SEBM017208
1
D475A-3 MACHINE MODEL
SERIAL No.
D475A-3
10601 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
D475A-3 mount the SDA12V140-1 engine. For details of the engine, see the 12V140-1 Series Engine Shop Manual.
© 2002 1 All Rights Reserved Printed in Japan 08-02(01)
00-1 8
CONTENTS No. of page
01
GENERAL ........................................................................
01-1
10
STRUCTURE AND FUNCTION ......................................
10-1
20
TESTING AND ADJUSTING ..........................................
20-1
30
DISASSEMBLY AND ASSEMBLY .................................
30-1
40
MAINTENANCE STANDARD .........................................
40-1
90
OTHERS...........................................................................
90-1
00-2 3
D475A-3
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D475A-3
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two 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 signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. 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.
00-3
SAFETY
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. 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, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19. Be sure to assemble all parts again in their original places. Replace any damaged parts 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 being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. 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.
F O R EW OR D
GENERAL
F O R EWOR D GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
F O R EW OR D
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark (123....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: volume to cover all Attachments volume: models
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume):
Item
¤
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
10 - 3 Item number (10. Structure and Function) Consecutive page number for each item.
fl 4
Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 10-4-1 10-4-2 10-5
00-6
Added pages
12-203 12-203-1 12-203-2 12-204
Remarks
Symbol
3 2
5 6
Tightening Places that require special attention for the tightening torque torque during assembly. Coat
Places to be coated with adhesives and lubricants, etc.
Places where oil, water or fuel Oil, water must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
F O R EW OR D
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4
• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
Allowable load
mm
kN
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
tons
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. ¤ Slinging with one 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. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
°
fl The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.
00-7
F O R EW OR D
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the table below when disassembling and connecting the coupler. Type 2
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
Disassembly
Type 1
00-8
F O R EW OR D
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2
• Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
• Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Type 1
00-9
F O R EW OR D
COATING MATERIALS
COATING MATERIALS fl The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. fl For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LT–1A
790–129–9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
LT–1B
790–129–9050
20 g (2 pes.)
• Used in places requiring an immediately effective, strong adhesive. Used for plasPolyethylene tics (except polyethylene, polyprophylene, container tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.
50 g
• Features: Resistance to heat and chemiPolyethylene cals container • Used for anti-loosening and sealant purpose for bolts and plugs.
LT–2
09940–00030
LT–3
790–129–9060 Adhesive: 1 kg (Set of adheHardening sive and agent: hardening 500 g agent)
LT–4
790–129–9040
250 g
Holtz MH 705
790–126–9120
75 g
• Used as adhesive or sealant for metal, glass and plastic. Can
Adhesives
Three bond 1735
790–129–9140
Tube
• Used as heat-resisting sealant for repairing engine.
50 g
• Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. container • Used mainly for adhesion of metals, rubbers, plastics and woods.
Aron-alpha 201
790–129–9130
2g
• Quick hardening type adhesive • Quick cure type (max. strength after 30 minPolyethylene utes) container • Used mainly for adhesion of rubbers, plastics and metals.
Loctite 648-50
79A–129–9110
50 cc
• Features: Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high temcontainer peratures.
LG-1
790–129–9010
200 g
LG-5
790–129–9080
1 kg
Gasket sealant
LG-6
00-10
Polyethylene • Used as sealant for machined holes. container
790–129-9020
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
• Used as sealant for various threads, pipe joints, flanges. Polyethylene container • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.
F O R EW OR D
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LG-7
790-129-9070
1 kg
Tube
• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
Three bond 1211
790–129–9090
100 g
Tube
• Used as heat-resisting sealant for repairing engine.
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding portion (to prevent from squeaking).
LM-P
09940-00040
200 g
Tube
• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A Various SYG2-160CA SYGA-160CNCA
Gasket sealant
Molybdenum disulphide lubricant
Grease
Molybdenum disulphide lubricant
SYG2-400M
• General purpose type Various
400 g (10 per case)
Various
Various
Belows type
• Used for normal temperature, light load bearing at places in contact with water or steam.
• Used for places with heavy load
00-11
F O R EW OR D
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12 14
10 13 17 19 22
16 18 20 22 24
24 27 30 32 36
279 ± 30 382 ± 39 549 ± 59 745 ± 83 927 ± 103
28.5 ± 3 39 ± 4 56 ± 6 76 ± 8.5 94.5 ± 10.5
27 30 33 36 39
41 46 50 55 60
1320 ± 140 1720 ± 190 2210 ± 240 2750 ± 290 3290 ± 340
135 ± 15 175 ± 20 225 ± 25 280 ± 30 335 ± 35
Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12
10 13 14 27
Nm
kgm 1.35 ± 0.15 3.2 ± 0.3 6.7 ± 0.7 11.5 ± 1 18 ± 2
13.2 ± 1.4 31 ± 3 66 ± 7 113 ± 10 177 ± 19
Nm
kgm 0.8 ± 0.2 1.9 ± 0.5 4.1 ± 0.6 8.4 ± 0.8
7.85 ± 1.95 18.6 ± 4.9 40.2 ± 5.9 82.35 ± 7.85
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS fl In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. SAD00483
Thread diameter
Width across flat
mm
mm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
00-12
Tightening torque Nm 24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
kgm 2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
F O R EW OR D
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS fl In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque
Thread diameter
Width across flat
mm
mm
Nm
10 12 16
14 17 22
65.7 ± 6.8 112 ± 9.8 279 ± 29
kgm 6.7 ± 0.7 11.5 ± 1 28.5 ± 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS fl Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Nominal No.
Thread diameter mm
02 03, 04 05, 06 10, 12 14
14 20 24 33 42
Width across flat mm Varies depending on type of connector.
Tightening torque Nm
kgm
34.3 ± 4.9 93.1 ± 9.8 142.1 ± 19.6 421.4 ± 58.8 877.1 ± 132.3
3.5 ± 0.5 9.5 ± 1 14.5 ± 2 43 ± 6 89.5 ± 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS fl Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Tightening torque
Width across flat mm
Nm
kgm
14 17 19 22 24 27 30 32 32 — 36 — —
7.35 ± 1.47 11.27 ± 1.47 17.64 ± 1.96 22.54 ± 1.96 29.4 ± 4.9 39.2 ± 4.9 49 ± 4.9 68.6 ± 9.8 107.8 ± 14.7 127.4 ± 19.6 151.9 ± 24.5 210.7 ± 29.4 323.4 ± 44.1
0.75 ± 0.15 1.15 ± 0.15 1.8 ± 0.2 2.3 ± 0.2 3 ± 0.5 4 ± 0.5 5 ± 0.5 7± 1 11 ± 1.5 13 ± 2 15.5 ± 2.5 21.5 ± 3 33 ± 4.5
00-13
F O R EW OR D
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter mm 6 8 10 12
Tightening torque Nm 10 24 43 77
± ± ± ±
kgm
2 4 6 12
1.02 2.45 4.38 7.85
± ± ± ±
0.20 0.41 0.61 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter mm 6 8 10 12 14
Tightening torque Nm 8 10 12 24 36
± ± ± ± ±
kgm 0.81 1.02 1.22 2.45 3.67
2 2 2 4 5
± ± ± ± ±
0.20 0.20 0.20 0.41 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1
00-14
Tightening torque Nm 3 8 12 15 24 36 60
± ± ± ± ± ± ±
1 2 2 2 4 5 9
kgm 0.31 0.81 1.22 1.53 2.45 3.67 6.12
± ± ± ± ± ± ±
0.10 0.20 0.20 0.41 0.41 0.51 0.92
F O R EW OR D
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS Copper wire Nominal number
Number of Dia. of strands Cross section strands (mm) (mm2)
Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
2
26
0.32
2.09
3.1
20
Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
17.6
230
Starting
109.1
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification 1
2
Pri- Code mary Color Code
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
W
B
B
R
Y
G
L
White
Black
Black
Red
Yellow
Green
Blue
WR
—
BW
RW
YR
GW
LW
Color White & Red 3
4
5
Code
WB
—
Color White & Black
—
WL Auxi- Code liary Color White & Blue
—
Code
WG
Color White & Green 6
—
—
Black & White Red & White Yellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red BR
RY
YG
GY
LY
Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
—
—
—
—
Code
—
—
—
Color
—
—
—
RG
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
— —
00-15
F O R EW OR D
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. details of the method of using the Conversion Table, see the example given below.
For
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, 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 two 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 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.
0 10 20 30 40
0
1
2
3
4
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
5
..........................................
B Millimeters to inches
0.197 0.591 0.984 1.378 1.772 C 50 1.969 2.008 2.047 2.087 2.126 2.165 A ........................................................................................... 60 2.362 2.402 2.441 2.480 2.520 2.559 70 2.756 2.795 2.835 2.874 2.913 2.953 80 3.150 3.189 3.228 3.268 3.307 3.346 90 3.543 3.583 3.622 3.661 3.701 3.740
00-16
1 mm = 0.03937 in
6
7
8
9
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
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
2.323 2.717 3.110 3.504 3.898
F O R EW OR D
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0
0
1
2
3
4
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
5
6
7
8
9
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
F O R EW OR D
CONVERSION TABLE
Liter to U.S. Gallon 1¶ = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon 1¶ = 0.21997 U.K. Gal
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
0
00-18
F O R EW OR D
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
F O R EW OR D
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
F O R EW OR D
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 or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
F O R EW OR D
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kw/rpm {HP/rpm} g/kwh {g/HPh}
00-22
}.
01
GENERAL
Specification dimension drawings.. ........... Specifications ............................................... Weight table ................................................ Table of fuel, coolant and lubricants.. ......
D475A-3
Ol- 2 Ol- 4 01-13 01-17
01-l 0
SPECIFICATION DIMENSION
GENERAL
SPECIFICATION .
DIMENSION
DRAWINGS
SEMI U-TILTDOZER + GIANT RIPPER
I-
DRAWINGS
Unit: mm
6120
-I
I
SVD02956
l
U-TILTDOZER + GIANT RIPPER
1 0
,
SVD02957
01-2 0
D475A-3
GENERAL
•
SUPER DOZER + COUNTERWEIGHT
D475A-3
SPECIFICATION DIMENSION DRAWINGS
Unit: mm
01-3 1 3
GENERAL
SPECIFICATIONS
SPECIFICATIONS •
SEMI U-TILTDOZER, U-TILTDOZER Machine model
D475A-3
Serial No.
10601 – 10684
10685 and up
75,200
75,700
91,350
91,850
• With above + variable giant ripper
98,650
99,150
• With above + ROPS cab + air conditioner • + perforated side cover
100,000
100,500
Operating weight
Weight
• Bare tractor • With above + semi U-dozer
Min. turning radius
kg
m
4.6
Gradeability
deg
30
Stability (front, rear, left, fight)
deg
35
Performance
Speed ranges
Forward 1st Forward 2nd
0 – 3.5 km/h
0 – 6.3
Forward 3rd
0 – 10.9
Reverse 1st
0 – 4.7
Reverse 2nd
km/h
0 – 8.4
119 {1.22}
144.16 {1.47}
145.2 {1.48}
155.93 {1.59}
156 {1.60}
157.89 {1.61}
159 {1.62}
Bare tractor
6,420
6,420
8,710
8,710
With semi U-dozer + variable giant ripper
11,560
11,570
With U-dozer + variable giant ripper
11,950
11,950
Bare tractor
3,600
3,610
5,265
5,265
6,205
6,205
Ground pressure
118.66 {1.21}
Overall length Dimensions
0 – 14.3
Overall height Overall Width
Reverse 3rd
01-4 1 5
Bare tractor With semi U-dozer With semi U-dozer + variable giant ripper
kPa {kg/cm2}
With above + ROPS cab + air conditioner + perforated side cover
With semi U-dozer mm
With semi U-dozer
mm
With U-dozer To top of ROPS To tip of exhaust pipe To top of intake duct
4,570 mm
4,420 3,760
D475A-3
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Dimensions
Serial No. Track gauge
4,365 mm
Track shoe width
710
Min. ground clearance
655
Name
SDA12V140
Type
4-cycle, water-cooled, V-type, vertical type, direct injection, with turbocharger, aftercooler mm
12 – 140 x 165
¬ {cc}
30.48 (30,480)
kW/rpm {HP/rpm}
641/2,000 {860/2,000}
Nm/rpm {kgm/rpm}
3,825/1,400 {390/1,400}
Max. speed at no load
rpm
2,150
Min. speed at no load
rpm
600
g/kW·h {g/HP·h}
204 {152}
Piston displacement
Performance
Rated horsepower
Engine
10685 and up 2,770
Length of track on ground
No. of cylinders – bore x stroke
Max. torque
Min. fuel consumption ratio Starting motor Alternator Battery Radiator core type Torque coveter
Transmission
Power train system
10601 – 10684
24 V, 7.5 kW x 2 24 V, 75 A 12 V, 200 Ah x 4 D type 3-element, single stage, single phase (with lock up clutch) Planetary gear type, multiple disc clutch, hydraulically actuated, force-feed lubrication gear pump, forward 3 speed, reverse 3 speed
Bevel gear shaft
Spiral bevel gear, splash type lubrication
Steering clutch
Wet type, multiple clutch disc, spring boosted, hydraulically actuated (manual type), interconnected with brake
Steering brake
Wet type, multiple clutch disc, spring boosted, hydraulically actuated (pedal operated, manually operated), interconnected with clutch
Final drive
D475A-3
Spur gear 1-stage, planetary gear 1-stage reduction gear, splash type lubrication
01-5 1 5
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Undercarriage
Serial No.
10601 – 10684
10685 and up
Suspension
Rigid, balancing beam type
Carrier roller
2 on each side
Track roller
7 on each side
Track shoe
Assembly type, single grouser, 40 each side, pitch: 317.5 mm, width: 710 mm
Power train + lubrication pump (tendem)
Gear type (BAL160 + 112 + 112)
Scavenging pump (tandem)
Gear type (BAR63 + 280)
PPC control pump (tandem with assist pump) MPa {kg/cm2}
Hydraulic pump
Max. pressure
Assist pump
Gear type (SAR(1)032) 20.6 {210}
Type
Gear type, tandem (SAL(4)140 + (3)100)
Discharge (at engine speed 2,000 rpm)
¬/min
465
Type
Gear type (SAR(3)100) (tandem with PPC control pump)
Discharge (at engine speed 2,000 rpm)
¬/min
193
Work equipment hydraulic system Main control Hydraulic cylinders valve Dimensions of blade Dimensions of blade tilt cylinder lift cylinder
Type For blade lift
1-spool pilot spool type, with demand spool
For blade tilt, ripper (Lo)
3-spool pilot spool type
For ripper (Hi)
2-spool pilot spool type
Type Cylinder bore
180
Outside diameter of piston rod
110
Piston stroke
1 5
mm
1,781
Max. distance between pins
3,121 (3,121)
Min. distance between pins
1,340 (1,340)
Cylinder bore
250
Outside diameter of piston rod
140
Piston stroke
mm
285
Max. distance between pins
1,983
Min. distance between pins
1,698
fl The figures in (
01-6
Double acting, piston type
) show the dimensions for the U-blade.
D475A-3
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Dimensions of blade dual tilt cylinder Hydraulic cylinders
Dimensions of ripper Dimensions of ripper lift cylinder tilt cylinder
Work equipment hydraulic system
Serial No.
