)
1
3) Display of coolant temperature gauge is different from actual engine coolant temperature. 4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor. q Signal voltage of engine coolant temperature sensor is input to engine controller and then the data is transmitted to machine monitor through CAN communication system. Related informaq Engine coolant temperature can be checked with monitoring function tion (Code: 04107 Coolant Temperature) Trouble
Cause
Procedure, measuring location, standard (value) and remarks a Turn starting switch ON or start engine and troubleshoot. Engine coolant temperature
Coolant temperature gauge level
105 °C
6
102 °C
5
100 °C
4
85 °C
3
60 °C
2
30 °C
1
Color of monitor light (a) Red
1 Defective machine monitor
Blue
Engine coolant temperature gauge and coolant 40-601 temperature monitor
D375A-6 (06)
40-561
Troubleshooting of electrical system (E-mode) E-8 Fuel gauge does not indicate properly
E-8 Fuel gauge does not indicate properly Failure
40-602
1) Fuel gauge does not indicate properly.
Related information
q
The input state (voltage signal) from the fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor voltage)
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FGS and connect T-adapter to male side.
Defective fuel level sensor 1 (Internal open or short circuit in wiring)
Between FGS (male) (1) and (2) a Fuel level sensor characteristics
FULL EMPTY
Between FGS (male) (2) and ground
Resistance
Approx. 4 z
Resistance Approx. 85 z Resistance
Max. 1 z
1. 2. 3. a
Turn starting switch to OFF position. Disconnect connector FGS and connect T-adapter to female side. Turn starting switch to ON position. Open circuit or short circuit If voltage is 0 V, wiring harness has open circuit or ground fault or short circuit, and 2 or ground fault or hot short if voltage is 24 V, wiring harness has hot short circuit. circuit in wiring harness a Voltage of approx. 3.3 V is applied to fuel level sensor signal lines through resistor inside machine monitor. Approx. 3.3 Between FGS (female) (1) and (2) Voltage V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CM01 and connect T-adapter to female side. Open or short circuit in wir- a Resistance accords with fuel level sensor characteristics table in cause 1. 3 ing harness a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below 1 z, wiring harness has short circuit. Approx. 4 – Between CM01 (female) (9) and (12) Resistance 85 z a If neither of causes 2 and 3 is the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors CM01 and FGS, and connect T-adapters to each female ness side. 4 (Open circuit in wiring or Between CM01 (female) (9) and FGS (female) (1) Resistance Max. 1 z defective contact) Between CM01 (female) (12) and FGS (female) (2)
Resistance
Max. 1 z
a If neither of causes 2 and 3 is the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors CM01 and FGS, and connect T-adapters to either female 5 ness side. (Contact with ground circuit) Between CM01 (female) (9) or FGS (female) (1) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and FGS, and connect T-adapter to female side of Short circuit in wiring harCM01. 6 ness a Check with circuit tester in continuity mode. No continuity Between CM01 (female) (9) and each pin other than (9) (No sound is heard) 7 Defective machine monitor
40-562
If cause is not found by the above checks, machine monitor is defective.
D375A-6 (06)
DRAFT Troubleshooting of electrical system (E-mode) E-8 Fuel gauge does not indicate properly
Circuit diagram related to fuel level gauge
2) Display of fuel level gauge is different from actual fuel level. 3) Display of fuel level gauge is different from display of fuel level monitor. Related infor- q Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel level sensor vol) mation Cause Procedure, measuring location, standard (value) and remarks a Turn starting switch ON or start engine and troubleshoot. Reading of fuel level Quantity of fuel Color of monitor light (a) gauge 1005 l 6 1 Defective machine monitor 756 l 5 556 l 4 Blue 398 l 3 276 l 2 144 l 1 Red Trouble
Fuel level gauge and fuel level monitor
D375A-6 (01)
40-563
DRAFT Troubleshooting of electrical system (E-mode) E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally 1) While power train oil temperature is rising normally, temperature gauge does not rise from white range (C). Trouble 2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H). q Torque converter oil temperature is considered as power train oil temperature. q Signal voltage of power train oil temperature sensor is input to power train controller and then Related information the data is transmitted to machine monitor through CAN communication system. q Torque converter (power train) oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Cause Defective torque converter oil 1 temperature sensor system 2 Defective machine monitor
Procedure, measuring location, standard (value) and remarks Power train oil temperature sensor system may be defective. Perform troubleshooting for failure codes [DGT1KA] and [DGT1KX]. If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
3) Display of power train temperature gauge is different from actual power train oil temperature. 4) Display of power train oil temperature gauge is different from display of power train oil temperature monitor. q Torque converter oil temperature is considered as power train oil temperature. q Signal voltage of power train oil temperature sensor is input to power train controller and then the Related informadata is transmitted to machine monitor through CAN communication system. tion q Torque converter (power train) oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) Cause Procedure, measuring location, standard (value) and remarks a Turn starting switch ON or start engine and troubleshoot. Power train oil tempera- Power train oil temperaColor of monitor light (a) ture ture gauge level 130 °C 6 Red 1 Defective machine monitor 120 °C 5 118 °C 4 90 °C 3 Blue 50 °C 2 0 °C 1 Trouble
Power train oil temperature gauge and power train oil temperature monitor
40-564
D375A-6 (01)
Troubleshooting of electrical system (E-mode) E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
40-605
1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C). 2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range. Related informa- q Hydraulic oil temperature can be checked with monitoring function tion (Code: 04401 Hyd Oil Temperature) Trouble
Cause
Procedure, measuring location, standard (value) and remarks
1 Perform troubleshooting for failure code [DGS1KX]. 2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. 4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. Related informa- q Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hyd Oil Temperature) tion Trouble
Cause
Procedure, measuring location, standard (value) and remarks a Turn starting switch ON or start engine and troubleshoot. Hydraulic oil temperature
Reading of hydraulic oil temperature gauge
105 °C
6
102 °C
5
98 °C
4
70 °C
3
20 °C
2
0 °C
1
Color of monitor light (a) Red
1 Defective machine monitor
Blue
Hydraulic oil temperature gauge and hydraulic 40-605 oil temperature monitor
D375A-6 (06)
40-565
DRAFT Troubleshooting of electrical system (E-mode) E-11 Contents of display by machine monitor are different from applicable machine
E-11 Contents of display by machine monitor are different from applicable machine Trouble Related information
q
Contents of display by machine monitor are different from applicable machine.
Cause 1 Defective machine monitor
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.)
E-12 Machine monitor does not display some items q q
Trouble Related information
Machine monitor does not display some items The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect.
Cause 1
Defective machine monitor (LCD panel)
2
Defective machine monitor (body)
Procedure, measuring location, standard (value) and remarks a Turn starting switch ON and carry out troubleshooting. When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. q Operation of switches: [4] + [F2] (Press simultaneously) If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-13 Function switch does not work Trouble Related information
q
Function switch does not work
Cause 1 Defective machine monitor
40-566
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-14 Operation mode does not change
E-14 Operation mode does not change Trouble 1) When operation mode switch is operated, display of operation mode monitor does not change. Related informa- q Before carrying out troubleshooting, check that no related failure code is displayed. tion (If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.) Cause 1 Defective machine monitor
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.)
Trouble
2) When operation mode is changed, engine output is not changed. q Engine output mode recognized by engine controller can be checked with monitoring function. Related informa(Code: 17500 Engine Power Mode) q Before carrying out troubleshooting, check that no related failure code is displayed. tion (If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.) Cause 1 Defective machine monitor 2 Defective engine controller
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.) Engine controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-15 Gearshift mode does not change Trouble
1) When gearshift mode switch is operated, display of speed mode section does not change. Before carrying out troubleshooting, check that no related failure code is displayed. Related information (If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed, troubleshoot them first.) q
Cause 1 Defective machine monitor 2 Defective power train controller
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.) Power train controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
Trouble
2) When gearshift mode is changed, gearshift setting of power train is not changed. Before carrying out troubleshooting, check that no related failure code is displayed. Related information (If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed, troubleshoot them first.) q
Cause 1 Defective machine monitor 2 Defective power train controller
D375A-6 (01)
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.) Power train controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
40-567
DRAFT Troubleshooting of electrical system (E-mode) E-16 Customize function does not operate normally
E-16 Customize function does not operate normally Trouble 1) When customize switch is operated, customize screen is not displayed. Related information Cause 1 Defective machine monitor
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.)
Trouble 2) When setting is changed on customize screen, setting of machine is not changed. Related information Cause 1 Defective machine monitor 2
Defective engine controller or defective power train controller
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective.(Since trouble is in system, troubleshooting cannot be performed.) Engine controller or power train controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-17 Customize memory function does not operate normally Trouble 1) When customize memory switch is operated, customize memory screen is not displayed. Related information Cause 1 Defective machine monitor
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
Trouble 2) When selection is changed on customize memory screen, setting of machine is not changed. Related information Cause 1 Defective machine monitor 2
Defective engine controller or defective power train controller
40-568
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.) Engine controller or power train controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-18 Alarm buzzer does not sound or does not stop
E-18 Alarm buzzer does not sound or does not stop Trouble Related information
q
Alarm buzzer does not sound or does not stop.
Cause 1 Defective machine monitor 2 Defective power train controller
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.) Power train controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-19 When starting switch is turned OFF, service meter is not displayed q
Trouble Related information
q
When starting switch is turned OFF, service meter is not displayed. While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously)
Cause 1
Defective backup power supply system
2 Defective machine monitor
Procedure, measuring location, standard (value) and remarks When starting switch is turned ON, if machine monitor displays nothing, backup power supply system may be defective. In this case, perform troubleshooting for "E-3 When starting switch is turned ON, machine monitor displays nothing". If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-20 Machine monitor cannot be set in service mode q
Trouble Related information
q
Machine monitor cannot be set in service mode If following switches are operated, machine monitor is set in service mode. Operation of switches: [4]+[1]o[2]o[3] (While pressing [4], press other switches in order)
Cause 1 Defective machine monitor
D375A-6 (01)
Procedure, measuring location, standard (value) and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
40-569
Troubleshooting of electrical system (E-mode) E-21 The ripper pin puller cylinder does not operate
E-21 The ripper pin puller cylinder does not operate q
Failure
40-610
The ripper pin puller cylinder does not work.
Related information Cause 1 Defective fuse FS22-4
2
Defective pin puller switch (Internal defect)
Procedure, measuring location, criteria and remarks If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. 2. Disconnect connector PLSW and connect T-adapter to male side. 3. Operate switch and troubleshoot. Pull
Resistance
Max. 1 z
Blow out
Resistance
Min. 1 Mz
Between PLSW (male) (1) and (2) 1. Turn starting switch to OFF position. 2. Disconnect connector PPL and connect T-adapter to male side.
3
Defective pin puller solenoid Between PPL (male) (1) and (2) (Internal defect)
Between PPL (male) (1) and ground
Resistance
10 – 40 z
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors ASUS and PHR. Open or short circuit in wir- 3. Remove fuse FS22-4. 4 ing harness 4. Turn pin puller switch to ON position (lead-in). Between terminal FS22-4 of fuse and ground Resistance 10 – 40 z a Pin puller solenoid resistance a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse FS22-4. 3. Disconnect connectors PLSW and PPL, and connect T-adapters to each female Open circuit in wiring harside. 5 ness Between PPL (female) (2) and ground Resistance Max. 1 z
Ground fault in wiring har6 ness (Contact with ground circuit)
7
Hot short in wiring harness (Contact with 24 V circuit)
Between PPL (female) (1) and PLSW (female) (2)
Resistance
Max. 1 z
Between fuse FS22-4 and PLSW (female) (1)
Resistance
Max. 1 z
a 1. 2. 3.
If cause 4 is not the cause for the trouble, this check is not required. Turn starting switch to OFF position. Remove fuse FS22-4. Disconnect connectors PLSW and PPL, and connect T-adapters to female side of PLSW.
Between PPL (female) (1) and PLSW (female) (2)
Resistance
Min. 1 Mz
Between PLSW (female) (1) and ground
Resistance
Min. 1 Mz
1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connectors PPL, and connect T-adapter to female side. Turn starting switch to ON position. Turn pin puller switch to OFF position (pull-out).
Between PPL (female) (1) and (2)
40-570
Voltage
Max. 1 V
D375A-6 (06)
DRAFT Troubleshooting of electrical system (E-mode) E-21 The ripper pin puller cylinder does not operate
Circuit diagram related to ripper pin puller cylinder
D375A-6 (01)
40-571
DRAFT Troubleshooting of electrical system (E-mode) E-22 Horn does not sound or does not stop
E-22 Horn does not sound or does not stop q
Trouble
q
Related information
q
The horn does not sound or does not stop. Troubleshoot for causes 1 – 7 and 9, when horn does not sound and for causes 2, 8 and 9 when horn does not stop. Troubleshooting at connector HRN (female) does not perform but perform at connector RDG because T-adapter for connector HRN is not prepared.
Cause 1 Defective fuse FS32-4
2 Defective horn switch
3 Defective wiring harness
4
Disconnection in wiring harness or horn
5 Disconnection in horn
Procedure, measuring location, standard (value) and remarks If fuse FS32-4 is broken, circuit probably has ground fault. In this case, troubleshoot cause 7 first. 1. Turn starting switch to OFF position. 2. Disconnect horn switch terminals (No polarity). 3. Turn horn switch ON/OFF and troubleshoot. OFF Resistance Min. 1 MΩ Between horn switch terminals ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Disconnect connector RDG and connect T-adapter to female side. 3. Turn starting switch ON position. 4. Turn horn switch ON. Between RDG (female) (3) and ground Voltage 20–30 V 1. Turn starting switch to OFF position. 2. Remove fuse FS32-4. 3. Turn horn switch ON. Between FS32-4 and ground Continuity a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector HRN. Between HRN(male) and ground Continuity
Disconnection in wiring harness If check of cause 4 is abnormal and check of cause 5 is normal, wiring harness is 6 (Disconnection or defective disconnected. contact) a If fuse is not broken, this check is not required. Ground fault of wiring harness 1. Turn starting switch to OFF position. 7 (Contact with GND circuit) 2. Disconnect connector HRN and insert T-adapter into RDG. Between RDG (female) (2) and ground Resistance Min. 1 MΩ 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector HRN and insert T-adapter into RDG. 8 (Contact with 24 V circuit) 3. Turn horn switch ON. Between RDG (female) (2) and ground Voltage Max. 1 V 9 Defective horn (Internal defect) If the cause cannot be found by above checks, horn may be defective.
40-572
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-22 Horn does not sound or does not stop
Circuit diagram related to horn
D375A-6 (01)
40-573
DRAFT Troubleshooting of electrical system (E-mode) E-23 Back-up alarm does not sound or does not stop
E-23 Back-up alarm does not sound or does not stop Trouble
1) Back-up alarm does not sound. q When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure codes Related infor[D161KA], [D161KB] are displayed, but in case of failure on the secondary side (contact side), no failmation ure code is displayed. Cause
1
2
3
4
5
6
7
Procedure, measuring location, standard (value) and remarks If fuse FS22-5 is broken, circuit probably has ground fault. In this case, trouDefective fuse FS22-5 bleshoot cause 6 first. 1. Turn starting switch to OFF position. Defective backup alarm relay 2. Replace backup alarm relay (connector: BKA) with another relay. (Internal disconnection or short 3. Turn starting switch ON position. circuit) 4. Perform reverse travel operation. If backup alarm sounds, original backup alarm relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector BKAL and connect T-adapter to female side. Defective wiring harness 3. Turn starting switch ON position. 4. Perform reverse travel operation. Between BKAL (1) and (2) Voltage 20 – 30V 1. Turn starting switch to OFF position. Disconnection in wiring harness 2. Disconnect connector BKA and connect T-adapter to female side. or backup alarm Between BKA (female) (5) and ground Continuity a If neither of causes 3 and 4 is the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring harness 2. Remove fuse FS22-5. (Disconnection or defective con- 3. Disconnect connectors BKA and BKAL and connect T-adapters to female tact) side of them. Between BKA (female) (5) and BKAL (female) (1) Resistance Max. 1 Ω Between BKAL (female) (2) and ground Resistance Max. 1 Ω Between BKA (female) (1), (3) and FS22-5 Resistance Max. 1 Ω a If fuse is not broken, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse FS22-5. Ground fault of wiring harness 3. Disconnect connectors BKA and BKAL and connect T-adapter to female (Contact with GND circuit) side of either of them. Between BKA (female) (1) or (3) and ground Resistance Min. 1 MΩ Between BKA (female) (5) and ground Resistance Min. 1 MΩ Defective backup alarm If cause cannot be found by above checks, back-up alarm may be defective. (Internal defect)
40-574
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-23 Back-up alarm does not sound or does not stop
Trouble 2) Back-up alarm does not stop. Related information Cause
1
Defective backup alarm relay (Internal disconnection or short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Defective backup alarm (Internal defect)
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Replace backup alarm relay (connector: BKA) with another relay. a The above can be checked with backup alarm relay removed only. 3. Turn starting switch ON position. If backup alarm stops, original backup alarm relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector BKAL and connect T-adapter to female side. 3. Turn starting switch ON position. Between BKAL (female) (1) and (2) Voltage Max. 1V Between BKAL (female) (1) and ground Voltage Max. 1V If cause cannot be found by above checks, back-up alarm may be defective.
Circuit diagram related to backup alarm
D375A-6 (01)
40-575
DRAFT Troubleshooting of electrical system (E-mode) E-24 Fan does not reverse
E-24 Fan does not reverse Trouble Fan does not rotate in reverse. Related infor- q See "Reverse rotation of hydraulic fan" in Machine monitor sections of Structure and Operation secmation tion. 1
Cause Defective fan reverse solenoid
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure codes [DW7BKA] and [DW7BKB].
Circuit diagram related to fan
40-576
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
E-25 The head lamp and rear lamp do not light up Trouble
1) Head lamp does not light up. q If section between headlamp relay and headlamps, one headlamp lights up. Related inforq If headlamp switch, diode or wiring harness common to right and left headlamps is defective, right and mation left headlamps and working lamp do not light up.
1 2
3
4
5
6
Cause Procedure, measuring location, standard (value) and remarks Defective head lamp (Breakage Since the head lamp may be defective, check its bulb for breakage. of bulb) Defective circuit breaker (CB105 If circuit breaker is turned ON, circuit probably has ground fault etc. or CB5) 1. Turn starting switch to OFF position. Defective head lamp relay 2. Replace relay (connector: LMFL or LMFR) with backup alarm relay (LMFR, LMFL) (connector: BKA). (Internal disconnection or short 3. Turn starting switch ON position. circuit) 4. Turn headlamp switch to ON position. If headlamp lights up, original headlamp relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector FLSW and connect T-adapter to male side. 3. Turn headlamp switch to ON/OFF position and troubleshoot. Defective head lamp switch a ON position is located in both directions. Between FLSW (male) (5) and (6), or OFF Resistance Min. 1 MΩ ON Resistance Max. 1 Ω between (4) and (5) 1. Turn starting switch to OFF position. 2. Disconnect connectors LMD1 and LMD2, and connect T-adapter to diode. Defective diode LMD1 or LMD2 a Measure in diode range of tester. (Internal disconnection or short Between LMD1 (male) (1) (+) and (2) (-) No continuity circuit) Between LMD1 (male) (2) (+) and (1) (-) Continuity Between LMD2 (male) (1) (+) and (2) (-) No continuity Between LMD2 (male) (2) (+) and (1) (-) Continuity a Check location where voltage abnormality occurs and locate defective point of wiring harness. 1. Turn starting switch to OFF position. 2. Disconnect connectors LHDR and LHDL, and connect T-adapters to female side of them. 3. Turn starting switch ON position. 4. Turn headlamp switch to ON position. Between LHDL (female) (1) and (2) Voltage 20 – 30V Between LHDR (female) (1) and (2) Voltage 20 – 30V a If no failure is detected by above checks, this check is not required. 1. Turn starting switch to OFF position. Disconnection in, or ground fault 2. Disconnect connectors LMFL and LMFR, and connect T-adapter to female of wiring harness side. 3. Turn starting switch ON position. 4. Turn headlamp switch to ON position. Between LMFL (female) (1) and (2) Voltage 20 – 30V Between LMFL (female) (3) and (2) Voltage 20 – 30V Between LMFR (female) (1) and (2) Voltage 20 – 30V Between LMFR (female) (3) and (2) Voltage 20 – 30V a If no failure is detected by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector FLSW and connect T-adapter to female side. 3. Turn starting switch ON position. Between FLSW (female) (5) and (2) Voltage 20 – 30V
D375A-6 (01)
40-577
Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
Cause
Procedure, measuring location, criteria and remarks a If cause 6 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors FLSW, LMD1, LMD2, LMFL, LMFR, LHDR, LHDL and KEY, and connect T-adapters to each female side.
Open circuit in wiring harness 7 (open circuit or defective contact)
Between LHDR (female) (2) and ground
Resistance
Max. 1 z
Between LHDL (female) (2) and ground
Resistance
Max. 1 z
Between LHDR (female) (1) and LMFR (female) (5)
Resistance
Max. 1 z
Between LHDL (female) (1) and LMFL (female) (5)
Resistance
Max. 1 z
Between LMFL (female) (1) and LMD1 (female) (1)
Resistance
Max. 1 z
Between LMD1 (female) (1) and LMD2 (female) (1)
Resistance
Max. 1 z
Between LMFL (female) (2) and ground
Resistance
Max. 1 z
Between LMFL (female) (3) and CB5 (2)
Resistance
Max. 1 z
Between LMFL (female) (1) and LMFR (female) (1)
Resistance
Max. 1 z
Between LMFL (female) (2) and LMFR (female) (2)
Resistance
Max. 1 z
Between LMFL (female) (3) and LMFR (female) (3)
Resistance
Max. 1 z
Between FLSW (female) (6) and LMD1 (female) (2)
Resistance
Max. 1 z
Between FLSW (female) (4) and LMD2 (female) (2)
Resistance
Max. 1 z
Between FLSW (female) (5) and KEY (female) (1)
Resistance
Max. 1 z
Between FLSW (female) (2) and ground
Resistance
Max. 1 z
a If cause 6 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors LMD1, LMD2, LMFL, LHDR and LHDL, and connect T-adapter to female side of LMFL.
Ground fault in wiring har8 ness Between LMFL (female) (1) and ground (Contact with ground circuit) Between LMFL (female) (3) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Between LMFL (female) (5) and ground
Resistance
Min. 1 Mz
40-578
D375A-6 (06)
DRAFT Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
Circuit diagram related to ripper point lamp
D375A-6 (01)
40-579
DRAFT Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
Trouble 2) Working lamp does not light up. Related infor- q If headlamps do not light up, see "1) Headlamp does not light up" first. mation
1 2
3
4
5
6
Cause Defective working lamp (Breakage of bulb)
Procedure, measuring location, standard (value) and remarks Since the working lamp may be defective, check its bulb for breakage.
When the fuse is blown, a ground fault may have probably occurred in the circuit. 1. Turn starting switch to OFF position. 2. Replace relay (connector: LMW) with backup alarm relay (connector: Defective working lamp relay BKA). (Internal disconnection or short cir3. Turn starting switch ON position. cuit) 4. Turn headlamp switch to ON position. If working lamp lights up, original working lamp relay is defective. a Check location where voltage abnormality occurs and locate defective point of wiring harness. 1. Turn starting switch to OFF position. 2. Disconnect connectors LWKR and LWKL, and connect T-adapters to female side of them. 3. Turn starting switch ON position. 4. Turn headlamp switch to ON position. Between LWKL (female) (1) and (2) Voltage 20 – 30V Between LWKR (female) (1) and (2) Voltage 20 – 30V a If no failure is detected by above checks, this check is not required. Disconnection in, or ground fault of 1. Turn starting switch to OFF position. wiring harness 2. Disconnect connector LMW and connect T-adapter to female side. 3. Turn starting switch ON position. 4. Turn headlamp switch to ON position. Between LMW (female) (1) and (2) Voltage 20 – 30V Between LMW (female) (3) and (2) Voltage 20 – 30V a If no failure is detected by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector FLSW and connect T-adapter to female side. 3. Turn starting switch ON position. Between FLSW (female) (5) and (2) Voltage 20 – 30V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse FS22-2. 3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters to female side of them. Between LWKR (female) (2) and ground Resistance Max. 1 Ω Between LWKL (female) (2) and ground Resistance Max. 1 Ω Disconnection in wiring harness (Disconnection or defective contact) Between LWKR (female) (1) and LMW (female) Resistance Max. 1 Ω (5) Between LWKL (female) (1) and LMW (female) Resistance Max. 1 Ω (5) Between LMW (female) (1) and LMFL (female) Resistance Max. 1 Ω (1) Between LMW (female) (2) and ground Resistance Max. 1 Ω Between LMW (female) (3) and FS22-2 Resistance Max. 1 Ω a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse FS22-2. Ground fault of wiring harness 3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters (Contact with GND circuit) to female side of LMW. Between LMW (female) (3) and ground Resistance Min. 1 MΩ Between LMW (female) (5) and ground Resistance Min. 1 MΩ
Defective fuse (FS22-2)
40-580
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
Circuit diagram related to ripper point lamp
D375A-6 (01)
40-581
DRAFT Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
Trouble
3) Back-up lamp and ripper point lamp do not light. If fuse, back-up lamp relay, back-up lamp switch or common wiring harness of back-up lamp and ripRelated inforper point lamp is defective, neither of back-up lamp and ripper point lamp does not light up (If either mation of back-up lamp and ripper point lamp lights up, this check is not required). q For related circuit diagram, see 2). q
1 2 3
4
5
6
7
Cause Defective rear lamp (Breakage of bulb) Defective ripper point lamp (Broken bulb) Defective fuse FS22-1
Procedure, measuring location, standard (value) and remarks Since the rear lamp may be defective, check its bulb for breakage. Since the ripper point lamp may be defective, check its bulb for breakage.
If fuse FS22-1 is broken, circuit probably has ground fault. 1. Turn starting switch to OFF position. 2. Replace relay (connector: LMRE) with backup alarm relay (connector: Defective back-up lamp relay BKA). (Internal disconnection or short cir3. Turn starting switch ON position. cuit) 4. Turn back-up lamp switch to ON position. If back-up lamp lights up, original back-up lamp relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector RLSW and connect T-adapter to male side. Defective rear lamp switch 3. Turn back-up lamp switch to ON/OFF position and troubleshoot. OFF Resistance Min. 1 MΩ Between RLSW (female) (5) and (6) ON Resistance Max. 1 Ω a Check location where voltage abnormality occurs and locate defective point of wiring harness. 1. Turn starting switch to OFF position. 2. Disconnect connectors LREL, LRER and LRP, and connect T-adapter to female side of them. 3. Turn starting switch ON position. 4. Turn back-up lamp switch to ON position. Between LREL (female) (1) and (2) Voltage 20 – 30V Between LRER (female) (1) and (2) Voltage 20 – 30V Between LRP (female) (1) and (2) Voltage 20 – 30V Disconnection in, or ground fault of a If no failure is detected by above checks, this check is not required. 1. Turn starting switch to OFF position. wiring harness 2. Disconnect connector LMRE and connect T-adapter to female side. 3. Turn starting switch ON position. 4. Turn back-up lamp switch to ON position. Between LMRE (female) (1) and (2) Voltage 20 – 30V Between LMRE (female) (3) and (2) Voltage 20 – 30V a If no failure is detected by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector RLSW and connect T-adapter to female side. 3. Turn starting switch ON position. Between RLSW (female) (5) and (2) Voltage 20 – 30V a If cause 6 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse FS22-1. 3. Disconnect connectors FLSW, DIODE, FLP, LHDR, LHDL and KEY, and connect T-adapters to female side of them. Between LRER (female) (2) and ground Resistance Max. 1 Ω Between LREL (female) (2) and ground Resistance Max. 1 Ω Between LRP (female) (2) and ground Resistance Max. 1 Ω Disconnection in wiring harness Between LRER (female) (1) and LMRE (female) (5) Resistance Max. 1 Ω (Disconnection or defective conBetween LREL (female) (1) and LMRE (female) (5) Resistance Max. 1 Ω tact) Between LRP (female) (1) and LMRE (female) (5) Resistance Max. 1 Ω Between LRP (female) (2) and ground Resistance Max. 1 Ω Between LMRE (female) (1) and RLSW Resistance Max. 1 Ω (female)(1), (6) Between LMRE (female) (2) and ground Resistance Max. 1 Ω Between LMRE (female) (3) and FS22-1 Resistance Max. 1 Ω Between RLSW (female) (5) and KEY (female) (1) Resistance Max. 1 Ω Between RLSW (female) (2) and ground Resistance Max. 1 Ω
40-582
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-25 The head lamp and rear lamp do not light up
8
Ground fault of wiring harness (Contact with GND circuit)
D375A-6 (01)
a 1. 2. 3.
If cause 6 is not the cause for the trouble, this check is not required. Turn starting switch to OFF position. Remove fuse FS22-1. Disconnect connectors LRER, LREL, LRP, LMRE and RLSW, and connect T-adapter to female side of LMRE. Between LMRE (female) (1) and ground Resistance Min. 1 MΩ Between LMRE (female) (3) and ground Resistance Min. 1 MΩ Between LMRE (female) (5) and ground Resistance Min. 1 MΩ
40-583
DRAFT Troubleshooting of electrical system (E-mode) E-26 Windshield wiper does not operate
E-26 Windshield wiper does not operate Trouble 1) None of the wipers operate. Related information Cause 1
Defective CB105 circuit breaker
2
Disconnection in, or ground fault of wiring harness
3
Disconnection in wiring harness (Disconnection or defective contact)
4
Ground fault of wiring harness (Contact with ground circuit)
Procedure, measuring location, standard (value) and remarks If CB105 circuit breaker is turned ON, the circuit probably has ground fault. In this case, perform troubleshooting for cause 4 first. 1. Turn starting switch to OFF position. Between terminal (B) in cab fuse box and ground Voltage 20–30V a If cause 2 is not the cause for the trouble, this check is not required. a If CB105 circuit breaker is turned ON, reset it first. 1. Turn starting switch to OFF position. Between battery relay BRC terminal and cab fuse Resistance Max. 1 Ω box (B) terminal a If neither of causes 1 and 2 is the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Remove terminal (B) from cab fuse box. Between terminal (B) in cab fuse box (Wiring harResistance Min. 1 MΩ ness side) and ground
Circuit diagram related to wiper
40-584
D375A-6 (01)
Troubleshooting of electrical system (E-mode) E-26 Windshield wiper does not operate
Trouble Related information
2) Front windshield wipers do not operate. q q
T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.) For related circuit diagram, see Trouble 1).
Cause
Procedure, measuring location, criteria and remarks
Defective fuse 4 in cab fuse If fuse shown at left is broken, circuit probably has ground fault. In this case, perform 1 box troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Defective front wiper motor 2. Disconnect connector CN-9 and connect T-adapter to male side. 2 (Internal open circuit in wirBetween CN-9 (male) (2) and (5) Continuity ing) 1. Turn starting switch to OFF position. 2. Disconnect connector CN-12. 3. Turn front wiper switch ON and OFF, and troubleshoot. 3 Defective front wiper switch Between CN-12 (male) (3) and (4)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
Between CN-12 (male) (4) and (5)
4 Power supply line
1. Turn starting switch to ON position. a If any abnormality occurs, go to Cause 6 and Trouble 1). Between terminal (4) in cab fuse box and ground
Open circuit in wiring harness 5 (open circuit or defective contact)
1. Turn starting switch to OFF position. 2. Remove fuse 4 from cab fuse box. 3. Turn front wiper switch to ON position. Between terminal (4) in cab fuse box (Wiring harness side) and ground
Voltage
20 – 30 V
Continuity
1. Turn starting switch to OFF position. Between terminal (4) in cab fuse box and ground
Voltage
20 – 30 V
Ground fault in wiring har- a If cause 4 is not the cause for the trouble, this check is not required. 6 ness 1. Turn starting switch to OFF position. (Contact with ground circuit) 2. Remove fuse 4 from cab fuse box. 3. Disconnect connectors CN-9 and CN-12. Between terminal (4) in cab fuse box (Wiring harness Resistance Min. 1 Mz side) and ground
D375A-6 (06)
40-585
Troubleshooting of electrical system (E-mode) E-26 Windshield wiper does not operate
Trouble Related information
3) Rear wiper does not operate. q q
T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.) For related circuit diagram, see Trouble 1).
Cause 1
Procedure, measuring location, criteria and remarks
Defective fuse 2 in cab fuse If fuse shown at left is broken, circuit probably has ground fault. In this case, perform box troubleshooting for cause 6 first.
1. Turn starting switch to OFF position. Defective rear wiper motor 2. Disconnect connector CN-4 and connect T-adapter to male side. 2 (Internal open circuit in wirBetween CN-4 (male) (2) and (1) Continuity ing) 1. Turn starting switch to OFF position. 2. Disconnect connector CN-14. 3. Turn rear wiper switch ON and OFF, and troubleshoot. 3 Defective rear wiper switch Between CN-14 (male) (3) and (4)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
Between CN-14 (male) (4) and (5)
4 Power supply line
1. Turn starting switch to ON position. a If any abnormality occurs, go to Cause 6 and Trouble 1). Between terminal (2)in cab fuse box and ground
Open circuit in wiring harness 5 (open circuit or defective contact)
1. Turn starting switch to OFF position. 2. Remove fuse 2 from cab fuse box. 3. Turn rear wiper switch to ON position. Between terminal (2) in cab fuse box (Wiring harness side) and ground
Voltage
20 – 30 V
Continuity
1. Turn starting switch to OFF position. Between terminal (2)in cab fuse box and ground Voltage 20 – 30 V Ground fault in wiring har- a If cause 4 is not the cause for the trouble, this check is not required. 6 ness 1. Turn starting switch to OFF position. (Contact with ground circuit) 2. Remove fuse 2 from cab fuse box. 3. Disconnect connectors CN-4 and CN-14. Between terminal (2) in cab fuse box (Wiring harness Resistance Min. 1 Mz side) and ground
40-586
D375A-6 (06)
Troubleshooting of electrical system (E-mode) E-26 Windshield wiper does not operate
Trouble Related information
4) Left door wiper does not operate. q q
T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.) For related circuit diagram, see Trouble 1).
Cause 1
Procedure, measuring location, criteria and remarks
Defective fuse 5 in cab fuse If fuse shown at left is broken, circuit probably has ground fault. In this case, perform box troubleshooting for cause 6 first.
1. Turn starting switch to OFF position. Defective left door wiper 2. Disconnect connector CN-18 and connect T-adapter to male side. motor 2 (Internal open circuit in wirBetween CN-18 (male) (2) and (3) Continuity ing) 1. Turn starting switch to OFF position. 2. Disconnect connector CN-11. 3. Turn left door wiper switch ON and OFF, and troubleshoot. 3
Defective left door wiper switch
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
Between CN-11 (male) (3) and (4)
Between CN-11 (male) (4) and (5)
4 Power supply line
1. Turn starting switch to ON position. a If any abnormality occurs, go to Cause 6 and Trouble 1). Between terminal (5) in cab fuse box and ground
Open circuit in wiring harness 5 (open circuit or defective contact)
1. Turn starting switch to OFF position. 2. Remove fuse 5 from cab fuse box. 3. Turn left door wiper switch ON. Between terminal (5) in cab fuse box (Wiring harness side) and ground
Voltage
20 – 30 V
Continuity
1. Turn starting switch to OFF position. Between terminal (5) in cab fuse box and ground Voltage 20 – 30 V Ground fault in wiring har- a If cause 4 is not the cause for the trouble, this check is not required. 6 ness 1. Turn starting switch to OFF position. (Contact with ground circuit) 2. Remove fuse 5 from cab fuse box. 3. Disconnect connectors CN-18 and CN-11. Between terminal (5) in cab fuse box (Wiring harness Resistance Min. 1 Mz side) and ground
D375A-6 (06)
40-587
Troubleshooting of electrical system (E-mode) E-26 Windshield wiper does not operate
Trouble Related information
5) Right door wiper does not operate. q
T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
Cause 1
Procedure, measuring location, criteria and remarks
Defective fuse 3 in cab fuse If fuse shown at left is broken, circuit probably has ground fault. In this case, perform box troubleshooting for cause 6 first.
Defective right door wiper 1. Turn starting switch to OFF position. motor 2. Disconnect connector CN-17 and connect T-adapter to male side. 2 (Internal open circuit in wirBetween CN-17 (male) (2) and (3) Continuity ing) 1. Turn starting switch to OFF position. 2. Disconnect connector CN-13. 3. Turn right door wiper switch ON and OFF, and troubleshoot. 3
Defective right door wiper switch
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
Between CN-13 (male) (3) and (4)
Between CN-13 (male) (4) and (5)
4 Power supply line
1. Turn starting switch to ON position. a If any abnormality occurs, go to Cause 6 and Trouble 1). Between terminal (3) in cab fuse box and ground
Open circuit in wiring harness 5 (open circuit or defective contact)
1. Turn starting switch to OFF position. 2. Remove fuse 3 from cab fuse box. 3. Turn right door wiper switch ON. Between terminal (3) in cab fuse box (Wiring harness side) and ground
Voltage
20 – 30 V
Continuity
1. Turn starting switch to OFF position. Between terminal (3) in cab fuse box and ground Voltage 20 – 30 V Ground fault in wiring har- a If cause 4 is not the cause for the trouble, this check is not required. 6 ness 1. Turn starting switch to OFF position. (Contact with ground circuit) 2. Remove fuse 3 from cab fuse box. 3. Disconnect the connectors CN-17 and CN-13. Between terminal (3) in cab fuse box (Wiring harness Resistance Min. 1 Mz side) and ground
40-588
D375A-6 (06)
DRAFT Troubleshooting of electrical system (E-mode) E-26 Windshield wiper does not operate
Circuit diagram related to wiper
D375A-6 (01)
40-589
DRAFT Troubleshooting of electrical system (E-mode) E-27 Window washer does not operate
E-27 Window washer does not operate Trouble
1) Front window washer does not operate. q If wiper also does not operate, see E-26 1) or 2). Related q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without information T-adapter). Cause
Defective front window washer 1 motor (Internal defect) (Internal disconnection)
2 Defective front wiper switch
Disconnection in wiring harness 3 (Disconnection or defective contact)
4
Ground fault of wiring harness (Contact with ground circuit)
40-590
Procedure, measuring location, standard (value) and remarks a Check that rear window washer sprays water normally. 1. Turn starting switch to OFF position. 2. Replace connector WSFR with WSRR. 3. Turn starting switch to ON position. 4. Turn front window washer switch to ON position. If rear window washer sprays water, original front window washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector CN-12 and connect T-adapter to male side. 4. Turn switch ON and OFF, and troubleshoot. OFF Resistance Min. 1 MΩ Between CN-12 (male) (1) and (2) ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Remove fuse 4 from cab fuse box. 3. Turn front window washer switch to ON position. Between terminal (4) in cab fuse box (Wiring harContinuity ness side) and ground 1. Turn starting switch to OFF position. 2. Remove fuse 4 from fuse box. 3. Disconnect connectors CN-12 and WSFR. Between terminal (4) in cab fuse box (Wiring harResistance Min. 1 MΩ ness side) and ground
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-27 Window washer does not operate
Circuit diagram related to window washer
D375A-6 (01)
40-591
DRAFT Troubleshooting of electrical system (E-mode) E-27 Window washer does not operate
Trouble
2) Rear window washer does not operate. q If wiper also does not operate, see E-26 1) or 3). Related inforq T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without mation T-adapter). Cause
1
Defective rear window washer motor (Internal disconnection)
2
Defective rear wiper switch
3
Disconnection in wiring harness (Disconnection or defective contact)
4
Ground fault of wiring harness (Contact with ground circuit)
40-592
Procedure, measuring location, standard (value) and remarks a Check that front window washer sprays water normally. 1. Turn starting switch to OFF position. 2. Replace connector WSFR with WSRR. 3. Turn starting switch to ON position. 4. Turn rear window washer switch to ON position. If front window washer spouts water, original rear window washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector CN-14 and connect T-adapter to male side. 4. Turn switch ON and OFF, and troubleshoot. OFF Resistance Min. 1 MΩ Between CN-14 (male) (1) and (2) ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. 2. Remove fuse 2 from cab fuse box. 3. Turn rear window washer switch to ON position. Between terminal (2) in cab fuse box (Wiring harContinuity ness side) and ground 1. Turn starting switch to OFF position. 2. Remove fuse 2 from fuse box. 3. Disconnect connectors CN-14 and WSRR. Between terminal (2) in cab fuse box (Wiring harResistance Min. 1 MΩ ness side) and ground
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-27 Window washer does not operate
Circuit diagram related to window washer
D375A-6 (01)
40-593
DRAFT Troubleshooting of electrical system (E-mode) E-27 Window washer does not operate
Trouble
3) Right door window washer does not operate. q If wiper also does not operate, see E-26 1) or 5). Related infor- q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without T-adapter). mation q For related circuit diagram, see 1). Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks a Check that left door window washer sprays water normally. 1. Turn starting switch to OFF position. 2. Replace connector WSLH with WSRH. Defective right door washer motor 3. Turn starting switch to ON position. (Internal disconnection) 4. Turn right door window washer switch to ON position. If left door window washer sprays water, original right door window washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. Defective right door wiper switch 3. Disconnect connector CN-13 and connect T-adapter to male side. 4. Turn switch ON and OFF, and troubleshoot. OFF Resistance Min. 1 MΩ Between CN-13 (male) (1) and (2) ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Disconnection in wiring harness 2. Remove fuse 3 from cab fuse box. (Disconnection or defective con- 3. Turn right door window washer switch to ON position. tact) Between terminal (3) in cab fuse box (Wiring harContinuity ness side) and ground 1. Turn starting switch to OFF position. 2. Remove fuse 3 from fuse box. Ground fault of wiring harness 3. Disconnect connectors CN-13 and WSRH. (Contact with ground circuit) Between terminal (3) in cab fuse box (Wiring harResistance Min. 1 MΩ ness side) and ground
40-594
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-27 Window washer does not operate
Trouble
4) Left door window washer does not operate. q If wiper also does not operate, see E-26 1) or 4). Related infor- q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without T-adapter). mation q For related circuit diagram, see 1). Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks a Check that right door window washer sprays water normally. 1. Turn starting switch to OFF position. 2. Replace connector WSLH with WSRH. Defective left door washer motor 3. Turn starting switch to ON position. (Internal disconnection) 4. Turn left door window washer switch to ON position. If right door window washer sprays water, original left door window washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect ground strap. 3. Disconnect connector CN-11 and connect T-adapter to male side. Defective left door wiper switch 4. Turn switch ON and OFF, and troubleshoot. OFF Resistance Min. 1 MΩ Between CN-11 (male) (1) and (2) ON Resistance Max. 1 Ω 1. Turn starting switch to OFF position. Disconnection in wiring harness 2. Remove fuse 5 from cab fuse box. (Disconnection or defective con- 3. Turn left door window washer switch to ON position. tact) Between terminal (5) in cab fuse box (Wiring harContinuity ness side) and ground 1. Turn starting switch to OFF position. 2. Remove fuse 5 from fuse box. Ground fault of wiring harness 3. Disconnect connectors CN-11 and WSLH. (Contact with ground circuit) Between terminal (5) in cab fuse box (Wiring harResistance Min. 1 MΩ ness side) and ground
D375A-6 (01)
40-595
DRAFT Troubleshooting of electrical system (E-mode) E-28 Electric priming pump does not operate or does not stop automatically
E-28 Electric priming pump does not operate or does not stop automatically Trouble Related information 1 2
3
4
5
6
7
8
q
Electric priming pump does not operate or does not stop automatically.
Cause Low battery charge level
Procedure, measuring location, standard (value) and remarks Battery charge level may be low. Check battery directly. If circuit breaker CB7 is turned OFF, circuit probably has ground fault. (Check Defective circuit breaker CB7 cause No. 5) 1. Disconnect ground strap. 2. Disconnect connectors EPP, and connect T-adapter to female side. Disconnection in wiring harness 3. Connect ground strap. (Drive power supply system) Between EPP (1) - (2) Voltage 20 – 30V (Disconnection in wiring or defec1. Disconnect ground strap (to turn constant power supply OFF). tive contact in connector) 2. Disconnect connectors EPP, and connect T-adapter to female side. Between EPP (female) (2) and ground Resistance Max. 1 Ω 1. Disconnect ground strap (to turn constant power supply OFF). 2. Disconnect connectors EPP, and connect T-adapter to female side. Ground fault in wiring harness 3. Disconnect connectors USB, EG1 and EFP. (Contact with GND circuit) Between EPP (female) (1) and ground Resistance Min. 1 MΩ Between EPP (female) (3) and ground Resistance Min. 1 MΩ 1. Disconnect ground strap. 2. Disconnect connectors EPP, and connect T-adapter to female side. 3. Connect ground strap. Defective electric priming pump 4. Defective electric priming pump ON Between EPP (3) and (4) Voltage 20 – 30V q If lamp flashes but output voltage is defective or if result of troubleshooting 1-4 is normal and lamp does not flash, electric priming pump is defective. Defective electric priming pump When electric priming pump does not stop automatically, electric priming switch (Malfunction or automatic pump switch may be defective. stop failure) (Turn toggle switch OFF to stop pump and then replace switch.) q Lamp blinks but stops in about 5 seconds. Overload on electric priming * If pump is overloaded, power supply is turned OFF automatically to protect pump circuit (Priming switch is reset automatically). 1. Disconnect ground strap. 2. Disconnect connectors EPP, and connect T-adapter to male side. Trouble in electric priming pump Between EFP (male) (1) and (2) Resistance 1–3Ω Between EFP (male) (1) – pump body Resistance Min. 1 MΩ Between EFP (male) (2) – pump body Resistance Min. 1 MΩ
40-596
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-28 Electric priming pump does not operate or does not stop automatically
Circuit diagram related to electric priming pump
D375A-6 (01)
40-597
DRAFT Troubleshooting of electrical system (E-mode) E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) Trouble Related information
q q
The ORBCOMM terminal does not operate normally (Data are not transmitted). Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine. Cause
1
2
3
Procedure, measuring location, standard (value) and remarks After 3 minutes or later from VHMS startup, check the VHMS controller decimal point (dot LED at right lower position of 7-segment display) (*1) or check the machine monitor display (*2). *1 Lamp is Power is not applied to ORBCOMM terminal or the communiTerminal power supply is abnormal or OFF cation with VHMS controller is abnormal. Power is applied to ORBCOMM terminal and the communicasatellite is not captured *1 Lamp is tion with VHMS controller is normal. But it does not capture ON satellite. Power is applied to ORBCOMM terminal, capturing satellie *1 Flashing and the communication with VHMS controller is normal. 1. Disconnect ground strap. 2. Turn starting switch to OFF position. 3. Disconnect connectors KOM1 and V4B, and connect T-adapters to female side of them. a Constant power supply is used. When disconnecting connector and Disconnection in wiring harness carrying out troubleshooting, take care. (Disconnection or defective contact in Between KOM1 (female) (36), (39) and VF2 connector) Resistance Max. 1 Ω (male) (5) Between KOM1 (female) (37), (38) and ground Resistance Max. 1 Ω Between V4B (female) (3)–KOM1 (female) (11) Resistance Max. 1 Ω Between V4B (female) (4)–KOM1 (female) (4) Resistance Max. 1 Ω Between V4B female) (10)–KOM1 (female) (5) Resistance Max. 1 Ω 1. Disconnect ground strap. 2. Turn starting switch to OFF position. Defective ORBCOMM terminal 3. Disconnect connectors KOM1, and connect T-adapter to female side. (When LED is turned OFF) 4. Connect ground strap. Between KOM1 (female) (36) and (37) Voltage 20 – 30V Between KOM1 (female) (39) and (38) Voltage 20 – 30V
*1 Location of VHMS controller decimal point (dot LED at right lower position of 7-segment display)
*2 Checking on the machine monitor 1) Turn starting switch to ON position. 2) Switch machine monitor to Service menu. 3) Select Monitoring. 4) Enter "99003".
40-598
D375A-6 (01)
DRAFT Troubleshooting of electrical system (E-mode) E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
Circuit diagram related to ORBCOMM terminal
D375A-6 (01)
40-599
DRAFT Troubleshooting of electrical system (E-mode) E-30 Gear cannot be shifted
E-30 Gear cannot be shifted Trouble Related information
q
Gear cannot be shifted (Shift switch does not work).
Cause Trouble in shift operation switch q Shift up switch 1 q Shift down switch q Shift switch (Optional-type lever) Internal defect of transmis2 sion clutch
40-600
Procedure, measuring location, standard (value) and remarks a When failure code related to shift operation switch is not displayed. Press shift operation switch for more than 10 seconds. If any of following failure code is displayed at this time, carry out troubleshooting for it. [DD12KA], [DD12KB], [DD13KA], [DD13KB], [DDK5KA], [DDK5KB] a When failure code related to shift operation switch is displayed. Carry out troubleshooting for displayed failure code. The inside of the transmission clutch is supposed to be defective, check it directly.
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table
Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. Trouble Trouble in machine Related inforInformation related to detected trouble or troubleshooting mation Cause
Standard value in normal state/Remarks on troubleshooting
1
Possible causes and standard value for judgment
2
3
Possible causes of trouble (Given numbers are reference numbers, which do not indicate priority)
q Standard value to determine possible causes q Remarks on judgment
4
D375A-6 (01)
40-601
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) List of Failure Modes and Causes
List of Failure Modes and Causes Hydraulic components
Related to work equipment
Related to power train
40-602
Q
Q
Q Q
Q
EPC valve Self-pressure reducing valve
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Hydraulic tank strainer
For steering clutch For brake clutch
For gearshift clutch
Power train pump Torque converter operation valve Torque converter relief valve Transmission main relief valve Transmission operation valve Steering valve For lockup clutch For forward-reverse clutch
Failure modes No force (No drawbar pull). No travel (at 2nd or 3rd speed). No travel at all gear speeds. Machine travels only in one direction forward or in reverse. Large time lag at gear speed shifting or forward-reverse shifting. Steering is not possible. Steering is possible only on one side. Steering overrun occurs. Brake does not work. Torque converter is not locked-up. Power train oil overheats. All work equipment operates slowly or lacks power. All work equipment does not operate. Blade lift speed is slow or lacks power. Blade tilt speed is slow or lacks power. Ripper lift speed is slow or lacks power Ripper tilt 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 (giant ripper attachment machine). Blade pitch does not work (dual tilt attachment machine). Abnormal sound comes out from around work equipment pump. Fan speed is abnormal (sound and/or vibration are abnormally large or engine overheats).
Servo valve
Main pump
ECMV
Main body
Components causing failures
Q Q Q Q Q Q
Q
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q
D375A-6 (01)
Q
Q Q Q Q Q
D375A-6 (01) Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Q Fan pump Fan motor Brake pedal linkage Parking brake linkage
Hydraulic cylinder Ripper pin-puller solenoid valve Pitch selection solenoid valve
LS check valve
Pressure compensation valve
Suction valve
LS relief valve
Main relief valve
Unload valve
Spool
Valve body
PPC valve PPC lock valve
Hydraulic components Control valve
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
QQ Q QQ Q Q Q Q Q Q Q
Q
Q Q
Steering clutch (disc, plate, etc.) Brake clutch (disc, plate, etc.) Inside of transmission Inside of torque converter PTO Engine Cooling system Loosening of piping clamp, air in hydraulic oil and oil leakage
Q
Q Q Q Q Q Q
QQ Diagnosis codes
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) List of Failure Modes and Causes
Mechanical system
H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11 H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-19 H-20
H-21
Q
H-22 H-23
Q Q
H-24
40-603
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Machine lacks power(or drawbar pull)
H-1 Machine lacks power(or drawbar pull) Trouble Related information
q q q
Power is low (Insufficient drawbar pull) When Manual transmission or show slip control is selected for the gear shift mode, and when operation is in the E mode, the contents of this section are not applied. Make sure that hydraulic oil level of power train is normal, and start troubleshooting. Cause
1
2
3
Possible causes and standard value in normal state
4
5
6
7
40-604
Standard value in normal state/Remarks on troubleshooting a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Defective engine or transMeasuring conditions Engine speed F3 stall 1,450 rpm mission Stall in F3 + Relief of work equip1,400 rpm ment system (Pitch back) Defective power train pump The power train pump is assumed to be defective; directly check it. a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Torque converter Torque converter Internal defect of torque conPCCS lever inlet pressure outlet pressure verter 0.44 – 0.74 MPa 0.69 – 1.08 MPa All neutral position {4.5 – 7.5 kg/cm2} {7.0 – 11.0 kg/cm2} a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Transmission PCCS lever main relief pressure 2.53 – 3.12 MPa Defective set pressure of All neutral position {25.8 – 31.8 kg/cm2} transmission main relief a Prepare with starting switch OFF, then carry out troubleshooting valve and internal defect without turning starting switch ON. Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly. q Free length of spring: 120.3 mm q Number of shims: 4 a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at low idling speed. Transmission clutch Clutch pressure FWD Min. 2.06 MPa {Min. 21.0 kg/cm2} Operation failure of transREV Min. 2.06 MPa {Min. 21.0 kg/cm2} mission valve (ECMV) 1ST Min. 1.86 MPa {Min. 19.0 kg/cm2} 2ND Min. 2.06 MPa {Min. 21.0 kg/cm2} 3RD Min. 2.06 MPa {Min. 21.0 kg/cm2} a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (dragIf machine does not move when engine is low-idling and F2 shift is ging) of brake selected, braking is applied (troubleshoot by referring to "H-9 Brake system does not operate". If the result of the troubleshooting in cause 6 is abnormal, the parking Defective parking brake brake lever or brake pedal linkage is not assumed to be adjusted norlever or brake pedal linkage mally. Directly check it.
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Machine lacks power(or drawbar pull)
Cause
Possible causes and standard value in normal state
D375A-6 (01)
Standard value in normal state/Remarks on troubleshooting a After checking that the transmission main relief pressure is normal. a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed.+ PCCS lever Left stroke end Right stroke end Min. 2.4 MPa 0 MPa Left clutch pressure {Min. 24 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.4 MPa Right clutch pressure 8 Defective steering clutch {0 kg/cm2} {Min. 24 kg/cm2} 0 MPa Min. 2.4 MPa Left brake pressure {0 kg/cm2} {Min. 24 kg/cm2} Min. 2.4 MPa 0 MPa Right brake pressure {Min. 24 kg/cm2} {0 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of "H-6 Steering is not possible." Internally defective transmis- The transmission is assumed to be defective internally; directly check 9 sion it.
40-605
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-2 Machine cannot travel (at 2nd or 3rd each speed)
H-2 Machine cannot travel (at 2nd or 3rd each speed) Trouble
q q
Related information
q q
Machine cannot start (at 2nd or 3rd gear speed) Before performing troubleshooting, check that the power train oil level is normal. Before performing troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) If any one of failure code of [15SFL1], [15SFLH], [15SGL1] or [15SGLH] is displayed, perform troubleshooting for the failure code first. Cause
Possible causes and standard value for judgment
40-606
Standard value /Remarks on troubleshooting a Prepare with starting switch to OFF position , then run the engine at full speed to perform troubleshooting. Torque converter Torque converter outInternal defect of torque conPCCS lever 1 inlet pressure let pressure verter 0.69 – 1.08 MPa 0.44 – 0.74 MPa Neutral for all controls {7.0 – 11.0 kg/cm2} {4.5 – 7.5 kg/cm2} a Prepare with starting at switch OFF positon , then run the engine at low speed to perform troubleshooting. Transmission clutch Clutch pressure Defective operation of transMin. 2.06 MPa 2 2ND mission valve (ECMV) {Min. 21.0 kg/cm2} Min. 2.06 MPa 3RD {Min. 21.0 kg/cm2} Defective operation (drag- The operation at the parking brake may be defective (drags) , Check 3 ging) of parking brake the linkage or valves. a Move the machine to flat ground and start the engine to perform troubleshooting. Defective operation (dragRun the engine at low speed and set the gear to F2. If the machine 4 ging) of brake move, the brake drags. (Perform the troubleshooting for "H-9 Brake does not work.") a Prepare with starting switch at OFF position , then run the engine at full speed to perform troubleshooting PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.4 MPa Left clutch pressure {0 kg/cm2} {Min. 24 kg/cm2} 0 MPa Min. 2.4 MPa Defective steering clutch, or Right clutch pressure {0 kg/cm2} {Min. 24 kg/cm2} 5 brake 0 MPa Min. 2.4 MPa Left brake pressure {0 kg/cm2} {Min. 24 kg/cm2} Min. 2.4 MPa 0 MPa Right brake pressure {Min. 24 kg/cm2} {0 kg/cm2} When the oil pressure is abnormal, perform the troubleshooting for "H-6 machine cannot turn." Internal defect of transmis6 Transmission may have an internal defect. Check it directly. sion
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-3 Machine cannot travel at any gear speeds
H-3 Machine cannot travel at any gear speeds Trouble
q q
Related information
q
Machine can not travel at any gear speeds Performing troubleshooting, check that the power train oil level is normal. If any one of failure code of [1500L0], [2201L1], [2201LH], [2202L1], [2202LH], [DDT5KA], [DDT5KB], [DK30KX], [DK30KZ], [DK55KX] or [DK55KZ] is displayed, perform troubleshooting for the failure code first.
Cause Defective power train 1 pump
Possible causes and standard value for judgment
D375A-6 (01)
Standard value /Remarks on troubleshooting The power train pump is may be defective. Check it directly.
a Prepare with starting switch at OFF position, then run the engine at full speed to perform troubleshooting. Incorrect set pressure of Transmission PCCS lever 2 transmission main relief main relief pressure valve 2.53 – 3.12 MPa Neutral for all controls {25.8 – 31.8 kg/cm2} a Prepare with starting switch at OFF position, then perform troubleshooting leaving starting switch intact. Defective operation of Directly check that the spring length and the number of shims are normal 3 transmission main relief and also that the spool moves smoothly. valve q Free length of spring: 120.3 mm q Number of shims: 4 sheets a After checking that the transmission main relief pressure is normal. a Prepare with starting at OFF position, then run the engine at low speed to perform troubleshooting. Transmission clutch Clutch pressure Defective operation of FWD Min. 2.06 MPa {Min. 21.0 kg/cm2} 4 transmission valve REV Min. 2.06 MPa {Min. 21.0 kg/cm2} (ECMV) 1ST Min. 1.86 MPa {Min. 19.0 kg/cm2} 2ND Min. 2.06 MPa {Min. 21.0 kg/cm2} 3RD Min. 2.06 MPa {Min. 21.0 kg/cm2} a After checking that the transmission main relief pressure is normal. a Move the machine to level ground, raise parking the brake lever, run the engine at full speed to perform troubleshooting.(Before starting troubleshooting ,check that transmission main relief pressure is norDefective operation of mal). 5 brake Brake pedal Brake oil pressure (right and left) Release Min. 2.4 MPa {Min. 24 kg/cm2} 0 MPa Depressed {0 kg/cm2} a After checking that the transmission main relief pressure is normal. a Prepare with starting at switch OFFposition, raise parking brake lever to release the brake , run the engine at full speed to perform troubleshooting (Before starting troubleshooting ,check that transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end Min. 2.4 MPa 0 MPa Defective seal of steering Left clutch pressure 2} 6 {Min. 24 kg/cm {0 kg/cm2} clutch or brake Min. 2.4 MPa 0 MPa Right clutch pressure {Min. 24 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.4 MPa Left brake pressure {0 kg/cm2} {Min. 24 kg/cm2} Min. 2.4 MPa 0 MPa Right brake pressure {Min. 24 kg/cm2} {0 kg/cm2} Internal defect of steer7 The inside of the steering clutch may be defective, check it directly. ing clutch and brake Perform troubleshooting for the failure codes [DDQ2KA], [DDQ2KB], Malfunction of parking [DDQ2L4] and [dDQ2L4]. 8 brake lever switch Even if failure code is not displayed, check that switch operates normally. Internal defect of trans9 The inside of transmission clutch may be defective. Check it directly. mission clutch
40-607
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-4 Machine travels only in one direction, forward or reverse
H-4 Machine travels only in one direction, forward or reverse Trouble
q q
Related information
q q
Machine travels only in one direction ,forward or in Reverse. Before performing troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) If any one of failure code of [15SAL1], [15SALH], [15SBL1] or [15SBLH] is displayed, perform troubleshooting for the failure code first. Cause
1 Possible causes and standard value in normal state
2 3
4
40-608
Standard value /Remarks on troubleshooting a Prepare with starting switch at OFFposition, then run the engine at low speed to perform troubleshooting. q Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Transmission clutch Clutch pressure Min. 2.06 MPa FWD {Min. 21.0 kg/cm2} Defective operation of transMin. 2.06 MPa REV mission valve (ECMV) {Min. 21.0 kg/cm2} Min. 1.86 MPa 1ST {Min. 19.0 kg/cm2} Min. 2.06 MPa 2ND {Min. 21.0 kg/cm2} Min. 2.06 MPa 3RD {Min. 21.0 kg/cm2} Defectively sealed of trans- If the result of the test for cause 4 shows malfunction of the brake, mission clutch the clutch seal may be defective. Check it directly. Internal defect of transmis- The inside of the transmission clutch is supposed to be defective. sion clutch Check it directly. a Move the machine to flat ground and start the engine to perform troubleshooting. Defective operation (dragRun the engine at low speed mode and set to gear to F2. If the ging) of brake machine does not move, the brake drags. (Perform the troubleshooting for "H-9 Brake does not work").
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-5 Large time lag at gear shifting or directional change
H-5 Large time lag at gear shifting or directional change Trouble Related information
Possible causes and standard value in normal state
D375A-6 (01)
q
Large time lag at gear shifting or directional change.
q
Before performing troubeshooting ,check that the power train oil level is normal.
Cause Standard value /Remarks on troubleshooting 1 Defective power train pump The power train pump may be defective. Check it directly. a Prepare by turning starting switch at OFF position, then run the engine at full speed to perform troubleshooting. Transmission PCCS lever main relief pressure Defective operation of trans2 2.45 – 2.94 MPa mission main relief valve Neutral for all controls {25.0 – 30.0 kg/cm2} When the oil pressure is abnormal, clean the valve and then check the oil pressure again. a Prepare with starting switch at OFF position , then perform trouble starting switch intact.. Defective operation of trans- Directly check that the spring free length and the number of shims are 3 normal and that the spool moves smoothly. mission main relief valve q Free length of spring: 120.3mm q Number of shims: 4 a After checking that the transmission main relief pressure is normal. a Prepare by turning starting switch at OFF position, then run the engine at low speed to perform troubleshooting . Transmission clutch Clutch pressure Min. 2.06 MPa FWD {Min. 21.0 kg/cm2} Min. 2.06 MPa Operation failure of transREV 4 {Min. 21.0 kg/cm2} mission valve (ECMV) Min. 1.86 MPa 1ST {Min. 19.0 kg/cm2} Min. 2.06 MPa 2ND {Min. 21.0 kg/cm2} Min. 2.06 MPa 3RD {Min. 21.0 kg/cm2} Defectivly sealed transmis- When the standard values for the cause 3 are not satisfied, the clutch 5 sion clutch seal may be defective. Check it directly. Internal defect of transmis6 Inside of transmission clutch may be defective. Check it directly. sion clutch a Move the machine to flat ground and start the engine to perform troubleshooting. Defective operation of brake If machine does not move when engine is low-idling and F2 shift is 7 (dragging) selected, braking is applied (troubleshoot by referring to "H-9 Brake system does not operate". 8 Type of oil used Check if an oil other than the specified oil (T030) is being used.
40-609
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-6 Machine connot turn
H-6 Machine connot turn Trouble Related information
q q q
Machine connot turn. Before performing troubleshooting, check that the power train oil level is normal. Before performing troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
1
Possible causes and standard value for judgment
2
3 4 5
40-610
Standard value /Remarks on troubleshooting a Prepare with engine started , then run the engine at low speed whild performing troubleshooting. Defective operation of Raise machine by using blade and ripper, run tracks with gear at F3 brake (or R3), and make steering operation .If track stops running, brake is defective. (Perform troubleshooting for "H-9 Brake does not work".) a Prepare with starting switch at OFF positon, then run the engine at full speed to perform troubleshooting PCCS lever Left stroke end Right stroke end 0MPa Min. 2.4MPa Left clutch pressure 2} {0 kg/cm2} {Min. 24 kg/cm Defective operation of 0MPa Min. 2.4MPa steering clutch valve Right clutch pressure 2 {0 kg/cm } {Min. 24 kg/cm2} (ECMV) 0MPa Min. 2.4MPa Left brake pressure 2 {0 kg/cm } {Min. 24 kg/cm2} Min. 2.4MPa 0MPa Right brake pressure 2 {Min. 24 kg/cm } {0 kg/cm2} Defectively sealed steering When standard values for the cause 2 are not satisfted, the clutch clutch seal may be sealed diffectively. Check it directly. Internal defect of steering Steering clutch may be defective, check it directly. clutch Defective operation of steering potentiometer of Perform troubleshooting related to steering potentiometer. travel control lever
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-7 Machine turns only to one side
H-7 Machine turns only to one side Trouble Related information
q q q
Machine turns only to one side. Before performing troubleshooting, check that the power train oil level is normal. Before performing troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
1
Possible causes and standard value for judement
2
3 4 5
D375A-6 (01)
Standard value /Remarks on troubleshooting a Prepare with engine started, then run the engine at low speed while performing troubleshooting. Raise machine by using blade and ripper, drive it in F3 (or R3), and Defective operation of brake steer it in direction in which machine cannot turn. If track shoe stops at this time, brake is defective. (Carry out troubleshooting for "H-9 Brake does not work".) a Prepare with starting switch at OFF position, then run the engine at full speed to perfrom troubleshooting. PCCS lever Left stroke end Right stroke end 0MPa Min. 2.4MPa Left clutch pressure 2} {0 kg/cm2} {Min. 24 kg/cm Defective operation of steerMin. 2.4MPa 0MPa Right clutch pressure ing clutch valve (ECMV) {Min. 24 kg/cm2} {0 kg/cm2} 0MPa Min. 2.4MPa Left brake pressure 2 {0 kg/cm } {Min. 24 kg/cm2} Min. 2.4MPa 0MPa Right brake pressure 2 {Min. 24 kg/cm } {0 kg/cm2} Defectively sealed steering When the standard the cause 2 are not satisfied , the clutch seal may clutch be sealed defectively. Check it directly. Internal defect of steering Steering clutch may be defective, check it directly. clutch Defective operation of steering potentiometer of travel Perform troubleshooting related to steering potentiometer. control lever
40-611
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Machine overruns at turnning
H-8 Machine overruns at turnning Trouble Related information
q
Machine overruns at turnning. Before performing troubleshooting, check that the power train oil level is normal. Before performing troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
q q
Cause
Possible causes and standard value for judgment
Standard value /Remarks on troubleshooting a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting. Raise the machine by using the blade and run the engine with gear at 1 Defective operation of brake F3 travel (or R3 travel) and make steering operation. If the shoe stops running ,the brake is defective. (Perform the troubleshooting for “H-9 Brake does not work.”) When track shoe does not stop running in the troubleshooting for the Defective operation of steercause 1, the steering clutch is defective. (Perform the troubleshooting 2 ing clutch fro “H-6 Machine cannot turn.”)
H-9 Brake does not work Trouble
q q
Related information
q q
Brake does not work. Before performing troubleshooting, check that the power train oil level is normal. Before performing troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) If failure code [DK40KA] or [DK40KB] is displayed, perform diagnoses for the failure code first . Cause
1 2
Possible causes and standard value for judgment
3
4 5
40-612
Standard value /Remarks on troubleshooting a Start the engine to perform troubleshooting. Depress the brake pedal, shift the gear to F2 and run the engine at Degradation of brake full speed. If the machine moves, the brake performance is degraded. Defective operation of brake Brake pedal, linkage and the brake valve may not work normally. pedal Check them directly. a Prepare with starting switch at OFF position, then run the engine at full speed to perfrom troubleshooting. PCCS lever Left stroke end Right stroke end Min. 2.4MPa 0MPa Left clutch pressure {Min. 24 kg/cm2} {0 kg/cm2} Defective operation of steerMin. 2.4MPa 0MPa Right clutch pressure ing brake valve (ECMV) {Min. 24 kg/cm2} {0 kg/cm2} 0MPa Min. 2.4MPa Left brake pressure {0 kg/cm2} {Min. 24 kg/cm2} Min. 2.4MPa 0MPa Right brake pressure {Min. 24 kg/cm2} {0 kg/cm2} When standard the cause 3 are not satisfied , the brake seals may be Defective brake seal defective. Check it directly. Internal defect of brake Brakes may be defective. Check it directly.
D375A-6 (01)
Troubleshooting of hydraulic and mechanical system (H-mode) H-10 Torque converter does not lock up
H-10 Torque converter does not lock up Failure Related information
40-6 1
q
The torque converter does not lock up.
q
Before performing troubleshooting, check that the power train oil level is normal. Before performing troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) If any one of failure code of [DDTSL1], [DDTSLH], [DXH1KA], [DXH1KB], [DXJBKA] or [DXJBKB] is displayed, perform diagnoses for the failure code first.
q q
Cause
Standard value in normal condition/Remarks on troubleshooting
1 Defective power train pump The power train pump may be defective. Check it directly.
Defective operation of torque 2 converter lock up valve (ECMV) Possible causes and standard value for judgment
a Prepare with starting switch at OFF position, then run the engine at full speed to perform troubleshooting. Clutch pressure Torque converter
At lock up
Stator clutch Lockup clutch
2.50 – 2.79 MPa {25.5 – 28.5 kg/cm2} 1.24 – 1.54 MPa {12.7 – 15.7 kg/cm2}
3
Defectively sealed of lock up When standard value for the case 2 is not satisfied, the lock up clutch clutch may sealed defectively. Check it directly.
4
Internal defect of lock up clutch
Lock up clutch may be defective. Check it directly. a Prepare with starting at switch OFF position, then run the engine at full speed to perform troubleshooting.
Measurement conditions Internal defect of torque con5 F3,torque converter stall verter F3,torque converter stall + Work equipment relief (pitch back)
D375A-6 (06)
Engine speed 1,450rpm 1,170rpm
40-613
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-11 Power train oil overheats
H-11 Power train oil overheats Trouble
q q
Related information
q
q
Overheating of power train oil Make sure that hydraulic oil level of power train is normal, and start troubleshooting. Make sure that power train oil temperature gauge indication matches actual oil temperature of torque converter and start troubleshooting. (If no match, follow "E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally".) Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
1 Defective engine system
Possible causes and standard value in normal state
40-614
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 of brake (dragging)
6
Defective operation (slide) of steering clutch
7
Defective operation of brake (Slip)
8
Defective power train oil cooler
Standard value in normal state/Remarks on troubleshooting Engine cooling system may be defective and engine output may be increased abnormally. Carry out troubleshooting according to Engine volume, Shop manual. The power train pump is supposed to be defective, or air is supposed to have entered from the suction circuit. Check them directly. a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Torque converter Torque converter PCCS lever inlet pressure outlet pressure 0.69 – 1.08 MPa 0.44 – 0.74 MPa All neutral position {7.0 – 11.0 kg/cm2} {4.5 – 7.5 kg/cm2} The inside of the transmission clutch is supposed to be defective (the clutch slides). Check it directly. a Start the engine for troubleshooting. If machine does not move when engine is low-idling and F2 shift is selected, braking is applied (troubleshoot by referring to "H-9 Brake system does not operate". The inside of the steering clutch is supposed to be defective (the clutch slides). Check it directly. a Start the engine for troubleshooting. If the machine cannot be stopped completely while performing F3 stall, the brake is slipping. Check the filter element for clogging.
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-12 All work equipment operates too slow or lacks power
H-12 All work equipment operates too slow or lacks power Trouble Related information
q
All work equipment operates slowly or lacks power.
q
Make sure that hydraulic oil level is normal, and start troubleshooting.
Cause Defective PTO (work equip1 ment pump drive) Defective work equipment 2 large pump Defective work equipment 3 small pump
4
5
Possible causes and standard value in normal state
6
7
8
9
10
11 12
D375A-6 (01)
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. a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Defective operation of Work equipment control levers Unload pressure unload valve 2.45 (+1.37/0) MPa All neutral position {25 (+14/0) kg/cm2} a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Improper pressure set to Blade lever Main relief pressure main relief valve for blade lift Min. 26.5 MPa valve Raise {Min. 270 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 a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Improper pressure set to Blade lever Main relief pressure main relief valve for blade tilt Min. 26.5 MPa ripper Lo valve Raise {Min. 270 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 a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Defective pressure setting or Work equipment control levers LS relief pressure defective operation of LS Min. 24.52 MPa relief valve At stroke end {Min. 250 kg/cm2} a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Malfunction of self pressure Work equipment control levers Control relief pressure reducing valve (PPC basic Min. 3.1 MPa pressure) All neutral position {Min. 32 kg/cm2} If cause 8 is detected, oil may be leaking in PPC valve. Check PPC Internal leak of PPC valve valve directly. Operation failure of check Directly inspect the check valve for clogging. valve of PPC control circuit
40-615
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-13 All work equipment does not operate
H-13 All work equipment does not operate Trouble Related information
q
All work equipment does not operate.
q
Make sure that hydraulic oil level is normal, and start troubleshooting.