10601 – 10684
Cylinder bore (both left and right)
250
Outside diameter of piston rod (both left and right)
140
Piston stroke (both left and right)
mm
1,983
Min. distance between pins (both left and right)
1,698
Cylinder bore
250
Outside diameter of piston rod
120
Piston stroke
mm
2,175
Min. distance between pins
1,530
Cylinder bore
250
Outside diameter of piston rod
140
Piston stroke
mm
Performance Dimensions
540
Max. distance between pins
2,020
Min. distance between pins
1,480 Control valve assembled type (externally installed) Hydraulic semi U-tiltdozer, Hydraulic U-tiltdozer
Blade support method
Semi U-dozer
645
Max. distance between pins
Type
Work equipment
285
Max. distance between pins (both left and right)
Hydraulic tank
D475A-3
10685 and up
Brace type
Max. blade lifting height (from ground level)
mm
1,620
Max. blade lowering depth (from ground level)
mm
800
Max. tilt
mm
1,250
Blade cutting angle variation
deg
±6
Blade capacity
m3
35.9
Blade width
mm
5,265
Blade height
mm
2,610
Blade cutting angle
deg
52
01-7 1 5
GENERAL
SPECIFICATIONS
Machine model
D475A-3
01-8 1 5
Performance Dimensions Performance Dimensions Performance Performance Performance Dimensions
Semi U-dozer + pitch U-dozer + pitch Giant ripper
Multi-shank ripper
Work equipment
U-dozer
Serial No.
10601 – 10684
10685 and up
Max. blade lifting height (from ground level)
mm
1,620
Max. blade lowering depth (from ground level)
mm
800
Max. tilt
mm
1,345
Blade cutting angle variation
deg
±6
Blade capacity
m3
42.3
Blade width
mm
6,205
Blade height
mm
2,610
Blade cutting angle
deg
52
Max. tilt
mm
1,410
Max. pitch angle
deg
6
Max. pitch-back angle
deg
6
Max. tilt
mm
1,660
Max. pitch angle
deg
6
Max. pitch-back angle
deg
6
Max. digging depth
mm
1,180
Max. lifting height
mm
1,140
Ripping angle of point (standard)
deg
45 (adjustable steplessly 32.5 – 54.0)
Max. width of beam
mm
3,080
No. of shanks
3
Max. digging depth
mm
1,800
Max. lifting height
mm
1,140
Ripping angle (standard)
deg
45 (adjustable steplessly 34 – 56)
Max. width of beam
mm
1,477
No. of shanks
1
D475A-3
GENERAL
•
SPECIFICATIONS
SUPER DOZER Machine model
D475A-3
Serial No.
10601 – 10684
10685 and up
75,200
75,700
104,500
105,000
Weight
Operating weight • Bare tractor
kg
• Super dozer + ROPS cab + air conditioner • + counterweight Min. turning radius
m
4.6
Gradeability
deg
30
Stability (front, rear, left, fight)
deg
35
Speed ranges
Performance
Forward 1st Forward 2nd
0 – 3.5 km/h
0 – 6.3
Forward 3rd
0 – 10.9
Reverse 1st
0 – 4.7
Reverse 2nd
km/h
0 – 8.4
Ground pressure
Bare tractor
Dimensions Overall Overall height Overall Width length
Reverse 3rd
Bare tractor
D475A-3
Super dozer + ROPS cab + air conditioner + counterweight
0 – 14.3
mm
103.95 {1.06}
104.25 {1.07}
145.14 {1.48}
146.19 {1.49} 6,420
mm Super dozer + counterweight
10,370
Bare tractor
3,600
3,610
6,465
6,465
mm With super dozer To top of ROPS To tip of exhaust pipe To top of intake duct
4,570 mm
4,420 3,760
01-9 1 5
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10601 – 10684
Dimensions
Track gauge
10685 and up 2,770
Length of track on ground
4,365 mm
Track shoe width
810
Min. ground clearance
655
Name
SDA12V140
Type
4-cycle, water-cooled, V-type, vertical type, direct injection, with turbocharger, aftercooler
No. of cylinders – bore x stroke
mm
12 – 140 x 165
¬ {cc}
30.48 (30,480)
kW/rpm {HP/rpm}
632/2,000 {848/2,000}
Nm/rpm {kgm/rpm}
3,825/1,400 {390/1,400}
Max. speed at no load
rpm
2,150
Min. speed at no load
rpm
600
g/kW·h {g/HP·h}
204 {152}
Piston displacement
Performance
Engine
Rated horsepower Max. torque
Min. fuel consumption ratio Starting motor Alternator Battery Radiator core type Torque coveter
Power train system
Transmission
24 V, 75 A 12 V, 200 Ah x 4 D type 3-element, single stage, single phase (with lock up clutch) Planetary gear type, multiple disc clutch, hydraulically actuated, force-feed lubrication gear pump, forward 3 speed, reverse 3 speed
Bevel gear shaft
Spiral bevel gear, splash type lubrication
Steering clutch
Wet type, multiple clutch disc, spring boosted, hydraulically actuated (manual type), interconnected with brake
Steering brake
Wet type, multiple clutch disc, spring boosted, hydraulically actuated (pedal operated, manually operated), interconnected with clutch
Final drive
01-10 1 5
24 V, 7.5 kW x 2
Spur gear 1-stage, planetary gear 1-stage reduction gear, splash type lubrication
D475A-3
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Undercarriage
Serial No.
10601 – 10684
10685 and up
Suspension
Rigid, balancing beam type
Carrier roller
2 on each side
Track roller
7 on each side
Track shoe
Assembly type, single grouser, 40 each side, pitch: 317.5 mm, width: 810 mm
Power train + lubrication pump (tendem)
Gear type (BAL160 + 112 + 112)
Scavenging pump (tandem)
Gear type (BAR63 + 280)
PPC control pump (tandem with assist pump) MPa {kg/cm2}
Type Discharge (at engine speed 2,000 rpm)
Discharge (at engine speed 2,000 rpm)
20.6 {210} Gear type, tandem (SAL(4)140 + (3)100)
¬/min
Type
Work equipment hydraulic system Main control Hydraulic cylinders valve Dimensions of blade Dimensions of blade pitch cylinder lift cylinder
Assist pump
Hydraulic pump
Max. pressure
Gear type (SAR(1)032)
465 Gear type (SAR(3)100) (tandem with PPC control pump)
¬/min
193
Type For blade lift
1-spool pilot spool type, with demand spool
For blade pitch
3-spool pilot spool type
Type Cylinder bore
200
Outside diameter of piston rod
110
Piston stroke
mm
1,781
Max. distance between pins
3,121 (3,121)
Min. distance between pins
1,340 (1,340)
Cylinder bore
250
Outside diameter of piston rod
140
Piston stroke
mm
285
Max. distance between pins
1,983
Min. distance between pins
1,698
Hydraulic tank
D475A-3
Double acting, piston type
Control valve assembled type (externally installed)
01-11 1 5
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10601 – 10684
Type
Hydraulic super dozer (pitch dozer)
Performance Dimensions
Super dozer
Work equipment
Blade support method
01-12 1 5
10685 and up
Cylinder type
Max. blade lifting height (from ground level)
mm
1,620
Max. blade lowering depth (from ground level)
mm
800
Max. tilt
mm
1,660 (blade tip angle: 52°)
Blade cutting angle variation
deg
±6
Blade capacity
m3
45.0
Blade width
mm
6,465
Blade height
mm
3,220
Blade cutting angle
deg
42 – 67
D475A-3
GENERAL
WEIGHT TABLE
WEIGHT TABLE ¤ This weight table is a guide for use when transporting or when handling components. •
SEMI U-TILTDOZER, U-TILTDOZER
Unit: kg
Machine model Serial No.
D475A-3 10601 – 10684
10685 and up
Engine, damper assembly
3,940
• Engine assembly
3,740
• Damper assembly
214
Main radiator assembly
528
Sub. radiator assembly
162
Oil cooler assembly
157
Fuel tank assembly (when full)
858 (2,330)
Power train unit
4,980
• Torque converter, PTO assembly
750
• Transmission assembly
1,350
• Transmission valve assembly
70
• Steering clutch, brake assembly
2,290
• Steering valve assembly
26
Final drive assembly (each side)
3,575
Main frame assembly
9,120
Track group assembly (each side)
11,050
11,180
• Track frame (each side)
2,988
2,996
664
708
• Track roller assembly (single, each)
—
222
• Track roller assembly (double, each)
214
237
• Carrier roller assembly (each)
102
106
12,940
13,220
Pivot shaft assembly (each side)
370
370
Equalizer bar
598
598
• Idler assembly (each side)
Track shoe assembly (710 mm width)
Hydraulic tank assembly
498
• Main control valve (blade lift)
69
• Main control valve (blade tilt, ripper)
46
fl The figures in (
D475A-3
) show the dimensions for the U-blade.
01-13 1 5
GENERAL
WEIGHT TABLE
Unit: kg
Machine model Serial No.
D475A-3 10601 – 10684
10685 and up
Blade lift cylinder assembly (each side)
445
Blade tilt cylinder assembly
519
Tiltdozer assembly
14,500 (17,700)
• Blade
7,420 (10,750)
• Straight frame (L.H.)
1,817 (1,817)
• Straight frame (R.H.)
1,817 (1,817)
• Tilt cylinder assembly
519 (519)
Variable giant ripper assembly
5,698
• Shank assembly
1,040
• Ripper lift cylinder assembly
386
• Ripper tilt cylinder assembly
392
Radiator guard assembly
5,020
• Radiator guard
2,280
• Blade lift cylinder assembly (each side)
445
Radiator mask (with grille) (each side)
99
Engine underguard (front)
267
Engine underguard (rear)
324
Power train underguard (front)
340
Power train underguard (rear)
448
Hood
160
Fender (L.H.)
430
Fender (R.H.)
540
ROPS mount assembly
1,034
ROPS assembly
982
Floor frame assembly
291
Cab assembly
415
Operator’s seat assembly
52
fl The figures in (
01-14 1 5
) show the dimensions for the U-blade.
D475A-3
GENERAL
•
WEIGHT TABLE
SUPER DOZER
Unit: kg
Machine model Serial No.
D475A-3 10601 – 10684
10685 and up
Engine, damper assembly
3,940
• Engine assembly
3,740
• Damper assembly
214
Main radiator assembly
528
Sub. radiator assembly
162
Oil cooler assembly
157
Fuel tank assembly (when full)
858 (2,330)
Power train unit
4,980
• Torque converter, PTO assembly
750
• Transmission assembly
1,350
• Transmission valve assembly
70
• Steering clutch, brake assembly
2,290
• Steering valve assembly
26
Final drive assembly (each side)
3,575
Main frame assembly
9,120
Track group assembly (each side)
11,050
11,180
• Track frame (each side)
2,988
2,996
• Idler assembly (each side)
664
708
• Track roller assembly (single, each)
195
222
• Track roller assembly (double, each)
214
237
• Carrier roller assembly (each)
102
100
13,780
14,060
Pivot shaft assembly (each side)
370
370
Equalizer bar
598
598
Track shoe assembly (810 mm width)
Hydraulic tank assembly
498
• Main control valve (blade lift)
69
• Main control valve (blade tilt, ripper)
46
D475A-3
01-15 1 5
GENERAL
WEIGHT TABLE
Unit: kg
Machine model Serial No.
D475A-3 10601 – 10684
10685 and up
Blade lift cylinder assembly (each side)
478
Blade pitch cylinder assembly (each side)
530
Super dozer assembly
19,700
• Blade
11,620
• Straight frame (L.H.)
1,818
• Straight frame (R.H.)
1,818
• Pitch cylinder assembly (each side)
530
Counterweight
6,040
Radiator guard assembly
5,020
• Radiator guard
2,280
• Blade lift cylinder assembly (each side)
478
Radiator mask (with grille) (each side)
99
Engine underguard (front)
267
Engine underguard (rear)
324
Power train underguard (front)
340
Power train underguard (rear)
448
Hood
160
Fender (L.H.)
430
Fender (R.H.)
540
ROPS mount assembly
1,034
ROPS assembly
982
Floor frame assembly
291
Cab assembly
415
Operator’s seat assembly
52
01-16 1 5
D475A-3
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS Serial No.: 10601 – 10684 RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE –22 –30
–4 –20
14 –10
32 0
50 10
68 20
86 30
CAPACITY (¬) 104°F 40°C
Specified
Refill
126
121
410
210
2.4
2.4
145
145
24
24
420
140
75
75
2.0 – 2.2
2.0 – 2.2
SAE 30 SAE 10W
Engine oil pan
SAE 10W-30 SAE 15W-40
Power train oil pan (incl. torque converter, transmission and bevel gear cases)
SAE 30 SAE 10W
Damper case Recoil spring
Engine oil
SAE 30
Pivot shaft (each) SAE 10W SAE 10W-30
Hydraulic system
SAE 15W-40 SAE 140 Final drive case (each)
SAE 85W-140 SAE 80W-90
Idler (each)
Gear oil
Track roller (each)
GO 140B
Carrier roller (each) Fuel tank Cooling system
D475A-3
2.25 – 2.45 2.25 – 2.45 1.120 – 1.225 1.120 – 1.225
Diesel fuel Coolant
ASTM D975 No. 2
1,670
—
Main circuit: 230 Sub circuit: 65
— —
ASTM D975 No. 1
Add antifreeze
01-17 1 5
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
Serial No.: 10685 and up RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE –22 –30
–4 –20
14 –10
32 0
50 10
68 20
86 30
CAPACITY (¬) 104°F 40°C
Specified
Refill
126
121
410
210
2.4
2.4
145
145
24
24
420
140
75
75
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
1.25 – 1.35
1.25 – 135
1,670
—
Main circuit: 230 Sub circuit: 65
— —
SAE 30 SAE 10W
Engine oil pan
SAE 10W-30 SAE 15W-40
Power train oil pan (incl. torque converter, transmission and bevel gear cases)
SAE 30 SAE 10W
Damper case Recoil spring
Engine oil
SAE 30
Pivot shaft (each) SAE 10W SAE 10W-30
Hydraulic system
SAE 15W-40 SAE 140 Final drive case (each)
SAE 85W-140 SAE 80W-90
Idler (each)
Gear oil
Track roller (each)
GO 140B
Carrier roller (each) Fuel tank Cooling system
01-18 1 5
Diesel fuel Coolant
ASTM D975 No. 2 ASTM D975 No. 1
Add antifreeze
D475A-3
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %. Fuel sulphur content
Change interval of oil in engine oil pan
0.5 to 1.0 %
1/2 of regular interval
Above 1.0 %
1/4 of regular interval
ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute
(2) When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W40), but be sure to add single grade oil that matches the temperature in the table on the left. (5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
D475A-3
01-19 1 5
10
STRUCTURE AND FUNCTION
Engine, power train cooling system drawing ................................................... 10- 2 Power train ................................................... 10- 3 Power train skeleton .................................... 10- 4 Power train hydraulic piping diagram ....... 10- 5 Power train hydraulic circuit diagram ....... 10- 6 Torque converter and PTO ......................... 10- 9 Torque converter valve ............................... 10-16 Transmission ................................................ 10-25 Transmission control valve ......................... 10-32 Steering, brake control ................................ 10-48 Transfer, bevel gear shaft, steering ........... 10-52 Transfer, bevel pinion ................................. 10-53 Steering control valve ................................. 10-56 Final drive ..................................................... 10-64 Track frame ................................................... 10-68 Track roller bogie ......................................... 10-70
D475A-3
Hydraulic tank ............................................ 10- 71 PPC valve .................................................... 10- 72 Main control valve ..................................... 10- 84 Pin-puller hydraulic system drawing ....... 10- 92 Pin-puller hydraulic circuit drawing ......... 10- 92 Pin-puller solenoid valve ........................... 10- 93 Air conditioner ........................................... 10- 95 Engine control ............................................ 10- 96 Engine control system ............................... 10- 97 Engine control system with electronic engine throttle controller .................... 10-100 Machine monitor system .......................... 10-102 Mode selection system ............................. 10-111 Electrical equipment .................................. 10-117 Torque converter lock-up control system .................................................. 10-121
10-1 1 4
STRUCTURE AND FUNCTION
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
Slim02960
1. 2. 3. 4. 5. 6. 7. 8.
Main radiator Sub radiator Turbocharger Aftercooler Engine Power train oil cooler Water pump (for main radiator) Water pump (for sub radiator)
1o-2 0
Outline The radiator consists of two systems: The main radiator and sub radiator. The main radiator system carries out cooling for the engine and power train oil cooler; the sub radiator system carries out cooling for the aftercooler. There are water pumps for each system. l
l
l
D475A-3
STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN I
2
9. 14
SVD02961
Outline . The power
generated by engine (I) has its torsional vibration dampened by damper (21, and then passes through universal joint (31, and is transmitted to torque converter (7). The power from the engine is transmitted through oil by torque converter (7) to the input shaft (turbine shaft) of transmission (8) in accordance with the change in the load. There is a lock-up clutch assembled to the torque converter, and when the rotating speed beyond the torque converter becomes higher, the lock-up clutch is engaged. When this happens, the drive case and turbine form one unit, so the power from the engine is transmitted directly to the transmission input shaft. Transmission (8) uses a combination of a planetary gear system and hydraulic equipment to reduce the speed and shift the gears (forward: 3 gears, reverse: 3 gears). It connects two sets of clutches selected with the gear shift lever according to the change in the load, and transmits the power from the transmission to transfer (14) from output shaft. The power entering transfer (14) has its
D475A-3
speed reduced. Its speed is further reduced by the bevel pinion and bevel gear of the bevel gear shaft, and it is then divided at right angles to the left and right and transmitted to the respective steering clutches (9). The power transmitted from the bevel gear shaft to the final drive is used to steer the machine by engaging or disengaging steering clutch (9). The steering lever is operated to disengage the steering clutch on the side to which the machine is to be steered in order to change the direction of travel. The size of the turning radius is controlled by steering brake (IO) installed to the outside of the steering clutch. Steering brake (IO) uses the same disc system that is used for the steering clutch. The power output from the steering clutch enters final drive (1 I), where it is reduced, and rotates sprocket (12). Final drive is a double reduction type consisting of a single stage spur gear and single stage planetary gear system. It rotates the sprocket-to drive track shoe (13) and move the machine.
10-3 0
POWER TRAIN SKELETON
STRUCTURE AND FUNCTION
POWER TRAIN SKELETON
16
15 SVDO2962
1. Engine (SDA12V140)
2. 3. 4.
5.
Damper Universal joint Power train, hydraulic, lubricating pump (BAL160+112+112) Hydraulic pump (SAL1 40+100)
1o-4 0
6. Hydraulic pump (SAR100+32) 7. Torque converter 8. Transmission 9. Steering clutch 10. Steering brake
11. 12. 13. 14. 15. 16.
Final drive Sproket Track shoe Transfer Transfer drive gear Bevel pinion
17. Bevel gear 18. PTO 19. Scavenging pump
D475A-3
STRUCTURE
AND
FUNCTION
POWER TRAIN HYDRAULIC
POWER TRAIN
HYDRAULIC
PIPING
DIAGRAM
PIPING DIAGRAM
a
SVD02963
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Torque converter oil filter Power train oil filter Power train lubricating oil filter Torque converter valve Transmission control valve Steering control valve Power train oil strainer Oil tank Power train pump (BAL160+112+112) Scavenging pump Power train oil cooler
D475A-3
a. b. c. d. e. f. g. h. i. j.
Torque converter inlet pressure pick-up port (IN) Torque converter lock-up pressure pick-up port (LU) Stator clutch pressure pick-up port (SC) Left clutch pressure pick-up port (LC) Left brake pressure pick-up port (LB) Right brake pressure pick-up port (RB) Right clutch pressure pick-up port (RC) Transmission reducing pressure pick-up port (Fl) Transmission relief pressure pick-up port (TM) Torque converter outlet pressure pick-up port (OUT)
1o-5 0
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
POWER TRAIN HYDRAULIC
/.
fl
l ,f
CIRCUIT DIAGRAM
L_______j_________i
z
I L-_--_-______----------__---------___,
I
_-
:---
1
1 --I
‘I
1 L
zz :
Y
z
as
r;
z : s
SVD03079
1O-6 0
D475A-3
STRUCTURE
AND FUNCTION
1. Oil tank 2. Power train oil strainer 3. Power train pump 4. Torque converter charge pump 5. Power train lubrication pump 6. Power train oil filter 7. Torque converter oil filter 8. Power train lubrication oil filter 9. Main relief valve 10. Priority valve 11. Modulating valve 12. Quick return valve 13. Reducing valve 14. Pilot valve 15. Reverse spool 16. Forward spool 17. 3rd speed spool 18. 2nd speed spool 19. 1st speed spool 20. Transmission speed spool 21. Transmission F-R spool 22. Reverse clutch 23. Forward clutch 24. 3rd clutch 25. 2nd clutch 26. 1st clutch 27. Torque converter relief valve 28. Torque converter 29. Oil cooler 30. Steering clutch and brake lubrication 31. Torque converter case 32. Torque converter lock-up valve 33. Modulating valve 34. Torque converter lock-up clutch 35. Modulating valve 36. Stator clutch 37. Torque converter lock-up solenoid valve 38. Steering check valve 39. R.H. steering valve 40. R.H. brake valve 41. L.H. brake valve 42. L.H. steering valve 43. Steering clutch 44. Steering brake 45. Steering case 46. Transmission lubrication valve 47. Transmission lubrication 48. PTO Lubrication 49. Scavenging pump 50. Solenoid for pin puller
D475A-3
POWER TRAIN
A. B. C. D. E.
HYDRAULIC
CIRCUIT
DIAGRAM
Transmission main relief pressure pickup port Transmission reducing pressure pickup port Transmission pilot pressure pickup port Torque converter relief pressure pickup port Torque converter regulator pressure pickup
Port F. Torque converter lockup pressure pickup port G. Torque converter stator clutch pressure pickup port H. R.H. steering clutch pressure pickup port I. R.H. steering brake pressure pickup port J. L.H. steering brake pressure pickup port K. L.H. steering clutch pressure pickup port L. Reverse oil pressure switch M. Forward oil pressure switch N. 3rd speed oil pressure switch 0. 2nd speed oil pressure switch P. 1st speed oil pressure switch Q. Modulating oil pressure sensor
1o-7 0
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO /n\
A. B. C. D.
Power train pump installed position Scavenging pump installed position Fan drive pump installed position Hydraulict pump installed position
D475A-3
n+
SJDO2965
1o-9 a
TORQUE CONVERTER AND PTO
STRUCTURE AND FUNCTION
\ 3i
2$
2i1 2i 2’6 i5 i4
23 2b
Ill
A-A
SJD02966
10-10 0
D475A-3
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
1. Coupling 2. Seal cage 3. Input shaft (59 teeth) 4. Front housing 5. Idler gear (74 teeth) 6. Idler gear shaft 7. Clutch housing 8. Drive case 9. Turbine 10. Rear housing 11. Stator 12. Pump 13. Stator shaft 14. Bearing cage 15. Retainer 16. Shaft 17. Transmission input shaft 18. Stator shaft boss 19. Stator clutch housing 20. Return spring 21. Stator clutch plate 22. Stator clutch disc 23. Stator clutch piston 24. Turbine boss 25. Lock-up clutch disc 26. Lock-up clutch plate 27. Lock-up clutch piston 28. Scavenging pump gear (65 teeth) 29. Seal seat 30. Spacer 31. Cover 32. Hydraulic pump gear (61 teeth) 33. Power train pump drive gear (61 teeth) 34. Drive shaft 35. Cover
D475A-3
10-11 0
STRUCTURE
AND FUNCTION
Outline l The torque converter is a 3-element, single-stage, l-phase torque converter, and it forms a single structure with the transmission. To improve the fuel consumption and ease of operation and to reduce consumption of the engine horsepower, a wet-type, multiple-disc clutch type torque converter lock-up device and a wet-type, double-disc stator clutch device are assembled inside it. l When the machine is carrying out continuous low-load dozing or grading operations, it is more efficient if the power of the engine is transmitted directly to the transmission input shaft. To achieve this, a lock-up clutch actuated by hydraulic pressure is assembled inside the torque converter. When the torque converter is locked up (the pump and turbine form one unit), the oil supplied from the torque converter relief valve does not stop, so the oil leaving the turbine from the pump is given unneeded direction by the stator, and this resists the rotation of the pump and turbine (the oil is churned). To prevent this, a stator clutch similar to the lock-up clutch is built in. This allows the stator to rotate freely when the torque converter is locked up. The oil then moves together with rotation of the pump and turbine; it is discharged from the pump and turbine with little resistance, and is returned to the pump. * The condition for the torque converter to enter the lock-up range and torque converter range are as follows. l Lock-up range When both of the following conditions are fulfilled: Torque converter output shaft speed: Above 1,360 rpm Transmission set pressure: Above 1.96 MPa (20 kg/cm*} l Torque converter range When either of the following conditions are fulfilled. Torque converter output shaft speed: Below 1,330 rpm Transmission set pressure: Below 1.5 MPa (15 kg/cm*}
10-12 0
TORQUE
CONVERTER
AND
PTO
Structure Pump (12) forms one unit with coupling (I), shaft (31, clutch housing (71, and drive case (8), and is rotated by the power from the engine. Turbine (9) forms one unit with turbine boss (24) and transmission input shaft (turbine shaft) (171, and is rotated by oil from the pump. Stator (11) forms one unit with stator shaft (13) and stator shaft boss (181, and is locked to rear housing (IO) by the stator clutch. The lock-up clutch consists of three parts: clutch plate (26) (meshed with drive case (811, clutch disc (25) (meshed with turbine boss (2411, and clutch piston (27) (that slides inside housing (71, which forms one unit with the drive case). The stator clutch consists of three parts: clutch disc (22) (meshed with boss (18) that is connected by a spline to stator shaft (1311, clutch plate (21) (supported by a pin to clutch housing (19) and rear housing (IO)), and clutch piston (23) (that slides inside the rear housing). The PTO consists of input shaft (31, idler gear (5), scavenging pump drive gear (28). hydraulic pump drive gear (32), and power train pump drive gear (33).
D475A-3
STRUCTURE
AND FUNCTION
Path of transmission of motive force 1. Lock-up clutch OFF, stator clutch ON When lock-up clutch (25) is OFF, the connection between drive case (8) and turbine (9) is cut; and when stator clutch (22) is ON, rear housing (IO) and stator shaft (13) are connected, so stator (11) is locked and the torque converter provides the normal functions of a torque converter. The power generated by the engine passes through the damper and universal joint, and is transmitted to coupling (I). Input shaft (31, clutch housing (71, drive case (81, and pump (12) rotate as one unit. The motive force from the pump uses oil to rotate turbine (91, and is transmitted to transmission input shaft (171, which forms one unit with the turbine.
TORQUE
I
3
7
9
CONVERTER
10 II
AND PTO
12 13 17
SVDO2!l67
2.
Lock-up clutch ON, stator clutch OFF When lock-up clutch (25) is ON, drive case (8) and turbine (9) are connected to form one unit; and when stator clutch (22) is OFF, the connection between rear housing (IO) and stator shaft (13) is cut, so stator (II) follows the rotation of pump (12) and turbine (9). The power generated by the engine passes through the damper and universal joint, and is transmitted to coupling (I). Input shaft (3), clutch housing (71, drive case (81, and pump (12) rotate as one unit. In addition, the drive case and turbine (9) are connected by the clutch, so the oil is not used. The motive force is transmitted directly to the turbine and transmission input shaft (17).
SVDO2!368
D475A-3
10-13 0
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
Flow of oil Oil set to within 0.87 MPa (8.7 kg/cm*) by the torque converter relief valve flows from port A, passes through the oil hole inside rear housing (IO), and enters pump (12). The pump is always being rotated by the power from the engine, so the oil entering the pump is given centrifugal force, and enters turbine (9). The turbine is rotated by the centrifugal force of the oil. The turbine forms one unit with transmission input shaft (171, so the motive force received by the turbine is transmitted to the transmission. The oil leaving the turbine is sent to stator (11) and enters the pump again, but some of the oil passes from the stator through port B and is sent to the oil cooler.
l
SVD02969
10-14 0
D475A-3
TTORQUE CONVERTER VALVE
STRUCTURE AND FUNCTION
TORQUE CONVERTER
VALVE
A-A
Pl
1
P’3
b SJD02970
1. Valve body 2. Torque converter relief valve 3. Valve spring 4. Valve spring 5. Main relief valve 6. Cover 7. Piston 8. Piston spring 9. Piston 10. Stator clutch modulating valve 11. Lock-up clutch modulating valve 12. Cover 13. Piston 14. Piston spring (Small) 15. Piston
10-16 0
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Valve spring (Outer) Valve spring (Inner) Stopper Load piston Cover Cover Valve spring Valve body Lock-up selector valve Piston Cover
Lock-up solenoid valve assembly 27. Cover 28. 29. 30. 31.
Coil Spring Plunger Valve seat holder
32. 33. 34. 35.
Valve seat Spring Valve seat Cap
P.
Stator clutch pressure pickup port P3. Lock-up clutch pressure pickup port P8. Main relief pressure pickup port PIO. Lock-up clutch initial pressure pickup port Pll. Stator clutch initial pressure pickup port T. From torque converter pump
D475A-3
STRUCTURE
AND FUNCTION
1
2
3
T-TORQUE CONVERTER
4
5
6
21
22
23
24
25
VALVE
26
E-E
27
/ 20
19
18
17
16
15
14
D-D
SBD00662
Outline . The torque converter valve is installed at the top of the rear housing of the torque converter and consists of the following six types of valves. 1. Main relief valve Main relief valve (5) sets the hydraulic pressure to 2.7 - 3.0 MPa (27.0 - 30.4 kg/cm21 in the transmission, steering clutch, brake and torque converter lock-up clutch, and stator clutch circuits. 2. Torque converter relief valve Torque converter relief valve (2) sets the inlet pressure of the torque converter to within 0.87 MPa 18.7 kg/cm21 to protect the torque converter from abnormally high pressure. 3. Torque converter lock-up valve Lock-up selector valve (24) acts to switch the lock-up clutch and stator clutch ON t) OFF.
D475A-3
4.
5.
6.
Torque converter lock-up solenoid valve Solenoid valve receives an electrical signal from the lock-up controller and switches the pilot pressure to lock-up selector valve (24). It operates lock-up selector valve (24) and switches the two clutches ON t) OFF. Stator clutch modulating valve Modulating valve (IO) sets the clutch pressure to 2.7 MPa I27 kg/cm21 to protect the stator clutch from abnormally high pressure and acts to raise the pressure of oil from lock-up selector valve (24) gradually until it reaches the set pressure. Lock-up clutch modulating valve Modulating valve (I I) acts in the same way as stator clutch modulating valve (IO) and sets the clutch pressure to 1.3 MPa I13 kg/ cm”) to protect the stator clutch from abnormally high pressure.
10-17 0
STRUCTURE
AND
FUNCTION
TTORQUE
Operation of main relief valve l The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to rise. l When the pressure in the circuit rises, the oil entering port B pushes piston (9). The reaction force compresses spring (41, moves main relief valve (5) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure in the circuit at this point is 2.7 - 3.0 MPa (27.0 - 30.4 kg/cm*).