Cause Defective PTO (work equip1 ment pump drive) Defective work equipment 2 large pump Defective work equipment 3 small pump
4
5
6 Possible causes and standard value in normal state
7
8
9
10
11
12
40-616
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. Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Defective operation of Work equipment control levers Unload pressure unload valve 2.45(+1.37/0) MPa All neutral position {25(+14/0) kg/cm2} a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Improper pressure set to Blade lever Main relief pressure main relief valve for blade lift Min. 26.5 MPa valve Raise {Min. 270 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 a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Improper pressure set to Blade lever Main relief pressure main relief valve for blade tilt Min. 26.5 MPa ripper Lo valve Raise {Min. 270 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 a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Defective pressure setting or Work equipment control levers LS relief pressure defective operation of LS 27.44 ± 1.37 MPa relief valve At stroke end {280 ± 14 kg/cm2} a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Malfunction of self pressure Work equipment control levers Control relief pressure reducing valve (PPC basic Min. 3.1 MPa pressure) All neutral position {Min. 32 kg/cm2} Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the lock valve lever linkage or the lock valve directly. a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed. Operation failure of check Work equipment control levers Control relief pressure valve of PPC control circuit Min. 3.1 MPa All neutral position {Min. 32 kg/cm2}
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-14 Blade lift cylinder speed is too slow or lacks power
H-14 Blade lift cylinder speed is too slow or lacks power Trouble
q q q
Related information
q q
Blade lift cylinders speed is too slow or lacks power. Before performing troubleshooting, check that hydraulic tank oil level is normal. Check whether the blade is remodeled. When hydraulic drift rate of the blade lift cylinders is also high, perform troubleshooting for “H-18 Excessive hydraulic drift of blade Lift cylinders.” If either one of failure code of [DDNALD] or [DDNFLD] is displayed, troubleshooting corresponding to such code are to be reformed. Cause
Possible causes and standard value for judgement
Standard value /Remarks on troubleshooting a Prepare with starting switch OFF, then run the engine of the full speed position to perform troubleshooting. Defective operation of PPC Blade control lever PPC valve output pressure 1 valve Min. 3.1 MPa Raise stroke end {Min. 32 kg/cm2} Defective operation of blade Operation of the blade lift valve spool may be defective. Check it 2 lift control valve (spool) directly. Air entering blade lift cylin- Air blade lift cylinders.Bleed air and check whether the phenomenon 3 ders changes.
H-15 Blade tilt cylinder speed is too slow or lacks power Trouble
q q q
Related information
q q
Blade tilt cylinders speed is too slow or lacks power. Before performing troubleshooting, check the hydraulic oil level is normal. Check whether the blade is remodeled. When the hydraulic drift rate of the blade tilt cylinders is also high, perform troubleshooting for “H-19 Excessive hydraulic drift of blade tilt cylinders.” If either one of failure code of [DDNZLD] or [DDN3LD] is displayed, troubleshooting corresponding to such code are to be performed. Cause
Possible causes and standard value for judgement
D375A-6 (01)
Standard value /Remarks on troubleshooting a Prepare with starting switch OFF, then run the engine at the full speed position to performe troubleshooting. Defective operation of PPC Blade control lever PPC valve output pressure 1 valve Min. 3.1 MPa Raise stroke end {Min. 32 kg/cm2} Defective operation of blade Operation of the blade tilt valve spool may be defective.Check it 2 tilt control valve (spool) directly. Air entering blade tilt cylin- Air may enter the blade tilt cylinders.Bleed air and check wether the 3 ders phenomenon changes.
40-617
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-16 Ripper lift cylinder speed is too slow or lacks power
H-16 Ripper lift cylinder speed is too slow or lacks power Trouble
q q q
Related information
q q
Ripper lift cylinders speed is too slow or lacks power. Before performing troubleshooting, check the hydraulic tank oil level is normal. Check whether the ripper is remodeled. When the hydraulic drift rate of the ripper lift cylinders is also high, perform troubleshooting for “H-20 Excessive hydraulic drift of ripper Lift cylinders.” If either one of failure code of [DDNBLD] or [DDNCLD] is displayed, troubleshooting corresponding to such code are to be performed. Cause
1 Possible causes and standard value for judgement
2
3
4
Standard value /Remarks on troubleshooting a Prepare with starting switch OFF, then run the engine at the full speed position to perform troubleshooting Defective operation of PPC Ripper control lever PPC valve output pressure valve Min. 3.1 MPa Raise stroke end {Min. 32 kg/cm2} Defective operation of ripper Operation of the ripper lift control valve may be defective.Check it lift control valve (Spool) directly. The operation of the suction valve for the ripper lift control valve may be Defective operation of ripper defective. Check it directly. lift control valve (suction a Judgment may be made by checking a change of phenomenon after valve) exchanging suction valves on the head side and on the bottom side. Air entering ripper lift cylin- Air may enter The ripper lift cylinders.Bleed air and check whether the der phenomenon changes.
H-17 Ripper tilt cylinder speed is too slow or lacks power Trouble
q q
Related information
q q
Ripper tilt cylinders speed is too slow or lacks power. Before performing troubleshooting, check that the hydraulic oil level tank is normal. Check whether the ripper is remodeled. If either one of [DDNDLD] or [DDNELD] is displayed, troubleshooting corresponding to such code are to be performed first. Cause
Possible causes and standard value for judgement
1
Defective operation of PPC valve
2
Defective operation of ripper tilt control valve(spool)
Defective operation of rip3 per tilt operation valve(suction valve) 4
40-618
Air entering ripper tilt cylinders
Standard value /Remarks on troubleshooting a Prepare with starting switch OFF, then run the engine at full speed position to perform troubleshooting Ripper lever PPC valve output pressure Min.3.1 MPa Tilt stroke end {Min. 32 kg/cm2} Operation of the ripper tilt control valve spool may be defective. Check it directly. Operation of the suction valve for the ripper tilt control valve may be defective. Check it directly. a Judgement may be made by checking a change of phenomenon after exchanging suction valves on the head side and on the bottom side. Air may enter ripper tilt cylinders. Bleed air and check whether the phenomenon changes.
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-18 Excessive hydraulic drift of blade lift cylinder
H-18 Excessive hydraulic drift of blade lift cylinder Trouble Related information
q q q
Excessive hydraulic drift of blade lift cylinders. Check whether the blade is remodeled. Before performing troubleshooting, check that no oil leaks in the work equipment circuit. Cause
Possible causes and standard value for judgement
1
Defectively sealed blade lift control valve (spool)
2
Defectively sealed of blade lift cylinder
Standard value /Remarks on troubleshooting a Prepare with the engine started, then stop the engine to perform troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes higher,sealing of the blade lift control valve spool may be sealed defectively. 1. Use the blade lift cylinders to thrust the blade againment the ground, and raise the front of the machine. 2. Stop the engine, and release the work equipment lock lever. 3. Set the blade control lever to LOWER side, and check whether the speed changes. The blade lift cylinders may be sealed defectively. Check it directly.
Raise blade about 1,000 mm above the ground and check hydraulic Defective fitting of quick drop drift of its cutting edge. valve q 400 mm /15 min a Prepare by starting the engine, and troubleshoot by rotating engine at high idling speed. Troubleshoot using the following procedure and if the work equipment pump pressure is below the limit, cylinder piston valve is defective. 1. Raise the blade about 1,000 mm and hook the end bit on a rock or other object. (Do not move the blade.) Operation failure of piston 2. Raise blade in the above conditions, and measure the pump pres4 valve sure. 3. If pump pressure is within the limit, cylinder piston valve is defective. 4. Disassemble the cylinder, and check piston valve. Blade lever Blade Pump pressure 24.5 MPa Raising stroke end Cannot move {250 kg/cm2} 3
H-19 Excessive hydraulic drift of blade tilt cylinder Trouble Related information
q q q
Excessive hydraulic drift of tilting blade tilt cylinder. Check whether the blade is remodeled. Before performing troubleshooting, check that no oil leaks in the work equipment circuit. Cause
Possible causes and standard value for judgement
D375A-6 (01)
1
Defectively sealed blade tilt control valve (spool)
2
Defectively sealed blade tilt cylinder
Standard value /Remarks on troubleshooting a Prepare with the engine started, then stop the engine to performing troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes higher, the sealing of the blade tilt control valve spool may be defective. 1. Use the blade tilt cylinder to thrust the blade against the ground, and raise the right of the machine. 2. Stop the engine, and release the work equipment lock lever. 3. Set the blade contorl lever to the right tilt side, and check whether the speed changes. a Prepare with starting switch OFF, then run the engine at the full speed position to perform troubleshooting Blade tilt cylinder Oil leak from cylinder Right tilt stroke end 12 cc/min
40-619
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-20 Excessive hydraulic drift of ripper lift cylinder
H-20 Excessive hydraulic drift of ripper lift cylinder Trouble Related information
q q q
Excessive hydraulic drift of ripper lift cylinders. Check whether the ripper is remodeled. Before performing troubleshooting, check that no oil leaks the circuits in the work equipment before troubleshooting. Cause
Possible causes and standard value for judgement
1
Defectively sealed of ripper lift control valve (spool)
2
Defectively sealed of ripper lift cylinder
Standard value /Remarks on troubleshooting a Prepare with the engine started, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes higher, sealing of the ripper lift control valve (Hi) may be defective. 1. Use the ripper lift cylinders to thrust the ripper against the ground, and raise the rear of the machine. 2. Stop the engine, and release the work equipment lock lever. 3. Set the ripper control lever to the LOWER side, and check whether the speed changes. a Prepare with starting switch OFF, then run the engine at full speed position to perform troubleshooting Ripper lift cylinder Oil leak from cylinder LOWER stroke end 12 cc/min
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) Trouble Related information
q
The ripper pin puller cylinder does not operate.
q
Check that the transmission main relief pressure is normal before troubleshooting. Cause
Possible causes and standard value for judgment
40-620
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch at OFF position, then run the engine at high speed to perform troubleshooting Pin puller working Pin puller switch Measuring position pressure Push-in Cylinder bottom side Min. 2.2 MPa Pull-in Cylinder head side {Min. 22 kg/cm2}
1
Defective operation of pin puller solenoid
2
Internal defect of pin puller cylinder
Pin puller cylinder may be defective internally. Check it directly
3
Defective fuse FS2-2(20A) for pin puller
Check fuse for breakage. If it is broken, short circuit has probably occurred. Check wiring harness of related circuit.
D375A-6 (01)
DRAFT Troubleshooting of hydraulic and mechanical system (H-mode) H-22 Blade pitch does not work (machine with dual tilt specification)
H-22 Blade pitch does not work (machine with dual tilt specification) q
Trouble Related information
The blade pitch does not work. If either one failure code of [DW5AKA] or [DW5AKB] is displayed, failure diagnoses corresponding to such code are to be performed first.
q
Cause Defective operation of blade 1 pitch selector solenoid valve Defective function of blade 2 pitch control valve (Spool) Defective operation of blade 3 pitch cylinder
Possible causes and standard value for judgment
4
Defective function of blade pitch switch
Standard value in normal state/Remarks on troubleshooting Operation of the blade pitch selector valve may be defective. Check it directly . Operation of the blade pitch cylinder may be defective. Check it directly. Operation of the blade pitch cylinder may be defective. Check it directly. Perform troubleshooting related to blade pitch switch. Even if failure code is not displayed, check that switch operates normally.
H-23 Abnormal noise from around work equipment pump Trouble Related information
Possible causes and standard value for judgment
q
Abnormal noise from around work equipment pump.
q
Befor performing troubleshooting , check hydraulic oil lever is normal.
Cause 1 Inappropriate oil Clogged hydraulic tank 2 strainer 3 Air inhaled in suction circuit 4
D375A-6 (01)
Standard value in normal state/Remarks on troubleshooting The oil may be inappropriate. Check it directly. The strainer of the hydraulic tank may be clogged. Check it directly. Air may be inhaled in the suction circuit of the work machine pump. Check the circuit directly.
Internal defect of work equipThe work equipment pump may be defective. Check it directly. ment pump
40-621
Troubleshooting of hydraulic and mechanical system (H-mode) H-24 Abnormal fan rotation (noise and/or vibration are abnormally large or engine overheats)
H-24 Abnormal fan rotation (noise and/or vibration are abnormally large 40-675 or engine overheats) Trouble Related information
q
Abnormal fan rotation (noise and/on vibration are abnormally large or engine overheats)
q
Before performing troubleshooting, check that oil level in hydraulic tank is normal. Cause
1 Defective engine speed
Defective PTO (fan pump drive)
2
Possible causes and standard value for judgment
Defect in fan pump or fan motor
3
Standard value in normal state/Remarks on troubleshooting a Start engine to performing troubleshooting. Measuring conditions Engine speed Engine at low idling 750 ± 50 rpm Engine at high idling 1,900 (0/-50) rpm If engine speed is not increased to specification, perform troubleshooting for "S-5 Engine dose not rotate smoothly(hunting)". Fan pump drive of PTO may be defective. Check it directly. a Prepare with starting switch at OFF position, then run engine at high idle to perform troubleshooting. Fan pump EPC circuit source presMeasurement conditions sure Min. 3.1 MPa – {Min. 32 kg/cm2} a Prepare with starting switch at OFF position, then run engine at high idle to perform troubleshooting. Measurement conditions Fan drive circuit pressure 15.7 ± 2.5 MPa Fan 100 % mode {160 ± 25 kg/cm2} a Prepare with starting switch at OFF position, then run engine at high idle to perform troubleshooting. Measurement conditions Fan speed Fan 100 % mode Max. 1,110 rpm The fan may be broken or installed defectively. Check itself directly.
4 Defective fan Defective sensor for engine water temperature, power 5 Any of these sensors may be defective. Check them directly. train oil temperature, or hydraulic oil temperature
H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator) Trouble Related information
q q
Operator's seat isolator quakes abnormally. When operator's seat isolator quakes largely, it makes shocks.
— Cause
Possible causes and standard value for judgment
40-622
1
Breakage of laminated rubber
Standard value in normal stage/Remarks on troubleshooting The laminated rubber may be broken. Perform Testing and adjusting, "Breakage of rubber".
2 Malfunction of damper
The damper may malfunction. Perform Testing and adjusting, "Oil leakage from damper".
3 Breakage of stopper rubber
The stopper rubber may be broken. Perform Testing and adjusting, "Breakage of stopper rubber".
D375A-6 (07)
Troubleshooting of hydraulic and mechanical system (H-mode) H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator)
D375A-6 (07)
40-623
DRAFT Troubleshooting of engine (S-mode) Method of using troubleshooting chart
Troubleshooting of engine (S-mode) Method of using troubleshooting chart This troubleshooting chart is divided into four sections: Questions, Check items, Causes and Troubleshooting. First, use the Questions and Check items to select highly probable causes among the Causes. The Questions and Check items allows for the selection based on the failure symptoms or simple inspection results without using troubleshooting tools. Next, use troubleshooting tools or perform direct inspection to check the selected causes in the order of probability to determine the real cause. Questions: Questions placed in the sections A and B in the table on the next page are those to be answered by the user or operator. Questions in section A are for basic information about the failure. Depth and accuracy of their answers to the questions in section B may depend on their skill level. Check items: Check items placed in the section C in the table on the right are to be simply checked by the technician to select highly probable causes. Causes: The technician selects highly probable causes from among the Causes based on the answers to the Questions in sections A and B and the check results of Check items in section C.
Troubleshooting: The Troubleshooting indicates the items to be checked by the serviceman in order to ultimately check that the selected causes are truly the defect factors by using troubleshooting tools or making direct checking starting with probable causes of higher order. This troubleshooting chart marks the content of the questions and check items with E, Q or w according to their closer relationship with the causes. E: A cause that can be referred to in relation to the question or check item. Q: A cause that relates to the question or check item. w: A cause particularly probable among those marked with Q above. a Count the priority level of each marking as w > Q when determining the cause. Don’t count E when determining the cause. The item with this marking may be counted, however, if no difference is present than this and the cause cannot be determined.
40-624
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) Method of using troubleshooting chart
D375A-6 (01)
40-625
DRAFT Troubleshooting of engine (S-mode) Method of using troubleshooting chart
Exhaust smoke is black (Incomplete combustion) Let us assume that a problem of "Exhaust smoke is black" occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; "Exhaust smoke gradually became black", "Power was lost gradually", and "Dust indicator piston indicates red zone".
40-626
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) Method of using troubleshooting chart
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] section. The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 - Step 3 shown below.
D375A-6 (01)
40-627
DRAFT Troubleshooting of engine (S-mode) S-1 Engine does not start easily
S-1 Engine does not start easily Cause
q q q q
Electrical system is defective. Fuel level is low. Air intake is in short supply. Wrong fuel selection. Coolant leaks into exhaust pipe.
Troubleshooting
Check items
Questions
a Common rail fuel injection system (CRI) controls the fuel injection timing electrically. Therefore, there are cases where the engine does not start before the crankshaft makes two revolutions maximum after starting operation. This is not an abnormal state, however.
Check recent repair history Degree of use Operated for long period Ease of start- Gradually became worse Starts when warm ing Non-specified fuel is being used Replacement of filters is not performed according to Operation & Maintenance Manual. Engine oil must be added more frequently. Preheat monitor does not light up during preheating or at low temperature. Charge monitor indicates abnormal charging during operation. Dust indicator lamp piston indicates red zone. Clogged breather hole in fuel tank cap Leaking from fuel piping No response or heavy resistance is felt when operating priming pump. Starting motor rotates engine slowly. When engine and air bleeding plug is removed from fuel filter, fuel does is rotated with not flow out. starting motor, and spill hose is separated from injector, spill flow is small. When exhaust manifold, are touched immediately after starting engine, temperature of manifold for some cylinders is low. Engine does not rey smoothly , and combustion is irregular. Engine hunts (rotation is irregular). Blowby gas is excessive. Inspect air cleaner directly. Removing EGR cooler inlet gas pipe causes coolant containing antifreeze to flow out (*1). When compression pressure is measured, the pressure is low. Air is discharged when bleeding from fuel system. Inspect fuel filter and strainer directly. Inspect feed pump gauze filter directly. Perform troubleshoot for "Rail Press Very Low Error" (*2) Engine speed does not change even when running engine with some cylinder cut out. Intake air heater mount does not warm up during preheating operation. Does voltage B – E appear between alternator terminals 25 Yes and 30V with engine running at low idle? None Specific gravity of electrolyte and voltage of battery are low Remedy
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Clogged air cleaner element Cracked EGR cooler (coolant mixing in the exhaust) Defective contact between valve and valve seat Wear of piston ring or cylinder Clogged breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogged fuel filter element Clogged feed pump gauze filter Stuck or seized supply pump plunger Defective injector Defective intake air heater system Defective alternator (regulator) Defective alternator (generator) Defective or deteriorated battery
General causes that engine does not start easily
For *1 and *2, see the next page 40-628
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-1 Engine does not start easily
*1: EGR cooler inlet gas pipe Loosen 4 mounting bolts (1) of gas pipe connected to the EGR cooler inlet and check for the outflow of coolant. Condensed water from cooled exhaust gas may come out in small quantity but it is no problem if colorless and transparent.
*2:Troubleshooting by failure code (Display of code), Code[CA559] , and Code [CA2249]
D375A-6 (01)
40-629
DRAFT Troubleshooting of engine (S-mode) S-2 Engine does not start
S-2 Engine does not start a) Engine does not crank
Defective starting switch
Defective starting motor (safety relay section) Defective starting motor (motor section) Defective wiring of starting circuit
Defective battery relay
Defective battery terminal connection
Defective or deteriorated battery
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Check recent repair history Degree of use of Operated for long period machine When starting Horn does not sound. switch is set to Horn volume is slow. ON position. Battery electrolyte is low. Cable is loosely connected to battery terminal. No operating sound from battery relay when starting switch is set to ON position. When starting switch is set to START position, pinion does not come out. When starting Speed of rotation is low. switch is set to Grating noise is heard. START position, Soon pinion again. the starting pinion comes out, Ratting noise is heard and engine does not turn. but Removing EGR cooler outlet gas pipe causes coolant containing antifreeze to flow out (*1). Inspect flywheel ring gear directly Specific gravity of electrolyte and voltage of battery are low. There is no voltage (B – E) between battery relay terminals 20 Set starting and 30V. switch to OFF When terminals B and C of starting switch are connected, engine position, connect starts. the cord, then set When safety relay outlet terminals B and C are connected, engine starting switch to starts. ON position to perform trouble- When safety relay outlet terminals B and C are connected, engine does not start. shooting
Replace
Troubleshooting
Check items
Questions
General causes that engine does not rotate q Seized inside engine See the troubleshooting for "S-4 Engine stops during operations". q Coolant leaking inside cylinder causes water hammer. q Electrical system is defective.
Demaged flywheel ring gear
Cracked EGR cooler (coolant mixing in the exhaust)
Cause
For *1, see the next page
40-630
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-2 Engine does not start
*1: EGR cooler inlet gas pipe Loosen 4 mount bolts (1) of gas pipe connected to the EGR cooler inlet and check for the outflow of coolant. Condensed water from cooled exhaust gas may come out in small quantity but it is no problem if colorless and transparent.
D375A-6 (01)
40-631
DRAFT Troubleshooting of engine (S-mode) S-2 Engine does not start
Cause Improper fuel used Insufficient fuel in tank Clogged breather hole in fuel tank cap Leakage or clogging of air in fuel piping, or air in fuel piping Clogged fuel filter element Clogged feed pump gauze filter Seizure or abnormally wear of feed pump Broken supply pump shaft or key Stuck or seized supply pump plunger Defective supply pump PCV Wrong connection of supply pump PCV Defective operation of overflow valve (does not close) Defective operation of flow damper Defective fuel injector
b) Engine rotates but no exhaust smoke comes out (Fuel is not injected)
Check recent repair history Degree of use of Operated for long period EEE machine Exhaust smoke suddenly stopped coming out (when starting again). wQ w w w Replacement of filters is not performed according to Operation & Maintew w E nance Manual. Fuel tank is found to be empty. w Clogged breather hole in fuel tank cap. Q w Rust and water are dectected when fuel tank is drained. Q QQ Q Q When fuel filter is removed, no fuel is inside the fuel filter. w w Leakage from fuel piping w and air bleeding plug is removed from fuel filter, fuel When engine is Q Q wQ does not flow out. rotated with startand spill hose is separated from injector, spill flow is Q w w w w ing motor, small. Air is discharged when bleeding air from the fuel system. Inspect the fuel filter directly. Inspect the fuel feed pump gauze filter directly. Inspect feed pump directly. Perform troubleshoot for "Rail Press Very Low Error" (*1) Perform troubleshoot for "PCV1 Error (*2) or PCV2 Error" (*3) Inspect overflow valve directly. Engine can start when operated in cylinder cut out mode. Remedy
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Troubleshooting
Check items
Questions
General causes that engine rotates but no exhaust smoke comes out q Fuel is not being supplied. q Supply of fuel is extremely small. q Improper selection of fuel (particularly in winter)
*1: Troubleshooting by failure code (Display of code), Code [CA559] and Code [CA2249] *2: Troubleshooting by failure code (Display of code), Code [CA271] and Code [CA272] *3: Troubleshooting by failure code (Display of code), Code [CA273] and Code [CA274]
40-632
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-2 Engine does not start
Cause Clogged air cleaner element Wear of valve system (valve, rocker lever, etc.) Worn piston ring or cylinder liner Improper fuel Clogged breather hole in fuel tank cap Leakage or clogging of fuel piping, or air in fuel piping Clogged fuel filter, strainer Clogged feed pump gauze filter Stuck or seized supply pump plunger Clogged injection nozzle or defective spray Defective or deteriorated battery Defective coolant temperature sensor or defective wiring harness Defective intake air heater system
c) Exhaust smoke comes out but engine does not start (Fuel is injected)
Check recent repair history Degree of machine Operated for long period E EE E operation Engine suddenly failed to start. w w Q Non-specified fuel is being used. Q Q Replacement of filters is not performed according to Operation & Maintew ww nance Manual Engine oil must be added more frequently. w Preheat monitor does not light up during preheating or at low temperature. w Dust indicator piston indicates red zone. w Clogged breather hole in fuel tank cap. w Rust and water are detected when fuel tank is drained. ww When fuel filter is removed, no fuel is inside the fuel filter. w Leakage from fuel piping w Starting motor rotates engine slowly. w When engine is rotated, abnormal sound is generated around cylinder head. w and air bleeding plug of the fuel filter is removed, fuel When engine is Q ww does not flow out. rotated with starting and spill hose is separated from injector, spill flow is w motor small. When exhaust manifolds are touched immediately after starting engine, w temperature of manifold for some cylinders is low. Inspect air cleaner directly. q Inspect valve system directly q When compression pressure is measured, pressure is low q Air is discharged when bleeding air from the fuel system. Inspect the fuel filter, strainer directly. Inspect the fuel feed pump gauze filter directly. Perform troubleshoot or "Rail Press Very Low Error" (*1). Testing a single unit injector indicates defective spraying. Specific gravity of electrolyte and voltage of battery are low. Coolant temperature gauge indication is not normal (if equipped the gauge). Intake air heater mounting portion does not warm up during preheating. Remedy
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Troubleshooting
Check items
Questions
General causes that exhaust smoke comes out but engine does not start q Starting motor lacks in rotating force due to defective electrical system. q Supply of fuel is small. q Small air intake q Improper selection of fuel
*1: Troubleshooting by failure code (Display of code) , Code [CA559], and Code [CA2249] D375A-6 (01)
40-633
DRAFT Troubleshooting of engine (S-mode) S-3 Engine does not rev up smoothly (response-up is poor)
S-3 Engine does not rev up smoothly (response-up is poor)
Confirm recent repair history Degree of use of machine Operated for long period Engine pick-up suddenly became poor Non-specified fuel is being used Replacement of filters has not been carried out according to OperaEngine oil must be added more frequently Dust indicator is red Clogged air breather hole in fuel tank cap Rust and water are observed when fuel tank is drained Leakage from fuel piping No response or heavy resistance felt when operating priming pump When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blue under light load Color of exhaust gas Black When engine is cranked, abnormal noise is heard from around cylinWhen engine is cranked, abnormal noise is heard from around turboHigh idle 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
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40-634
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Inspect air cleaner directly q Carry out troubleshooting for "EGR valve abnormality (*1)" or q "Bypass valve abnormality (*1)". When compression pressure is measured, the oil pressure is low. q q Inspect valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q Air is discharged when the air is bled from the fuel system Inspect the fuel filter, strainer directly Inspect the fuel feed pump gauze filter directly Carry out troubleshoot by "Rail Press Very Low Error (*2)" Speed of some cylinders does not change when operated in reduced Remedy
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Troubleshooting
Check items
Questions temperature
Clogged air cleaner element
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Clogged feed pump gauze filter Stuck or seized supply pump plunger Defective operation of flow damper (excessive injector leakage) Clogged injection nozzle, defective spray
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Seizure and interference of turbocharger Worn piston ring, cylinder liner Clogged air breather hole in fuel tank cap Leakage, clogging, air in fuel piping Clogged fuel filter, strainer
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Insufficient intake of air Insufficient supply of fuel Fuel injection condition not normal Improper selection of fuel Controller in derate control mode (Controlling injection capacity (output) due to an error in the electrical system) EGR valve is stuck in open state (Shortage of air intake due to excessive EGR gas)
Replace Replace Clean Correct Clean
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Cause
Defective EGR valve or bypass valve Defective contact of valve and valve seat Improper valve clearance
General causes why engine does not pick up smoothly
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-3 Engine does not rev up smoothly (response-up is poor)
*1: Troubleshooting by failure code (Display of code), Codes [CA1228] and [CA1625] or Codes [CA1628] and [CA1629] *2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
D375A-6 (01)
40-635
DRAFT Troubleshooting of engine (S-mode) S-4 Engine stops during operation
S-4 Engine stops during operation General causes why engine stops during operations
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Replace Replace Replace Add Clean Correct Clean Clean Replace Replace Replace
Replace
Inspect controller power supply wiring Check starting switch wiring Remedy
Carry out troubleshooting in H-mode
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Inspect valve system directly Check piston and connecting rod directly Check crankshaft bearing directly Inspect gear train directly Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly
Trouble power train
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Confirm recent repair history Degree of use Operated for long period of machine Abnormal noise was heard and engine stopped suddenly Condition when Engine overheated and stopped engine stopped Engine stopped slowly There was hunting and engine stopped Non-specified fuel is being used Replacement of filters not carried out according to Operation & Maintenance Manual Fuel level monitor indicates low fuel level Fuel tank is found to be empty Clogged air breather hole in fuel tank cap Leakage from fuel piping Rust and water are detected when fuel tank is drained Metal particles are found when oid pan is drained Does not turn at all When engine is Turns in opposite direction cranked manuMoves by the amount of gear backlash ally Supply pump shaft does not turn Engine rotates, but stops when load is applied to machine
Correct Correct
Troubleshooting
Check items
Questions
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Broken auxiliary equipment (pump, compressor, etc.) Defective engine controller power supply Defective starting switch
q
Seized parts inside engine Insufficient supply of fuel Overheating Trouble in power train
Broken, seized piston or connecting rod Broken, seized crankshaft metal Broken, seized gear train Insufficient fuel in tank Clogged air breather hole in fuel tank cap Leakage, clogging in fuel piping Clogged fuel filter, strainer Clogged feed pump gauze filter Broken, seized feed pump Broken supply pump shaft, key Stuck or seized supply pump plunger
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Breakage of valve system (valve, rocker lever, etc.)
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Cause
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
40-636
D375A-6 (01)
Troubleshooting of engine (S-mode) S-5 Engine does not rotate smoothly (hunting)
S-5 Engine does not rotate smoothly (hunting)
40-68
Low setting of low idle speed Malfunction of EGR valve Operated for long period Occurs at a certain speed range Occurs at low idle Condition of hunting Occurs even when speed is raised Occurs on slopes Replacement of filters not carried out according to Operation & Maintenance Manual Fuel tank is found to be empty Clogged air breather hole in fuel tank cap Rust and water are found when fuel tank is drained
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Leakage from fuel pipe Carry out troubleshoot by "EGR Valve Servo Error (*1)" Carry out troubleshoot by "Bypass Valve Servo Error (*2)" Air is discharged when the air is bled from the fuel system Inspect feed pump gauze filter directly Inspect fuel filter, strainer directly Speed of some cylinders does not change when operated in reduced cylinder mode Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*3)” Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*4)”
Remedy
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Troubleshooting
Check tems
Questions
Confirm recent repair history Degree of use of machine
Replace Replace Correct or replace Correct or replace
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Air in fuel system Defective speed sensor (Error at degree that it is not indicated) Defective EGR valve
Insufficient fuel in tank Clogged air breather hole in fuel tank cap Leakage, clogging, air in fuel piping Clogged feed pump gauze filter Clogged fuel filter, strainer
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Cause Defective operation of flow damper (excessive injector leakage) Clogged injector and/or defective spray (dirt in injector) Defective Ne speed sensor, defective wiring harness Defective Bkup speed sensor, defective wiring harness
General causes why engine does not rotate smoothly
*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625] *2: Troubleshooting by failure code (Display of code), Code [CA1628], and Code [CA1629] *3: Troubleshooting by failure code (Display of code), Code [CA689] *4: Troubleshooting by failure code (Display of code), Code [CA778]
D375A-6 (06)
40-637
DRAFT Troubleshooting of engine (S-mode) S-6 Engine lacks power (or output shortage)
S-6 Engine lacks power (or output shortage)
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Defective fuel temperature sensor and/or wiring harness
Defective charge pressure sensor or defective wiring harness
Defective mounting of charge pressure sensor (air leak)
Defective drive of injector (signal, solenoid)
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Clogged injector and/or defective spray (dirt in injector)
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Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter, strainer
Clogged, leaking fuel piping
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder liner
Improper valve clearance
Defective contact of valve, valve seat
Seized turbocharger, interference of turbocharger
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Inspect air cleaner directly Inspect air intake piping directly When charge (boost) pressure is measured, the oil pressure is low When compression pressure is measured, it is found to be low Inspect valve clearance directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to “No-pressure feed by supply When a cylinder is cut out for reduced cylinder mode operation, engine Check the mount of charge (boost) pressure sensor directly Carry out troubleshoot by "Chg Air Press Sensor Error (*2)" Carry out troubleshooting according to “Abnormality in fuel tempera-
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Confirm recent repair history Degree of use 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 Oil must be added more frequently Dust indicator is red Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Black Color of exhaust gas Blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is generated around turboWhen engine is cranked, abnormal sound is generated around cylinder High idle speed is too low High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive
Adjust
Troubleshooting
Check items
Questions
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Clogged air cleaner element
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Insufficient intake of air Insufficient supply of fuel Defective condition of fuel injection Improper selection of fuel There is overheating o See the troubleshooting for "S-14 Coolant Temperature too High (Overheat)" Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Clean
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Cause
Air leakage from air intake piping
General causes why engine lacks output
For *1, *2 and *3, see the next page
40-638
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-6 Engine lacks power (or output shortage)
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249] *2: Troubleshooting by failure code (Display of code), Code [CA122], and Code [CA123] *3: Troubleshooting by failure code (Display of code), Code [CA263], and Code [CA265]
D375A-6 (01)
40-639
Troubleshooting of engine (S-mode) S-7 Exhaust smoke is black (Incomplete combustion)
S-7 Exhaust smoke is black (Incomplete combustion)
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Troubleshooting
Check items
Questions
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Confirm recent repair history Degree of use Operated for long period Suddenly became black Color of exhaust gas Gradually became black Blue under light load Non-specified fuel is being used Oil must be added more frequently Suddenly Power was lost Gradually Dust indicator is red Muffler is crushed Leakage of air between turbocharger and cylinder head, loose clamp Operates in low-temperature mode even at normal temperaWhen exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is generated When engine is cranked, abnormal sound is generated Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly , and combustion is irreguBlow-by gas is excessive When hose from injector to spill collection portion is disconnected, spill flow is found to be abnormally high
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Inspect air cleaner directly q When turbocharger is rotated by hand, it is found to be heavy q Carry out troubleshooting for "EGR valve abnormality (*1)" or q "Bypass valve abnormality (*1)" When compression pressure is measured, it is found to be q Inspect valve clearance directly q When muffler is removed, exhaust color returns to normal Carry out troubleshoot by "Rail Press Very Low Error (*2)" Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to “Abnormality in coolRemedy
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Insufficient intake of air Excessive injection of fuel Defective condition of fuel injection Improper selection of fuel There is overheating o See the troubleshooting for "S-14 Coolant Temperature too High (Overheat)" Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system) EGR valve is stuck in open state (There is much EGR gas and intake of air is insufficient.) EGR gas pressure piping is clogged (Exhaust gas is mixed in intake air during acceleration and deceleration)
Repair
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Clean Replace Replace Replace Adjust
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Cause Clogged air cleaner element Seized turbocharger, interference of turbocharger Defective EGR valve Defective contact of valve, valve seat Improper valve clearance Leakage of air between turbocharger and cylinder head Crushed, clogged muffler Worn piston ring, cylinder liner Stuck, seized supply pump plunger Clogged, seized injector Worn fuel injector Clogged fuel spill piping (on cylinder head side) Improper fuel injection timing Defective fuel injection pressure Defective coolant temperature sensor or defective wiring harness
General causes why exhaust smoke is black
40-690
For *1, *2 and *3, see the next page 40-640
D375A-6 (06)
Troubleshooting of engine (S-mode) S-7 Exhaust smoke is black (Incomplete combustion)
*1: Troubleshooting by failure code (Display of code), Codes [CA1228] and [CA1625] *2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249] *3: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]
D375A-6 (06)
40-641
Troubleshooting of engine (S-mode) S-8 Oil is consumption is excessive(or exhaust smoke is blue)
S-8 Oil is consumption is excessive(or exhaust smoke is blue) General causes why oil consumption is excessive
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Troubleshooting
Check items
Questions
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Abnormal oil combustion Extended operation for long hours in low or high idle (continuous no load operation for 20 minutes and longer inhibited) Oil leakage to outside Wear of lubricating system
Dust sucked in from intake system Wear and damage of valve (stem,guide and seal) Worn seal at turbine end Turbocharger Worn seal at blower end Oil leakage from EGR valve system Clogged breather or breather hose Broken piston ring Wear of piston ring and cylinder liner Worn, damaged rear seal surface Broken oil cooler Leakage from oil cooler Leakage from oil filter Leakage from oil piping Leakage from oil drain plug Leakage from oil pan, cylinder head, etc.
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Cause
Confirm recent repair history Degree of use of machine Operated for long period E EE E E Oil consumption suddenly increased w Q Engine oil must be added more frequently Q w Q Engine oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w Pipe clamps for intake system are loose w Inside of turbocharger air intake outlet pipe is contaminated with oil w Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w There is oil in coolant w Oil level in damper chambers on applicable machine side increasw ing. Color of exhaust gas blue under light load Q w w Excessive Q QQ w w Amount of blow-by gas None w When intake manifold is removed, dust is found inside q When intake manifold is removed, inside is contaminated abnorq mally Excessive play of turbocharger shaft qq When EGR valve is removed, exhaust port is contaminated with oil q Check breather and breather hose directly q When compression pressure is measured, the oil pressure is low q q Inspect rear oil seal directly q Pressure-tightness test of oil cooler shows there is leakage q q There is external leakage of oil from engine q q q q Remedy
40-642
Correct Correct Replace Replace Replace Clean Replace Replace Replace Replace Replace Correct Correct Correct Correct
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40-692
D375A-6 (06)
DRAFT Troubleshooting of engine (S-mode) S-9 Engine oil becomes contaminated quickly
S-9 Engine oil becomes contaminated quickly
Confirm recent repair history Degree of use Operated for long period EEEE Non-specified fuel is being used Q Oil must be added more frequently Q w Even when engine oil temperature rises, oil filter clogging monitor indicates clogw Q ging Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is dirty with oil w Engine oil temperature rises quickly w Blue under light load w Color of exhaust gas Black Excessive Q Q w Amount of blow-by gas None w
D375A-6 (01)
(See S-7)
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Remedy
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Replace
Excessive play of turbocharger shaft When EGR valve is removed, exhaust port is found to be smeared with oil. When compression pressure is measured, it is found to be low Check breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
Clogged oil filter
Clogged oil cooler
Clogged breather, breather hose
Worn piston ring, cylinder liner
Worn valve, valve guide
Worn EGR valve guide
Defective seal at turbocharger turbine end
Cause
Replace
Troubleshooting
Check items
Questions
General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load
40-643
DRAFT Troubleshooting of engine (S-mode) S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive General causes why fuel consumption is excessive
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Defective coolant temperature sensor or defective wiring harness
Defective injector operation
Defective common rail fuel pressure
Defective supply pump plunger
Defective feed pump oil seal
Defective injector spray
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Remedy
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Remove head cover and inspect directly Inspect feed pump oil seal directly Carry out troubleshoot by "Rail Press Very Low Error (*1)" Speed of some cylinders does not change when operated in reduced cylinder mode Spill flow is excessive when spill hose is separated from injector Carry out troubleshoot by "Coolant Temp Sensor Error (*2)"
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Correct
Fuel leakage to outside There is irregular combustion Oil increasing, smelling of diesel oil When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high Torque converter stall or hydraulic pump relief speed is high Black Color of exhaust gas White
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Condition of fuel consumption
Operated for long period More than for other machines of same model Gradually increased Suddenly increased
Replace
Confirm recent repair history Degree of use of machine
Correct
Troubleshooting
Check items
Questions
Leakage of fuel inside head cover
q
Leakage of fuel Fuel injection condition (fuel pressure and injection timing) not normal Excessive fuel injection
Fuel leakage from fuel filter, piping, etc
q
Correct
q
Cause
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249] *2: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]
40-644
D375A-6 (01)
Troubleshooting of engine (S-mode) S-11 Oil mixes into coolant(coolant blows back or is reduced)
S-11 Oil mixes into coolant(coolant blows back or is reduced)
40-695
Broken hydraulic oil cooler, power train oil cooler
Broken oil cooler core/O-ring
Insufficient protrusion of cylinder liner
Cracks inside cylinder block
Broken cylinder head or cylinder head gasket
Clogged, broken oil cooler
Cause
General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system q Internal leakage in hydraulic oil cooler or power train oil cooler
Degree of use
E
Operated for long period
Q Q Q Q
Gradually occurred
Q
Q
Q Q
w
Hard water is being used as coolant
w
There are excessive air bubbles in radiator, coolant spurts back
w w
When hydraulic oil or power train oil is drained, water is found
w
q q
Inspect cylinder block directly
q q
Check cylinder liner directly
D375A-6 (06)
Replace
Replace
Remedy
Replace
q
Pressure-tightness test of oil cooler shows there is leakage
-
q
Pressure-tightness test of cylinder head shows there is leakage
Perform troubleshooting for H-mode
Hydraulic oil or power train oil on applicable machine side is milky
Replace
Check items
Oil level has risen and oil is milky
Troubleshooting
E
Q
Sudden overheated Oil level
Replace
Questions
Confirm recent repair history
40-645
DRAFT Troubleshooting of engine (S-mode) S-12 Engine pressure monitor lights up (drop in engine oil pressure)
S-12 Engine pressure monitor lights up (drop in engine oil pressure)
q
Troubleshooting
Check items
Questions
q
Leakage, clogging or wear of lubricating system Defective hydralic control Wrong oil selection (viscosity not appropriate) Oil deteriorated by overheating
Check recent repair history Degree of use of machine Operated for long period Engine oil pressure monitor lights up. Non-specified oil is used. Replacement of filters is not perform according to Operation & Maintenance. Manual Lights up with engine at low dile. Lights up with engine at low and idle. Engine oil pressure monitor Lights up with machine on a slope. Lights up occasionally. Oil level monitor indicates low amount of oil (when monitor is installed) Oil level in oil pan is low Leakage or crushing of external hydraulic pipe. Oil is cloudy white or smells of diesel oil. Metal particles are found when oil is drained from oil pan.
E
E
Q w
E
Q w w w Q
Q w
w w
Metal particles are found in oil filter. Inspect oil pan strainer and pipe directly. Oil pump rotation is heavy or it has play. Oil pump relief valve or spring is failed or damaged. Inspect oil filter directly. Relief valve of EGR oil pump is damaged or has oil leak. Inspect EGR hydraulic piping visually. Perform troubleshooting for "Eng Oil Press. Sensor Error"(*1)
q
Q Q Q
w
w w
Metal particles are found when oil is drained from oil filter.
Remedy
E Q w Q w
Q w
w Q q q See S - 13
q
q
w
Q
q
q
q
q
q
Replace Add Clean Clean Replace Adjust Replace Repair Replace Replace Replace
q
Cause Wear of metal journal Lack of oil in oil pan Water or fuel in oil Clogged strainer inside oil pan Clogged or brakage of pipe inside oil pan Defective oil pump Defective oil pump relief valve Clogged oil filter Leaking, crushed or clogging of hydraulic pipe Defective EGR oil pump Leakage from EGR oil pressure piping Defective oil pressure sensor and/or defective wiring harness
General causes that oil pressure drops
*1: Troubleshooting by failure code, Codes [CA135] and [CA141]
40-646
D375A-6 (01)
Troubleshooting of engine (S-mode) S-13 Oil level rises (Coolant or fuel mixes into oil)
S-13 Oil level rises (Coolant or fuel mixes into oil)
40-698
General causes that oil level rises
Q Q Q Q
E E
w w
Q Q
E w
w
Defective seals for auxiliarise (pump or compressor)
E
w
Q
w
Defect inside supply pump
Clogged water pump drain hole (breather hole) or defective seal
Internal cracks in cylinder block
Leakage of fuel inside head cover
Broken cylinder head or head gasket
Cracked EGR cooler (Entry of coolant)
Q Q Q
Q Q
w w
w
w
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
Replace
Removing EGR cooler inlet gas piping causes coolant containing antifreeze to q flow out (*1) When compression pressure is measured, pressure is low. q Remove head cover and check directly. q Inspect cylinder block and liner directly. q q Inspect rear oil seal directly. q Pressure test of cylinder head shows it leaks. q Remove water pump and inspect directly. q Remove supply pump and inspect directly. q Inspect seals for auxiliaries directly. q Replace
Questions Check items Troubleshooting
Check recent repair history. Degree of use of machine Operated for long period Fuel consumption is increased. Coolant must be added more frequently. Oil in coolant. Engine oil smells of diesel fuel. Oil become clouded. After starting engine, drops of water come out of muffler. When engine is run at idle with radistor cap open a large number of air bubbles appear or coolant blows back. Exhaust smoke is white. Clogged water pump drain hole (weep hole). Coolant comes out when water pump drain hole (weep hole) is cleaned. Oil level in clutch or damper chambers of machine lower Oil level in hydraulic tank of machine decreases.
Broken oil cooler core or O-ring
Coolant mixing into oil (oil becomes clouded) Fuel mixing into oil (smells diluted diesel fuel) a If oil mixes into the coolant, perform troubleshooting for "S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)" q
Worn or damaged rear seal surface
q
Damagee O-ring for cylinder liner or pitted cylinder liner due to pitting corrosion.
Cause
For *1, see the next page.
D375A-6 (06)
40-647
DRAFT Troubleshooting of engine (S-mode) S-13 Oil level rises (Coolant or fuel mixes into oil)
*1: EGR cooler inlet gas pipe Loosen 4 mounting bolts (1) of gas pipe connected to the EGR cooler inlet and check for the outflow of coolant. Condensed water from cooled exhaust gas may come out in small quantity but it is no problem if colorless and transparent.
40-648
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-14 Coolant temperature rises too high (overheating)
S-14 Coolant temperature rises too high (overheating) General causes that coolant temperature becomes too high
q
Troubleshooting
Check items
Questions
q
Check recent repair history Degree of use of machine Condition of overheating
Operated for long period Engine overheat suddenly Engine tends to overheat. Coolant temperature rises quickly. Coolant temperature gauge Coolant temperature does not go down below red range Radiator coolant level monitor indicates low level Engine oil level has risen, oil is cloudy white Cloudy white oil is floating on coolant Coolant in radiator has excessive air bubbles and blows backs. When light bulb is held behind radiator, no light passes. Radiator shroud and inside of under cover are clogged with dirt or mud. Coolant leaks from cracks in the radiator hose or clamps are loosened. Coolant flows out from radiator overflow hose. Power train oil temperature gauge enters red range faster than engine coolant temperature gauge Inspect EGR cooler directly for coolant leakage. When compression pressure is measured, pressure is low. Inspect cylinder liner directly. Inspect oil cooler directly. Temperature difference between top and bottom radiator tanks is excessive. When function test is preformed on thermostat, it does not open even at cracking temperature. Temperature difference between top and bottom radiator tanks is slight. Inspect radiator core directly. When function test is preformed on the radiator cap, cracking pressure is low. Inspect fan pulley directly. When coolant temperature is measured, it is found to be normal. Measured fan speed is low. Remedy
D375A-6 (01)
EEE Q
Qw Q
EE
Q Q
Qww w
w Q w
wQ w
w
w w
w
w w w
q
q
q
q
q q q
q q q
q q
Carry out troubleshooting in Carry out troubleshooting in
q
Lack of cooling air (deformed or damaged fan) Drop in heat dissipation efficiency Defective coolant circulation system Rise of power train oil temperature Defective fan drive pump or fan motor
Water leakage from EGR cooler Broken cylinder head, head gasket Hole drilled by damages or pitching of cylinder liner O-ring Clogged or broken oil cooler Lack of coolant Broken water pump Defective operation of thermostat Clogged or crushed radiator fins Clogged radiator core Defective radiator cap (pressure valve) Wear of fan pulley Defective coolant temperature gauge Rise of power train oil temperature Defective fan drive pump or fan motor
q
Replace Replace Replace Replace Add Replace Replace Correct Correct Replace Correct Replace -
q
Cause
40-649
DRAFT Troubleshooting of engine (S-mode) S-15 Abnormal noise is heard
S-15 Abnormal noise is heard General causes that abnormal noise is heard q
Noise from defective parts Abnormal combustion q Air sucked in from intake system a Detemine whether the noise from inside or outside before proceeding with troubleshooting. a When engine is not fully warmed up, engine noise rises slightly because it runs in the low temperature mode. This is not abnormal, however. a When the engine is accelerated, it runs in the acceleration mode, where engine noise remains slightly higher for about 5 seconds maximum, This is not abnormal, however.
Check recent repair history Degree of use of machine Abnormal noise
Operated for long period Gradually occurred. Sudden overheated.
E QQ
QQQ
Q
Q
Non-specified fuel is used Engien oil must be added more frequently. w Metal particles are found when oil is drained from oil filter. Q w w Leakage of air between turbocharger and cylinder head w When engine is rotated, abnormal noise is heard from around turbocharger. w When engine is rotated, abnormal noise comes out around EGR gas piping. w When engine is rotated, abnormal noise is heard from around cylinder head. w w When engine is rotated, abnormal noise is heard from around muffler. w When exhaust manifolds are touched immediately after starting engine, temperature of manifold for some cylinders is low. Blue during light load operation w Color of exhaust smoke Black. Qw Q Engine rev-up is poor and combustion is abnormal. Abnormal noise is loud when engine is accelerated. Q Q Q Blowby gas is excessive w When turbocharger is rotated by hand, it is found to be heavy. Inspect EGR gas piping directly. Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears. Inspect valve clearance directly. When compression pressure is measured, pressure is low. Inspect gear train directly. Inspect fan directly. Engine speed does not change when running engine with some cylinder cut out. Abnormal noise is heard only when engine is started. Use real-time monitoring mode to check. Remedy
40-650
q
q
q
q
q
q
qq
Q
wQ
w Q
q qq q
q
Replace Replace Replace Repair Replace Adjust Replace Replace Replace Repair Replace Replace Replace
Troubleshooting
Check items
Questions
q
Air leakage from piping between turbocharger and cylinder head Brakage of turbocharger Crack of or gas leakage from EGR gas piping Seizave or interfevance of valve system (valve, rocker lever, etc.) Defec inside muffler (dividing board out of position) Improper valve clearance Excessive wear of piston ring or cylinder liner Improper gear train backlash Missing or seizure of gear train bushing Deformed fan Clogged or seized injector Dirt caught in injector Defective fuel injection timing (defective coolant temperature sensor)
Cause
D375A-6 (01)
Troubleshooting of engine (S-mode) S-16 Vibration is excessive
S-16 Vibration is excessive
40-702
General causes that vibration is excessive
q
Remedy
D375A-6 (06)
q
Broken parts in damper
Wear of front support spigot joint
Misalignment of engine and torque convertor
Loose engine mounting bolts or broken cushions
Worn camshaft bushing
Improper gear train backlash
q
q
q
q
q
q Replace
Inspect valve system directly. Inspect main bearing and connecting rod metal directly. Inspect gear train directly. Inspect camshaft bushing directly. Inspect engine mounting bolts and cushions directly. When face runout and radial runout are inspected, they are found to be incorrect. Inspect front support portion directly. Inspect inside of damper directly.
Q Q Q Q Q w w Q Q Q Q Q Q Q Q
Adjust
w
E
Replace
Exhaust smoke is black.
Q Q w w Q
EE
Replace
Non-specified fuel is being used Metal particles are found when oil is drained from oil filter. Metal particles are found when oil is drained from oil pan. Oil pressure is when running engine low at low idle. Vibration occurs when running engine at mid-range speed. Vibration follows engine speed.
E
Replace
Q
Replace
Vibration
Operated for long period Suddenly increased. Gradually increased.
Replace
Questions Check items Troubleshooting
Check recent repair history Degree of use
Worn main bearing or connecting rod bearing
Defective parts (abnormal wear, breakage,etc) Misalignment of engine and chassis q Abnormal combustion a If there is abnormal noise together with the vibration, perform troubleshooting also for “S-15 Abnormal noise is heard”. q
Replace
q
Stuck valve system (valve, rocker lever, etc.)
Cause
40-651
DRAFT Troubleshooting of engine (S-mode) S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls) General causes why that cannot be bled
Check recent repair history Degree of use of macine Operated for long period
EE
Non-specified fuel is being used
Q Q
Clogged water separator screen Clogged fuel filter Low battery charge level
Fuel tank is empty w Fuel tank breather cap is clogged w Fuel leaks from fuel piping w Switch lamp does not blink w w Q Lamp blinks but pump operation sound is not When electric priming w w heard. pump switch is operated Pump operation sound is heard but fuel does Q Q Q Q w w w Q Q not flow out of hose return soon. Air bleeding valve is closed Fuel valve (supply side) is closed Fuel valve (return side) is closed Water drain valve and air intake plug of water separator are loosened Water drain valve of fuel pre-filter is loosened There is flaw or dirt on sealing face of fuel pre-filter or main filter Check air bleeding pipe and orifice directly (see Note 1) Check fuel piping (supply side and return side) directly (for clogging and breakage) Check electric priming pump directly Check electric priming system directly (see E-28 in E-mode) Check water separator screen directly Check fuel filter for clogging (see failure code CA559, Note 2) Remedy
40-652
q
q q
q q q
q
q q
q q
q
q
Clean Replace Charge
Troubleshooting
Check items
Questions
q
Leaking or clogging of fuel piping or air in it Clogged air bleeding pipe Malfunction of electric priming pump Malfunction of electric priming pump switch Defective wiring harness of electric priming pump
q
Correct Correct Replace Replace Replace
q
Electric priming pump does not operate. Fuel is not supplied or is supplied very little. Fuel valve or air bleeding valve is not set properly. Air bleeding piping is clogged. Fuel return piping is clogged.
Lack of fuel Improper setting of air bleeding valve (closed) Improper setting of fuel valve (closed) Clogged fuel tank breather hole
q
Add Correct Correct Correct
q
Cause
D375A-6 (01)
DRAFT Troubleshooting of engine (S-mode) S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then
Note 1: Check of air bleeding pipe for clogging q Remove joint bolt (1) and blow clean compressed air into hole a of the orifice to check for clogging. q Remove air bleeding pipes (2) and (3) and blow compressed air against its both ends to check for clogging.
D375A-6 (03)
40-653
DRAFT Troubleshooting of engine (S-mode) S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then
40-654
D375A-6 (01)
DRAFT
D375A-6 SEN001879-00
Bulldozer D375A-6 Shop Manual
Machine model
Serial number
D375A-6
60001 and up
50 Disassembly and assembly
D375A-6 (02)
50-1
DRAFT Contents
Contents 50 Disassembly and assembly General information on disassembly and assembly ..................................................................... How to read this manual ............................................................................................................ Coating materials list.................................................................................................................. Special tools list ......................................................................................................................... Sketches of special tools ........................................................................................................... Engine and cooling system ........................................................................................................... Removal and installation of fuel supply pump assembly ........................................................... Removal and installation of fuel injector assembly .................................................................... Removal and installation of cylinder head assembly ................................................................. Removal and installation of radiator guard assembly ................................................................ Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler). Removal and installation of radiator........................................................................................... Removal and installation of hydraulic oil cooler ......................................................................... Removal and installation of aftercooler...................................................................................... Removal and installation of engine assembly............................................................................ Removal and installation of engine hood assembly................................................................... Removal and installation of engine front seal ............................................................................ Removal and installation of engine rear seal ............................................................................. Removal and installation of fan drive assembly......................................................................... Removal and installation of fan motor assembly ....................................................................... Removal and installation of fuel tank assembly ......................................................................... Power train.................................................................................................................................... Removal and installation of damper assembly .......................................................................... Disassembly and assembly of damper assembly ...................................................................... Removal and installation of power train unit assembly .............................................................. Disconnection and connection of power train unit assembly ..................................................... Disassembly and assembly of PTO assembly........................................................................... Disassembly and assembly of torque converter assembly ........................................................ Disassembly and assembly of TORQFLOW transmission assembly ........................................ Disassembly and assembly of steering case assembly............................................................. Removal and installation of power train pump and lubrication pump assembly ........................ Removal and installation of scavenging pump assembly .......................................................... Removal and installation of final drive assembly ....................................................................... Disassembly and assembly of final drive assembly................................................................... Undercarriage and frame .............................................................................................................. Removal and installation of track frame assembly..................................................................... Removal and installation of idler assembly................................................................................ Disassembly and assembly of idler assembly ........................................................................... Removal and installation of recoil spring assembly ................................................................... Disassembly and assembly of recoil spring assembly............................................................... Removal and installation of track roller assembly...................................................................... Disassembly and assembly of track roller assembly ................................................................. Removal and installation of carrier roller assembly ................................................................... Disassembly and assembly of carrier roller assembly ............................................................... Removal and installation of bogie assembly.............................................................................. Disassembly and assembly of bogie assembly ......................................................................... Removal and installation of first bogie assembly ....................................................................... Separation and connection of track shoe assembly .................................................................. Overall disassembly and assembly of track shoe ...................................................................... Link press press-fitting jig dimensions ....................................................................................... Disassembly and assembly of one link assembly in the field .................................................... 50-2
50 - 4 50 - 4 50 - 6 50 - 9 50 - 16 50 - 24 50 - 24 50 - 28 50 - 33 50 - 49 50 - 54 50 - 59 50 - 61 50 - 62 50 - 63 50 - 70 50 - 73 50 - 75 50 - 79 50 - 81 50 - 83 50 - 86 50 - 86 50 - 90 50 - 93 50 - 100 50 - 109 50 - 115 50 - 125 50 - 153 50 - 169 50 - 170 50 - 171 50 - 173 50 - 186 50 - 186 50 - 191 50 - 192 50 - 196 50 - 201 50 - 203 50 - 206 50 - 209 50 - 210 50 - 214 50 - 219 50 - 221 50 - 226 50 - 230 50 - 247 50 - 248 D375A-6 (02)
Contents
Disassembly and assembly of master link................................................................................. 50 - 253 Removal and installation of pivot shaft assembly ...................................................................... 50 - 257 Removal and installation of equalizer bar.................................................................................. 50 - 258 Disassembly and assembly of equalizer bar bushing................................................................ 50 - 262 Removal and installation of segment tooth................................................................................ 50 - 264 Hydraulic system .......................................................................................................................... 50 - 266 Removal and installation of hydraulic tank assembly ................................................................ 50 - 266 Removal and installation of work equipment pump assembly ................................................... 50 - 269 Removal and installation of fan pump assembly ....................................................................... 50 - 273 Removal and installation of control valve assembly .................................................................. 50 - 275 Disassembly and assembly of control valve assembly.............................................................. 50 - 277 Disassembly and assembly of blade PPC valve assembly ....................................................... 50 - 282 Disassembly and assembly of ripper PPC valve assembly ....................................................... 50 - 285 Disassembly and assembly of hydraulic cylinder assembly ...................................................... 50 - 287 Disassembly and assembly of ripper pin puller cylinder assembly ............................................ 50 - 295 Work equipment............................................................................................................................ 50 - 298 Removal and installation of blade assembly.............................................................................. 50 - 298 Disassembly and assembly of blade assembly ......................................................................... 50 - 300 Disassembly and assembly of giant ripper assembly ................................................................ 50 - 304 Cab and its attachments ............................................................................................................... 50 - 308 Removal and installation of ROPS guard .................................................................................. 50 - 308 Removal and installation of operator’s cab assembly................................................................ 50 - 309 Removal and installation of floor frame assembly ..................................................................... 50 - 313 Removal and installation of air conditioner unit assembly ......................................................... 50 - 318 Removal and installation of operator's seat isolator .................................................................... 50-323-1 Disassembly and assembly of operator's seat isolator................................................................ 50-323-2 Electrical system ........................................................................................................................... 50 - 324 Removal and installation of transmission controller assembly and steering controller assembly50 - 324 Removal and installation of engine controller assembly............................................................ 50 - 325 Removal and installation of VHMS controller assembly ............................................................ 50 - 327 Removal and installation of machine monitor assembly............................................................ 50 - 328
D375A-6 (07) (02)
50-3
DRAFT General information on disassembly and assembly How to read this manual
General information on disassembly and assembly How to read this manual (Rev. 2009.01) 1. Removal and installation of assemblies Special tools q Special tools which are necessary for removal or installation of parts are described as A1, ... X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N : Tools newly developed for this model. They have a new part number respectively. R : Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank: Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installion is shown with the mark ([*1], [*2]...which corresponds to the mark in “Removal” section). q Common tools that are necessary for installation are described as [1], [2]•••etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. k : Precautions related to work safety. a : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5 : Amount of oil or coolant to be replenished. Sketch of special tool Various special tools are illustrated for the local manufacture.
q
Removal In “Removal” section, the work procedures, precautions and know-how to do the work and the amount of oil and coolant to be drained are discribed. q Common tools that are necessary for removal are described as [1], [2]•••etc. and their part numbers, part names and quantities are not described. q Various symbols used in the “Removal” section are explained and listed below. k : Precautions related to work safety. a : Guidance or precautions for the work [*1]: This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component q
50-4
D375A-6 (02)
DRAFT General information on disassembly and assembly How to read this manual
2. Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new existing special tools N : Tools newly developed for this model. They have a new part number respectively. R : Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank:Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and amount of the oil and coolant to be replenished are described. q Common tools that are necessary for the disassembly work are indicated as [1],[2]•••etc. and their part numbers, part names, and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k : Precautions related to work safety a : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque 5 : Amount of oil or coolant to be replenished Sketch of special tool Various special tools are illustrated for the local manufacture.
q
Disassembly In “Disassembly” section, the work procedures, precautions and know-how to do the work, and amount of the oil and coolant drained are described. q Common tools that are necessary for the disassembly work are indicated as [1], [2]•••etc. and their part numbers, part names, and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k : Precautions related to work safety a : Guidance or precautions for the work 6 : Amount of oil or coolant drained. q
D375A-6 (02)
50-5
DRAFT General information on disassembly and assembly Coating materials list
Coating materials list (Rev. 2009. 08) a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Category
Komatsu code
Part No.
Capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
790-129-9040
50 g
LT-3
790-129-9060 (Set of adhesive and hardener)
LT-4 Holtz MH 705 ThreeBond 1735
Main features and applications q
Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
q
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
Polyethylene container
q q
Features: Resistance to heat and chemicals. Use to fix and seal bolts and plugs.
Adhesive: 1 kg Hardener: 500 g
Can
q
Use to bond and seal metal, glass and plastics.
790-129-9040
250 g
Polyethylene container
q
Use to seal plugs for blank holes
790-129-9120
75 g
Tube
q
Heat-resistant seal used to repair engines.
q
50 g
Polyethylene container
2g
Polyethylene container
Instanetaneous adhesive. Curing time: From 5 sec. to 3 min. Use mainly to bond metals, rubbers, plastics, and woods. Instanetaneous adhesive. Quick-curing type (max. strength is obtained after 30 minutes) Use mainly to bond rubbers, plastics, and metals. Features: Resistance to heat and chemicals. Use for fitted portions subjected to high temperature. Use to seal various threaded portions, pipejoints, and flanges. Use to seal taper plugs, elbows, and nipples for hydraulic piping. Features: Silicon-based heat and cold-resistant sealant. Use to seal flange surfaces and threaded portions. Use to seal oil pan, final drive case, etc. Features: Silicon-based quick-curing sealant. Use to seal flywheel housing, intake manifold, thermostat old, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Use to seal transfer case, etc. Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. Can be coated with paint.
790-129-9140
q q q
Aron-alpha 201
790-129-9130
q q
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
1 kg
Polyethylene container
q q q
LG-5
790-129-9080
q q
Liquid gasket
LG-6
200 g
Tube
q q q
LG-7
790-129-9170
1 kg
Tube
LG-8 ThreeBond 1207B
419-15-18131
100 g
Tube
LG-9 ThreeBond 1206D
50-6
790-129-9160
q q q q
790-129-9310
200 g
Tube q
D375A-6 (02)
DRAFT General information on disassembly and assembly Coating materials list
Seizure Molybdenum disulfide prevention compound lubricant
Liquid gasket
Category
Komatsu code LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 LM-P
Capacity
Container
790-129-9320
200 g
Tube
Main features and applications q q q
200 g
Tube
q
790-129-9090
100 g
Tube
q
Liquid gasket used to repair engine.
q
Use to prevent galling and seizure of press-fitted portions, shrinkage-fitted portions, and threaded portions. Use to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from galling. Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.
09940-00040
200 g
Tube q q
―
09995-00250
190 g
Can q
q
LC-G NEVER-SE EZ
―
―
Can
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG0-400LI-A (*) SYG0-160CNLI (*)
Various
Various
Molybdenum disulfide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
400 g × 10 400 g × 20 16 kg
Hyper White G2-T, G0-T (*) *: For cold district
SYG2-400T-A SYG0-400T-A (*) SYG2-16CNT SYG0-16CNT (*)
400 g 16 kg
Biogrease G2-B G2-BT (*) *: For use at high temperature and under high load
SYG2-400B SYG2-400BT (*) SYGA-16CNB SYGA-16CNBT (*)
400 g 16 kg
G2-S ThreeBond 1855
―
200 g
q
Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.
q
Use for parts under heavy load. Caution: q Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. q Use this grease for work equipment pins only when installing them, but do not use it afterward.
q
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type container Can
Bellows-type container Can
Bellows-type container Can
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc. Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
q
q
q
Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.
q
Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. Use for oil seals of the transmission, etc.
Tube q
D375A-6 (02)
Use as lubricant/sealant when installing the radiator hoses to the water tubes. Can be coated with paint. Feature: Can be used together with solid gaskets. Use for covers of the transmission case and steering case etc.
790-129-9330
q
G2-LI G0-LI (*) *: For cold district
Grease
Part No.
50-7
DRAFT General information on disassembly and assembly Coating materials list
Category
Komatsu code
Part No.
Capacity
Container
Main features and applications
SUNSTAR PAINT PRIMER580 417-926-3910 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT 22M-54-27230 PRIMER 435-95
Caulking material
Adhesive
SUNSTAR GLASS PRIMER 435-41
50-8
22M-54-27240
SUNSTAR SASH 22M-54-27250 PRIMER GP-402 SUNSTAR PENGUINE SEAL580 417-926-3910 SUPER “ S" or “ W" Sika Japan, Sikaflex 20Y-54-39850 256HV SUNSTAR PENGUINE 22M-54-27210 SUPER 560 SUNSTAR PENGUINE 417-926-3920 SEAL No. 2505 SEKISUI SILICONE 20Y-54-55130 SEALANT GE TOSHIBA SILICONES 22M-54-27220 TOSSEAL3 81
2 kg
Can q
20 ml
Glass container
20 ml
Glass container
20 ml
Glass container
150 ml
Can
20 ml
Glass container
For adhered window glass
G2-U-S 427-12-11871 ENS grease
Feature: Urea (organic system) grease with heat resistance and long life, can be packed into the confined space and left intact until next overhaul. Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease. q
Use as primer for painted cab sheet metal surface. (Effective period: four months after date of manufacture)
q
Use as primer for glass. (Effective period: four months after date of manufacture)
q
Use as primer for painted cab sheet metal surface. (Effective period: four months after date of manufacture) Use as primer for black ceramic-coated glass surface and for hard polycarbonate-coated surface. (Effective period: four months after date of manufacture) Use as primer for sash (anodized aluminum surface). (Effective period: four months after date of manufacture) Use “S" in high-temperature season and “W" in low-temperature season as adhesive for glass. (Effective period: four months after date of manufacture) Use as adhesive for glass. (Effective period: six months after date of manufacture) Use as adhesive for glass. (Effective period: six months after date of manufacture)
q
q
q
320 ml
Polyethylene container
310 ml
Polyethylene container
320 ml
Ecocart (Special container)
320 ml
Polyethylene container
333 ml
Polyethylene container
333 ml
Cartridge
q
For adhered window glass
Primer
Grease
q
q
q
Use to seal glass-to-glass joints. (Effective period: four months after date of manufacture)
q
Use to seal front window. (Effective period: six months after date of manufacture)
q
Use to seal glass-to-glass joint. Translucent white seal. (Effective period: 12 months after date of manufacture)
D375A-6 (02)
DRAFT General information on disassembly and assembly Special tools list
Special tools list
Device
Symbol
Part No.
Part name
2
795-799-5410 Adapter 795-799-5420 Remover 795T-675-1110 Socket
3
795-931-1100
1
Seal puller assembly
Engine assembly
A
5
6 7 Torque converter valve assembly
C
1 2 TORQFLOW transmission assembly
D
3
4
5
D375A-6 (02)
Work item and remarks
t 1 Removal and installation of t 1 fuel injector assembly q 1 NQ Removal and installation of t 1 engine front seal and rear seal
Push tool (For oil seal) Push tool 795T-621-1171 (For dust seal) 795-902-1460 Bolt 01582-02218 Nut Push tool 795T-621-1161 (For standard seal and sleeved seal) Push tool 795T-621-1190 (For sleeved seal) 01050-32235 Bolt 01050-32245 Bolt
t 1
Q
t 1
Q
790-331-1120
Wrench (angle)
q 1
791-451-1000 790-101-2102 790-101-1102 790-413-1010
Remover Puller (294 kN {30 ton}) Pump Bracket
t t t t
790-501-5000
Repair stand(100 V)
t 1
790-415-1011
Bracket
t 1
750-501-5000
Repair stand(100 V)
t 1
791-615-1130
Push tool
t 1
791-615-1200 791-615-1210 135-A90-1150 01580-01008 01641-51032 791-615-1101 791-615-1111 135-A90-1150 01580-01008 01641-51032 799-301-1600
Ring assembly q Ring q Bolt q Nut q Washer Ring assembly q Ring q Bolt q Nut q Washer Oil leak checker
t 1 1 1 1 2 t 1 1 1 1 2 t 1
795T-621-1180 4
Necessity Q'ty N/R Sketch
a Tools with part number 79 QT-QQQ-QQQQ means that they are not available from Komatsu Ltd. (i.e. tools to be made locally). a Necessity: t . . . . . . Special tools that cannot be substituted and should always be used q . . . . . . Special tools that will be useful if available and are substitutable with tools available on the market a Distinction of new and existing special tools. N: . . . . . . Tools newly developed for this model. They have a new part number respectively. R: . . . . . . Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank: . . . Tools already available for other models. They can be used without any modification. a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketches of special tools")
t 3 t 3
Removal and installation of engine front seal
t 1
Q
t 1
Q engine rear seal
Removal and installation of
t 5 t 5
1 1 1 1
Tightening of cylinder head bolt Removal and installation of radiator guard assembly Disassembly and assembly of torque converter assembly Disassembly and assembly of TORQFLOW transmission assembly Removal and installation of snap ring
Installation of No.3 ring gear
Installation of No.1 ring gear
Checking actuation of piston
50-9
DRAFT
Device
Symbol
1 2
3 Final drive assembly
4 J 5
6
7 8
1 Idler assembly
L
2 3 4
1 Recoil spring assembly
M 2
22
Track frame assembly
L 23
24
50-10
Part No.