CONVERTER
From pump
VALVE
SBDO0663
Operation of torque converter relief valve l The oil relieved from the main relief valve and the oil from torque converter charge pump flows into the torque converter from port C, and at the same time passes through orifice b and enters port D. When the oil fills the torque converter, the pressure starts to rise.
From pump
.
If the pressure in the torque converter rises abnormally high, the oil entering port D pushes piston (9). The reaction force compresses spring (3), moves relief valve (2) to the right in the direction of the arrow, and opens ports C and E. When this happens, the oil at port C is relieved to port E, and is drained to the oil tank. The pressure in the circuit at this point is below 0.87 MPa (8.7 kg/cm*).
To
torque
converter
From pump
lo-18 0
SBDO0664
To oil tank
SBWO665
D475A-3
STRUCTURE AND FUNCTION
lTORQUE
CONVERTER VALVE
Operation of torque converter lock-up valve, solenoid valve The torque converter lock-up valve supplies oil to switch the lock-up and stator clutch built into the torque converter ON t) OFF. The lock-up valve is actuated by the pilot pressure from the solenoid valve that is actuated when it receives an electrical signal from the lock-up controller. When the lock-up switch on the panel at the front of the operator’s compartment is pressed ON (the indicator lamp inside the switch lights up), the auto-lock-up system is actuated, and when the torque converter reaches the lock-up range, the lock-up controller, which has received signals from the two sensors, connects the solenoid to the ground and current flows. The hydraulic circuit is switched and pilot pressure is sent to the lock-up valve to lock up the torque converter. l
l
D475A-3
10-19 0
STRUCTURE
1.
Travel
TTORQUE
AND FUNCTION
in torque 32
converter
CONVERTER
VALVE
drive
29 Deactivated
SBDO1285
When range, valves of the N and
the machine is in the torque converter the solenoid valve is DEACTIVATED, so (32) is pushed to the left in the direction arrow by the tension of spring (29). Ports P open.
32
29
I*
fib
The oil from the pump flows ports P and N into port L of the lock-up valve. When the pressure inside the circuit rises, piston (25) is pushed to the left in the direction of the arrow, and the piston pushes out lock-up selector valve (24) to the left.
Deactivated
ator utch
SBDOl287
1O-20 0
D475A-3
STRUCTURE AND FUNCTION
When lock-up selector valve (24) moves to the left in the direction of the arrow, ports F and G and ports H and K close, and ports F and H and ports G and J open. When this happens, the oil from the pump flows from port F to port H, and becomes the back
2.
lTORQUE
CONVERTER VALVE
pressure of the stator clutch piston. When the pressure in the circuit rises, the stator clutch is engaged. At the same time, the oil that is the back pressure of the lock-up clutch piston is drained from port G to port J, and the lock-up clutch is disengaged.
Travel in direct drive
When the machine is in the direct drive range, the solenoid valve is EXCITED, so plunger (30) is pushed to the right in the direction of the arrow and valve (32) is moved. Port P closes and ports N and M open. When this happens, oil from the pump stops at P. The high-pressure oil at port L is drained from port N to port M. When the pilot pressure at port L is lost, piston (25) and lock-up selector valve (24) are returned to the right in the direction of the arrow by the tension of spring (22).
D475A-3
Ports F and H and ports G and J close, and ports F and G and ports H and K open. When this happens, the oil from the pump flows from port F to port G, and becomes the back pressure of the lock-up clutch piston. When the pressure in the circuit rises, the lock-up clutch is engaged. At the same time, the oil that is the back pressure of the stator clutch piston is drained from port H to port K, and the stator clutch is disengaged.
1o-21 0
STRUCTURE
AND
FUNCTION
TTORQUE
CONVERTER
VALVE
Operation of stator clutch, lock-up clutch modulating valve . The modulating valves are in the circuit between the lock-up selector valve and the inlet ports of the two sets of clutches. When the clutch is switched ON, the modulating valve acts to raise the pressure on the piston gradually until it reaches the set pressure so that the clutch is engaged smoothly, thereby reducing any shock to the torque converter or transmission. * The following explanation of operation takes the stator clutch as the example, but the operation of the lock-up clutch is the same. However, the oil flow to the clutch during direct drive or torque converter drive is the reverse. 1.
Travel in direct drive When the machine enters the direct drive range, the oil at port L of lock-up selector valve (24) returns to the solenoid valve and is drained. When this happens, lock-up selector valve (24) is pushed to the right in the direction of the arrow by the tension of spring (22). Ports F and H close, and ports H and K open, and the oil at port H is drained from port K. When the hydraulic pressure at port H is lost, modulating valve (IO) is returned to the right in the direction of the arrow by the tension of spring (161, and ports H and Q open fully. At this point, the actuating pressure of the stator clutch is drained from port H to port K, and the clutch is disengaged.
From Pump
To solenoid valve
SBD01291
1o-22 0
D475A-3
TTORQUE CONVERTER VALVE
STRUCTURE AND FUNCTION
2.
Travel in torque converter drive
From Pump
When the machine is in the torque converter drive range, the oil from the solenoid valve enters port L of lock-up selector valve (24) and moves the lock-up selector valve to the left in the direction of the arrow. Ports F and G, and ports H and K close, and ports F and H open. A circuit is then formed from port F through modulating valve (IO) to the stator clutch. The oil from the pump flows from port F to the stator clutch, and the pressure in the circuit starts to rise.
I/I
As the hydraulic pressure in the circuit rises, the oil passing through orifice d in modulating valve (IO) pushes piston (131, and the reaction force moves the modulating valve to the left in the direction of the arrow to throttle ports 0 and H. Port Q is connected with port S that applies back pressure to load piston (191, and moves the load piston to the right in the direction of the arrow to compress spring (16). The tension of spring opens port Q and H. This operation is repeated intermittently to increase the load of spring (16). While this is happening, the hydraulic pressure gradually increases, and finally stops at the position where ports 0 and H are closed to complete the rise in hydraulic pressure. The hydraulic pressure at this point is 2.5 + 0.1 MPa (25 f 1 kg/cm*]. The hydraulic pressure of the lock-up clutch is 1.3’:’ MPa {13+: kg/cm?.
D475A-3
I
II
From Pump
From solenoid valve
SBD01293
From solenoid
1O-23
TRANSMISSION
STRUCTURE AND FUNCTION
TRANSMISSION
A4
SJD02971
1. 2. 3. 4.
Input shaft Transmission valve Front case Rear case
D475A-3
1o-25 0
STRUCTURE AND FUNCTION
TRANSMISSION
\,
SVD02972
1O-26 0
D475A-3
STRUCTURE AND FUNCTION
TRANSMISSION
5. Front cover Sun gear for REVERSE (32 teeth)
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.
Ring gear for REVERSE (89 teeth) Pinion shaft Planet pinion for REVERSE (25 teeth) Ring gear for REVERSE (82 teeth) Pinion shaft Ring gear for FORWARD (89 teeth) Planet pinion for FORWARD (25 teeth) Sun gear for FORWARD (39 teeth) Ring gear for 3rd (89 teeth) Planet pinion for 3rd (25 teeth) Sun gear for 3rd (39 teeth) Ring gear for 2nd (89 teeth) Planet pinion for 2nd (21 teeth) Pinion shaft Sun gear for 2nd (47 teeth) Carrier for 2nd 1st clutch inner drum 1st clutch piston 1st clutch piston housing Output shaft Collar Drive shaft (for sensor) 2nd clutch piston Piston housing for 2nd Carrier for FORWARD, 3rd 3rd clutch piston Piston housing for FORWARD, 3rd Clutch piston for FORWARD Carrier for REVERSE Piston housing for REVERSE REVERSE clutch piston Tie rod pin Clutch spring Washer spring Clutch disc Tie bolt Clutch plate
D475A-3
1 O-27 a
STRUCTURE
AND
TRANSMISSION
FUNCTION
Outline l The transmission is a forward 3 gear, reverse 3 gear transmission that consists of a combination of a planetary gear system and disc clutches. l The transmission actuates the control valve to use hydraulic pressure to fix two of the clutches in the five sets of planetary gears and disc clutches to select one rotating direction and one gear speed. l The clutches are locked as follows: No. 1 clutch for REVERSE, No. 2 clutch for FORWARD, No. 3 clutch for 3rd, No. 4 clutch for 2nd and No. 5 clutch for 1st. No. of plates and discs used Clutch No. No. No. No. No. No.
1 2 3 4 5
clutch clutch clutch clutch clutch
No. of plates
No. of discs
6 6 4 3 5
7 7 5 4 6
Gear speed, clutch combination Gear speed FORWARD 1st 2nd 3rd
Clutch combination
No. 2 No. 2 No. 2
NEUTRAL
No.5
REVERSE 1st 2nd 3rd
No. 1 No. 1 No. 1
1O-28 a
l l l
l l l
(engaged)
No. 5 No. 4 No. 3
No. 5 No. 4 No. 3
D475A-3
STRUCTURE
AND FUNCTION
TRANSMISSION
Operation of disc clutch l To lock ring gear (7), a disc clutch is used. The clutch consists of piston (361, plates (38), discs (39), pins (42) and piston return springs (37). The internal teeth of the disc engage with the external teeth of the ring gear. The teeth on the outside diameter of the plate engage with pins (42) secured by housing (35). Clutch engaged (locked) . Oil from the control valve flows under pressure through the port in housing (35) to the back of piston (36). The piston presses plates (38) and discs (39) together, and the resulting frictional force stops the rotation of discs (391, so ring gear (7) meshing with the internal teeth of the disc is locked.
SVD02973
Clutch disengaged (free) When the supply of pressure oil from the control valve is shut off, piston (36) is returned to its original position by the force of piston return spring (37). This relieves the frictional force between plates (38) and discs (391, making ring gear (7) free. Washer spring (43) installed between the plates at the pin acts to speed up the return of the piston when the clutch is disengaged, and also to separate the plate and disc cleanly to prevent continued rotation.
.
SVD02974
D475A-3
1o-29 0
STRUCTURE AND FUNCTION
OPERATION FORWARD
TRANSMISSION
OF TRANSMISSION 1ST
No. 1
No. 2
No. 3
No. 4
No. 5
SVDO2975
For FORWARD Ist, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (I) is transmitted to output shaft (25). No. 2 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks ring gear (13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18). The motive force from the torque converter is transmitted to input shaft (I). The rotation of the input shaft is transmitted through sun gear (11) to planet pinion (12).
1O-30 a
.
.
Ring gear (13) is locked in position by No. 2 clutch, so planet pinion (12) rotates carrier (32), which is on the inside of ring gear (13). No. 5 clutch is also engaged, so the No. 5 gear (22), sun gears (17) and (21L planet pinions, ring gears (15) and (181, and No. 4 carrier (30) form one unit. In addition, carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25). Output shaft (25) rotates at the same speed as carrier (32).
D475A-3
TRANSMISSION
STRUCTURE AND FUNCTION
REVERSE 1ST
No. 1
No.‘2
No. 3
No. 4
No. 5
SVOO2976
For REVERSE Ist, No. 1 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (I) is transmitted to output shaft (25). No. 1 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks carrier (34) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18). The motive force from the torque converter is transmitted to input shaft (1). The rotation of the input shaft is transmitted through sun gear (6) to planet pinion (9).
D475A-3
Carrier (34) is locked in position by No. 1 clutch, so the rotation of planet pinion (9) rotates ring gear (IO). Ring gear (IO) rotates in the opposite direction from the input shaft, and it rotates carrier (32). No. 5 clutch is engaged, so No. 5 gear (221, sun gears (17) and (21), planet pinions, ring gears (15) and (181, and No. 4 carrier (30) form one unit. In addition, carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).
10-31 0
STRUCTURE
AND
TRANSMISSION
FUNCTION
TRANSMISSION
CONTROL
VALVE
CONTROL VALVE
SJD02977
A. B. C.
Priority pressure pickup port Pilot pressure pickup port Load piston back pressure pickup port
1O-32 0
D. Lubrication E. F.
relief pressure pickup port Reducing pressure pickup port Modulating pressure pickup port
D475A-3
TRANSMISSION
STRUCTURE AND’ FUNCTION
CONTROL VALVE
.12
2d
is
II
i5
i4
i3
A-A I
J
32
M
\
B-0
D475A-3
34 SJDD2978
1o-33 0
TRANSMISSION
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
Valve body Priority valve Spring (small) Spring (large) Stopper Pilot reducing valve Spring Plug Modulating valve spring (large) Modulating valve spring (small) Modulating load piston Stopper Transmission lubrication valve Spring Stopper Piston Spring Piston Reducing valve Spring Quick return valve Stopper Modulating valve Piston Spring Piston Valve body Reverse valve spool Forward valve spool 3rd speed valve spool 2nd speed valve spool 1st speed valve spool Spring Stopper Pilot line filter Valve seat Lower valve Upper valve Speed and directional selector valve
G. H. I. J. K. L. M.
To reverse clutch To forward clutch To 3rd clutch From power train pump From lubrication pump To 1st clutch To 2nd clutch
1o-34 0
CONTROL VALVE
spool
D475A-3
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
PILOT REDUCING VALVE OUTLINE l The pilot reducing valve is in the circuit between the pump and the priority valve. It sets the pilot pressure to 1 .I MPa {II .O kg/ cm21 to actuate the 5 sets of speed valve spools. The pressure at the inlet port of the pilot reducing valve is always maintained at 1.96 MPa 120 kg/cm*} by the priority valve. This means that there is no effect from any momentary drop in the transmission circuit pressure when the transmission is shifted, and it can actuate the speed valve spool.
OPERATION The oil from the pump passes through the pilot line filter and enters port B from port A. It then flows to port C of the 5 sets of valves When the oil flow from the pump increases and the pressure rises, the oil passing through orifice a and entering port E pushes piston (23). The reaction force compresses spring (12) and moves valve (I 1) to the right in the direction of the arrow. When this happens, ports A and B close, and no more oil from the pump enters port B or beyond. The pressure at this point is 1.1 MPa 111.0 kg/cm?. In the pilot circuit, when the transmission is shifted, two of the speed valve spools are connected to the drain circuit, so the pressure beyond port B drops. When this happens, valve (11) is returned to the left in the direction of the arrow by the tension of spring (12). Ports A and B open, and the oil from the pump flows to port B and beyond to maintain the hydraulic pressure in the pilot circuit at a constant level.