Part name
Necessity Q'ty N/R Sketch
General information on disassembly and assembly Special tools list
790-337-1001
Lifting tool
t 1
791-580-3200 790-101-2102 790-101-1102 791-580-3300 790-101-2102 790-101-1102 790-431-1071 791-580-3400 790-101-2102 790-101-1102 791-580-3500 790-101-2102 790-101-1102 790-431-1230 790-101-2102 790-101-1102 790-431-1250 791T-630-2210 792-530-1630 790-101-2510 790-101-2570 01580-01613 01643-31645 790-101-2102 790-101-1102 791-515-1520 791-685-8310 791-601-1000 791-730-1110 01580-12722 01643-32780 790-101-2102 790-101-1102 791-685-8501 790-101-1600 790-101-1102 791-635-3160 195-30-68610 01010-62450 01010-62455 19M-54-11770 01643-32460 198-30-66190 195-30-69540 01011-82410 01011-82420 19M-54-11770 195-30-69550
Remover Puller (294 kN {30 ton}) Pump Installer Puller (294 kN {30 ton}) Pump Installer Remover Puller (294 kN {30 ton}) Pump Installer Puller (294 kN {30 ton}) Pump Remover and installer Puller (294 kN {30 ton}) Pump Guide Plate Stud Block Washer Nut Washer Puller (294 kN {30 ton}) Pump Installer Push tool Oil pump Bolt Nut Washer Puller (294 kN {30 ton}) Pump Compressor Cylinder (686 kN {70 ton}) Pump Extension Plate Bolt Bolt Washer Washer Collar Plate Bolt Bolt Washer Collar
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
791-685-1320
Lifting tool
t 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 1 1 1 1 1 4 4 1 1 1 1 1 1 1 6 6 6 6 6 6 2 2 2 4 2
Work item and remarks Removal and installation of final drive assembly Separation of sprocket hub assembly and bearing Press-fitting of bearing (sprocket hub assembly)
N
Installation of floating seal Disassembly of hub shaft assembly Press-fitting of bearing (hub shaft assembly) Removal and installation of planetary gear shaft
Q
Installation of gear assembly
Press fitting of bushing
Installation of floating seal Press fitting of seal guide Adding oil
Removal of pin
Disassembly and assembly of recoil spring assembly N
N N N
Locking bogie assembly
N N Removal and installation of track frame assembly
D375A-6 (02)
DRAFT
Device
Symbol 8 9 10 11 12
Track roller assembly
L 22
23
Carrier roller assembly
L
4 5 6 7
1 2 3 14 4 5 6 7 1 2 3 4 15 5 6 Bogie assembly L 7 8 1 2 3 16 4 5 6
791T-630-2220 796-670-1020 791T-630-2230 791-601-1000 790-401-1700 790-401-1761 790-401-1540 790-401-1770 195-30-68610 01010-62450 01010-62455 19M-54-11770 01643-32460 198-30-66190 195-30-69540 01011-82410 01011-82420 19M-54-11770 195-30-69550 791-601-1000 791-515-1520 791-830-1770 791-630-1270 791-630-2260 790-201-2730 791-630-2270 01580-12419 01643-32460 790-101-4000 790-101-1102 791-630-2280 790-201-2770 791-630-2250 790-434-1070 01580-13629 01643-33690 790-101-4000 790-101-1102 791-630-2260 791-630-2270 01580-12419 01643-32460 790-101-4000 790-101-1102
Part name Plate Installer Push tool Oil pump Lifting tool Adapter Shackle T-bolt Plate Bolt Bolt Washer Washer Collar Plate Bolt Bolt Washer Collar Oil pump Installer Push tool Wrench Plate Spacer Screw Nut Washer Puller (490 kN {50 ton}) Pump Adapter Spacer Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 1 1 2 2 6 6 6 6 6 6 2 2 2 4 2 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 2 2 1 1 1 3 3 3 1 1
17
791T-630-2290 Guide
t 2
18 19
791-530-1510 791-601-1000 195-30-68610 01010-62450 01010-62455 19M-54-11770 01643-32460 198-30-66190 195-30-69540 01011-82410 0101-82420 19M-54-11770 195-30-69550
t t t t t t t t t t t t t
22 Bogie assembly L
23
D375A-6 (02)
Part No.
Necessity Q'ty N/R Sketch
General information on disassembly and assembly Special tools list
Installer Oil pump Plate Bolt Bolt Washer Washer Collar Plate Bolt Bolt Washer Collar
1 1 6 6 6 6 6 6 2 2 2 4 2
Work item and remarks
Q Press fitting of bushing Installation of floating seal
Q Press fitting of seal guide Supplying oil
Lifting of rack roller assembly N
N Locking bogie assembly
N N
N N Disassembly and assembly of carrier roller assembly
Pulling out shaft and ring
Press fitting of pin assembly
Q
Alignment of track frame and bogie pin holes Installation of floating seal Supplying oil
N
N N N
Fixing of bogie assembly
N N
50-11
DRAFT
Device
No. 1 bogie assembly
Symbol 1 2 3 14 4 5 6 7 1 2 3 4 15 5 6 7 8 1 2 3 16 4 L 5 6
50-12
Plate Spacer Screw Nut Washer Puller (490kN {50ton}) Pump Adapter Spacer Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump
t t t t t t t t t t t t t t t t t t t t t
1 1 3 3 3 1 1 1 1 1 1 2 2 1 1 1 3 3 3 1 1
Work item and remarks
Pulling out shaft and ring
Press fitting of pin assembly
Q
Alignment of track frame and bogie pin holes Installation of floating seal Supplying oil
791T-630-2290 Guide
t 2
18 19
3
791-646-7900
Installer Oil pump Bracket (L. H) Bracket (R.H) Bolt Washer Lifting tool q Tube q Plate q Grip q Eyebolt q Washer q Washer q Nut Push tool Pin brush Push tool (For large plug)
t t t t t t
1 2
790-434-1350 791-601-1000 791-630-1860 791-630-1870 01010-62760 01643-32780 791T-630-1900 791T-630-1910 791T-630-1920 07283-38973 04530-11628 01643-31645 01643-31232 01582-01210 791-646-7351 791-660-7460
t 1
Drive-in of large plug
4
791-701-3000 or 791-601-1000
Seal checker Oil pump
t 2
Filling with oil
5
791-932-1110
t 1
Drive-in of small plug
6
791-632-1021 791-632-1300 791-632-1260 791-632-1270 791-632-1220 791-632-1230 791-632-1240 791-685-5730 791-632-1250 791-632-1280 01252-30605 01580-01210
Push tool (For small plug) Installer Push tool assembly q Push tool q Adapter q Adapter (small) q Ring q Plate q Bar q Ring q Spring q Bolt q Nut
t 1 t 1 N 1 1 1 1 1 1 1 1 1 1
Installation of seal assembly
21
R
791-630-2260 790-201-2730 791-630-2270 01580-12419 01643-32460 790-101-4000 790-101-1102 791-630-2280 790-201-2770 791-630-2250 790-434-1070 01580-13629 01643-33690 790-101-4000 790-101-1102 791-630-2260 791-630-2270 01580-12419 01643-32460 790-101-4000 790-101-1102
Part name
17
1 2 20 3 4
Track shoe assembly
Part No.
Necessity Q'ty N/R Sketch
General information on disassembly and assembly Special tools list
1 2 3 4 5 8 6 7 8 9 10 11
1 1 1 N Setting bogie to installed posi1 N 2 tion 2 q 1 Q 1 Q 1 Q Installation of track roller 1 assembly 1 1 2 2 t 1 Removal of pin small plug t 1 Cleaning of pin hole
Assembly of link
D375A-6 (02)
DRAFT
Device
Symbol 1 2 3 4 5 9 6 7 8 9 10 11 1 10 2 3 1 2 3 4 5 6
Track shoe assembly
D375A-6 (02)
R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Part No. 791-632-1200 791-632-1260 791-632-1270 791-631-1210 791-632-1230 791-632-1240 791-685-5730 791-632-1250 791-632-1280 01252-30650 01580-01210 791-632-1290 791-685-5730 01580-01210 791-646-7351 791-660-7460 791-646-7900 791-701-3000 or 791-601-1000 791-932-1110 791-632-1021 791-632-1100 791-632-1130 790-434-1610 01010-51440 791-685-9510 791-685-9520 791-685-9520 791-685-9550 04530-12030 791-685-9560 791-126-0150 791-685-9540 791-632-1140 791-680-5520 01010-51030 791-632-1150 791-685-9620 791-632-1180 791-680-5543 791-632-1170 791-680-5551 791-680-9630 791-632-1160 195-32-61210 790-101-4300 790-101-1102 790-101-4200 791-680-1630
Part name
Necessity Q'ty N/R Sketch
General information on disassembly and assembly Special tools list
Push tool assembly Push tool q Adapter q Adapter (large) q Ring q Plate q Bar q Ring q Spring q Bolt q Nut Push tool assembly Bar Nut Push tool Pin brush Push tool (for large plug)
t 1 N 1 1 1 1 1 1 1 1 1 1 t 2 N 1 1 t 1 t 1 t 1
Seal checker Oil pump
t 2
Push tool (for small plug) Installer Remover & installer assembly q Adapter q Guide q Bolt q Frame q Rod q Frame q Nut q Eyebolt q Bolt q Adapter q Rod q Adapter q Guide q Bolt q Pusher q Extension q Adapter q Adapter q Guide q Guide q Adapter q Guide Bolt Cylinder (1,470 kN {150 ton}) Pump Cylinder (294 kN {30 ton}) Spacer
t 1 t 1 t 1 1 1 2 1 1 1 3 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 t 1 t 1 t 1 t 1 N
q
Work item and remarks
Assembly of link
Disassembly and assembly of one link assembly in field
50-13
DRAFT
Device
Symbol 1 2 3 4 5 6
7 Track shoe assembly
R
8
9 Track shoe assembly
R
10
50-14
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 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 1 2 3
Part No. 791-646-7351 791-660-7460 791-646-7900 791-701-3000 or 791-601-1000 791-932-1110 791-632-1021 791-632-1100 791-632-1130 790-434-1610 01010-51440 791-685-9510 791-685-9530 791-685-9520 791-685-9550 04530-12030 791-685-9560 791-126-0150 791-685-9540 791-632-1140 791-680-5520 01010-51030 791-632-1150 791-685-9620 791-632-1180 791-630-5543 791-632-1160 791-680-5551 791-680-9630 791-632-1160 195-32-61210 790-101-4300 790-101-1102 790-101-4200 791-680-1630 791-632-1300 791-632-1260 791-632-1270 791-632-1220 791-632-1230 791-632-1240 791-685-5730 791-632-1250 791-632-1280 01252-30605 01580-01210 791-632-1200 791-632-1260 791-632-1270 791-632-1210 791-632-1230 791-632-1240 791-685-5730 791-632-1250 791-632-1280 01252-30650 01580-01210 791-632-1290 791-632-1260 01580-01210
Part name Push tool Pin brush Push tool (for large plug) Seal checker
Necessity Q'ty N/R Sketch
General information on disassembly and assembly Special tools list
Work item and remarks
t 1 t 1 t 1 t 2
Oil pump Push tool (for small plug) Installer Remover & installer assembly q Adapter q Guide q Bolt q Frame q Rod q Frame q Nut q Eyebolt q Bolt q Adapter q Rod q Adapter q Guide q Bolt q Pusher q Extension q Adapter q Adapter q Guide q Guide q Adapter q Guide Bolt Cylinder (1,470 kN {150 ton}) Pump Cylinder (294 kN {30 ton}) Spacer Push tool assembly q Push tool q Adapter q Pin (small) q Ring q Plate q Bar q Ring q Spring q Bolt q Nut Push tool assembly q Push tool q Adapter q Pin (large) q Ring q Plate q Bar q Ring q Spring q Bolt q Nut Push tool assembly Bar Nut
t 1 t 1 t 1 1 1 2 1 1 1 3 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 2 t 1 t 1 t 1 t 1 t 1 N 1 1 1 1 1 1 1 1 1 1 t 1 N 1 1 1 1 1 1 1 1 1 1 t 2 N 1 1
Disassembly and assembly of master link
Disassembly and assembly of master link
D375A-6 (02)
DRAFT
Device
Pivot shaft assembly
Equalizer bar
Equalizer bar bushing
Symbol 1 2 3 4 5 6 7 8 9
P
N
N
1
1 2 3 4 5 6 7
2
1
2 Hydraulic cylinU der assembly
3
4
Hydraulic cylinU der assembly
5
6
1
2 Ripper pin puller cylinder assembly
U 3 4 5 7
D375A-6 (02)
Part No. 791T-650-2330 791T-650-2340 790-201-3310 790-101-2510 790-101-2570 01580-01613 01643-31645 790-105-2300 790-101-1102 791-650-1300 791-735-1123 790-434-1050 01580-02419 01643-32460 790-101-2102 790-101-1102 791T-650-2410 791T-650-2420 790-438-1110 791-112-1180 790-101-2540 790-101-2102 791-101-1102
Part name
Necessity Q'ty N/R Sketch
General information on disassembly and assembly Special tools list
t t t t t t t t t
790-201-1702 790-201-1841 790-201-1861 790-101-5021 01010-50816 790-201-1500 790-201-1650 790-201-1670 790-101-5021 01010-50816 790-720-1000 796-720-1680 07281-01589 796-720-1720 07281-02429 796-720-1690 07281-02169 790-102-4300
Sleeve Plate Bolt Block Washer Nut Washer Jack assembly Pump Remover q Sleeve q Screw q Nut q Washer Puller (294 kN {30 ton}) Pump Bracket Bracket Screw Nut Washer Puller (294 kN {30 ton}) Pump Cylinder Repair stand Push tool kit q Push tool q Push tool q Grip q Bolt Push tool kit q Plate q Plate q Grip q Bolt Expander Ring Clamp Ring Clamp Ring Clamp Wrench
t 1 1 1 1 1 t 1 1 1 1 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
790-102-4310
Pin
t 2
790-502-1003
Cylinder Repair stand
q 1
790-201-1702 790-201-1721 790-101-5021 01010-50816 790-201-1500 790-201-1530 790-101-5021 01010-50816 790-720-1000 796-720-1630 07281-00709 790-102-2302
Push tool kit q Push tool q Grip q Bolt Push tool kit q Plate q Grip q Bolt Expander Ring Clamp Wrench
t 1 1 1 1 t 1 1 1 1 t 1 t 1 t 1 t 1
790-502-1003
q
q q
t t t t t t t
1 1 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1
q 1
Work item and remarks
N Q N Q
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
N Q N Q Disassembly and assembly of equalizer bar bushing
Disassembly and assembly of hydraulic cylinder assembly
Press fitting of bushing
Press fitting of seal
Installation of bearing
Disassembly and assembly of ripper cylinder piston assembly Assembly and disassembly of ripper pin puller cylinder assembly Press fitting of bushing
Press fitting of dust seal
Press fitting of dust seal Tightening cylinder head
50-15
DRAFT General information on disassembly and assembly Sketches of special tools
Sketches of special tools Caution: Komatsu will not accept any responsibility for any special tools manufactured according to these sketches. A2 Socket
A4 Push tool (for oil seal)
50-16
D375A-6 (02)
DRAFT General information on disassembly and assembly Sketches of special tools
A4 Push tool (for dust seal)
A5 Push tool (for standard seal and sleeved seal)
D375A-6 (02)
50-17
DRAFT General information on disassembly and assembly Sketches of special tools
A5 Push tool (for sleeved seal)
L1 Plate
50-18
D375A-6 (02)
DRAFT General information on disassembly and assembly Sketches of special tools
L8 Plate
L10 Push tool
D375A-6 (02)
50-19
DRAFT General information on disassembly and assembly Sketches of special tools
L17 Guide
L21 Lifting tool
50-20
D375A-6 (02)
DRAFT General information on disassembly and assembly Sketches of special tools
L21 Tube
L21 Plate
D375A-6 (02)
50-21
DRAFT General information on disassembly and assembly Sketches of special tools
P1 Sleeve
P2 Plate
50-22
D375A-6 (02)
DRAFT General information on disassembly and assembly Sketches of special tools
N2-1 Bracket
N2-2 Bracket
D375A-6 (02)
50-23
DRAFT Engine and cooling system Removal and installation of fuel supply pump assembly
Engine and cooling system Removal and installation of fuel supply pump assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. a Remove the wiring clamp and move the wiring aside.
5. Remove common rail cover (5). a Pull up the cover at an angle toward the front side to remove. 6. Disconnect wiring connectors (6). a Wiring connectors: PCV1, PCV2
1. Close the fuel valve under the fuel tank. 2. Open the left side cover and remove lower side cover (1).
7. Loosen clamps (8), (9), and (10) of high-pressure pipes (7) between the supply pump and the common rail, and remove the high-pressure pipes (7).
3. Remove covers (2) and (3). 4. Disconnect common rail wiring (4).
50-24
D375A-6 (02)
Engine and cooling system Sketches of special tools
8. Remove the fuel pre-filter. a The fuel pre-filter may be removed first.
11. Remove the mounting bolts of brackets (16) and (17) and remove the fuel supply pump assembly (18).
9. Remove tubes (11), (12), (13), and (14). [*1]
12. Remove the following parts from fuel supply pump assembly (18). 1) Oil tube (19) 2) Plate (20) 3) Overflow valve (21)
10. Disconnect G sensor connector (15) on the opposite side of the supply pump. 4) 5) 6) 7)
D375A-6 (07) (02)
Nut (23) Washer (24) Coupling (25) Key (26)
50-25
Engine and cooling system Sketches of special tools
Installation 1. Install the following parts to fuel supply pump assembly (18). 1) Key (26) 2) Coupling (25) 3) Washer (24) 4) Nut (23) 3 Nut (23): 176 – 196 Nm {18 – 20 kgm}
5) Plate (20) 6) Oil tube (19) a Replace gaskets (GA) and (G10) with new ones. q GA : Accessory to supply pump q G10: Part No. (07005-01012) 7) Overflow valve (21) 3 Plate (20) mounting bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 3 Oil tube (19) joint bolt: Upper side: 7.9 – 12.7 Nm {0.8 – 1.3 kgm} Lower side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} 3 Overflow valve (21): 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3. Install fuel supply pump assembly (18) and lower bracket (17). 3 Fuel supply pump mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} 3 Lower bracker (17) mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} 4. Install oil tube (22). a Replace 4 gaskets (G) with new ones. (Part number: 07005 -01012.) 3 Oil tube (22) joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
2. Place the fuel supply pump assembly to the drive case according to the following procedure. a Match part (A) of the fuel supply pump drive gear where there is one tooth missing with part (AA) of the coupling where there is one spline missing to place the fuel supply pump assembly.
50-26
D375A-6 (02) (07)
Engine and cooling system Sketches of special tools
High-pressure pipe k When handling the high-pressure pipe and clamp, observe the following. q Never bend the high-pressure pipe to install or use it in other locations. q Install the specified clamp to the specified position securely and tighten it to the specified torque. q Do not apply lubricant to the high-pressure pipe sleeve nuts and the threads of the mating part. a Axial force in the tightening can be excessive, potentially damaging the high-pressure pipe. k Before installing the high-pressure pipe, check it for the following defects. If it has any defect, replace it with new one since fuel may leak. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
q
Carry out the subsequent installation in the reverse order to removal.
[*1]
3
3
3
k
5. Connect G sensor connector (15). 6. Tighten high-pressure pipe (7) partially. 7. Tighten clamps (8) to (10) partially. 8. Tighten high-pressure pipe (7) to the specified torque. 3 High-pressure pipe sleeve nut: 39.2 – 44.1 Nm {4.0 – 4.5 kgm}
q
Tube (12) Joint bolt (Supply pump side): 14.8 – 19.6 Nm {1.51 – 1.99 kgm} Sleeve nut:43 – 47 Nm {4.4 – 4.8 kgm} Tube (13) Joint bolt (Overflow valve): 14.8 – 19.6 Nm {1.51 – 1.99 kgm} Joint bolt (Supply pump side): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Sleeve nut (Fuel block side): 24 – 27 Nm {2.4 – 2.7 kgm} Tube (14) Joint bolt (Supply pump side): 14.8 – 19.6 Nm {1.51 – 1.99 kgm} Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
Make sure that a clearance of 10 mm minimum is provided between the high-pressure pipe and adjacent wiring harness. If not, secure the clearance by repositioning the wiring harness. Air bleeding Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".
9. Tighten clamps (8) to (10) to the specified torque. 3 Clamp bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm} 10. Install cover (11) at 2 places. a When installing it ,direct the slit down ward.
D375A-6 (07) (02)
50-27
DRAFT Engine and cooling system Removal and installation of fuel injector assembly
Removal and installation of fuel injector assembly 35. Disconnect high-pressure pipe clamps (7) and (8). a A clamp is provided on the fuel supply pump side.
Symbol
A
Part No.
795-799-5410 795-799-5420 2 795T-675-1110 1
Part name
Adapter Remover Socket
Necessity Q'ty New/remodel Sketch
Special tools
t 1 t 1 q 1 N Q
Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 36. Remove clamp (9). 1. Perform steps 1 to 31 of “Removal and installation of cylimder head assembly”. (See "Removal and installation of cylinder head assembly")
37. Remove covers (10).
32. Disconnect high-pressure pipe clamps (1) - (3). 33. Remove tubes (4) and (5).
[*1]
34. Remove bracket (6).
50-28
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of fuel injector assembly
38. Disconnect sleeves (11) and (12) at 6 places each.
41. Remove terminal mounting nuts (15). a Loosen the nuts alternately.
39. Remove high-pressure pipes (13).
42. Remove wiring harness assembly mounting bolts (16) and spacer (17).
40. Remove cylinder head cover (14). 43. Remove fuel injector holder (21).
44. Using tool A1, remove fuel injector assembly (22). a Hook the end of tool A1 onto hole (H) of the fuel injector to pull out. a Never grip the solenoid valve on the top of the fuel injector with pliers, etc. to pull out. a The figure shows the fuel injector after the rocker arm and shaft assembly is removed.
a If tool A2 is not available, disconnect sleeve (12) from above. q Tool A2
D375A-6 (02)
50-29
DRAFT Engine and cooling system Removal and installation of fuel injector assembly
Installation 1. Fuel injector a Check that the injector mounting bore is free from dirt. 2 O-ring: Engine oil (EO30)
2) Install terminal mounting nuts (15) and wiring harness fixing bolts (16). a Tighten the terminal mounting nuts alternately 3 Terminal mounting nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
1) Install gasket (22) and O-rings (24) and (25) to fuel injector (26). a Take care not to fit O-ring (25) to center groove (A). 2) Install fuel injector (22) to adapter (27) and injector holder (21). 3) Attach spherical washer (29) to bolt (30) and then tighten the bolt to fasten injector holder (31) partially. 2 Spherical washer: Engine oil (EO30) a The bolt of injector holder (21) is to be tightened to the specified torque after tightening the high-pressure pipe pantially.
3. High-pressure pipe k When handling the high-pressure pipe and clamp, observe the following. q Never bend the high-pressure pipe to install or use it in other locations. q Install the specified clamp to the specified position securely and tighten it to the specified torque. q Do not apply lubricant to the high-pressure pipe sleeve nuts and the threads of the mating part. a If lubricant is applied, the axial force becomes too high and can break the high-pressure pipe.
2. Injector wiring harness 1) Install spacer (17). a Install the spacer with its slit (B) up.
50-30
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of fuel injector assembly k
Before installing the high-pressure pipe, check it for the following defects. If it has any defect, replace it with new one since fuel may leak. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
5) Tighten high-pressure pipe sleeve nuts (11) and (12) to the specified torque by using the spanner type torque wrench. 3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm} a After finishing the work, check that O-ring (32) is not projected from the end of the sleeve nut (12). 6) Install cylinder head cover (14). a A different tightening torque is employed for No. 2 cylinder head cover mounting bolt alone. 3 Cylinder head cover mounting bolt: No. 1, 3, 4, 5, and 6 cylinders: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} No.2 cylinder:59 – 74 Nm {6 – 7.5 kgm}
1) Install O-ring (32) to sleeve (31) of high-pressure pipe (13). 2 O-ring: Engine oil (EO30) 2) Tighten sleeve nut (12) partially aligning it with connector (28) of the injector. a When it is difficult to engage sleeve nut (12) with the threaded portion, turn sleeve nut (12) with the spanner while pushing sleeve nut (12) toward the injector by use of a short bar or the like. 3) Tighten the common rail side sleeve nut (11) partially, too. 4) Tighten injector holder (21) to the specified torque. 3 Injector holder mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
D375A-6 (02)
50-31
DRAFT Engine and cooling system Removal and installation of fuel injector assembly
4. High-pressure pipe clamp 1) Install the clamps on the high-pressure pipes according to the following procedure. 1] Finger-tighten 17 high-pressure pipe clamps (33) in the position indicated in the figure. 2] Finger-tighten common rail side clamp bracket (34) and clamp (9) and then tighten clamp (9). 3 Common rail side clamp bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm} 3] Tighten common rail side clamp bracket (34) to the specified torque. 4] Tighten high-pressure pipe clamps (33). 3 High-pressure pipe clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 5] Install covers (10) on the common rail side sleeve nuts. a When installing it, direct the slit downward.
q
k
q
Make sure that a clearance of 10 mm minimum is provided between the high-pressure pipe and adjacent wiring harness. If not, secure the clearance by repositioning the wiring harness. Bleeding air Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".
Carry out the subsequent installation in the reverse order to removal.
[*1]
3 3
Tube (4) joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Tube (5) sleeve nut: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a Refer to the precautions in "Installation of cylinder head" for the installation.
50-32
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
Removal and installation of cylinder head assembly 4. Loosen the clamp and disconnect exhaust tube (2).
Adapter Remover Socket Wrench (angle)
5. Disconnect exhaust temperature sensor wiring (3).
t 1 t 1 q 1 N Q q 1
6. Remove front heat insulation cover (4), center heat insulation cover (5), and rear heat insulation cover (6).
Q'ty
Sketch
795-799-5410 795-799-5420 A 2 795T-675-1110 6 790-331-1120 1
Part name
New/remodel
Part No.
Necessity
Symbol
Special tools
7. Disconnect the muffler drain tube. Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If the coolant temperature is high, wait until it decreases to avoid scalding yourself with the hot coolant, and then disconnect the heater hose and drain the coolant.
8. Lift off muffler (7). 4 Muffler assembly: 75 kg 9. Remove muffler mounting bracket (8).
1. Drain the coolant. 6 Coolant: 120 l 2. Remove the engine hood assembly. For details, see "Removal and installation of hood assembly". 3. Remove left and right lower side covers (1). 4 Left lower side cover: 40 kg Right lower side cover: 50 kg
10. Disconnect fuel hoses (9) and (11).
[*1]
11. Disconnect tube (10).
[*2]
12. Remove fuel pre-filter assembly (12).
D375A-6 (02)
50-33
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
13. Remove fuel tube clamps (17).
18. Lift off engine oil filter assembly (23).
14. Remove fuel tubes (18), (18-1), and (19). [*3] 15. Disconnect connector TOIL (20). a Drive lock (L) upward to pull out the connector. 16. Disconnect connector POIL (21) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector POIL (21). 17. Remove tube assembly (22). 19. Disconnect wiring harnesses (24)
20. Disconnect water tube (25). 21. Remove EGR valve and cooler assembly (26) and exhaust tube (27).
50-34
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
22. Remove each tube of the turbocharger. q Lubricating oil tube (28) q Lubricating oil drain tube (29) q Coolant tube (30) q Coolant drain tube (31).
[*4]
24. Lift off turbocharger and exhaust manifold assembly (32). [*5] 4 Turbocharger and exhaust mainfold assembly:120 kg
25. Remove breather and tube assembly (33). 26. Remove wiring harness covers (34) and (35).
23. Disconnect connectors V30 (31-1) and V29 (31-2). 27. Disconnect connector PFUEL(36). 28. Remove common rail cover (37).
D375A-6 (02)
50-35
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
29. Disconnect 6 injector connectors (38).
37. Remove clamp (52).
30. Disconnect connector CN6 (39).
38. Remove covers (53) and (54).
31. Remove wiring harness bracket (40).
39. Loosen clamps (55) and (56). 40. Remove high-pressure tube assembly (57). 41. Disconnect connector (58). 42. Disconnect fuel hose (120). 43. Disconnect connector PIM (121).
32. Disconnect high-pressure pipe clamps (41) to (43). 33. Remove tubes (44) to (46).
[*6]
34. Remove brackets (47) and (48).
35. Disconnect high-pressure pipe clamps (49) and (50). 36. Remove fuel tube (51).
50-36
[*7]
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
44. Disconnect wiring harness clamp (59) from rear side of the fuel supply pump.
50. Disconnect sleeves (69). 51. Remove high-pressure pipes (70).
45. Disconnect the connector from the bottom of clamp (59).
52. Remove bracket (71). 46. Disconnect connectors PCV1 (60) and PCV2 (61).
53. Remove 4 mounting bolts (73) of air intake manifold assembly (72) from the radiator side.
47. Disconnect harness clamps (62). 48. Remove tubes (63) to (65).
[*8]
49. Remove fuel supply pump assembly (66). a Do not loosen overflow valve (ofv). a Do not remove oil tube (t) and plate (p).
.
.
D375A-6 (02)
50-37
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
54. Disconnect high-pressure pipe sleeve nut (75) on the injector side. a If tool A2 is available, you can work from the side, not from above.
a Tool A2
55. Remove high-pressure pipes (74). 56. Sling air intake manifold assembly (72). a Install eyebolt [1] to the mounting hole of bracket (71) (described above) and sling air intake manifold assembly (72) by using lifting tool [2].
60. Remove air intake connector (76). a Since the tube convexly bites into the inside of the air intake connector (part A), take care not to damage the tube when removing the air intake connector.
61. Lift off air intake manifold assembly (72). 4 Air intake manifold assembly:110 kg
57. Remove the mounting bolts of air intake manifold assembly (72), leaving some of them tightened. 58. Install guide bolts [3]. a Use the filter mounting bolt as the guide bolt. a The tube convexly bites into the inside of the connector. Thus, take care not to demage the tube when removing the air intake connector by using the guide bolts. (See the following section)
.
59. Remove the remaining mounting bolts of air intake manifold assembly (72).
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D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
62. Remove brackets (77). 63. Remove turbocharger lubrication tube (78) and coolant tube (79). 64. Remove air vent tube (80).
68. Remove terminal mounting nuts (82). a Loosen the nuts alternately. 69. Remove wiring harness assembly mounting bolts (83) and spacer (84). 70. Loosen locknut (85) and then loosen adjustment screw (86). 65. Remove pin (A) and then push in bolt (B). 71. Remove rocker arm assembly (87) 66. Rotate the crankshaft by using bolt (B) as a barring location to set the No. 1 or No. 6 cylinder to the compression top dead center. a Remove plug (BB) to check the result visually. a For above operation, see Testing and adjusting, "Testing and adjusting valve clearance".
72. Remove push rods (88). 73. Remove crosshead assemblies (89). 74. Remove rocker arm housing (90). 75. Remove fuel injector holder (91). 67. Remove cylinder head cover (81). a Check that you can move the rocker arm of the No. 1 or No. 6 cylinder with fingers by the distance of the valve clearance.
76. Using tool A1, remove fuel injector assembly (92). D375A-6 (02)
50-39
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
a Remove the assembly by hooking the end of tool A1 onto hole (H) of the fuel injector. a Never grip the solenoid valve on the top of the fuel injector with pliers, etc to pull out.
77. Lift off cylinder head assembly (93). 4 Cylinder head assembly:50 kg 78. Remove the cylinder head gasket.
50-40
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
Installation 1. Cylinder head assembly 1) Install the cylinder head gasket. 2) Sling and install cylinder head assembly (93). 4 Cylinder head assembly:50 kg a If there are 5 punch marks on the head of a bolt, do not reuse that bolt but replace it. a Tighten the mounting bolts in the order shown in the figure. 2 Cylinder head assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Cylinder head assembly mounting bolts (1 – 7): 1st time: 245 ± 9.8 Nm {25 ± 1 kgm} 2nd time: 382.5 ± 9.8 Nm {39 ± 1 kgm} 3rd time: 90 – 120 ° retightening a Use tool A6 (See the tool table) to retighten. When not using tool A6, make marks on the cylinder head and bolt using paint, etc., and then retighten the bolt to 90 120 ° (target: 120 °). 3 cylinder head assembly mounting bolt (8 and 9): 93.2 – 103 Nm {9.5 – 10.5 kgm}
D375A-6 (02)
a After tightening the bolt, make punch mark "(a)" on the main bolt head (Do not make it when new bolt is used, however).
50-41
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
2. Fuel injector a Check that the fuel injector mounting bore is free from dirt or other particles. 2 O-ring: Engine oil (EO30)
a Do not forget to install O-ring (OR). 3 Rocker arm housing mounting bolt: 78.4 – 93.2 Nm {8.0 – 9.5 kgm}
1) Install gasket (94) and O-rings (95) and (96) to fuel injector (92). a Take care not to fit O-ring (95) to center groove (A). 2) Insert fuel injector (92) to adapter (97) and injector holder (91). 3) Attach spherical washer (100) to bolt (99) and then tighten injector holder (91) partially. 2 Spherical washer: Engine oil (EO30) 6) Install crossheads (89).
a Injector holder (91) is to be tightened to the specified torque after installing the intake manifold and tightening the high-pressure pipe partially. 4) Install push rods (88). a Check that the push rod end is securely placed in the cam follower socket. 5) Apply liquid gasket and then install rocker arm housing (90). 2 Rocker arm housing: Liquid gasket (LG-7) a Apply the liquid gasket 2 to 3 mm in bead diameter along the housing groove as shown in the figure.
50-42
7) Adjust the crossheads according to the following procedure. 1] Loosen locknut (102) and then loosen adjustment screw (103) to a position where it will not touch valve stem (104). 2] Hold the rocket arm contact face on the crosshead with the finger to keep the crosshead in contact with valve stem (105) on the push rod side. 3] Slowly tighten adjustment screw (103) and check the position at which adjustment screw (103) touches valve stem (104). 4] Screw in adjustment screw (103) further by 20 ° – 30 ° from the contacting position against valve stem (104).
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
5] While holding adjustment screw (103) to prevent it from moving, tighten locknut (102). 3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm}
4. Injector wiring harness 1) Install spacer (84). a Install the spacer with its slit (B) up.
3. Rocker arm assembly 1) Install rocker arm assembly (87). a Install each rocker arm assembly with the riveted side of its shaft facing the front side of the engine. a When installing, direct the wider seat of the shaft to the rocker arm housing. a Make sure that the ball of adjustment screw (86) is securely placed in the push rod socket. a When tightening the mounting bolt, check that adjustment screw (86) does not press the push rod. 2 Theaded portion and seat surface of rocker arm assembly mounting bolt: Engine oil (EO30) 3 Rocker arm assembly mounting bolt : 235.2 – 254.8 Nm {24 – 26 kgm} a Adjust the valve clearance. For details, see Testing and adjusting, "Testing and adjusting valve clearance". 3 Locknut (85): 57.8 – 77.4 Nm {5.9 – 7.9 kgm} a After tightening the locknut, check the valve clearance again.
D375A-6 (02)
2) Install terminal mounting nuts (82) and wiring harness fixing bolts (83). a Tighten the terminal mounting nuts alternately 3 Terminal mounting nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
50-43
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
5. Air intake manifold assembly: 1) Place connector (76) on air lifted intake manifold assembly (72) being lifted. a Since the tube convexly bites into the inside of the air intake connector (part A), take care not to damage the tube when installing the air intake connector. 4 Air intake manifold and connector assembly: 135 kg
2) Install air intake manifold assembly (72). a Tighten the mounting bolts in the order shown in the figure.
k
Before installing the high-pressure pipe, check it for the following defects. If it has any defect, replace it with new one since fuel may leak. q Check the taper seal of the connecting part (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and dent (c). q Check part (d) (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
1) Install O-ring (106) to high-pressure pipe sleeve (101). 2 O-ring: Engine oil (EO30) 2) Tighten sleeve nut (75) partially aligning it with connector (98) of the injector. a If sleeve nut (75) does not catch the threads, press the end of sleeve nut (75) with a small rod, etc. toward the injector and turn the spanner.
6. High-pressure pipe k When handling the high-pressure pipe and clamp, observe the following. q Never bend the high-pressure pipe to install or use it in other locations. q Install the specified clamp to the specified position securely and tighten it to the specified torque. q Do not apply lubricant to the high-pressure pipe sleeve nuts and the threads of the mating part. a If lubricant is applied, the axial force becomes too high and can break the high-pressure pipe.
50-44
3) Tighten the common rail side sleeve nuts (69) partially, too. 4) Tighten injector holder (91) to the specified torque. 3 Injector holder mounting bolt: 58.9 – 73.5 Nm {6.0 – 7.5 kgm}
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
5) Tighten high-pressure pipe sleeve nuts (69) and (75) to the specified torque by using the spanner type torque wrench. 3 Sleeve nut : 39.2 – 44.1 Nm {4 – 4.5 kgm} a After finishing the work, check that O-ring (106) is not projected from the end of the sleeve nut (75).
6) Install cylinder head cover (81). a A different tightening torque is employed only for No. 2 cylinder mounting bolt. 3 Cylinder head cover mounting bolt : No. 1, 3, 4, 5, and 6 cylinders: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} No. 2 cylinder: 59 – 74 Nm {6 – 7.5 kgm} 7) Install air vent tube (80). 3 Air bleeding tube joint bolt (cylinder head side): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} 8) Install turbocharger coolant tube (79) and lubricating oil tube (78).
D375A-6 (02)
9) Install brackets (77).
7. High-pressure pipe clamp 1) Install the high-pressure pipe clamps according to the following procedure. 1] Finger-tighten 17 high-pressure pipe clamps (107) in the position indicated in the figure. 2] Finger-tighten common rail side clamp bracket (108) and clamp (52) and then tighten clamp (52). 3 Common rail side clamp bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm} 3] Tighten common rail side clamp bracket (108) to the specified torque. 4] Tighten high-pressure pipe clamps (107). 3 High-pressure pipe side clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 5] Install covers (53) on the common rail side sleeve nuts. a When installing it, direct the slit downward.
50-45
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
8. Fuel supply pump a If overflow valve (ofv) is loosened or oil tube (t) and plate (p) are removed, install them, referring to "Removal and installation of fuel supply pump assembly".
1) Place the fuel supply pump assembly to the drive case according to the following procedure. a Match part (A) of the fuel supply pump drive gear where there is one tooth missing with part (AA) of the coupling where there is one spline missing to place the fuel supply pump assembly.
3 3
Fuel supply pump (66) mounting bolt: 59 – 74 Nm {6 – 7.5 kgm} Lower bracket (111) mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
9. High-pressure pipe k Handle the high-pressure pipe and clamp in the same way as the pipe between the fuel injector and common rail (noted in the foregoing) is handled. 1) Tighten high-pressure pipes (57) partially. 2) Tighten clamps (55), (56) and (109) partially. 3) Tighten bracket (110) partially. 4) Tighten high-pressure pipes (57) to the specified torque. 3 High-pressure pipe sleeve nut: 39.2 – 44.1 Nm {4.0 – 4.5 kgm} 5) Tighten clamps (55), (56) and (109) to the specified torque. 3 Clamp bolt : 9.8 ± 1.0 Nm {1 ± 0.1 kgm} 6) Tighten bracket (110) to the specified torque. 7) Install covers (54).
50-46
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
q
Carry out the subsequent installation in the reverse order to removal.
[*1]
3 3
Fuel hose (9):90 – 95 Nm {9.2 – 9.7 kgm} Sleeve nut of fuel hose (11): 43 – 47 Nm {4.4 – 4.8 kgm}
[*2]
3
a Tighten the mounting bolts in the order shown in the figure. 2 Exhaust manifold mounting bolt: Seizure prevention compound (LC-G) (NEVER-SEEZ (BOSTIK) or equivalent) 3 Exhaust manifold mounting bolt: 1st time:39.2 – 58.8 Nm {4.0 – 6.0 kgm} 2nd time:98.1 – 122.6 Nm {10 – 12.5 kgm}
Tube (10) joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*3]
3 3 3 3
Tube (18-1) joint bolt (filter side): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Tube (18-1) joint bolt (supply pump side): 14.8 – 19.6 Nm {1.51 – 1.99 kgm} Tube (18-2) joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Tube (19) joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*4]
3
3
Coolant tube (30) Joint bolt:24.5 – 34.3 Nm {2.5 – 3.5 kgm} Sleeve:24.5 – 59 Nm {2.5 – 6.0 kgm} Lubricating oil tube (28), coolant tube joint bolt (31):24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*5] Exhaust manifold assembly 1. If the exhaust manifold assembly was divided, apply adhesive (heat-resistant sealant) to joints (A) (2 places) when assembling. 2 Exhaust manifold joint: Adhesive (HOLTS MH705)
D375A-6 (02)
50-47
DRAFT Engine and cooling system Removal and installation of cylinder head assembly
Reference Installation of turbocharger assembly 1. Lift and install turbocharger assembly (112). 4 Turbocharger:55 kg 2 Turbocharger mounting bolt and nut: Seizure prevention compound (LC-G) (NEVER-SEEZ (BOSTIK) or equivalent) 3 Turbocharger mounting bolt and nut: 78.5 – 88.3 Nm {8.0 – 9.0 kgm}
k
q
Make sure that a clearance of 10 mm minimum is provided between the high-pressure pipe and adjacent wiring harness. 10 mm not, secure the clearance by repositioning the wiring harness. Bleeding air Bleed air from the fuel circuit. For detail, see Testing and adjusting, "Bleeding air from fuel circuit".
[*6]
3 3 3
Oil tube (44) joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} Tubes (45) and (46) and sleeve nut: 54 – 93 Nm {5.5 – 9.5 kgm} Tube (46) joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*7]
3
Tube (51) joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*8]
3 3 3
3
50-48
Oil tube (63) joint bolt (supply pump side): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Oil tube (63) joint bolt (block side): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Tube (65) Joint bolt (supply pump side): 14.8 – 19.6 Nm {1.51 – 1.99 kgm} Sleeve nut:43 – 47 Nm {4.4 – 4.8 kgm} Tube (64):19.6 – 29.4 Nm {2.0 – 3.0 kgm}
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of radiator guard assembly
Removal and installation of radiator guard assembly
791-451-1000 Remover Puller A 7 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump
Sketch
Part name
N/R
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1 t 1 t 1
Removal a Move the machine forward and backward to set the master link of the track shoe away from the radiator guard. k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If the radiator coolant temperature is high, wait until the temperature decreases to avoid getting scalded, and then drain the coolant or disconnect the radiator hoses/tubes. 1. Sling the blade lift cylinders. 2. Remove the lock plate and remove connecting pin (1) on the piston rod side of the blade lift cylinder.
5. Drain the hydraulic oil and coolant. 6 Hydraulic:130 l 6 Coolant: 120 l 6. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 7. Disconnect radiator inlet hose (4). [*1] a Disconnect the hose from the radiator and reposition the hose on the engine side. 8. Disconnect air vent hose (5). [*2] a Disconnect the hose from the radiator, remove the 2 clamps, and reposition the hose on the engine side.
3. Start the engine and retract the piston rod fully and bind it with a wire so that it does not come off. 4. Lift up blade lift cylinder (2) and fix bracket (2-1) to cylinder fixing portion (A) of the radiator guard.
D375A-6 (02)
50-49
DRAFT Engine and cooling system Removal and installation of radiator guard assembly
9. Remove clamp (20). 10. Remove air conditioner condenser (21) without disconnecting the air conditioner hoses. a Place air conditioner condenser on the track shoes. k When disconnecting the air conditioner hoses, collect the refrigerant, referring to "Removal and installation of floor frame assembly".
15. Loosen U-bolt (9) of the aftercooler outlet tube. 16. Disconnect aftercooler outlet tube (8). [*3] a Do not loosen hose clamp (MC). 17. Disconnect blade pipes (10) and (11).
11. Disconnect oil cooler hose (22).
12. Open the undercover. For details, see "Removal and installation of engine assembly". 13. Disconnect two fan motor hoses (6). 14. Disconnect radiator outlet tube (7).
50-50
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of radiator guard assembly
18. Sling the radiator guard assembly, remove the pin lock bolt, and push rear pin (12) toward the inside of the radiator guard to take it out using tool A7. a Remove the shoe plates to secure a working space.
20. Lift off radiator guard and blade lift cylinder assembly (14). a When removing, take extreme care not to damage the wiring, pipes, etc. 4 Radiator guard and blade lift cylinder assembly:3,300 kg (Radiator guard assembly only: 2,750 kg)
19. Remove the lock plate and pull front pin (13) toward the outside of the radiator to remove it using tool A7.
Installation Carry out installation in the reverse order to removal.
q
[*1]
3
Radiator inlet hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3
D375A-6 (02)
Air vent hose clamp: 3.3 ± 0.5 Nm {0.34 ± 0.05 kgm}
50-51
DRAFT Engine and cooling system Removal and installation of radiator guard assembly
[*3] MIKALOR clamps (MC10), (MC20), (MC23) a Use a new MIKALOR clamp. 1) Set each hose to the original position. (Hose insertion depth: 80 mm) 2) Set bridge (BR) under the clamp bolt and secure at least 5 mm of overlap (b) between the bridge and band (BD). 3) Tighten the clamp. a Do not use an impact wrench for tightening. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) q When reusing the hose a Install the clamp aligning it with the clamp mark made on the hose. 3 Clamp bolt (BC): Min. 6 Nm {0.6 kgm}
q
When using a new hose a Tighten the clamp so that dimension BDG is as follows. MC10: 7 - 10 mm MC20: 17 - 20 mm MC23: 20 - 23 mm
Constant torque clamp (CTC) 3 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} (TC): Turbocharger
50-52
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of radiator guard assembly
q
Refilling of coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 120 l
q
Refilling of oil (Hydraulic tank) Supply 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. 5 Hydraulic tank: 130 l
D375A-6 (02)
50-53
DRAFT Engine and cooling system Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler) Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If the radiator coolant temperature is high, wait until the temperature decreases to avoid getting scalded, and then drain the coolant or disconnect the radiator hoses.
a Place air conditioner condenser on the track shoes. k When disconnecting the air conditioner hoses, collect the refrigerant, referring to "Removal and installation of floor frame assembly".
1. Drain the coolant. 6 Coolant: 120 l 2. Drain the hydraulic oil. 6 Hydraulic: 130 l 3. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly".
10. Open the undercover. For details, see "Removal and installation of engine assembly".
4. Disconnect radiator inlet hose (3).
[*1]
11. Disconnect hydraulic oil cooler upper hose (7) and lower hose (7-1).
5. Disconnect air vent hose (4).
[*2]
6. Remove the mounting bolts and disconnect aftercooler duct (5). [*3] a Do not loosen clamp (MC). 7. Disconnect four wiring clamps (6) and disconnect each wiring connector. q Headlamp intermediate: CN-LHD q Radiator guard intermediate: CN-RDG q Fan motor: FAR2 q Horn: CN-HRN q Radiator coolant level sensor: CN-WLD
8. Remove clamp (20). 9. Remove air conditioner condenser (21) without disconnecting the air conditioner hoses. 50-54
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
12. Disconnect radiator outlet tube (8). 13. Disconnect aftercooler outlet tube (9). a Do not loosen clamp (MC).
16. Remove two upper mounting bolts (12) on both the left and right sides. [*4] 17. Remove lower mounting bolts (12-1) on both the left and right sides. a Remove the bolts through the fan.
14. Remove radiator mask (10) and remove left and right fan nets (11). 18. Lift off cooling assembly (13). 4 Cooling assembly:480 kg
15. Remove shroud (22).
D375A-6 (02)
50-55
DRAFT Engine and cooling system Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
Installation q Carry out installation in the reverse order to removal. a When installing the cooling assembly, adjust the direction of windbreaker rubbers (R) so that they do not get caught.
[*1]
3
Radiator inlet hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3
50-56
Air vent hose clamp: 3.3 ± 0.5 Nm {0.34 ± 0.05 kgm}
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
[*3][*4] MIKALOR clamps (MC10), (MC20), (MC23) a Use a new MIKALOR clamp. 1) Set each hose to the original position. (Hose insertion depth: 80 mm) 2) Set bridge (BR) under the clamp bolt and secure at least 5 mm of overlap (b) between the bridge and band (BD). 3) Tighten the clamp. a Do not use an impact wrench for tightening. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) q When reusing the hose a Install the clamp aligning it with the clamp mark made on the hose. 3 Clamp bolt (BC): Min. 6 Nm {0.6 kgm}
q
When using a new hose a Tighten the clamp so that dimension BDG is as follows. MC10: 7 - 10 mm MC20: 17 - 20 mm MC23: 20 - 23 mm
Constant torque clamp (CTC) 3 10.5 ± 0.5Nm {1.07 ± 0.05 kgm} (TC): Turbocharger
D375A-6 (02)
50-57
DRAFT Engine and cooling system Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
q
Refilling of coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 120 l
q
Refilling of oil (Hydraulic tank) Supply 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. 5 Hydraulic tank: 130 l
50-58
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of radiator
Removal and installation of radiator 7. Remove cushions (7) and plates (8). Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If the radiator coolant temperature is high, wait until the temperature decreases to avoid getting scalded, and then drain the coolant or disconnect the radiator hoses. 1. Drain the coolant. 6 Coolant: 120 l 2. Remove the radiator upper cover. For details, see "Removal and installation of engine hood assembly". 3. Remove stay (1).
8. Lift off radiator (9). 4 Radiator:25 kg
4. Disconnect upper hose (2). 5. Remove front bolts (3) of bracket (6) and remove mounting bolts (4). 6. Remove collar (5) and bracket (6).
D375A-6 (02)
50-59
DRAFT Engine and cooling system Removal and installation of radiator
Installation 1. Install the radiator unit. a Replace O-rings (10) with new ones. a Apply detergent (undiluted) to the O-rings. a Remove the fan net and check that the convex part of the radiator is matched with the concave part of the lower tank, and then install the radiator securely.
2) Install collar (5) upside down (with 13 mm side up) and tighten mounting bolt (4). a This compresses cushion (7). (L1oL2) 3) Tighten mounting bolts (3) of bracket (6). 4) Remove mounting bolt (4).
5) Install collar (5) again in the normal direction (with 6 mm side up). 6) Tighten mounting bolt (4). 7) Check clearance (L3). q Clearance (L3): Approx. 7 mm
2. Install radiator mounting brackets (6) and cushions (7) according to the following procedure. 1) Set plate (8), cushion (7) and bracket (6) on the mounting boss of radiator (9). a At this time, fit bracket (6) tightly to the mounting seat of upper tank (11). (You may tighten bracket mounting bolts (3) partially)
3. Carry out the subsequent installation in the reverse order to removal. q
50-60
Refilling of coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 120 l
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of hydraulic oil cooler
Removal and installation of hydraulic oil cooler Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Drain the hydraulic oil. 6 Hydraulic:130 l 2. Open the left side cover and remove lower side cover (1). 4 Lower side cover: 40 kg
Installation q Carry out installation in the reverse order to removal. q
Refilling of oil (Hydraulic tank) Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the supply. Then, check the oil level again. 5 Hydraulic tank: 130 l
3. Disconnect upper hydraulic oil cooler hose (2).
4. Open the undercover. 5. Disconnect lower hydraulic oil cooler hose (3). 6. Remove the upper and lower mounting bolts and remove hydraulic oil cooler assembly (4). 4 Hydraulic oil cooler assembly: 105 kg
D375A-6 (02)
50-61
DRAFT Engine and cooling system Removal and installation of aftercooler
Removal and installation of aftercooler 5. Open the undercover. Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
6. Remove lower mounting bolts (4) of the aftercooler.
1. Remove the radiator upper cover. For details, see "Removal and installation of engine hood assembly". 2. Remove right stay (1). 3. Remove upper mounting bolts (2) of the aftercooler. 4. Open the right side cover and disconnect aftercooler inlet duct (3). a Loosen the mounting bolts of the aftercooler that is not being removed, too.
7. Lift off aftercooler (5). 4 Aftercooler: 40 kg
Installation Carry out installation in the reverse order to removal.
q
50-62
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine assembly
Removal and installation of engine assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If the radiator coolant temperature is high, wait until the temperature decreases to avoid getting scalded, and then drain the coolant or disconnect the radiator hoses. 1. Drain the coolant. 6 Coolant: 120 l 2. Using sling [1], gradually open the undercover of the engine and power train.
5. Disconnect starting motor wiring (2) and wiring clamp (3). 6. Close heater valve (4) and disconnect heater pipes (5a) and (5b). 7. Disconnect four heater pipe clamps (6). 8. Disconnect nine wiring connectors (7a) to (7g). 9. Disconnect two wiring clamps (8). 10. Remove wiring connector bracket (9).
3. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 4. Remove left and right lower side covers (1). 4 Left lower side cover: 40 kg Right lower side cover: 50 kg
D375A-6 (02)
50-63
DRAFT Engine and cooling system Removal and installation of engine assembly
11. Disconnect radiator outlet hose (10) from the engine.
15. Disconnect fuel supply hose (15).
[*2]
16. Disconnect fuel return hoses (16a) and (16b). a Disconnect the hose clamps.
12. Loosen locknut (11) and fully tighten belt tension adjustment bolt (12). [*1] 17. Disconnect wiring connectors (17). 13. Remove belt (13). 14. Disconnect air conditioner compressor (14). a Do not disconnect the air conditioner hoses from the air conditioner compressor. a Remove all clamps from the air conditioner hoses. a Place air conditioner compressor (14) on the track shoes. k When disconnecting the air conditioner hoses, collect the refrigerant, referring to "Removal and installation of floor frame assembly". 18. Disconnect radiator inlet hose (18).
[*3]
19. Disconnect air vent hose (19).
[*4]
20. Disconnect aftercooler ducts (20) and air hose (21). [*5]
50-64
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine assembly
21. Disconnect aftercooler outlet tube (22). [*6] a Loosen clamp (23) and disconnect the tube at the hose clamping point. 22. Disconnect oil cooler pipes (24) and (25).
6) Disconnect air conditioner hose clamps (38). (This task is not necessary if the air conditioner hoses are disconnected.)
23. Remove the bulkhead bracket according to the following procedure. 1) Remove relay protection cover (26) at the rear of the bulkhead bracket.
7) Sling bulkhead bracket (39) and remove mounting bolts (40).
2) Disconnect electrical intake air heater relay wiring (27) to (29). 3) Disconnect wiring connectors PRT2 (30), SS8A (31) and PRT1 (32). 4) Disconnect wiring clamps (33), (34) and (35). 5) Remove electrical intake air heater relay bracket assembly (36) and sensor bracket assembly (37).
D375A-6 (02)
50-65
DRAFT Engine and cooling system Removal and installation of engine assembly
8) While slinging bulkhead bracket (39), disconnect starting motor cable clamps (41) from bulkhead bracket (39).
9) Remove bulkhead bracket (39) and sub tank (42) as a unit. 4 Bulkhead bracket assembly: 250 kg
25. Remove dashboard front duct (44).
26. Sling universal joint (45), remove the mounting bolts, and remove the universal joint. [*7] 4 Universal joint assembly: 40 kg 27. Remove front mounting bolts (46) and rear mounting bolts (47). [*8]
24. Remove damper case oil level gauge (43) and the bracket as a unit.
50-66
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine assembly
28. Remove the engine assembly according to the following procedure. 1) Install the lifting tools to parts [A] and [B].
Installation q Carry out installation in the reverse order to removal. [*1] a Install the belt. For details, see Testing and adjusting (Part 1), "Replacement and adjusting of alternator and air conditioner compressor belts". [*2]
3
Fuel supply hose:90 – 95 Nm {9.2 – 9.7 kgm}
[*3]
3
2) Lift up engine assembly (48). 4 Engine assembly:3,320 kg 3) While moving engine assembly (48) toward the front of the machine, operate the chain block to raise the front of the engine to slant the engine assembly. 4) After the front and rear portions of the engine assembly (48) clear the machine body parts (the aftercooler assembly), turn the engine assembly toward the right of the machine by 90 degrees to allow it to clear the blade lift cylinder and cab, and then remove it. a When removing, take care not to damage the wiring and hoses.
D375A-6 (02)
Radiator inlet hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3
Air vent hose clamp: 3.3 ± 0.5 Nm {0.34 ± 0.05 kgm} [*5] [*6] MIKALOR clamps (MC10), (MC20), (MC23) a Use a new MIKALOR clamp. 1) Set each hose to the original position. (Hose insertion depth: 80 mm) 2) Adjust the position of bridge (BR) so that the bridge is under the band. a Secure at least 5 mm of overlap (b) between the bridge and band (BD). 3) Tighten clamp bolt (BC). a Do not use an impact wrench for tightening. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) q When reusing the hose a Install the clamp aligning it with the clamp mark made on the hose. 3 Clamp bolt (BC): Min. 6 Nm {0.6 kgm} q When using a new hose a Tighten the clamp so that dimension BDG is as follows. MC10:7 – 10 mm MC20:17 – 20 mm MC23: 20 – 23 mm
50-67
DRAFT Engine and cooling system Removal and installation of engine assembly
Constant torque clamp (CTC) 3 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} (TC): Turbocharger
50-68
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine assembly
[*7]
3
Universal joint mounting bolt: 156.9 – 196.1 Nm {16 – 20 kgm}
[*8]
3
q
Engine mounting bolt: 823 – 1,029 Nm {84 – 105 kgm}
Refilling of coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 120 l
D375A-6 (02)
50-69
DRAFT Engine and cooling system Removal and installation of engine hood assembly
Removal and installation of engine hood assembly 5. Remove right cover (3-1) and left cover (3-2). Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Remove radiator upper inspection cover (1).
6. Remove cover (3). 7. Remove precleaner cover (4).
2. Disconnect headlamp connector LHD (1-1). 3. Disconnect reservoir tank hose (1-2). 4. Lift off radiator upper cover (2). 4 Radiator upper cover:80 kg
8. Disconnect connectors EG5(5-1) and EG4(5-2) at the right rear of the hood. 9. Disconnect clamp (5-3) at the right rear of the hood.
50-70
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine hood assembly
10. Disconnect connector RDG (6) at the front of the hood.
16. Remove rear mounting bolts (11). a Take care not to drop plate NP.
11. Loosen the clamp and remove air cleaner hose (7). [*1] a Securely cover the air cleaner outlet and the air intake port on the impeller side of the turbocharger to prevent foreign matter from entering.
17. Remove front mounting bolts (12a).
[*2]
12. Remove the bolts and remove KOMACLONE hose and tube assembly (8) from the muffler.
13. Disconnect reservoir tank hose (9) from the reservoir tank. 14. Disconnect reservoir tank hose clamp (9a). 15. Disconnect duct (10).
D375A-6 (02)
50-71
DRAFT Engine and cooling system Removal and installation of engine hood assembly
18. Lift up engine hood assembly (12). 4 Engine hood assembly: 350 kg
Installation Carry out installation in the reverse order to removal. [*1] 3 Air cleaner hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
q
[*2] Install the front mounting bolts according to the following procedure. 1) Install resin plates (14) so that hood (13) is sandwitched between them. 2) Install washer (15). 3) Install bolt (16).
q
50-72
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine front seal
Removal and installation of engine front seal 4. Remove dust seal (7).
Seal puller assembly Push tool (for oil 795T-621-1180 seal) A Push tool (for 4 795T-621-1171 dust seal) 795-902-1460 Bolt 01582-02218 Nut 3 795-931-1100
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools 5. Remove front seal (8) according to the following procedure.
t 1 t 1
Q
t 1
Q
t 3 t 3
Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Remove the radiator guard assembly. For details, see "Removal and installation of radiator guard assembly".
1) Change the end of tool A3 to the hook type one. 2) Hitch the hook to the metal ring of front seal (8). 3) Remove the front seal with impact of slide hammer (SH). q
Tool A3
2. Sling crankshaft pulley and damper assembly (1). 3. Lift off crankshaft pulley and damper assembly (1). [*1] 4 Crankshaft pulley and damper assembly (1): 40 kg
a CS : Crankshaft
D375A-6 (02)
50-73
DRAFT Engine and cooling system Removal and installation of engine front seal
Installation 1. Clean, degrease and then dry the front cover contact surface on the front seal. 2. Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean, degrease, and dry the seal lip sliding surface (peripheral surface of the crankshaft). a Check that the crankshaft end face corners, seal lip sliding surface and housing are free from dents, burrs, rust, oil, grease or water. 3. Install front oil seal (8) according to the following procedure. a Before installing the seal, check that crankshaft end face corners, seal lip sliding surfaces and housing are free from flaws, burr, fins, rust, etc. a When installing the seal, do not apply oil or grease to the crankshaft and seal lip. Wipe off oil from the crankshaft thoroughly. 1) Install the oil seal directing its side stamped with "IN" toward the inside of the engine. a The "OUT" stamped side is directed toward the outside of the engine.
3) Using tool A4 (for dust seal), press fit dust seal (7) to the front cover to dimension (b) shown in the figure. a Dust seal press fitting dimension (b): 2 mm (Projection from the front cover end face)
q
Carry out the subsequent installation in the reverse order to removal.
[*1]
3
a Take care not to install the wrong end. 2) Using tool A4 (for oil seal), press fit oil seal (8) to the front case to dimension (a) shown in the figure. a Oil seal press fitting dimension (a): 18.5 mm (when measured from the front cover end face)
50-74
Crankshaft pulley mounting bolt: 1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm} 2nd time: 225.4 – 264.6 Nm {23 – 27 kgm} 3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine rear seal
Removal and installation of engine rear seal
Symbol
Part No.
Part name
Seal puller assembly Push tool 795T-621-1161 (for standard seal A and sleeved seal) 5 Push tool 795T-621-1190 (for sleeved seal) 01050-32235 Bolt 01050-32245 Bolt 3 795-931-1100
Necessity Q'ty New/remodel Sketch
Special tools
t 1 t 1
Q
t 1
Q
t 5 t 5
Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Remove the damper assembly. For details, see "Removal and installation of damper assembly". 2. Remove one of the mounting bolts of flywheel (1) and install guide bolt [1]. 3. Using eyebolt [2], sling flywheel (1) and remove the remaining mounting bolts. [*1] 4. Move flywheel (1) toward this side and lift it off. k Since the socket portion of the flywheel is shallow, the flywheel may fall suddenly. Take care not to get your finger caught. 4 Flywheel: 85 kg
D375A-6 (02)
5. Remove rear seal (2). a Take care not to damage the seal installation position on the flywheel housing and the seal contact surface on the crankshaft. a Before removing, slightly tap the front seal once to unstick it. a When rear seal (2) is fixed too hard to the flywheel housing (FWH), perform the following procedure. a The left one in the following figure shows the standard seal and the right one shows the sleeved seal. 1] Change the end of tool A3 to the drill type one. 2] Drill several holes about 3 mm in diameter in rear seal (2). 3] Set tool A3 to the drilled hole. 4] Remove the rear seal with impact of slide hammer (SH). a For the sleeved seal, cut sleeve (5) using a chisel and hammer to remove it. a Take care not to damage crankshaft (4). a Remove all the broken pieces of the rear seal.
q
Tool A3
50-75
DRAFT Engine and cooling system Removal and installation of engine rear seal
Installation a Check the wear of the crankshaft and select the type of the Teflon seal (laydown lip seal) to install, "standard seal" or "sleeved seal", depending on the wear of the crankshaft. a If the crankshaft is worn to a degree of luster (you can feel the wear with the pad of your finger and the wear depth is a maximum of 10 mm) and there are no scratches, install standard seal (A). In other cases, install sleeved seal (B). a (3): Shows the plastic inside cylinder doubling as the Installation guide. a (5): Shows the sleeve. a Don't remove Installation guide (3) from rear seal (2) before Installation. a Handle rear seal (2) and sleeve (5) as a unit. Don't try to separate them.
a Clean, degrease and then dry the flywheel housing contact surface on the rear seal. a Clean, degrease, and dry the seal lip sliding surface (peripheral surface of the crankshaft). a Check that the crankshaft end face corners, seal lip sliding surface and housing are free from burrs, dents, rust, etc.
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Installation procedure for standard seal a Do not apply grease, oil, etc. to the seal lip sliding surface. 1) Set the large inside diameter side "(2)" of plastic inside cylinder (3) of rear seal (b) to the end of crankshaft (4). a Take care not to install the wrong end of the plastic inside cylinder.
q
2) Hold the metal ring of rear seal (2) with both hands and push it in firmly. 3) After pushing in rear seal (2), remove plastic inside cylinder (3). a When removing the inside cylinder, take care not to damage the seal lip.
D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of engine rear seal
4) Tighten the bolts evenly to press fit rear seal (2) until the end face of tool A5 touches the end face of crankshaft (4). a Oil seal press fitting dimension (when measured from the crankshaft end face) (a):20 mm a After press fitting the rear seal, remove the red sealant layer from its periphery.
q
Installation procedure for sleeved seal a When installing the rear seal, do not apply oil, grease, etc. to the crankshaft, the inside cylindrical surface (C) of the sleeve, or the seal lip surface. 1) Set sleeve and rear seal assembly (6) to tool A5 (for press fitting the sleeved seal). 3 Sleeve inside cylindrical surface (C): Liquid gasket (LG-7) 2) Place sleeve (5) of the rear seal to the end face of crankshaft (4) and tighten the five bolts evenly to press fit sleeve and rear seal assembly (6) until the end face of tool A5 touches the end face of the crankshaft (4).
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3) Remove tool A5 (for press fitting the sleeved seal) and install tool A5 (for press fitting the standard seal). 4) Tighten the five bolts evenly to press fit sleeve and rear seal assembly (6) until the end face of tool A5 (for press fitting the standard seal) touches the end face of crankshaft (4). a Use the bolts (stem length: 45 mm) to tighten tool A5 (for press fitting the standard seal) first, and then tighten tool A5 (for press fitting standard seal) with the bolts (stem length 35 mm). a Driving depth of rear seal (a) (from crankshaft end face): 20 mm a After press fitting the rear seal, remove the red sealant layer from its periphery.
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Carry out the subsequent installation in the reverse order to removal.
[*1] Flywheel assembly a If there are 5 punch marks on the head of a bolt, do not reuse that bolt but replace it. a Fix the flywheel by using the bolt holes in the flywheel and flywheel housing so that the flywheel does not turn. a Tighten the mounting bolts in the order shown in the figure. 2 Flywheel assembly mounting bolt: Engine oil
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DRAFT Engine and cooling system Removal and installation of engine rear seal 3
Flywheel assembly mounting bolt: 1st time: 196.1 ± 19.6 Nm {20 ± 2 kgm} 2nd time: 460.9 ± 19.6 Nm {47±2kgm} 3rd time: 90 – 120 ° Retightening a After tightening the bolt, make a punch mark (a) on its head. (When a new bolt is used, do not make a punch mark on its head.)
Measure radial runout and facial runout of the flywheel using dial gauge [1]. a Standard radial and facial runout:
q
Measurement items Radial runout Facial runout
Tolerance (mm) Approx. 0.13 0.0005 × Diameter of measuring point
a When the measured value is out of the standard, determine the cause by disassembling the flywheel.
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D375A-6 (02)
DRAFT Engine and cooling system Removal and installation of fan drive assembly
Removal and installation of fan drive assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Drain the hydraulic oil. 6 Hydraulic oil: 130 l
5. Remove fan nets (4), (5), and (6). 6. Remove wiring harness clamp (7) and disconnect the connector.
2. Remove radiator mask (1).
7. Disconnect fan motor pipes (8), (9), and (10).
3. Remove mark plate (2).
4. Remove bracket (3). a Disconnect the horn connector and then remove it.
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DRAFT Engine and cooling system Removal and installation of fan drive assembly
8. Lift off fan drive assembly (11). [*1] 4 Fan drive assembly: 200 kg a Install the wire to the left and right of the fan drive, lift it at a point, and pull out it evenly to remove.
Installation q Carry out installation in the reverse order to removal. [*1] a Ensure that position (m) of the reflector tape for measuring the fan speed is of the specified dimension. Distance (m) from fan blade end: Max. 5 mm a After installing the fan, check clearance (l) between the fan blade and the shroud. If the clearance is larger or smaller than the specified dimension, adjust it. Clearance (l): 6 + 3/ - 1 mm
q
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Refilling of oil (Hydraulic tank) Supply 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. 5 Hydraulic tank: 130 l
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DRAFT Engine and cooling system Removal and installation of fan motor assembly
Removal and installation of fan motor assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Remove the fan drive assembly. For details, see "Removal and installation of fan drive assembly". 2. Remove the mounting bolt and lock plate (1). [*1] 3. Remove nut (2).
[*2]
4. Using puller [1], remove fan (3). [*3]
5. Remove the four mounting bolts and fan motor assembly (4). 4 Fan motor assembly: 60 kg
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DRAFT Engine and cooling system Removal and installation of fan motor assembly
Installation q Carry out installation in the reverse order to removal. [*1] Be sure to adjust the hole of lock plate (1) by turning nut (2) in the tightening direction. [*2]
3
Mounting (2): 1,079 – 1,275 Nm {110 – 130 kgm} a After tightening the nut, measure dimension (d) shown in the following figure. q Min: 1.2 mm q Max: 3.0 mm
[* 3] a Wipe off dirt from fitting parts (P) of the fan motor and fan boss and degrease those parts.
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DRAFT Engine and cooling system Removal and installation of fuel tank assembly
Removal and installation of fuel tank assembly 7. Remove cover (12). Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Remove (1) and (2).
8. Disconnect fuel return hoses (13).
2. Open fuel drain valve (3) to drain fuel. 6 Fuel: 1,200 l (at full) 3. Close fuel stop valve (4), and disconnect fuel drain hose (5). 4. Remove mounting bolts (7) of filter assembly (6), and remove filter assembly (6) together with the fuel hose. 5. Close fuel drain valve (3), and disconnect hose clamps (8). 6. Remove mounting bolt (10) of bracket (9), and disconnect fuel drain hose (11).
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9. Disconnect wiring connector FGS (14) of the fuel level sensor.
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DRAFT Engine and cooling system Removal and installation of fuel tank assembly
10. Remove three mounting bolts (15) from each side of the fuel tank.
Installation q
Carry out installation in the reverse order to removal.
(Refilling) Fill fuel through the fuel filler port. 5 Fuel tank: 1,200 l (at full)
11. Lift off fuel tank assembly (16). 4 Fuel tank assembly: 600 kg (tank only) a Reference: 1,500 kg (when tank is full)
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DRAFT Engine and cooling system Removal and installation of fuel tank assembly
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DRAFT Power train Removal and installation of damper assembly
Power train Removal and installation of damper assembly Removal k k k
Park the machine on a level surface and lower the work equipment to the ground. Set the parking brake lever and work equipment lock lever in the lock position. Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
1. Open left and right engine side covers (1) and lock them. a Check that they are securely locked. 5. Open undercover (7) slowly using lifting tools [1].
2. Remove cover (2). 3. Remove cover (3).
4. Remove covers (4), (5) and (6).
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DRAFT Power train Removal and installation of damper assembly
6. Remove universal joint assembly (8). [*1] a Sling the universal joint assembly and lower it to remove. 4 Universal joint assembly: 40 kg
9. Remove divider board (11).
10. Remove bolt (12) and remove holder (13). [*2] 11. Remove coupling (14). 7. Loosen drain plug (9) to drain damper case oil. 6 Damper case: 2.1 l
.
8. Remove oil level gauge (10) and bracket as a unit.
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DRAFT Power train Removal and installation of damper assembly
12. Remove the damper cover according to the following procedure. [*3] 1) Using eyebolt [1] attached to the damper, sling damper cover (15). 2) Remove two damper cover mounting bolts (16) marked with a in the drawing, and install guide bolts [2]. k Be sure to use guide bolts to prevent the damper cover from coming off abruptly. (M12 x 1.75 x 200 mm) 3) Remove the remaining damper cover mounting bolts (16) marked with *, and lift off damper cover (15). a If it is difficult to remove the damper cover, use forcing screws [3] (M12 x 1.75). a Install forcing screws [3] at 3 places, and tighten them evenly. 4 Damper cover: 75 kg
a Tighten forcing screws [3] evenly. Damper assembly: 70 kg
4
14. If bearing (19) is damaged, remove bearing (19).
13. Remove the damper according to the following procedure. [*4] 1) Using eyebolt [4], sling damper (17). 2) Install guide bolts [5]. k Be sure to use guide bolts to prevent the damper from coming off abruptly. (M16 x 2 x 200 mm) 3) Remove mounting bolts (18), and lift off damper (17). a If it is difficult to remove the damper, use forcing screws [3].
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DRAFT Power train Removal and installation of damper assembly
Installation q
Carry out installation in the reverse order to removal.
[*5] Fill gap (a) at the hatched area in the illustration with grease (G2-LI) by approx. 50% (11 g).
[*1]
3
Universal joint mounting bolt: 156.8 - 196 Nm {16 - 20 kgm}
[*2]
3
Holder mounting bolt : 245 - 309 Nm {25 - 31.5 kgm}
[*3] a Install the damper cover according to the following procedure. 1) Using guide bolts [2] (M12 x 1.75 x 200 mm), position the damper cover. 2) Finger-tighten twelve mounting bolts (16) (indicated by * mark). 3) Remove guide bolts [2] and finger-tighten the remaining two bolts. 4) While tightening fourteen mounting bolts gradually and evenly, press fit bearing (19) and damper shaft (3) to install.
(Refilling) Fill the damper case with oil. 5 Damper case: 2.1 l (engine oil EO-DH)
[*4] a Using guide bolts [5] (M12 x 2 x 200 mm), position the damper.
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DRAFT Power train Disassembly and assembly of damper assembly
Disassembly and assembly of damper assembly Disassembly of damper assembly 1. Place the damper assembly on block [1].
6. Remove seal (7) from each of flanges (2) and (5).
2. Remove mounting nuts (1) and remove flange (2) using forcing screws [2].
Disassembly of damper cover assembly 1. Remove bearing (8) and oil seal (9) from cover (10). 3. Remove shaft (3).
2. Remove oil seal (11) from retainer (12).
4. Remove rubbers (4). 5. Using forcing screws [2], remove flange (5) from body (6).
.
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DRAFT Power train Disassembly and assembly of damper assembly
Assembly of damper assembly 1. Install seal (7) to each of flanges (2) and (5). a Install the seal with the lip facing the inside as shown in the figure.