Speed
valve spool
Speed
valve spool
l
D475A-3
SXD0308 I
1o-35 0
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
PRIORITY VALVE OUTLINE The priority valve is in the circuit between the pilot reducing valve and the modulating valve. When the transmission is shifted, even if the hydraulic pressure in the transmission suddenly drops, the priority valve closes the passage between the transmission circuit and the pilot circuit. This maintains the hydraulic pressure in the steering circuit and pilot circuit that operates the 5 valve spools, and prevents any problem when shifting the transmission. l
OPERATION 1. Start + completion of shifting of transmission The oil from the pump enters port A of pilot valve (11) and port F of priority valve (7). The oil entering port F, then passes through orifice d and enters port H. When the oil flow from the pump increases and the pressure rises, the oil entering port H pushes piston (23). The reaction force compresses springs (8) and (91, and moves valve (7) to the right in the direction of the arrow. When this happens, ports F and G open, and the oil from the pump flows from port G to the modulating valve. The hydraulic pressure at this point is 1.96 MPa I20 kg/cm*). After this, the oil entering the modulating valve from port G rises to the modulating valve set pressure of 2.55 MPa I26 kg/cm*). after shifting 2. Immediately When the transmission shift lever is operated, the hydraulic pressure in port G and beyond suddenly drops to close to 0 because of the movement of the modulating valve. When this happens, the hydraulic pressure at port F also drops, but when this pressure becomes 1.96 MPa {20 kg/cm*), valve (71, which is being pushed to the right in the direction of the arrow by the oil at port H, is returned to the left by the tension of springs (8) and (91, and the passage between port F and G is closed. As a result, the pressure at port F, that is, the pressure at the inlet port of the pilot valve, does not drop beyond this point, but is maintained at 1.96 MPa (20 kg/cm*) to ensure that the pilot pressure is kept at the set pressure.
lo-36 0
To modulatrne
valve
SXDO3082
To modulating
valve
SXD03083
G’@ To modulating
E valve
-0 SXDO3084
D475A-3
TRANSMISSION
STRUCTURE AND FUNCTION
MODULATING
CONTROL VALVE
VALVE
OUTLINE . The modulating
.
l
valve consists of the modulating valve and quick return valve, and acts to modulate the pressure. When the transmission shift lever is operated to change the speed range, the clutch is engaged by the piston, but if high pressure is suddenly applied, the piston will engage the clutch suddenly. This will cause the machine to start moving suddenly and will subject the machine to excessive shock. To avoid this, the modulating valve is installed. When the transmission shift lever is operated to shift the speed range, the modulating valve allows the pressure on the piston to rise slowly to the set pressure so that the clutch can be engaged smoothly and so that there will be no shock when starting. This improves the durability of the power train, and also gives a more comfortable ride. The diagram on the right shows the time intervals and the rise in pressure when using the modulating valve. For example, if the transmission is shifted from Fl to F2, the oil from the pump passes through the speed valve spool to the 2nd clutch and fills the circuit up to the clutch piston port. The time taken to fill the circuit up to the clutch piston port is called the FILLING TIME; the pressure is 0 - 0.3 MPa 10 - 3 kg/cm*). The time taken from the point where the hydraulic pressure starts to rise (after the oil fills the circuit up to the clutch piston port) to the point where it reaches the set pressure is called the BUILD-UP TIME. The total time for the filling time and buildup time is called the MODULATING TIME.
DA75A-3
MPa Modulating {ks/cm'i 2.9 _ (30)
~
6
Filling
time time
,
Build-up
time
2.5 _ (25)
1.0 _ (10)
0 0
0.5 Time
1.0 (Sec.) SXD03085
1o-37 0
STRUCTURE
AND
TRANSMISSION
FUNCTION
Operation Immediately after shifting When the transmission shift lever is switched and the clutch is engaged, the passage from the pump to the clutch piston port is opened and the oil flows to the clutch piston port. When this happens, the passage between ports B and D is restricted by orifice b, so a difference in pressure is generated, and quick return valve (22) is moved to the left in the direction of the arrow by the pressure at port B. This connects port E and drain port G, and removes the back pressure of load piston (I I). When this happens, modulating valve (24) is moved to the left in the direction of the arrow by the tension of springs (9) and (101, and load piston (11) is returned to the right. Pressure starting to rise, during rise When the oil sent under pressure from the pump fills the circuit from port A to the clutch piston port, the hydraulic pressure starts to rise. When this happens, the difference in pressure on the two sides of orifice b of quick return valve (22) is lost, and the quick return valve is moved to the right in the direction of the arrow to close the passage between port E and drain port G. The oil flows from orifice a of modulating valve (24) to port C, and pushes piston (27). Because of the reaction force, modulating valve compresses springs (9) and (IO), and moves to the right in the direction of the arrow to throttle the circuit from port A to port B. At the same time, the oil flowing from orifice c in quick return valve (22) through the central port passes through orifice d and enters port F from port E. It becomes the back pressure of load piston (I I), moves the load piston to the left in the direction of the arrow and compresses springs (9) and (IO).
From
To
’
D’,’ clutch
VALVE
priority
@‘b
8
cylinder
Drain
From
CONTROL
‘12 ‘d Drain
SXDO3066
Drinritv
21
From
priority
2!
3088
lo-38 0
D475A-3
STRUCTURE AND FUNCTION
3.
During rise in oil pressure, completion of rise As the pressure in the circuit rises, the back pressure of load piston (I I) increases. When the movement of the load piston to the left increases, modulating valve (24) opens the passage between ports A and B because of the tension of springs (9) and (IO). As the pressure at port C pushing piston (27) increases, modulating valve (24) moves to the right in the direction of the arrow due to the reaction force, compresses springs (9) and (IO), and closes ports A and B. By repeating this operation intermittently, the load of springs (9) and (IO) increases and the pressure rises gradually. Finally load piston (11) contacts the valve body and does not move any further. When this happens, modulating valve (24) stops at the position where the passage from port A to port B is closed, and the rise in hydraulic pressure at this point is 2.55 MPa (26 kg/cm?. The oil from the pump is relieved from the main relief valve assembled in the torque converter valve assembly
D475A-3
TRANSMISSION
From
priority
From
Priority
CONTROL VALVE
1o-39 0
STRUCTURE
AND FUNCTION
REDUCING
VALVE
Outline l The reducing valve is in the circuit between the modulating valve and the 1st speed valve spool. It reduces the pressure applied to the 1st clutch to 2.16 MPa 122 kg/cm*), and protects the seal ring of the 1st clutch circuit. The hydraulic pressure in the circuit as a whole is set to 2.55 MPa 126 kg/cm*) by the modulating valve. Operation l The oil from the modulating valve flows from port A and some passes through port B and flows to the 1st valve spool and clutch, and at the same time, passes through orifice a and enters port C. The remaining oil flows to the valve spools
for the other speeds. When the circuit up to the clutch that has been shifted becomes filled with oil and the pressure rises according to the operation of the modulating valve, the oil entering port C from port B through orifice a pushes piston (17). The reaction force compresses spring
TRANSMISSION
CONTROL
VALVE
From modulating valve
8 To FORWARD. REVERSE. 2nd. 3rd clutches
8 To 1st clutch SXD03091
From modulatlne
(21) and moves valve (20) to the left in the direction of the arrow. When this happens, ports A and B close, and the oil from the pump no longer enters beyond port B. The hydraulic pressure at this point is 2.16 MPa (22 kg/cm*). 8 To FORWARD. REVERSE. 2ndg3rd clutches
1O-40 0
Q To 1st clutch
SXD03092
D475A-3
TRANSMISSION
STRUCTURE AND FUNCTION
TRANSMISSION
CONTROL VALVE
LUBRICATION VALVE
Outline l
The transmission lubrication valve is assembled to the transmission control valve, and protects the transmission and PTO lubrication circuit from abnormally high pressure. The source of oil for the lubrication circuit is the lubrication pump; this is a different line from the hydraulic oil circuit for the power train.
Operation . The oil from the lubrication pump passes through port A and flows to the transmis-
From
modulating
sion and PTO lubrication circuit. The oil entering port A passes through orifice a and enters port B. In this condition, if there is any abnormally high pressure generated by clogging of the lubrication circuit or increase in the viscosity of the oil caused by a drop in the oil temperature, the oil entering port B compresses spring (15) and moves valve (14) to the left in the direction of the arrow. This opens ports A and C and relieves the oil in the lubrication circuit to port C. The hydraulic pressure at this point is 0.3 MPa I3 kg/cm*).
valve
To
@ Drain g
clutch
SXrJ03093
From
modulating
valve
To
D475A-3
1st
; g : ttt
1st
clutch
Drain
’
’ ’ SXD03094
10-41 0
STRUCTURE AND FUNCTION
TRANSMISSION
CONTROL VALVE
SPEED AND DIRECTIONAL SELECTOR VALVE SPOOL
\
“\
(’
“----
R
F-F F
2nd
D-D
3rd
G-G
1st
E-E
5
lo-42 0
A-A
SWD02994
D475A-3
STRUCTURE AND FUNCTION
TRANSMISSION
CONTROL VALVE
Functions The speed
and directional selector valves are installed between the five speed valve spools and the drain circuit. When the gearshift lever in the operator’s compartment is operated, the pilot pressure is switched to actuate two of the five speed valve spools. Oil from the modulating valve then flows to the clutch and selects the direction and speed.
1. 2. 3. 4. 5. 6. 7. 8. 9. IO.
Speed selector lever stopper Speed selector valve spool Directional selector valve spool Valve body Valve seat Detent spring Detent lever Directional lever Directional lever shaft Speed selector lever shaft
D475A-3
1o-43 0
STRUCTURE
TRANSMISSION
AND FUNCTION
Operation 1. Transmission
VALVE
shift lever at neutral
From valve
Drain
CONTROL
From Pilot reducing
modulating
From
reducing
When the transmission shift lever is at the neutral position, directional selector valve (3) is at neutral and speed selector valve (2) is at 1st. Ports G of each speed valve spool (IO) - (131, port H of the directional selector valve spool, and port J of the speed selector valve spool are closed. Port G of 1st spool (14) and port J of the speed range selector valve spool are connected through orifice f. In this condition, the oil from the pilot valve passes from port F through orifice a and enters ports G of each speed valve spool (IO) - (131, where it stops. When this happens, there is no differential pressure on the two sides of orifice a, that is, port F and port G, so speed valves (IO) - (13) are pushed to the right by the tension of spring (15). Port A and port B are closed, and port B
valve
valve
SXDO3095
and port C are kept open. 1st spool (14) is throttled by orifice a and enters port G. However, the oil is drained from port G to port J, so a pressure difference is generated on the two sides of orifice a, that is, at port F and port G. When the pressure at port F becomes greater than the total of the pressure at port G and the tension of spring (15L it pushes the FORWARD valve spool and 1st valve spool out to the left. The 1st valve spool opens the circuit between ports D and E, and the oil from the reducing valve passes from port D to port E and flows to the 1st clutch. When the hydraulic pressure rises, the clutch is engaged. Therefore, the oil from the modulating valve enters port A and stops. The oil entering each clutch is drained from port B to port C.
D475A-3
.
STRUCTURE AND FUNCTION
2.
When
gearshift
TRANSMISSION
lever is at FORWARD
From valve
1st
From Pilot reducing
modulating
CONTROL VALVE
valve REVERSE clutch
G
FORWARD clutch
Q Drain
I3
clutch
2nd
clutch
1st
clutch
B From
reducing
valve
When the gearshift lever is placed at FORWARD Ist, directional selector valve spool (3) moves “P. In addition, port G of FORWARD valve spool (III and drain port H are connected through orifice b. At this point, port G of 1st valve spool (14) and drain port J are connected through orifice f. In this condition, the oil from the pilot valve passes from port F of the FORWARD valve spool and 1st spool, is throttled by orifice a and enters port G. However, the oil is drained from port G to ports H and J, so a pressure difference is generated on the two sides of orifice a, that is, at port F and port G. When the pressure at port F becomes greater than the total of the pressure at port G and the tension of spring (151, it pushes the FORWARD valve spool and 1st valve spool out to the left.
D475A-3
3rd
SXD03096
The FORWARD valve spool closes the circuit between ports B and C, and opens the circuit between ports A and B. Therefore, the oil from the modulating valve flows from port A, enters port B, and flows into the FORWARD clutch. When the hydraulic pressure rises, the clutch is engaged. The 1st valve spool opens the circuit between ports D and E, and the oil from the reducing valve passes from port D to port E and flows to the 1st clutch. When the hydraulic pressure rises, the clutch is engaged.
1o-45 0
TRANSMISSION
STRUCTURE AND FUNCTION
3.
CONTROL VALVE
When gearshift lever is at FORWARD 2nd
From valve
From Pilot reducino valve
modulatine
FORWARD clutch
7
Drain
From
reducing
When the gearshift lever is placed at FORWARD 2nd from FORWARD Ist, only speed selector valve spool (2) moves up. When this happens, port G of 1st valve spool (14) and drain port J are closed, and port G of 2nd valve spool (13) and drain port J are connected through orifice e. In this condition, the oil from the pilot valve passes from port F of the 2nd valve spool, is throttled by orifice a and enters port G. However, the oil is drained from port G to port J, so a pressure difference is generated on the two sides of orifice a, that is at port F and port G. When the pressure at port F becomes greater than the total of the pressure at port G and the tension of spring (151, it pushes the 2nd valve spool to the left.
1 O-46 0
Irn,,,,,, <
valve
,.:,
r
@
3rd
clutch
2nd
clutch
1st
clutch
Drain
SXD03097
The 2nd valve spool closes the circuit between ports B and C, and opens the circuit between ports A and B and ports C and E. Therefore, the oil from the modulating valve flows from port A, enters port B, and flows into the 2nd clutch. When the hydraulic pressure rises, the clutch is engaged. The oil at the 1st clutch passes from port E, is drained to port C, and the 1st clutch is disengaged.
D475A-3
STRUCTURE AND FUNCTION
STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL
SVD02572
lo-48 0
D475A-3
STEERING, BRAKE CONTROL
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9.
Brake pedal Safety lever Rod (from joystick) Joystick (steering) Limit switch Rod (from brake pedal) Steering control valve Rod (for left steering) Parking brake lever (from safety lever) 10. Cable 11. Rod (for right steering) 12. In-line servo valve
Lever, pedal positions 0: NEUTRAL 0: STRAIGHT TRAVEL FORWARD 0: STRAIGHT TRAVEL REVERSE 0: LEFT CLUTCH DISENGAGED 0: LEFT CLUTCH DISENGAGED, LEFT BRAKE APPLIED @: RIGHT CLUTCH DISENGAGED 0: RIGHT CLUTCH DISENGAGED, 8: 0: @: @I:
RIGHT BRAKE APPLIED BRAKE RELEASED BRAKE APPLIED FREE LOCK
Outline Joystick (4) moves rods (1 I) and (8) to operate the steering clutch and brake. (The steering clutch and brake are interconnected.) Brake pedal (1) moves rod (6) to operate only the brake. In this case, the brake is used for stopping the machine, so both the left and right brakes are applied at the same time. If joystick (4) is moved slightly to the left, the left steering clutch is partially disengaged and the machine turns gradually to the left. If joystick (4) is moved fully to the left, the left steering clutch is completely disengaged, and in addition, the left steering brake is applied, so the machine turns sharply to the left. Safety lever (2) is interconnected with parking brake lever (9), and also acts as a parking brake.
D475A-3
1o-49 0
STEERING, BRAKE CONTROL
STRUCTURE AND FUNCTION
Operation
-
wu
SVD02658
1O-50 0
D475A-3
STRUCTURE AND FUNCTION
STEERING, BRAKE CONTROL
Operation Turning left When the joystick is moved from the neutral position to LEFT, pilot spool (4) and input spool o&.0; servo valve move to the rear of the The oil from the power train pump always enters chamber A from port P, so orifice a of piston (3) opens, and the oil passes through passage c. As a result, the oil pressure in chamber B rises. When this happens, piston (3) is pushed to the rear of the machine by the oil pressure, and assists the operating effort of the steering valve through joint (I). Turning right When the joystick is moved from the neutral position to RIGHT, pilot spool (4) and input spool (2) of the servo valve move to the front of the machine. The oil from the power train pump always enters chamber A from port P, so orifice b of pilot spool (4) opens, and the oil pressure goes down. When this happens, piston (3) is pushed to the front of the machine, and assists the operating effort of the steering valve through joint (I).
D475A-3
10-51 0
STRUCTURE
AND
TRANSFER,
FUNCTION
TRANSFER,
BEVEL GEAR SHAFT,
BEVEL GEAR SHAFT, STEERING
‘C
1. 2. 3. 4. 5. 6.
Input shaft Transmission Steering control valve Steering case Breather Torque converter output shaft speed sensor
A.