2. Install flange (5) to body (6), while matching their bolt holes with each other. 2 Mating face of flange: Liquid gasket (LG-4) a Check that the mating faces are free from dents, rust, oil, grease and water, and apply the liquid gasket to the surfaces of both the flange and the body.
5. Install flange (2). 2 Mating face of flange: Liquid gasket (LG-6) a Check that the mating faces are free from dents, rust, oil, grease and water, and apply the liquid gasket to the surfaces of both the flange and the body. 6. Set the bolts and tighten mounting nuts (1).
3. Place the flange and body assembly on the block and set shaft (3). 4. Install the rubbers. a Check the installed positions of large rubber (4a) and small rubber (4b). (Install the large rubber to large diameter side (R) of body (BD) and install the small rubber to small diameter side (r).) a When installing the rubbers, apply grease (G2-LI)) to all surfaces of the rubbers, the outside of the shaft, and the inside of the body (BD). a After installing the rubbers, supply grease (G2-LI) of approx. 30 % (190 g) to gaps (CL) (16 places) between the shaft and body.
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DRAFT Power train Disassembly and assembly of damper assembly
Assembly of damper cover assembly 1. Using push tool [3], press fit oil seal (11) to retainer (12). 2 Oil seal press fitting surface on retainer: Liquid gasket (LG-1) a Apply a thin film of the liquid gasket to the inside of the retainer and wipe off any liquid gasket that is squeezed out. 2 Oil seal lip: Grease (G2-LI)
2. Using push tool [4], press fit bearing (8) to cover (10).
3. Using push tool [5], press fit oil seal (9) to cover (10). 2 Oil seal press fitting surface on cover: Liquid gasket (LG-1) a Apply a thin film of the liquid gasket to the inside of the cover and wipe off any liquid gasket that is squeezed out. 2 Oil seal lip portion: Grease (G2-LI)
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DRAFT Power train Removal and installation of power train unit assembly
Removal and installation of power train unit assembly Removal k Park the machine on a level place and lower the work equipment to the ground completely. k Set the parking brake lever and work equipment lock lever in the lock position. k Release the residual pressure in the hydraulic tank and piping. For details, see Testing and adjusting, "Releasing residual pressure in work equipment cylinders". k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Drain the oil from the hydraulic tank. 6 Hydraulic tank: 130 l 2. Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly". 3. Remove the ROPS guard. For details, see "Removal and installation of ROPS guard". 4. Remove the operator cab assembly. For details, see "Removal and installation of operator cab assembly". 5.
Remove the floor frame assembly. For details, see "Removal and installation of floor frame assembly".
7. Sling universal joint assembly (2) and lower it to remove. [*1] 4 Universal joint assembly: 40 kg
6. Using sling [1], open undercover (1) gradually.
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DRAFT Power train Removal and installation of power train unit assembly
8. Disconnect wiring connectors (3) from bracket (3a).
12. Disconnect wiring connectors VDA (9), LRR (10), FD2 (11), and VDB (12).
9. Disconnect wiring clamps (4) and (5).
13. Disconnect wiring clamps (13) and (14). 14. Remove bracket (15).
10. Disconnect wiring (6) and (7). 15. Disconnect ripper lift hoses (16) and ripper tilt hoses (17).
11. Disconnect wiring connector 241 (8).
16. Disconnect ripper pin puller hoses (18).
.
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DRAFT Power train Removal and installation of power train unit assembly
17. Disconnect hose (19) and clamps (20).
18. Disconnect return hoses (21) to (24) running to the hydraulic tank.
21. Disconnect work equipment hose (29) from the work equipment valve.
22. Disconnect hose clamps (30) to (33). 19. Disconnect work equipment valve hose (25).
20. Disconnect suction tube (26) from coupling (27) and flange (28).
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DRAFT Power train Removal and installation of power train unit assembly
23. Disconnect oil cooler hose (34) on the left side of the torque converter from the torque converter.
24. Disconnect oil cooler hose (35) at the left bottom of the power train.
25. Remove damper oil level gauge (36).
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DRAFT Power train Removal and installation of power train unit assembly
26. Remove cover (37).
27. Pull out left and right drive shafts (39) according to the following procedure. [*3] 1) Remove cover (38). 2) Install eyebolt [2] to drive shaft (39). 3) Pull out drive shaft (39). a If the drive shaft cannot be pulled out, push up the shoe grouser by using jack [3] from the ground to rotate the sprocket clockwise or counterclockwise, and set it to a position where the shaft can be pulled out easily. a Pull out the shaft until it touches the sprocket.
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DRAFT Power train Removal and installation of power train unit assembly
28. Remove left and right rear mount caps (40).
29. Loosen left and right rear coupling clamps (41). [*2] a Reposition the clamp toward the main frame, and open the coupling to reposition the seal toward the main frame.
32. Remove four power train mounting bolts (44) each on the left and right sides. [*4]
33. Lift off power train assembly (45). a Install sling to parts [A] and [B] and lift up the power train assembly while balancing it horizontally.
30. Remove oil filler tube clamp (42) of the power train case. 31. Remove bracket (43).
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DRAFT Power train Removal and installation of power train unit assembly
Installation q
Carry out installation in the reverse order to removal.
q
Bleeding air Bleed air from the piping. For details, see Testing and adjusting, "Bleeding air from work equipment cylinders".
a When installing the power train unit assembly, focus your attention on the mating face of the coupling in order not to damage the seal of the coupling. [*1] 3 Universal joint mounting bolt: 156.8 – 196 Nm {16 – 20 kgm} [*2]
3
Mounting nut of rear coupling clamp: 4.9 – 8.82 Nm {0.5 – 0.9 kgm}
[* 3] a If the drive shaft cannot be inserted, push up the shoe grouser by using a jack from the ground to rotate the sprocket clockwise or counterclockwise, and set it to a position where the shaft can be inserted easily. [*4] a Install left front mount (46a) and right front mount (46b) of the power train unit with the tap holes (t) on their side facing the front of the machine.
Refilling of oil (Hydraulic tank) a Supply 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. 5 Hydraulic tank:130 l (Power train oil) Refilling of oil (Power train case) a Supply 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. Reference Power train case:150 l (Power train oil)
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DRAFT Power train Disconnection and connection of power train unit assembly
Disconnection and connection of power train unit assembly 2) FA2 (7), intermediate connector (8) Disconnection a Before disconnecting the wires and hoses, fit them with tags to show their connecting locations. 1. Lift power train unit assembly (1) and place it on blocks [1] to [4]. a Use blocks of sufficient height so that the oil can be easily drained. 2. Drain the oil from the power train case. 6 Power train case:150 l 3) SLB (9), FLB (10), SRB (11), FRB (12), FRC (13), SRC (14), FLC (15), SLC (16)
3. Disconnect the following wiring connectors and remove the wiring. a Disconnect all the related wiring clamps. 1) SSTC (2), FSTC (3), SLUC (4), FLUC (5), FA1 (6)
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4) STB (17), TM1 (18), TC1 (19)
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DRAFT Power train Disconnection and connection of power train unit assembly
5) TOP (20), 453 (21)
4. Remove hydraulic hoses (22) to (36). a Remove hoses (24) and (28) as a unit.
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DRAFT Power train Disconnection and connection of power train unit assembly
5. Disconnect the fifteen pressure pickup hoses and remove them together with the central pressure pickup bracket according to the following procedure. 1) Remove suction tube (37). 2) Remove covers (38) and (39).
3) Disconnect steering clutch pressure pickup hoses (40) and (42) and brake pressure pickup hoses (41) and (43). (Hose band color) Left clutch pressure (40): Black Left brake pressure (41): White Right clutch pressure (42): White/Black Right brake pressure (43): Yellow
4) Disconnect transmission gear shift clutch pressure pickup hoses (44) to (48). (Hose band color) 1st (44): Red 3rd (45): Yellow/Black Reverse (46): Red/Blue 2nd (47): White/Yellow Forward (48): White/Blue
5) Disconnect torque converter output pressure pickup hose (49). (Hose band color): White/Red
.
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DRAFT Power train Disconnection and connection of power train unit assembly
6) Disconnect pressure pickup hoses (50) to (53) connected to the ECMV valves. (Hose band color) Transmission main relief pressure (50): Torque converter inlet pressure (51): Blue Lockup clutch pressure (52): Yellow/Red Stator clatch pressure (53): Yellow/Blue 7) Disconnect power train lubrication pressure pickup hose (54). 8) Remove pressure pickup hose (55) and pressure pickup block (56) as a unit. 6. Remove hydraulic tube (88) between the torque converter and transmission.
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7. Remove the following parts. 1) Oil level gauge (57) 2) Oil filler pipe (58) 3) Oil filter assembly (59) 4 Oil filter assembly: 120 kg 4) Strainer assembly (60) 4 Strainer assembly: 50 kg 5) Work equipment pump assembly (61) 4 Work equipment pump assembly: 110 kg 6) Power train pump and lubrication pump assembly (62) 4 Power train pump and lubrication pump assembly: 40 kg 7) Scavenging pump assembly (63) 4 Scavenging pump assembly: 25 kg 8) Fan pump assembly (64) 4 Fan pump assembly: 80 kg
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DRAFT Power train Disconnection and connection of power train unit assembly
8. Disconnect the steering case assembly according to the following procedure. 1) Remove case mounting bolts (65). 2) Remove case (66) and bearing cage assembly (67) and torque converter speed sensor (67a) as a unit. 3) Remove shaft (68). [*1]
9. Disconnect the PTO unit assembly according to the following procedure. 1) Remove coupling (71). 2) Remove front mount (71a). 4 Front mount: 150 kg
4) Sling steering case assembly (69). 5) Remove two mounting bolts (70) and install two guide bolts [5]. 6) Remove remaining mounting bolts (70). 7) Lift off steering case assembly (69). [*2] 4 Steering case assembly: 1,800 kg a Lift the steering case assembly by 3-point lifting and disconnect it along the guide bolts. a After disconnecting the steering case assembly, remove the guide bolts.
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DRAFT Power train Disconnection and connection of power train unit assembly
3) Remove bracket (72).
4) Remove eye plates (73), reverse them, and install them in the same positions at the left and right.
2] Shorten sling [7] to slant “PTO, torque converter and transmission” assembly (74).
3] Disconnect sling [6] from the transmission and use lifting tool [8] to connect sling [6] to the PTO unit. 4] Shorten sling [6] to set “PTO, torque converter and transmission” assembly (74) upright.
5) Place “PTO, torque converter and transmission” assembly (74) on blocks with the PTO unit up according to the following procedure. 1] Install slings [6] and [7]. a Install sling [7] so that its length is adjustable.
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DRAFT Power train Disconnection and connection of power train unit assembly
6) Sling oil pan case (75) and remove two mounting bolts (76), eight mounting bolts (77) and four mounting bolts (78). 7) Lift off oil pan case (75). [*3] 4 Oil pan case: 110 kg
9) Remove retainer (80). [*4] a Note the thickness and quantity of the shims. 10)Remove snap ring (81) and spacer (82).
11)Remove the PTO assembly mounting bolts. 12)Lift off the PTO assembly. 4 PTO assembly: 300 kg 10. Sling torque converter assembly (89) and remove the nineteen mounting bolts. [*5] a The upper three mounting bolts are installed from the transmission side. 11. Lift off torque converter assembly (89). 4 Torque converter assembly: 550 kg
8) Sling PTO assembly (79).
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DRAFT Power train Disconnection and connection of power train unit assembly 3
Connection q
Steering case mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
Carry out connection in the reverse order to disconnection.
[*1] a Check that shaft (68) is inserted in boss (83) at the end of the transmission input shaft.
[*3] When installing the gasket, carefully observe the following. a Use a new gasket. a Check that the mating faces of the case and cover are free from dents, rust, oil, grease and water. a Apply liquid gasket to both the mating faces of the case and cover. 2 Mating faces of case and cover: Liquid gasket (LG-6) a Apply liquid gasket continuously around the tap holes and bolt holes as shown in the figure. (Positions to apply liquid gasket) (L1): Intermediate position between inside face of oil pan case and tap holes or bolt holes (L2): Center of inside and outside faces of oil pan case (Quantity of liquid gasket to apply) B x H = 2 to 5 cc
q
.
a When installing case (66) and bearing cage assembly (67), check that shaft (68) is inserted in drum (84) of the bearing cage assembly securely and then install the case mounting bolts.
(OUT): Outside face of oil pan case (IN): Inside face of oil pan case (TP): Tap hole (HL): Bolt hole
[*2] a When installing steering case (69), install guide bolts [5] and install the steering case along them. D375A-6 (02)
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DRAFT Power train Disconnection and connection of power train unit assembly
a Set shims (87) as shown in the figure so that they do not block forcing screw tap holes (H) of retainer (80).
[*4] q Adjust the retainer shim according to the following procedure. 1) Install retainer (80) without inserting any shim and tighten the mounting bolts to the following torque. 2 Oil seal: Grease (G2-LI) 3 Retainer mounting bolt: 9.8 Nm {1 kgm} 2) Using thickness gauges, measure clearance (a) between retainer (80) and PTO housing (86). a Measure clearance (a) at 4 places (A, B, C, and D) on the periphery and calculate the average.
[*5]
3
Torque converter assembly mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
Refilling of oil (power train case) a Supply oil through oil filler to the specified level. a After installing the power train unit assembly on the machine, start the engine to circulate the oil through the system. Then, check the oil level again. 5 Power train case:150 l (Power train oil)
3) Determine the total thickness of the shim pack and select shims to tbe installed in clearance (a). a Total shim thickness: (a) + 0 - 0.05 mm a Available shims: 0.15 mm, 0.2 mm, 0.5 mm 4) Install the shims of the calculated thickness and tighten the mounting bolts of retainer (80) to the specified torque. 3 Retainer mounting bolt : 58.8 – 73.5 Nm {6 – 7.5 kgm} a Determine the quantity and thickness of the shims so that the thickness is the same on both the left and right sides.
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DRAFT Power train Disassembly and assembly of PTO assembly
Disassembly and assembly of PTO assembly Disassembly
3) Using puller [2], remove bearings (5) and (6) from gear (7).
1. PTO lubrication tube Sling PTO assembly and remove lubrication tube (1). a Remove the three lubrication tubes installed on the opposite side, then lower the assemble on blocks with its face to be jointed to the torque conventer up.
3. Power train pump gear assembly 1) Using forcing screws [1], pull out cover assembly (8) and lift it off. 2) Using the puller, remove gear assembly (10) from cover (9).
2. Work equipment and PPC pump gear assembly 1) Using forcing screws [1], pull out cover assembly (2) and lift it off. 2) Using puller [2], remove gear assembly (3) from cover (4).
3) Using puller [2], remove bearings (11) and (12) from gear (13).
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DRAFT Power train Disassembly and assembly of PTO assembly
4) Reverse the PTO case and remove cover (14). 4. Scavenging pump gear 1) Remove snap ring (15) from under the PTO case, then remove gear (16).
4) Remove bearing outer races (21) and (22) from gear (23).
5. Idler gear assembly 1) Remove plate (17).
6. PTO case 1) Remove race assembly (24) and bearing outer race (25) as a unit.
2) Reverse the PTO case and remove shaft assembly (18) by using forcing screws [1]. a Since the bearing outer race and gear assembly come off the bottom of the PTO case, place wooden blocks under them to protect them from being damaged. 3) Remove plugs (19) and push out bearing inner race (20) by using forcing screws. a After removing the bearing, install the plugs.
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DRAFT Power train Disassembly and assembly of PTO assembly
2) Remove bearing inner races (26) and (27) from race (28).
Assembly a Clean all parts, and check them for dirt and damage before installing. a Check that the snap ring is fitted securely in the groove. 1. Bearing 1) Using the push tool, press fit bearing (32) to the case. a Drop approx. 6 cc of power train oil (TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns. 2) Install snap ring (31).
3) Remove bearing outer race (29). 4) Remove sleeve (30).
7. Bearing Remove snap ring (31) and bearing (32).
D375A-6 (02)
2. PTO case 1) Install sleeve (30) to the case. a Install the sleeve with the chamfered inside edge facing down. a Expand-fit the sleeve. 2) Using the push tool, press fit bearing outer race (29).
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DRAFT Power train Disassembly and assembly of PTO assembly
3) Using the push tool, press fit bearing inner races (27) and (26) to race (28).
4) Install race assembly (24). 2 Inside surface of race: Molybdenum disulfide lubricant (LM-P) 5) Using the push tool, press fit bearing outer race (25). a Drop approx. 6 cc of power train oil (TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns.
2) Using push tool [4], press fit bearing inner race (20) to the shaft. 3) Fit the O-ring and install shaft assembly (18).
4) Turn over the PTO case and install gear assembly (33). 5) Press fit bearing spacer (34) and bearing inner race (35). a Drop approx. 6 cc of power train oil (TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns.
. 3. Idler gear 1) Using push tool [3], press fit bearing outer races (22) and (21) to gear (23).
.
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DRAFT Power train Disassembly and assembly of PTO assembly
6) Install plate (17). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 110.35 ± 12.25 Nm {11.25 ± 1.25 kgm}
2) Using push tool [5], press fit bearings (11) and (12) to gear (13).
4. Scavenging pump gear 1) Install gear (16). 2 Spline: Grease (G2-LI)
2) Install snap ring (15) from under the PTO case. 5. Power train pump gear assembly 1) Fit the O-ring and install cover (14).
D375A-6 (02)
3) Using push tool [6], press fit gear assembly (10) to cover (9). 2 Gear spline: Grease (G2-LI) 4) Fit the O-ring, then hoist cover assembly (8) to install to the case. a If the cover assembly does not fit in the case, tap its periphery evenly with a plastic hammer to install. a Drop approx. 6 cc of power train oil (TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns.
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DRAFT Power train Disassembly and assembly of PTO assembly
6. Work equipment pump and PPC pump gear assembly 1) Using push tool [5], press fit bearings (5) and (6) to gear (7).
7. Lubrication tube Sling the PTO assembly and install lubrication tube (1). a Install three lubrication tubes also on the opposite side.
2) Using push tool [6], press fit gear assembly (3) to cover (4). a Set the assembly with the side where the bearing end face is flush with the gear end face facing the cover. 2 Gear spline: Molybdenum disulphide grease (LM-G) 3) Fit the O-ring, then hoist cover assembly (2) and install to the case. a If the cover assembly does not fit in the case, tap its periphery evenly with a plastic hammer to install. a Drop approx. 6 cc power train oil (TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns.
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D375A-6 (02)
DRAFT Power train Disassembly and assembly of torque converter assembly
Disassembly and assembly of torque converter assembly
Symbol
Part No.
790-413-1010 C
790-501-5000
Part name
Bracket Repair stand (100 V)
Necessity Quantity New/remodel Sketch
Special tools
t 1
t 1
Disassembly q
Preparatory work Set torque converter assembly (56) to tool C.
2) Using eyebolt [1] , remove lockup clutch and drive case assembly (4). 3) Disassemble the lockup clutch and drive case assembly according to the following procedure. 1] Remove two seal rings (5). 2] Using forcing screws [2], remove input shaft (6).
1. Torque converter valve assembly Remove torque converter valve assembly (1). 2. Draining of oil Remove two drain plugs (2) to drain the oil in the pump case. a After draining the oil, tighten the plugs. 3. Lockup clutch and drive case assembly 1) Leaving two mounting bolts (3) in position, remove other mounting bolts, then place the assembly with the input shaft side up and remove the remaining two mounting bolts.
D375A-6 (02)
3] Remove snap ring (7) and plate (8). 4] Set the assembly with the clutch housing side down, and using forcing screws [3], remove turbine (9).
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DRAFT Power train Disassembly and assembly of torque converter assembly
5] Set the assembly with the clutch housing side up and remove the housing and piston assembly (10) by using eyebolts [4]. a When the assembly is removed, the piston may fall out, so support it by hand when removing 6] Remove piston (11) from housing (12).
7] Remove seal ring (13) from the piston. 8] Remove seal ring (14) from the housing.
9] Using push tool [5], remove bearing (15) from the housing.
10] Remove two discs (16) and one plate (17) from drive case (18). a Keep the disc and plate on a flat surface so that they do not warp.
4. Stator assembly 1) Remove snap ring (19), then remove stator assembly (20). 2) Disassemble the stator assembly as follows. 1] Remove snap ring (21), then remove race (22) from stator (23).
2] Remove snap ring (24) from stator (23).
5. Pump assembly 1) Remove snap ring (25). 2) Remove pump assembly (26). 50-116
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DRAFT Power train Disassembly and assembly of torque converter assembly
3) Disassemble the pump assembly as follows. 1] Remove retainer (27). 2] Remove bearing and guide assembly (28) from pump (29).
7. Spring Remove springs (33). 8. Spring, disc, and plate Remove springs (34), two discs (35), and one plate (36). a Keep the disc and plate on a flat place so that they do not warp. 9. Pin Remove pins (37).
3] Remove bearing outer race (30) from guide (31). 6. Stator clutch housing Set the assembly with the stator clutch housing up and remove stator clutch housing (32). 10. Inner gear Remove snap ring (38), then remove inner gear (39). 11. Piston Remove piston (40) from case (41).
.
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of torque converter assembly
1) Remove seal ring (42) from the piston. 2) Remove seal ring (43) from the case.
12. Stator shaft assembly 1) Tap stator shaft assembly (44) with a plastic hammer to remove it from case (45). 2) Disassemble the stator shaft assembly as follows. 1] Using push tool [6], remove shaft assembly (45) from the stator shaft assembly.
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2] Remove snap ring (47) and remove bearing inner race (48), bushing (49), and seal ring (50) from the shaft. 3] Remove seal ring (51) and remove plate (54) 4] Remove snap ring (53) and plate (54).
5] Using push tool [7], remve bearing (55).
D375A-6 (02)
DRAFT Power train Disassembly and assembly of torque converter assembly
Assembly a Clean all parts, and check them for dirt and damage before installing. a Check that the snap ring is fitted securely into the groove. q
Preparatory work Set case (41) to tool C..
1. Stator shaft assembly 1) Assemble the stator shaft assembly according to the following procedure. 1] Using the push tool, press fit bearing (55) to stator shaft (52). 2] Install plate (54), and secure it with snap ring (53). 3] Install the seal ring (51). a After installing the seal ring, apply grease (G2-LI) to securely fix the seal ring to the shaft.
D375A-6 (02)
4] Install seal ring (50) to the shaft. a After installing the seal ring, apply grease (G2-LI) to securely fix the seal ring to the shaft. 5] Using push tool [9], press fit bushing (49). a When press fitting the bushing, take care not to deform it.
6] Using push tool [10], press fit bearing inner race (48). 7] Install snap ring (47) to fix the bearing inner race.
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DRAFT Power train Disassembly and assembly of torque converter assembly
2) Tap stator shaft (52) with a plastic hammer to press fit the bearing portion to the case. 3) Set shaft (46) to the stator shaft and press fit the bearing by using the push tool. 4) Turn over the case and tighten mounting bolts of the shaft from the case end. 2 Periphery of seal ring: Grease (G2-LI) 3 Mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
a Install the seal ring as shown in the figure since it has directional properties. (P: Direction of pressure)
3) Install piston (40) to case (41). 2 Seal ring contact surface: Grease (G2-LI)
2. Piston 1) Install seal ring (43) to the case. 2 Periphery of seal ring: Grease (G2-LI) a Install the seal ring as shown in the figure since it has directional properties. 2) Install seal ring (42) to the piston. 2 Periphery of seal ring: Grease (G2-LI)
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3. Inner gear Install inner gear (39) and secure it with snap ring (38).
D375A-6 (02)
DRAFT Power train Disassembly and assembly of torque converter assembly
4. Pin Install pins (37). 5. Plate, disc, and spring Install one plate (36), two discs (35), and springs (34). 6. Spring Install springs (33).
2] Set bearing and guide assembly (28) to pump (29), then tap the assembly with a plastic hammer to press fit the bearing portion. 3] Install retainer (27). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm} 2) Install pump assembly (26), a When installing the pump, take care not to damage the seal ring fitted to the shaft. 3) Install snap ring (25).
7. Stator clutch housing Install stator clutch housing (32). a Check that the springs are fitted securely in the holes in the housing and piston. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 110.35 ± 12.25 Nm {11.25 ± 1.25 kgm} 8. Pump assembly 1) Assemble the pump assembly as follows. 1] Using the push tool, press fit bearing outer race (30) to guide (31). a Drop approx. 6cc of power train oil (TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns.
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of torque converter assembly
9. Stator assembly 1) Assemble the stator assembly as follows. 1] Install snap ring (24) to stator (23).
2] Install two discs (16) and one plate (17).
2] Install race (22) to stator (23) and fix it with snap ring (21). 2) Install stator assembly (20) to the stator shaft, and secure it with snap ring (19).
3] Install seal ring (14) to the housing. 2 Periphery of seal ring: Grease (G2-LI) 4] Install seal ring (13) to the piston. 2 Periphery of seal ring: Grease (G2-LI) 10. Lockup clutch and drive case assembly 1) Assemble the lockup clutch and drive case assembly as follows. 1] Set turbine (9) to block [11], and set drive case (18) to the turbine.
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DRAFT Power train Disassembly and assembly of torque converter assembly
5] Install piston (11) to housing (12). 2 Seal ring contact surface: Grease (G2-LI) a When installing, take care not to damage the seal ring. 6] Using eyebolts [4], install housing and piston assembly (10). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 110.35 ± 12.25 Nm {11.25 ± 1.25 kgm}
2) Using eyebolt [1], install lockup clutch and drive case assembly (4). a When installing, match oil groove (a) of the turbine with drain plugs (2).
3) Tighten mounting bolts (3). a Check that drain plugs (2) are tightened. 3 Mounting bolt: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} 3 Drain plug : 11.25 ± 1.45 Nm {1.15 ± 0.15 kgm} 7] Press fit bearing (15) by using the push tool. 8] Install plate (8), and secure it with snap ring (7). 9] Install input shaft (6). 2 Mounting bolt: Adhesive LT-2 3 Mounting bolt: 277.0 ± 31.9 Nm {28.5 ± 3.25 kgm} 10] Install two seal rings (5).
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of torque converter assembly
11. Torque converter valve assembly Install torque converter valve assembly (56). a Tighten the mounting bolts uniformly in turn and be careful not to tighten them unevenly. 3 Mounting bolt: 49.0 ± 4.9 Nm {5.0 ± 0.5 kgm} 12. Remove the torque converter assembly from tool C.
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D375A-6 (02)
DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
Disassembly and assembly of TORQFLOW transmission assembly 2. Control valve assembly 1) Remove nut (2-1) from connector (P). 2) Remove cover (2). a Note that cover (2) is wired.
1 2
3 D
4
5
790-415-1011 Bracket Repair stand (100 750-501-5000 V) 791-615-1130 Push tool 791-615-1200 Ring assembly 791-615-1210 q Ring 135-A90-1150 q Bolt 01580-01008 q Nut 01641-51032 q Washer 791-615-1101 Ring assembly 791-615-1111 q Ring 135-A90-1150 q Bolt 01580-01008 q Nut 01641-51032 q Washer 799-301-1600 Oil leak tester
t
1
t
1
t t
1 1 1 1 1 2 1 1 1 1 2 1
t
t
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
3) Remove sleeves (3). 4) Remove control valve assembly (4). (G): Gasket
1. Preparatory work Set transmission assembly (1) to tool D1.
3. Lubrication valve assembly Remove lubrication valve assembly (5).
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
4. Front case 1) Set the transmission assembly with the input shaft up. 2) Using eyebolts, remove front case (6).
3) Using eyebolt [2], lift off input shaft and No. 1 carrier assembly (8). 4) Reverse the input shaft and No. 1 carrier assembly and remove seal ring (9).
5. Input shaft and No. 1 carrier assembly 1) Remove seventeen tie bolts (7). 2) Using forcing screws [1], disconnect input shaft and No. 1 carrier assembly (8). a Tighten the forcing screws evenly and take care not to twist the input shaft and No. 1 carrier assembly.
5) Disassemble the input shaft and No. 1 carrier assembly according to the following procedure. 1] Remove snap ring (10) and remove No. 2 sun gear (11). 2] Remove spacer and bearing assembly (12).
3] Using the push tool, remove ball bearings (13) and (14) from spacer (15).
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DRAFT Power train Disassemblyandassemblyof TORQFLOWtransmissionassembly
4] Remove No. 1 sun gear (16). 5] Remove spacer (17).
6] Using eyebolt [3], sling housing and No. 1 carrier assembly (18) and set it on the blocks. a Lower the input shaft end to the ground and make a clearance of approx. 20 mm between the "housing and No. 1 carrier assembly" and the blocks. 7] Remove snap ring (19).
10] Remove snap ring (24) from housing and No. 1 carrier assembly (20). 11] Set the housing and No. 1 carrier assembly on the blocks and remove housing (25) from No. 1 carrier assembly (26) by using push tool [4].
12] Remove snap ring (27) from housing (25). 13] Reverse the housing and set it on the blocks and remove seal ring (146).
8] Tap the housing with a plastic hammer to drop housing and No. 1 carrier assembly (20) onto the blocks and remove input shaft assembly (21). 9] Using the press, remove ball bearing (22) from input shaft (23).
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
14] Using push tool [5], remove ball bearing (28) from the housing. 15] Remove spacer (29) from No. 1 carrier assembly (26).
16] Reverse the No. 1 carrier assembly, remove snap ring (30), and remove collar (31). 17] Reverse the No. 1 carrier assembly, pull out shafts (33) halfway from carrier (32), remove balls (34), and remove shafts (33). a Take care not to lose the balls and store them carefully.
6. No. 1 disc, plates, and springs 1) Remove twelve springs (37). 2) Remove six discs (38), six springs (40), and five plates (39) in turn to remove the guide plate. a Keep the disc and plate on a flat place so that they do not warp.
7. No. 1 clutch ring gear Remove No. 1 clutch ring gear (41).
18] Remove gears (34) and thrust washers (35) from the carrier. 19] Remove needle bearings (36) from gears (34).
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
8. No. 1 housing 1) Using eyebolt [5], remove No. 1 housing assembly (42).
9. No. 2 disc, plate, and spring 1) Remove twelve springs (47). 2) Remove six discs (48), five plates (49), and six springs (50) in turn. a Keep the disc and plate on a flat place so that they do not warp.
2) Disassemble the No. 1 housing assembly according to the following procedure. 1] Remove piston (43) from housing (44). 3) Remove seventeen sleeves (51).
2] Remove seal ring (45) from piston (43). 3] Remove seal ring (46) from housing (44).
D375A-6 (02)
4) Remove seal ring (52) from the No. 2 and No. 3 carrier assembly. 5) Remove six torque pins (53). 6) Remove twelve guide pins (54).
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
10. No. 1 ring gear and No. 2 and No. 3 carrier assembly 1) Using eyebolts [6], lift off "No. 1 ring gear, No. 2 and No. 3 carrier" assembly (55).
2) Disassemble the "No. 1 ring gear, No. 2 and No. 3 carrier" assembly according to the following procedure. 1] Remove seal rings (57) and (58). 2] Remove ring (59).
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3] Pull out shafts (61) halfway from carrier (60), remove balls (62), and remove shafts (61). a Take care not to lose the balls and store them carefully.
4] Remove gears (63) and thrust washers (64) from the carrier. 5] Remove needle bearings (65) from gears (63). a Since No. 2 and No. 3 carrier assembly (60) is embedded in No. 1 ring gear (66), they cannot be disassembled.
D375A-6 (02)
DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
11. No. 2 ring gear Remove No. 2 ring gear (67).
2] Remove seal ring (72) from piston (69). 3] Remove seal ring (73) from piston (70).
12. No. 2 and No. 3 housing assembly 1) Using eyebolts [7], remove No. 2 and No. 3 housing assembly (68) together with the upper and lower pistons. a Bind the lower piston with a wire to prevent it from coming off.
4] Remove seal rings (74) and (75) from housing (71).
2) Disassemble the No. 2 and No. 3 housing assembly according to the following procedure. 1] Remove pistons (69) and (70) from housing (71).
D375A-6 (02)
13. No. 3 disc, plate, and spring 1) Remove the guide plate and remove twelve springs (76). 2) Remove four discs (77), four springs (79), and three plates (78) in turn. a Keep the disc and plate on a flat surface so that they do not warp.
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
14. No. 3 and No. 4 clutch plate Using eyebolts [8], remove plate (80).
15. No. 4 disc, plate, and spring 1) Remove three discs (81), three springs (83), and two plates (82) in turn and remove guide plate (147). a Keep the disc and plate on a flat place so that they do not warp. 2) Remove six torque pins (84).
16. No. 4 housing assembly 1) Using eyebolts [9], remove housing assembly (85) and the piston as a unit.
2) Disassemble the No. 4 housing assembly according to the following procedure. 1] Remove piston (86) from housing (87).
2] Remove seal ring (88) from piston (86). 3] Remove seal ring (89) from housing (87).
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D375A-6 (02)
DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
17. "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly 1) Operate tool D1 to turn the transmission assembly sideways. 2) Remove plate (90). 3) Remove snap ring (91) and plate (92).
7) Disassemble the "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly according to the following procedure. 1] Remove two seal rings (56) from the housing. 2] Remove seal ring (118) from the input shaft.
4) Remove snap ring (93) and spacer (94). 3] Remove snap ring (96) and remove No. 3 sun gear (97). 4] Remove collar and bearing assembly (98).
5) Set the transmission assembly with the No. 4 carrier up. 6) Using eyebolts [10], sling "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly (95) and hit the bottom of the output shaft with a copper hammer to remove.
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
5] Using the push too, remove ball bearing (99) from collar (100).
6] Using eyebolts [11], remove No. 3 ring gear and No. 4 carrier assembly (101) together with the No. 4 sun gear. 7] Remove No. 4 sun gear (102) from No. 3 ring gear and No. 4 carrier assembly (101).
10] Remove snap ring (106) and remove collar (107) from No. 3 ring gear and No. 4 carrier assembly (101). 11] Remove seal ring (108) from collar (107).
12] Pull out shaft (110) halfway from carrier (109), remove balls (111), and remove shafts (110). a Take care not to lose the balls and store them carefully. 13] Remove gears (112) and thrust washers (113) from the carrier. 14] Remove needle bearings (114) from gears (112).
8] Reverse the No. 3 ring gear and No. 4 carrier assembly and remove hub (103). 9] Remove seal rings (104) and (105) from hub (103).
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
15] Reverse carrier (109) and remove snap ring (115). 16] Reverse the carrier and remove ball bearing (116) by using the push tool. a Since No. 4 carrier (109) is embedded in No. 3 ring gear (117), they cannot be disassembled.
17] Set output shaft and housing assembly (118) on the blocks with the output side of the output shaft up. 18] Using the forcing screws, disconnect input shaft and housing assembly (118) and remove it by using eyebolts [12]. a Tighten the forcing screws evenly to disconnect the output shaft and housing assembly.
D375A-6 (02)
19] Remove six discs (119), six springs (121), and five plates (120) from housing (122) in turn. a Keep the disc and plate on a flat surface so that they do not warp.
20] Set the output shaft and housing assembly to the press and remove housing assembly (123) from output shaft assembly (124) by using push tool [13]. a Set blocks [14] under the housing assembly to prevent the housing assembly from falling out.
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
21] Set housing assembly (123) to the press and compress the spring to remove snap ring (125) by using tool D2. a Operate the press slowly to push up the spring evenly. 22] Remove retainer (126) and spring (127) from housing (128).
23] Remove piston (129) from the housing. Remove seal ring (130) from piston (129).
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24] Remove seal ring (131) from housing (128). 25] Remove snap ring (132) from the housing. 26] Using the push tool, remove ball bearing (133) from the housing.
27] Remove snap ring (134) and remove needle bearing (135) from input shaft (124). 28] Reverse the output shaft, remove snap ring (136), and remove the roll bearing (137) from the output shaft.
D375A-6 (02)
DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
18. Rear case assembly 1) Remove collar (138) from rear case (139).
Assembly a Clean all the parts thoroughly (oil holes etc. in particular), check them for dirt and dents, and apply engine oil to the sliding parts before installing. a Apply grease (G2-LI) to each spline. 1. Preparatory work Set rear case (139) to tool D1.
2) Remove seal ring (140) from collar (138).
2. Rear case assembly 1) Install seal ring (149) to collar (138). a Direct the seal ring as shown in the figure below. 2 Seal ring: Grease (G2-LI)
3) Reverse the rear case, remove snap ring (141), and remove ball bearing (142).
D375A-6 (02)
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
2) Reverse rear case (139) and install collar (138). a Take care not to get the seal ring caught.
3. Output shaft assembly 1) Using the push tool, press fit needle bearing (135) to output shaft (124) and fix it with snap ring (134). 2) Using the push tool, press fit ball bearing (142) to the output shaft.
6) Reverse rear case (139), set output shaft assembly (124) to the case, and press fit the bearing portion by using the push tool. 7) Install snap ring (141).
8) Install plate (92), and fit it with snap ring (91).
3) Install spacer (94) and fix it with snap ring (93). 2 Inside surface of spacer: Molybdenum disulphide lubricant (LM-P) 4) Install plate (90). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm} 5) Install seal ring (118). 2 Seal ring: Grease (G2-LI)
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D375A-6 (02)
DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
4. "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly 1) Assemble the "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly according to the following procedure. q When No. 3 ring gear and No. 4 carrier are supplied individually: Using tool D3, compress ring (143), set No. 3 ring gear (117) on No. 4 carrier (109), and tap No. 3 ring gear (117) with a plastic hammer to install. a Check that the ring is fitted securely into the groove.
1] Using the push tool, press fit ball bearing (116) to carrier (109) and fix it with snap ring (115).
D375A-6 (02)
2] Reverse the carrier. 3] Install needle bearings (114) to gears (112), fit thrust washers (113) to both sides of the gears, and set them to the carrier. 4] Fit balls (111) and install shafts (110) to the carrier. a Check that each gear rotates smoothly.
5] Install seal ring (108) to collar (107). 2 Seal ring : Grease (G2-LI) 6] Install collar (107) to No. 3 ring gear and No. 4 carrier assembly (101), alining its dowel hole with the dowel pin, and fix it with snap ring (106). a Tap the dowel pin fitting portion with a plastic hammer until the clearance between the mating faces is eliminated.
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
7] Install seal rings (105) and (104) to hub (103). 2 Seal ring: Grease (G2-LI) 8] Install hub (103) to No. 3 ring gear and No. 4 carrier assembly (101). a Take care not to get the seal ring caught.
10] Install six discs (119), six springs (121), and five plates (120) in turn.
11] Using the push tool, press fit ball bearing (133) to housing (128) and fix it with snap ring (132).
9] Using eyebolts [15], install housing (122) to No. 3 ring gear and No. 4 carrier assembly.
12] Install seal ring (131) to the housing. a Install the seal ring as shown in the figure below. 2 Seal ring: Grease (G2-LI)
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
13] Install seal ring (130) to piston (129). a Install the seal ring as shown in the figure below. 2 Seal ring: Grease (G2-LI) 14] Install piston (129) to housing (128). a Take care not to get the spring caught.
15] Set springs (127) and retainer (126) to the housing. a Set the three springs as shown in the following figure. 16] Set housing assembly (123) to the press and compress the springs to install snap ring (125) by using tool D2. a Installed load of spring: 2,175 N {222 kg}
D375A-6 (02)
17] Using bolt [16], install housing assembly (123). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 176.4 ± 19.6 Nm {18 ± 2 kgm} 18] Install two seal rings (56) to the housing. 2 Seal ring: Grease (G2-LI)
2) Reverse rear case (139) and "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly (95). 3) Using eyebolts [10], set "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly (95) to the rear case and output shaft. a Take care not to get the seal ring caught.
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
4) Using push tool [17], press fit the bearing portion of "No. 3 ring gear, No. 4 carrier and No. 5 clutch" assembly (95) to the output shaft.
5. No. 4 sun gear Install No. 4 sun gear (102). 2 Spline: Molybdenum disulphide lubricant (LM-P)
2) Install collar and bearing assembly (98). a Install the assembly with collar flange side up. 3) Install No. 3 sun gear (97) and fix it with snap ring (96). 2 Spline: Molybdenum disulphide lubricant (LM-P)
7. No. 4 housing assembly 1) Install seal ring (89) to housing(87). a Direct the seal ring as shown in the figure below. 2 Seal ring: Grease (G2-LI) 2) Install seal ring (88) to piston (86). a Direct the seal ring as shown in the figure below. 2 Seal ring: Grease (G2-LI)
6. No. 3 sun gear 1) Using the push tool, press fit ball bearing (99) to collar (100). 2 Spline: Molybdenum disulphide lubricant (LM-P)
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
3) Install piston (86) to housing (87). a Take care not to get the seal ring caught.
4) Using eyebolts [9], install No. 4 housing assembly (85) aligning the dowel holes with the dowel pins. a Tap the dowel pin fitting portions with a plastic hammer until the clearance between the mating faces is eliminated.
9. No. 3 and No. 4 clutch plate Using eyebolts [8], install plate (80) aligning the dowel holes with the dowel pins. a Tap the dowel pin fitting portions with a plastic hammer until the clearance between the mating faces is eliminated.
10. No. 3 disc, plate, and spring 1) Install four discs (77), four springs (79), and three plates (78) alternately. 2) Install twelve guide pins (54). a Guide pin length: 360 mm 3) Install twelve springs (76) and install the guide plate. a Spring free length: 97 mm
8. No. 4 disc, plate, and spring 1) Install six torque pins (84). a Torque pin length: 162 mm 2) Install guide plate (147), and install three discs (81), three springs (83) and two plates (82) in turn.
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11. No. 1 ring gear and No. 3 housing assembly 1) Install seal rings (74) and (75) to housing (71). a Install the seal ring as shown in the figure. 2 Seal ring: Grease (G2-LI)
4) Install pistons (70) and (69) to housing (71). a Take care not to get the seal ring caught. a Bind piston (70) with a fine wire to prevent it from falling when the housing is lifted up.
2) Install seal ring (73) to piston (70). a Direct the seal ring as shown in the figure. 2 Seal ring: Grease (G2-LI) 3) Install seal ring (72) to piston (69). a Direct the seal ring as shown in the figure. 2 Seal ring: Grease (G2-LI)
5) Install housing assembly (68) aligning the dowel holes with the dowel pins. a Tap the dowel pin fitting portions with a plastic hammer until the clearance between the mating faces is eliminated.
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
12. No. 2 ring gear Install ring gear (67).
13. "No. 1 ring gear and No. 2 and No. 3 carrier" assembly 1) Assemble the "No. 1 ring gear and No. 2 and No. 3 carrier" assembly according to the following procedure. q When No. 1 ring gear, No. 2 and No. 3 carrier are supplied individually: Using tool D4, compress ring (144), set No. 1 ring gear (66) on No. 2 and No. 3 carrier (60), and tap the No. 1 ring gear (66) with a plastic hammer to install. a Check that the ring is fitted securely into the groove.
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1] Install needle bearings (65) to gears (63), fit thrust washers (64) to both sides of the gears, and set them to carrier (60).
2] Fit balls (62) and install shafts (61) to the carrier. a Check that each gear rotates smoothly.
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3] Install ring (59) to the carrier. a Check that the ring is fitted securely into the groove. 4] Install seal rings (58) and (57) to the carrier. 2 Seal ring: Grease (G2-LI) a Align seal ring (58) with the carrier and fix it with grease (G2-LI).
14. No. 2 disc, plate, and spring 1) Install six torque pins (53). a Torque pin length: 199 mm 2) Install seal ring (52) to the No. 2 and No. 3 carrier. 2 Seal ring: Grease (G2-LI)
3) Install seventeen sleeves (51). 2) Using eyebolts [6], install "No. 1 ring gear and No. 2 and No. 3 carrier" assembly (55). a Take care no to get the seal ring caught.
3) Using push tool [18], press fit the bearing portion of "No. 1 ring gear and No. 2 and No. 3 carrier assembly" (55).
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
a Install sleeve (51) into the bolt hole marked with *, with the slit (part S) down.
4) Install twelve springs (47). a Spring free length: 70 mm 5) Install six discs (48), four springs (50), and five plates (49) in turn. a Align the notches of the oil grooves on the periphery of the discs.
3) Install piston (43) to housing (44). a Take care not to get the seal ring caught.
4) Using eyebolts [5], install housing (42) aligning the dowel holes with the dowel pins. a Check that the springs are fitted securely into the grooves of the housing. a Tap the dowel pin fitting portions with a plastic hammer until the clearance between the mating faces is eliminated.
15. No. 1 housing assembly 1) Install seal ring (46) to housing (44). a Install the seal ring as shown in the figure. 2 Seal ring: Grease (G2-LI) 2) Install seal ring (45) to piston (43). a Direct the seal ring as shown in the figure. 2 Seal ring: Grease (G2-LI)
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16. No. 1 clutch ring gear Install No. 1 clutch ring gear (41).
17. No. 1 disc, plate, and spring 1) Install the guide plate and install twelve springs (37). a Spring free length: 66 mm 2) Install six discs (38), six springs (40), and five plates (39) in turn.
2] Fit balls (34) and install shafts (33) to the carrier. 3] Install collar (31) to the carrier and fix it with snap ring (30).
4] Using push tool [19], press fit ball bearing (28) to plate (25) and fix it with snap ring (27).
18. Input shaft and No. 1 carrier assembly 1) Assemble the input shaft and No. 1 carrier assembly according to the following procedure. 1] Install needle bearings (36) to gears (34), fit thrust washers (35) to both sides of the gears, and set them to carrier (32).
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DRAFT Power train Disassembly and assembly of TORQFLOW transmission assembly
5] Reverse the plate and install seal ring (146). a Align seal ring with the plate and fix it with grease (G2-LI). 6] Install spacer (29) to No. 1 carrier assembly (26).
11] Install snap ring (19).
7] Set plate (25) to No. 1 carrier (26), press fit the bearing portion with push tool [20] and fix it with snap ring (24).
12] Turn the input shaft and No. 1 carrier assembly sideways and install spacer (17). 13] Install No. 1 sun gear (16). 2 Spline: Molybdenum disulphide lubricant (LM-P) 8] Using the press, install ball bearing (22) to input shaft assembly (23). 9] Set housing and No. 1 carrier assembly (20) to the blocks. 10] Using eyebolt [3], install input shaft assembly (18) to the housing and No. 1 carrier assembly.
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14] Using the push tool, press fit ball bearings (13) and (14) to spacer (15).
15] Install spacer and bearing assembly (12). a Install the assembly with the small-diameter bearing toward the No. 1 sun gear. 2 Spline: Molybdenum disulphide lubricant (LM-P) 16] Install No. 2 sun gear (11) and fix it with snap ring (10). 2 Spline: Molybdenum disulphide lubricant (LM-P)
3) Evenly tighten four tie bolts (12) on the diagonal line. 4) Tighten remaining tie bolts (12). 3 Tie bolt: 259.7 ± 14.7 Nm {26.5 ± 1.5 kgm}
17] Install seal ring (9) to the No. 1 carrier. a Align seal ring with the carrier and fix it with grease (G2-LI). 2) Reverse input shaft and No. 1 carrier assembly (8) and set it to the No. 1 housing by using eyebolt [2]. a Take care not to get the seal ring caught. a Lower the input shaft slowly while checking that its end does not interfere with the output shaft bearing.
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19. Checking piston stroke Using tool D5, check the stroke of each clutch piston. a Air pressure: 490 – 588 kPa {5 – 6 kg/cm2} a Standard stroke of piston Piston Stroke (mm)
No. 1 No. 2 No. 3 No. 4 6.7 7.0 5.6 4.7
No. 5 7.0
20. Front case Fit the O-ring and install front case (6) by using the eyebolts. a Lower the front case gradually while checking that it does not interfere with other parts.
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21. Output shaft bearing 1) Set the transmission assembly with the output shaft side up. 2) Using the push tool, press fit roller bearing (137) to the output shaft and fix it with snap ring (136). a Take care not to hit or scratch the cage or rollers of the bearing. Use a push tool of a size which pushes only the outer race.
22. Lubrication valve assembly Install lubrication valve assembly (5).
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23. Control valve assembly 1) Install gasket (G) to the control valve. 3 Mounting bolt: 49.0 ± 4.9 Nm {5.0 ± 0.5 kgm} 2) Install the O-rings to sleeves (3). 2 All O-rings: Grease (G2-LI)
(OUT): Outside face of cover (IN): Inside face of cover (HL): Bolt holes
3) Install nut (2-1) to connector cover (2). 2 Nut: 39.6 – 42.4 Nm {4.0 – 4.3 kgm} 4) Install cover (2). a Check that the mating faces of the case and cover (2) are free from dents, rust, oil, grease and water. 2 Both mating faces of case and cover (2): Liquid gasket (LG-6) a Apply liquid gasket continuously around the bolt holes as shown in the figure. (Positions to apply liquid gasket) (L1): Intermediate position between bolt holes and inside face of cover (L2): Center of inside and outside faces of cover (Quantity of liquid gasket to apply) B x H = 2 - 5 cc
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DRAFT Power train Disassembly and assembly of steering case assembly
Disassembly and assembly of steering case assembly Disassembly 1. Clutch and brake assembly 1) Using the eyebolts, sling the clutch and brake assembly. Remove the mounting bolts to remove clutch and brake assembly (3). a Remove the clutch and brake assembly from the opposite side in the same way. a When removing the clutch and brake assembly, take care not to scratch or damage discs and plates.
5] Reverse the clutch and brake assembly. Using eyebolts [3], separate clutch assembly (9) from brake assembly (10).
2) Remove the clutch and brake assembly as follows: 1] Remove plate (4), then remove collar (5). 2] Remove plate (6).
3) Disassemble the clutch assembly as follows: 1] Remove stopper (11). 2] Remove disc (12), springs (13), and plates (14) in turn. a Keep the disc and plate on a flat surface so that they do not warp.
3] Using forcing screws [1], remove sleeve (7). 4] Using puller [2], pull out bearing inner race (8) from the sleeve.
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3] Remove torque pins (15). 4] Using eyebolts, remove clutch hub (16). 5] Remove plate (17), using forcing screws [4].
6] Remove outer race (18) from the plate. 7] Remove bearing and cage assembly (19).
8] Remove plate (21) and nut (22) from cage (20). 9] Remove bearing and inner race (23), spacers (24) and (25), and bearing outer race (26).
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10] Remove clutch cage (27) by using eyebolts. 11] Remove seal ring (28) from the clutch cage. 12] Remove piston (29). 13] Remove seal ring (30) from the piston.
14] Remove bearing outer race (31) from the clutch cage. 15] Remove Belleville springs (32).
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DRAFT Power train Disassembly and assembly of steering case assembly
16] Using eyebolts [6], remove brake hub (33). 17] Remove bearing (34) from the brake hub.
7] Remove seal ring (44) from the piston.
8] Remove Belleville springs (45). 4) Disassemble the brake assembly as follows: 1] Remove stopper (35). 2] Remove discs (36), springs (37), and plates (38) in turn. a Keep the disc and plate on a flat surface so that they do not warp.
2. Shaft Remove left and right shafts (46).
3] Using eyebolts [7], remove brake cage (39). 4] Remove bearing outer race (40) and seal ring (41) from the brake cage.
3. Lubrication tube Remove lubrication tubes (47), (47-1), and (47-2).
5] Remove torque pins (42). 6] Remove piston (43). D375A-6 (02)
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2) Disassemble transfer and gear housing assembly (50) as follows: 1] Place the transfer and gear assembly onto blocks. 2] Remove lubrication tube (51). 2-1] Remove the cage and bearing assembly.
4. Pipe 1) Remove left and right pipes (48). 2) Remove pipe (49).
3] Using the push tool, remove bearing (53) from cage (52a). 4] Remove drive gear (54).
5. Steering control valve and seat assembly Remove steering control valve and seat assembly (2). 4 Steering control valve and seat assembly: 75 kg a Check that lubrication tubes are already removed. 5] Using puller [10], remove both sides of bearing inner races (55) on both sides of the gear. 6] Remove lubrication tube (56).
6. Transfer and gear housing assembly 1) Install guide bolts [8] on housing assembly (50). Lift off the housing assembly using the eyebolts [9].
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DRAFT Power train Disassembly and assembly of steering case assembly
7] Using eyebolts [11], remove pinion housing assembly (57). a Note the quantity and thickness of the shims for installation purpose. 8] Using forcing screws, remove cover (58). 9] Remove holder (59).
15] Remove bearing (70) from the case. 16] Remove bearing (71) from the case.
10] Pull out pinion gear (60) by pressing the pinion shaft using the press. 11] Remove the holder, and remove bearing inner race (61) from pinion gear (60) by using puller [12]. 12] Remove cage and bearing assembly (62).
7. Right cage 1) Turn the steering case to put the right cage up. 2) Remove cage and bearing assembly (72). a Note the quantity and thickness of the shims for installation purpose. 3) Remove the bearing outer race from the cage bearing assembly. 4) Using eyebolts [14], remove cage (73). 13] Remove collar (63) from gear (64). 14] Using push tool [13], remove bearing outer races (65) and (69), bearing inner races (66) and (67), and collar (68).
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8. Bevel gear and shaft assembly 1) Remove bevel gear and shaft assembly (74) using eyebolts. 2) Disassemble bevel gear and shaft assembly (74) as follows: 1] Remove the reamer bolts, and remove bevel gear (75) from shaft (76).
2] Using puller [15], remove bearing inner races (77) and (78) from the shaft. 9. Left cage 1) Turn the steering case to put the left side of the case up, and remove cage and bearing assembly (79). a Note the quantity and thickness of shims for installation purpose.
2) Remove bearing outer race (80) from the cage and bearing assembly.
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Assembly a Clean all parts, and check them for dirt and damage before installing. a Apply engine oil to the rotating part of the bearing, and rotate it several times. a Also, apply engine oil to the sliding parts before installing. a Check that the snap ring securely fit into the groove. 1. Left cage 1) Using the push tool, press fit bearing outer race (80) to the cage. 2) Install the shims and install cage and bearing assembly (79). a Standard thickness of shim: 2 mm 3 Cage and bearing assembly mounting bolts: 176.4 ± 19.6 Nm {18 ± 2 kgm}
2. Bevel gear and shaft assembly 1) Assemble the bevel gear and shaft assembly as follows: 1] Using push tool [16], press fit bearing inner races (78) and (77). 2] Set bevel gear (75) to shaft (76), and secure them by tightening the reamer bolts. 3 Reamer bolt : 274.4 ± 29.4 Nm {28 ± 3 kgm} 2) Install bevel gear and shaft assembly (74) using the eyebolts.
3. Right cage 1) Using eyebolts [14], install cage (73) in position.
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2) Install the shims and install cage and bearing assembly (72). a Standard thickness of shims: 2 mm 3 Cage and bearing assembly mounting bolts: 176.4 ± 19.6 Nm {28 ± 2 kgm}
3] Press fit bearing outer race (69) into the cage using the push tool. 4] Install bearing inner races (67), (66) and collar (68). 5] Using the push tool, press fit bearing outer race (65).
4. Preload adjustment Adjust the rotating force of the bevel gear shaft by adjusting the thickness of shims on the cage. a Rotate the bevel gear two or three times, and place the push-pull scale onto the tip of the gear teeth to measure the force. a Rotating force (when bevel gear is not engaged): 4.9 – 5.88 N {0.5 – 0.6 kg} (Rotating torque: 23.52 – 28.42 Nm {2.4 – 2.9 kgm})
6] Using push tool [18], press fit inner race (61) to pinion gear (60). 7] Install the holder. 3 Holder mounting bolt : 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm} 8] Install gear (64) and collar (63) to the pinion gear. 2 Spline of gears: Molybdenum disulphide lubricant (LM-P)
5. Transfer and gear housing assembly 1) Assemble the transfer and gear housing assembly according to the following procedure. 1] Press fit transfer gear bearing (71) into the case using push tool [16]. 2] Using push tool [17], press fit pinion bearing (70) into the case.
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DRAFT Power train Disassembly and assembly of steering case assembly
9] Using push tool [19], press fit cage and bearing assembly (62). 10] Install holder (59). 3 Holder mounting bolt : 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
11] Tighten the mounting bolts of cover (58) in the order shown in the following figure and to the torque shown below, to install the cover temporarily. 3 Mounting bolts: 49 Nm {5 kgm}
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12] Check clearance (A) between the cover and cage, and check that it is as follows. a Clearance (A) : 0.48 ± 0.27 mm a Make sure that the variation of entire periphery is 0.05 mm maximum, bearings have been press fitted completely and are not at an angle.
13] Tighten the mounting bolts of cover (58) to the specified toque in the following order. 3 Mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
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14] Installing the shims to pinion housing assembly (57), and install the housing using eyebolts [11]. a Standard thickness of shims: 2 mm 15] Install lubrication tube (56).
18] Using push tool [21], press fit bearing (53). 19] Install bearing assembly (52) to the case. 20] Install lubrication tube (51) together with the block.
16] Using push tool [20], press fit bearing inner races (55) to both sides of the drive gear. 17] Set drive gear (54) to the case. 2 Spline of gear: Molybdenum disulphide lubricant (LM-P)
2) Install guide bolt [8] to the steering case. Using eyebolts [9], install transfer and gear housing assembly (50) in position. 3 Mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
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DRAFT Power train Disassembly and assembly of steering case assembly
6. Adjusting backlash and tooth contact 1) Adjusting backlash Testing Apply the probe of dial gauge [22] to the tooth surface at the top of the bevel gear at right angle to the surface. Holding the bevel pinion stationary, wiggle the bevel gear forward and and backward, and read the gauge at this time. a Standard backlash: 0.3 – 0.4 mm a Measure the backlash at diagonal three points or more.
Adjusting If the measured backlash is out of the standard range, adjust it according to the following procedure: 1] When backlash is too small Adjust the thickness of the shim pack for the bevel pinion to move it in direction (A). Or, adjust the thickness of the shim packs for the bearing cages of the bevel gear shaft to move the bevel gear in direction (B).
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2] When backlash is too large Adjust the thickness of the shim pack for the bevel pinion to move it in direction (C). Or, adjust the thickness of the shim packs for the bearing cages of the bevel gear shaft to move the bevel gear in direction (D). a When adjusting the thickness of the shim packs for the bearing cages of the bevel gear shaft, if the thickness of the shim pack on one side is decreased, increase the thickness on the other side by the same quantity and vice versa, in order not to change the preload of the bearings.
2) Adjusting tooth contact Testing 1] Apply red lead thinly to the tooth surfaces of the bevel pinion and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern left on tooth surfaces of the bevel gear. (Be): Big end (Se): Small end (Rt): Root of tooth (Tt): Top of tooth
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2] The standard values for the tooth contact are as follows: (From the small end of the bevel gear) a) Width of tooth contact: 30 – 75% b) Center of tooth contact: 25 – 50% c) Position of tooth contact: 25 – 50% a The standard values for the tooth contact must be satisfied under the following conditions; the taper roller bearings supporting the bevel gear are given with the preload, the bevel gear is meshed only with the bevel pinion, and no load is applied. a Check that the center of tooth contact is at the center of the tooth height and there is not a strong contact at the dedendum. The contact pattern must be made in almost the same position when the bevel gear is rotated in forward and reverse directions. (Be): Big end (Se): Small end
2] If the bevel pinion is too close to the center line of the bevel gear, the contacts are at the convex faces close to the big end and concave faces close to the small end of the bevel gear. [Adjustment] The adjustment is the same as that described in step 1] except for reversed direction (A) of the bevel pinion and for reversed direction (B) of the bevel gear. a When changing the position of the bevel gear, if the thickness of the shim pack on one side is decreased, increase the thickness on the other side by the same quantity and vice versa, in order not to change the preload of the bearings.
Adjusting If the tooth contact pattern is not proper, adjust the tooth contact according to the following procedure. 1] If the bevel pinion is too far from the center line of the bevel gear, the contacts are at the convex faces colse to the samll end and at the concave faces close to the big end of the bevel gear. [Adjustment] Adjust the thickness of the shim pack for the bevel pinion to move the bevel pinion in direction (A) . Also move the bevek gear in direction (B) by adjusting the thickness of the shim packs for bearing cages of the bevel gear shaft, then check the tooth contact pattern and backlash again.
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DRAFT Power train Disassembly and assembly of steering case assembly
7. Steering control valve and seat assembly 1) Install steering control valve and seat assembly (2) in position. 2) As for the mounting bolts, tighten them after installing pipes (48) described in the next step. q Mounting bolt: 49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
8. Pipes 1) Install pipe (49). 2) Install left and right pipes (48).
9. Shaft Install left and right shafts (46).
10. Lubrication tube Install lubrication tubes (47), (47-1), and (47-2).
11. Clutch and brake assembly 1) Assemble the clutch and brake assembly as follows: 1] Install Belleville springs (45). a Set the belleville springs back to back to install. 2] Install seal ring (44) to piston (43).
3] Install piston (43). 4] Install torque pins (42). 5] Install seal ring (41) and bearing outer race (40) to the brake cage using the push tool.
.
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6] Using eyebolts [7], install brake cage (39) in position. 3 Mounting bolt: 110.25 ± 12.25 Nm {11.25 ± 1.25 kgm} 7] Install plates (38), springs (37), and discs (36) in position. a Check that a mating face between the disc and plate is free from scratches and foreign materials. Then, apply a thin film of engine oil to the surface and install.
2] Install brake hub (33) to the clutch housing, using eyebolts [6]. 3] Install Belleville springs (32). a Set the Belleville springs back to back to install.
4] Install outer race (31) to the clutch cage. 5] Install seal ring (30) to the piston. 6] Install piston (29).
8] Install stopper (35). 3 Mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm} 2) Assemble the clutch assembly as follows: 1] Using the push tool, install bearing (34) to the brake hub.
7] Install seal ring (28) to the clutch cage. 8] Using eyebolts, install clutch cage (27) to the housing.
9] Install bearing inner race (26), spacers (25) and (24), and bearing inner race (23) to cage (20). 50-166
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10] Tighten nut (22) and install plate (21). a Using the push tool, hold the cage with the press, and use a hook wrench to tighten the nut.
11] Install bearing and cage assembly (19) in position. 12] Using the push tool, install outer race (18) to the plate.
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13] Install plate (17). 3 Mounting bolt: 110.25 ± 12.25 Nm {11.25 ± 1.25 kgm} 14] Set the guide bolts to the housing. 15] Using eyebolts, install clutch hub (16) in position. a Check that the rotating force of the housing is 29.4 N {3 kg} or less and that the housing rotates smoothly. 16] Install torque pins (15).
17] Install plates (14), springs (13), and discs (12) in turn. a Check that a mating face between the disc and plate is free from scratches and foreign materials. Then, apply a thin film of engine oil to the surfaces before installing. 18] Install stopper (11). 3 Mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
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3) Connect the clutch assembly to the brake assembly as follows: 1] Using eyebolts [13], install brake assembly (10) to clutch assembly (9). 2] Using push tool [14], press fit bearing inner race (8) to the sleeve.
4] Install plate (6). 3 Mounting bolt: 110.25 ± 12.25 Nm {11.25 ± 1.25 kgm} 5] Fit collar (5) and install plate (4). 4) Install the clutch brake assembly using eyebolts. 3 Mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
3] Set sleeve (7) to the clutch and brake assembly.
12. Final drive shaft Install left and right final drive shafts (83) in position. a If the bevel gear is locked and it is hard to insert the final drive shaft, release the steering brake and insert the shaft. Remove plugs (81) and bolts (82). Then, screw in the bolts in the plug holes to compress the clutch spring in order to release the brake.
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DRAFT Power train Removal and installation of power train pump and lubrication pump assembly
Removal and installation of power train pump and lubrication pump assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine, and disconnect the cable from the negative terminal of the battery.
Installation q Carry out installation in the reverse order to removal.
1. Remove the power train underguard (front). 4 Power train underguard (front): 280 kg 2. Remove cover (1).
3. Disconnect tube (2). 4. Lift off power train pump and lubrication pump assembly (3). 4 Power train pump and lubrication pump assembly: 50 kg
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DRAFT Power train Removal and installation of scavenging pump assembly
Removal and installation of scavenging pump assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine, and disconnect the cable from the negative terminal of the battery.
Installation q Carry out installation in the reverse order to removal. q
Refilling (Power train case) Supply 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.
1. Remove the power train underguard (front). 4 Power train underguard (front): 280 kg 2. Disconnect inlet tube (1). a The oil in the piping will leak out, so prepare a container to catch the oil. 3. Disconnect outlet tube (2). 4. Remove scavenging pump assembly (3).
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DRAFT Power train Removal and installation of final drive assembly
Removal and installation of final drive assembly
Symbol
Part No.
Part name
J 1 790-337-1001 Lifting tool
Necessity Q'ty New/remodel Sketch
Special tools
t 1
Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine, and disconnect the cable from the negative terminal of the battery. 1. Separate the track shoe assembly. For details, see "Separation of track shoe assembly". 2. Raise the machine off the ground by using jacks or ripper, and set stand [1] under the frame. 3. Remove covers (1) and (2).
5. Remove three bolts from the final drive, and install tool J1 instead. 6. Sling final drive assembly (5), remove the mounting bolts, and remove the final drive. [*2] 4 Final drive assembly: 2,300 kg
4. Pull out drive shaft (4) as follows: [*1] 1) Remove cover (3). 2) Install eyebolts [2] to the drive shaft. 3) Pull out drive shaft (4). a If it is difficult to pull out the shaft, push up the shoe grouser by using jack [3] or other device set on the ground to move the sprocket backward and forward, and set the sprocket to a position where the shaft can be pulled out easily. a Pull the shaft to a point where it touches the sprocket.
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DRAFT Power train Removal and installation of final drive assembly
Installation q Carry out installation in the reverse order to removal. [*1] a If it is difficult to insert the shaft into position, push up the shoe grouser by using a jack or other device set on the ground to move the sprocket backward and forward, and set the sprocket to a position where the shaft can be inserted easily. [*2]
2 3
q
Final drive assembly mounting bolt : Adhesive (LT-2) Final drive assembly mounting bolt : 1,720 ± 190 Nm {175 ± 20 kgm}
Refilling (Final drive case) Supply the oil through the oil filler port to the specified level. 5 Final drive case: Approx. 61 l (TO 30)
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DRAFT Power train Disassembly and assembly of final drive assembly
Disassembly and assembly of final drive assembly Disassembly
2
3 4
J
5
6
7
8
791-580-3200 Remover Puller 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump 791-580-3300 Installer Puller 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump 790-431-1071 Installer 791-580-3400 Remover Puller 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump 791-580-3500 Installer Puller 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump Remover and 790-431-1230 installer Puller 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump 790-431-1250 Guide
D375A-6 (02)
t 1 t 1 t 1 t 1
Sketch
Part name
Q'ty
Part No.
New/remodel
Symbol
Necessity
Special tools 1. Draining oil Remove the drain plug and drain the oil from the final drive case. 6 Final drive case: Approx. 61 l 2. Sprocket 1) Place the final drive assembly on blocks (approx. 50 mm high). 2) Remove sprocket (1).
t 1 t 1 t 1 N t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
3. Cover Using eyebolts [1], remove cover (2).
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DRAFT Power train Disassembly and assembly of final drive assembly
4. Hub 1) Remove plate (3). 2) Using eyebolts [2], lift off hub (4).
4) Remove bearing inner race (8) from the sprocket hub assembly. 5. Sprocket hub assembly 1) Remove holder (5).
2) Using tool J2, disconnect sprocket hub assembly (6) at the press-fitting portion of bearing (7). 3) Using eyebolts [3], remove sprocket hub assembly (6).
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5) Turn over the sprocket hub assembly, then remove floating seal cover (9) and bearing outer races (10) and (11). 6) Remove floating seal (12) from the floating seal cover. a Take care not to damage the floating seal, and keep it in a safe place.
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DRAFT Power train Disassembly and assembly of final drive assembly
6. Wear guard Lift off wear guard (13). 7. Cover assembly 1) Using eyebolts [4], remove cover assembly (14).
4] Remove the plate, then remove ring gear (19). 8. Carrier assembly 1) Remove carrier assembly (20) by using eyebolts [5]. 2) Disassemble the cover assembly as follows. 1] Remove floating seal cover (15). 2] Remove floating seal (16) from the floating seal cover. a Take care not to damage the floating seal, and keep it in a safe place.
2) Disassemble the carrier assembly as follows. 1] Place the carrier assembly on the block (approx. 100 mm high). 2] Remove spacer (26) and bearing (26-1).
3] Remove spacer (17) and bearing inner race (18).
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DRAFT Power train Disassembly and assembly of final drive assembly
3] Remove holders (21). 4] Using tool J7, remove planetary gear shafts (22).
5] Remove planetary gears (23), bearing inner races (24A) and (24B), and spacers (24C).
9. Sun gear and shaft assembly 1) Remove sun gear and shaft (25). 2) Remove plate (25-1) and bearing inner race (26-2). 3) Remove plate (25-2) and sun gear (27).
10. Hub and shaft assembly 1) Remove plate (28).
6] Pull out bearing outer races (24D). 2) Using tool J5, pull out hub assembly (29) and bearing inner race (30) from shaft assembly (31).
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DRAFT Power train Disassembly and assembly of final drive assembly
3) Disassemble the hub assembly according to the following procedure. 1] Remove gear (32) from hub (33). 2] Remove hub (33) from boss (34). 3] Using the puller, remove bearing outer races (35) from boss (34).
11. Cage assembly 1) Using eyebolts [7], remove cage assembly (39). 2) Remove shims (40). a Note the quantity and thickness of shims for installation purpose.
4) Using eyebolts [6], pull out shaft assembly (31) from the case. 5) Disassemble the shaft assembly as follows. 1] Remove collar (36). 2] Remove bearing inner race (37) and collar (38).
3) Disassemble the cage assembly as follows: 1] Using puller [8], remove bearing outer race (41). 2] Remove oil seal (42).
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DRAFT Power train Disassembly and assembly of final drive assembly
12. Gear assembly 1) Remove gear assembly (44). 2) Using puller [9], remove bearing inner races (45) and (46) from the gear.
Assembly a Clean all parts, and check them for dint and dents. Apply engine oil to the sliding surface before installing. 1. Oil seal and bearing outer race 1) Using push tools [11], install oil seals (49). a Install the lower oil seal with its pressure receiving side down and the top oil seal with its pressure receiving side up. 2 Oil seal lip: Grease (G2-LI) 2 Oil seal press-fitting surface: Liquid gasket (LG-1) a Apply a thin film of liquid gasket on the inside surface of the case and wipe off any liquid gasket that is squeezed out.
13. Outer race and oil seal 1) Using puller [10], remove bearing outer race (48). 2) Remove oil seal (49) from the case.
2) Press fit bearing outer race (48) with push tool [13].
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DRAFT Power train Disassembly and assembly of final drive assembly
2. Gear assembly 1) Using push tool [14], press fit bearing inner races (46) and (45) to the gear. 2) Set tool J8 to the case to install gear assembly (44) in position. a Do not remove tool J8 until the cage is installed.
2] Press fit bearing outer race (41) with push tool [15].
2) Using eyebolts [7], set case assembly (39) to the case, and equally tighten the cage mounting bolts (C) and (D). 3 Mounting bolt: 14.7 Nm {1.5 kgm} 3. Cage assembly 1) Assemble the cage assembly as follows. 1] Using push tool [11], install oil seals (42). a Install the lower oil seal with its pressure receiving side down and the top oil seal with its pressure receiving side up. 2 Oil seal lip (OL): Grease (G2-LI) 2 Oil seal press-fitting surface (OP): Liquid gasket (LG-1) a Apply a thin film of liquid gasket on the inner surface of the case and wipe off any liquid gasket that is squeezed out.
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DRAFT Power train Disassembly and assembly of final drive assembly
3) Using feeler gauge [16] as shown in the figure below, measure the clearances (a) and (b) between cage (A) and case (B), at the two points "m" distance away from bolts (C) and (D), respectively. 4) Determine total thickness (c) of the shim pack and select shims to use according the table below. 5) Insert the shims selected in Step 4 in position, and tighten four cage mounting bolts. 3 Mounting bolt: 227.3 ± 80.85 Nm {23.25 ± 8.25 kgm} a Equally tighten the bolts while rotating the gear by hand, and then remove tool J8.
4. Hub and shaft assembly 1) Assemble the shaft assembly as follows. 1] Install collar (38). 2] Press fit bearing inner race (37) by using push tool [17]. 3] Install collar (36).
2) Using eyebolts [6], install shaft assembly (31) to the case. 3) Assemble the hub assembly as follows. 1] Using the push tool, press fit bearing outer race (35) to boss (34).
(a) + (b) [mm] Larger than
Below
1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.2 5.4 5.6
1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.2 5.4 5.6 5.8
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Number of shims to be used t= 0.1
t = 0.5
1 2 3 4 1 2 3 4
1 1 1 1 1
1 2 3 4 1 2 3 4 5
1 1 1 1 1 1
t = 1.0 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2
Total thickness of shims (c) [mm] 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0
D375A-6 (02)
DRAFT Power train Disassembly and assembly of final drive assembly
2] Set boss (34) to hub (33). 4) Set shaft assembly (31) to hub assembly (29). Using tool J6, press fit bearing (30) portion.
5) Tighten mounting bolts of hub assembly (29). 3 Mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm} 6) Install plate (28). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 548.8 ± 58.8 Nm {56 ± 6 kgm} 7) Install gear (32). 3 Mounting bolt: 539 ± 49 Nm {55 ± 5 kgm}
6. Carrier assembly 1) Assemble the carrier assembly as follows. a As each bearing of the planetary gear is a selective combination part, match the ID marks on the inner race, outer race and spacer when assembling. *1. Bearing ID mark *2. Spacer ID mark (ID mark "MZ-12B" is an example in this figure.)
1] Install the rings and spacer to the planetary gear. Using push tool [18], press fit upper and lower bearing outer races (24D) into position. 5. Sun gear 1) Install inner race (26-2) to the shaft of plate (25-1). 2) Install sun gear (27) to the shaft of plate (25-2). 3) Install shaft (25).
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DRAFT Power train Disassembly and assembly of final drive assembly
2] Install spacer (24C) and bearing inner races (24B) and (24A) to each planetary gear (23), and set it to the carrier.
3] Using tool J7, press fit planetary gear shaft (22) in position. a Press fit the shaft gradually matching the holes of the bearing and spacer. 4] Install holder (21). 3 Mounting bolt: 548.8 ± 58.8 Nm {56 ± 6 kgm} a After tightening the bolts, check that each gear rotates smoothly.
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2) Install bearing (26-1) and spacer (26) to carrier assembly (20).
3) Using eyebolts [5] , install carrier assembly (20). 7. Cover assembly 1) Assemble the cover assembly as follows. 1] Fit ring gear (19) and install the plate. a Install the plate with its chamfered surface up.
D375A-6 (02)
DRAFT Power train Disassembly and assembly of final drive assembly
2] Using tool J3, press fit bearing inner race (18). 3] Install spacer (17).
a Install the floating seal cover with its cut-out portion facing down as shown in the diagram below. 4] Using tool J4, press fit floating seal (16) to the floating seal cover. a Thoroughly degrease and dry the O-ring and O-ring contact surfaces of the floating seal before installing. a After installing the floating seal, check that its leaning is less than 1 mm.
2) Using eyebolts [4], hoist cover assembly (14) to install. a Apply the 1216 ThreeBond adhesive to the mating surfaces. 8. Wear guard Hoist wear guard (13) to install. 5] Install floating seal cover (15). a Fit a cork plug in the forcing tap.
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DRAFT Power train Disassembly and assembly of final drive assembly
9. Sprocket hub assembly 1) Using tool J4, install floating seal (12) to the floating seal cover. a Thoroughly degrease and dry the O-ring and O-ring contact surfaces of the floating seal before installing. a After installing the floating seal, check that its leaning is less than 1 mm.
4) Set bearing (8) to the sprocket hub assembly.
5) Using eyebolts [3], sling sprocket hub assembly (6) and set it to the cover. a Check that the sliding surface of floating seal is free from dirt, and apply a thin film of engine oil on it. 2) Using the push tool, press fit bearing outer races (11) and (10). 3) Install floating seal cover (9).
6) Using tool J3, press fit bearing (7) portion. a Press fit the sprocket hub assembly while rotating it by hand.
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DRAFT Power train Disassembly and assembly of final drive assembly
7) Install holder (5). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
12. Sprocket Install sprocket (1). 2 Mounting bolt: Molybdenum disulphide lubricant (LM-P) 3 Mounting bolt: 1,813 ± 98 Nm {185 ± 10 kgm} 13. Refilling of oil Tighten the drain plug, and supply engine oil through the filler port. 5 Final drive case: Approx. 61 liters a After installing the final drive assembly on the machine, finally check that the oil is at the specified level.
10. Hub 1) Lift hub (4) using eyebolts [2], and install the hub in position. 2) Install plate (3).
11. Cover Using eyebolts [1], install cover (2) in position.
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DRAFT Undercarriage and frame Removal and installation of track frame assembly
Undercarriage and frame Removal and installation of track frame assembly
Symbol
Part No.
195-30-68610 01010-62450 01010-62455 22 19M-54-11770 01643-32460 198-30-66190 L 195-30-69540 01011-82410 23 01011-82420 19M-54-11770 195-30-69550 24 791-685-1320
Part name
Plate Bolt Bolt Washer Washer Collar Plate Bolt Bolt Washer Collar Lifting tool
Necessity Q'ty New/remodel Sketch
Special tools
t t t t t t t t t t t t
6 6 6 6 6 6 2 2 2 4 2 1
N
N N N
N N
5. Using tools L22 and L23, lcok the bogies. 6. Remove cover (1).
Removal 1. Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 1-1. Place blocks [3] (at right and left sides) between the equalizer bar and frame, to lock the equalizer bar.
2. Raise the machine off the ground by using the ripper or a crane, place stands [1] under the frame, and lift the rear of machine off the ground. k Stand [1] must be able to support the weight of 25 tons or more . 3. Place hydraulic jack [2] (490 kN {50 ton}) at the center of the equalizer bar, and lift the front of the machine off the ground. 4. Sling the track frame assembly.
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DRAFT Undercarriage and frame Removal and installation of track frame assembly
7. Remove cover (2). 8. Remove grease tube (4). 9. Remove cover (3). 10. Loosen front and rear bolts (6-1). a Bolt: M30; Width across flats: 46 mm 11. Remove cover (5).
[*1]
13. Remove the mounting bolts and remove cover (7) from the track frame.
[*1] [*2]
14. Remove cover (8).
12. Place a pad on the rear of pin (6), and drive out the pin by hammering. [*3] a If the equalizer bar hole is not aligned with the track frame hole, the pin cannot be removed easily. Adjust the lifting height of the track frame properly. a Put "UP" mark on the top of the pin for installation purpose.
15. Disconnect lower hose (9) and upper hose (10) of the blade tilt cylinder. a Perform this step for only the right track frame of the single tilt specification machine, or both track frames of the dual tilt specification machine. 16. Remove the mounting bolts and cover (11). a Take care not to damage the hose connected to the inside face of the cover.
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DRAFT Undercarriage and frame Removal and installation of track frame assembly
17. Disconnect hoses (12) and (13) from the inside face of cover (11), and remove cover (11). [*4] a Perform this step for only the right track frame of the single tilt specification machine, or both track frames of the dual tilt specifications machine. a Note the color of hose band for installation purpose. (Single tilt) (12a) (13a) Right track frame: Red (Dual tilt) (12a) (13a) Right track frame: Red (12a) (13a) Left track frame: Blue RH: Both dual tilt and single tilt specifications LH: Dual tilt specification
19. Remove seal (15) and cover (14) as a unit. [*6] a Perform this step for only the right track frame of the single tilt specification machine, or both track frames of the dual tilt specifications machine. 20. Remove washer (16) and spacer (17).
LH: Dual tilt specification RH: Both dual tilt and single tilt specifications
21. Using tool L24, lift off track frame assembly (18). 4 Track frame: 7,940 kg (each)
18. Remove cover (14). [*5] a Three mounting bolts are used on the track frame, and six bolts are used on the pivot frame. a Take care not to damage O-rings. a As the oil drains from the pivot shaft case, place an oil container to receive it. 6 Pivot shaft case:18 l
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DRAFT Undercarriage and frame Removal and installation of track frame assembly
Installation a Take care not to install seal (19) twisted to the track frame. a When replacing seal (19), see "Removal and installation of pivot shaft assembly".
q
Carry out the subsequent installation in the reverse order to removal.
[*1] a Install covers (2) and (3), and tighten bolts (6-1). 3 Covers (2) and (3): 245 – 309 Nm {25 – 31.5 kgm} [*2]
3
Bolt (6-1): 1,960 – 2,450 Nm {200 – 250 kgm}
[*3]
2 Inside surface of bushing: Grease (G2-LI) a Install pin (6) with the "UP" mark on it up, a mark put upon removal. a Align the notch of pin (6) with the left and right of machine. 2
Apply G2-LI grease on (GR) portions before installing equalizer bar (EB), bushing (7) and pin (6). a Before installing pin (6), adjust the lifting height of the track frame so that the hole of equalizer bar (EB) matches the center of track frame hole. a When aligning the pin holes, never insert your fingers in them. 2 Bushing contact surface on pivot shaft: Molybdenum disulphide lubricant (LM-P) a When replacing the pivot shaft bushing of track frame assembly, install a new bushing with its abutment joint up.
D375A-6 (02)
.
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DRAFT Undercarriage and frame Removal and installation of track frame assembly
[*4] q Install the hoses taking care not to install hoses with wrong band colors. a Hose band colors (Single tilt specification) (12a) (13a) Right track frame: Red (Dual tilt specification) (12a) (13a) Right track frame: Red (12a) (13a) Left track frame: Blue RH: Both dual tilt and single tilt specifications LH: Dual tilt specification
[*5] a Install cover (14) using three bolts (indicated by arrows). [*6] a Completely degrease the contact surface (15) of seal when mounting it. 2 Contact surface of seal (15): Liquid gasket (LG-6) a Be careful not to twist the seal when installing it.
q
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Refilling (Pivot shaft case) Supply oil through the oil filler to the specified level. 5 Pivot shaft case: 18 l (EO30)
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of idler assembly
Removal and installation of idler assembly Removal 1. Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 2. Remove scraper (1). a Remove the inside scraper, too. 3. Remove cover (2). a Remove the inside cover, too.
Installation q Carry out installation in the reverse order to removal. a For both the right and left idler assemblies, install the assembly with the oil filler plug facing the left side of machine. a Tighten idler cap mounting bolts in the following order. Tightening order: 1] Two bolts at side (a) 2] Two bolts at side (b) 3] Two bolts at side (a) 4] Tighten all bolts to the specified torque. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 1,470 - 1,813 Nm {150 - 185 kgm} a After tightening the idler cap mounting bolts, check that clearance (c) between the bottom of idler cap and the yoke is zero.
4. Sling the idler assembly, and remove idler cap (3). a For both the left and right idler assemblies, a ball is installed to the left idler cap. Take care not to lose the ball. 5. Lift off idler assembly (4). 4 Idler assembly: 480 kg
D375A-6 (02)
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DRAFT Undercarriage and frame Disassembly and assembly of idler assembly
Disassembly and assembly of idler assembly 4. Turn over idler assembly (1).
Symbol
Part No.
791T-630-2210 791-530-1630 790-101-2510 790-101-2570 1 01580-01613 01643-31645 L 790-101-2102 790-101-1102 2 791-515-1520 3 791-685-8310 4 791-601-1000
Part Name
Necessity Quantity N/R Sketch
Special tools
Plate Rod Block Washer Nut Washer
t t t t t t
Puller (294 kN {30 ton})
t 1
Pump Installer Push tool Oil pump
1 2 1 2 2 2
Q
5. Remove the mounting bolts. Using eyebolts [3], remove shaft (5) and the retainer as a unit. 6. Using puller [4], remove retainers (3) and (7), and seal guide (6).
t 1 t 1 t 1 1
Disassembly 1. Remove the oil filler plug to drain oil. 6 Idler: 0.95 – 1.05 l 2. Place idler assembly (1) on blocks [1] (approx. 140 mm high).
7. Remove seal guides (2) and (6) from retainers (3) and (7) respectively.
3. Remove mounting bolts, then using forcing screws [2], remove seal guide (2), retainer (3) and plate (4) as a unit.
8. Remove plates (4) and (8) from the respective retainers.
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DRAFT Undercarriage and frame Disassembly and assembly of idler assembly
9. Remove respective floating seals (9) from seal guides (2) and (6). a Keep the floating seal in a safe place so that it does not get damaged. 10. Remove respective floating seals (10) from retainers (3) and (7). a Keep the floating seal in a safe place so that it does not get damaged.
Assembly a Clean all parts and check them for dirt and damage before installing. 1. Place bushings (11) and tool L1 on idler (12), and press fit bushings (11) in position. a First, center the bushing with a plastic hammer, then press fit with the puller. a Press fit the bushing so that press-fitting dimension (a) from the end face of the idler to the top surface of the bushing is as follows. q Press-fitting dimension (a): 17 ± 0.5 mm
11. Remove bushings (11) from idler (12). 2. Using tool L2, install respective floating seals (10) to seal guides (3) and (7). a Completely degrease and dry the O-ring and the O-ring contact surfaces (hatched portions) of floating seal. a Apply oil to the sliding surface of floating seal, and take care not to allow dirt and foreign matter to attach on the seal. a After installing the floating seal, check that its leaning is less than 1 mm and that the protrusion (a) of the seal is between 7 to 11 mm.
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DRAFT Undercarriage and frame Disassembly and assembly of idler assembly
3. Install retainer (3) with the O-ring and plate (4) to the idler. a Check that the plate can be turned smoothly with the hand.
.
4. Using eyebolts [3], install idler (12) to shaft (5). a Place blocks (approx. 140 mm high) under the idler. 5. Turn over the idler assembly. a Tie the shaft with wire to prevent it from falling out.
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6. Install retainer (7) with the O-ring and plate (8) to the idler.
7. Using tool L2 install respective floating seals (9) to seal guides (2) and (6). a For installation procedures, refer to Step 2.
8. Set seal guide (2) to the shaft, and press fit seal guide (2) by using tool L3. a Press-fitting force of seal guide: 43 – 71 kN {4.4 – 7.2 tons}
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of idler assembly
a Press fit the seal guide so that press-fitting dimension (b) from the end face of the shaft to the top surface of the seal guide is as follows. q Press-fit dimensions (b): 102 ± 0.2 mm a Turn over the idler assembly and repeat the same procedure to press fit the seal guide (6) on the opposite side.
9. Using tool L4, supply oil to the specified level and tighten the oil filler plug. 6 Idler: 0.95 – 1.05 l (GO140) 3 Oil filler plug: 206 ± 49 Nm {21 ± 5 kgm} VT: To vacuum tank OP: To oil pump
D375A-6 (02)
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DRAFT Undercarriage and frame Removal and installation of recoil spring assembly
Removal and installation of recoil spring assembly 5. Lift off trunnion (3). 4 Trunnion: 75 kg
791-730-1110 Bolt 01580-12722 Nut 01643-32780 Washer M 1 Puller 790-101-2102 (294 kN {30 ton}) 790-101-1102 Pump
t 6 t 6 t 1
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1 t 1
Removal 1. Separate the track shoe assembly. For details, see “Separation and connection of track shoe assembly.” k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 2. Drain the oil from the recoil cylinder chamber by using the oil pump. 6 Recoil cylinder chamber: Approx. 50 l
6. Remove cover (4). a Remove both the inside and outside covers. 7. Using tool M1, remove pin (5). [*1] a Remove both the inside and outside pins.
3. Using eyebolts [1], remove cover (1). 4 Cover:40 kg 4. Remove cover (2).
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DRAFT Undercarriage and frame Removal and installation of recoil spring assembly
8. Lift off the idler and idler cushion assembly (6). [*2] a Keep the assembly horizontal by using lever blocks, and take care not to damage the oil seal installed on the track frame during removal. 4 Idler and idler cushion assembly: 2,180 kg
2) Loosen idler yoke assembly mounting bolts (9) on diagonally opposite sides gradually in turn. [*4] k For safety reasons, no one is allowed to be in front of the idler yoke during the work. k The recoil spring mounted in the recoil cylinder is under the installed load of approximately 500 kN {approx. 51 tons}. Never loosen the mounting bolts quickly. Gradually loosen the bolts until clearance (a) between the idler yoke and recoil cylinder flange (FL) becomes 8 to 12 mm.
9. Disconnect idler cushion assembly (7) from idler yoke assembly (8) according to the following procedure. [*3] 1) Place idler yoke assembly (8) on the ground, and sling idler cushion assembly (7). a Check the welded area of idler cushion assembly (7) for any defect. a Protect the chrome plated bushing (CP) by covering it with cloths.
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DRAFT Undercarriage and frame Removal and installation of recoil spring assembly
3) Check that the loosening torque of all the bolts suddenly drop. If so, it indicates that the installed load of the recoil spring is not applied on the mounting bolts. Then, remove all bolts. a 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. k If the torque is not reduced in Steps (2) or (3) and if the loosening torque is still large, recoil spring set bolt (10) may be broken or shaft end nut (11) may fall out. In such a case, the idler yoke assembly may fly off to the front of the machine. Disassemble it as follows: k Do not allow anyone to remain in front of the idler yoke or at the back of the recoil cylinder until the idler yoke assembly is separated from the idler cushion assembly and the recoil spring is removed.
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1] Prepare the following parts of tool M1: q Bolt [1] (6 bolts): Part No. 791-730-1110 q Nut [2] (6 nuts): Part No. 01580-12722 q Washer [3] (6 washers): Part No. 01643-32780 (may be used ones)
2] Remove six bolts marked with*, then install bolts [1], nuts [2], and washers [3]. a Check that dimension (L) is below 30 mm. a Screw in bolts [1] until they reach the bottom of yoke threaded holes. 3] Remove remaining twelve bolts (those not marked). 4] Hold bolts [1] with a wrench to prevent them from turning, and loosen two nuts [2] simultaneously on diagonally opposite sides. a Take care not to let the load bear on only one bolt.
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of recoil spring assembly
5] Loosen bolts until the recoil spring is extended completely and the loosening torque of nuts [2] is reduced. Then, remove bolts [1]. a When clearance (b) reaches approx. 230 mm, the spring is extended completely.
12. Disassemble piston assembly (15) as follows. 1) Remove wear rings (16) from the piston. 2) Remove snap ring (17), then remove packing (18).
13. Remove recoil spring assembly (19). 4 Recoil spring assembly: 550 kg 10. Remove ring (12).
14. Remove holder (20) from the recoil spring assembly. 11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15).
D375A-6 (02)
50-199
DRAFT Undercarriage and frame Removal and installation of recoil spring assembly
Installation q Carry out installation in the reverse order to removal. 3 Cover mounting bolt: 277 ± 32 Nm {28.25 ± 3.25 kgm} [*1] a Before installing the pin, align the dowel hole in the track frame with the dowel pin on the recoil cylinder by using a pinch bar. [*2] a Keep the assembly horizontal by using lever blocks, and take care not to damage the oil seal installed on the track frame during installation. [*3] a If the recoil spring set bolt is broken or the shaft end nut falls out, see "Disassembly and assembly of idler cushion assembly". [*4]
2 3
Idler yoke assembly mounting bolt : Adhesive (LT-2) Idler yoke assembly mounting bolt : 1,519 – 1,911 Nm {155 – 195 kgm}
a To prevent a trapped air in the cylinder, pump in grease as follows: 1) Refill the cylinder with approx. 1.3 liters of grease. 2) Set the cylinder with the drain hole up, then loosen the lubricator. 3) Push the piston until it reaches the stopper to remove any air and excess grease from the cylinder.
50-200
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of recoil spring assembly
Disassembly and assembly of recoil spring assembly 4. Remove rear pilot (5), spacer (6), bolt (7), and pilot (8) from spring (4).
Symbol
M 2
Part No.
Part Name
Necessity Quantity N/R Sketch
Special tools
791-685-8501
Compressor
t 1
790-101-1600
Cylinder (980 kN {100 ton})
t 1
790-101-1102 791-635-3160
Pump Extension
t 1 t 1
Disassembly 1. Set recoil spring assembly (1) to tool M2. k As the spring is under high installed load, so set the assembly correctly to the tool. a Installed load of spring: Approx. 500 kN {approx. 51 tons}
2. Apply hydraulic pressure slowly to compress the spring, then remove lock plate (2) and remove nut (3). 3. Release hydraulic pressure gradually and relieve tension of the spring.
D375A-6 (02)
50-201
DRAFT Undercarriage and frame Disassembly and assembly of recoil spring assembly
Assembly 1. Install pilot (8), bolt (7), spacer (6), and rear pilot (5) to spring (4), and set them to tool M2.
3. Install nut (3), and install lock plate (2) in position. a To prevent the nut from protruding from the end of bolt (7), make a clearance of 0 – 1.0 mm between the nut and lock plate. a Bring lock plate (2) and bolt (7) (CE portion) into tight contact to secure. 2 Lock plate mounting bolt: Adhesive (LT-2) 4. Gradually release hydraulic pressure to reduce the spring tension, and them remove recoil spring assembly (1) from tool M2.
k
As the spring will be under high installed load, so set them correctly to the tool.
2. Apply hydraulic pressure gradually to compress the spring until the spring installed length is the standard length. a Installed length (a) of spring: 1,329.5 mm a Installed load of spring: 500 kN {50,994 kg}
50-202
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of track roller assembly
Removal and installation of track roller assembly
790-401-1700 790-401-1761 12 790-401-1540 790-401-1770 195-30-68610 01010-62450 01010-62455 22 L 19M-54-11770 01643-32460 198-30-66190 195-30-69540 01011-82410 23 01011-82420 19M-54-11770 195-30-69550
D375A-6 (02)
Lifting tool Adapter Shackle T-bolt Plate Bolt Bolt Washer Washer Collar Plate Bolt Bolt Washer Collar
t t t t t t t t t t t t t t t
1 1 2 2 6 6 6 6 6 6 2 2 2 4 2
Sketch
Part name
Q'ty
Part No.
New/remodel
Symbol
Necessity
Special tools
Removal 1. Decrease the track tension. For details, see "Separation and connection of track shoe assembly". k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
N
N N N
2. Install tools L22 or L23 to lock bogie assembly (1) to be removed. [*1] S: Single flange type D: Double flange type
N N
50-203
DRAFT Undercarriage and frame Removal and installation of track roller assembly
3. Raise the machine until track roller assembly (2) leaves the track by operating the blade and ripper. 4. Place steel plate [1] on the track and operate the blade and ripper to lower the machine until the track roller assembly comes in contact with the steel plate. a Operate the blade and ripper slowly, running the engine at the low speed.
7. Using the crane and tool L12, pull out track roller assembly (2) on the steed plate to the outside of the machine. 4 Track roller assembly: 150 kg (single flange) 160 kg(double flange)
5. Remove the mounting bolts, and place track roller assembly (2) on steed plate [1]. 6. Raise the machine until track roller assembly (2) leaves the bogie by operating the blade and ripper.
50-204
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of track roller assembly
Installation q Carry out installation in the reverse order to removal. [*1] a After removing tool L22, replace the mounting bolt of cover (3) with the normal bolt. 3 Cover mounting bolt : 927 ± 103 Nm { 94.5 ± 10.5 kgm}
a Note that the installation location differs between single flange and double flange track roller assemblies. Install them in the correct locations. S : Single flange D: Double flange a Install the track roller assembly with the oil filler plug outside.
D375A-6 (02)
50-205
DRAFT Undercarriage and frame Disassembly and assembly of track roller assembly
Disassembly and assembly of track roller assembly 6. Using the press, remove seal guide (6), retainer (7) and plate (8) as a unit from the shaft.
Symbol
Part No.
8 9 L 10 11
791T-630-2220 796-670-1020 791T-630-2230 791-601-1000
Part Name
Plate Installer Push tool Oil pump
Necessity Q’ty New/remodel Sketch
Special tools
t t t t
1 1 1 1
7. Remove seal guides (2) and (6) from retainers (3) and (7).
Q Q
Disassembly 1. Remove oil filler plug to drain oil. 6 Track roller: 1.4 – 1.5 l 2. Place track roller assembly (1) on block [1]. 3. Remove the mounting bolts, then using forcing screws [2], remove seal guide (2), retainer (3) and plate (4) as a unit.
8. Remove respective floating seals (9) from seal guides (2) and (6). a Keep the floating seal in a safe place to protect it from damage.
4. Turn over the track roller assembly. 5. Remove the mounting bolts, then using eyebolts [3], remove shaft (5) and the retainer as a unit.
50-206
9. Remove respective floating seals (10) from retainers (3) and (7). a Keep the floating seal in a safe place to protect it from damage.
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of track roller assembly
10. Remove bushings (11) from roller (12).
3. Using tool L9, install respective floating seals (10) to retainers (3) and (7). 4. Install the O-rings, and install retainers (3) and (7) and plate (8) to the roller. a Check that the plate can be turned smoothly with the hand.
Assembly a Clean all parts, and check them for dirt and damage before installing. 1. Set roller (12) on the press. Using tool L8, press fit bushings (11) in position. a First, center the bushing by using a plastic hammer, then press fit it with the press. a Press fit the bushing so that press-fitting dimension (a) from the end face of the roller to the top surface of the bushing is as follows . q Press-fitting dimensions (a): 17 ± 0.5 mm 2. Set shaft (5) to the roller.
D375A-6 (02)
5. Using tool L9, install respective floating seals (9) to seal guides (2) and (6). 6. Using tool L10, press fit seal guide (2) to the shaft. a Seal guide press-fitting force: 36 – 63 kNm {3.7 – 6.4 ton}
50-207
DRAFT Undercarriage and frame Disassembly and assembly of track roller assembly
a Press fit the seal guide so that press-fitting dimension (b) from the end face of the shaft to the top surface of the seal guide is as follows. q Press-fitting dimensions (b): 77 ± 0.2 mm a Turn over the track roller assembly and press fit seal guide (6) on the opposite side according to the above procedure.
7. Using tool L11, refill with the specified amount of oil and tighten the oil filler plug. 6 Track roller: 1.4 ± 1.5 l (GO140) 3 Oil filler plug:206 ± 49 Nm {21 ± 5 kgm}
50-208
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of carrier roller assembly
Removal and installation of carrier roller assembly Removal 1. Decrease the track tension. For details, see "Sepatation and connection of track shoe assembly". k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
Installation Carry out installation in the reverse order to removal.
q
[*1] a Make a clearance (a) of 1.75 mm between the carrier roller and support. 2 Carrier roller assembly mounting bolt : Adhesive (LT-2) 3 Carrier roller assembly mounting bolt : 662 – 829 Nm {67.5 – 84.5 kgm}
2. Push up the track by using hydraulic jack [1]. 3. Lift off carrier roller assembly (1). 4 Carrier roller assembly: 75 kg
D375A-6 (02)
[*1]
50-209
DRAFT Undercarriage and frame Disassembly and assembly of carrier roller assembly
Disassembly and assembly of carrier roller assembly 5. Using tool L7, remove nut (4).
Symbol 4 5 L 6 7
Part No. 791-601-1000 791-515-1520 791-830-1770 791-630-1270
Part Name Oil pump Installer Push tool Wrench
Necessity Quantity N/R Sketch
Special tools
t t t t
6. Using puller [2], remove the press-fitted seal guide, and remove bearing (5) and roller (6) as a unit using eyebolts.
1 1 1 1
Disassembly 1. Remove the oil filler plug to drain oil. a Drain the oil while rotating the shaft. 6 Carrier roller: 0.7 – 0.8 l 2. Place carrier roller assembly (1) on block [1]. 3. Remove the mounting bolts and cover (2). 7. Remove bearing outer race (7) from the roller. 4. Remove snap ring (3). 8. Remove seal guide (8) and bearing inner race (9) as a unit by using puller [3].
50-210
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of carrier roller assembly
9. Remove floating seal (10) from seal guide (8).
Assembly a Clean all parts, and check them for dirt and damage before installing. 1. Press fit bearing inner race (9) with push tool [5]. 2. Press fit bearing outer race (7) with push tool [6].
10. Remove seal guide (11) with push tool [4]. 11. Remove floating seal (12) from seal guide (11).
3. Set roller (6) and bearing inner race (5) to the shaft. 4. Using push tool [7], press fit bearing inner race (5) to the shaft. a Press fit the bearing inner race, turning the roller, until the roller becomes a little hard to turn.
.
D375A-6 (02)
50-211
DRAFT Undercarriage and frame Disassembly and assembly of carrier roller assembly
5. Using tool L7, tighten nut (4). 3 Nut: 98 Nm {10 kgm} a After the nut is tightened, If the nut hole is not aligned with the shaft hole, loosen the nut to align them. 6. Install snap ring (3). a Check that the end play (clearance between bearing and nut) is within 0.01 – 0.22 mm.
7. Install cover (2) with the O-ring.
8. Using tool L5, install floating seal (10) to seal guide (8). 9. Fit the O-ring to seal guide (8) and install them, matching the dowel hole to the dowel pin. a Completely degrease and dry the O-ring and the O-ring contact surfaces (shaded area) of the floating seal before installing. Also, take care not to allow dirt to attach the floating seal contact surfaces. a After installing the floating seal, check that its learning is less than 1 mm and that the protrusion (a) of the seal is between 7 to 11 mm.
50-212
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of carrier roller assembly
10. Using tool L5, install floating seal (12) to seal guide (11). a For precautions for installing the floating seal, see a in Step 9. 11. Using tool L6, press fit seal guide (11) in position. a Press fit the seal guide so that dimension (a) between the shaft end surface and seal guide top surface is 158.75 ± 0.2 mm. a After press-fitting of the seal guide, check that its learning from the shaft is less than 1 mm.
12. Using tool L4, supply the specified amount of oil and tighten the oil filler plug. 6 Carrier roller: 0.7 – 0.8 l (GO140) 3 Oil filler plug: 157 – 255 Nm {16 – 26 kgm}
D375A-6 (02)
50-213
DRAFT Undercarriage and frame Removal and installation of bogie assembly
Symbol
1 2 3 4 14 5
Part No.
791-630-2260 790-201-2730 791-630-2270 01580-12419 01643-32460
6 790-101-4000 L
7 1 2 3 4 15 5 6
790-101-1102 791-630-2280 790-201-2770 791-630-2250 790-434-1070 01580-13629 01643-33690
7 790-101-4000 8 790-101-1102
Part name
Plate Spacer Screw Nut Washer Puller (490 kN {50 ton}) Pump Adapter Spacer Plate Screw Nut Washer Puller (490kN {50ton}) Pump
Necessity Q'ty New/remodel Sketch
Special tools
t t t t t
Symbol
1 2 3 16 4
1 1 3 3 3
1 1 1 1 1 2 2
L
6 17 18 19
22
t 1 t 1
791-630-2260 791-630-2270 01580-12419 01643-32460
5 790-101-4000
t 1 t t t t t t t
Part No.
23
790-101-1102 791T-630-2290 791-530-1510 791-601-1000 195-30-68610 01010-62450 01010-62455 19M-54-11770 01643-32460 198-30-66190 195-30-69540 01011-82410 01011-82420 19M-54-11770 195-30-69550
Part name
Necessity Q'ty New/remodel Sketch
Removal and installation of bogie assembly
Plate Screw Nut Washer Puller (490 kN {50
t t t t
Pump Guide Installer Oil pump Plate Bolt Bolt Washer Washer Collar Plate Bolt Bolt Washer Collar
t t t t t t t t t t t t t t t
1 3 3 3
t 1 1 2 1 1 6 6 6 6 6 6 2 2 2 4 2
Q N
N N N
N N
Removal 1. Decrease the track tension. For details, see "Separation and connection of track shoe assembly". k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 2. Install tool L22 or L23 to lock the bogie assembly to be removed.
50-214
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of bogie assembly
3. Raise the machine body until the track rollers leave the track links, by operating the blade and ripper. k Place a block between the track roller and the track link so that the machine does not lower. 4. Set block [1] outside of the track shoes, matching it to the height of the track link.
8. Removal of shaft and ring 1) Set tool L14 in position. 2) Push out shaft (3) and ring (4) to the opposite side simultaneously. a Pressing force: 137.2 – 274.4 kN {14 – 28 tons} Pressing force C 1.8 x Average pressure (Set the pressing force by adjusting the relief pressure of the link press.)
5. Place steel plate [2] on the track shoes and block [1]. 6. Operate the blade and ripper to lower the machine until the track roller of bogie assembly (1) touches steel plate [2]. a Operate the blade and ripper slowly, running the engine at low speed.
3) Remove respective floating seals (5) from the end faces of rings (4) and (7). a Keep the floating seal in a safe place so that it does not get damaged.
7. Remove (outside and inside) covers (2).
D375A-6 (02)
50-215
DRAFT Undercarriage and frame Removal and installation of bogie assembly
4) Set tool L15 in position. 5) Pull out spacer (6) and rings (7) and (8). a Pulling force: 205.8 – 382.2 kN {21 – 39 tons}
13. Last bogie 1) Perform Step 1 and Steps 3 to 6 for the last bogie. 6) Remove spacer (6). 7) Remove spacer (9) and floating seals (10) between rings (7) and (8). a Keep the floating seal in a safe place so that it does not get damaged. 8) Pull out the shaft and rings on the opposite side of the bogie according to above steps 1) to 7).
2) Sling bogie assembly (1). 3) Loosen roller cap bolts (20) for approx. 20 mm. (Loosen both the inside and outside bolts.) 4) Hit the end of shaft (21) with a hammer to remove track roller assembly (22). a Take care not to damage the dowel pin installed to the shaft of the track roller assembly. (Insertion depth of dowel pin: 5 – 6 mm) 5) Remove roller cap bolts (20), and place track roller assembly (22) on the steel plate, and pull it out. 4 Track roller assembly: 150 kg 6) Remove cover (23).
9. Remove tool L22 or L23 that locks the bogie to be removed. 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. k Place a block between the track roller and track link so that the machine does not lower. 12. Sling bogie assembly (1), slide it on steel plate [2] to remove. 4 Bogie assembly: 720 kg
50-216
7) Perform Steps 9 to 13 to remove bogie assembly (1). 4 Bogie assembly: 150 kg
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of bogie assembly
Installation 1. Assembly of pin assembly. 1) Using tool L18, install respective floating seals (5) to rings (4) and (7). Also, install respective floating seals (10) to the opposite surface of ring (7) and to ring (8). a Completely degrease the O-ring and the O-ring contact surfaces of floating seal before installing. a Check that the leaning of the floating seal is less than 1 mm.
2. Apply lever block [3] between the guard of bogie assembly (1) and that of the bogie assembly on the opposite side, slide bogie assembly (1) on the steel plate, and place it in the mounting position.
3. Align pin holes of the track frame and bogie with each other, and set guidance tool L17 in position.
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 Part (a) of ring (8) and ring (4) (approx. 10 mm): Molybdenum disulphide lubricant (LM-P) 4. Press fitting of pin assembly 1) Set tool L16 and cover (2) in position.
D375A-6 (02)
50-217
DRAFT Undercarriage and frame Removal and installation of bogie assembly
2) Press fit the pin assembly. a Install the pin assembly with arrow (a) on its end face up (when it is mounted on the machine). a Push in the pin assembly with cover (2). a Push in the pin assembly to machined face (b) of the bogie. 2 Periphery of pin: Molybdenum disulphide lubricant (LM-P) a Press-fitting force of pin assembly: 245 – 441 kN {25 – 45 tons}
6. Press fit the pin assembly on the opposite side of the bogie according to above steps 3 and 4. 7. Tighten the mounting bolts of pin assembly cover (2) (2 covers on inside and outside). 3 Cover mounting bolt: 927 ± 103 Nm {94.5 ± 10.5 kgm}
8. Adjust the track tension. For details, see Testing and adjusting "Inspection and adjustment of track tension". 5. Refilling Using tool L19, refill with the specified amount of oil. a Oil supply pressure: 0.49 MPa {5 kg/cm2} 5 Pin assembly: 95 –115 cc (GO140)
50-218
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of bogie assembly
Disassembly and assembly of bogie assembly
Symbol
L
1 2 3 16 4
Part No.
791-630-2260 791-630-2270 01580-12419 01643-32460
5 790-101-4000 6 790-101-1102 19 791-601-1000
Part Name
Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump Oil pump
Necessity Q’ty New/remodel Sketch
Special tools
t t t t
1 3 3 3
3. Remove the pin assembly following the same procedure as described in the "Removal of bogie assembly". (See Step 8.) 4. Disconnection of bogie Disconnect inner bogies (4) from outer bogie (5).
t 1 t 1 t 1
Disassembly 1. Track roller assembly Reverse bogie assembly (1). Then, lift off two track roller assemblies (2).
2. Remove cover (3).
D375A-6 (02)
50-219
DRAFT Undercarriage and frame Disassembly and assembly of bogie assembly
Assembly 1. Assembly of pin assembly Assembly the pin assembly following the same procedure as described in the "Installation of bogie assembly". (See Steps 3 to 5.)
4. Refilling Using tool L19, supply the specified amount of oil. a Oil supply pressure: 0.49 MPa {5 kg/cm2} 5 Pin assembly: 90 – 115 cc (GO140)
2. Set inner bogies (4) to outer bogie (5). 3. Press-fitting of pin assembly 1) Set tool L16 and cover (3) in position. 2) Press fit the pin assembly. a Install the pin assembly with arrow (a) on its end face up (when it is mounted on the machine). a Push in the pin assembly with cover (3). a Push in the pin assembly to the machined surface of the bogie and maintain step (b) of 5 mm between the bogie and the pin assembly. 2 Periphery of pin: Molybdenum disulphide lubricant (LM-P) a Total press fitting force of pin assembly : 245 – 441 kN {25 – 45 ton}
5. Press fit the pin assembly at the opposite side of bogie in the same way as shown in Steps 3 and 4. a After press-fitting of pin assembly, rock the small bogie so that it can move smoothly. 6. Tighten the mounting bolts of pin assembly cover (3) (two covers, inside and outside). 3 Cover mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} 7. Track roller assembly Lift and install two track roller assemblies (2) to bogie assembly (1). 2 Track roller mounting bolt: Adhesive (LT-2) 3 Track roller mounting bolt: 1,180 – 1,470 Nm {120 – 150 kgm}
50-220
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of first bogie assembly
Removal and installation of first bogie assembly
Symbol
1 2 3 4 14 5
Part No.
791-630-2360 790-201-2730 791-630-2270 01580-12419 01643-32460
6 790-101-4000 7 1 2 3 4 5 15 6
790-101-1102 791-630-2280 790-201-2770 791-630-2250 790-434-1070 01580-13629 01643-33690
7 790-101-4000
L 16
8 1 2 3 4
790-101-1102 791-630-2260 791-630-2270 01580-12419 01643-32460
5 790-101-4000 6 17 18 19
790-101-1102 791T-630-2290 790-434-1350 791-601-1000
1 791-630-1860 20 2 791-630-1870 3 01010-62760 4 01643-32780 791T-630-1900 791T-630-1910 791T-630-1920 21 07283-38973 04530-11628 01643-31645 01643-31232 01582-01210
D375A-6 (02)
Part name
Plate Spacer Screw Nut Washer Puller (490 kN {50 ton}) Pump Adapter Spacer Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump Guide Installer Oil pump Bracket (L, H) Bracket (R, H) Bolt Washer Lifting tool q Tube q Plate q Grip q Eyebolt q Washer q Washer q Nut
Necessity Q'ty New/remodel Sketch
Special tools
t t t t t
1 1 3 3 3
t 1 t t t t t t t
1 1 1 1 1 2 2
Removal 1. Separate the track shoe assembly. For details, see “ Separation and connection of track shoe assembly.” 2. Raise the machine so that the track rollers of the second bogie assembly leave the track link, by operating the blade and ripper. k Place a block between track roller and track link so that the machine does not lower. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative terminal of the battery. 3. Install eyebolts to the pad mounting bolts (two M12 bolts) at the rear of the first bogie assembly, and lift the first bogie assembly (1).
t 1 t t t t t
1 1 3 3 3
t 1 t t t t
1 2 1 1
Q
t 1 N t 1 N t 2 t 2 q 1 1 1 1 1 1 2 2
Q Q
50-221
DRAFT Undercarriage and frame Removal and installation of first bogie assembly
4. Place an steel plate between the track shoe and roller, and loosen roller cap bolts (2) for approx. 20 mm. (both inside and outside) 5. Hit the end face of shaft (3) with a hammer to remove track roller assembly (4). a Take care not to break the dowel pin installed on the front side (oil plug side) of the track roller assembly. (Insertion depth of dowel pin: 5 – 6 mm)
9. Pulling out shaft and ring 1) Set tool L14 in position. 2) Push out shaft (7) and ring (8) to the opposite side simultaneously. a Pressing force: 137.3 – 274.6 kN {14 – 28 tons} a To avoid an interference with the idler when pressing the ring, pump grease in the track tension adjusting section in advance to move the idler cushion forward.
6. Remove roller cap bolts (2), place track roller assembly (4) on the steel plate, and pull it out from the machine. 4 Track roller assembly: 150 kg
3) Remove respective floating seals (9) from the end faces of rings (8) and (12). a Keep the floating seal in a safe place so that it does not get damaged.
7. Sling first bogie (5) by using tool L20. 8. Remove cover (6).
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D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of first bogie assembly
4) Set tool L15 in position.
Installation 1. Assembly of pin assembly 1) Using tool L18, install respective floating seals (9) to rings (8) and (12). Also, install respective floating seals (10) to the opposite surface of ring (12) and to ring (13). a Completely degrease the O-ring and the O-ring contact surfaces of the floating seal before installing. a Check that the leaning of the floating seal is less than 1 mm.
5) Pull out spacer (11) and rings (12) and (13). a Pulling force: 205.8 – 382.2 kN {21 – 37 tons} 6) Remove spacer (11). 7) Remove spacer (14) and floating seals (10) between rings (12) and (13). a Keep the floating seal in a safe place so that it does not get damaged.
2) 3) 4) 5) 6)
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 Part (a) of ring (13) and ring (8) (approx. 10 mm): Molybdenum disulphide lubricant (LM-P)
10. Lower bogie (5) on the steel plate and pull it out. 4 Bogie assembly: 110 kg
D375A-6 (02)
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DRAFT Undercarriage and frame Removal and installation of first bogie assembly
2. Place bogie (5) on steel plate [1], and slide them beneath the center of the mounting position. 3. Using tool L20, set the bogie to the mounting position.
2) Press fit the pin assembly. a Install the pin assembly with arrow (a) on its end face up (when it is mounted on the machine). a Push in the pin assembly with cover (6). a Push in the pin assembly to machined surface (b) of the bogie and maintain step of 5 mm between bogie and pin assembly. 2 Periphery of pin: Molybdenum disulphide lubricant (LM-P) a Press-fitting force of pin assembly: 245 – 441 kN {25 – 45 ton}
4. Align the pin holes of the track frame and bogie, and install guidance tool L17 in position.
6. Refilling Using tool L19, supply the specified amount of oil. a Oil supply pressure: 0.49 MPa {5 kg/cm2} 5 Pin assembly: 95 – 115 cc (GO140)
5. Press-fitting of pin assembly 1) Set tool L16 and cover (6) in position.
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DRAFT Undercarriage and frame Removal and installation of first bogie assembly
7. Press fit the pin assembly at the opposite side of the bogie following the same procedure in Steps 5 and 6. 8. Install covers (6) (two covers, inside and outside). 9. Install eyebolts to the bolt holes of the pad mounting bolts (M12 x 2 pieces) of bogie (5) and sling the bogie.
10. Insert tool L21 into the shaft of track roller assembly (4), lift and balance the track roller assembly, and place it on the track shoes. 4 Track roller assembly: 150 kg
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11. Gradually lower the machine and when the clearance between bogie (5) and shaft (3) becomes approx. 20 mm, install cap (15) and tighten bolts (2) partially. 12. Matching the dowel hole with the dowel pin, tighten bolts (2) to the specified torque. 2 Cap mounting bolt: Adhesive (LT-2) 3 Cap mounting bolt: 1,180 – 1,470 Nm {120 – 150 kgm}
13. Adjust the track tension. For details, see Testing and adjusting, "Inspection and adjustment of track tension".
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DRAFT Undercarriage and frame Separation and connection of track shoe assembly
Separation and connection of track shoe assembly Separation 1. Remove the blade assembly. For details see "Removal and installation of blade assembly". 2. Remove cover (1).
Checking before separation of the track shoe assembly k In some cases, it may be extremely dangerous to separate the track shoe assembly. To prevent danger, perform the following checks before separation of the track shoe assembly. k Do not loosen the lubricator more than one turn. q Loosen lubricator (2) of the adjustment cylinder to drain the grease. Move the machine forward a short distance and check that the track tension is decreased. a When the track tension is decreased, follow the procedure in the "Separation of track shoe assembly (normal)".
a Because the machine needs to move later, do not disconnect battery cables.
q
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If the track tension is not decreased and is still high, a problem may have occurred inside the track frame (such as damaged recoil spring case, broken recoil spring set bolts, or coming off of shaft end nut). a If the track tension is not decreased, follow the procedure in the "Separation of track shoe assembly (when track frame has internal defect)".
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DRAFT Undercarriage and frame Separation and connection of track shoe assembly
Separation of track shoe assembly (When track frame has internal defect) a If any abnormality is detected by "Checking before separation of track shoe assembly", perform the following procedure. k If a problem has occurred inside the track frame, the track shoe may spring back when the assembly is separated. Also, the idler may fly out when the track shoe assembly is separated. This is potentially very dangerous. Be sure to separate the track shoe assembly as follows.
4. Sling the front end of master link (3), move the machine backward slowly to spread track shoe assembly (5). a Length of track: Approx. 12.5 m
1. Loosen lubricator (2), and move the machine backward and forward to drain the grease. [*1] k Do not loosen lubricator (2) more than one turn. a Check that all the grease is discharged.
2. Move the machine forward slowly to press the trach shoes on the idler side against large block [3] or a wall (or a blade of another machine of same size). When the recoil spring is compressed and the track shoe assembly sags, stop the machine and apply the brake. Locate master link (3) between the idler and front carrier roller. a Apply lever lock [4] between the carrier roller support and link to assure safety. 3. Remove track shoe (4) and separate master link (3). [*2]
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DRAFT Undercarriage and frame Separation and connection of track shoe assembly
Separation of track shoe assembly (normal) a If no abnormality is detected by "Checking before separation of track shoe assembly", perform the following procedure. 1. Position the master link properly. a Locate master link (3) above the idler (a little backward from the center). a Place blocks [1] between the carrier rollers and place block [2] under the front track so that the mating faces of master link do not open until the master bolts are removed.
2. Loosen lubricator (2). [* 1] k Do not loosen lubricator (2) more than one turn.
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3. Remove track shoe (4). [*2] a Loosen each of four bolts by one or two turns. Check that they can be unscrewed smoothly, and then remove them. Do not remove only one bolt without loosening the other three. a If a bolt does not turn smoothly and it is unscrewed forcibly, the threads of the bolt and master link (3) may be damaged.
4. Sling the front end of the master link, move the machine backward slowly to spread track shoe assembly (5). a Length of track: Approx. 12.5 m k For purposes of safety, check that no one remains in front of the idler.
D375A-6 (02)
DRAFT Undercarriage and frame Separation and connection of track shoe assembly
Connection q Perform connection in the reverse to separation. [*1] a Adjust the track tension. For details, see Testing and adjusting, “Testing and adjusting track tension”. [*2] a Finger-tighten the four bolts until the mating faces of the master link are fitted. a If the bolts are tightened forcibly before the master link mating faces are fitted, the threads of bolts and master link may be damaged. a Tighten the bolts in the order shown in the figure. 2 Shoe bolt: Molybdenum disulfide lubricant (LM-P) 3 Shoe bolt: (Master link) Initial torque: 686 ± 69 Nm {70 ± 7 kgm} Retightening angle: 180° ± 10° (Regular link) Initial torque: 1,372 ± 140 Nm {140 ± 14 kgm} Retightening angle: 120° ± 10°
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
Overall disassembly and assembly of track shoe
Symbol
1 2 3
Part No.
Part name
791-646-7351 Push tool 791-660-7460 Pin brush Push tool 791-646-7900 (For large plug)
4
791-701-3000 Seal checker or 791-601-1000 Oil pump
5
791-932-1110
6
Push tool (For small plug)
Necessity Q'ty New/remodel Sketch
Special tools
t 1 t 1 t 1
t 2
t 1
791-632-1021 Installer t 1 Push tool assem1 791-632-1300 t 1 N bly 1 2 791-632-1260 q Push tool 3 791-632-1270 4 791-632-1220
q
Adapter
1
q
A d a p t e r (small)
1
5 791-632-1230
q
Ring
1
7 6 791-632-1240
q
Plate
1
7 791-685-5730
q
Bar
1
8 791-632-1250
q
Ring
1
9 791-632-1280
q
Spring
1
10 01252-30605
q
Bolt
1
11 01580-01210
q
Nut
1
R
Overall disassembly a For the overall disassembly of the track shoe assembly, see Parts judgment guide, “Undercarriage, Lubricated track" and Parts judgment guide, “Undercarriage, Reversing procedure for pin and bushing.". 1. Removal of track shoe Lift the track shoe assembly and place the assembly on the floor with shoes (1) up. Remove the track shoes by using shoe bolt impact wrench [1]. a If shoe bolt (2) is not loosened (if its rotational torque is not reduced to zero) even after it is loosened by one turn, loosen other bolts so that the bolt can be loosened smoothly. a Forcibly rotating the bolt the rotational torque of which is not reduced to zero may cause adhesive transformation between the bolt and link, which may require repairs. a When repositioning the track shoe assembly, take care not to damage the master links. a If the shoe nut needs to be removed by gas cut, keep the temperature in the seal section below 80 °C to prevent thermal deterioration of the seals and take measures to prevent the spatters from entering through the clearances between the links.
Push tool assemt 1 N bly 1 2 791-632-1260 q Push tool 1 791-632-1200
3 791-632-1270 4 791-632-1210
q
Adapter
1
q
A d a p t e r (large)
1
5 791-632-1230
q
Ring
1
8 6 791-632-1240
q
Plate
1
7 791-685-5730
q
Bar
1
8 791-632-1250
q
Ring
1
9 791-632-1280
q
Spring
1
10 01252-30650
q
Bolt
1
11 01580-01210
q
Nut
1
Push tool assemt 2 N bly 9 2 791-685-5730 Bar 1 3 01580-01210 Nut 1 1 791-632-1290
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2. Disassembly of track links 1) Place the link assembly on the link press and hit it with a hammer to fit the bushing to jaw [2] firmly. a If the link tread or outer periphery of the bushing is worn, adjust the height of jaw [2] or guide plate to align the pin or bushing with the disassembly jigs so that the pin-bore or bushing-bore in the link is not damaged during disassembly.
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
a If the pin or bushing is not aligned with the jig, the bore in the link may be damaged or the pin or bushing may be broken during disassembly. a Using tool R5, drive in the small plug of the pin after disassembly so that the work place does not become dirty.
3) Return the left cylinder and operate the right cylinder to pull out the pin and bushing from the right link simultaneously.
4) Return the right cylinder, take out the right and left links, pins, bushings and spacers, and feed the next set of the link assembly to the jaw. k Because the broken wedge ring has sharp edges, take care not to cut your hands with them. a If the bushing end faces and its sealing surface are damaged, oil will leak. Accordingly, handle them carefully.
2) Operate the left cylinder to pull out the pin and bushing from the left link simultaneously. a Check the pulling-out force of the pin and bushing to see if the press-fitting force is obtained, that is required when they are reused by being turned 180 degree. a The wedge ring is broken with a bang. This sound does not indicate abnormality
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
3. Checking Check the removed parts for following items, then determine to reuse them for a lubricated track or grease-lubricated track, depending on the check results. a For judgment of reuse of the parts, see Parts judgment guide, “Undercarriage, Lubricated track". 1) Check the parts visually for damage. If a parts seems to be damaged, check it by dye penetrant test or magnaflux inspection. If it has any crack, it cannot be reused. Discard it. 2) Measure the outside diameter of the press-fitting portions of the pin and bushing and the inside diameter of the link bores where the pin and bushing are press fitted to by using micrometer [5] and cylinder gauge [6], to see if the allowable interference is obtained. Note that the standard interference must be secured between the pin and link when they are reused for a lubricated track. a If the allowable interference is not obtained, replace the parts with new ones. a For the dimensional criteria, see "Maintenance standard".
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a Precautions for storage 1) Store the seal without removing it from the link so that the link bore does not rust, and take care not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing press-fitting bores, shoe mounting surface of the link, and mating face of the master link. 3) Apply rust-preventive oil to the all surfaces of the pin, bushing, and spacer prior to storage. Take extreme care not to damage the bushing end faces.
D375A-6 (02)
DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
Overall assembly a For the overall assembly of the track shoe assembly, see Parts judgment guide, “Undercarriage, Lubricated track" and Parts judgment guide, “Undercarriage, Reversing procedure for pin and bushing.". Reusing the link assembly for lubricated track 1. Preparatory work 1) Cleaning of seal assembly Remove the seal assembly from the link, divide it into seal ring (3) and load ring (4), and clean them. a Clean seal ring (3) and load ring (4) quickly because they are easily deteriorated by the cleaning agent (trichloroethylene, etc.). Wipe off the cleaning agent with a cloth from them.
2) When reusing the pin, chamfer the edges of its end faces with a grinder. Remove the nodules formed on its press-fitting portions with the grinder. a If the edge of its end face is worn and sharpened, the press-fitting portion of the pin may cause galling, resulting in oil leak. 3) Clean the dirty links, pins, bushings, and spacers. Remove the nodules formed on the link and bushing with the grinder, too. a Clean the parts immediately before the assembly because they easily rust. a Do not grind the bushing end faces because doing so may cause oil leak.
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4) If the large plug was removed from the pin, drive in large plug (5) by using tool R3. At this time, clean the pin hole in advance by using tool R2. 1] Insert the plug in the hole of the guide through the plug inserting window. 2] Press the bar with hand until the plug stops. 3] Press the plug with the bar until the guide touches the pin. 4] Hit the bar with a hammer to drive in the plug. a Driving distance (a) from pin end face: 11 ± 2 mm a If chamfered face of the pin hole is lost due to wear, chamfer it by using a small-sized grinder (grindstone end angle: 45 ° – 60 °) so that the plug is not damaged. a If the hole face of the pin is chamfered with the grinder, clean the pin hole again by using tool R2. a Apply oil (GO90) on the outside periphery of the plug, and drive it with its smaller diameter end facing pin (6).
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
5) Installation of seal assembly Clean the bores of the link, and push in the seal to the bottom by using tool R6. a Do not apply oil to the link bores and the seal assembly (portion (d)) because any adhered oil causes the seal to turn and its sealing performance is lowered. Accordingly, take care not to allow any oil to adhere to the seal when installing the seal to the link bore.
6) Adjust the installed dimensions of the link press press-fitting jigs to keep the protrusion of the pin and bushing constant and to keep the installed dimensions of the seal within the standard range. a If the pin end faces (portion P) or link side faces (portions Q and R) are worn, add the wear reduction to the standard installed dimensions of the press-fitting jigs so that the right and left protrusions of the pin and bushing are even.
.
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
7) Adjust the relief pressure of the link press so that the pressing force of the press does not exceed the standard value. a If the pressing force is excessive, the spacer is pressed against the bushing excessively. As a result, the spacer may be broken or abnormal wear may occur between the spacer and bushing end face. a Pressing force for pin and bushing: 980 kN {100 ton} Pressing force C 1.8 x Average pressure (Adjust the relief pressure of the link press to obtain the pressing force.)
2. Assembly of link 1) Apply oil (GO90) on the mating faces of pin and bushing with a clean brush and assemble them, then set them on the bushing jaw of the link press. a When reusing the bushing (by turning it 180 degree), set it with the worn outside surface facing the shoe mounting face of the link (set the bushing on the link press with the face up).
2) Set the right and left master links having bushing-bore with their shoe mounting faces up, and press fit them to the bushing. a At this time, use the master links having pin-bore as supports. a Bushing press-fitting force: 196 – 343 kN {20 – 35 ton}
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
3) While checking the distance between the shoe bolt holes of the right and left master links by using the shoe bolt pitch gage, press fit the master links to the bushing until the distance is the standard value. a Remove all steel chips generated by the press-fitting process completely with compressed air.
4) Turn over the master links and check that they are press fitted in parallel. 5) Measure the right and left protrusions of the bushing by using depth gauge [7]. a Adjust the link press press-fitting jigs so that the right and left protrusions of the bushing are even.
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6) Send out the master link portion, and then set the next pins and bushings. a Install the pin, even it is reused, with its cross hole (its direction is indicated with mark (e)) facing the link tread as in the case of new one. If it is not installed so, the strength of the assembly may be lowered. Accordingly, indicate the direction of the cross hole on the end face to prevent wrong installation.
7) Apply liquid gasket (198-32-19890) to all surfaces of pin press-fitting portion (f) and link bore (g). a This prevents the galling of the pin press-fitting portion that may cause oil to seep out.
D375A-6 (02)
DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
8) Set the right link and install the spacer to the pin. a Check that the seal surfaces and bushing end faces are free from dirt, then apply oil (GO90) on them using a clean cloth or brush. a Wipe the spacer with a clean cloth before installing.
9) Using the right jig as receiver jig and the left jig as pusher jig, press fit the pin and bushing simultaneously. a Press fit them smoothly because bumpy press-fitting may cause the seal to come off the link. When the seal comes off the link, stop the press-fitting and set the seal to the link correctly, then restart the press-fitting. a Press-fitting force for pin and bushing: 392 – 686 kN {40 – 70 ton}
10)Use minor adjustment spacer (8) to press fit the pin until its end face reaches the bottom of the receiver jig. a Adjust the depth of the receiver jig hole so that the right and left protrusions of the pin are even.
11)Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.
12)By using the left jig as receiver jig, and the right jig as pusher jig, press fit the left link. a When press fitting, take care that the right and left seals and spacers do not come off. a Press-fitting force for pin and bushing: 392 – 686 kN {40 – 70 ton}
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
13)Perform the press fitting until the link, spacers, and bushing are mutually fitted. a 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 raise the pressure of the link press to that level while performing the press fitting. For the relief pressure settings, see "Preparatory work." a Check that adjacent two sets of links pivot on the pin.
15)Set the ring on jig R8.
16)Match the jig to the pin-bore of the link and push the ring in until the ring is fitted in the pin groove. a A click is heard when the ring is fitted in the pin groove.
14)Using the shoe bolt pitch gage, check that the distance between the shoe bolt holes is within the standard range. a If the distance between the shoe bolt holes is longer than the standard range, disassemble and check for abnormality, then assemble them again if no abnormality is found. a If the distance between the shoe bolt holes is less than the standard range and the track shoe cannot be installed, then wear of the spacer or bushing end face may exceeds the allowable limit. In this case, disassemble it and replace the relevant part.
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17)Using jig R9, install the ring into the pin groove on the other side similarly.
D375A-6 (02)
DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
18)Press the ring by using jig R10. a Pressing force: 294 – 372 kN {30 – 38 ton}
a For cold or extremely cold district, supply Komatsu genuine engine oil (150-09-19270 or 195-32-61990), which has excellent low-temperature characteristics, instead of oil (GO90). a If the charged oil pressure is increased too much, it has bad effects on the seals. a Supply oil (d) up to the level (a) where depth (L) of the hollow of the hole of pin (c) is in the following range when the pin is left with the small plug side (b) up (the link assembly placed on its side) for thirty minutes. a Dimension (L): 40 – 70 mm
19)Use tool R4 for each link assembly to remove air from inside the pin, and check the sealing performance. a Keep the degree of vacuum inside the pin at 86.7 – 93.3 kPa {650 – 700 mmHg} for 5 seconds to check that the pressure does not change. If the pressure changes, disassemble the link assembly to check the seals. If no abnormality is found, assemble them. 21)After supplying oil, drive in the small plug to the specified position by using tool R5. a Apply oil (GO90) on the outside periphery of the small plug. a Drive in the plug to the following depth. Driving depth from end face: 7.5 ± 1 mm
20)Use tool R4 to supply oil (GO90) until the charged pressure rises to 196.1–294.2 kPa {2–3 kg/cm2}.
22)Install the master links having pin-bore at last. a Check that the right and left master links are press fitted in parallel.
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
3. Installation of track shoe 1) Place the link assembly on the bed, and install track shoes (1) by using shoe bolt impact wrench [1] and torque wrench. 3 Shoe bolt (2) (Regular link) Initial torque: 1,372 ± 140 Nm {140 ± 14 kgm} Retightening angle: 120° ± 10° 2 Shoe bolt: Molybdenum disulphide lubricant (LM-P)
2) For the track that has two master link joints and consists of two track shoe assemblies, connect the two track shoe assemblies as follows. Place the two assemblies on a level place in a line with the track shoes up. Pull master links with pin-bore (1) of one assembly and master links with bushing-bore (2) together to contact their mating faces each other. Place shoe (3) on the master links, and finger-tighten shoe bolts (4) for master link so that their mating faces are in close contact. Then tighten the bolts to the specified torque to complete the connection. 2 Shoe bolt: Molybdenum disulphide lubricant (LM-P) 3 Shoe bolt (Master link) Initial torque: 686 ± 68.6 Nm {70 ± 7 kgm} Retightening angle: 180° ± 10°
a Tighten the bolts in the order of [1] – [4].
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
Reusing the link assembly for grease lubricated track 1. Cleaning of seal assembly 1) Cleaning of seal assembly q Remove seal assembly from the link, divide it into seal ring (3) and load ring (4), and clean them. a Clean seal ring (3) and load ring (4) quickly because they are easily deteriorated by the cleaning agent. Wipe off the cleaning agent with a cloth from them.
3) Clean any dirty surfaces among the outside periphery of the pin, spacer surface, and end faces and inside surface of the bushing. 4) Drive in the large plug by using tool R3. 1] Insert the plug in the hole of the guide through the plug inserting window. (Apply oil to the plug.) 2] Press the bar with hand until the plug stops. 3] Press the plug with the bar until the guide touches the pin. 4] Hit the bar with a hammer to drive in the plug. a Driving distance (a) from pin end face: Large plug: 11 ± 2 mm a If the plug was not removed from the pin when disassembling the track shoe assembly, reuse as it is.
2) When reusing the pin, chamfer the edges of its end faces with a grinder to allow for smooth press fitting.
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
5) Apply grease on the outside periphery of the pin and surfaces of the spacer. 6) Installation of seal assembly q Clean the bores of the link, and push in the seal to the bottom by using tool R6. a Do not apply grease to the link bores and the seal assembly because any adhered grease causes the seal to turn and its sealing performance is lowered.
2. Assembly of link 1) Apply lithium grease (G2-LI) on the mating faces of the pin and bushing and assemble them, then set them on the bushing jaw of the link press. a When reusing the bushing (by turning it 180 degree), set it with the worn outside surface facing the shoe mounting face of the link (set the bushing on the link press with the face up).
7) Adjust the installed dimensions of the link press press-fitting jigs to keep the protrusion of the pin and bushing constant and to keep the installed dimensions of the seal within the standard range. a For the standard dimensions of the link press press-fitting jigs, see "Link press press-fitting jig dimensions." a If the pin end faces (portion P) or link side faces (portions Q and R) are worn, add the wear reduction to the standard installed dimensions of the press-fitting jigs so that the right and left protrusions of the pin and bushing are even.
2) Set the right and left master links having bushing-bore with their shoe mounting faces up, and press fit them to the bushing. a At this time, use the master links having pin-bore as supports. a Bushing press-fitting force: 196 – 343 kN {20 – 35 ton}
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
3) While checking the distance between the shoe bolt holes of the right and left master links by using the shoe bolt pitch gage, press fit the master links to the bushing until the distance is the standard value. a Remove all steel chips generated by the press-fitting process completely with compressed air. 4) Turn over the master links and check that they are press fitted in parallel.
5) Measure the right and left protrusions of the bushing by using depth gauge [7]. a Adjust the link press press-fitting jigs so that the right and left protrusions of the bushing are even.
D375A-6 (02)
6) Send out the master link portion, and then set the next pins and bushings. a Install the pin, even it is reused, with its cross hole (its direction is indicated with mark (e)) facing the link tread as in the case of new one. If it is not installed so, the strength of the assembly may be lowered. Accordingly, indicate the direction of the cross hole on the end face to prevent wrong installation.
a If a pin has worn outside periphery, it is to be installed with its un-worn periphery toward the traction side. Even in this case, the pin must be installed with its cross hole facing the link tread.
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
7) Set the left and right links, and operate the left and right press-fittng jigs to press fit the pin and bushing simultaneously. a Press fit them smoothly because bumpy press-fitting may cause the seal to come off the link. When the seal comes off the link, stop the press-fitting and set the seal to the link correctly, then restart the press-fitting. a Pressing force for pin and bushing: 980 kN {100 ton} Pressing forceC1.8 x Average pressure (Adjust the relief pressure of the link press to obtain the pressing force.)
9) Set the ring on jig R8.
10)Match the jig to the pin-bore of the link and push the ring in until the ring is fitted in the pin groove. Using jig R9, install the ring into the pin groove on the other side similarly. a A click is heard when the ring is fitted in the pin groove.
8) Check the distance between the shoe bolt holes by using the shoe bolt pitch gage, and when it reaches the standard range, stop the press-fitting.
11)Press the ring by using jig R10. a Pressing force: 294 – 372 kN {30 – 38 ton}
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
12)Pump in grease. a Pump in grease (d) up to the level (a) where depth (L) of the hollow of the hole of pin (c) is in the following range when the pin is left with the small plug side (b) up (the link assembly placed on its side). a Dimension (L): 40 – 70 mm
3. Installation of track shoe (to regular links) Place the link assembly on the bed, and install track shoes (1) by using shoe bolt impact wrench [1] and torque wrench. 2 Shoe bolt (2): Molybdenum disulphide lubricant (LM-P) 3 Shoe bolt (2) (Regular link) Initial torque: 1,372 ± 140 Nm {140 ± 14 kgm} Retightening angle: 120° ± 10°
13)After pumping in grease, drive in the small plug to the specified position by using tool R5. a Drive in the plug to the following depth. Driving depth from end face: 7.5 ± 1 mm
14)Install the master links having pin-bore at last. a Check that the right and left master links are press fitted in parallel.
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DRAFT Undercarriage and frame Overall disassembly and assembly of track shoe
4. Connection of track consisting of two track shoe assemblies Place the two assemblies on a level place in a line with the track shoes up. Pull master links with pin-bore (1) of one assembly and master links with bushing-bore (2) together to contact their mating faces each other. Place shoe (3) on the master links, and finger-tighten shoe bolts (4) for master link so that their mating faces are in close contact. Then tighten the bolts to the specified torque to complete the connection. 2 Shoe bolt: Molybdenum disulphide lubricant (LM-P) 3 Shoe bolt (Master link) Initial torque: 686 ± 68.6 Nm {70 ± 7 kgm} Retightening angle: 180° ± 10° a Tighten the bolts in the order of [1] – [4].
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D375A-6 (02)
DRAFT Undercarriage and frame Link press press-fitting jig dimensions
Link press press-fitting jig dimensions
Unit: mm (a) (b) (c)
Jig dimensions 4.2 2.0 52.1
Precaution The link receiving face of jaw(1) must be vertical. Replaceable wear plate (2) shown below is desirable.
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DRAFT Undercarriage and frame Disassembly and assembly of one link assembly in the field
Disassembly and assembly of one link assembly in the field
1 2 3 4 5 6 1 2 3 4 R 5 6 7 8 9 7 10 11 12 13 14 15 16 17 18 19 20
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Part No.
Part name
791-646-7351 Push tool 791-660-7460 Pin brush Push tool (for 791-646-7900 large plugs) 791-701-3000 Seal checker oil or pump 791-601-1000 Push tool (for 791-932-1110 small plug) 791-632-1021 Installer Remover & 791-632-1100 installer assembly 791-632-1130 q Adapter 790-434-1610 q Guide 01010-51440 q Bolt 791-685-9510 q Frame 791-685-9530 q Rod 791-685-9520 q Frame 791-685-9550 q Nut 04530-12030 q Eyebolt 791-685-9560 q Bolt 791-126-0150 q Adapter 791-685-9540 q Rod 791-632-1140 q Adapter 791-680-5520 q Guide 01010-51030 q Bolt 791-632-1150 q Pusher 791-685-9620 q Extension 791-632-1180 q Adapter 791-680-5543 q Adapter 791-632-1170 q Guide
t 1 t 1 t 1
Symbol
21 22 23 24
t 2
R 7 25
t 1
26
t 1
27
t 1
28
1 1 2 1 1 1 3 1 4 1 1 1 1 1 1 1 1 1 1
Part No.
Part name
791-680-5551 q Guide 791-680-9630 q Adapter 791-632-1160 q Guide 195-32-61210 Bolt Cylinder 790-101-4300 (1,470 kN {150 ton}) 790-101-1102 Pump Cylinder 790-101-4200 (294 kN {30 ton}) 791-680-1630 Spacer
Necessity Q'ty New/remodel Sketch
Symbol
Necessity Q'ty New/remodel Sketch
Special tools
1 1 1 2 t 1 t 1 t 1 t 1 N Q
Disassembly q Separate the track shoe assembly. For details, see “Separation and connection of track shoe assembly.” a Move the machine forward or backward to bring the link assembly to be disassembled to a position where tool 7 can be easily installed on the link when the track shoe assembly is separated. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Install tool R7-2 on link (1) with R7-24, and install tool R7-3 to the link with R7-4. a Use the shoe bolts for installing R7-24.
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of one link assembly in the field
2. Assemble tools R7-25 and R7-5 to R7-11, then sling them to place on the shoe.
4. Set tools R7-13 to R7-16, connect tool R7-26, and then apply oil pressure to pull out the pin (2).
3. Insert tool R7-12 from the cylinder side, and install it by using two R7-8.
a If cylinder reaches its stroke end, connect tool R7-17 and repeat the work.
D375A-6 (02)
50-249
DRAFT Undercarriage and frame Disassembly and assembly of one link assembly in the field
5. Set tools R7-27 and R7-28 in the middle of the links to be disassembled on their tread side, connect tool R7-26, then apply oil pressure to open the links by 5 – 6 mm to disconnect them.
6. Repeat steps 1 to 4 to pull out another pin (3) on the other side.
7. Repeat step 5 to remove links (4).
Assembly 1. Assemble the link sub-assembly according to the following procedure. 1) Set tool R7-18 to the bushing-bore end of link (5), and press fit bushing (6). a Bushing press-fitting force: 196 – 294 kN {20 – 35 ton}
2) Set tool R7-19 to the pin-bore end of the link, and press fit pin (7). a Install the pin with the cross hole (a) facing link tread (b). a Press-fitting force for pin: 206 – 323 kN {21 – 33 ton}
50-250
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of one link assembly in the field
2. Set link sub-assembly (8) to the link to be connected.
4. Similarly to the disassembly procedure, set tools R7-25, R7-5 to R7-12,R7-17 to the links. 5. Use tools R7-19 and R7-21 to press fit the pin-bore end and use tools R7-22, R7-1, and R7-21 to press fit the bushing-bore end of the link. Press fit them alternately. a First press fit the pin-bore end of the link. When the bushing is partially inserted into the link bore, remove tool R7-20 that is installed in step 3, then press fit the bushing-bore end of the link. a Press-fitting force for pin: 206 – 323 kN {21 – 33 ton} a Press-fitting force for bushing: 196 – 294 kN {20 – 30 ton}
3. Set counterpart link (9) and support it with tool R7-20.
6. Similarly to the disassembly procedure, use tools R7-27 and R7-28 to push open links (10) to be connected.
D375A-6 (02)
50-251
DRAFT Undercarriage and frame Disassembly and assembly of one link assembly in the field
7. Set link (11) to be connected to link (10), fix them by using tool R7-23, and then remove tools R7-27 and R7-28.
8. Similarly to the disassembly procedure, set tools R7-2 to R7-12 and press fit pin (12) to the links. 2 Pin press-fitting hole in link: Liquid gasket (198-32-19890) a Set the pin with its side hole facing the link tread. a Press-fitting force for pin: 412 – 646 kN {42 – 66 ton} a If the cylinder reaches its stroke end, add tool R7-17, and R7-14 to R7-16, then repeat the work.
50-252
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of master link
Disassembly and assembly of master link
1 2 3 4 5 6 1 2 3 4 5 6 7 R 8 9 10 11 12 7 13 14 15 16 17 18 19 20 21 22 23 24 25
D375A-6 (02)
Part name
791-646-7351 Push tool 791-660-7460 Pin brush Push tool (for 791-646-7900 large plug) 791-701-3000 Seal checker oil or pump 791-601-1000 Push tool (for 791-932-1110 small plug) 791-632-1021 Installer Remover & 791-632-1100 installer assembly 791-632-1130 q Adapter 790-434-1610 q Guide 01010-51440 q Bolt 791-685-9510 q Frame 791-685-9530 q Rod 791-685-9520 q Frame 791-685-9550 q Nut 04530-12030 q Eyebolt 791-685-9560 q Bolt 791-126-0150 q Adapter 791-685-9540 q Rod 791-632-1140 q Adapter 791-680-5520 q Guide 01010-51030 q Bolt 791-632-1150 q Pusher 791-685-9620 q Extension 791-632-1180 q Adapter 791-680-5543 q Adapter 791-632-1160 q Guide 791-680-5551 q Guide 791-680-9630 q Adapter 791-632-1160 Guide 195-32-61210 Bolt Cylinder 790-101-4300 (1,470 kN {150 ton})
t 1 t 1
Sketch
Part No.