Center of bevel gear shaft Center of crankshaft Center of bevel gear
B. C.
1 O-52 0
STEERING
SWD02998
D475A-3
STRUCTURE
AND FUNCTION
TRANSFER,
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
TRANSFER,
BEVEL PINION
BEVEL PINION
Input shaft Drive shaft Drive gear (27 teeth) Rear cover support Torque converter output shaft speed sensor Bearing cage Drum Cover Bearing cage Driven gear (30 teeth) Bevel pinion (22 teeth)
D475A-3
1o-53 0
TRANSFER, BEVEL PINION
STRUCTURE AND FUNCTION
BEVEL GEAR SHAFT,
STEERING
CLUTCH, BRAKE
L..-__J \
1o-54 0
‘A
SWD03000
D475A-3
TRANSFER, BEVEL PINION
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Brake output shaft Bushing Pin Clutch piston Pin Clutch plate (8 each) Clutch disc (8 each) Stopper Inner drum Cylinder Bearing cage Bevel gear (37 teeth) Bearing cage Steering shaft Piston spring Outer drum Stopper Clutch plate (8 each) Clutch disc (9 each) Inner drum Cylinder Clutch piston Piston spring Housing
D475A-3
Outline l
.
The steering clutches are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the joystick is operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. The steering brakes are wet, multiple-disc clutches with a spring booster. They are interconnected with the clutch and are hydraulically actuated by a steering valve that is actuated when the brake pedal and joystick are operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. The steering brakes are designed so that when the engine has stopped, the back pressure of the brake piston drops and the brakes are applied without the brake pedal being depressed. However, when the engine is started again, the brake is released as the hydraulic pressure inside the circuit rises, so the parking brake lever must always be locked.
1o-55 0
STEERING CONTROL VALVE
STRUCTURE AND FUNCTION
STEERING CONTROL VALVE
y--l 2
/ 4
6
6
I
I’ll---J-,‘-/
5
7 A
‘9
z-z
B
IO
Y-Y
G
F SAD01336
1O-56 0
D475A-3
STEERING CONTROL VALVE
STRUCTURE AND FUNCTION
/
/
27
26
I
i2
25
21
x-x
-20 SAD01337
A. To right clutch B. P port C. To right brake D. To left brake E. Clutch valve drain F. Brake valve drain G. To left clutch
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Right steering lever Brake lever Left steering lever Parking brake lever Body Cover Cover Parking brake valve Check valve Roller (parking brake)
D475A-3
11. Right brake valve 12. Valve spring (clutch valve) 13. Piston (clutch valve) 14. Right clutch valve 15. Bolt (clutch valve) 16. Modulating spring (clutch valve) 17. Guide (clutch valve) 18. Roller (right steering) 19. Roller (brake)
20. Roller (left steering) 21. Guide (brake valve) 22. Modulating spring (brake valve) 23. Bolt (brake valve) 24. Left clutch valve 25. Left brake valve 26. Piston (brake valve) 27. Valve spring (brake valve)
1o-57 0
STRUCTURE AND FUNCTION
STEERING CONTROL VALVE
Outline . The steering
.
control valve is in the circuit between the power train pump (through the main relief valve) and the pistons of the steering clutch and brake. It consists of two sets of steering valves and brake valves. If the joystick (steering, directional) is moved to the right or left, the steering clutch is disengaged. If the joystick is moved further, the brake is also applied. It is possible to adjust between gradual and sharp turning by the amount the joystick is operated. If the brake pedal is depressed, both the left and right brakes are applied, and the machine will stop. The above operations are carried out by switching the steering control valve, which is interconnected with the lever and pedal. The steering control valve sends oil from the power train pump to the steering clutch and brake, and operates each disc clutch.
Valve control l
The steering control valve is operated by left and right steering levers (I) and (31, which are interconnected with the joystick, and parking brake lever (4) and brake lever (21, which are interconnected with the brake pedal. Left and right steering levers (I) and (3) use a cam to interconnect the steering valve and brake valve inside the steering control valve to carry out control.
1O-58 0
D475A-3
STRUCTURE
AND FUNCTION
STEERING
Operation 1. Joystick at neutral, brake pedal released (Clutch engaged, brake released, parking
Joust
ick
Brake
CONTROL
VALVE
brake OFF)
Pedal
Brake
Clutch
To main
relief
valve Clutch
Brake
Parkins
l
When the joystick is at the NEUTRAL position and the brake pedal is released, levers (I), (21, and (3) are also at the NEUTRAL position. The oil ports of each valve are opened or closed by the spring tension. The oil from the power train pump passes through the main relief valve and enters port A of check valve (9). Some of the oil entering port A flows to port B of left and right steering valves (24) and (I 41, and stops there. Then, the oil from the back pressure port of the clutch piston
D475A-3
l
brake
OFF
SAD01339
returns from port C to drain port H, and the clutch is engaged by the tension of the clutch spring. The rest of the oil pushes open check valve (91, enters port E of left and right brake valves (25) and (I I), and flows from port F to the back pressure port of the brake piston. When the oil pressure in the circuit rises, the piston moves to the left in the arrow direction, compresses the brake spring, and releases the brake.
1o-59 0
STRUCTURE
2.
AND FUNCTION
Joystick operated half way to left (left clutch disengaged, brake released,
STEERING
parking
CONTROL
VALVE
brake OFF)
“_fJJ ii
,‘: ON Parkins
.,
brake
OFF SAD01340
.
.
.
When the joystick is operated half way to the left, roller (20) of lever (3) pushes bolt (15) to the left in the arrow direction, and compresses modulating spring (16). The reaction moves steering valve (24) to the left in the arrow direction. Then, port C and drain port H are closed, and ports B and C are opened. The oil from the power train pump enters port C from port B. Some of it flows to the clutch piston port to form the back pressure, and the rest passes through orifice b and enters port D. The oil entering port D pushes piston (131, and the reaction compresses spring (16) and moves valve (24) to the right in the arrow direction. This closes ports B and C, so no oil goes beyond port C, and the oil pressure is maintained without rising any further. If the joystick is operated further to the left, the above operation is repeated, and when roller (20) of lever (3) reaches the position where it contacts bolt (23) of the brake valve,
1 O-60 a
.
the oil pressure beyond port C rises to the set pressure 2.5 + 0.1 MPa 125 f 1 kg/cm21 of the reducing valve and the clutch is completely disengaged. The oil pressure beyond port C is determined by the tension of modulating spring (161, which changes the load according to the amount the joystick is moved. Therefore, if the joystick is moved only slightly, the oil pressure beyond port C is set low and the clutch is partially disengaged. If the joystick is moved a greater distance, the oil pressure is set high and the clutch is completely disengaged. Port J is connected to port C and reduces the operating force of lever (31, pushing bolt (15) out to the left in the arrow direction. However, the oil pressure at port J (the booster pressure) follows the oil pressure of port C, which changes in accordance with the change in the amount of joystick movement, so the operating force of the joystick also changes.
D475A-3
STRUCTURE
3.
STEERING
AND FUNCTION
Joystick operated fully to left (clutch disengaged, left brake applied,
parking
CONTROL
VALVE
brake OFF)
utch L. H. clutch disengaged L. H. Brake IPP I
G C
,ake
Joust
ick
ON Parking
K .A
brake
OFF SAD01341
If the joystick is operated fully to the left from the condition in Item 2, roller (20) of lever (3) pushes bolt (23) to the left in the arrow direction, and compresses modulating spring (22). The reaction to this moves brake valve (25) to the left in the arrow direction. Then, ports E and F close, and port F and drain port H open. The oil from the power train pump goes from port A, pushes open check valve (91, and enters port E, where it stops. Some of the oil which flows to the brake piston port and acts as the back pressure is drained from port F to port H. The rest of the oil passes from port F through orifice c and enters port G. However, when the oil beyond port F is drained to port H, the oil pressure drops. The oil entering port G pushes piston (261, and the reaction force pushing valve (25) to the right in the arrow
D475A-3
l
l
direction becomes smaller, so valve (25) is moved to the left in the arrow direction by the tension of return spring (27). This closes ports F and H, and maintains the oil pressure beyond F so that it does not drop. If the joystick is operated further to the left, the above operation is repeated, and when it is operated fully, the brake is fully applied. The oil pressure beyond port F is determined by the tension of return spring (271, which changes the load according to the amount the joystick is moved. So, if the joystick is moved only slightly, the oil pressure beyond port F is set high and the brake is partially applied. If the joystick is moved a greater distance, the oil pressure is set low and the brake is fully applied. Port K is connected to port E and reduces the operating force of lever (3) pushing bolt (23) out to the left in the arrow direction.
lo-61 0
STEERING CONTROL VALVE
STRUCTURE AND FUNCTION
4.
Brake pedal depressed (clutch engaged, brake applied, parking brake OFF1
Joystick neutral
at
Brake
pedal
OFF
Y
H.
Brake
H.
Clutch
H.
Clutch
H.
Brake
I ::
l
ON_ Parking
brake
OFF
SAD01342
.
When the brake pedal is depressed, two rollers (19) of lever (2) push left and right bolts (23) to the left in the arrow direction, and left and right brake valves (25) and (11) are actuated in the same way as in Item 3. Therefore, the oil pressure is set according to the amount the brake pedal is operated, and it is possible to adjust the braking force. The left and right steering levers are not operated, so the clutch is engaged.
1 O-62 a
D475A-3
STRUCTURE
5.
STEERING
AND FUNCTION
Parking brake ON (clutch engaged, brake applied,
Joystick
at
Brake
joystick
at neutral,
CONTROL
VALVE
brake pedal released)
pedal
Brake
Clutch
Clutch
Brake
SAD01 343
l
When the joystick safety lever is placed at the LOCK position, roller (IO) of lever (4) pushes parking brake valve (8) to the left in the arrow direction. Check valve (9) is pushed by parking brake valve (8), and moves to the left in the arrow direction in the same way, so port A and port E are closed. The oil flowing to the brake piston port and forming the back pressure passes from port
D475A-3
.
F through port E, then passes through check valve (9) and parking brake valve (8) and is drained. Parking brake valve (8) remains pushed in by lever (4) and roller (IO), so the back pressure of the brake piston port continues to drop. As a result, the brake is fully applied and is held in this condition. Even if the engine is started again, check valve (9) remains closed, so the brake is kept applied.
1O-63 0
STRUCTURE AND FUNCTION
FINAL DRIVE
FINAL DRIVE
SJD03001
Outline l
The final drive is a single stage spur gear, single stage planetary gear reduction type. The lubrication is of splash type using the rotation of the gears. The final drive can be removed and installed as a single unit.
1O-64 0
l
Floating seal (I) is installed to the rotating sliding portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.
D475A-3
FINAL DRIVE
STRUCTURE AND FUNCTION
I
A-A
1. 2. 3. 4. 5. 6. 7.
Floating seal Sun gear Carrier Hub Cover Sprocket boss Sprocket teeth
D475A-3
8. 9. 10. 11. 12. 13. 14.
Floating seal guard Cover Planetary pinion Ring gear Cover No. 1 gear No. 1 gear hub
SJD03002
15. 16. 17. 18. 19. 20.
No. 1 pinion Final drive case Bearing cage Boss Shaft Wear guard
1O-65 0
FINAL DRIVE
STRUCTURE AND FUNCTION
PATH OF POWER TRANSMISSION
9
IO
II
13
SJD03003
1O-66 0
D475A-3
STRUCTURE AND FUNCTION
l
FINAL DRIVE
The power from the bevel gear and steering clutch is transmitted to No. 1 pinion (15). It then passes through No. 1 gear (131, which is meshed with the No. 1 pinion, and is transmitted to sun gear (2) to rotate it. The rotation of sun gear (2) is transmitted to planet pinion (IO), but ring gear (II), which is meshed with the planet pinion, is fixed to cover (91, so the planet pinion rotates on its own axis and moves around the sun gear along the ring gear. Then, the rotating force of sun gear (2) forms the rotating force of carrier (31, which supports the planet pinion, and is transmitted to sprocket hub (4). The direction of rotation of carrier (3) is the same as that of sun gear (2). The rotating force transmitted to sprocket hub (4) is transmitted to sprocket teeth (7).
D475A-3
1 O-67 0
STRUCTURE AND FUNCTION
TRACK FRAME
TRACK FRAME Serial No.: 10601 – 10684
Outline • The track roller uses an X-shape bogie mount to increase the ground contact area between the track shoe and ground surface on rough surfaces, thereby increasing the drawbar pull. • The X-shape bogie is fitted with rubber pads to absorb the shock from the ground surface. Track roller, bogie Track roller flange type and bogie arrangement Bogie Track roller
10-68 1 5
Applicable
1st
Inner
Outer
Inner
Outer
Inner
Outer
D
D
D
D
D
D
D
Semi U, U specification
S
D
S
D
S
D
S
Superdozer specification
D475A-3
TRACK FRAME
STRUCTURE AND FUNCTION
_-12
13 __-___? I
A-A
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
_-__---
I
SWD02579
Idler Recoil spring assembly Carrier roller Track frame Sprocket Sprocket guard Track roller bogie Track roller Track roller support guard Cap Idler yoke Cylinder Guide
D475A-3
1O-69 0
STRUCTURE AND FUNCTION
TRACK FRAME
Serial No.: 10685 and up
Outline • The track roller uses an K-shape bogie mount to increase the ground contact area between the track shoe and ground surface on rough surfaces, thereby increasing the drawbar pull. • The K-shape bogie is fitted with rubber pads to absorb the shock from the ground surface. Track roller, bogie Track roller flange type arrangement Applicable 1st
2nd
3rd
4th
5th
6th
7th
S
D
D
D
D
D
S
10-69-1 5
Semi U, U specification
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
TRACK FRAME
Idler Recoil spring assembly Carrier roller Track frame Sprocket Sprocket guard Track roller bogie Track roller Cap Idler yoke Cylinder Guide
D475A-3
10-69-2 5
STRUCTURE AND FUNCTION
TRACK ROLLER BOGIE
TRACK ROLLER BOGIE Serial No.: 10601 – 10684
Outline • One track roller is mounted to each of inner bogie (3) and outer bogie (4) to ensure that the track roller and track shoe are always in contact. • Rubber mount (1) is used to absorb the machine vibration caused by contact with the ground.
10-70 1 5
1. 2. 3. 4. 5.
Cartridge pin Floating seal Bushing Inner bogie Outer bogie
6. 7. 8. 9.
Plug Bogie mount cap Rubber mount Track roller
D475A-3
STRUCTURE AND FUNCTION
TRACK ROLLER BOGIE
Serial No.: 10685 and up
Outline • The track rollers are installed to small bogie (6). The track rollers and track shoes are always in contact. • The vibration of the machine from the ground surface is absorbed by rubber mount (5).
D475A-3
1. Guide 2. Cap 3. Track roller assembly (double) 4. Large bogie
5. Rubber mount 6. Small bogie 7. Track roller assembly 8. Cover 9. Cartridge pin
10-70-1 5
HYDRAULIC TANK
STRUCTURE AND FUNCTION
HYDRAULIC
TANK
A-A
SWD03004
1. 2. 3. 4. 5. 6. 7. 8.
Oil level gauge Blade lift valve Blade tilt, ripper low valve Oil filler Breather Bypass valve Filter Tube
D475A-3
PI: From large pump P2: From small pump A: To blade lift cylinder B: To blade lift cylinder Al:To blade tilt cylinder
head bottom head
Bl: A2: B2: A3: B3:
To To To To To
blade ripper ripper ripper ripper
tilt cylinder bottom lift cylinder head lift cylinder bottom tilt cylinder head tilt cylinder bottom
10-71 0
STRUCTURE AND FUNCTION
PPC VALVE
PPC VALVE FOR BLADE LIFT, TILT
P2
P4
P
P3
Pl
T
SJD03028
P. T. PI. P2. P3.
P4.