New/remodel
Symbol
Necessity Q'ty
Special tools Symbol
7
t 1 t 2 t 1 t 1
8
t 1 1 1 2 1 1 1 3 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 2
R
9
10
Part No.
Part name
26 790-101-1102 Pump Cylinder 27 790-101-4200 (294 kN {30 ton}) 28 791-680-1630 Spacer Push tool assem1 791-632-1300 bly 2 791-632-1260 q Push tool 3 791-632-1270 q Adapter 4 791-632-1220 q Pin (small) 5 791-632-1230 q Ring 6 791-632-1240 q Plate 7 791-685-5730 q Bar 8 791-632-1250 q Ring 9 791-632-1280 q Spring 10 01252-30605 q Bolt 11 01580-01210 q Nut Push tool assem1 791-632-1200 bly 2 791-632-1260 q Push tool 3 791-632-1270 q Adapter 4 791-632-1210 q Pin (large) 5 791-632-1230 q Ring 6 791-632-1240 q Plate 7 791-685-5730 q Bar 8 791-632-1250 q Ring 9 791-632-1280 q Spring 10 01252-30650 q Bolt 11 01580-01210 q Nut Push tool assem1 791-632-1290 bly 2 791-685-5730 Bar 3 01580-01210 Nut
N N e S e Q w/ k c 't re et e y m c ss od h ity el t 1 t 1 t 1 t 1 N 1 1 1 1 1 1 1 1 1 1 t 1 N 1 1 1 1 1 1 1 1 1 1 t 2 N 1 1
t 1
50-253
DRAFT Undercarriage and frame Disassembly and assembly of master link
Disassembly a For the method of using tool R7, see "Disassembly of one link assembly in the field." 1. Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see “Separation of track shoe assembly”. 2. Disassembly of track shoe assembly Disconnect the all master link joints to divide the track into two track shoe assemblies. 3. Removal of master link q For master pin type 1) Gas cutting of regular link Gas cut the links along the wavy lines, and remove the hatched parts. q Necessary special tool: Gas cutting machine
2) Removal of regular link Press pin (1) downward as shown by the arrow by using the press to pull it out from link (2), and then pull out the pin (1) and the other link (2) as a unit from bushing (3).
50-254
For master link type 1) Gas cut and removal of master link with bushing-bore. Gas cut the pin and bushing along the wavy lines and remove the hatched parts. Move master links (4) vertically as shown by the arrow to remove them, and then pull out remaining pins (5a) and (5b) press fitted in respective regular links (2) by moving them vertically as shown by the arrow using the press. q Necessary special tools: 1. Gas cutting machine 2. Tool R7
q
2) Removal of master link with pin-bore Gas cut the master links along the wavy lines and remove the hatched parts. Press pin (6) downward as shown by the arrow by using the press to pull it out from link (2a), then pull out pin (6) and link (2b) as a unit from bush (3). q Special tools: 1. Gas cutting machine 2. Tool R7
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of master link
Assembly a For the method of using tool R7, see "Disassembly of one link assembly in the field."
2) Set spacers (6) and seal assemblies (7) to the bores of links (2a) to be connected. (3): Bushing
1. Assembly of master links with bushing-bore 1) Press fit master links with bushing-bore (4) to bushing (3) using the press. a When press fitting the left and right master links, take care so that the links are fit in parallel. a Do not damage the mating face of the master link and the end faces of the bushing. Unit: mm L1
184 ± 0.7
L2
253.4±0.7
D1
33 Drill
D2
30 × 2.0
2. Installation of master link with bushing-bore 1) Increase the space between the links at the centers of their treads by using tool R7 as shown in the figure. a: 5 mm (Increase by 10 mm between the ends of the links.)
D375A-6 (02)
3) Match the pin bores of the links and the bores for bushing (3) of the master links, and fix them with guide pin [1].
4) Press fit pin (5) by using tool R7 to install master links with bushing bore (4). 2 Pin press-fitting bore in link: Liquid gasket (198-32-19890) a Install the pin with its cross hole facing the link tread. 5) Install the rings by using tool R7 and tools R8, R9, and R10.
50-255
DRAFT Undercarriage and frame Disassembly and assembly of master link
6) Install the track shoe to the links of the connecting part. 7) Drive in large plug (8) by using tool R3, pump in oil by using tool R4, and then drive in small plug (9) by using tool R5.
a When press fitting the right and left master links, take care so that the links are in parallel (both for master links with bushing bore and pin-bore). a Do not damage the mating face of the master link and the end faces of the bushing. a Adjust the end play of the connecting part (the thrust end play between the links connected with the pin) to 0 - 0.13 mm. a Take care not to allow dirt, sand, or dust to attach the seal, spacer, end face of the bushing, and the master link mating face with tap holes. 3. Assembly of master link with pin-bore 1) Set spacers (6) and seal assemblies (7) to the bores of master links (4a). (3): Bushing
50-256
2) Pass pin (5) through bushing (3), set right and left master links with pin-bore (4), and press fit them from both sides by using tool R7. 3) Install the rings by using tool R7 and tools R8, R9, and R10. 4) Drive in large plug (8) by using tool R3, pump in oil by using tool R4, and then drive in small plug (9) by using tool R5.
4. Connection of master links Place the two track shoe assemblies on a level place in a line with the track shoes up. Pull master links with pin-bore (4a) of one assembly and master links with bushing-bore (4b) together to contact their mating faces each other. Place the track shoe on the master links, and finger-tighten the shoe bolts for master link so that their mating faces are in close contact. Then tighten the bolts to the specified torque to complete the connection. 3 Shoe bolt (Master link) Initial torque: 686 ± 68.6 Nm {70 ± 7 kgm} Retightening angle: 180° ± 10°
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of pivot shaft assembly
Removal and installation of pivot shaft assembly 3. Remove seal (2), then remove cover (3).
[*2]
791T-650-2330 791T-650-2340 790-201-3310 790-101-2510 790-101-2570 01580-01613 01643-31645 790-105-2300 790-101-1102
Sleeve Plate Bolt Block Washer Nut Washer Jack assembly Pump
t t t t t t t t t
1 1 2 1 2 2 2 1 1
Sketch
1 2 3 4 P 5 6 7 8 9
Part name
Q'ty
Part No.
New/remodel
Sym -bol
Necessity
Special tools
N Q N Q
Removal 1. Remove the track frame assembly. For details, see "Removal of track frame assembly". 2. Sling pivot shaft assembly (1), remove the mounting bolts, and pull out the pivot shaft assembly using forcing screws [1]. [*1] 4 Pivot shaft assembly: 390 kg
D375A-6 (02)
Installation q Carry out installation in the reverse order to removal. [*1]
2
Pivot shaft press-fitting surface: Molybdenum disulphide lubricant (LM-P)
[*2] a Press fit the seal (2) to the pivot shaft using tool P. 2 Seal press-fitting surface: Liquid gasket (LG-6) a Check that press-fitting dimension (a) of the seal from the end face of the shaft is the specified dimension. q Press-fitting dimension (a) : 665 ± 1.0 mm
50-257
DRAFT Undercarriage and frame Removal and installation of equalizer bar
Removal and installation of equalizer bar
791-650-1300 791-735-1123 790-434-1050 01580-02419 N 1 01643-32460 790-101-2102 790-101-1102
Remover Sleeve Screw Nut Washer Puller (294 kN {30 ton}) Pump
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
4. Remove washer (4), then remove spacer (5). a Oil will flow out from the pivot case, so use a container to receive the oil. 6 Pivot case: 18 l
t 1 1 1 1 t 1 t 1
Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position.
5. Place hydraulic jack [1] (490 kN {50 ton }) under the radiator guard.
1. Remove the engine underguard and the power train underguard (front). 4 Engine underguard: 290 kg Power train underguard (front): 280 kg 2. Remove pivot shaft cover (1). a For the right track frame, disconnect four blade tilt cylinder hoses from the cover. a Because the machine will be raised up using the blade, install blind plugs to the tilt cylinder hoses. 3. Remove seal (2) and washer (3) as a unit. a Perform this procedure for only right track frame. [*1]
6. Remove cover (6).
[*2]
7. Remove grease tube (7-1). 8. Remove cover (7).
[*2]
9. Loosen clamping bolts (9-1) and (9) of the equalizer bar side pin. [*3] a Bolt: M30, Width accross flats: 46 mm
50-258
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of equalizer bar
10. Remove cover (8).
12. Repeat steps 6 - 11 to remove the side pin on the other side. 13. Operate hydraulic jack [1] slowly, and lower the machine to the position where the left and right equalizer bar touches both track frames. 14. Disconnect lubrication tube (12). 15. Remove two lockplates (13).
[*5]
.
16. Remove center pin (14) using tool N1. [*6] a If the equalizer bar hole is not aligned with the main frame hole, the pin cannot removed easily. Adjust the height of the main frame by operating hydraulic jack [1]. 11. Remove side pin (10). [*4] k Support the track frame on the opposite side with a block as it lowers when the pin is removed. a If the equalizer bar hole is not aligned with the track frame hole, the pin cannot be removed easily. Adjust the height of the equalizer by operating hydraulic jack [1]. a Put an "UP" mark at the top of the pin.
D375A-6 (02)
50-259
DRAFT Undercarriage and frame Removal and installation of equalizer bar
17. Raise the front of the machine by operating the blade, and place stand [3] under the radiator guard.
Installation q Carry out installation in the reverse order to removal. [*1] a Degrease the press-fitting surface of the seal. 2 Seal press-fitting surface: Liquid gasket (LG-6) a Be careful not to install the seal twisted. [*2] a Install covers (6) and (7), then tighten bolts (9) and (9-1). 3 Covers (6) and (7): 245 – 309 Nm {25 – 31.5 kgm} [*3]
18. Sling equalizer bar (15) and remove it clearing the main frame and the track frames. k Do not lower the machine after removing the equalizer bar. 4 Equalizer bar assembly: 500 kg
50-260
3
Bolts (9) and (9-1): 1,960 – 2,450 Nm {200 – 250 kgm}
[*4]
2 Inside surface of bushing: Grease (G2-LI) a Before installing the pin, adjust the height of the main frame by operating hydraulic jack [1] to align the equalizer bar hole with that of track frame hole. a Install pin (10) with the "UP" mark up, a mark put upon removal.
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of equalizer bar
[*5]
3
Lock plate mounting bolt : 549 ± 59 Nm {56 ± 6 kgm}
[*6]
2
Equalizer bar bushing and main frame bushing: Grease (G2-LI) a Before installing the pin, operate the crane to align the main frame hole with the equalizer bar hole. q
Refilling Supply oil through the oil filler to the specified level. 5 Pivot case: 18 l (SAE30)
D375A-6 (02)
50-261
DRAFT Undercarriage and frame Disassembly and assembly of equalizer bar bushing
Disassembly and assembly of equalizer bar bushing 3) Set tool N2 to remove side bushing (4) from equalizer bar (5).
Symbol
Part No.
1 2 3 N 2 4 5
791T-650-2410 791T-650-2420 790-438-1110 791-112-1180 790-101-2540
Part name
Bracket Bracket Screw Nut Washer Puller 6 790-101-2102 (294kN {30ton}) 7 790-101-1102 Pump
Necessity Q'ty New/remodel Sketch
Special tools
t t t t t
1 N Q 1 N Q 1 2 2
t 1 t 1
Disassembly 1. Center bushing 1) Remove center bushings (1).
2. Guide bushing 1) Remove seals (2). 2) Remove snap ring (3).
50-262
D375A-6 (02)
DRAFT Undercarriage and frame Disassembly and assembly of equalizer bar bushing
Assembly 1. Side bushing 1) Set side bushing (4) and tool N2 to press fit side bushing (4) to equalizer bar (5). 2 Outside surface of side bushing: Molybdenum disulphide lubricant (LM-P) a Install the side bushing in the direction shown in the following figure.
1] Install the outer bushing with split faces (a) (jointed face) level. 2] Set the greasing holes (b) of the inner and outer bushings at an angle. a Press-fitting force for side bushing: 34.3 – 73.5 kN {3.5 – 7.5 ton}
D375A-6 (02)
2) Install snap ring (3). a After installing the snap ring, fill parts (c) before and after the side bushing with grease (G2-LI). 2 Grease to be supplied to side bushing: 0.3 l 3) Press fit seals (2) by using the press. a Press-fitting force for seal: 9.8 – 29.4 kN {1 – 3 ton} a Press fit the seal so that its metal ring does not protrude from the end face of the equalizer bar. 2 Seal lip: Grease (G2-LI)
2. Center bushing Press fit bushings (1) by using the press. 2 Outside surface of center bushing: Molybdenum disulphide lubricant (LM-P) a Press-fitting force for center bushing: 4.9 – 186.2 kN {5 – 19 ton}
50-263
DRAFT Undercarriage and frame Removal and installation of segment tooth
Removal and installation of segment tooth Removal 1. Set the segment tooth to be removed to a position where it can be removed easily (between the track and track frame). k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
Installation q Carry out installation in the reverse order to removal. 2
3
Seat of segment tooth mounting nut: Molybdenum disulphide lubricant (LM-P) Segment tooth mounting nut: 1,813 ± 98 Nm {185 ± 10 kgm}
2. Remove covers (1) and (2).
3. Remove the mounting bolts and remove the segment tooth (3). a Before removing all mounting bolts, insert the bar [1] into the upper mounting bolt hole, then slide the segment tooth outward to remove it. 4 Segment tooth: 35 kg
50-264
D375A-6 (02)
DRAFT Undercarriage and frame Removal and installation of segment tooth
D375A-6 (02)
50-265
DRAFT Hydraulic system Removal and installation of hydraulic tank assembly
Hydraulic system Removal and installation of hydraulic tank assembly Removal k k k
k
Park the machine on a level surface and lower the work equipment to the ground. Set the parking brake lever and work equipment lock lever in the lock position. Release the internal pressure of the hydraulic tank and residual pressure inside the piping. For details, see Testing and adjusting "Releasing residual pressure of hydraulic circuit". Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
1. Drain the hydraulic tank. 6 Hydraulic tank: 130 l 2. Sling undercover (1) and lower it by using lifting tool [1]. a Because one side of the undercover is hinged, remove bolts on the other side to sling the undercover.
3. Loosen drain valve (2) to drain oil in the suction hose. a Prepare a container to catch the oil, and take care not to allow the drained oil to splash any.
4. Remove covers (3) and (4).
.
50-266
D375A-6 (02)
DRAFT Hydraulic system Removal and installation of hydraulic tank assembly
5. Disconnect main valve return hose (5) and fan motor return hose (6) from the hydraulic tank.
6. Disconnect suction tube (8). 7. Disconnect following return hoses (9) to (15). (9): Self-pressure reducing valve drain hose (10): Work equipment pump drain hose (11): Fan motor drain hose (12): Blade PPC drain hose (13): Ripper PPC drain hose (14): Fan pump (LPV90) drain hose (15): Fan pump (LPV30) drain hose
D375A-6 (02)
8. Remove four hydraulic tank mounting bolts (16).
9. Lift off hydraulic tank assembly (17). 4 Hydraulic tank assembly: 240 kg
[*1]
50-267
DRAFT Hydraulic system Removal and installation of hydraulic tank assembly
Installation q Carry out installation in the reverse order to removal. a Install the tank assembly properly, so that the tank side is flush with the fender outside surface. Difference (d): Max. 3 mm
(Refilling) Supply 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. 5 Hydraulic tank: 130 l q
Air bleeding Bleed air from the piping. For details, see Testing and adjusting "Bleeding air from hydraulic circuit".
50-268
D375A-6 (02)
DRAFT Hydraulic system Removal and installation of work equipment pump assembly
Removal and installation of work equipment pump assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Release the internal pressure of the hydraulic tank and residual pressure inside piping. For details, see Testing and adjusting "Releasing residual pressure of hydraulic circuit". k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Drain the hydraulic tank. 6 Hydraulic tank: 130 l 2. Sling undercover (1) and lower it by using lifting tool [1]. a Because one side of the undercover is hinged, remove bolts on the other side to sling the undercover.
3. Loosen drain valve (2) to drain oil in the suction hose. a Prepare a container to catch the oil, and take care not to allow the drained oil to splash any.
4. Remove the floor plate and brake pedal assembly according to the following procedure. 1) Remove inspection cover (3).
.
D375A-6 (02)
50-269
DRAFT Hydraulic system Removal and installation of work equipment pump assembly
2) Disconnect connectors DEC (4) and BRK (5). 3) Remove the mounting bolts of floor plate (6). 4) Remove brake rod (7) according to the following procedure. [*1] 1] Raise floor plate (6) and support it with a block. 2] Remove cotter pin (8), and then remove nut (9) under floor plate (6). 3] Disconnect brake rod (7). a Note the installed dimensions of the rod for installation purpose. 5) Remove floor plate and brake pedal assembly (6).
5. Remove the cover according to the following procedure. 1) Remove covers (10), (11) and (12). 2) Remove headlamp protection cover (13). 3) Remove the mounting bolts of battery case (14) and reposition battery case (14) outward. 4) Remove covers (15) and (16).
6. Remove damper case oil level gauge (17) and bracket (18) as a unit from the damper case.
50-270
D375A-6 (02)
DRAFT Hydraulic system Removal and installation of work equipment pump assembly
7. Disconnect hose (19). a Also disconnect two hose clamps.
8. Disconnect mounting bracket (20) of the wiring clamp from filter assembly (21). 9. Disconnect wiring clamps (22), (23), and (24) from filter assembly (21). 10. Remove twelve mounting bolts (25) and (25a) of the filter assembly.
k
Never operate the crane while implementing steps 2) and 3). This is very dangerous.
4) Pull out filter assembly (21) toward frame (29) keeping the assembly level.
5) Lift off filter assembly (21) at an angle gradually.
11. Remove filter assembly (21) according to the following procedure. [*2] 1) Lift filter assembly (21) to the position very close to frame (26). 2) Disconnect tube (27). 3) Disconnect connector (28).
D375A-6 (02)
50-271
DRAFT Hydraulic system Removal and installation of work equipment pump assembly
12. Remove hose (30). 13. Disconnect suction tube clamp (31).
q
[*3]
Carry out installation in the reverse order to removal.
[*1] a Install the brake rod according to the installed dimensions noted when it is removed. a Be sure to bend the split pin installed on the cotter pin. a Adjust the brake rod. For details, see Testing and adjusting "Adjusting brake pedal and parking brake lever". [*2] a Install the filter assembly aligning it with the block so that the O-ring does not come off. 14. Disconnect hose (32). 15. Disconnect tube (33) from work equipment pump assembly (34).
[*3]
3
Clamp mounting bolt: 24.5 – 29.4 Nm {2.5 – 3.0 kgm}
q
Refilling (hydraulic tank) Supply 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. 5 Hydraulic tank: 130 l
q
Air bleeding Bleed air from the piping. For details, see Testing and adjusting "Bleeding air from the work equipment cylinder".
16. Remove four mounting bolts (35) of the work equipment pump. 17. Sling work equipment pump assembly (34), then lower it to remove. 4 Work equipment pump assembly:110 kg
.
50-272
D375A-6 (02)
DRAFT Hydraulic system Removal and installation of fan pump assembly
Removal and installation of fan pump assembly . Removal k Park the machine on a level surface and lower the work equipment to the ground. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k Loosen the oil filler cap of the hydraulic oil tank gradually to release the internal pressure of the hydraulic tank.
9. Loosen suction tube clamp (8) and disconnect suction tube (9).
1. Drain the oil from the hydraulic tank. 6 Hydraulic tank: 130 l 2. Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly." 3. Remove the ROPS guard. For details, see "Removal and installation of ROPS guard assembly." 4. Remove the operator cab assembly. For details, see "Removal and installation of operator cab assembly."
10. Remove two mounting bolts (10) and lift off fan pump assembly (11). 4 Fan pump assembly: 80 kg a Steps 2 to 5 are not required when removing the pump unit only.
5. Remove the floor frame assembly. For details, see "Removal and installation of floor frame assembly." 6. Disconnect pilot valve sensor connector FA2 (2). 7. Disconnect four hose clamps (3). 8. Disconnect hoses (4) to (7).
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DRAFT Hydraulic system Removal and installation of fan pump assembly
Installation q
Carry out installation in the reverse order to removal.
(Refilling) Supply 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. 5 Hydraulic tank: 130 l q
Air bleeding a Bleed air from the piping. For details, see Testing and adjusting "Bleeding air from fan pump".
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DRAFT Hydraulic system Removal and installation of control valve assembly
Removal and installation of control valve assembly . Removal . k Park the machine on a level surface and lower the work equipment to the ground. k Release the internal pressure of the hydraulic tank and residual pressure inside piping. For details, see Testing and adjusting "Releasing residual pressure of hydraulic circuit". k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. a Note the connection points of each disconnected hose.
3. Disconnect three hose clamps (9).
4. Disconnect wiring connector (10).
1. Remove covers (1) and (2).
2. Disconnect PPC hoses (3) to (8). (hose band color) (3): White (4): Green (5): Black/Blue (6): Brown (7): Black (8): Yellow
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Hydraulic system Removal and installation of control valve assembly
5. Disconnect hoses (11) to (24). (11): Ripper tilt BACK (12): Ripper tilt IN (13): Ripper lift RAISE (14): Ripper lift LOWER (15): Blade left tilt BACK (Only for dual tilt specification machine) (16): Blade left tilt DUMP (Only for dual tilt specification machine) (17): Blade right tilt BACK (18): Blade right tilt DUMP (19): Blade lift RAISE (20): Blade lift LOWER (21): Blade lift RAISE (22): Blade lift LOWER (23): From work equipment pump (24): To work equipment pump Ls port
6. Remove four control valve mounting bolts (25). 7. Lift off control valve assembly (26). 4 Control valve assembly: 130 kg
Installation Carry out installation in the reverse order to removal.
q
(Refilling) Supply 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. 5 Hydraulic tank: 130 l q
Air bleeding Bleed air from the piping. For details, see Testing and adjusting "Bleeding air from the work equipment cylinder".
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Hydraulic system Disassembly and assembly of control valve assembly
Disassembly and assembly of control valve assembly
a This section provides only the precautions when assembling the control valve assembly. Assembly a Clean all parts, check them for dirt and damage, and apply oil to the sliding surfaces before installing.
3. Assembly of suction valve assembly Check that O-ring (38) is fitted to suction valve assembly (37), and install suction valve assembly (37) to valve body (1). 3 Suction valve assembly (37): 176.6 – 196.1 Nm {18 – 20 kgm}
1. Assembly of main relief valve assembly Check that O-ring (3) is fitted to main relief valve assembly (2), and install main relief valve assembly (2) to valve body (1). 3 Main relief valve assembly (2): 176.6 – 196.1 Nm {18 – 20 kgm}
4. Assembly of check valve assembly 1) Install valve (39) and spring (40) to valve body (1). 2) Fit backup ring (42) and O-ring (41) to plug (43), and install plug (43) to valve body (1). 3 Plug (43): 176.6 – 196.1 Nm {18 – 20 kgm}
2. Assembly of LS relief valve assembly a Install backup ring (15), O-rings (16) and (17) to LS relief valve assembly (14), and install LS relief valve assembly (14) to valve body (1). 3 LS relief valve assembly (14): 137 – 157 Nm {14 – 16 kgm}
5. Assembly of check valve assembly Check that O-ring (45) is fitted in check valve assembly (44), and install check valve assembly (44) to valve body (1). 3 Check valve assembly (44): 58.8 – 78.5 Nm {6 – 8 kgm}
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DRAFT Hydraulic system Disassembly and assembly of control valve assembly
6. Installation of plug 1) Installation of plug (46) 1] Install retainer (50) to valve body (1). 2] Install O-ring (47) and backup ring (42) to plug (46). 3 Plug (46): 274.6 – 367.7 Nm {28 – 37.5 kgm} 2) Installation of plugs (51) to (60) a Check that O-ring or backup ring is fitted to each plug, and then install the plug to valve body (1). 3 Plug: (51) (2 places): 176.6 – 196.1 Nm {18 – 20 kgm} (52) (2 places), (53) and (58) (2 places): 19.6 – 27.5 Nm {2 – 2.8 kgm}
(Blade tilt valve) 7. Assembly of suction valve assembly 1) Install spool (19a) to valve body (1a). 2) Fit spring (20a), O-ring (23a), backup ring (22a) and O-ring (21a) to plug (24a), and install plug (24a) to valve body (1a). 3 Plug (24a): 372.7 – 465.8 Nm {38 – 47.5 kgm}
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(54), (55): 107.8 – 140.7 Nm {11.0 – 15.0 kgm} (56): 29.4 – 39.2 Nm {3 – 4.8 kgm} (57): 107.7 – 161.8 Nm {12 – 16.5 kgm} 3) Installation of plugs (58) and (59) 1] If plugs (58) (2 places) are removed, wrap sealing tape around the thread portion when installation. 3 Plug (58): 58.9 ± 6.9 Nm {6 ± 0.7 kgm} 2] If plugs (59) (11 places) have been removed, replace with new ones. a The plug is a dry-seal type with special nylon coated on its threads. 3 Plug (59): 7.8 – 13.7 Nm {0.8 – 1.4 kgm}
8. Assembly of suction safety valve assembly Fit O-ring (31a) to suction safety valve assembly (30a), and install suction safety valve assembly (30a) to valve body (1a). 3 Suction safety valve assembly (30a): 176.6 – 196.1 Nm {18 – 20 kgm}
D375A-6 (02)
DRAFT Hydraulic system Disassembly and assembly of control valve assembly
9. Assembly of check valve assembly 1) Install valve (25a) and spring (24a) to valve body (1). 2) Fit backup ring (28a) and O-ring (27a) to plug (29a), and install plug (29a) to valve body (1). 3 Plug (29a): 176.6 – 196.1 Nm {18 – 20 kgm} 10. Assembly of check valve assembly Fit O-ring (33a) to check valve assembly (32a), and install check valve assembly (32a) to valve body (1). 3 Check valve assembly (32a): 58.8 – 78.5 Nm {6 – 8 kgm}
11. Installation of plug 1) Fit O-ring (35a), O-ring (36a), backup ring (37a) to plug (34a), and install plug (34a) to valve body (1). 3 Check valve assembly (32a): 58.8 – 78.5 Nm {6 – 8 kgm} 2) If plugs (38a) (2 places) are removed, replace with new ones. a The plug is a dry-seal type with special nylon coated on its threads. 3 Plug (38a): 7.8 – 13.7 Nm {0.8 – 1.4 kgm}
(Ripper lift valve) 12. Assembly of check valve assembly 1) Install valve (14b) and spring (15b) to valve body (1b). 2) Fit spring (15b), backup ring (17b) and O-ring (16b) to plug (18b), and install plug (18b) to valve body (1b). 3 Plug (18b): 176.6 – 196.1 Nm {18 – 20 kgm}
14. Assembly of check valve assembly Fit O-ring (20b) to check valve assembly (19b), and install check valve assembly (19b) to valve body (1b). 3 Check valve assembly (19b): 58.8 – 78.5 Nm {6 – 8 kgm}
13. Assembly of suction valve assembly Fit O-ring (22b) to suction valve assembly (21b), and install suction valve assembly (21b) to valve body (1b). 3 Suction valve assembly (21b): 176.6 – 196.1 Nm {18 – 20 kgm}
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DRAFT Hydraulic system Disassembly and assembly of control valve assembly 3
15. Installation of plug 1) Installation of plug (27b) 1] Install plug (23b) to valve body (1b). 2] Fit O-ring (24b), backup ring (25b) and O-ring (26b) to plug (27b), and install plug (27b) to valve body (1b).
Plug (27b): 176.6 – 196.1 Nm {18 – 20 kgm} 2) If plug (28b) is removed, replace with new one. a The plug is a dry-seal type. Special nylon is coated on its threads. 3 Plug (28b): 7.8 – 13.7 Nm {0.8 – 1.4 kgm}
(Ripper tilt valve) 16. Assembly of check valve assembly 1) Install valve (14c) and spring (15c) to valve body (1c). 2) Fit spring (15c), backup ring (17c) and O-ring (16c) to plug (18c), and install plug (18c) to valve body (1c). 3 Plug (18c): 176.6 – 196.1 Nm {18 – 20 kgm} 17. Assembly of suction valve assembly Fit O-ring (22c) to suction valve assembly (21c), and install suction valve assembly (21c) to valve body (1c). 3 Suction valve assembly (21c): 176.6 – 196.1 Nm {18 – 20 kgm} 18. Assembly of check valve assembly Fit O-ring (20c) to check valve assembly (19c), and install check valve assembly (19c) to valve body (1c). 3 Check valve assembly (19c): 58.8 – 78.5 Nm {6 – 8 kgm}
19. Installation of plug 1) Installation of plug (27c) 1] Install plug (23c) to valve body (1c). 2] Fit O-ring (24c), backup ring (25c) and O-ring (26c) to plug (27c), and install plug (27c) to valve body (1c). 3 Plug (27c): 176.6 – 196.1 Nm {18 – 20 kgm} 2) Installation of plug (28c) Fit O-ring (29c), backup ring (30c) and O-ring (31c) to plug (28c), and install plug (28c) to valve body (1c). 3 Plug (28c): 176.6 – 196.1 Nm {18 – 20 kgm}
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3) If plugs (32c) and (33c) are removed, replace with new ones. a The plug is a dry-seal type with special nylon coated on its threads. 3 Plug: (32c)(4 places): 16.7 ± 2.9 Nm {1.7 ± 0.3 kgm} D375A-6 (02)
DRAFT Hydraulic system Disassembly and assembly of control valve assembly
(33c)(3 places): 7.8 – 13.7 Nm {0.8 – 1.4 kgm}
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DRAFT Hydraulic system Disassembly and assembly of blade PPC valve assembly
Disassembly and assembly of blade PPC valve assembly .
a This section provides only the precautions when assembling the blade PPC valve assembly. a As the parts look alike, note the locations to which they are installed during disassembly. a Spare part cannot be supplied individually for the following parts. If any of them needs to be replaced, replace the blade PPC valve assembly with new one. (2),(3),(4),(5),(6),(7),(8),(9), (11),(12),(13),(14),(15),(16),(17), (18),(19),(20),(21),(22),(23),(24), (39),(40),(41),(42),(43),(44) a Do not remove nipples (39) to (41) unless it is necessary.
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DRAFT Hydraulic system Disassembly and assembly of blade PPC valve assembly
Assembly 1. Install the blade RAISE valve. 1) Install valve (2) to valve body (1). 2) Install shims (3) and spring (4) to valve (2). a Install spring (4) with its small diameter (inside diameter) end facing shims (3). 3) Install spring (5), retainer (6), piston (7), spring (8), shim (3), piston (9) and seat (10). a When installing piston (7), apply grease (G2-LI) to the periphery of the piston and inner surface of the body bore. a When installing piston (9), apply grease (G2-LI) to the inner surface of the body bore. 2. Install the blade LOWER valve. 1) Install valve (11) to valve body (1). 2) Install shims (3) and spring (12) to valve (11). a Install spring (12) with its small diameter (inside diameter) end facing shims (3). 3) Install spring (13), retainer (14), piston (7), shims (42), retainer (15), balls (16), collar (17), spring (18), spacers (19) and piston (44). a When installing piston (7), apply grease (G2-LI) to the periphery of the piston and inner surface of the body bore. a When installing piston (44), apply grease (G2-LI) to the inner surface of the body bore. 3. Install the blade tilt valve. 1) Install valve (2) to valve body (1). 2) Install shims (3) and spring (20) to valve (2). a Install spring (20) with its small diameter (inside diameter) end facing shims (3). 3) Install spring (21), retainer (22), piston (23), shim (43) and piston (24). a When installing piston (23), apply grease (G2-LI) to the periphery of the piston and inner surface of the body bore. a When installing piston (24), apply grease (G2-LI) to the inner surface of the body bore.
8. Install plates (31) and (32). 3 Mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 9. Install joint (33). a When installing joint (33) to body (29), apply Loctite in the following manner. 1] When installing the joint, apply a drop (approx. 0.02 g) of Loctite (No. 648) to each female thread portion (A) (2 places) of the valve body. Before installing the joint, degrease its male threads and female threads of the valve body with Drysol and dry them. 2] Drop LOCTITE to the following positions. (L): 5 – 7 mm from end surface 2 Body female threads (A): Adhesive (Loctite No. 648) 3 Joint (33): 39 – 49 Nm {4 – 5 kgm}
a Apply gear oil grease (G2-LI) to the sliding portion of the joint. (J portion): Apply grease (G2-LI) 7 – 10 ml to entire circumference. (P portion): Apply gear oil 0.2 – 0.4 ml to the sliding portions (4 places) between joint and pin.
4. Install orifice (25). 3 Orifice: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 5. Fit O-rings (26) and (27), and install plate (28). 6. Fit O-rings (26) and (27), and install valve body (29). 7. Install seal (30) to valve body (29).
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DRAFT Hydraulic system Disassembly and assembly of blade PPC valve assembly
10. Install boot (37) and disc (35), and tighten nut (36). 1) Install disc (35), so that each bolt (38) is positioned at the center of each side of disc (35) to prevent the disc from interfering with any bolt (38) during compound operation. 2) When installing disc (35), adjust the play at lever end (400 mm from the fulcrum of the lever) to 1 - 6 mm. 3) Holding disc (35) with tool [1], tighten nut (36). a At this time, allow valve body (29) or plate (31) to have play (a) and (b), and lock with tool [2]. 3 Nut (36): 93.1 – 112.7 Nm {9.5 – 11.5 kgm}
a After installing the disc, adjust the disc height. For details, see Testing and adjusting, "Adjusting PPC valve".
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DRAFT Hydraulic system Disassembly and assembly of ripper PPC valve assembly
Disassembly and assembly of ripper PPC valve assembly a This section provides only the precautions when assembling the ripper PPC valve assembly. a Spare part is not available for nipples (18) and (19). Do not remove them unless necessary. Assembly
a Install spring (4) with its small diameter end (inside diameter) facing shims (3). 3. Install springs (5) and (6), retainer (7) and piston (8). a Springs (5) and (6) having different number of turns are used for the oil pressure ports shown below. Take care not to install wrong springs. Port P1, P2 P3, P4
Total number of turns 11 9
a Each port is stamped on the bottom of the valve body. a When installing piston (8), coat the outside surface of the piston and the inside surface of the bore in the valve body with grease. 2 Piston: Grease (G2-LI) 4. Install seat (9) and seal (10) to valve body (1). 5. Install plates (11) and (12). 3 Mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kg} 6. Install joint (13). a When installing joint (13) to valve body (1), apply Loctite in the following manner. 1] When installing the joint, apply a drop (approx. 0.02 g) of Loctite (No. 648) to each female thread portion (A) (2 places) of the valve body. Before installing the joint, degrease its male threads and the female threads of the valve body with Drysol and dry them. 2] Drop LOCTITE to the following positions. (L): 5 – 7 mm from end face 2 Body female threads (A): Adhesive (Loctite No. 648) 3 Jonit (13): 39 – 49 Nm {4 – 5 kgm}
1. Install valve (2) to valve body (1). 2. Install shims (3) and spring (4) to valve (2).
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DRAFT Hydraulic system Disassembly and assembly of ripper PPC valve assembly
a Apply gear oil and grease (G2-LI) to the sliding portions of the joint. (J portion): Apply grease (G2-LI) 7 – 10 ml to entire circumference. (P portion): Apply gear oil 0.2 – 0.4 ml to the sliding portions (4 places) between the joint and pin.
7. Install disc (14) and boot (15), and tighten with nut (16). 3 Nut: 69 – 88 Nm {7 – 9 kgm} a After installing the disc, adjust the disc height. For details, see Testing and adjusting, "Adjusting PPC valve".
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of hydraulic cylinder assembly Disassembly
Symbol
Part No.
1 790-502-1003 790-201-1702 790-201-1841 2 790-201-1861 790-101-5021 01010-50816 790-201-1500 790-201-1650 3 790-201-1670 U 790-101-5021 01010-50816 4 790-720-1000 796-720-1680 07281-01589 796-720-1720 5 07281-02429 796-720-1690 07281-02169 790-102-4300 6 790-102-4310
D375A-6 (02)
Part name
Stand Push tool kit q Push tool q Push tool q Grip q Bolt Push tool kit q Plate q Plate q Grip q Bolt Expander Ring Clamp Ring Clamp Ring Clamp Wrench Pin
Necessity Q'ty New/remodel Sketch
Special tools
t 1 t 1 1 1 1 1 t 1 1 1 1 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 2
1. Cylinder tube Remove the cylinder tube. 2. Quick drop valve assembly a Perform this procedure for only the blade lift cylinder. 1) Remove quick drop valve assembly (1).
2) Disassemble the quick drop valve assembly according to the following procedure. 1] Remove elbow (2). 2] Remove spring (3), washer (4), and valves (5) and (6), and pull out collar (7).
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
3. Piston rod assembly 1) Set cylinder assembly (8) to tool U1. 2) Remove head assembly (9). 3) Pull out piston rod assembly (10). a Put an oil container under the cylinder to receive the oil.
2) Remove bolt (11). 3) Remove spacer (12). 4) Remove valve (13) from spacer (12). (Only for lift cylinder) 5) Remove piston assembly (14). 6) Remove backup rings (15) and O-ring (16). 7) Remove retainer (17). (Only for lift cylinder)
4. Piston assembly q Blade lift cylinder, and blade tilt cylinder 1) Set piston rod assembly (10) to tool U1.
. 8) Disassemble the piston assembly according to the following procedure. 1] Remove wear ring (18). 2] Remove piston rings (19). a Do not reuse valve (V) and seat (S). BL: Blade lift cylinder BT: Blade tilt cylinder
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
Ripper lift cylinder and ripper tilt cylinder 1) Set piston rod assembly (10) to tool D1.
q
2) Remove lock screw (31) of piston assembly (30). q Screw size: M12 × pitch 1.75
a If screw (31) cannot be removed because it is punched too tight, screw in it deeply into the hole once, tap the hole by using tap [1], then remove the screw.
3) Using tool U6, remove piston assembly (30) from piston rod (32).
4) Disassembly of the piston assembly 1] Remove the backup ring and O-ring (33). 2] Remove wear ring (34). 3] Remove piston ring (35).
.
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
5. Cylinder head assembly 1) Remove cylinder head assembly (20) from the piston rod.
Assembly a Apply engine oil to the sliding surfaces of each part and install the packings, dust seals, and O-rings, taking care not to damage them. 1. Cylinder head assembly 1) Assemble the cylinder head assembly according to the following procedure. 1] Using tool U2, press fit bushing (28) to the cylinder head 2] Install snap ring (27). 3] Install buffer ring (26) and rod packing (25). 4] Using tool U3, press fit seal (24). 5] Install snap ring (23).
2) Disassemble the cylinder head assembly according to the following procedure. 1] Remove O-ring (21) and backup ring (22).
2] Remove snap ring (23), then remove dust seal (24). 3] Remove rod packing (25) and buffer ring (26). 4] Remove snap ring (27), then pull out bushing (28).
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
6] Install backup ring (22) and O-ring (21).
2) Install cylinder head assembly (20) to the piston rod.
a Replace valve (V) and seat (S)with new ones.
2. Piston assembly q Blade lift cylinder and blade tilt cylinder 1) Assemble the piston assembly according to the following procedure. 1] Using tool U4 expand piston ring (19). a 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 (19) from tool U4, and install it to the piston. 3] Set tool U5, to compress piston ring (19). 4] Install wear ring (18) to the piston.
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
2) Install retainer (17). (Only for lift cylinder) 3) Install O-ring (16) and backup rings (15). a Apply grease to the O-ring and backup rings so that the backup rings do not separate from each other. 4) Install piston assembly (14). 5) Install valve (13) to the spacer. (Only for lift cylinder) 6) Install spacer (12) and tighten the mounting bolts (11). a After tightening the mounting bolts, leave the piston and piston rod assembly for 30 minutes. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: Lift cylinder 98–122.6 Nm {10–12.5 kgm} Tilt cylinder 157 – 196 Nm {16 – 20 kgm}
5] Install backup rings and O-ring (33). a Install the backup rings after warming it in hot water at about 50 – 60°C. a Apply grease to the O-ring and backup rings, so that the backup rings do not separate from each other.
2) Install the piston assembly to piston rod (10), and set the piston rod to tool U1.
Ripper lift cylinder and ripper tilt cylinder 1) Assembly of the piston assembly 1] Using tool U4, expand piston ring (35). a Set the piston ring to tool U4, and turn the handle 8 – 10 turns to expand the piston ring. 2] Remove piston ring (35) from tool U4 and intall it to piston. 3] Using tool U5, compress piston ring (35).
q
4] Install wear ring (34). 50-292
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
3) When reusing piston rod (32) and piston assembly (30), take the following steps for installation. a Remove any flash or burr on the threaded portion by using a file or other tool. a Clean the parts thoroughly and remove metal chips and dust. 1] Screw piston assembly (30) into piston rod (32) by using tool U6, and tighten the piston assembly until the tapped holes are aligned.
4) When using new parts for either or both of piston rod (10) and piston assembly (30), take the following steps for installation. 1] Using tool U6, tighten piston assembly (30). 3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} 2] Make a hole to install the screw. a Apply the drill tip to the groove where the piston and piston rod are engaged, and make a horizontal hole. q Dimensions of a screw hole (mm): Tap hole diameter: 10.3 Tap hole depth: 27 Tap used: 12 x 1.75 Tap depth: 20 3] Remove steel chips and dust and clean the assembly completely.
2] Install screw (31) to piston (30). a Install the screw after degreasing and drying its threads adequately. a After installing the screw, punch it at four points on it periphery. 2 Threads of screw: Adhesive(Loctite No.262) 3 Screw: 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
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DRAFT Hydraulic system Disassembly and assembly of hydraulic cylinder assembly
4] Install screw (31). a Install the screw after degreasing and drying the threads completely. a After tightening the screw, punch it at four points on its periphery. 2 Threads of screw: Adhesive (Loctite No.262) 3 Screw: 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
4. Quick drop valve assembly a Perform this procedure for only the blade lift cylinder. 1) Install the quick drop valve assembly as follows. 1] Install collar (7), and install valves (6) and (5), washer (4), and spring (3).
2) Install quick drop valve assembly (1). 3. Piston rod assembly 1) Set cylinder (8) to tool U1. 2) Install piston rod (10) to cylinder (8). a Apply grease to the sealing part of the piston. a Push in the piston rod fully 3) Push in head assembly (9) to the cylinder and tighten the mounting bolts. a Apply grease to the backup ring.
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5. Cylinder tube Install the cylinder tube.
D375A-6 (02)
DRAFT Hydraulic system Disassembly and assembly of ripper pin puller cylinder assembly
Disassembly and assembly of ripper pin puller cylinder assembly
Symbol
Part No.
1 790-502-1003 790-201-1702 790-201-1721 2 790-101-5021 01010-50816 790-201-1500 790-201-1530 U 3 790-101-5021 01010-50816 4 790-720-1000 796-720-1630 5 07281-00709 7 790-102-2302
Part name
Cylinder repair stand Push tool kit q Push tool q Grip q Bolt Push tool kit q Plate q Grip q Bolt Expander Ring Clamp Wrench
Necessity Q'ty New/remodel Sketch
Special tools
t 1 t 1 1 1 1 t 1 1 1 1 t 1 t 1 t 1 t 1
Disassembly 1. Cylinder assembly 1) Set pin puller cylinder assembly (1) to tool U1. 2) Using tool U7, remove cylinder head assembly (2) and piston rod (3) as a unit. a Put an oil container under the cylinder to receive the oil.
2. Cylinder head assembly 1) Remove cylinder head assembly (2) from piston rod (3).
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DRAFT Hydraulic system Disassembly and assembly of ripper pin puller cylinder assembly
2) Remove O-ring (5) and backup ring (6). 3) Remove O-ring (7). 4) Remove snap ring (8), then remove dust seal (9). 5) Remove rod packing (10), and remove bushing (11).
Assembly a Apply engine oil to the sliding surfaces of each part and install the packings, dust seals, and O-rings, taking care not to damage them. 1. Piston rod assembly 1) Using tool U4, expand piston ring (12). a Set the piston ring to the tool and turn the handle 8 – 10 turns to expand the ring. 2) Remove piston ring (12) from the tool, then install it to piston rod (3). 3) Using tool U5, compress piston ring (12).
3. Piston rod assembly Remove piston ring (12) from piston rod (3).
.
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DRAFT Hydraulic system Disassembly and assembly of ripper pin puller cylinder assembly
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 the cylinder with block [1]. 2) Install piston rod (3) and cylinder head assembly (2) as a unit. a Apply grease to the sealing part of the piston. a Apply grease to the backup ring. a Push in the piston fully. 3) Using tool U7, 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).
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DRAFT Work equipment Removal and installation of blade assembly
Work equipment Removal and installation of blade assembly Removal k
Park the machine on a level place and lower the work equipment to the ground completely.
1. Set blocks [1] securely under left and right straight frames (9).
k
Release the residual pressure from the piping. For details, see "Releasing residual pressure of work equipment cylinder" in Testing and adjusting.
6. Remove right and left covers (5).
2. Sling lift cylinder assembly (2). 3. Remove lock plate (1), and remove connecting pin (1a) on the piston rod side of the blade lift cylinder. 4. Start the engine and retract piston rod (3) fully.
7. Disconnect hose (6). a Plug the hose to prevent dust etc. from entering the piping. 8. Remove left and right trunnion caps (7). 9. Remove blade assembly (8). [*1] a Start the engine and move the machine slowly in reverse to separate the blade assembly from the trunnions.
5. Lift cylinder (2) and bracket (4) as a unit, and secure it to the radiator guard at position (A). a Bind with wire to prevent the piston rod from pulling out. a Use the same procedure to separate the cylinder on the opposite side from the blade.
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DRAFT Work equipment Removal and installation of blade assembly
Installation q Carry out installation in the reverse order to removal. [*1] a Adjust height (b) of the right and left straight frames and distance (c) between the frames by using blocks [1] so that the dimensions are as follows. q Height at trunnion (b) : Apporx. 863 mm q Distance (c) between frames: Apporx. 3,484 mm
q
Refilling (hydraulic tank) Supply 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.
D375A-6 (02)
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DRAFT Work equipment Disassembly and assembly of blade assembly
Disassembly and assembly of blade assembly Disassembly k
Place blocks [1] and [2] under the right and left straight frames and blade to support the blade securely.
1. Remove right frame covers (1) and (2). 2. Disconnect tilt cylinder hoses (3).
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3. Sling tilt cylinder assembly (4), remove the lock plate, and remove pin (5). 4. Remove the lock plate, remove pin (6), and remove tilt cylinder assembly (4). 4 Tilt cylinder assembly: 380 kg
5. Set block [3] under right center brace (7), and remove the mounting bolt of cap (8) on the right straight frame side. a Shims are fitted in the cap. Note the quantity and thickness of the shims for installation purpose.
D375A-6 (02)
DRAFT Work equipment Disassembly and assembly of blade assembly
6. Sling right straight frame (9) and disconnect right center brace (7). 7. Remove the lock plate, remove pin (10), and remove right straight frame (9). 4 Straight frame: 1,150 kg
8. Sling tilt brace (11), remove the lock plate, and remove pin (12) from the blade.
11. Sling center brace (15), remove the mounting bolts to remove cap (16). Then remove right and left center braces (15) and (7). a Shims are fitted in the cap. Note the quantity and thickness of the shims for installation purpose. 4 Center brace: 220 kg
12. Sling blade (17), and lay down the blade. 4 Blade: 4,900 kg
9. Remove the lock plate, remove pin (13), and lift off tilt brace (11). 4 Tilt brace: 200 kg 10. Disconnect the left center brace using the same procedure as steps 5 to 7, and remove left straight frame (14).
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DRAFT Work equipment Disassembly and assembly of blade assembly
Assembly a Check the quantity and thickness of the removed shims, and fit shims of the same quantity and same thickness to the original locations. a To adjust the shims, see Testing and adjusting, "Adjusting blade".
3. Sling right straight frame (9), install pin (10), and secure with the lock plate. 4 Straight frame: 220 kg 4. Sling right straight frame (9) and set the ball of right center brace (7) to right straight frame (9).
1. Sling blade (17), place blocks or stands under the blade to support the blade. 4 Blade: 4,900 kg
5. Install the shims to cap (8) of right center brace (7), and tighten the mounting bolt. a Standard thickness of shims: 4.5 mm 2. Sling center brace (15), install shim(s), and tighten the mounting bolt of cap (16). a Set a block under the center brace to align its height with the height of the straight frame. a Standard thickness of shims: 4.5 mm 4 Center brace: 220 kg a Install center brace (7) of the opposite side in the same manner.
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DRAFT Work equipment Disassembly and assembly of blade assembly
6. Sling tilt cylinder assembly (4), install pin (6), and secure with the lock plate. 4 Tilt cylinder assembly: 380 kg
10. Install left straight frame (14) using the same procedure as steps 3 to 5, and connect the left center brace.
7. Install pin (5), and secure with the lock plate.
11. Sling tilt brace (11), install pin (13), and secure with the lock plate. 4 Tilt brace: 200 kg 12. Install pin (12), and secure with the lock plate.
8. Connect tilt cylinder hoses (3). 9. Install right frame covers (2) and (1). 13. Greasing After assembly, apply sufficient amount of grease to the points indicated by arrows in the figure. 2 Greasing points of work equipment: Grease (G2-LI)
D375A-6 (02)
50-303
DRAFT Work equipment Disassembly and assembly of giant ripper assembly
Disassembly and assembly of giant ripper assembly Disassembly 1. Stop the machine with its track riding on blocks [1], and lower the blade to the ground. k Set the parking brake to the lock position. 2. Sling the shank, then operate the pin-puller switch to pull out the shank pin. 3. Raise the ripper fully, and lower the shank to remove. 4 Shank: 470 kg
a Start the engine, retract the piston rod fully, and lower the tilt cylinder assemble on top of the lift cylinder. k After stopping the engine, release the residual pressure from the piping. For details, see Testing and adjusting "Releasing residual pressure of work equipment cylinder". 7. Disconnect four lift cylinder hoses (4), four tilt cylinder hoses (5), and two pin puller cylinder hoses (6).
4. Set stand [2] under the arm and beam.
8. Sling tilt cylinder assembly (7), remove pin (8), and remove tilt cylinder assembly (7). 4 Tilt cylinder assembly : 270 kg 5. Sling the lift cylinder assembly and remove pin (2). a Start the engine, retract the piston rod fully, and lower the lift cylinder assembly on top of the arm. 6. Sling the tilt cylinder assembly and remove pin (3).
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D375A-6 (02)
DRAFT Work equipment Disassembly and assembly of giant ripper assembly
9. Sling lift cylinder assembly (9), remove pin (10), and remove lift cylinder assembly (9). 4 Lift cylinder assembly : 350 kg
10. Sling beam (11), remove right and left pins (12), and remove beam (11). 4 Beam: 2,000 kg
11. Sling arm (13), remove right and left pins (14), and remove arm (13). 4 Arm: 1,000 kg
D375A-6 (02)
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DRAFT Work equipment Disassembly and assembly of giant ripper assembly
Assembly 1. Sling arm (13) and set it to the mounting position, install right and left pins (14), and secure them with the lock plates. 4 Arm: 1,000 kg a Set a stand under the arm.
2. Sling beam (11) and set it to the mounting position, install right and left pins (12), and secure them with the lock plates. 4 Beam: 2,000 kg a Set a stand under the beam.
4. Sling tilt cylinder assembly (7) and set it to the mounting position. Install pin (8), and secure it with the lock plate. 4 Tilt cylinder assembly: 270 kg
5. Connect two pin puller cylinder hoses (6), four tilt cylinder hoses (5), and four lift cylinder hoses (4).
6. Sling the tilt cylinder assembly, start the engine to extend the piston rod to align the pin holes. Install pin (3), and secure it with the lock plate. 3. Sling lift cylinder assembly (9) and set it to the mounting position. Install pin (10), and secure it with the lock plate. 4 Lift cylinder assembly : 350 kg
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7. Sling the lift cylinder assembly, start the engine to extend the piston rod to align the pin holes. Install pin (2), and secure it with the lock plate.
D375A-6 (02)
DRAFT Work equipment Disassembly and assembly of giant ripper assembly
8. Make both tracks of the machine ride blocks [1], stop the machine and lower the blade to the ground. k Set the parking brake in the lock position. 9. Operate the ripper to raise the machine slightly to remove stand [2]. 10. Raise the ripper fully, pass wire through the shank holder, then raise the shank slowly, align the pin holes, and operate the pin puller switch to insert the shank pin. 11. Raise the blade, and run the machine off blocks [1]. 12. Bleed air from the cylinders. For details, see Testing and adjusting "Bleeding air from hydraulic cylinder".
D375A-6 (02)
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DRAFT Cab and its attachments Removal and installation of ROPS guard
Cab and its attachments Removal and installation of ROPS guard Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
Installation q Carry out installation in the reverse order to removal. [*1]
3
ROPS guard mounting bolt : 1,519–1,911 Nm {155–195 kgm}
[*2] q
1. Remove antenna (1).
Installed direction of ROPS guard
2. Sling ROPS guard (2), and remove the twelve mounting bolts. [*1] 3. Lift off ROPS guard (2). 4 ROPS guard: 700 kg
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[*2]
D375A-6 (02)
DRAFT Cab and its attachments Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab assembly Removal k Park the machine on a leve surface surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. 1. Remove the ROPS guard. For details, see "Removal and installation of ROPS guard." 2. Remove cover (1) on the left side of the operator’s cab. 5. Remove three mounting bolts (8) of lower angle (7).
3. Disconnect wiring connectors CN19 CN12VS (3), CN21 (4) and CN20 (5).
(2),
4. Disconnect four window washer hoses (6). [*1] a Pull the wires and window washer hoses into the operator’s cab.
D375A-6 (02)
6. Remove back side cover (9) of the monitor panel.
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DRAFT Cab and its attachments Removal and installation of operator’s cab assembly
7. Remove angle (10).
10. Remove covers (13), (14) and (15).
8. Remove the operator’s cab mounting bolt according to the following procedure. 1) Remove right and left covers (11).
11. Remove twenty-one mounting bolts (indicated by * mark) and lift off operator’s cab assembly (16). 4 operator’s cab assembly: 500 kg
9. Remove right and left covers (12).
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D375A-6 (02)
DRAFT Cab and its attachments Removal and installation of operator’s cab assembly
Installation a Before installing the operator’s cab, loosen the mounting bolts of angle (7) and those of angle (10) inside the operator’s cab.
2) Sling operators cab assembly (16), and bond seal (19) to the mating face.
1. Seal 1) Fit seal (17) to guide plate (18) of the air conditioner box. 2 Part (A) on outside of seal (sealing face agaist cab): Grease (G2-LI)
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DRAFT Cab and its attachments Removal and installation of operator’s cab assembly
2. Operator’s cab assembly 1) Lower the operator’s cab assembly slowly to the floor frame. a Take care not to shift or damage the seal. a Check that the air conditioner duct seal on the cab mates tightly with the air conditioner duct of the dashboard. a Lower the operator’s cab assembly carfully, as the clearance between the air conditioner duct on the cab and the monitor is small. 2) Tighten twenty-one mounting bolts (indicated by * mark) partially. a Note that the mounting bolts to be used at the door portions differ in bolt length and washer size from other mountinh bolts. a Check that air conditioner bracket (20) is fitted securely to the seal installed to the cab (21). a Check joint (B) between the seal and floor frame for gap. If a clearance is found, remove the cab, and reinstall it correctly. If the clearance is small, seal it with sealant.
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3) Tighten the mounting bolts to the specified torque, that are tightened partially in step 2. 4) Tighten the mounting bolts of angle (7) and those of angle (10) inside the cab to the specified torque. a Perform the subsequent installation in the reverse order to removal from step 7. [*1] a When connecting the window washer hoses, match their band colors.
D375A-6 (02)
DRAFT Cab and its attachments Removal and installation of floor frame assembly
Removal and installation of floor frame assembly Removal k Park the machine on a leve surface surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If you drain the coolant or disconnect the heater hose when the coolant or disconnect the high, you may be scalded. In this case, wait until the coolant temperature lowers and then drain the coolant of disconnect the heater hose. a Note the installed positions of the hoses and wirings for installation purpose. a Plug the disconnected hoses to prevent oil from flowing out. 1. Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask a qualified distributor for collection and charge of the refrigerant (R134a). a Never discharge the refrigerant (R134a) into the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Therefore, put on safety glasses, safety gloves and working suits with long sleeves when collecting or charging the refrigerant. q Quantity of refrigerant: 1,100 ± 100 g 2. Drain the hydraulic oil. 6 Hydraulic tank: 130 l (refill capacity) 3. Drain the coolant. 6 Radiator: 120 l 4. Remove the ROPS guard. For details, see "Removal and installation of ROPS guard." 5. Remove the fuel tank assembly. For details, see "Removal and installation of fuel tank assembly." 6. Remove the operator’s cab assembly. For details, see "Removal and installation of operator’s cab assembly." 7. Remove the cover’s according to the following procedure. 1) Remove cover (1). 2) Remove cover (2). 3) Remove cover (3). 4) Remove cover (4).
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DRAFT Cab and its attachments Removal and installation of floor frame assembly
8. Remove cover (5). 9. Disconnect clamp (6). 10. Disconnect wiring connector (7).
17. Disconnect two clamps (23).
18. Disconnect clamps (24) and (25). 11. Disconnect two air conditioner hoses (8). [*1] a Plug the hoses to prevent entry of dirt and water. 12. Disconnect heater hose clamp (9). 13. Disconnect two heater hoses (10). a Close the heater valve on the engine side. 14. Remove clamp (11) and disconnect air hose (12). [*2]
15. Disconnect ground wire (13). 16. Disconnect following wiring connectors (14) to (22). (From left top) VED (14), PWR (15), USL (16) (From right top) VED (17), VDB (18), PL2 (19), PL1 (20), PL1 (21), PL1 (22)
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D375A-6 (02)
Cab and its attachments Removal and installation of floor frame assembly
19. Disconnect PPC hose (26) (band color: green). 20. Disconnect hydraulic hose (27). 21. Disconnect clamp (28). 22. Disconnect ripper PPC hose (29).
23. Remove wiring connectors RT1 (30), RPU (31), RTB (32), and BLD (33).
a Take care not to loosen the turnbuckle in wrong direction since it has left-hand threads.
26. Disconnect right levers (38) and PPC valve as a unit from the console according to the following procedure. 1) Remove armrest (39). 2) Remove the mounting bolts of console cover (40). 3) Remove each lever cover (41) from the console cover and pull the console cover away from levers (38). a Lift up the console cover carefully since the wiring connectors are installed to its back side. 4) Disconnect wiring connectors PLSW (42) and HNSW (43) from the back side of the console cover. 5) Remove console cover (40). 6) Roll up lever cover (41) and remove four mounting bolts (44) of each lever. 7) Lower the levers and PPC valve as a unit below the console.
24. Remove pin (34) to disconnect parking brake cable (35) from lever (36). [*3] a Note the installed dimensions of the cable before disconnecting it. (Nut position: N) 25. Remove pin (37) to disconnect brake rod (38) from lever (39). [*4] a Note the installed dimension of the brake rod before disconnecting it.
D375A-6 (02) (06)
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Cab and its attachments Removal and installation of floor frame assembly
27. Remove left console cover (45).
28. Remove four mounting bolts (47) each at the right rear and left rear of the floor frame. [*5]
29. Remove four mounting bolts (48) at the left front of the floor frame. [*6] 30. Remove mounting bolt (49) at the right front of the floor frame. [*7]
q Disconnect ground wire (46)
31. Lift off floor frame assembly (50). a Lift the assembly while checking all the hoses and wirings are disconnected. a After removing the floor frame assembly, remove the spacer on the right front mount. 4 Floor frame assembly: 600 kg
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D375A-6 (02) (06)
DRAFT Cab and its attachments Removal and installation of floor frame assembly
Installation q Carry out installation in the reverse order to removal. [*1] a Install the hose without twisting it. a When installing the air conditioner circuit hose, take care not to allow dint, dust and water to enter it. a Check that the O-ring is fitted to the air conditioner hose adapter before tightening the adapter a When connecting the refrigerant hose, apply compressor oil for new refrigerant (R134a) (Denso: ND-OIL8 or Zexcel: ZXL100PG (equivalent to PAG 46)) to the O-ring.
3
[*4] a Install the brake rod to the turnbuckle, set it to the installed dimension noted when it was removed. a Be sure to bend the cotterpin securely. a Adjust the brake rod. For details, see testing and adjusting,”Adjusting brake pedal and parking brake parking brake lever.” [*5][*6] 3
Mounting bolts at the right rear, left rear and left front sides: 338.1 ± 39.2 Nm {34.5 ± 4 kgm}
[*7]
3
Mounting bolt at right front: 1,370 - 1,666 Nm {140 - 170 kgm}
q
Refilling of coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant:120 l
q
Charging air conditioner with refrigerant Charge the air conditioner circuit with refrigerant (R134a). a Quantity of refrigerant: 1,100 ± 100 g
Tightening torque for air conditioner gas piping.
Thread size 16 x 1.5 22 x 1.5 24 x 1.5
Tightening torque 12.23 ± 1.47 Nm {1.35 ± 0.15 kgm} 22.05 ± 2.45 Nm {2.25 ± 0.25 kgm} 31.85 ± 2.45 Nm {3.25 ± 0.25 kgm} 5.39 ± 1.47 Nm {0.55 ± 0.15 kgm}
M6 bolt (receiver portion) M6 bolt 9.8 ± 1.96 Nm {1.0 ± 0.2 kgm} (compressor portion)
[*2]
3
Air hose clamp: 6.8 ± 0.49 Nm {0.69 ± 0.05 kgm}
[*3] a Install the cable to the bracket setting it to the dimension noted when the cable was removed. a Be sure to bend the cotter pin securely. a Adjust the parking brake. For details, see Testing and adjusting, "Adjusting PCCS lever".
D375A-6 (02)
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DRAFT Cab and its attachments Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner unit assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery. k If you drain the coolant or disconnect the heater hose when the coolant temperature is high, you may be scalded. In this case, wait until the coolant temperature lowers and then drain the coolant or disconnect the heater hose. a Note the installed positions of the hoses and wirings for installation purpose. a Plug the disconnected hoses to prevent oil from flowing out. 1. Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask a qualified distributor for collection and charge of the refrigerant (R134a). a Never discharge the refrigerant (R134a) into the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on safety glasses, safety gloves and long sleeved work clothes when collecting or charging the refrigerant. q Quantity of refrigerant: 1,100 ± 100 g 2. Drain the coolant. 6 Radiator: 120 l
4. Disconnect two air conditioner hoses (5). [*1] a Plug the hoses to prevent entry of dirt, dust and water. 5. Disconnect heater hose clamp (6). 6. Disconnect two heater hoses (7). a Close the heater valve on the engine side. 7. Loosen clamp (8) and remove duct (9). [*2]
3. Remove the covers according to the following procedure. 1) Remove cover (1). 2) Remove cover (2). 3) Remove cover (3). 4) Remove cover (4).
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DRAFT Cab and its attachments Removal and installation of air conditioner unit assembly
8. Disconnect wiring connectors DS3 (10), DS1 (11), DS2 (12), DS4 (13), and DS5 (14).
10. Remove monitor cover (16). [*3] a Four connectors are installed at the back of the cover. Disconnect the connectors before removing the cover. (From left top) (17): FLSW (18): RLSW
(From right top) (19): ADH (20): OPSW
9. Open air conditioner filter cover (15).
D375A-6 (02)
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DRAFT Cab and its attachments Removal and installation of air conditioner unit assembly
11. Remove covers (21a) and (21b). 12. Remove right and left foot rests (22). 13. Remove right and left ducts (23).
[*4]
16. Disconnect wiring connector AC1 (26).
17. Remove four mounting bolts (27) and disconnect monitor assembly (28) from the dashboard of the monitor. a Wires are connected to the back side. Pull out the monitor assembly toward you carefully.
14. Remove cover (24). 15. Remove right and left covers (25).
18. Disconnect wiring connectors CM01 (29) and CM02 (30).
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D375A-6 (02)
Cab and its attachments Removal and installation of air conditioner unit assembly
19. Disconnect wiring connectors AC2 (31) and AC3 (32).
23. Remove back side cover (36) of the monitor panel.
20. Disconnect four relay wiring connectors (33). 21. Disconnect wiring connector (34) of the servomotor. 22. Disconnect wiring connector M26 (35).
24. Disconnect dummy connector (37) from clip (38). 25. Disconnect clamp (40) of wiring (39).
D375A-6 (02) (06)
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DRAFT Cab and its attachments Removal and installation of air conditioner unit assembly
26. Remove two mounting bolts (41a), (41b), and (41c) of the air conditioner unit assembly each, and remove air conditioner unit assembly (42). (41a): 2 places at right and left of lower part on this side (41b): 2 places at right and left of lower part on engine side (41c): 2 places at upper part on engine side
(a): Installed position of bolts (41a) (b): Installed position of bolts (41b) (c): Installed position of bolts (41c)
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D375A-6 (02)
DRAFT Cab and its attachments Removal and installation of air conditioner unit assembly
Installation q Carry out installation in the reverse order to removal. [*1] a Install the hose without twisting it. a When installing the air conditioner circuit hose, take care not to allow dint, dust and water to enter it. a Check that the O-ring is fitted to the air conditioner hose adapter before tightening the adapter. a When connecting the refrigerant hose, apply compressor oil for new refrigerant (R134a) (Denso: ND-OIL8 or Zexcel: ZXL100PG (equivalent to PAG 46)) to the O-ring.
3
Tightening torque for air conditioner gas plping.
Thread size 16 x 1.5 22 x 1.5 24 x 1.5
Tightening torque 12.23 ± 1.47 Nm {1.35 ± 0.15 kgm} 22.05 ± 2.45 Nm {2.25 ± 0.25 kgm} 31.85 ± 2.45 Nm {3.25 ± 0.25 kgm} 5.39 ± 1.47 Nm {0.55 ± 0.15 kgm}
M6 bolt (receiver portion) M6 bolt 9.8 ± 1.96 Nm {1.0 ± 0.2 kgm} (compressor portion)
[*2]
3
[*3][*4] a Adjust the monitor panel plate position according to the following procedure. 1) Tighten bolts (A) and (B) partially. 2) Tighten bolts (A) so that gaps (C) are set uniform in horizontal and vertical directions to prevent interference between the monitor panel, SW panel, and cover. 3) Tighten bolts (B).
Air hose clamp: 6.8 ± 0.49 Nm {0.69 ± 0.05 kgm}
D375A-6 (02)
q
Charging air conditioner with refrigerant Charge the air conditioner circuit with refrigerant (R134a).
q
Refilling of coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant:120 l
50-323
Cab and its attachments Removal and installation of operator's seat isolator
Removal and installation of operator's seat isolator a Machine with operator's seat isolator
3. Remove operator's seat (1). 4 Operator's seat:
Removal 1. Disconnect power connector (2) of operator's seat (1).
50 kg
2. Remove four M8 nuts (4) securing operator's seat (1) and bracket (3).
4. Remove four M12 nuts (6) securing operator's seat isolator (5) and turntable.
Installation Perform installation in the reverse order to removal.
q
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D375A-6 (07) (02)
Cab and its attachments Disassembly and assembly of operator's seat isolator
Disassembly and assembly of operator's seat isolator a Machine with operator's seat isolator Disassembly q Perform disassembly in the reverse order to assembly. Assembly 1. Install stopper rubbers (3) to two stopper bosses (2) of base plate (1). a Hitch one side of stopper rubber (3) to the groove of the boss and press it with a round bar to install it to the boss.
2. Install four laminated rubbers (4) to base plate (1) with eight M10 bolts (5). 3 Laminated rubber mounting bolt: 40 Nm {4.08 kgm}
3. Install collar (7) to damper mounting pin (6) of the base plate with the tapered side down.
D375A-6 (02) (07)
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Cab and its attachments Disassembly and assembly of operator's seat isolator
4. Install protection tube (9) side of damper (8) to the mounting pin of the base plate.
5. Install slotted head nut (10) and pass cotter pin (11) and bend it to secure. (2 places)
7. Insert the top plate mounting pin into free side (15) of the damper installed to the top plate and remove the tape.
8. Match the holes of the top plate with the mounting screws of the laminated rubbers and secure them with eight M10 bolts (5). 3 Laminated rubber mounting bolt: 40 Nm {4.08 kgm}
6. Put collar (13) to the damper mounting pin of top plate (12) with the tapered side down and secure it with tape (14) to prevent it from falling. 9. Place plate (16) on the stopper pin and secure it with two M10 bolts (17).
10. Turn over the top plate, install slotted head nut (10) to the mounting pin, and pass cotter pin (11) and bend it to secure. (Two places)
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D375A-6 (07) (02)
Cab and its attachments Disassembly and assembly of operator's seat isolator
D375A-6 (02) (07)
50-323-4 50-327
DRAFT Electrical system Removal and installation of transmission controller assembly and steering controller assembly
Electrical system Removal and installation of transmission controller assembly and steering controller assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
Installation q Carry out installation in the reverse order to removal.
1. Remove plate (1).
2. Disconnect transmission controller wiring connector (2) and steering controller wiring connector (3). Remove the mounting bolts, and remove transmission controller assembly (4) and steering controller assembly (5).
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D375A-6 (02)
DRAFT Electrical system Removal and installation of engine controller assembly
Removal and installation of engine controller assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
3. Disconnect wiring connectors EGC1(4) and EGC2(5). a E: Ground cable
EGC3(3), [*1]
1. Open the left side cover and remove lower side cover (1).
4. Remove the mounting bolt and remove engine controller assembly (6).
2. Remove controller box cover (2).
Installation q Carry out installation in the reverse order to removal. [*1]
3
Screw: 2.82 Nm {0.288 kgm}
.
D375A-6 (02)
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DRAFT Electrical system Removal and installation of engine controller assembly
a Reference q Power supply connector EGC3(5) seal replacement procedure Seal part No.: 1010-074-0406 [DEUTSCH JAPAN] 1) Using tweezers [1], pinch the claw to remove cover (8).
2) Remove seal (9) by using tweezers [1].
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D375A-6 (02)
DRAFT Electrical system Removal and installation of VHMS controller assembly
Removal and installation of VHMS controller assembly Removal k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever in the lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
5. Remove the mounting bolts and remove controller case cover (4).
1. Lift off cover (1) on the left side of the operators cab.
6. Remove the mounting bolts and remove VHMS controller assembly (5).
2. Disconnect wiring connector (2). 3. Disconnect wiring clamp (2a). 4. Disconnect main harness cap (3).
Installation q Carry out installation in the reverse order to removal.
D375A-6 (02)
50-327
DRAFT Electrical system Removal and installation of machine monitor assembly
Removal and installation of machine monitor assembly Installation k Park the machine on a level surface and lower the work equipment to the ground. k Set the parking brake lever and work equipment lock lever to lock position. k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
2. Remove four mounting bolts (6) and disconnect machine monitor assembly (7) from the dashboard. a Wrings are connected in the back side. Be careful of this when pulling it toward you.
1. Remove monitor cover (1). [*1] a Four connectors are installed at the back of the cover. Disconnect the connectors before removing the cover. (From upper left) (From upper right) (2): FLSW (4): ADH (3): RLSW (5): OPSW
3. Disconnect wiring connectors CM01 (8) and CM02 (9). 4. Remove four mounting bolts (10) and remove machine monitor assembly (7).
50-328
D375A-6 (02)
DRAFT Electrical system Removal and installation of machine monitor assembly
Installation Carry out installation in the reverse order to removal. [*1] a Adjust the machine monitor panel plate position according to the following procedure. 1) Tighten bolts (A) partially. 2) Tighten bolts (A) so that gaps (C) are set uniform in horizontal and vertical directions to prevent interference between the momitor cover and the monitor or the switch panel.
D375A-6 (02)
50-329
DRAFT Electrical system Removal and installation of machine monitor assembly
50-330
D375A-6 (02)
60-1
D375A-6
Bulldozer D375A-6 Shop Manual
Machine model
Serial number
D375A-6
60001 and up
60 Maintenance standard
D375A-6 (06)
6-01
60-1
60-1
DRAFT Contents
Contents 60 Maintenance Standard Engine and cooling system Engine mount............................................................................................................................................... 60 3 Cooling fan pump......................................................................................................................................... 60 5 Cooling fan motor......................................................................................................................................... 60 - 12
Power train Power train unit ............................................................................................................................................ Damper and universal joint .......................................................................................................................... Torque converter and PTO .......................................................................................................................... Main relief valve and torque converter relief valve....................................................................................... Lockup clutch ECMV and stator clutch ECMV............................................................................................. Scavenging pump ........................................................................................................................................ Transmission control.................................................................................................................................... Transmission................................................................................................................................................ Transmission lubricating oil relief valve ....................................................................................................... Power train and lubrication pump ................................................................................................................ Transfer, bevel gear shaft and steering unit ................................................................................................ Steering control valve .................................................................................................................................. Steering clutch ECMV and steering brake ECMV........................................................................................ Parking brake valve ..................................................................................................................................... Final drive .................................................................................................................................................... Sprocket.......................................................................................................................................................