From PPC charge PPC lock valve) To hydraulic tank To blade lift valve To blade lift valve To blade tilt valve To blade tilt valve
1O-72 0
valve port P2 (through
(LOWER) port PA (RAISE) port PB (Left tilt) port PA1 (right tilt) port PBl
D475A-3
PPC VALVE
STRUCTURE AND FUNCTION
A-A
SJD03029
1. Spool Metering spring 3. Centering spring 4. Piston 5. Disc
2.
D475A-3
6. 7. 8. 9. 10.
Nut (for lever joint) Joint Plate Retainer Body
1o-73 0
STRUCTURE
AND
PPC VALUE
FUNCTION
Operation
11 At neutral (il PPC valve for blade lift Ports PA and PB of the blade lift control valve, and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control notch f2 in spool (I).
(ii) PPC valve for blade tilt Ports PA1 and PBI of the blade tilt control valve, and ports P3 and P4 of the PPC valve are connected to drain chamber D through fine control notch f2 in spool (I).
;;;;,control
PBl
,,,,
,
SWD03030
SWD03031
1o-74 0
D475A-3
STRUCTURE
2)
During fine control (neutral + fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed; spool (I) is also pushed by metering spring (21, and moves down. When this happens, notch f2 for fine control is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the charging pump passes through notch fl for fine control and goes from port PI to port PA. When the pressure at port PI becomes higher, spool (I) is pushed back and notch fl for fine control 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 PI. When this happens, spool (I) moves up or down so that the force of metering spring (2) is balanced with pressure at port PI. The relationship in the position of the spool (I) and body (IO) (notch fl, f2 for fine control is at a point midway between drain chamber D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port PI also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber PA (the same as the pressure at port PI) and the force of the control valve spool return spring are balanced.
D475A-3
PPC VALVE
AND FUNCTION
IO,
P
SW003032
1o-75 0
STRUCTURE
31
AND
FUNCTION
PPC VALVE
During fine control (When control lever is returned) When disc (5) starts to be returned, spool (I) is pushed up to the force of centering spring (3) and the pressure at port PI. When this happens, notch f2 for fine control is connected to drain chamber D, and the pressure oil at port PI is released. If the pressure at port PI drops too far, spool (I) is pushed down by metering spring (2), and notch fl for fine control is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port PI recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from notch f2’ for fine control in the valve on the side that is not working. The oil passes through port P2 and enters chamber PB to fill the chamber with oil.
SWDO3033
4)
At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (I), notch f2 for fine control is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through notch fl for fine control and flows to chamber PA from port PI, and pushes the control valve spool. The oil returning from chamber PB from port P2 through notch f2’ for fine control and flows to drain chamber D.
1 O-76 0
D475A-3
STRUCTURE AND FUNCTION
PPC VALVE
51 Blade operated to FLOAT When piston (4) at port PI (LOWER side) is pushed by disc (5) and moves down, protrusion a of the piston contacts ball (11) during the downward stroke. (The detent starts to be actuated.) If piston (4) is pushed further, ball (1 I) pushes up collar (12), which is being held by detent spring (131, and moves to the outside, so the ball passes over protrusion a of the piston. At this point, piston (4’) at the opposite side is pushed up by the spring (14). As a result, the oil inside chamber F flows through b and c and enters chamber E, and piston (4’) follows disc (5). Passage d is interconnected with port PI, so it is under more or less the same pressure as port PI. Chamber E is normally interconnected with drain chamber D, but when ball (11) passes over protrusion a of the piston, passage d and chamber E (which were shut off) are interconnected and pressurized oil flows. At the same time, the control valve also moves to the FLOAT position, so the blade circuit is set to the FLOAT condition. The pressurized oil inside chamber E pushes up piston (4’1, so even if the lever is released, it is held at the FLOAT position. 61
SWDO3035
Blade released from FLOAT When disc (5) is returned from the FLOAT position, it is pushed down by a force greater than the pressure of the oil in chamber E. For this reason, chamber E is shut off from passage d and is connected to the drain chamber. Therefore, the oil pressure inside chamber E is lost, and the FLOAT position is released.
D475A-3
1o-77 0
WC VALVE
STRUCTURE AND FUNCTION
FOR RIPPER
I
‘b
B---i
a
I
I
I
h-ia. b. c.
P port (from charge pump) T port (to hydraulic tank) P2 port (blade RIGHT TILT/ripper
lo-78 0
SYDoO313
d.
e. TILT IN)
f.
P4 port (blade LOWER/ripper RAISE) Pl port (blade LEFT TILT/ripper TILT BACK) P3 port (blade RAISE/ripper LOWER)
D475A-3
PPC VALVE
STRUCTURE AND FUNCTION
A-A
B-B
D-D
E-E SYD00314
1. 2. 3. 4. 5. 6.
D475A-3
Spool Metering spring Centering spring Piston Disc Nut (for lever joint)
7. 8. 9. 10. 11.
Joint Plate Retainer Body Filter
1o-79 0
PPC VALVE
STRUCTURE AND FUNCTION
Operation 1)
Blade
At neutral Ports A and B of the control valve and ports PI, P2, P3, and P4 of the PPC valve are connected to drain chamber trol hole f of spool (I).
D through
Lower
lift
Blade Left
Raise
tilt Right
fine conSVD03098
Ripper
Ripper
tilt
lift
-_-.-
SVDO3099
1 O-80 0
D475A-3
STRUCTURE
PPC VALVE
AND FUNCTION
21 During fine control (neutral + fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed; spool (I) is also pushed by metering spring (21, and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the charging pump passes through fine control hole f and goes from port PI to port A. When the pressure at port PI becomes higher, spool (I) 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 PI. When this happens, spool (I) moves up or down so that the force of metering spring (2) is balanced with the pressure at port PI. The relationship in the position of the spool (I) and body (IO) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port PI also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port PI) and the force of the control valve spool return spring are balanced.
D475A-3
I)
Control valve
(5
P&3 ,,,,
SVD03101
lo-81 0
PPC VALVE
STRUCTURE AND FUNCTION
3)
During fine control (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port PI. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port PI is released. If the pressure at port PI drops too far, spool (I) is pushed down by metering spring (21, and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port PI recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil. SVDO3102
41 At full stroke When disc (5) pushes down piston (41, and retainer (9) pushes down spool (I 1, fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber A from port PI, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.
Control valve SVD03103
1 O-82 0
D475A-3
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
MAIN CONTROL VALVE BLADE LIFT VALVE
PL \
I
I
0 ii //
PA SJD03036
Outline . Demand valve is assembled to the blade lift valve, and the oil from the two hydraulic pumps is merged by check valve. With the demand valve, the oil from the large pump becomes the pilot pressure, and at the same time, the oil from the ripper circuit or the blade lift circuit through shuttle valve also becomes the pilot pressure, so the oil from the two hydraulic pumps is used efficiently.
lo-84 0
PI. P2. A. B. T. PA. PB. PL.
From large pump From small pump To blade lift cylinder head To blade lift cylinder bottom To hydraulic tank From blade lift PPC valve port P2 From blade lift PPC valve port PI From ripper Lo valve
D475A-3
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
c-c
D-D SJD03037
1. 2. 3. 4.
Check Small Check Check
5. 6. 7.
Valve body Return spring Blade lift valve
D475A-3
valve spring pump circuit check valve valve valve spring
8. 9. 10. 11. 12. 13. 14.
Shuttle valve seat (plug) Shuttle valve ball Shuttle valve seat (plug) Retainer Return spring (for FLOAT) Case Demand valve spring
15. 16. 17. 18. 19. 20 21.
Demand valve RAISE suction valve Suction valve spring LOWER suction valve Main relief valve Main relief, shuttle valve Shuttle valve
1 O-85 0
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
BLADE LIFT VALVE MAIN RELIEF, SHUTTLE
VALVE
PL
A4
IO
9
I T
8
2
7 PD
3 6 4 5’ A-A
1O-86 0
Z
SElD01368
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Valve body Piston Shuttle valve Shuttle valve spring Plug Valve seat Main relief valve poppet Main relief valve spring Sleeve Main relief pressure adjustment screw
PL. From shuttle valve inside ripper valve PB. From shuttle valve inside blade lift valve PD.To demand valve pilot port T. To hydraulic tank
D475A-3
MAIN CONTROL VALVE
Outline The main relief valve is in the circuit between the hydraulic tank and the ripper circuit and blade lift circuit through shuttle valve (3). The oil pressure in the blade lift circuit, that is, the large pump circuit, is set at 20.6 MPa 1210 kg/cm*}. The shuttle valve is in the circuit between the demand valve through the main relief valve and the blade lift circuit and ripper circuit. It selects the two circuits to apply the pilot pressure to the demand valve. In other words, it selects either the blade lift circuit or the ripper circuit. When the work equipment is not being used (when the control lever is at neutral) the shuttle valve connects the blade lift circuit and the pilot port of the demand valve by the tension of spring (4).
l
l
1 O-87 a
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
BLADE TILT, RIPPER LO VALVE
PA3
PA2
PA1
A3
A2
Al
B \
I
l-l
SJD03038
P. Al. Bl. A2.
From small pump To blade tilt cylinder head To blade tilt cylinder bottom To ripper tilt cylinder head (through ripper Hi valve PAI) B2. To ripper tilt cylinder bottom (through ripper Hi valve PBI) A3. To ripper lift cylinder head (through ripper Hi valve PB2) B3. To ripper lift cylinder bottom (through ripper Hi valve PA21
1O-88 0
CO. PL. PAI. PA2.
PA3. PBI. PB2. PB3.
To To To To To To To To
demand valve shuttle valve inside blade tilt PPC valve ripper tilt PPC valve ripper lift PPC valve blade tilt PPC valve ripper tilt PPC valve ripper lift PPC valve
blade lift valve P3 (left tilt) P2 (tilt in) P3 (lower) P4 (right tilt) PI (tilt back) P4 (raise)
D475A-3
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
A-A
c-c SJD03039
1. 2. 3. 4. 5. 6. 7. 8.
Blade tilt valve Ripper tilt valve Ripper lift valve Valve body Return spring O-ring Case Main relief pressure adjustment screw
D475A-3
,9. Sleeve
10. 11. 12. 13. 14. 15. 16. 17.
Main relief valve body Poppet spring Main relief valve poppet Valve seat Main relief valve spring Main relief valve Valve seat Check valve
18. 19. 20. 21. 22.
Check valve spring Valve seat Shuttle valve seat (plug) Shuttle valve ball Shuttle valve seat
1O-89 0
MAIN CONTROL VALVE
STRUCTURE AND FUNCTION
RIPPER HIGH VALVE
PA1
P B-1
A2-1 I
Al
I
A4
Bl-1
_
_
c4
B?-1
PA2 /
>B2
_ SWD03040
1O-90 0
P: PAI: PBI: PA2: PB2: Al-l: Bl-1: Al-2: Bl-2: A2-1: B2-1: A2-2: B2-2: T:
From large pump From low valve tilt back From low valve tilt on From low valve ripper raise From low valve ripper lower To right tilt cylinder head To right tilt cylinder bottom To left tilt cylinder head To left tilt cylinder bottom To right lift cylinder head To right lift cylinder bottom To left lift cylinder head To left lift cylinder bottom To hydraulic tank
D475A-3
STRUCTURE
AND
MAIN
FUNCTION
CONTROL
VALVE
A-A
c-c 1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11.
Check valve Check valve spring Plug Fixed differential pressure valve (for ripper tilt) Valve body Shuttle valve seat Shuttle valve bail Valve body Plug Fixed differential pressure valve spring Fixed differential pressure valve (for ripper lift)
D475A-3
D-D
SWD0304 I
12. Fixed differential pressure valve (for ripper lift) 13. Fixed differential pressure valve (for ripper tilt) 14. Ripper tilt high valve 15. Valve return spring 16. Plug 17. Ripper lift high valve 18. Suction valve spring 19. Suction valve
10-91 0
PIN-PULLER HYDRAULIC SYSTEM DRAWING PIN-PULLER HYDRAULIC CIRCUIT DRAWING
STRUCTURE AND FUNCTION
PIN-PULLER HYDRAULIC
SYSTEM
DRAWING @To transmission circuit To torque converter lock-up
PIN-PULLER HYDRAULIC
circuit
CIRCUIT DRAWING
[
To transmission valve circuit To torque converter lock-up
P---
circuit
I
*
I
clutch
!_
T
,(T
I*
!_
To transmission lubrication
To R.H steerins
r: I
)(
To R.H steerins
brake
To L.H steering
brake
1. 2. 3. 4. 5. 6.
i-
L__
To L.H steerins
L___--_--_------__
II
1O-92 0
11
in
11
clutch
7. 8. 9. IO.
Power train oil tank Oil strainer Power train pump Oil filter Main relief valve Steering control valve Pin-puller solenoid valve Pin-puller cylinder Steering case Scavenging pump
19
0475k3
PIN-PULLER SOLENOID VALVE
STRUCTURE AND FUNCTION
PIN-PULLER SOLENOID
VALVE
i
I Pi P /
SVD03007
1. Plug
2. 3. 4. 5. 6. 7. 8. 9.
Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly
A. B. C. D.
To pin-puller cylinder head From power train pump To pin-puller cylinder bottom To steering case
D475A-3
1o-93 a
STRUCTURE
PIN-PULLER
AND FUNCTION
SOLENOID
VALVE
Operation 1.
Pin-puller switch at PUSH IN position When the pin-puller switch is turned to the PUSH IN position, no current flows to solenoid (9) and it is deactivated. When this happens, spool (5) opens ports A and B and ports C and D, and the oil from the power train pump flows from port A to port B and enters the bottom of pin-puller cylinder (IO). The oil entering the bottom end of the cylinder increases the hydraulic pressure in the circuit and extends the cylinder. Shank mounting pin (11) is pushed into shank (13).
2.
Pin-puller switch at PULL OUT position When the pin-puller switch is turned to the PULL OUT position, current flows to solenoid (9) and it is excited. When this happens, the solenoid pushes out push pin (81, and spool (5) moves to the left in the direction of the arrow. Ports A and B and ports C and D close, and ports A and C and ports B and D open. The oil from the power train pump flows from port A to port C and enters the head of pinpuller cylinder (IO). The oil entering the head end of the cylinder increases the hydraulic pressure in the circuit and retracts the cylinder. Shank mounting pin (11) is pulled out of shank (13).
1o-94 0
From
power
train
Pump
Switch
at-PUSH
IN’r~osition
From
power
train
Dump
Switch
at’PULL
OUT’position
D475A-3
STRUCTURE
AND
AIR CONDITIONER
FUNCTION
AIR CONDITIONER AIR
CONDITIONER PIPING
sv003010
1. 2. 3. 4. 5. 6. 7. 8. 9.
Air conditioner compressor Condenser Refrigerant piping Window defroster Side defroster Air conditioner unit Vent Blower motor Valve (hot water outlet)
D475A-3
10. 11. 12. 13.
Hot water pickup piping Receiver tank Hot water return piping Valve (hot water inlet)
A. B. C.
Fresh air Recirculated Hot air/cold
air air
1o-95 0
STRUCTURE AND FUNCTION
ENGINE CONTROL
ENGINE CONTROL
1. Battery relay (Right) 2. Battery (Right) 3. Decelerator pedal 4. Starting switch 5. Throttle potentiometer 6. Engine controller 7. Machine controller 8. Fuel control dial 9. Battery (left) 10. Battery relay (left) 11. Starting motor 12. Fuel injection pump (left) (electronic engine throttle
Outline . Engine control is carried out in the following
controller)
.