60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 -
14 16 19 22 23 24 25 26 30 31 32 38 39 40 41 44
Track frame.................................................................................................................................................. 60 Idler cushion................................................................................................................................ 60 Idler .............................................................................................................................................................. 60 Track roller ................................................................................................................................................... 60 Carrier roller ................................................................................................................................................. 60 Track roller bogie ......................................................................................................................................... 60 Track shoe ................................................................................................................................................... 60 Main frame ................................................................................................................................................... 60 Suspension .................................................................................................................................................. 60 -
46 48 50 52 54 55 56 60 62
Undercarriage and frame
Hydraulic system PPC valve .................................................................................................................................................... Hydraulic cylinder......................................................................................................................................... Quick drop valve .......................................................................................................................................... Work equipment pump................................................................................................................................. Control valve ................................................................................................................................................ Self-pressure reducing valve .......................................................................................................................
60 60 60 60 60 60 -
67 72 75 76 79 85
60 60 60 60 -
87 88 92 94
Work equipment Cylinder stay ................................................................................................................................................ Blade............................................................................................................................................................ Cutting edge and end bit.............................................................................................................................. Ripper ..........................................................................................................................................................
60-2
D375A-6
Engine and cooling system Engine mount
Engine and cooling system
60-3
Engine mount
60-3
Unit: mm
No.
Item
1
Clearance between bracket and cushion
2
Clearance between bracket and bushing
3 Free height of mount rubber
D375A-6 (08)
Criteria Standard size
Tolerance Shaft Hole + 0.018 + 0.078 70 - 0.012 + 0.032 0 + 0.1 180 - 0.25 0 Standard size 102
Remedy Standard clearance 0.014 – 0.090
Clearance limit
0 – 0.35
0.75
0.2 Replace
Repair limit 100
60-3
DRAFT Engine and cooling system Engine mount
60-4
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Cooling fan pump Type: LPV90 + 30
General view
D375A-6
60-5
DRAFT Engine and cooling system Cooling fan pump
LPV90 hydraulic pump General view
60-6
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Sectional view
D375A-6
60-7
DRAFT Engine and cooling system Cooling fan pump
LPV30 hydraulic pump General view
60-8
D375A-6
DRAFT Engine and cooling system Cooling fan pump
Sectional view
D375A-6
60-9
DRAFT Engine and cooling system Cooling fan pump
Servo valve
60-10
D375A-6
DRAFT Engine and cooling system Cooling fan pump
D375A-6
60-11
DRAFT Engine and cooling system Cooling fan motor
Cooling fan motor Type: LMF180 (150) General view
60-12
D375A-6
DRAFT Engine and cooling system Cooling fan motor
Sectional view
Unit: mm No.
Check item
Criteria
Remedy
Standard size
1
Spool return spring
Free length × Installed length outside diameter 83.8 × 19
D375A-6
67.5
Repair limit Installed load
Free length
Installed load
172 N {17.5}
-
137 N {14}
Replace spring if damaged or deformed.
60-13
Power train Power train unit
Power train
60-14
Power train unit
60-14
60-14
D375A-6 (04)
Power train Power train unit
D375A-6 (04)
60-15
DRAFT Power train Damper and universal joint
Damper and universal joint
60-16
D375A-6
DRAFT Power train Damper and universal joint
Unit: mm No.
1
Item
Clearance between flywheel housing and cover
2
Clearance between flywheel and damper
3
Outside diameter of oil seal contact surface of coupling
Criteria Tolerance
Standard size
Remedy Standard clearance
Clearance limit
Shaft
Hole
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
Tolerance
Repair limit
110
0 - 0.035
109.9
4
Outside diameter of oil seal contact surface of output shaft
110
0 - 0.035
109.9
5
Dimension between bearing and holder
53
± 0.1
52.7
D375A-6
Replace
60-17
DRAFT Power train Damper and universal joint
60-18
D375A-6
DRAFT Power train Torque converter and PTO
Torque converter and PTO
D375A-6
60-19
DRAFT Power train Torque converter and PTO
60-20
D375A-6
DRAFT Power train Torque converter and PTO
Unit:mm No.
Item
Criteria
Remedy
Standard size
Tolerance
Repair limit
125
0 - 0.063
124.8
2
Inner diameter of seal ring contact surface of retainer
190
+ 0.046 0
190.5
3
Inside diameter of seal ring contact surface of sleeve
110
+ 0.035 0
110.2
4
Backlash between PTO drive gear and scavenging pump gear
0.25 – 0.42
5
Backlash between PTO drive gear and idler gear
0.204 – 0.516
1
6
Outside diameter of coupling oil seal contact surface
Thickness of lockup clutch disc
5.4
± 0.1
4.9
Thickness of lockup clutch plate
5.0
± 0.1
4.5
Total thickness of lockup clutch assembly
15.8
± 0.17
14.3
Thickness of stator clutch disc
5.4
± 0.1
4.9
Thickness of stator clutch plate
5.0
± 0.05
4.5
Total thickness of stator clutch assembly
15.8
± 0.15
14.7
Apply hard chrome plating or replace
Replace
7
Standard size
8
Stator clutch return spring
Free length Installed length Installation load Free length Installation load 54.1
D375A-6
Repair limit
37.0
125.5 N {12.8 kg}
50.9
106.9 N {10.9 kg}
60-21
DRAFT Power train Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve
Unit: mm No.
Item
Criteria Tolerance
1
2
Clearance between main relief valve and valve body Clearance between torque converter relief valve and valve body
Remedy Standard clearance
Clearance limit
+ 0.016 0
0.035 – 0.061
0.08
+ 0.016 0
0.035 – 0.061
0.08
Standard size Shaft
Hole
40
- 0.035 - 0.045
40
- 0.035 - 0.045
Replace
Standard size
3
4
Main relief valve spring
Torque converter relief valve spring
60-22
Free length
Repair limit
Installed length Installation load
120.3
102
1,419 N {144.7 kg}
116.92
86.3
645.1 N {65.83 kg}
Free length
Installation load
116.7
1,348 N {137.5 kg}
113.4
613 N {62.5 kg}
D375A-6
DRAFT Power train Lockup clutch ECMV and stator clutch ECMV
Lockup clutch ECMV and stator clutch ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D375A-6
60-23
DRAFT Power train Scavenging pump
Scavenging pump
No. 1
Item
Criteria -
Spline shaft rotating torque
Type
-
Delivery Oil: TO10 Oil temperature: (45 - 50 °C)
Rotating speed (rpm)
Discharge pressure MPa {kg/cm2}
BAR 63 1,743 BAR 277
60-24
Remedy
Standard delivery (l/min)
Acceptable delivery (l/min)
63.3
-
276.8
-
0.15 {1.5}
-
D375A-6
DRAFT Power train Transmission control
Transmission control PCCS Lever a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage output and operating efforts.
D375A-6
60-25
DRAFT Power train Transmission
Transmission
60-26
D375A-6
DRAFT Power train Transmission
D375A-6
60-27
DRAFT Power train Transmission
60-28
D375A-6
DRAFT Power train Transmission
No.
Item Standard size
1
R clutch spring (12 pcs)
2
F clutch spring (12 pcs)
3
3rd and 2nd clutch spring (12 pcs)
4
1st clutch spring (3 pcs)
5 6 7 8 9
Total thickness of R clutch consisting of 6 discs and 6 plates Total thickness of F clutch consisting of 6 discs and 5 plates Total thickness of 3rd clutch consisting of 4 discs and 4 plates Total thickness of 2nd clutch consisting of 3 discs and 3 plates Total thickness of 1st clutch consisting of 6 discs and 5 plates
10 Thickness of clutch disc 11 Thickness of clutch plate
12
13
Wear of transmission input shaft seal ring Wear of front cover and R clutch carrier seal ring
Wear of F clutch and 3rd clutch 14 carrier seal ring (small)
15
Wear of F clutch and 3rd clutch carrier seal ring (large)
R, F, 3rd, 2nd 1st R, F, 3rd, 2nd 1st
50.3
± 0.33
47.1
36.4
± 0.28
34.3
27.3
± 0.24
25.7
50.0
± 0.33
46.8
4.8
± 0.1
4.3
5.0
± 0.1
4.5
4.3
± 0.1
3.9
4.0
± 0.1 - 0.01 - 0.03
3.6
Width
3.0
Thickness
3.5
± 0.1
3.35
Width
4.0
- 0.01 - 0.04
3.6
Thickness
4.0
± 0.15
3.85
Width
4.0
- 0.01 - 0.03
3.6
Thickness
5.0
± 0.15
4.85
Width
4.0
- 0.01 - 0.04
3.6
Thickness
4.0
± 0.15
3.85
Width
4.0
- 0.01 - 0.04
3.6
Thickness
5.0
± 0.15
4.85
Width
4.0
- 0.01 - 0.03
3.6
Thickness
5.1
± 0.12
4.95
Width
4.5
- 0.01 - 0.03
4.1
Thickness
6.0
± 0.15
5.85
Width
4.5
- 0.01 - 0.03
4.1
Thickness
5.8
± 0.15
5.65
Width
5.0
- 0.01 - 0.03
4.5
Thickness
6.0
± 0.15
5.85
17 Wear of 1st clutch gear seal ring
18 Wear of 1st clutch gear seal ring
20
Wear of transmission output shaft seal ring Wear of 1st clutch piston housing seal ring
Backlash between R and F clutch sun gear and planetary pinion Backlash between R clutch planetary pinion 22 and ring gear teeth Backlash between F, 3rd and 2nd clutch 23 planetary pinion and ring gear teeth Backlash between 3rd and 2nd clutch plane24 tary pinion and ring gear
21
D375A-6
Repair limit
Free length Installed length Installed load Free length Installed load 126 N 107 N 66.0 57.0 62.0 {12.8 kg} {10.9 kg} 219 N 186 N 70.0 60.3 65.8 {22.3kg} {19.0 kg} 149 N 127 N 97.0 82.4 91.2 {15.2 kg} {12.9 kg} 2,910 N 3,420 N 7.75 6.75 {297 kg} {349 kg} Standard size Tolerance Repair limit 54.6 ± 0.35 51.4
16 Wear of 1st clutch collar seal ring
19
Unit: mm Remedy
Criteria
2.7
Replace
0.13 – 0.40 0.13 – 0.40 0.14 – 0.40 0.13 – 0.37
60-29
DRAFT Power train Transmission lubricating oil relief valve
Transmission lubricating oil relief valve
60-30
D375A-6
DRAFT Power train Power train and lubrication pump
Power train and lubrication pump BAL 180 + 112
Unit: mm No.
1
2
Item
Side clearance
Clearance between plain bearing inside diameter and gear shaft outside diameter
Criteria Type
Standard clearance
Clearance limit
BAL180
0.07 – 0.12
0.15
BAL112
0.04 – 0.10
0.13
0.060 – 0.145
0.20
BAL180 BAL112 Type
3
Pin driving depth
Remedy
Standard size
Tolerance
Repair limit
14
0 - 0.5
-
Replace
BAL180 BAL112
4
Spline shaft rotating torque
Delivery
-
(Oil: E010-CD Oil temperature: 45 – 50 °C) (Engine speed at 1900 rpm)
D375A-6
5.9 Nm {0.6 kgm} or less
Type
Rotating speed (rpm)
Discharge pressure MPa {kg/cm2}
Standard delivery (l/min)
Acceptable delivery (l/min)
BAL180
2,033
2.5 – 2.7 {26 – 28}
334
308
BAL112
2,033
0.26 {2.7}
210
200
60-31
DRAFT Power train Transfer, bevel gear shaft and steering unit
Transfer, bevel gear shaft and steering unit Machines without VHMS controller
60-32
D375A-6
DRAFT Power train Transfer, bevel gear shaft and steering unit
Unit: mm No.
Item
Criteria Standard clearance
1
Clearance limit
3
Adjust or replace
Backlash between transfer gears 0.24 - 0.63
2
Remedy
Thickness of collar between transfer gear and bearing Standard shim thickness for bearing cage mount
D375A-6
0.75
Standard size
Tolerance
Repair limit
24
± 0.1
23.6
Replace
2.0
Adjust shim
60-33
DRAFT Power train Transfer, bevel gear shaft and steering unit
Machines equipped with VHMS controller
60-34
D375A-6
DRAFT Power train Transfer, bevel gear shaft and steering unit
Unit: mm No.
Item
Criteria Standard clearance
1
Clearance limit
3
Adjust or replace
Backlash between transfer gears 0.24 - 0.63
2
Remedy
Thickness of collar between transfer gear and bearing Standard shim thickness for bearing cage mount
D375A-6
0.75
Standard size
Tolerance
Repair limit
24
± 0.1
23.6
Replace
2.0
Adjust shim
60-35
DRAFT Power train Transfer, bevel gear shaft and steering unit
Bevel gear shaft, steering clutch, and steering brake
60-36
D375A-6
DRAFT Power train Transfer, bevel gear shaft and steering unit
Unit: mm No.
1
Item
Plate for steering brake and clutch
Disc for steer-
Criteria
Remedy
Standard size
Tolerance
Repair limit
Thickness
2.9
± 0.1
2.6
Strain
-
Max. 0.3
0.4
Repair or replace
Thickness
4.7
± 0.1
4.2
Replace
Strain
-
Max. 0.3
0.4
Repair or replace
Replace
2 ing brake and clutch
3
Total thickness of brake plate and disc assembly
68.4
± 0.42
65.4
4
Total thickness of clutch plate and disc assembly
68.4
± 0.42
65.4
Backlash between brake
Standard clearance
Repair limit
0.17 - 0.52
1.0
0.3 - 0.4
0.75
Replace
5 or clutch disc and brake hub
6
Backlash between bevel gear and pinion
Tolerance
Standard clearance
Clearance limit
+ 0.081 0
0.5 - 0.781
–
+ 0.072 0
0.100 - 0.244
–
Standard size
7
Inside diameter of seal ring contact surface of cage
Shaft
Hole
290
- 0.5 - 0.7
245
- 0.100 - 0.172
Inside diameter of piston
8 seal ring contact surface of piston
Standard size
9 Brake spring
10 Clutch spring
Adjust or replace
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
17.1
11.2
38.7 kN {3,950 kg}
16.6
36.8 kN {3,750 kg}
17.55
11.6
37.9 kN {3,860 kg}
17.0
36.0 kN {3,670 kg}
Standard interference
Interference limit
- 0.026 - 0.019
0.019 or less
Tolerance Standard size Interference between 11 bevel gear and reamer bolt 16
Shaft
Hole
+ 0.019 + 0.001
+ 0.027 0
12
Runout of back face of bevel gear
13
Preload of bevel gear shaft Standard rotating torque: 4.9 – 5.9 Nm {0.5 – 0.6 kgm} taper roller bearing (At tip of bevel gear teeth not meshed with bevel pinion: 23.5 – 28.4 N {2.4 – 2.9 kg})
14
Standard shim thickness of bearing cage
D375A-6
Repair limit: 0.05 (measure after installing to bevel gear shaft)
2.0
Replace
Repair or replace Adjust Adjust shim
60-37
DRAFT Power train Steering control valve
Steering control valve
60-38
D375A-6
DRAFT Power train Steering clutch ECMV and steering brake ECMV
Steering clutch ECMV and steering brake ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D375A-6
60-39
DRAFT Power train Parking brake valve
Parking brake valve
Unit: mm
No.
Item
Criteria Tolerance Shaft
Hole
Standard clearance
- 0.020 - 0.030
+ 0.011 0
0.020 – 0.041
Standard size
1
Clearance between parking brake valve spool and valve body 14
2
Outside diameter of dust seal and Standard size U-packing contact surface of park14 ing brake valve spool
Parking brake valve spool spring
Free length 65
60-40
Replace 0.05
Repair limit
- 0.020 - 0.030
13.9
Repair hard chrome plating or replace
Repair limit
Installed length Installed load 47.7
Clearance limit
Tolerance
Standard size
3
Remedy
38.2 N {3.9 kg}
Free length Installed load 63.1
Replace
36.4 N {3.71 kg}
D375A-6
DRAFT Power train Final drive
Final drive
D375A-6
60-41
DRAFT Power train Final drive
60-42
D375A-6
DRAFT Power train Final drive
Unit: mm
No.
Item
1
Backlash between No.1 pinion and No.1 gear
Criteria
Remedy
Standard clearance
Clearance limit
0.25 - 0.99
1.5
2
Backlash betwee sun gear and planetary pinion
0.22 - 0.81
1.5
3
Backlash between planetary pinion and ring gear
0.25 - 0.81
1.5
Standard size
Repair limit
4
Outside diameter of oil seal contact surface of No.1 pinion
115.0
114.9 Replace
5
Thickness of thrust collar of inner body roller bearing
25.14
24.9
6
Thickness of thrust coller of No.1 gear boss roller bearing
10.0
9.5
7
Dimensions from cover mounting face to button head
24.0
22.5
8
Clearance between pinion shaft and carrie
85
9 10
Tolerance
Standard size
Shaft
Hole
Standard clearance
Clearance limit
- 0.036 - 0.058
- 0.024 - 0.059
- 0.023 - 0.034
0.1
Standard shim thickness for No.1 pinion bearing cage
2
Dimension of end face of final drive cover and end face of bearing
Adjust
7 (0/-0.2)
11 Clearance of floating seal guard
4.1 - 5.3 Standard size
Repair limit
47
18
12 Wear of wear guard
D375A-6
Rebuild or replace
60-43
DRAFT Power train Sprocket
Sprocket
Unit: mm
No.
1
2
Item
Criteria
Remedy
Standard size
Repair limit
433
417
28.7
22.7
Wear of tooth tip
Thickness of tooth root
60-44
Replace or rebuild by build up welding
D375A-6
DRAFT Power train Sprocket
Full-scale drawing of sprocket tooth profile
D375A-6
60-45
DRAFT Undercarriage and frame Track frame
Undercarriage and frame Track frame
60-46
D375A-6
DRAFT Undercarriage and frame Track frame
Unit: mm
No.
1
2
Item
Criteria
Remedy
Item
Repair limit
Bend
7 (per length 3,000)
Torsion
3 (per level length 300)
Dents (pipe portion)
12
Deformation of track frame outer casing
Clearance between inner casing and stopper protruding portion
3
Clearance between track frame and stopper
4
Press-fitting force for cartridge pin
D375A-6
Standard size
Tolerance
Repair or replace
Standard clearance
Clearance limit
+ 0.3 0
0.15 - 0.65
3.0
+ 0.063 0
0.043 0.163
1.0
Shaft
Hole
60
- 0.15 - 0.35
161
- 0.043 - 0.106
245 – 441 kN {25 – 45 ton}
-
60-47
DRAFT Undercarriage and frame Idler cushion
Idler cushion
60-48
D375A-6
DRAFT Undercarriage and frame Idler cushion
Unit: mm
No.
Item
Criteria
Remedy
Standard size
1
Recoil spring
Free length Installed length Installed load 1,461
2
Clearance between outer diameter of outer sleeve bushing and inner diameter of outer sleeve
Repair limit
Standard size
1,230.5
499.7 kN {50,994 kg}
Tolerance
Free length
Installed load
1,440
458.5 kN {46,790 kg}
Standard clearance
Clearance limit
Outer bushing
Outer sleeve
380
- 0.058 - 0.228
+ 0.317 + 0.060
0.118 – 0.545
0.8
135
- 1.000 - 1.300
+ 0.063 0
1.000 – 1.363
–
3
Clearance between adjustment cylinder and bushing
4
Press-fitting force for inserting outer sleeve bushing into outer sleeve
49.0 – 109.8 kN {5.0 – 11.2 ton}
5
Press-fitting force for installing outer sleeve bushing to spring cylinder
91.2 – 322.6 kN {9.3 – 32.9 ton}
6
Clearance between recoil spring mounting nut and lock plate
7
Press-fitting force for cartridge pin
8
Clearance between bogie and idler cap
9
Clearance between bogie and roller cap
D375A-6
Replace
Adjust
0 – 1.0 245 – 441 kN {25 – 45 ton}
–
Standard clearance
Clearance limit
0.266 – 0.940
0.05
0.42 – 1.4
0.05
Replace
60-49
DRAFT Undercarriage and frame Idler
Idler
60-50
D375A-6
DRAFT Undercarriage and frame Idler
Unit: mm
No.
Item
Criteria Standard size
Repair limit
1
Outside diameter of protuding portion
927
-
2
Outside diameter of tread
880
855
3
Depth of tread
23.5
36
4
Thickness of tread
32.5
20
5
Total width
294
-
6
Overall with of tread
79.0
87.5 Tolerance
Standard size
7
Clearance between shaft and bushing 155
8
Shaft
Hole
- 0.350 - 0.413
+ 0.198 - 0.053
Rebuild by build-up welding or replace
Standard clearance
Clearance limit Replace bushing
0.297 - 0.611
-
Standard size
Repair limit
252
-
Rebuild by build-up welding or replace
Collar width of shaft
Tolerance Standard size
9
Remedy
Interference between shaft and ring 95
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
Adjust or replace
Standard size
Tolerance
Repair limit
95
- 0.410 - 0.484
- 0.5
11 Outside diameter of shaft
D375A-6
Replace
60-51
DRAFT Undercarriage and frame Track roller
Track roller
2nd – 7th track roller (double flanged roller)
q
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
310
-
Outer diameter of flange (inside flange)
300
-
3
Outside diameter of tread
270
210
4
Thickness of tread
60
30
5
Overall width
358
-
6
Width of tread
82
-
7
Width of flange (outside flange)
29
14
8
Width of flange (inside flange)
27
12
9
Collar width of shaft
306
-
1
Outer diameter of flange (outside flange)
2
Clearance between shaft and 10 bushing
Standard size 140
Interference between shaft and 11 seal ring
Standard size 75
60-52
Shaft
Hole
Standard clearance
Clearance limit
- 0.350 - 0.413
+ 0.260 + 0.010
0.360 – 0.673
-
Tolerance Shaft
Hole
+ 0.046 +0
- 0.13 - 0.18
Standard Interference interference limit 0.130 – 0.226
Replace bushing
Replace
-
Standard clearance
Clearance limit
0.44 - 0.91
-
12 End play
13 Outside diameter of shaft
Tolerance
Rebuild by build-up welding or replace
Adjust or replace
Standard size
Tolerance
Repair limit
74.5
0 - 0.12
- 0.2
Replace
D375A-6
Undercarriage and frame Track roller
1st and 8th track roller (single flanged roller)
q
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
314
–
2 Outside diameter of tread
280
205
3 Thickness of tread
65
27.5
4 Overall width
358
–
5 Width of tread
82
–
6 Width of flange
29
14
7 Collar width of shaft
306
–
1 Outside diameter of flange
8
Clearance between shaft and bushing
9 Interference between shaft and ring
10 End play
D375A-6 (04)
Tolerance Shaft Hole -0.350 +0.260 140 -0.413 +0.010 Tolerance Standard size Shaft Hole +0.046 -0.13 75 0 -0.18 Standard clearance Standard size
0.44 – 0.91
Rebuild by build-up welding or replace
Standard clearance
Clearance limit
0.350 – 0.673
–
Standard Interference interference limit 0.130 – 0.226 Clearance limit –
Replace bushing
Replace
– Adjust or replace
60-53
DRAFT Undercarriage and frame Carrier roller
Carrier roller
Unit: mm
No.
1
Item
Criteria
Remedy
Standard size
Repair limit
242
-
Outside diameter of flange
2
Outside diameter of tread
210
185
3
Width of tread
79
-
4
Thickness of tread
40
27.5
5
Width of flange
23
12
6
Standard size Interference between shaft and ring 90
7
Clearance between shaft and support
Standard size 86
8
Rebuild by build-up welding or replace
Tolerance Standard interference Shaft
Hole
+ 0.245 + 0.185
+ 0.035 0
0.150 - 245
Tolerance Standard clearance Shaft
Hole
0 - 0.2
+ 0.350 0
Replace
0 - 0.550
Standard clearance
Clearance limit
0 - 0.22
-
Axial play of roller
60-54
D375A-6
Undercarriage and frame Track roller bogie
Track roller bogie
60-5
Unit: mm
No.
Item
1 Press-fitting force for cartridge pin Clearance between bogie and cap
2 (average of front and rear clearances)
D375A-6 (04)
Criteria
Remedy
245–441 kN {25–45 ton}
–
Standard clearance
Clearance limit
0.42–1.4
0.05
Replace
60-55
DRAFT Undercarriage and frame Track shoe
Track shoe
a Portion P shows the link on the side where the bushing is pressed fitted.
60-56
D375A-6
DRAFT Undercarriage and frame Track shoe
Unit: mm
No.
1
Item
Criteria
Remedy
Standard size
Repair limit
280.3
283.3
Link pitch
Reverse Standard size
2
3
4
5
6
Light load
Heavy load
98.5
90
92.5
18.8
10.3
12.8
Outside diameter of bushing
Thickness of bushing
Standard size
Repair limit
181
163
56
38
Height of link
Thickness of link (bushing press-fitting portion) One side
Both side
1.4
2.8
Clearance between links
Tolerance
8
Interference between bushing and link
Interference between regular pin and link
Rebuild by build-up welding or replace
-
Standard interference
Standard size
7
Turn 180° or replace
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 (Degree)
1,372 ± 137 {140 ± 14}
120 ± 10
686.4 ± 68.6 {70 ± 7}
180 ± 10
Adjust or replace
a. Regular link
9
Shoe bolt b. Master link
D375A-6
Retighten
60-57
DRAFT Undercarriage and frame Track shoe
Single grouser shoe
Unit: mm
No.
1
2
Item
Criteria
Remedy
Standard size
Repair limit
93
30
116
53
Height of grouser
Overall height of shoe
60-58
Repair by lug welding or replace
D375A-6
DRAFT Undercarriage and frame Track shoe
D375A-6
60-59
DRAFT Undercarriage and frame Main frame
Main frame
60-60
D375A-6
DRAFT Undercarriage and frame Main frame
Unit: mm
No.
1
Item
Interference between steering case and bushing
Criteria
275
2
Clearance between steering case and final drive cage
Tolerance
Standard size
Shaft
Hole
+ 0.108 + 0.056
+ 0.052 0
Tolerance
Standard size
Remedy Standard Interference interference limit 0.004 0.108
Min. 0 Clearance limit
Shaft
Hole
Standard clearance
332
- 0.018 - 0.075
+ 0.057 0
0.018 0.132
0.2
3
Clearance between bracket and cushion
70
+ 0.018 - 0.012
+ 0.046 0
- 0.018 0.058
0.1
4
Clearance between ripper beam mounting pin and bushing
120
- 0.036 - 0.090
+ 0.166 + 0.028
0.064 0.256
1.5
5
Clearance between ripper cylinder mounting pin and bushing
100
- 0.036 - 0.090
+ 0.287 + 0.200
0.236 0.377
1.5
6
Clearance between radiator guard mounting pin and bushing
80
- 0.030 - 0.076
+ 0.371 + 0.269
0.299 0.477
1.5
7
Clearance between radiator guard mounting pin and bushing
90
- 0.036 - 0.090
+ 0.369 + 0.267
0.303 0.459
1.0
8
Clearance between equalizer bar shaft and bushing
120
- 0.036 - 0.090
+ 0.243 + 0.101
0.137 0.333
1.0
9
Protrusion of rubber on seal end face
Standard size
Repair limit
1
0.5
10
Free height of front cab mount rubber
105
103
11
Free height of rear cab mount rubber
58
56
12
Press-fitting force for ripper beam mounting bushing
44.1 – 117.6 kN {4.5 – 12 ton}
13
Press-fitting force for ripper cylinder mounting bushing
58.8 – 171.6 kN {6 – 17.5 ton}
14
Press-fitting force for radiator guard mounting bushing
98.0 – 181.4 kN {10 – 18.5 ton}
15
Press-fitting force for radiator guard mounting bushing
58.8 – 137.3 kN {6 – 14 ton}
16
Press-fitting force for equalizer bar shaft mounting bushing
31.4 – 105.9 kN {3.2 – 10.8 ton}
D375A-6
Replace
Adjust
60-61
DRAFT Undercarriage and frame Suspension
Suspension
60-62
D375A-6
DRAFT Undercarriage and frame Suspension
Unit: mm
No.
1
2
3
Item
Clearance between center pin and bushing
Clearance between side pin and bushing
Interference between side pin boss and bushing
Criteria Standard size
Tolerance
Remedy
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
Tolerance Shaft
Hole
+ 0.045 + 0.027
- 0.028 - 0.068
Clearance limit
Replace bushing
Standard Interference interference limit 0.055 0.113
4
Press-fitting force for center pin bushing
49.0 – 186.3 kN {5 – 19 ton}
5
Press-fitting force for side pin bushing
34.3 – 73.5 kN {3.5 – 7.5 ton}
-
-
D375A-6
60-63
DRAFT Undercarriage and frame Suspension
*1 *2
. Indicates the left suspension of single tilt specification machine. . Indicates the right suspension of single tilt specification machine. Indicates the left and right suspension of dual tilt specification machine.
60-64
D375A-6
DRAFT Undercarriage and frame Suspension
Unit: mm No.
Item
Criteria Tolerance Standard size
Interference between thrust washer and seal
Remedy Standard Interference interference limit
Shaft
Hole
230
+ 0.213 + 0.098
- 0.180 - 0.226
0.278 0.439
-
7
Interference between thrust washer and seal
165
+ 0.140 + 0.100
- 0.061 - 0.124
0.161 0.264
-
8
Interference between pivot shaft and seal
213
+ 0.096 + 0.050
- 0.115 - 0.187
0.165 0.283
-
6
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
Standard size
9
10
Clearance between pivot shaft and bushing
Clearance between pivot shaft and bushing
D375A-6
Replace
Replace bushing
60-65
DRAFT Undercarriage and frame Suspension
60-66
D375A-6
DRAFT Hydraulic system PPC valve
Hydraulic system PPC valve Blade PPC valve General view
D375A-6
60-67
DRAFT Hydraulic system PPC valve
Sectional view
60-68
D375A-6
DRAFT Hydraulic system PPC valve
Ripper PPC valve General view
D375A-6
60-69
DRAFT Hydraulic system PPC valve
Sectional view
60-70
D375A-6
DRAFT Hydraulic system PPC valve
Unit: mm
No.
Item
Criteria
Remedy
Standard size
1
Centering spring (for ports P3 and P4)
Free length x Installed length Outside diameter
Repair limit Installed load
Free length
Installed load
50.35 × 15.5
34
55.9 N {5.7 kg}
-
44.7 N {4.56 kg}
2
Centering spring (for ports P1 and P2)
50.05 × 15.5
34
71.4 N {7.28 kg}
-
57.1 N {5.82 kg}
3
Metering spring
26.53 × 8.15
24.9
16.7 N {1.7 kg}
-
13.3 N {1.36 kg}
D375A-6
If damaged or deformed, replace spring
60-71
Hydraulic system Hydraulic cylinder
Hydraulic cylinder
60-72
Blade lift cylinder
Blade tilt cylinder (for single tilt)
Pin puller cylinder
Blade tilt cylinder (for dual tilt)
60-72
D375A-6 (04)
Hydraulic system Hydraulic cylinder
Unit: mm
NO
Item
Criteria Standard size Blade lift
1
90
0.096 – 0.364
–
Pin puller
30
- 0.065 - 0.117
+ 0.133 + 0.007
0.072 – 0.250
0.55
Blade tilt (Dual tilt )
110
- 0.036 - 0.090
+ 0.261 + 0.047
0.083 – 0.351
–
Blade lift
65
- 0.3 - 0.5
+ 0.5 + 0.2
0.5 – 1.0
2
105
- 0.120 - 0.207
+ 0.035 0
0.120 – 0.242
0.5
75
- 0.200 - 0.300
+ 0.200 0
0.200 – 0.500
1.0
75
- 0.200 - 0.300
+ 0.200 0
0.200 – 0.500
1.0
75
- 0.200 - 0.300
+ 0.423 + 0.342
0.542 – 0.723
1.0
75
- 0.200 - 0.300
+ 0.423 + 0.342
0.542 – 0.723
1.0
29
- 0.100 - 0.200
+ 1.300 + 1.200
1.3 – 1.5
–
26
- 1.1 - 1.2
± 0.1
1.0 – 1.3
–
and bushing Clearance between cylBlade lift inder support shaft bushing and yoke Clearance between pis- (Single tilt) ton rod supporting shaft and bushing Blade tilt (Dual tilt) Blade tilt
5
Clearance between cyl- (Single tilt) inder bottom support Blade tilt shaft and bushing (Dual tilt)
Clearance between pis-
6 ton rod spherical sur7
Pin puller
face and cap Clearance between cylPin puller inder bottom support shaft and boss
D375A-6 (04)
0.693
+ 0.274 + 0.060
Blade tilt
4
Clearance limit
- 0.036 - 0.090
Clearance between pis-
3
Standard clearance 0.084 – 0.347
110
Clearance between pis- Blade tilt (Single tilt) ton rod and bushing
2 ton rod supporting shaft
Tolerance Shaft Hole - 0.036 + 0.257 - 0.090 + 0.048
Remedy
Replace
60-73
DRAFT Hydraulic system Hydraulic cylinder
q
Ripper lift cylinder
q
Ripper tilt cylinder
Unit: mm
No.
Item
Criteria Standard size
1
2
3
Tolerance
Remedy
Shaft
Hole
Standard clearance
110
- 0.036 - 0.090
+ 0.274 + 0.060
0.096 0.364
0.697
Ripper tilt
110
- 0.036 - 0.090
+ 0.274 + 0.060
0.096 0.364
0.697
Ripper lift
100
- 0.036 - 0.090
+ 0.207 + 0.120
0.156 0.297
1.0
Ripper tilt
100
- 0.036 - 0.090
+ 0.207 + 0.120
0.156 0.297
1.0
Ripper lift Clearance between cylinder bottom support shaft and bushing Ripper tilt
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
Clearance between piston rod and bushing Ripper lift
Clearance between piston rod support shaft and bushing
60-74
Clearance limit
Replace
D375A-6
DRAFT Hydraulic system Quick drop valve
Quick drop valve
Unit: mm
No.
Item
Criteria Tolerance Standard size
1
Clearance between spool and valve body 38.0
Shaft
Hole
- 0.011 - 0.016
+ 0.010 0
Remedy Standard clearClearance limit ance 0.011 - 0.026
0.03 Replace
Standard size
2
Valve spring
D375A-6
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}
60-75
DRAFT Hydraulic system Work equipment pump
Work equipment pump Type: HPV190 General view
60-76
D375A-6
DRAFT Hydraulic system Work equipment pump
Sectional view
D375A-6
60-77
DRAFT Hydraulic system Work equipment pump
60-78
D375A-6
Hydraulic system Control valve
Control valve 6-spool valve for dual tilt Appearance
D375A-6 (04)
60-79 60-79 60-79
60-79
DRAFT Hydraulic system Control valve
Sectional view(1/4)
60-80
D375A-6
DRAFT Hydraulic system Control valve
Unit:mm
No.
Item
Criteria
Remedy
Standard size
1
Steering signal spring (only for blade lift)
Repair limit
Freelength x Outside diameter
Installed length
Installation load
Free length
Installation load
73.9 × 30
68.5
202 N {20.6 kg}
-
162 N {16.5 kg}
2
Steering signal spring (for blade tilt)
51.12 × 31.3
47.8
279 N {28.5 kg}
-
224 N {22.8 kg}
3
Spool return spring (for ripper)
51.7 × 31.3
50
140 N {14.3 kg}
-
112 N {11.4 kg}
4
Steering signal spring (only for blade lift)
54.7 × 36.5
33.5
217 N {22.1 kg}
-
174 N {17.7 kg}
5
Load check valve spring
20.8 × 12.2
13.5
12.7 N {1.3 kg}
-
10.2 N {1.04 kg}
6
Pressure compensation valve spring
108.3 × 29.5
81
562 N {57.3 kg}
-
449 N {45.8 kg}
7
Unload valve spring
86.7 × 30
66
193 N {19.63 kg}
-
154 N {15.7 kg}
D375A-6
If damaged or deformed, replace spring
60-81
DRAFT Hydraulic system Control valve
(2/4)
60-82
D375A-6
DRAFT Hydraulic system Control valve
(3/4)
Unit:mm
No.
Item
Criteria
Remedy Repair limit
Standard size
1
2
Suction valve spring
Check valve spring
D375A-6
Freelength x Outside diameter
Installed length
Installation load
Free length
Installation load
64.9 × 12.5
56
6.37 N {0.65 kg}
-
5.10 N {0.52 kg}
9.4 × 4.6
7.75
0.49 N {0.05 kg}
-
0.39 N {0.04 kg}
If damaged or deformed, replace spring
60-83
DRAFT Hydraulic system Control valve
(4/4)
Unit:mm
No.
Item
Criteria
Remedy Repair limit
Standard size
1
2
Check valve spring
Suction valve spring
60-84
Freelength x Outside diameter
Installed length
Installation load
Free length
Installation load
27.9 × 6.5
22.5
14.7 N {1.5 kg}
_
11.8 N {1.2 kg}
46.8 × 7.5
40.6
5.49 N {0.56 kg}
_
If damaged or deformed, replace spring
4.41 N {0.45 kg}
D375A-6
Hydraulic system Control valve
5-spool valve for single tilt Appearance
D375A-6 (04)
60-84-1 60-84-1
60-84-1
Hydraulic system Control valve
Sectional view (1/4)
60-84-2
60-84-2
D375A-6 (04)
Hydraulic system Control valve
Unit: mm
No.
1
2 3 4 5 6
Item
Criteria
Standard size Free length x OutLoad at Installed length side diameter installed length 202 N 73.9 × 30 68.5 {20.6 kg} Steering signal spring 94.1 N 51.12 × 31.3 50 (for blade tilt) {9.6 kg} Spool return spring (for 140 N 51.7 × 31.3 50 ripper) {14.3 kg} Steering signal spring 217 N 54.7 × 36.5 33.5 (only for blade lift) {22.1 kg} Load check valve 12.7 N 20.8 × 12.2 13.5 spring {1.3 kg} 193 N Unload valve spring 86.7 × 30 66 {19.63 kg} Steering signal spring (only for blade lift)
D375A-6 (04)
Remedy Repair limit Load at Free length installed length 162 N — {16.5 kg} 75.3 N — If damaged or {7.7 kg} deformed, replace 112 N — spring {11.4 kg} 174 N — {17.7 kg} 10.2 N — {1.04 kg} 154 N — {15.7 kg}
60-84-3
Hydraulic system Control valve
(2/4)
60-84-4
60-84-
D375A-6 (04)
Hydraulic system Control valve
60-84-5
(3/4)
Unit: mm
No.
Item
1 Suction valve spring
2 Check valve spring
D375A-6 (04)
Criteria
Remedy
Standard size Repair limit Load at Free length x Load at Installed length Free length If damaged or installed length Outside diameter installed length deformed, replace 5.10 N 6.37 N 64.9 × 12.5 56 — spring {0.52 kg} {0.65 kg} 0.49 N 0.39 N 9.4 × 4.6 7.75 — {0.05 kg} {0.04 kg}
60-84-5
Hydraulic system Control valve
60-84-6
(4/4)
Unit: mm
No.
1
2
Item
Check valve spring
Suction valve spring
60-84-6
Criteria Standard size Free length x OutLoad at installed Installed length side diameter length 14.7 N 27.9 × 6.5 22.5 {1.5 kg} 5.49 N 46.8 × 7.5 40.6 {0.56 kg}
Remedy Repair limit Free length ― ―
Load at installed length 11.8 N {1.2 kg} 4.41 N {0.45 kg}
If damaged or deformed, replace spring
D375A-6 (04)
DRAFT Hydraulic system Self-pressure reducing valve
Self-pressure reducing valve General view
D375A-6
60-85
DRAFT Hydraulic system Self-pressure reducing valve
Sectional view
No.
Item
Criteria
Remedy
Standard size
1
Pressure reducing value main spool spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
70.91 × 18
56
250 N {25.52 kg}
-
200 N {20.4 kg}
2
Pressure reducing valve pilot spring
17.8 × 7.2
12.7
28.0 N {2.86 kg}
-
22.5 N {2.29 kg}
3
Safety valve spring
16.13 × 7.8
13.4
61.8 N {6.3 kg}
-
49.4 N {5.04 kg}
4
Spool return spring
19.15 × 7.2
16.05
19.6 N {2.0 kg}
-
15.7 N {1.6 kg}
60-86
If damaged or deformed, replace spring
D375A-6
DRAFT Work equipment Cylinder stay
Work equipment Cylinder stay
Unit: mm
No.
Item
Criteria Tolerance Shaft
Hole
Standard clearance
Clearance limit
150
- 0.085 - 0.148
+ 0.063 0
0.085 0.211
0.5
2
Clearance between cylinder yoke and bushing
115
- 0.072 - 0.126
+ 0.054 0
0.072 0.180
0.5
3
Clearance between lift cylinder support shaft and bushing
105
- 0.120 - 0.207
+ 0.035 0
0.120 0.242
0.5
1
Clearance between cylinder yoke and bushing
D375A-6
Standard size
Remedy
Replace
60-87
Work equipment Blade
Blade
60-8
Semi-U dozer (The figure shows a single tilt specification machine. The spill guard is optional.)
60-8
60-88
D375A-6 (04)
DRAFT Work equipment Blade
Unit: mm
No.
1
Item
Clearance between brace pin and brace
Criteria Standard size
Tolerance
Remedy Standard clearance
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
Clearance between brace pin and bracket
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 spherical surfaces of center brace and cap
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
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
+ 0.063 0
+ 0.174 + 0.134
0.071 0.174
1
10
Clearance between spherical surfaces of trunnion and cap
200
- 0.5 - 1.0
+ 0.5 0
0.5 - 1.5
8
11
Clearance between joint and bracket
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 surfaceand cap
170
- 0.2 - 0.3
+ 0.3 0
0.2 - 0.6
1
18
Clearance between lift cylinder head pin and cylinder
65
- 0.3 - 0.5
+ 0.5 + 0.2
0.5 - 1.0
2
19
Clearance between lift cylinder head pin and cross joint
65
- 0.3 - 0.5
+ 0.3 0
0.3 - 0.8
2
20
Clearance between bracket and side pin
65
- 0.3 - 0.5
+ 0.3 0
0.3 - 0.8
2
21
Clearance between cross joint and side pin
65
- 0.3 - 0.5
+ 0.5 + 0.2
0.5 - 1.0
2
Replace
Adjust shims or replace
Replace
Adjust shims or replace
Replace
D375A-6
60-89
Work equipment Blade
Full-U dozer (The figure shows a dual tilt specification machine)
60-90
60-90
D375A-6 (04)
DRAFT Work equipment Blade
Unit: mm
No.
1
Item
Clearance between brace pin and brace
Criteria Standard size
Tolerance
Remedy Standard clearance
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
Clearance between brace pin and bracket
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 spherical surfaces of center brace and cap
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
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
+ 0.063 0
+ 0.174 + 0.134
0.071 0.174
1
10
Clearance between spherical surfaces of trunnion and cap
200
- 0.5 - 1.0
+ 0.5 0
0.5 - 1.5
8
11
Clearance between joint and bracket
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
18
Clearance between lift cylinder head pin and cylinder
65
- 0.3 - 0.5
+ 0.5 + 0.2
0.5 - 1.0
2
19
Clearance between lift cylinder head pin and cross joint
65
- 0.3 - 0.5
+ 0.3 0
0.3 - 0.8
2
20
Clearance between bracket and side pin
65
- 0.3 - 0.5
+ 0.3 0
0.3 - 0.8
2
21
Clearance between cross joint and side pin
65
- 0.3 - 0.5
+ 0.5 + 0.2
0.5 - 1.0
2
Replace
Adjust shims or replace
Replace
Adjust shims or replace
Replace
D375A-6
60-91
DRAFT Work equipment Cutting edge and end bit
Cutting edge and end bit (Standard)
Unit: mm No.
1
Item
Criteria
Remedy
Standard size
Repair limit
495
340
Height of end bit, outside Replace
2
Width of end bit
740
600
3
Height of end bit, inside
395
335
4
Height of cutting edge
406
335 (264 after reversed)
60-92
Reverse or replace
D375A-6
DRAFT Work equipment Cutting edge and end bit
(If equipped)
Unit: mm No.
1
Item
Criteria
Remedy
Standard size
Repair limit
478
380
Height of end bit, outside Replace
2
Width of end bit
734
600
3
Height of end bit, inside
393
300
4
Height of cutting edge
406
335 (264 after reversed)
D375A-6
Reverse or replace
60-93
Work equipment Ripper
Ripper
60-94
Variable multi-shank ripper
60-94
60-94
D375A-6 (04)
Work equipment Ripper
Giant ripper
60-95
Unit: mm
No.
1
2 3 4
Item Clearance between bushing and pin for bracket and arm connection Clearance between bushing and pin for beam and arm connection Clearance between cylinder mounting pin and bushing Clearance between shank and mounting pin
5 Wear of point 6 Wear of protector
D375A-6 (04)
Criteria Tolerance Shaft Hole - 0.036 + 0.208 120 - 0.090 + 0.125 - 0.036 + 0.208 120 - 0.090 + 0.125 - 0.036 + 0.207 100 - 0.090 + 0.120 Standard size Tolerance
Standard size
82
Remedy Standard clearance
Clearance limit
0.161 – 1.5 0.298 0.161 – 1.5 0.298 0.156 – 1.5 0.207 Repair limit
± 0.3
Replace
–
Standard size
Repair limit
420
255
155
115
60-95
DRAFT Work equipment Ripper
60-96
D375A-6
DRAFT
D375A-6 SEN07777A-00
BULLDOZER D375A-6 Shop Manual
Machine model D375A-6
Serial number 60001 and up
80 Appendix Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 2 Caution about refrigerant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 3 Air conditioner component- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 4 Configuration and function of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 6 Outline of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 7 Air conditioner unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 10 Blower unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 14 FRESH/RECIRC air changeover damper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 15 Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 16 Condenser- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 17 Receiver drier - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 18 Air conditioner control panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 20
D375A-6 (01)
80-1
DRAFT Contents
Contents 80 Appendix Air Conditioner.................................................................................................................................................. Caution about refrigerant .............................................................................................................................. Air conditioner component ............................................................................................................................ Configuration and function of refrigeration cycle........................................................................................... Outline of refrigeration cycle ......................................................................................................................... Air conditioner unit ........................................................................................................................................ Blower unit .................................................................................................................................................... FRESH/RECIRC air changeover damper ..................................................................................................... Compressor .................................................................................................................................................. Condenser .................................................................................................................................................... Receiver drier................................................................................................................................................ Air conditioner control panel ......................................................................................................................... Procedure for testing and troubleshooting .................................................................................................... Circuit diagram and arrangement of connector pins ..................................................................................... System diagram ............................................................................................................................................ Part and connector locations ........................................................................................................................ Testing temperature control .......................................................................................................................... Testing FRESH/RECIC air changeover ........................................................................................................ Testing relay ................................................................................................................................................. Troubleshooting chart 1 ................................................................................................................................ Troubleshooting chart 2 ................................................................................................................................ Information in troubleshooting table.............................................................................................................. Troubleshooting for power supply system (Air conditioner does not operate) .............................................. Troubleshooting for compressor system (Air is not cooled).......................................................................... Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) .......................... Troubleshooting for temperature control....................................................................................................... Troubleshooting for FRESH/RECIRC air changeover .................................................................................. Troubleshooting with gauge pressure........................................................................................................... Connection of service tool............................................................................................................................. Precautions for disconnecting and connecting ............................................................................................. Handling of compressor oil ...........................................................................................................................
80-2
80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 -
3 3 4 6 7 10 14 15 16 17 18 20 22 24 26 28 32 32 34 36 38 40 42 44 48 54 56 58 60 62 64
D375A-6 (01)
DRAFT Air Conditioner Caution about refrigerant
Air Conditioner Caution about refrigerant k
Collect the air conditioner refrigerant (R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or receiver drier and so on. a Ask a qualified shop for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective goggles, gloves and working suits with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualifier person.
D375A-6 (01)
80-3
DRAFT Air Conditioner Air conditioner component
Air conditioner component
80-4
D375A-6 (01)
DRAFT Air Conditioner Air conditioner component
A: B: C: D: E: F:
Front window glass warm/cool air outlet Overhead warm/cool air outlet Side warm/cool air outlet Front warm/cool air outlet Recirculation air inlet Fresh air inlet
Specifications Refrigerant Refrigerant refill capacity (g)
R134a Approx. 1,100 ± 100
1. Condenser 2. Air conditioner unit 3. Fresh air filter 4. Blower unit 5. Refrigerant piping 6. Receiver drier 7. Compressor 8. Air intake cap 9. Hot water return pipe 10. Hot water supply pipe 11. FRESH/RECIRC air changeover damper 12. Recirculation air filter 13. Air conditioner control panel 14. Sight glass
D375A-6 (01)
80-5
DRAFT Air Conditioner Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle Cycle (Component) Location
Compressor
Condenser
Expansion valve
Evaporator
Engine compartment
Front of radiator
In operator’s cab (In air conditioner unit)
In operator’s cab (In air conditioner unit)
Condenses refrigerant to discharge heat absorbed in evaporator. (condensation of refrigerant)
Lowers temperature and pressure of refrigerant liquid and gas for easy evaporation with throttle. Controls flow rate, too. (Throttle of refrigerant)
Evaporates refrigerant to absorb heat from (or cool) air around evaporator. (Evaporation of refrigerant)
GasoLiquid Constant pressure change
LiquidoLiquid and gas Adiabatic expansion
Liquid and gas oGas Cnstant pressure change
Circulates refrigerant gas and increases its temperature and pressure so that it can be Function liquefied easily in condenser. (Compression of refrigerant) GasoGas State of refrigerAdiabatic compresant sion
80-6
D375A-6 (01)
DRAFT Air Conditioner Outline of refrigeration cycle
Outline of refrigeration cycle The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly liquefying and vaporizing. 1. Compression (Compressor) The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into a state where it can be easily liquefied at the ambient temperature. The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and pressure at which it can be easily liquefied when cooled to the ambient temperature. 2. Condensation (Condenser) The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from the compressor. The heat released to the outside from the condenser is called condensation heat. The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the compressor. The refrigerant liquefied in the condenser is sent to the receiver drier, where moisture is removed. In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist. The temperature (condensation temperature) and the pressure (condensation pressure) at which the gaseous refrigerant is liquefied are proportional to each other. Reference: The pressure varies depending on the condensation temperature of the refrigerant. 3. Expansion (Expansion valve) The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily evaporated by the throttle action (*1). The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it is sent to the evaporator is called expansion. The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate simultaneously. The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure). The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is supplied to the evaporator. D375A-6 (01)
(*1) Throttle action If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the flow will be generated. The liquid expands when it passes through the narrow section and rushes into the passage where the sectional area is larger,and consequently, its pressure and temperature are reduced. Heat is not transferred from or to the outside during the throttle action. 4. Evaporation (Evaporator) The evaporator evaporates the liquid refrigerant (superheated vapor). The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins (air in the cab). After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the temperature inside the cab. The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant in the evaporator The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrigerant is evaporated are proportional to each other. The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
80-7
DRAFT Air Conditioner Outline of refrigeration cycle
Relationship between refrigerant and defective air conditioning q The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat from inside the cab. q If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning. q If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the compressor in liquid form, which will cause the compressor to compress the liquid and may damage the components. q If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the refrigerant flow, and may result in defective air conditioning.
80-8
D375A-6 (01)
DRAFT Air Conditioner Outline of refrigeration cycle
D375A-6 (01)
80-9
DRAFT Air Conditioner Air conditioner unit
Air conditioner unit
80-10
D375A-6 (01)
DRAFT Air Conditioner Air conditioner unit
A: B: C: D:
Refrigerant inlet (From condenser) Refrigerant outlet (To compressor) Hot water inlet Hot water outlet
1: Evaporator 2: Heater core 3: Expansion valve 4: Air mix servomotor 5: Air mix door 6: Blower resistor 7: Evaporator temperature sensor 8: Hot water valve 9: Dual pressure switch 10: Compressor clutch relay 11: Condenser relay (Not used)
Functions of major components Evaporator q Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion valve (3). Air from the blower fan is cooled and dehumidified when passing through the evaporator fins. Heater core Heater core (2) is warmed by the hot water (engine coolant ) being sent from the engine. Air from the blower fan is warmed as it passes through the heater core fins.
q
Air mix servomotor
Outline q The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool down or warm up the air in the cab. Temperature control When the temperature control switch on the air conditioner control panel is operated, the air conditioner control panel controls the air mix servomotor (4) which opens or closes the air mix door (5) and hot water valve (8) to adjust the temperature.
q
Overcooling (freeze) prevention q Evaporator temperature sensor (7) varies its electrical resistance according to temperature. q The air conditioner control panel converts the variation in resistance of the evaporator temperature sensor (7) into voltage and uses the voltage for detecting the evaporator (1) temperature. q The air conditioner control panel activates the compressor clutch relay (10) to stop the compressor and to prevent the evaporator (1) from freezing. Air flow control When the air flow control switch on the air conditioner control panel is operated, the air conditioner control panel controls the blower motor of the blower unit through blower resistor (6) to adjust the air flow.
q
D375A-6 (01)
When the switch on the air conditioner control panel is operated, the motor drive power (24 V) is supplied to servomotor terminal (3) or (5). q The rotation direction of the motor changes according to the terminal that receives the power. q The variable resistor is built into the servomotor, and its resistance changes as the motor rotates. q A voltage of 5V is supplied to the variable resistor from the air conditioner control panel, and the air conditioner control panel detects the motor rotation angle based on the potential difference. q When the air mix door reaches the position specified by the air conditioner control panel, the air conditioner control panel stops current output to the servomotor to stop the air mix door. a Do not supply power directly between terminals (3) and (5) of the servomotor to drive the servomotor for testing purposes. q
80-11
DRAFT Air Conditioner Air conditioner unit
Expansion valve
A: When evaporator outlet temperature is high B: When evaporator outlet temperature is low C: From receiver drier (high-pressure refrigerant) D: To compressor (low-pressure refrigerant) 1. Expansion valve 1a. Needle valve 1a-1. Diaphragm 1a-2. Thermoprobe 1b. Spring 2. Refrigerant gas 3. Evaporator Outline The expansion valve converts high pressure and high-temperature liquid refrigerant from the receiver drier to low-pressure, low-temperature misty refrigerant through the throttling action. q It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in the cab. q The temperature of the air blown out of the air vent is adjusted depending on the volume of refrigerant circulating in the evaporator (3). q
80-12
Structure q Box-shape expansion valve (1) consists of needle valve (1a), spring (1b), etc. q Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of needle valve (1a). q The opening angle of needle valve (1a) is determined based on the balance between the reaction force exerted by spring (1b) in a rightward direction, and force (Fg) of refrigerant gas (2) pushing needle valve (1a) through diaphragm (1a-1) in a leftward direction. q The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the opening angle of needle valve (1a).
D375A-6 (01)
DRAFT Air Conditioner Air conditioner unit
Operation q Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3). q After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2) in the diaphragm chamber (hatched area) through the thermoprobe (1a-2). q The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg) pushing the needle valve (1a). q The opening angle of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) through the diaphragm (1a-1) in a leftward direction. When evaporator (3) outlet temperature is high [Air in the cab is not cooled: condition (A) in the figure] q The refrigerant gas (2) pressure and the volume are increased. q The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve (1a) moves leftward. q As a result, the opening angle of the needle valve (1a) is increased and the refrigerant flow rate to the evaporator (3) is increased to improve cooling capacity. When evaporator (3) outlet temperature is low [Air in the cab is already cooled: condition (B) in the figure] q The refrigerant gas (2) pressure and the volume are decreased. q The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve (1a) is moved rightward by the spring force (1b). q The opening angle of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is reduced to lower the cooling capacity.
D375A-6 (01)
Dual pressure switch q The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or abnormally high. q Turning the dual pressure switch "OFF" causes the compressor clutch relay to turn "OFF". Then the magnetic clutch of the compressor is released in order to protect air conditioner components.
a LA or low: Abnormally low pressure a HA or high: Abnormally high pressure LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2} Evaporator temperature sensor To prevent the evaporator from freezing, the evaporator temperature sensor varies its electrical resistance with the evaporator temperature, and the temperature is monitored via the air conditioner control panel.
q
80-13
DRAFT Air Conditioner Blower unit
Blower unit
1. Blower motor 2. Blower fan 3. FRESH/RECIRC air changeover servomotor
FRESH/RECIRC air changeover servomotor
Outline q The blower unit consists of a blower motor (1), a blower fan (2) and a FRESH/RECIRC air changeover servomotor (3). The blower unit sends air into the cab. q When the FRESH/RECIRC air changeover switch on the air conditioner control panel is operated, the air conditioner control panel supplies a current to the servomotor (3). Functions of major components Blower motor q The blower motor (1) rotates the blower fan (2) to suck air and send it to the evaporator and heater core.
80-14
The FRESH/RECIRC air changeover servomotor (3) receives the drive current from the air conditioner control panel, and opens or closes the FRESH/RECIRC air changeover damper door to switch between the fresh air and recirculated air settings. q When the switch on the air conditioner control panel is operated, the motor drive power (24 V) is supplied to servomotor terminal (3) or (5). q The rotation direction of the motor changes according to the terminal that receives the power. a Do not supply power directly to drive the servomotor for testing purposes. q
D375A-6 (01)
DRAFT Air Conditioner FRESH/RECIRC air changeover damper
FRESH/RECIRC air changeover damper
1. Door open/close lever 2. FRESH/RECIRC air changeover door Outline q The door open/close lever (1) is connected to the FRESH/RECIRC air changeover servomotor of the blower unit with the cable and the FRESH/RECIRC air changeover door (2) is opened or closed by the operation of the FRESH/RECIRC air changeover servomotor.
D375A-6 (01)
80-15
DRAFT Air Conditioner Compressor
Compressor
A: Refrigerant inlet (From air conditioner unit) B: Refrigerant outlet (To condenser) 1. Pulley 2. Magnetic clutch 3. Relief valve
Function q The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated (liquefied) at the normal temperature. q Its built-in magnetic clutch (2) is engaged or disengaged according to the evaporator temperature and refrigerant pressure. q If the clutch is engaged, the power of the engine rotates the compressor shaft to drive the compressor. Specifications Number of cylinder – Bore x Stroke (mm) Piston capacity (cc/rev) Allowable maximum speed (rpm)
80-16
10 - 32 x 20.8 157.3 6,000
Refrigerant oil used
Denso:ND-OIL8 (For R134a)
Compressor oil refill capacity (cc)
180
D375A-6 (01)
DRAFT Air Conditioner Condenser
Condenser
A: Refrigerant inlet (From compressor) B: Refrigerant outlet (To receiver drier) Function q The condenser cools and liquefies the high pressure and high temperature misty refrigerant from the compressor.
Specifications Fin pitch (mm) Height × width × thickness (mm) Max. working pressure (MPa{kg/cm2})
4.0 350 x 570 x 16 3.6 {36}
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction of refrigerant becomes impossible. If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or reducing the cooling effect. Take extreme care not to crush or damage the fins when hangling and performing daily inspection.
D375A-6 (01)
80-17
DRAFT Air Conditioner Receiver drier
Receiver drier Function q The receiver drier temporarily stores the high pressure and high-temperature liquid refrigerant from the condenser so that it can be supplied to the evaporator according to the need of cooling. q It sends the stored refrigerant from its bottom to the evaporator, allowing the refrigerant to be liquefied completely ever when it contains bubbles due to the lowerd heat dissipation of the condenser. q The built-in filter and desiccating agent eliminate foreign substances in the circulation circuit and water content in the refrigerant. Specifications Effective volume (cc) Weight of desiccating agent (g)
370 290
A: Refrigerant inlet (From condenser) B: Refrigerant outlet (To air conditioner unit)
80-18
D375A-6 (01)
DRAFT Air Conditioner Receiver drier
D375A-6 (01)
80-19
DRAFT Air Conditioner Air conditioner control panel
Air conditioner control panel
NO
Model
1 Air conditioner switch
2 RECIRC/FRESH switch
3 Fan switch
4 Temperature control switch
80-20
Function Switch to start and stop cooling, drying or heating function (When the fan switch is turned "ON" and the air conditioner switch is pressed, the indicator lamp above the switch lights up.) Switch to select RECIRC or FRESH air (When the switch is pressed, the indicator lamp above the selected switch lights up.)
Operation OFFioON
RECIRC IO FRESH OFF: Off Switch to adjust fan speed in 4 levels LO: Low (When the switch is pressed, the indicator lamp above the t: Medium 1 selected switch lights up.) tt: Medium 2 HI: High Switch to adjust outlet air temperature in 8 levels Low tempera(The rough outlet air temperature is indicated by the tempera- tureioHigh temperture level indicator lamp above the switch.) ature
D375A-6 (03)
DRAFT Air Conditioner Air conditioner control panel
Outline q The air conditioner control panel has a CPU (Central Processing Unit) that processes the input signals from each sensor and the control signals from each switch, and displays them on the panel and controls the servomotors and relays. Input/Output signal AMP 172021-2-16P Pin No. Signal name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Power supply Blower main relay Blower medium 1 relay Blower medium 2 relay Blower high relay Compressor clutch relay NC (*) NC (*) Evaporator temperature sensor Air mix servomotor potentiometer signal NC (*) NC (*) Sensor GND DIS_SEL0 (GND) NC (*) Air mix servomotor potentiometer power supply
D375A-6 (01)
Input/Output signal Input Output Output Output Output Output Input Input Input Output -
AMP 172245-2-12P Pin No. Signal name 17 18 19 20 21 22 23 24 25 26 27 28
NC (*) NC (*) Air mix servomotor (B) Air mix servomotor (A) FRESH/RECIRC air changeover servomotor (FRESH) FRESH/RECIRC air changeover servomotor (RECIRC) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*)
Input/Output signal Output Output Output Output -
Output
80-21
DRAFT Air Conditioner Procedure for testing and troubleshooting
Procedure for testing and troubleshooting Reference: The air conditioner does not have a self-diagnosis function. 1. After basic check, find the defective part according to the problem that appears on the air conditioner. 2. Narrow down the probable causes by operating the switches on the control panel. However, if the air conditioner unit or control panel does not operate at all, check to see whether power is supplied to the control amplifier normally. If any part of the air conditioner unit or control panel operates, the power supply should be considered normal. 3. After narrowing down the probable causes, perform the relevant testing procedure to determine the defective part to be repaired. Basic flow of testing and troubleshooting
*1. Self-diagnosis function is not installed.
80-22
D375A-6 (03)
DRAFT Air Conditioner Procedure for testing and troubleshooting
*2. Simple check of refrigerant quantity through sight glass. Start the engine first, and then check the refrigerant level 5 minutes after turning the air conditioner switch ON. 1) If bubbles are continually seen, the quantity of refrigerant is insufficient. 2) If bubbles in the refrigerant appear intermittently, the quantity of refrigerant is appropriate. 3) When no bubble can be seen (transparent), the refrigerant is excessive or no refrigerant is in the system. However, there may be exception. In such cases, read the pressure gauge to judge the refrigerant level, referring to "Troubleshooting by gauge pressure". S: View through sight glass R: Refrigerant level in receiver dryer LR: Liquid refrigerant
*3. If the refrigerant is leaking, the compressor oil circulating in the air conditioner circuit is also leaking from the same place. In this case, retighten the pipe fitting by referring to the tightening torque table in "Precautions for connecting air conditioner piping". *4. Start the engine first and turn the air conditioner switch ON to check the noise.
D375A-6 (03)
80-23
DRAFT Air Conditioner Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins
80-24
D375A-6 (01)
DRAFT Air Conditioner Circuit diagram and arrangement of connector pins
Input/output signal of control panel Connector on control panel: AMP 172241-2 (DLI28PM) Connector on wiring harness: AC2: AMP 172021-2(DLI16PF) AC3: AMP 172245-2(DLI12PF) AC2 Pin No. 1 2 3 4 5 6 7 8
Code 24V RL-BM RL-ME1 RL-ME2 RL-HI RL-CC NC NC
9
TH-F
10
S-AM
11 12 13 14 15
NC NC GS GND NC
16
AMP-5V
AC3 Pin No. 17 18 19 20
Code NC NC M-AMB M-AMA
21
M-RFF
22
M-RFR
23 24 25 26 27 28
NC NC NC NC NC NC
q q q q q
Signal name 24V power supply Blower main relay Blower medium 1 relay Blower medium 2 relay Blower HI relay Compressor clutch relay
Evaporator temperature sensor (Thermistor voltage) A/M servo potentiometer voltage
Input/output Input Output Output Output Output Output
Input Input
Sensor GND GND
Output Input
A/M servo potentiometer 5V power supply
Output
Signal name
A/M servo B terminal A/M servo A terminal Fresh air terminal of FRESH/RECIRC air changeover servomotor Recirculated air terminal of FRESH/RECIRC air changeover servomotor
Input/output
Output Output Output
Output
NC: No connection RL-: Relay M-: Servomotor AM: Air mix RF: Recirculation/Fresh (recirculated/fresh air)
D375A-6 (01)
80-25
DRAFT Air Conditioner System diagram
System diagram a This air conditioner has manual temperature control only. (It is not Automatic air conditioner)
80-26
D375A-6 (03)
DRAFT Air Conditioner System diagram
Operation of control panel a The air conditioner does not have a self-diagnosis function. 1. The control panel controls the air conditioner according to each switch inputting. 2. The control panel adjust the temperature (AIR MIX) by controlling the air mix servomotor (A/MS). 3. The control panel switches the air between the recirculated air and fresh air by controlling FRESH/RECIRC air changeover servomotor (R/FS). 4. The control panel turns the blower main relay ON to drive the blower fan. 5. The control panel adjusts the air flow as follows. 1) The control panel turns ON one of the three relays of blower HI, blower Me1 or blower Me2. (If none of the three relays is turned ON, the air flow is set to "LO") 2) The terminal that connects to "ON" relay of the four blower resistor terminals is connected to the GND. 3) The current flowing into the blower motor changes, and consequently the blower fan speed changes to control the air flow. a The blower resistor has an overcurrent protection fuse in it. 6. The control panel senses the evaporator temperature with the evaporator temperature sensor. 7. The control panel controls ON/OFF of the compressor clutch relay to operate the compressor so that the evaporator does not freeze. a If the dual pressure switch detects abnormal pressure, it is turned OFF, then the compressor clutch relay is turned OFF and the compressor stops.
D375A-6 (03)
80-27
DRAFT Air Conditioner Part and connector locations
Part and connector locations The air conditioner unit, blower unit and various relays are in the dashboard. 1. Remove cover (1). a Right figure shows condition with cover (1) removed. q Circuit breaker CB4 (4th from the top) : For power supply for blower motor, air conditioner compressor and air conditioner unit (All equipment related to air conditioner) a If reset button (2) of the circuit breaker comes out, the circuit is cut off (OFF). In this case, push reset button (2) in. After setting starting switch to ON position, if the reset button does not come out but keeps pushed , it is no problem. If the reset button comes out soon after pushing, the electrical circuit may has a ground fault or another abnormality. (See "Troubleshooting for power supply system")
a Condition with cover (4) removed q AC2, AC3: Air conditioner control panel connectors q CP: Air conditioner control panel
4. Remove recirculated air filter cover (5). 5. Remove cover (6).
2. Pull out four switches (3) forward and disconnect each connector. 3. Remove cover (4).
80-28
D375A-6 (01)
DRAFT Air Conditioner Part and connector locations
a Condition with recirculated air filter cover (5) removed q BM: Blower motor q CN-B: Blower motor connector q R/FS: FRESH/RECIRC air changeover servomotor q CN-S: Connector of FRESH/RECIRC air changeover servomotor q MAIN: Blower main relay q CN-R1: Blower main relay connector q HI: Blower HI relay q CN-R2: Blower HI relay connector q ME1: Blower medium 1 relay q CN-R3: Blower medium 1 relay connector q ME2: Blower medium 2 relay q CN-R4: Blower medium 2 relay connector q CN-M26: Air conditioner intermediate connector (24V power supply, GND, compressor)
D375A-6 (01)
6. Disconnect connectors AC2 and AC3 and remove air conditioner control panel CP and its bracket as a unit. (Described above) a Condition with air conditioner control panel CP removed q AC1: Connector between air conditioner control panel and air conditioner unit 7. Remove brackets (7) and (8).
80-29
Air conditioner Parts and connectors layout
a Condition with brackets (7) and (8) removed A/MS: Air mix servomotor q CCR: Compressor clutch relay q CDR: Condenser relay (Not applicable for this machine) q TH: Evaporator temperature sensor q [1]: Blower resistor connector q [2]: Air mix servomotor connector q [3]: Evaporator temperature sensor connector q [4]: Dual pressure switch connector q [5]: Compressor clutch relay connector q [6]: Condenser relay connector (Not applicable for this machine) q
80-30
D375A-6 (06)
DRAFT Air Conditioner Part and connector locations
8. Remove the cover between operator cab and engine hood. 9. Remove bracket (9). 10. Remove duct (10).
q q
A/C UNIT: Air conditioner unit BR: Blower resistor
D375A-6 (01)
80-31
DRAFT Air Conditioner Testing temperature control
Testing temperature control Outline The angle of the door (damper) in the air conditioner unit is changed with air mix servomotor (AM/S) in order to switch the air path between the hot air path to the heater and the cold air path to the evaporator. Moreover, for heating, the hot water valve changes the quantity of the hot water from engine by controlling the opening angle of valve through the shaft and controls the outlet air temperature.The shaft and hot water valve lever can be seen from outside. . 1. With reference to "Parts and connector locations", remove the air conditioner control panel and its bracket as a unit. 2. Remove bracket (1).
Testing FRESH/RECIC air changeover Outline FRESH/RECIRC air changeover servomotor changes the angle of FRESH/RECIRC air changeover door (damper) through the lever and cable to switch the air between the recirculated air and fresh air. Visually check the operation of the lever and opening and closing of the door (damper). 1. Remove the recirculated air filter cover from lower part of the dashboard. 2. Check that cable (1) is not disconnected from the level. (Check its connection to the FRESH/RECIRC air changeover door (R/FD), too.) 3. Check that connector (CN-S) is connected securely. 4. Start the engine and turn the air conditioner ON. 5. Press the FRESH/RECIRC air changeover switch on the air conditioner control panel and visually check opening and closing of door (F/RD). 6. If door (R/FD) does not open or close, check that lever (2) of FRESH/RECIRC air changeover servomotor (R/FS) moves to the respective positions as shown in the figure when the RECIRC air or FRESH air is selected. F: FRESH air position R: RECIRC air position
3. Check that shaft (2) is not disconnected. 4. Check that connector [2] of air mix servomotor (A/MS) is connected securely. (Check for partial connection.) 5. Start the engine and turn the air conditioner ON. Set the temperature setting to the maximum and minimum with the control panel and check visually that lever (3) moves smoothly between COOL MAX and HOT MAX.
a For an electrical trouble, see "Troubleshooting for FRESH/RECIRC air changeover".
a For an electrical trouble, see "Troubleshooting for temperature control".
80-32
D375A-6 (03)
DRAFT Air Conditioner Testing FRESH/RECIC air changeover
D375A-6 (01)
80-33
Air conditioner Testing relay
Testing relay a If the air conditioner compressor is normal and the cool air flow rate is adjusted to the four levels, skip this test. a Listen closely to the relay to check the operation sound. Condenser relay CDR among six relays is not used. q Compressor clutch relay CCR, connector [5]: For ON/OFF of air conditioner compressor (clutch) q Blower main relay MAIN, connector R1: For ON/OFF of blower motor q Blower relays of HI, ME2 and ME1: For air flow adjustment 1. Remove the recirculated air filter cover from lower part of the dashboard. 2. With reference to the parts and connectors arrangement, remove cover (1). 3. Remove bracket (2).
4. Check the connection between connectors CN-R1 and CN-R4, and connector [5]. (Check for partial connection.) 5. Turn the starting switch to the ON position (with engine stopped) and turn the air conditioner switch ON. If the blower main relay is normal, it turns ON and you can hear its operation sound (click). 6. If the compressor clutch relay (CCR) is normal, it turns ON and you can hear its operation sound (click). a The control panel does not turn the compressor relay ON in the following cases. q When the evaporator temperature is 3°C or below (temperature sensed by the evaporator temperature sensor) a Compressor clutch relay (CCR) does not turn ON in the following cases. q When the dual pressure switch detects abnormal pressure (the dual pressure switch is OFF)
80-34
80-34 a If the fan sound is so large that you cannot hear the operation sound of the compressor relay, set the starting switch to OFF position and disconnect connector R1 and then perform the test.(*) 7. Operation check of relay responding to air flow switch operation a If the fan sound is so large that you cannot hear the operation sound of the compressor relay, set the starting switch to OFF position and disconnect connector R1 and then perform the test.(*) 1) Set starting switch to ON position (with engine stopped) and turn air conditioner switch ON. 2) Set the air flow to HI, ".." and "." in order to turn relays HI, ME2 and ME1 ON respectively. Check their operation sounds (click). a If the air flow is set to LO, ME1 relay turns OFF. q
X view
q
Y view
*: Since the connector R1 is disconnected, the blower does not start and the pressure in air compressor hose (high-pressure hose) may rise.
D375A-6 (06)
DRAFT Air Conditioner Testing relay
q
Testing for relay units a Since no T-adapter is available, it is actually impossible to check each relay while applying voltage to its coil. a Set the starting switch to the OFF position and remove the relays. a Common to each relay 1) The coil resistance between terminals (1) and (2) is 140 – 340 Ω 2) While the voltage (20 - 30 VDC) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are disconnected. 3) While the voltage (20 - 30 VDC) is applied between terminals (1) (+) and (2), terminals (3) and (4) are connected.
D375A-6 (01)
80-35
DRAFT Air Conditioner Troubleshooting chart 1
Troubleshooting chart 1 The numbers in the boxes are the item numbers in the troubleshooting table. 1.Cooling trouble
80-36
D375A-6 (01)
DRAFT Air Conditioner Troubleshooting chart 1
2.Heating trouble
D375A-6 (01)
80-37
DRAFT Air Conditioner Troubleshooting chart 2
Troubleshooting chart 2 1. Blower fan motor does not revolve or its speed is different from set value. a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)". Probable causes Defective blower main relay
Check method See “Testing relay” Check connector of blower fan motor for disconnection. Open circuit or defective conSee "Troubleshooting of blower motor system" and "Parts and nection of wiring harness connector locations". Check two lead wires of motor by using circuit tester. If there is not continuity, motor is defective. Defective blower fan motor See "Troubleshooting of blower motor system" and "Parts and connector locations". Defective blower resistor, Activate fan switches in order and check fan speed. blower ME1 relay, blower ME2 See "Troubleshooting of blower motor system" and "Testing relay, blower HI relay relay".
Remedy Replace Repair broken parts and connect correctly
Replace
Replace
2. Blower fan motor is normal but air flow is insufficient. Probable causes Large airflow resistance
Check method Check duct for crushing and clogging and filter for clogging Check duct joints. Air leakage through duct joints Check for defective duct seal and disconnection of duct Obstruction on suction side of Check evaporator for dirt and obstruction evaporator Defective evaporator tempera- Check evaporator for freeze. Check sensor clip. Check sensor for dirt. ture sensor Defective contact of evaporaCheck for frost on the hose near pressure switch (when freeztor temperature sensor or ing advances furthermore) defective expansion valve* * The evaporator temperature sensor and expansion valve are in the air conditioner unit.
Remedy Repair Repair Remove obstruction and clean
Repair or replace
3. Low/high pressure Probable causes
Check method
Excessive or insufficient refrigerant Insufficient refrigerant
Check the normal refrigerant quantity through sight glass. To be exact, check by connecting gauge manifold.
Excessive refrigerant
Judgment by pressure at inlet/outlet of compressor
80-38
Normal refrigerant pressure Low pressure side: Approx. 0.13-0.2 MPa {1.3–2.0 kg/cm2} High pressure side: Approx. 1.5-1.7 MPa {15-17 kg/cm2} Under following conditions: Temperature inside cab: 30 - 35 °C Engine speed: Approx.1,500 rpm
Remedy Collect the refrigerant and refill with proper amount of refrigerant. Repair leaking part, then refill with proper amount of refrigerant. Collect the refrigerant and refill with proper amount of refrigerant.
See Troubleshooting with gauge pressure
D375A-6 (03)
DRAFT Air Conditioner Troubleshooting chart 2
4. Compressor does not revolve at all or its speed is low. a See "Troubleshooting of compressor system (Air is not cooled)". Troubled part Possible cause Compressor Loosened compressor belt belt Trouble in compressor Insufficient compressor oil or Compressor seizure in the compressor Low battery voltage Disconnection or short circuit in coil Magnet clutch Disconnection of wiring harness or defective connection of ground wire Defective compressor clutch Relay relay Refrigerant Low/high pressure (Operation pressure of pressure switch) Pressure Defective pressure switch switch Diode
Defective diode(ACS)
Check method
Remedy
Check for excessive deflection of belt.
Adjust tension
Check for slipping of belt.
Repair or replace
Check for compressor overheat
See "Handling compressor oil"
Slip of clutch
Charge battery
Inspect with circuit tester (10 - 20 Ω)
Replace
Check ground wire and connections Repair See "Troubleshooting of compressor system". See “Testing relay”
Replace
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure
See "Troubleshooting of compressor system". Replace Check diode (ACS). See "Troubleshooting of compressor system".
Replace
5. Blower fan motor is normal but air flow is insufficient. Possible causes Large airflow resistance
Check method Remedy Check duct for crushing and clogging, and filter for clogging Repair Check duct joints for defective duct seal and disconnection of Air leakage through duct joints Repair duct Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or level is abnormal. Possible causes Low engine coolant temperature Low engine coolant level Insufficient circulation of engine coolant Contrary connection of IN and OUT heater hoses
Check method
Remedy
Warm up engine, and then check engine coolant temperature Find out cause Check coolant level in radiator Check engine coolant piping for clogging (Hose, pipe, and core)
Add coolant
Check the destination of heater hoses
Repair
Bleed air and repair
7. Fan speed is abnormal. Possible causes Fan speed is low (Defective fan motor EPC or hydraulic system)
Check method Remedy See "Testing fan motor speed" and "Testing fan pump circuit pressure" in chapter 30 "Testing and adjusting" of Shop Man- Repair ual.
8. Other abnormalities Possible causes Temperature cannot be controlled Fresh air and recirculated air cannot change. Excessive compressor oil Water leakage into the cab
D375A-6 (01)
Check method Remarks See "Testing temperature control" and "Troubleshooting for Common to cooling and temperature control" See "Testing Recirc/Fresh air changeover" and "Troubleshoot- heating ing for Recirc/Fresh air changeover" See "Handling compressor oil" Cooling only Clogging of drain hole
80-39
DRAFT Air Conditioner Information in troubleshooting table
Information in troubleshooting table Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before troubleshooting, understand the information fully. Trouble Related information Cause
1
2
Possible causes for trouble (Perform troubleshooting according to these numbers, however.)
4 defective
Problem that appears on machine Information related to detected trouble or troubleshooting Procedure, measuring location, standard (value) and remarks q Procedure q Measuring location a "Between A – B" means “Measure voltage or resistance and so on between A – B. q Standard value in normal condition to evaluate possible cause if it is applicable or not q Remarks requiredfor to evaluate the cause is correct (1) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless otherwise specified. q Connect the plus (+) lead to pin or harness indicated in the front. q Connect the minus (–) lead to a pin or harness indicated in the rear. (2) Example of troubleshooting by inspection of multiple items a Normal in 1 but abnormal in 2 At this time“ - defective” shown at left is applied
a If a wiring harness is burnt, replace it. q Disconnection in wiring harness The connector connection is defective or wiring harness is disconnected. q Ground fault A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth) circuit or chassis accidentally. q Hot short circuit A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit An independent wire in the harness abnormally comes into contact with one of another wire. (Defective insulation in connector or others) Related circuit diagram This is the excerpted circuit diagram related to trouble q The circuit diagram includes connector numbers and pin numbers related to the trouble. q See “Circuit diagram and arrangement of connector pins” and “Parts and connector locations” for connector location. q The circuit diagram shows the size and colors of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown a When there are 2 colors Example: WY: Yellow line on white background a The number before the wire color symbol indicates the wire size. q N.C.: Normally closed (Normally ON) q [1], [2],··· are numbers of unlabeled connectors. q Arrow (↔): Roughly indicates their mounting place on the machine.
80-40
D375A-6 (01)
DRAFT Air Conditioner Information in troubleshooting table
D375A-6 (01)
80-41
DRAFT Air Conditioner Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for power supply system (Air conditioner does not operate) Failure Air conditioner does not operate due to failure in power supply system Problem on q When control panel is operated, related LED does not light up. machine q Air conditioner ground is housed in the chassis wiring harness toghether with those of electric equipment installed on the machine and connected to the chassis ground. q For connectors etc., see "Parts and connector locations". Related infor- q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730 mation a T-adapter is not prepared for other connectors. q Turn starting switch to ON position and turn air conditioner switch A/C to ON position. At this time, if LED above A/C switch lights up for a moment and circuit breaker trips immediately, see "Troubleshooting for compressor system" and "Troubleshooting for blower motor system". Probable causes Activation of circuit breaker 1 (CB4) Defective wiring harness 2 (ground)
3 Defective wiring harness
Procedure, measuring location, standard (value) and remarks If circuit breaker trips, circuit probably has ground fault etc. 1. Turn starting switch to OFF position. 2. Disconnect connector AC2 from control panel. 3. Insert T-adapter into connector AC1. Between AC1 (1) and chassis ground Resistance Max. 1 a If circuit breaker trips, press its reset button in advance. 1. Turn starting switch to OFF position. 2. Disconnect connector AC2 from control panel. 3. Insert T-adapter into connector AC1. 4. Turn starting switch to ON position. Between AC1 (10) and (1) Voltage 20 – 30 V A a Perform the following when the test result "A" above is abnormal a If circuit breaker trips, press its reset button in advance. 1. Turn starting switch to OFF position. 2. Disconnect connector M26 and connect T-adapter to female side. 3. Turn starting switch to ON position. a If circuit breaker trips again or the test result "B" or "C" below is abnormal, wiring harness on machine body side is defective. Between M26 (2) and (6) Voltage 20 – 30 V B Between M26 (5) and (6) Voltage 20 – 30 V C a Perform the following when circuit breaker trips during test "A" above and the test results "B" and "C" above are normal. a If circuit breaker trips, press its reset button in advance. 1. Turn starting switch to OFF position. 2. Disconnect connector AC2 from control panel. 3. Insert T-adapter into connector AC1. 4. Disconnect connectors CN-B, R1 - R4 and [5]. 5. Turn starting switch to ON position. Between AC1 (10) and (1) Voltage 20 – 30 V D a If the test result "D" above is abnormal, air conditioner wiring harness is defective. a If circuit breaker trips during test "D" above, disconnect male side of connector AC1 and perform test again to see on which side wiring harness is defective, control panel side or air conditioner unit side. a If the test result "A" is abnormal and test result "D" is normal, see "Troubleshooting for compressor system" and "Troubleshooting for blower motor system".
Disconnection in wiring harness a If circuit breaker does not trip, check with circuit diagram. (on control panel side) 5 Defective control panel If cause is not found by above checks, control panel may be defective.
4
80-42
D375A-6 (03)
DRAFT Air Conditioner Troubleshooting for power supply system (Air conditioner does not operate)
Related electrical circuit diagram
D375A-6 (01)
80-43
DRAFT Air Conditioner Troubleshooting for compressor system (Air is not cooled)
Troubleshooting for compressor system (Air is not cooled) Failure
Air is not cooled because of trouble in compressor or refrigerant system
Problem on machine
q
When engine is started and A/C switch is pressed while the blower is turned ON, air is not cooled. Air conditioner compressor does not operate. q If refrigerant pressure is abnormal, air is not cooled because the compressor is not turned ON. q When evaporator temperature is below 3 °C, control panel does not turn compressor relay ON to prevent evaporator from freezing (this is normal operation.). Related infor- q For connectors etc., see "Parts and connector locations". q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730 mation a T-adapter is not prepared for connectors other than the above and for DT connectors. Accordingly, perform troubleshooting by using connectors which T-adapter is avilable for. q Since condenser relay is not used, it may be used as a replacement when replacing other relays. q
Probable causes
Procedure, measuring location, standard (value) and remarks
1. Turn starting switch to OFF position. 2. Disconnect connector FEN from air conditioner compressor and connect Defective air conditioner compresT-adapter to male side. 1 sor Between FEN (1) and ground (air conditioner com- ResisApprox. 15 pressor coil resistance) tance 1. Turn starting switch to OFF position. 2. Remove diode ACS. a Measure with circuit tester in diode range. 2 Defective diode Between ACS (male) (1) (+) and (2) (-) No continuity Max. 1 Between ACS (male) (2) (+) and (1) (-) Continuity Disconnection in wiring harness 3 (on machine side)
Ground fault of wiring harness 4 (Contact with ground circuit) (on machine side)
5
Defective compressor clutch relay (It does not turn ON)
6
Defective evaporator temperature sensor
80-44
1. Turn starting switch to OFF position. 2. Disconnect connector M26 and connect T-adapter to female side. Between M26 (female) (3) and ground ResisApprox. 15 (air conditioner compressor coil resistance) tance a If circuit breaker does not trip, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector FEN. 3. Insert T-adapter into connector M26. ResisBetween M26 (female) (3) and ground Min. 1 M tance ResisBetween M26 (female) (3) and (6) Min. 1 M tance q Referring to "Testing relay", check operation Click is A sound of compressor clutch relay. heard. a If the test result "A" above is normal, this check is not required. a Check that air flow can be controlled. 1. Turn starting switch to OFF position. 2. Replace compressor clutch relay with blower Me2 relay (CN-R4). 3. Turn starting switch to ON position. 4. Turn air conditioner switch ON. If compressor operates (air is cooled), original compressor clutch relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector AC1 and insert T-adapter into female side. Resis0°C 4.6 - 5.1 k tance Resis15°C 2.1 - 2.6 k Between AC1 (female) (15) and (17) tance Resis25°C 1.5 k tance
D375A-6 (03)
Air conditioner Troubleshooting for compressor system (Air is not cooled)
Probable causes
7 Defective pressure switch
Check of voltage 8 (Defective wiring harness or defective control panel)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector AC1 and connect T-adapter to female side. a The switch may be turned OFF normally. If the following is abnormal (switch is turned OFF), install pressure gauge to low-pressure side of air conditioner compressor and check refrigerant pressure. (See "Troubleshooting with gauge pressure".) Between AC1 (10) and (14) Resistance 240 ± 40 z (compressor relay coil resistance) k
When replacing pressure switch, collect refrigerant in advance.
1. 2. 3. 4.
Turn starting switch to OFF position. Insert T-adapter into connector AC1. Turn starting switch to ON position. Turn air conditioner switch ON.
Between AC1 (14) and (1) a 1. 2. 3. 9 Short circuit in wiring harness a
Voltage
Max. 1 V
If cause 7 is not the cause for the trouble, this check is not required. Turn starting switch to OFF position. Disconnect connectors M26, AC2, R1 - R4 and [5]. Insert T-adapter into connector AC1. Check with circuit tester in continuity mode.
Between AC1 (10) and each pin other than (10)
No continuity
Between AC1 (14) and each pin other than (14)
No continuity
10 Open circuit in wiring harness a Check with circuit diagram. 11 Defective control panel
D375A-6 (06)
If check result for cause 8 is abnormal and check results for causes 9 and 10 are normal, control panel is defective.
80-45
DRAFT Air Conditioner Troubleshooting for compressor system (Air is not cooled)
Related electrical circuit diagram
80-46
D375A-6 (01)
DRAFT Air Conditioner Troubleshooting for compressor system (Air is not cooled)
D375A-6 (01)
80-47
DRAFT Air Conditioner Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) Trouble Problem that appears on the machine
Air does not come out or air flow is abnormal because of trouble in blower motor system 1) Air does not come out in any air flow setting. q
When any fan switch is pressed, air does not come out.
q
Related information
For connectors, relays, etc., see "Parts and connector locations". Since condenser relay is not used, it may be used as replacement when replacing other relays. q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730 a T-adapter is not prepared for other connectors. q
Causes 1 Defective blower (fan) motor
2
Defective blower main relay (It does not turn ON)
Check of voltage 3 (Defective wiring harness or defective control panel)
4 Short circuit in wiring harness
5 Disconnection in wiring harness 6 Defective control panel
80-48
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector CN-B. Between CN-B (male) (1) and (2) Continuity q Referring to testing of relay, check turn-on sound of Click is A blower main relay. heard. a If the test result "A" above is normal, this check is not required. 1. Turn starting switch to OFF position. 2. Replace blower main relay with blower Me2 relay (CN-R4). 3. Turn starting switch to ON position. 4. Turn air conditioner switch ON. If air comes out, original blower main relay is defective. q Primary output to relay from control panel 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector AC1. 3. Turn starting switch to ON position. 4. Turn air conditioner switch ON. Between AC1(11) and (1) Voltage Max. 1 V a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors M26, AC2, R1 - R4 and [5]. 3. Insert T-adapter into connector AC1. a Check with tester in continuity mode. Between AC1 (11) and each pin other than (11) No continuity a Check with circuit diagram. If check result for cause 3 is abnormal and check results for causes 4 and 5 are normal, control panel is defective.
D375A-6 (01)
DRAFT Air Conditioner Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Related electrical circuit diagram
D375A-6 (01)
80-49
DRAFT Air Conditioner Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Trouble
Air does not come out or air flow is abnormal because of trouble in blower motor system 2) Air does not come out or air flow is abnormal in certain air flow setting.
Problem that appears on the Air does not come out or air flow is abnormal in certain air flow setting. machine q If air flow decreases (air does not come out) after a while in cooling mode, evaporator may have frozen. The possible causes for this trouble are as follows. 1) Compressor clutch relay is defective (kept ON) (See "Troubleshooting for compressor system", 5-A). 2) Evaporator temperature sensor mounting holder is removed (Remove and disassemble air condiRelated infortioner unit). mation 3) Expansion valve is not adjusted properly (Remove air conditioner unit and replace expansion valve). q For connectors, relays, etc., see "Parts and connector locations". q Since condenser relay is not used, it may be used as replacement when replacing other relays. q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730 a T-adapter is not prepared for other connectors. Causes
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to ON position. 2. Turn air conditioner switch ON. 3. Set air flow to each level in order. If air comes out only in air flow HI, blower resistor is defective. Defective blower resistor q Reference: Between [1] (male) (1) and (2) Approx. 1 (Breakage of fuse in blower Resistance a Fuses 600 Ω resistor) Approx. q Reference: Between [1] (male) (2) and (3) Resistance 900 Ω Approx. q Reference: Between [1] (male) (3) and (4) Resistance 530 Ω 1. Turn starting switch to ON position. 2. Turn air conditioner switch ON. 3. Set air flow to each level in order. q Replace corresponding relay in each of following checks. Following phenomena show: 1. Relay is kept turned ON, 2. Relay is not turned ON. 1. Air flow is HI in any air flow setting. 2. Air flow is LO when the air flow is set to HI. Defective blower HI relay, q Replace blower HI relay with condenser relay. If air flow becomes normal, orig2 blower Me2 relay or blower Me1 inal blower HI relay is defective. relay 1. Air flow HI and ".."is normal, but air flow is ".." even if the air flow set to"." or LO. 2. Air flow is LO when air flow is set to "..". q Replace blower Me2 relay with condenser relay. If air flow becomes normal, original blower Me2 relay is defective. 1. Air flow HI ,".." and "." is normal, but air flow is "." even if the air flow is set to LO. 2. Air flow is LO when air flow is set to ".". q Replace blower Me1 relay with condenser relay. If air flow becomes normal, original blower Me1 relay is defective. q Primary output to relay from control panel 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector AC1. 3. Turn starting switch to ON position. 4. Turn air conditioner switch ON. 5. Press each air flow switch and perform troubleshooting. Check of voltage Between AC1(13) and (1) HI Voltage Max. 1 V 3 (Defective wiring harness or Other than defective control panel) Between AC1(13) and (1) Voltage 20 – 30 V HI Between AC1(12) and (1) "··" Voltage Max. 1 V Other than Between AC1(12) and (1) Voltage 20 – 30 V ".." Between AC1(7) and (1) "·" Voltage Max. 1 V Other than Between AC1(7) and (1) Voltage 20 – 30 V
80-50
D375A-6 (01)
DRAFT Air Conditioner Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
a If cause 5 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors M26, AC2, CN-B, R1 - R4 and [5]. 4 Short circuit in wiring harness 3. Insert T-adapter into connector AC1. a Check with tester in continuity mode. Between AC1 (7) and each pin other than (7) No continuity Between AC1 (12) and each pin other than (12) No continuity Between AC1 (13) and each pin other than (13) No continuity 5 Disconnection in wiring harness a Check with circuit diagram. If check result for cause 3 is abnormal and check results for causes 4 and 5 are 6 Defective control panel normal, control panel is defective.
D375A-6 (01)
80-51
DRAFT Air Conditioner Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Related electrical circuit diagram
80-52
D375A-6 (01)
DRAFT Air Conditioner Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
D375A-6 (01)
80-53
DRAFT Air Conditioner Troubleshooting for temperature control
Troubleshooting for temperature control Failure Problem on machine
q
Temperature cannot be controlled
q
When temperature control switch is operated, temperature does not change.
q
Referring to "Testing temperature control", check connector [2] for defecive contact and mechanical trouble (desconnection of shaft, interference of lever, etc.) Related infor- q For connectors etc., see "Parts and connector locations". q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730, mation T-adapter for connector [2]: 799-601-2710 a T-adapter is not prepared for other connectors. Probable causes
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector [2] and connect T-adapter to male side. Between connector [2] (male) (4) and (1) Resistance 6 k a If air mix servomotor does not operate (the test result "C" below is abnormal) while the test results "A" and "B" below are normal, air mix servomotor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector [2] 3. Turn starting switch to ON position. 4. Turn air conditioner switch ON. Between connector [2] (4) and (1) Voltage 5V A 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector [2] 3. Turn starting switch ON position. 4. Turn air conditioner switch ON. 5. Press left triangle temperature control switch many times to set to minimum temperature in advance. 1 Defective air mix servomotor 6. Perform troubleshooting while pressing right triangle temperature control switch. 7. Press right triangle temperature control switch many times to set to maximum temperature in advance. 8. Perform troubleshooting while pressing left triangle temperature control switch. Between connector [2] (3) and (5) a Voltage appears for only approximately 1 second (only while hot water valve is moving) and polarity is reversed when right triangle and left triVoltage ± 24 V B angle temperature control switch is pressed. When right triangle switch (WARM side) is pressed, polarity of pin 3 becomes +. Between connector [2] (2) and (1) a Voltage changes only while hot water Varies Voltage C valve is moving (Voltage settles after below 5 V the door stops). a If cause 1 is not the cause for the failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors AC1 and [2], and connect T-adapters to female side of them. 2 Disconnection in wiring harness Between AC1 (2) and [2](4) Resistance Max. 1 Between AC1 (3) and [2](5) Resistance Max. 1 Between AC1 (4) and [2](3) Resistance Max. 1 Between AC1 (16) and [2](2) Resistance Max. 1 Between AC1 (17) and [2](1) Resistance Max. 1
80-54
D375A-6 (03)
DRAFT Air Conditioner Troubleshooting for temperature control
3 Short circuit in wiring harness
a If cause 1 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors M26, AC2, AC3 and [2]. 3. Insert T-adapter in connector AC1. a Check with tester in continuity mode. Between AC1 (2) and each pin other than (2) No continuity Between AC1 (3) and each pin other than (3) No continuity Between AC1 (4) and each pin other than (4) No continuity Between AC1 (19) and each pin other than (19) No continuity Between AC1 (20) and each pin other than (20) No continuity
Disconnection in wiring harness a Check with circuit diagram. (on control panel side) If check result for cause 1 is abnormal and check results for causes 2 and 4 are 5 Defective control panel normal, control panel is defective. 4
Related electrical circuit diagram
D375A-6 (01)
80-55
DRAFT Air Conditioner Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting for FRESH/RECIRC air changeover Trouble Problem that appears on the machine
q
Fresh air and recirculated air cannot switch between them. When FRESH/RECIRC air changeover switch on control panel is operated, fresh air or recirculated air does not switch between them. (FRESH/RECIRC air changeover door (damper) does not rotate) q Referring to "Testing FRESH/RECIRC air changeover", operate FRESH/RECIRC air changeover switch and check FRESH/RECIRC air changeover door (damper) for mechanical trouble (desconnection of cable, interference of lever, etc.) Related inforq For connectors etc., see "Parts and connector locations". mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730, T-adapter for connector S: 799-601-2710 a T-adapter is not prepared for other connectors. q
Causes
1
2
3
4 5
Procedure, measuring location, standard (value) and remarks a If FRESH/RECIRC air changeover servomotor does not operate while following is normal (See Testing FRESH/RECIRC air changeover), FRESH/RECIRC air changeover servomotor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CN-S. 3. Turn starting switch to ON position. 4. Turn air conditioner switch ON. Defective FRESH/RECIRC air 5. Perform troubleshooting while pressing RECIRC air switch and FRESH air switch. changeover servomotor a Voltage appears only for approx. 3 seconds (only while door is moving to FRESH or RECIRC position). From fresh Between CN-S(5) (+) and (3) (-) air to recirVoltage 24 V culated air From recirBetween CN-S(5) (-) and (3) (+) culated air to Voltage 24 V fresh air a If cause 1 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring harness 2. Disconnect connectors AC1 and [2] and connect T-adapter to female side of them. Between AC1(5) and CN-S(3) Resistance Max. 1 Ω Between AC1(6) and CN-S(5) Resistance Max. 1 Ω a If cause 1 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors M26, AC2, AC3 and [2]. Short circuit in wiring harness 3. Insert T-adapter into connector AC1. a Check with tester in continuity mode. Between AC1 (5) and each pin other than (5) No continuity Between AC1 (6) and each pin other than (6) No continuity Disconnection in wiring harness a Check with circuit diagram. (on control panel side) If check result for cause 1 is abnormal and check results for causes 2 to 4 are norDefective control panel mal, control panel is defective.
80-56
D375A-6 (01)
DRAFT Air Conditioner Troubleshooting for FRESH/RECIRC air changeover
Related electrical circuit diagram
D375A-6 (01)
80-57
DRAFT Air Conditioner Troubleshooting with gauge pressure
Troubleshooting with gauge pressure Referring to “Connection of service tool”, perform troubleshooting by reading the gauge pressure of the high-pressure and low-pressure lines in the refrigeration cycle. a The gauge pressure varies largely with the weather condition and operating condition of the machine. Check the gauge pressure under the pressure measurement conditions. q High-pressure line pressure is too high: Above approx. 2.5 MPa {25 kg/cm2} q High-pressure line pressure is too low: Below approx. 1 MPa {10 kg/cm2} q Low-pressure line pressure is too high: Above approx. 0.3 MPa {3 kg/cm2} q Low-pressure line pressure is too low: Below approx. 0.0 5MPa {0.5 kg/cm2} a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure or low-perssure line is abnormal.
Item Condition value Ambient temperature 20 – 50 °C Engine speed 1,500 rpm Air conditioner switch ON Fan switch HI Set temperature Full cool
Dual pressure switch a The swiths is normally "ON", and becomes "OFF" for compressor operation when it detects abnormal pressure.
q
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
80-58
D375A-6 (01)
Air conditioner Troubleshooting with gauge pressure
Indicated gauge pressure Pressure is normal
Cause
Check method
Air conditioner cycle is normal. If there is any trouble (cooling trouble), there is another cause. High-pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2} Low-pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Remedy
-
Collect refrigerant, then Bubble can be seen through sight glass refill with proper amount Insufficient refrigerant (*1)(*3) of refrigerant again (*2) There is a temperature difference between Replace Clogging of receiver drier inlet and outlet pipes of receiver drier. (*2) Tank is frosty Repair or replace Evaporator is frozen Replace receiver drier Low-pressure gauge Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to Collect refrigerant, then reads vacuum or defective contact of sensor (coming off freezing. refill with proper amount of mounting clip) (After setting to cool max. and HI fan of refrigerant again speed, air becomes not to be cooled.) (*2) Piping between receiver drier and compressor is clogged or crushed. Clean or replace Clogged or crushed piping If clogged completely, low-pressure gauge (*2) reads vacuum Collect refrigerant, then refill with proper amount Excessive refrigerant Connect gauge manifold of refrigerant again (*2) Clean, repair fins, or (Valve is opened too wide) (*3) (*2) Vacuum and then refill Bubble can be seen through sight glass with proper amount of Air in cycle parts (*3) refrigerant again (*2)
*1 If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check mainly on pipe joints and dirty parts with oil. *2 k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant again. *3 Sight glass is on the receiver drier .
D375A-6 (06)
80-59
DRAFT Air Conditioner Connection of service tool
Connection of service tool Symbol X
Part No. 799-703-1200
Part name Service tool kit
a Use the service tool kit for R134a. Service tool kit X (1): Gauge manifold (2): High pressure charging hose (red) (3): Low pressure charging hose (blue) (4): Quick joint (Hi) (Large diameter) (5): Quick joint (Lo) (Small diameter) (a): The thread is rough. So be careful not to loosen.
80-60
Connect the gauge manifold, hoses and other service tools according to the following procedure. 1. Close the high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1). 2. Connect red charging hose (2) to the (HI) side and blue charging hose (3) to the (LO) side of the gauge manifold. 3. Connect quick joints (4) and (5) to each hose. 4. Connect the quick joints (4) and (5) to the service valves (8) and (9) of the high and low-pressure pipings.
D375A-6 (01)
DRAFT Air Conditioner Connection of service tool
D375A-6 (01)
80-61
DRAFT Air Conditioner Precautions for disconnecting and connecting
Precautions for disconnecting and connecting Precautions for disconnecting
Precautions for connecting
k
q
Collect the air conditioner refrigerant (R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or receiver drier and so on. a Ask a qualified shop for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective goggles, gloves and working cloth with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person. q
q
q q
When connecting the piping, apply compressor oil NDOIL-8 for R134a to the O-rings. (See item 4. in “Handling of compressor oil”) Do not apply oil to the threads of a bolt, nut or union, however. Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged. Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers. Be sure to use two wrenches to tighten each nut (Use a torque wrench for tightening). Use one wrench to fix and tighten the nut with the other wrench to the specified torque.
When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nuts.
80-62
D375A-6 (01)
DRAFT Air Conditioner Precautions for disconnecting and connecting
Table of tightening torque for refrigerant pipe joint. Screw size Approx. M6 × 1.0 Approx. M16 × 1.5 Approx. M24 × 1.5
Unit: Nm {kgm} Tightening torque 3.9 – 6.9 {0.4 - 0.7} (Receiver drier) 8 - 12 {0.8 - 1.2} (A/C unit and compressor) 12 - 15 {1.2 - 1.5} 30 - 35 {3.1 - 3.6}
1. Engine 2. Compressor 3. Condenser 4. Receiver drier 5. Air conditioner unit
D375A-6 (01)
80-63
DRAFT Air Conditioner Handling of compressor oil
Handling of compressor oil 1. Control of compressor oil (Denso: ND-OIL8: For R134a) Compressor oil does not need to be checked or added so frequently as engine oil. Insufficiency or excess of compressor oil can cause the following troubles. Condition Contents Insufficiency of Lubrication trouble and seizure of comoil pressor Cooling trouble Excess of oil (Excessive oil stick to parts and lower heat exchange performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Adding of compressor oil k
Since refrigerant is dangerous and bad for environment, collect the refrigerant before disconnecting the air conditioner hose. See “Caution about refrigerant”. a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized. Be sure to use the specified oil for R134a (Denso: ND-OIL8) a Oil for R134a absorbs moisture very easily. Accordingly, fit the cap to the oil container immediately after using the oil to shield against the atmosphere. Store the oil container in a dry and ventilated place. a Precautions for using oil Oil for R134a may dissolve acrylic resin and polystyrene (excluding baked polystyrene paint film). Accordingly, do not stick oil to those plastics. Check compressor oil in the following cases, and then add new oil if necessary. q When much refrigerant is discharged because of leakage. q When the compressor is troubled and replaced. q When a cycle parts such as the air conditioner unit, condenser, receiver drier, evaporator unit, etc. is replaced. q
Quantity of oil to be added when cycle part is replaced Air conditioner par Air conditioner unit, evaporator Condenser Receiver drier Hose (Compressor – Cab) Hose (Compressor – Condenser) Hose(Condenser– Receiver driver) Hose (Cab – Receiver driver)
80-64
Quantity to be added (cc) Approx. 40 Approx. 40 Approx. 20 Approx. 30 Approx. 10 Approx. 10 Approx. 20
D375A-6 (01)
DRAFT Air Conditioner Handling of compressor oil
3. Compressor replacement q
In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely. In this case, flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (180 cc) filled in it.
4. Applying compressor oil to O-ring When connecting a pipe or hose, apply oil (Denso: ND-OIL8) to its O-ring to prevent refrigerant leakage.
Other cases a New compressor has 180 cc compressor oil in it. So drain excessive compressor oil before installing the new compressor as follows. 1) Prepare an oil container and drain oil from the old compressor. 2) Measure the quantity of the drained oil with a measuring cylinder, and note the quantity.
q
3) Drain below-mentioned quantity of oil from the new compressor. 180 cc – “the noted quantity”. EX. If drained oil quantity from removed compressor is 30cc, drain oil of 180 – 30 cc = 150 cc from new one.
D375A-6 (01)
80-65
DRAFT Air Conditioner Handling of compressor oil
80-66
D375A-6 (01)
SEN0500633-03
90-1
D375A-6
Bulldozer D375A-6 Shop Manual
Machine model
Serial number
D375A-6
60001 and up
90 Diagrams and drawings
D375A-6 (06)
9-01
90-1
90-1
Contents
Contents 90 Diagrams and drawings Hydraulic diagrams and drawings ........................................................................................... Symbols used in hydraulic circuit diagrams ......................................................................... Power train hydraulic diagrams and drawings ..................................................................... Hydraulic circuit diagram...................................................................................................... Electrical diagrams and drawings ........................................................................................... Symbols used in electrical circuit diagrams ......................................................................... Electrical circuit diagram ......................................................................................................
90-2
90-2 90- 3 90- 3 90- 5 90- 7 90- 9 90- 9 90- 13
D375A-6 (06)
Hydraulic diagrams and drawings Symbols used in hydraulic circuit diagrams
Hydraulic diagrams and drawings
90-3
Symbols used in hydraulic circuit diagrams
90-3 (Rev. 2010/02)
Symbol
Substance Main piping line Pilot or drain line Flexible pipe (hose, etc.) Lines intersecting without joining Lines joining (junction with a round black mark) Direction of flow Throttle in passage. Variable Electricity Spring Take-off port Take-off port and pressure gauge Check valves Suction (with strainer) Tank and return pipe Filter
Oil cooler Stop valve
Drive shaft䋨unidirectional䋩
Drive shaft䋨bidirectional䋩
D375A-6 (06)
90-3
DRAFT Hydraulic diagrams and drawings Symbols used in hydrauric cirxuit diagrams
Symbols
Substance Pump Note : Black triangle shows outlet port䋩
Variable capacity hydraulic pump Hydraulic motor (The figure shows bidirectional type.) Note䋺Two black triangles in the figure show direction of oil entering hydraulic motor 㩷㩷㩷㩷㩷㩷㩷㩷㩷depending on the oil entry port, the direction of rotation is reversed. Servo piston PPC valve
Control valve Single-acting solenoid
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve/ Safety valve/ Abnormal pressure prevention valve Pressure regulator valve/Safety valve/ Abnormal pressure prevention valve 䋨When the figure shows air pressure, being released to atmosphere.䋩 Bypass valve
Accumulator
Cylinder
Component Group
90-4
D375A-6
Power train hydraulic circuit diagram D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-5
Hydraulic circuit diagram(1/2)
Hydraulic circuit diagram(1/2) D375A-6
DUAL TILT SPEC. a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6 (04)
90-7
Hydraulic circuit diagram(2/2)
Hydraulic circuit diagram(2/2) D375A-6
SINGLE TILT SPEC. a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6 (04)
90-7-1
DRAFT Electrical diagrams and drawings Symbol use in electric circuit diagram
Electrical diagrams and drawings Symbol use in electric circuit diagram Symbol
Substance
Electric wire
Electric wire 䋨Wires intersecting without connecting䋩
Electric wire 䋨Wires intersecting and connecting (junction) with a round black mark 䋩 Electric wire (Bundled drawing style)
Terminal
Body ground
Ground using terminal
Contact Switch Push-button type switch (N.O. type) *N.O.: Normally Open Push-button type switch (N.C. type) *N.C.: Normally Close Pull-button type switch (N.O. type) *N.O.: Normally Open Pull-button type switch (N.C. type) *N.C.: Normally Close
Variable
Resistance (resistor)
Variable resistance (variable resistor)
D375A-6
90-9
DRAFT Electrical diagrams and drawings Symbol use in electric circuit diagram
Symbol
Substance
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (Zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector 䋨Note䋩 䊶Convex side of connecting portion (right in figure): male 䊶Concave side of connecting portion (left in figure): female *Figure shows a line disconnection status.
Plug and receptacle type connector (left: male, right: female) Note: Figure shows a line connection status.
Solenoid
Motor
90-10
D375A-6
DRAFT Electrical diagrams and drawings Symbol use in electric circuit diagram
Symbol
Substance
Lamp
Pressure switch (N.O. type) *N.O.: Normally Open Pressure switch (N.C. type) *N.C.: Normally Close Potentiometer
Fuel dial
Temperature sensor
Starting switch
Back up alarm
Horn
Buzzer
Antenna
D375A-6
90-11
DRAFT Electrical diagrams and drawings Symbol use in electric circuit diagram
90-12
D375A-6
Electrical circuit diagram (1/14)
Electrical circuit diagram (1/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-13
Electrical circuit diagram (2/14)
Electrical circuit diagram (2/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-15
Electrical circuit diagram (3/14)
Electrical circuit diagram (3/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-17
Electrical circuit diagram (4/14)
Electrical circuit diagram (4/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-19
Electrical circuit diagram (5/14)
Electrical circuit diagram (5/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-21
Electrical circuit diagram (6/14)
Electrical circuit diagram (6/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-23
Electrical circuit diagram (7/14)
Electrical circuit diagram (7/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-25
Electrical circuit diagram (8/14)
Electrical circuit diagram (8/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-27
Electrical circuit diagram (9/14)
Electrical circuit diagram (9/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-29
Electrical circuit diagram (10/14)
Electrical circuit diagram (10/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-31
Electrical circuit diagram (11/14)
Electrical circuit diagram (11/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-33
Electrical circuit diagram (12/14)
Electrical circuit diagram (12/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-35
Electrical circuit diagram (13/14)
Electrical circuit diagram (13/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-37
Electrical circuit diagram (14/14)
Electrical circuit diagram (14/14) D375A-6
D375A-6 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6
90-39
Index
Index A Accumulator 10-126 Adjusting blade 30-75 Adjusting brake pedal and parking brake lever 30-54 Adjusting fuel control dial and decelerator pedal 30-38 Adjusting play of PPC valve 30-68 Adjusting position of PCCS lever console 30-57 Adjusting ripper lever position 30-73 Adjusting transmission output speed sensor 30-52 Adjusting valve clearance 30-14 Adjusting work equipment lock lever 30-74 Adjustment method when controller has been replaced 30-140 Air conditioner component 80-4 Air conditioner control panel 80-20 Air conditioner unit 80-10
B Blade 60-88 Blade control lever (only for the machine with dual tilt specification) 10-145 Bleeding air from fan pump 30-37 Bleeding air from fuel circuit 30-31 Bleeding air from work equipment cylinders 30-72 Blower unit 80-14
C Cab 10-182 Cab mount 10-181 Carrier roller 60-54 Caution about refrigerant 80-3 Checking location of cause of hydraulic drift of blade and ripper 30-70 Checks before troubleshooting 40-11 Circuit diagram and arrangement of connector pins 80-24 Classification and procedures for troubleshooting 40-36 Coating materials list 50-6 Compressor 80-16 Condenser 80-17 Configuration and function of refrigerating cycle 80-6 Connection of service tool 80-60 Connection table for connector pin numbers 40-52 Connectors table and arrangement drawing 40-88 Control valve 10-158, 60-79 Conversion table 00-43 Cooling fan motor 10-26, 60-12 Cooling fan pump 10-6, 60-5 Cooling system 10-4 CRI engine control system 10-194 Cutting edge and end bit 60-92 Cylinder stay 10-180, 60-87
D Damper and universal joint 10-38, 60-16 Disassembly and assembly of blade assembly 50-300 Disassembly and assembly of blade PPC valve assembly 50-282 Disassembly and assembly of bogie assembly 50-219 Disassembly and assembly of carrier roller assembly 50-210 D375A-6 (07)
Disassembly and assembly of control valve assembly 50-277 Disassembly and assembly of damper assembly 50-90 Disassembly and assembly of equalizer bar bushing 50-262 Disassembly and assembly of final drive assembly 50-173 Disassembly and assembly of giant ripper assembly 50-304 Disassembly and assembly of hydraulic cylinder assembly 50-287 Disassembly and assembly of idler assembly 50-192 Disassembly and assembly of master link 50-253 Disassembly and assembly of one link assembly in the field 50-248 Disassembly and assembly of operator's seat isolator 50-323-2 Disassembly and assembly of PTO assembly 50-109 Disassembly and assembly of recoil spring assembly 50-201 Disassembly and assembly of ripper pin puller cylinder assembly 50-295 Disassembly and assembly of ripper PPC valve assembly 50-285 Disassembly and assembly of steering case assembly 50-153 Disassembly and assembly of TORQFLOW transmission assembly 50-125 Disassembly and assembly of torque converter assembly 50-115 Disassembly and assembly of track roller assembly 50-206 Disconnection and connection of power train unit assembly 50-100
E E-1 Engine does not start (starting motor does not turn) 40-547 E-2 Preheater does not operate 40-550 E-3 When starting switch is turned ON, machine monitor displays nothing 40-554 E-4 When starting switch is turned ON (before starting engine), basic check item lights up 40-556 E-5 Precaution item lights up while engine is running 40-558 E-6 Emergency stop item lights up while engine is running 40-560 E-7 Engine coolant temperature gauge does not indicate normally 40-561 E-8 Fuel gauge does not indicate properly 40-562 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally 40-564 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally 40-565 E-11 Contents of display by machine monitor are different from applicable machine 40-566 E-12 Machine monitor does not display some items 40-566 E-13 Function switch does not work 40-566 E-14 Operation mode does not change 40-567
1
Index
E-15 Gearshift mode does not change 40-567 E-16 Customize function does not operate normally 40-568 E-17 Customize memory function does not operate normally 40-568 E-18 Alarm buzzer does not sound or does not stop 40-569 E-19 When starting switch is turned OFF, service meter is not displayed 40-569 E-20 Machine monitor cannot be set in service mode 40-569 E-21 The ripper pin puller cylinder does not operate 40-570 E-22 Horn does not sound or does not stop 40-572 E-23 Back-up alarm does not sound or does not stop 40-574 E-24 Fan does not reverse 40-576 E-25 The head lamp and rear lamp do not light up 40-577 E-26 Windshield wiper does not operate 40-584 E-27 Window washer does not operate 40-590 E-28 Electric priming pump does not operate or does not stop automatically 40-596 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) 40-598 E-30 Gear cannot be shifted 40-600 Electrical diagrams and drawings 90-13 Emergency escape method when there is failure in power train 30-58 Engine and cooling system 10-4, 30-6 Engine control 10-184 Engine control system 10-185 Engine mount 60-3 Engine preheat (electrical intake air heater)control 10-216 Explanation of terms for maintenance standard 00-12
F Failure code ([DK60KA) Acceleration sensor: Disconnection 40-460 Failure code (1380MW) Lock up clutch Slip 40-109 Failure code (1500L0) Transmission clutch Abnormal 40-110 Failure code (15E0MW) Transmission clutch Slip 40-111 Failure code (15SAL1) Forward clutch Fill high 40-112 Failure code (15SALH) Forward clutch Fill Low 40-114 Failure code (15SBL1) Reverse clutch Fill high 40-116 Failure code (15SBLH) Reverse clutch Fill Low 40-118 Failure code (15SEL1) Speed 1st clutch Fill high 40-120 Failure code (15SELH) Speed 1st clutch Fill Low 40-122 Failure code (15SFL1) Speed 2nd clutch Fill high 40-124 Failure code (15SFLH) Speed 2nd clutch Fill Low 40-126 Failure code (15SGL1) Speed 3rd clutch Fill high 40-128 Failure code (15SGLH) Speed 3rd clutch Fill Low 40-130 Failure code (15SJL1) L/U Fill high 40-132 Failure code (15SJLH) L/U Fill low 40-134 Failure code (1800MW) P/T clutch Slip 40-136 Failure code (2201L1) Right clutch Fill high 40-138 Failure code (2201LH) Right clutch Fill low 40-140 Failure code (2202L1) Left clutch Fill high 40-142 Failure code (2202LH) Left clutch Fill low 40-144 Failure code (2300NR) Brake Themal Load Abnormality 40-146
2
Failure code (2301L1) Right brake Fill high 40-168 Failure code (2301LH) Right brake Fill low 40-150 Failure code (2301NR) Steering Brake RH Themal Load Abnormality 40-152 Failure code (2302L1) Left brake Fill high 40-154 Failure code (2302LH) Left brake Fill low 40-156 Failure code (2302NR) Steering Brake LH Themal Load Abnormality 40-158 Failure code (7RFAKA) ECM ACC CUT RELAY Disconnection 40-160 Failure code (7RFAKB) ECM ACC CUT RELAY Short circuit 40-162 Failure code (AA10NX) Air Cleaner Clogging 40-164 Failure code (AB00MA) Battery Charge Abnormal 40-166 Failure code (B@BAZG) Eng Oil Press Low 40-166 Failure code (B@BAZK) Eng Oil Level Low 40-167 Failure code (B@BCNS) Eng Water Overheat 40-168 Failure code (B@BCZK) Eng Water Level Low 40-169 Failure code (B@CENS) T/C Oil Overheat 40-170 Failure code (B@HANS) Hyd Oil Overheat 40-171 Failure code (B@HAZK) Hyd Oil Level Low 40-172 Failure code (CA111) ECM Critical Internal Failure 40-174 Failure code (CA115) Eng Ne and Bkup Speed Sens Error 40-176 Failure code (CA122) Chg Air Press Sensor High Error 40-178 Failure code (CA1228) EGR Valve Servo Error 1 40-256 Failure code (CA123) Chg Air Press Sensor Low Error 40-180 Failure code (CA131) Throttle Sensor High Error 40-182 Failure code (CA132) Throttle Sensor Low Error 40-184 Failure code (CA135) Eng Oil Press Sensor High Error 40-186 Failure code (CA141) Eng Oil Press Sensor Low Error 40-188 Failure code (CA144) Coolant Temp Sens High Error 40-190 Failure code (CA145) Coolant Temp Sens Low Error 40-192 Failure code (CA153) Chg Air Temp Sensor High Error 40-194 Failure code (CA154) Chg Air Temp Sensor Low Error 40-196 Failure code (CA1625) EGR Valve Servo Error 2 40-257 Failure code (CA1633) KOMNET Datalink Timeout Error 40-258 Failure code (CA187) Sens Supply 2 Volt Low Error 40-198 Failure code (CA212) Eng Oil Temp Sensor High Error 40-200 Failure code (CA213) Eng Oil Temp Sensor Low Error 40-202 Failure code (CA2185) Throt Sens Sup Volt High Error 40-259 Failure code (CA2186) Throt Sens Sup Volt Low Error 40-260 Failure code (CA221) Ambient Press Sens High Error 40-204 Failure code (CA222) Ambient Press Sens Low Error 40-206 Failure code (CA2249) Rail Press Very Low Error 40-261
D375A-6 (07)
Index
Failure code (CA227) Sens Supply 2 Volt High Error 40-208 Failure code (CA2271) EGR Valve Pos Sens High Error 40-262 Failure code (CA2272) EGR Valve Pos Sens Low Error 40-264 Failure code (CA234) Eng Overspeed 40-209 Failure code (CA2351) EGR Valve Sol Current High Error 40-266 Failure code (CA2352) EGR Valve Sol Current Low Error 40-268 Failure code (CA238) Ne Speed Sens Supply Volt Error 40-210 Failure code (CA263) Fuel Temp Sensor High Error 40-212 Failure code (CA265) Fuel Temp Sensor Low Error 40-214 Failure code (CA271) IMV/PCV1 Short Error 40-216 Failure code (CA272) IMV/PCV1 Open Error 40-217 Failure code (CA273) PCV2 Short Error 40-218 Failure code (CA274) PCV2 Open Error 40-219 Failure code (CA322) Inj #1 (L#1) Open/Short Error 40-220 Failure code (CA323) Inj #5 (L#5) Open/Short Error 40-222 Failure code (CA324) Inj #3 (L#3) Open/Short Error 40-224 Failure code (CA325) Inj #6 (L#6) Open/Short Error 40-226 Failure code (CA331) Inj #2 (L#2) Open/Short Error 40-228 Failure code (CA332) Inj #4 (L#4) Open/Short Error 40-226 Failure code (CA342) Calibration Code Incompatibility 40-232 Failure code (CA351) Injectors Drive Circuit Error 40-233 Failure code (CA352) Sens Supply 1 Volt Low Error 40-234 Failure code (CA386) Sens Supply 1 Volt High Error 40-236 Failure code (CA441) Battery Voltage Low Error 40-237 Failure code (CA442) Battery Voltage High Error 40-238 Failure code (CA449) Rail Press Very High Error 40-239 Failure code (CA451) Rail Press Sensor High Error 40-240 Failure code (CA452) Rail Press Sensor Low Error 40-242 Failure code (CA553) Rail Press High Error 40-244 Failure code (CA554) Rail Press Sensor In Range Error 40-245 Failure code (CA559) Rail Press Low Error 40-246 Failure code (CA689) Eng Ne Speed Sensor Error 40-250 Failure code (CA731) Eng Bkup Speed Sens Phase Error 40-252 Failure code (CA757) All Continuous Data Lost Error 40-253 Failure code (CA778) Eng Bkup Speed Sensor Error 40-254 Failure code (D110KB) Battery Relay Drive Short Circuit 40-270 Failure code (D130KA) Neutral relay Disconnection 40-272
D375A-6 (07)
Failure code (D130KB) Neutral relay Short circuit 40-274 Failure code (D161KA) Back-up alarm releay Disconnection 40-276 Failure code (D161KB) Back-up alarm releay Short circuit 40-278 Failure code (D182KZ) Preheater Relay Abnormality 40-280 Failure code (D190KA) ACC signal relay Disconnection 40-282 Failure code (D190KB) ACC signal relay Short circuit 40-284 Failure code (D1EFKA) Pre lub. motor relay Disconnection 40-286 Failure code (D1EFKB) Pre lub. motor relay Short circuit 40-288 Failure code (DAFRKR) Monitor Can communication lost (PT) 40-290 Failure code (dAFRKR) Monitor CAN communication lost (WE) 40-291 Failure code (DAFRMC) CAN Discon (Monitor Detected) 40-292 Failure code (DB2RKR) ENG cont. Can communication lost (PT) 40-297 Failure code (dB2RKR) ENG controller CAN communication lost (WE) 40-300 Failure code (DB90KT) WE controller Abnormality in controller 40-301 Failure code (DB91KK) WE controller Source voltage reduction 40-302 Failure code (DB92KK) WE controller Output voltage reduction 40-304 Failure code (DB97KK) WE cont. Sensor voltage 5 V (2) reduction 40-306 Failure code (DB99KQ) WE controller Type select signal 40-308 Failure code (DB9RKR) WE controller Can communication lost (PT) 40-309 Failure code (DBB0KK) VHMS controller Source voltage reduction 40-312 Failure code (DBB0KQ) VHMS connector connection abnormality 40-314 Failure code (DBB3KK) VHMS controller Source voltage reduction 40-316 Failure code (DBB5KP) VHMS Output sensor1 voltage reduction 40-318 Failure code (DBB6KP) VHMS Output sensor1 voltage reduction 40-320 Failure code (DBB7KP) VHMS Output sensor3 voltage reduction 40-322 Failure code (DBBQKR) PT cont. Can communication lost (VHMS) 40-323 Failure code (DBE0KT) PT controller Abnormality in controller 40-323 Failure code (DBE1KK) PT controller Source voltage reduction 40-324 Failure code (DBE2KK) PT controller Output voltage reduction 40-326 Failure code (DBE5KK) PT cont. Sensor voltage 5 V (1) reduction 40-328 Failure code (DBE6KK) PT cont. Sensor voltage 24 V reduction 40-330 Failure code (DBE7KK) PT cont. Sensor voltage 5 V reduction 40-332
3
Index
Failure code (DBE9KQ) PT controller Type select signal 40-334 Failure code (DBERKR) PT controller Can communication lost (WE) 40-335 Failure code (DD12KA) Shift up Sw Disconnection 40-338 Failure code (DD12KB) Shift up Sw Short circuit 40-340 Failure code (DD13KA) Shift down Sw Disconnection 40-342 Failure code (DD13KB) Shift down Sw Short circuit 40-344 Failure code (DD14KA) Parking lever Sw Dissconnection 40-346 Failure code (DD14KB) Parking lever Sw Short circuit 40-348 Failure code (DDB9L4) Reverse SW Signal disagreement 40-350 Failure code (DDE2KA) Pre lub. oil press sw Disconnection 40-352 Failure code (DDK3L4) Forward SW Signal disagreement 40-354 Failure code (DDK5KA) Shift switch disconnection 40-356 Failure code (DDK5KB) Shift switch short circuit 40-358 Failure code (DDN2LD) Blade tilt RH pressure SW abnormality 40-360 Failure code (DDN3LD) Blade tilt LH pressure SW abnormality 40-362 Failure code (DDN7KA) WEQ Knob Sw (down) Disconnection 40-364 Failure code (DDN7KB) WEQ Knob Sw (down) Short circuit 40-366 Failure code (DDN9KA) WEQ Knob Sw (up) Disconnection 40-368 Failure code (DDN9KB) WEQ Knob Sw (up) Short circuit 40-370 Failure code (DDNALD) Blade lift up pressure SW abnormality 40-372 Failure code (DDNBLD) Ripper lift up pressure SW abnormality 40-374 Failure code (DDNCLD) Ripper lift down pressure SW abnormality 40-376 Failure code (DDNDLD) Ripper tilt in pressure SW abnormality 40-378 Failure code (DDNELD) Ripper tilt back pressure SW abnormality 40-380 Failure code (DDNFLD) Blade lift down pressure SW abnormality 40-382 Failure code (DDNLKA) Weq lock Sw Disconnection 40-384 Failure code (DDNLKB) Weq lock Sw Short circuit 40-386 Failure code (DDT5KA) Neutral switch disconnection 40-388 Failure code (DDT5KB) Neutral switch short circuit 40-390 Failure code (DDT5KQ) Lever SPEC selection signal disagreement 40-392 Failure code (DDTSL1) S/C Fill high 40-394 Failure code (DDTSLH) S/C Fill low 40-396 Failure code (DGE5KX) Ambient temp sensor abnormality 40-398
4
Failure code (DGS1KX) Hyd oil temp signal abnormal 40-400 Failure code (DGT1KA) T/C oil temp sensor Abnormal 40-402 Failure code (DGT1KX) T/C oil temp sensor Abnormal 40-404 Failure code (DGT5KA) F exhaust temp sensor disconnection 40-406 Failure code (DGT5KB) F exhaust temp sensor short circuit 40-408 Failure code (DGT6KA) R exhaust temp sensor disconnection 40-410 Failure code (DGT6KB) R exhaust temp sensor short circuit 40-412 Failure code (DH21KA) Weq pressure sensor Disconnection 40-414 Failure code (DH21KB) Weq pressure sensor Short circuit 40-416 Failure code (DHE5KB) ENG blow-by pressure sensor disconnection 40-418 Failure code (DHE5KY) ENG blow-by pressure sensor short circuit 40-420 Failure code (DHT3KX) T/M oil pressure sensor abnormality 40-422 Failure code (DHT5KA) T/C in-pressure sensor Disconnection 40-424 Failure code (DHT5KB) T/C in-pressure sensor Short circuit 40-426 Failure code (DHT7KA) T/C out-pressure sensor Disconnection 40-428 Failure code (DHT7KB) T/C out-pressure sensor Short circuit 40-430 Failure code (DK10KA) Fuel control Dial Disconnection 40-432 Failure code (DK10KB) Fuel control Dial Short circuit 40-434 Failure code (DK30KA) ST lever 1 Disconnection 40-436 Failure code (DK30KB) ST lever 1 Short circuit 40-438 Failure code (DK30KX) ST lever Out of normal range 40-440 Failure code (DK30KZ) ST lever Disconnection or short circuit 40-440 Failure code (DK30L8) ST lever Signal mismatch 40-441 Failure code (DK31KA) ST lever 2 Disconnection 40-442 Failure code (DK31KB) ST lever 2 Short circuit 40-444 Failure code (DK40KA) Brake potentiometer Disconnection 40-446 Failure code (DK40KB) Brake potentiometer Short circuit 40-448 Failure code (DK55KX) FR lever Out of normal range 40-450 Failure code (DK55KZ) FR lever Disconnection or short circuit 40-450 Failure code (DK55L8) FR lever Signal mismatch 40-451 Failure code (DK56KA) FR lever 1 Disconnection 40-452 Failure code (DK56KB) FR lever 1 Short circuit 40-454 Failure code (DK57KA) FR lever 2 Disconnection 40-456 Failure code (DK57KB) FR lever 2 Short circuit 40-458 Failure code (DK60KB) Acceleration sensor Short circuit 40-462 Failure code (DKH1KA) Pitch angle sensor Disconnection 40-464
D375A-6 (07)
Index
Failure code (DKH1KB) Pitch angle sensor Short circuit 40-466 Failure code (DLF1KA) T/C out-speed sensor Disconnection 40-468 Failure code (DLM3KA) Fan rev. sensor Disconnection 40-469 Failure code (DLM3MB) Fan control Decline 40-470 Failure code (DLT3KA) T/M out-speed sensor Disconnection 40-471 Failure code (DLT3KB) T/M out-speed sensor Abnormal 40-472 Failure code (DW59KA) Blade dual selector SOL disconnection 40-473 Failure code (DW59KB) Blade dual selector SOL short circuit 40-474 Failure code (DW59KY) Blade dual selector SOL hot short 40-475 Failure code (DW5AKA) Blade pitch selector SOL disconnection 40-476 Failure code (DW5AKB) Blade pitch selector SOL short circuit 40-477 Failure code (DW5AKY) Blade pitch selector SOL hot short 40-478 Failure code (DW7BKA) Fan rev EPC Disconnection 40-479 Failure code (DW7BKB) Fan rev EPC Short circuit 40-480 Failure code (DWN3KA) Ssp solenoid Disconnection 40-481 Failure code (DWN3KB) Ssp solenoid Short circuit 40-482 Failure code (DWN3KY) SSP solenoid Short circuit 40-484 Failure code (DWN5KA) Fan pump solenoid 1 Disconnection 40-486 Failure code (DWN5KB) Fan pump solenoid 1 Short circuit 40-487 Failure code (DWN5KY) Fan pump solenoid 1 Hot Short 40-488 Failure code (DWNCKA) Fan pump solenoid 2 Disconnection 40-490 Failure code (DWNCKB) Fan pump solenoid 2 Short circuit 40-491 Failure code (DWNCKY) Fan pump solenoid 2 Hot Short 40-492 Failure code (DXH1KA) Lock-up ECMV Disconnection 40-494 Failure code (DXH1KB) Lock-up ECMV Short circuit 40-495 Failure code (DXH1KY) Lock-up ECMV Short circuit 40-496 Failure code (DXH4KA) 1st clutch ECMV Disconnection 40-498 Failure code (DXH4KB) 1st clutch ECMV Short circuit 40-499 Failure code (DXH4KY) 1st clutch ECMV Short circuit 40-500 Failure code (DXH5KA) 2nd clutch ECMV Disconnection 40-502 Failure code (DXH5KB) 2nd clutch ECMV Short circuit 40-503 Failure code (DXH5KY) 2nd clutch ECMV Short circuit 40-504
D375A-6 (07)
Failure code (DXH6KA) 3rd clutch ECMV Disconnection 40-506 Failure code (DXH6KB) 3rd clutch ECMV Short circuit 40-507 Failure code (DXH6KY) 3rd clutch ECMV Short circuit 40-508 Failure code (DXH7KA) R clutch ECMV Disconnection 40-510 Failure code (DXH7KB) R clutch ECMV Short circuit 40-511 Failure code (DXH7KY) R clutch ECMV Short circuit 40-512 Failure code (DXH8KA) F clutch ECMVDisconnection 40-514 Failure code (DXH8KB) F clutch ECMV Short circuit 40-515 Failure code (DXH8KY) F clutch ECMV Short circuit 40-516 Failure code (DXH9KA) Right clutch ECMV Disconnection 40-518 Failure code (DXH9KB) Right clutch ECMV Short circuit 40-519 Failure code (DXH9KY) Right clutch ECMV Hot Short 40-520 Failure code (DXHAKA) Left clutch ECMV Disconnection 40-522 Failure code (DXHAKB) Left clutch ECMV Short circuit 40-523 Failure code (DXHAKY) Left clutch ECMV Hot Short 40-524 Failure code (DXHBKA) Right brake ECMV Disconnection 40-526 Failure code (DXHBKB) Right brake ECMV Short circuit 40-527 Failure code (DXHBKY) Right brake ECMV Short circuit 40-528 Failure code (DXHCKA) Left brake ECMV Disconnection 40-530 Failure code (DXHCKB) Left brake ECMV Short circuit 40-531 Failure code (DXHCKY) Left brake ECMV Short circuit 40-532 Failure code (DXJBKA) S/C ECMV Disconnection 40-534 Failure code (DXJBKB) S/C ECMV Short circuit 40-535 Failure code (DXJBKY) S/C ECMV Short circuit 40-536 Failure code (DY2HKA) Pre lub. motor Disconnection 40-538 Failure code (F@BBZL) ENG blow-by pressure high level 40-540 Failure code (F@BYNR) F exhaust temp high level (2) 40-541 Failure code (F@BYNS) F exhaust temp high level (1) 40-542 Failure code (F@BZNR) R exhaust temp high level (2) 40-543 Failure code (F@BZNS) R exhaust temp high level (1) 40-544 Failure codes table 40-39 Final drive 10-103, 60-41 FRESH/RECIRC air changeover damper 80-15 Fuse locations table 40-105
5
Index
H H-1 No force (no drawbar pull) 40-604 H-2 No travel (at 2nd or 3rd speed) 40-606 H-3 No travel at all gear speeds 40-607 H-4 Machine travels only in one direction forward or in reverse 40-608 H-5 Large time lag at gear speed shifting or forward-reverse shifting 40-609 H-6 Steering is not possible 40-610 H-7 Steering is possible only on one side 40-611 H-8 Steering overrun occurs 40-612 H-9 Brake does not work 40-612 H-10 Torque converter is not lock-up 40-613 H-11 Power train oil overheats 40-614 H-12 All work equipment operates slowly or lacks power 40-615 H-13 All work equipment does not operate 40-616 H-14 Blade lift speed is slow or lacks power 40-617 H-15 Blade tilt speed is slow or lacks power 40-617 H-16 Ripper lift speed is slow or lacks power 40-618 H-17 Ripper tilt speed is slow or lacks power 40-618 H-18 Excessive hydraulic drift of blade lift 40-619 H-19 Excessive hydraulic drift of blade tilt 40-619 H-20 Excessive hydraulic drift of ripper lift 40-620 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) 40-620 H-22 Blade pitch does not work (dual tilt attachment machine) 40-621 H-23 Abnormal sound comes out from around work equipment pump 40-621 H-24 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats) 40-622 H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator) 40-622 Handling of compressor oil 80-64 Handling of connectors newly used for engines 00-23 Handling of electric equipment and hydraulic component 00-14 Handling of fuel system devices 30-24 Handling of no injection cranking operation 30-27 Handling of optional devices 30-149 Handling of reduced cylinder mode operation 30-27 Handling of voltage circuit of engine controller 30-139 How to read electric wire code 00-26 How to read the shop manual 00-10 How to read this manual 50-4 Hydraulic circuit diagram 90-7 Hydraulic cylinder 60-72 Hydraulic tank 10-124
I Idler 60-50 Idler cushion 10-110, 60-48 Information contained in troubleshooting table 40-545 Information in troubleshooting table 40-47,40-601,80-40 Initialization procedures for VHMS controller 30-152 Inspecting wear of sprocket 30-60 Inspection procedure of diode 30-148
6
M Machine monitor 10-198 Main frame 10-112, 60-60 Main relief valve and torque converter relief valve 10-48, 60-22 Measuring and adjusting work equipment oil pressure 30-62 Measuring compression pressure 30-16 Measuring fan speed 30-35 Method of disassembling and connecting push-pull type coupler 00-32 Method of using troubleshooting chart 40-624 Monitor system 10-196
N Notice of revision
1
O ORBCOMM system 10-230 Outline of refrigerating cycle 80-7 Overall disassembly and assembly of track shoe 50-230 Overall drawing of power train unit 10-34
P Palm command control system 10-217 Parking brake valve 10-99, 60-40 Part and connector locations 80-28 PCCS lever 10-58 Pin puller solenoid valve 10-143 Pin puller switch 10-142 Pm Clinic service 30-181 Points to remember when troubleshooting 40-9 Power train 10-32 Power train and lubricating pump 60-31 Power train hydraulic circuit diagram 90-5 Power train hydraulic equipment arrangement drawing 10-36 Power train unit 60-14 PPC control piping diagram 10-121 PPC lock valve 10-127 PPC valve 10-129, 60-67 Precautions for disconnecting and connecting in air conditioner piping 80-62 Precautions for replacing VHMS controller 30-175 Precautions when carrying out work 00-29 Preparation work for troubleshooting of electrical system 30-144 Procedure for testing and troubleshooting 80-22
Q Quick drop valve
10-141, 60-75
R
L Lamp system
Link press press-fitting jig dimensions 50-247 List of Abbreviation 00-39 List of Failure Modes and Causes 40-602 Lockup clutch ECMV and stator clutch ECMV 10-50, 60-23
10-215
Receiver drier
80-18
D375A-6 (07)
Index
Releasing remaining pressure in work equipment cylinders 30-72 Releasing residual pressure from fuel system 30-25 Removal and installation of aftercooler 50-63 Removal and installation of air conditioner unit assembly 50-318 Removal and installation of blade assembly 50-298 Removal and installation of bogie assembly 50-214 Removal and installation of carrier roller assembly50-209 Removal and installation of control valve assembly 50-275 Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler) 50-54 Removal and installation of cylinder head assembly 50-33 Removal and installation of damper assembly 50-86 Removal and installation of engine assembly 50-63 Removal and installation of engine controller assembly 50-325 Removal and installation of engine front seal 50-73 Removal and installation of engine hood assembly 50-70 Removal and installation of engine rear seal 50-75 Removal and installation of equalizer bar 50-258 Removal and installation of fan drive assembly 50-79 Removal and installation of fan motor assembly 50-81 Removal and installation of fan pump assembly 50-273 Removal and installation of final drive assembly 50-171 Removal and installation of first bogie assembly 50-221 Removal and installation of floor frame assembly 50-313 Removal and installation of fuel injector assembly 50-28 Removal and installation of fuel supply pump assembly 50-24 Removal and installation of fuel tank assembly 50-83 Removal and installation of hydraulic oil cooler 50-61 Removal and installation of hydraulic tank assembly 50-266 Removal and installation of idler assembly 50-192 Removal and installation of machine monitor assembly 50-328 Removal and installation of operator's cab assembly 50-309 Removal and installation of operator's seat isolator 50-323-1 Removal and installation of pivot shaft assembly 50-257 Removal and installation of power train pump and lubrication pump assembly 50-169 Removal and installation of power train unit assembly 50-93 Removal and installation of radiator 50-59 Removal and installation of radiator guard assembly 50-49 Removal and installation of recoil spring assembly 50-196 Removal and installation of ROPS guard 50-308 Removal and installation of scavenging pump assembly 50-170 Removal and installation of segment tooth 50-264 Removal and installation of track frame assembly 50-186 Removal and installation of track roller assembly 50-203 Removal and installation of transmission controller assembly and steering controller assembly 50-324 Removal and installation of VHMS controller assembly 50-327
D375A-6 (07)
Removal and installation of work equipment pump assembly 50-269 Replacing and adjusting alternator and air conditioner compressor belt 30-34 Request for opening ORBCOMM terminal 30-150 Ripper 60-94
S S-1 Engine does not start easily 40-628 S-2 Engine does not start 40-630 S-3 Engine does not pick up smoothly (follow-up is poor) 40-634 S-4 Engine stops during operation 40-636 S-5 Engine does not rotate smoothly (hunting) 40-637 S-6 Engine lacks output (or lacks power) 40-638 S-7 Exhaust smoke is black (Incomplete combustion) 40-640 S-8 Oil is consumed much (or exhaust gas color is blue) 40-642 S-9 Engine oil becomes contaminated quickly 40-643 S-10 Fuel consumption is excessive 40-644 S-11 Coolant contains oil (blows back or reduces)40-645 S-12 Oil pressure monitor lights up (drop in oil pressure) 40-646 S-13 Oil level rises (Water, fuel in oil) 40-647 S-14 Coolant temperature rises too high (Overheating) 40-649 S-15 Abnormal noise is made 40-650 S-16 Vibration is excessive 40-651 S-17 Air cannot be bled from fuel circuit (After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls) 40-652 Safety notice 00-5 Scavenging pump 10-55, 60-24 Self-pressure reducing valve 10-173, 60-85 Sensor 10-220 Sequence of events in troubleshooting 40-10 Separation and connection of track shoe assembly 50-226 Simple test procedure for brake performance 30-53 Sketches of special tools 50-16 Special functions of machine monitor (EMMS) 30-82 Special tool list 50-9 Specification drawing 01-3 Specifications 01-4 Sprocket 60-44 Standard tightening torque table 00-35 Standard value table for engine 20-3 Standard value table for machine 20-4 Steering and brake control 10-82 Steering clutch ECMV and steering brake ECMV 10-92, 60-39 Steering control valve 10-90, 60-38 Sudden stop prevention valve 10-101 Suspensions 10-114, 60-62 Symbols used in electrical circuit diagrams 90-9 Symbols used in hydraulic circuit diagrams 90-3 System diagram 80-26
T T-branch box and T-branch adapter table Table of contents Table of fuel, coolant and lubricants
40-102 00-2 01-11
7
Index
Testing and adjusting operator's cab 30-77 Testing and adjusting operator's seat isolator 30-81-1 Testing and adjusting track shoe tension 30-61 Testing blow-by pressure 30-19 Testing control circuit main pressure 30-65 Testing EGR valve drive oil pressure 30-22 Testing engine oil pressure 30-21 Testing engine speed 30-6 Testing exhaust gas color 30-12 Testing exhaust temperature 30-10 Testing fan circuit oil pressure 30-36 Testing FRESH/RECIC changeover 80-32 Testing fuel circuit for leakage 30-33 Testing fuel pressure 30-26 Testing intake air pressure (boost pressure) 30-8 Testing leakage from pressure limiter and return rate from injector 30-28 Testing leakage inside work equipment cylinder 30-71 Testing output pressure of ripper pin-puller solenoid valve 30-69 Testing power train oil pressure 30-40 Testing PPC valve output pressure 30-66 Testing relay 80-34 Testing temperature control 80-32 Tools for testing, adjusting, and troubleshooting 30-4 Torque converter and PTO 10-40, 60-19 Torque converter control valve 10-46 Track frame 10-108, 60-46 Track roller 60-52 Track roller bogie 10-111, 60-55 Track shoe 60-56 Transfer unit, bevel gear shaft and steering 10-84 Transfer, bevel gear shaft and steering unit 60-32 Transmission 10-62, 60-26 Transmission control 10-56, 60-25 Transmission ECMV 10-76 Transmission lubricating oil relief valve 10-81, 60-30 Troubleshooting chart 1 80-36 Troubleshooting chart 2 80-38 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) 80-48 Troubleshooting for compressor system (Air is not cooled) 80-44 Troubleshooting for FRESH/RECIRC air changeover 80-56 Troubleshooting for power supply system (Air conditioner does not operate) 80-42 Troubleshooting for temperature control 80-54 Troubleshooting method for disconnecting wiring harness of pressure sensor system 40-49 Troubleshooting with gauge pressure 80-58 Using method of KOMTRAX functions of ORBCOMM terminal 30-172
V Vehicle health monitoring system (VHMS)
10-224
W Weight table 01-9 Work equipment control 10-122 Work equipment hydraulic piping diagram 10-117 Work equipment pump 10-146, 60-76
8
D375A-6 (07)
Shop Manual
D375A-6 BULLDOZER Form Number: SEN05006-09
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12