1 O-96 0
two systems. 1. When the fuel control dial and decelerator pedal are operated, it controls the fuel injection pump with an electric signal. 2. When mode selection system is actuated The throttle signal and fuel control dial signal enter the machine controller, are processed together with other data, and are sent to the electronic engine throttle controller as the throttle command. The electronic engine throttle controller controls the fuel injection pump according to the command. A fuel injection pump with electronic governor is employed. (For details, see ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER.)
D475A-3
STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM .
Items listed for SSC do not apply to superdozer specification machine.
I
Engine
Panel
I
controller
CPU
Monitor
4
I
Tachometer display, Speed ranee display.
etc.
No. 3 throttle
CPU
No. I thrott fuel cant ro Startino
snitch
No. 2 throttle decelerator F.
Injection controll
amount solenoid
n
Ensine speed detection sensor
c
Outline The engine controller receives the manual signals from the No. 1 throttle and No. 2 throttle, and the No. 3 throttle, which is the control signal from the machine. It selects the lowest engine speed from among these and controls the electronic governor. The control signal from the No. 3 throttle includes the following. (1) High idling speed control (2) Shoe slip control (3) 3rd auto deceleration
D475A-3
R,
1.
Transmission condition
2.
3
sensor
r1 r
Torque converter speed sensor
Acceleration sensor
SVD0.3108
Example: When the transmission is at neutral, even if the throttle lever is set to the FULL position and the economy mode is selected, the engine speed is automatically set to partial.
1o-97 0
STRUCTURE
AND
FUNCTION
ENGINE
CONTROL
SYSTEM
High idling speed control Function When waiting for work, if the transmission control lever is placed at Neutral, the engine speed is automatically reduced to the deceleration speed to save fuel and reduce noise. . When the lever is operated, the engine speed rises immediately to the speed set by the lever.
l
Operation When control lever is at N If the engine speed is higher than the deceleration speed and the transmission control lever is returned to Neutral, the engine speed will immediately be reduced to 100 rpm less than Hi speed to the No. 1 deceleration speed. If 4 more seconds pass, the engine speed will be reduced to the No. 2 deceleration speed (see below) and will be held at this speed until the lever is operated.
No. 3 deceleration Function . R3 + when
1 O-98 0
speed
set to 1400 rpm by auto-deceleration shifting
D475A-3
ENGINE CONTROL SYSTEM
STRUCTURE AND FUNCTION
THROlTLE
POTENTIOMETER
+Eg)
Structure
of
circuit
SXD03109
1. 2. 3. 4. 5. 6. 7.
Connector Lever Body Potentiometer Coupling Shaft Stopper
D475A-3
Outline The throttle potentiometer is installed under the front of the operator’s cab and is interconnected by a link with the decelerator pedal. . When the decelerator pedal is operated, the link rotates the shaft of the throttle potentiometer and the resistance value changes. A constant voltage is applied between the No. 1 and No. 3 pins of the potentiometer, and the voltage signal corresponding to the operating position of the decelerator pedal is sent from the No. 2 pin to the SSC controller. l
1o-99 0
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER
STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM THROTTLE CONTROLLER SYSTEM
WITH ELECTRONIC ENGINE
DRAWING
Disolav
items:
I. Ene ine speed 2. Engine water temperature 3.Error code/caution/pilot
1
Governor Power source
Governor cut relay
Start ins switch
Start Rack Control rack
1 Rack
position
*
c
Self-diaonostic disolav
Hydraulic Piston
\
output
etc.
I
Engine controller
signal sianal
lamp
Operation data: I.Enein real-time monitor data ensrne speed. rack voltage. temperature. c 01 I nressure.water
Engine
speed sianal
B
Engine
speed signal
A
o
I
i Accelerator
sensor
,No. 3 throttle
Machine Variable structure
ore-stroke-
cant rol Electronic eovernor
I
controller
I
i SVD031 IO
Outline l
l
A fuel injection pump with electronic governor is used. The engine controller receives the signals from the sensor and switches, and transmits the control signal to the governor solenoid and pre-stroke solenoid (proportional solenoid).
l
The network provides commonality of the data and signals received from the engine controller and the other controllers, and this contributes to ensuring optimum control between the engine and the machine.
D475A-3
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROlTLE CONTROLLER
STRUCTURE AND FUNCTION
FUEL
INJECTION
PUMP
WITH
ELECTRONIC
GOVERNOR
STRUCTURAL DIAGRAM
SEE00589
1. Delivery
valve
2. Plunger barrel 3. Plunger 4. Hydraulic piston 5. Hydraulic control valve (quantity adjustment) 6. Hydraulic control valve (injection timing adjustment) 7. Gear pump (as seen from rear, left: oil, right: fuel) 8. Center bearing 9. Cam shaft 10. Roller 11. Tappet 12. Pump housing 13. Tappet guide 14. Spring nut
D475A-3
Function . After the governor
l
l
actuation pressure is adjusted by the hydraulic control valve in accordance with the command from the engine controller, it acts on the piston at the rear of the rack and moves the control rack to adjust the fuel injection amount. The fuel injection timing is adjusted by changing the length of the injection pump plunger. The plunger is formed of two parts, and by sending electronically controlled hydraulic pressure between these two parts, the length is changed to adjust the prestroke. The governor solenoid and pre-stroke solenoid are proportional solenoid, and they convert the input current from the controller into propulsion. This propulsion controls the spool of the hydraulic control valves (two valves: one for the governor and the other for the injection timing adjustment), and converts the input current into hydraulic power.
10-101 0
STRUCTURE AND FUNCTION
MACHINE .
MONITOR
MACHINE MONITOR SYSTEM
SYSTEM
Items listed for SSC do not apply to superdozer specification machine
Machine
controller
il Sensor
signal
: II
Engine controller
1
Sensor signals
Buzzer
CAUT I ON Central wornino
lamp
Battery
SVD03111
l
The machine monitor observes the condition of the machine through the sensors installed to various parts of the machine, and processes this information quickly. The system informs the operator of the condition of the machine by displaying the condition on the panel. The content of the panel displays can be broadly divided into the following. 1. Monitor portion that gives warnings when any abnormality occurs in the machine. 2. The gauge portion (coolant temperature, torque converter oil temperature, fuel level) that always informs the condition of the machine.
10402 0
3. 4.
l
l
Function to show error code. Function to monitor current and voltage of sensors and solenoids. Various modes selector switches for the shoe slip control are built into the monitor panel, and it acts as the control portion of the machine control system. The monitor panel has the switch functions for the shoe slip control mode selection and monitor display functions. It has a built-in CPU (Central Processing Unit), and processes the data and outputs the display. The monitor display uses a liquid crystal display (LCD). The switches are flat sheet switches.
D475A-3
STRUCTURE
Action Monitor
MACHINE
AND FUNCTION
by monitor
panel (all models)
and content
of action
Direction, speed range display Fl, R3, etc. is informed by S-NET based on value from transmission sensor.
Engine speed gauge display Pulse from engine speed sensor is converted to gauge value and informed to monitor panel by S-NET. Troubleshooting display When there is failure, appropriate error code is informed to monitor panel by S-NET. Depending on nature of failure, information is also sent to sound buzzer or light up caution lamp. (I) When normal User code (2) When in trouble data display mode Service code Monitor panel displays code on hourmeter display in turn with hourmeter value.
@ Method
@ Flow of signals
F. SW=ON R. SW=ON 1. SW=ON 2. SW = ON 3. SW=ON S-NET communication S-NET communication
Transmission speed sensor - controller monitor panel
S-NET communication
Sensors, solenoids controller - monitor panel
@ Method
@ Flow of signals
Engine speed sensor controller - monitor panel
panel display
@ Conditions
and content
of action
1) Displays condition of S-NET communication, sensors, and solenoids Item number, condition of equipment informed to monitor panel by S-NET. Monitor panel displays item on speed range display and applicable value on hourmeter display. 2) REVERSE slow button on monitor panel used to advance item Buzzer cancel switch used to return to previous item (26 items can be displayed.)
D475A-3
SYSTEM
panel display
@ Conditions
Monitor
MONITOR
S-NET communication Sensors - controller monitor panel
-
Monitor panel -controller - monitor panel
10-103 0
STRUCTURE
MONITOR
AND
MACHINE
FUNCTION
MONITOR
SYSTEM
PANEL
MONITOR
I
3
2
16
SXDO3112
1. 2. 3. 4. 5. 6. 7. 8. 9.
Display (speed range) Power train oil temperature gauge Engine water temperature gauge Charge lamp Engine oil pressure caution lamp Air cleaner clogging caution lamp Engine water temperature caution lamp Transmission oil temperature caution lamp Hydraulic oil temperature caution lamp
Outline The monitor panel consists of the monitor portion that gives out warning when any abnormality occurs in the machine, and the gauge portion and service meter that always indicate the condition of the machine. The monitor and gauge portions each have microcomputers that process the signals from each sensor and display the results. A liquid crystal display is used. For details of the items displayed on the monitor and gauge portion, see the table on the next page.
10. 11. 12. 13. 14. 15. 16. 17.
2.
CHECK items 1) After lighting up as explained in Section 1, if there is any abnormality in any CHECK item, that item flashes. 2) The CHECK items go out when the engine is started. (The rise in the engine oil pressure is used to judge if the engine is running or not, or if the voltage from the alternator is more than IOV.)
3.
CAUTION The caution items are checked from the time the engine is started until the time the engine is stopped. If there is any abnormality, the item flashes, and the warning lamp also flashes. If any item in CAUTION 2 flashes, the alarm buzzer also sounds. The monitor and warning lamps flash in an ON-OFF cycle of approx. 0.8 sec. The flashing cycle of the monitor may change slightly if the ambient temperature is low (approx. -10°C or below), but this is not an abnormality.
l
Operation 1. Power switched on (starting switch ON) I) All items on the gauge and monitor light up for 3 seconds. 2) The warning lamps light up for 2 seconds and the alarm buzzer sounds for 1 second.
* Ir
10-104 0
Preheater pilot lamp Radiator coolant level check lamp Engine oil level check lamp Fuel gauge Service meter Slow reverse mode selector switch Economy mode selector switch Lock up mode switch
D475A-3
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
.
MONITOR PANEL DISPLAY Display category
Symbol
Display item
43 b bc)
Display range
qadiator water level
Below low level
Sgine
oil level
Below low level
oil pressure
When sensor is abnormal or when wiring harness is disconnected
SAD01479
CHECK
Display method
Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: Flashes
SAD~l480
ingine SAD01481
3attery charge
When charge is defective
4ir cleaner clogging
When clogged: Less than -650 mmHz0
!ngine oil pressure
Below 49.03 kPa IO.5 kg/cm*}
Radiator water level
Below low level
Engine water temperature
When at highest level (108°C or above) on engine water temperature gauge
Torque converter 3il temperature
When at highest level (130°C or above) on torque converter temperature gauge
Hydraulic oil temperature
105 2 3°C or above
SAP00522
CAUTION 1
3
>
b----I
Display when normal: OFF Display when abnormal: ON
Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes
SWD03016
e a
SADOI4Sl
SAD01479
CAUTION 2
SAD01462
SAD01483
Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Alarm buzzer sounds
SAD01484
Pilot
7x7 SAD00708
D475A-3
Preheating
When preheating
;. Automatic When ambient temperature is less than approx. - 5°C and ENG HEAT sheet switch on switch panel is ON, lights up for 36 seconds, then flashes for 16 seconds to show that preheating is completed. !. Manual Preheating is continued while starting switch is held at HEAT position. Lighting up and flashing times are same as in Item iabove.
10-105 0
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
Display category
Symbol
Display method
Display range
Display item
108iZ"C
Red
al
102I:‘c 98°C
Engine water temperature
SAD01482
94% 83% 70°C
White
One place lights up to show applicable level
Torque converter oil temperature
Gauges SAD01483
I I HfJO’C
u-
FULL 6/r
Fuel level
Gre.3
517 4n
All lamps light up below applicable level
3n 2n
SAD01466
Service meter
Red
Hourmeter
From 0 to 99999
EMPTY
Actuated when alternator is charged. Advances by 1 hour for every hour.
SKD00631
lo-106 0
D475A-3
STRUCTURE
MONITOR
.
MACHINE
AND FUNCTION
PANEL
MONITOR
SYSTEM
FUNCTIONS
Items listed for SSC do not apply to superdozer
specification
machine.
1. Monitor panel functions a) Switching lock-up mode ON/OFF b) Setting economy mode to OFF, Mode 1, Mode 2 c) Switching REVERSE slow mode ON/OFF d) Switching shoe slip control mode ON/OFF e) Setting shoe slip mode level: Modes 1 - 5 Functions a), b), and c) are mounted on all specifications; shoe slip control specification machine.
Shoe slip control
l
functions
d) and e) are mounted
on the
specification
SJDO3017
.
No shoe slip control
SJD03018
*
2.
Economy mode functions: On bedrock or other jobsites where the shoes slip frequently, the power output is set as follows in each mode to reduce the frequency of deceleration operation. Economy mode 1: Set to 90% of full power Economy mode 2: Set to 70% of full power REVERSE slow mode: Set to 80% of full speed when traveling in reverse
Default settings when switch is turned ON a) For machines with the superdozer specification, most of the work is carried out with the lockup ON, so the lock-up mode is selected by default when the starting switch is turned ON. b) For machines with other than the superdozer specification, the operator can select the functions that are best for the jobsite, so all functions are turned OFF by default unless they are selected.
D475A-3
10-107 0
STRUCTURE
3.
MACHINE
AND FUNCTION
MONITOR
SYSTEM
Sensors Sensor
Type of sensor
Torque converter temperature Hydraulic
Radiator
I
oil
oil temperature
Engine oil level water
I level
I
Resistance
I
-
Contact
ON
Contact
I
-
-
I
abnormal ON
I
Resistance
Contact
When
normal OFF
OFF
ON
I
ON
I
-
Resistance
Fuel level
Engine oil pressure
When
Contact
Engine oil pressure Engine water temperature
method
OFF OFF -
sensor
Structure
of
circuit
SBD01537
1. 2. 3. 4. 5. 6.
lo-108 0
Plug Contact ring Contact Diaphragm Spring Terminal
D475A-3
STRUCTURE
MACHINE
AND FUNCTION
Engine cooling water temperature Torque converter oil temperature
1. 2. 3.
Structure
oil temperature
of
circuit
SBDOI 538
sensor
L-4-l 4
3
I
1. 2. 3. 4.
Switch Case Wire Connector
Radiator
I 1.
2. 3.
water
2
SYSTEM
sensor sensor
Connector Plug Thermistor
Hydraulic
MONITOR
I
.l
\
i 1
Structure
of
circuit
I
SAD01 536
temperature
sensor
3
SEW00291
Float Sensor Connector
D475A-3
10409 0
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
Fuel level sensor
u
Structure A-A
1. 2. 3. 4. 5. 6. 7.
Connector Float Arm Body Spring Contact Spacer
10-110 0
of
circuit SBD01539
Function l
The fuel 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 and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display on the monitor panel reaches a certain level, a warning lamp flashes.
D475A-3
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
MODE SELECTION SYSTEM (SHOE SLIP CONTROL SYSTEM) .
Items listed for SSC do not apply to superdozer
specification
machine.
SYSTEM DIAGRAM Mode select
ion
Panel
I
RiDPer
lever
Backup
buzzer
fl
Machine
controller FORWARD speed range sianal Speed ranae sianal (I. 2, 3)
I A
= 0
Torque converter outout shaft speed sensor sianal (20 pulse/rev) Ena ine speed sensor sianal
L
ro -Z .Z U_ C c .- .w fr E
Oecelarytor
Pedal
z;B
I
I,
r
--
0
Enaine controller
Transmission
oil
Pressure
sianal SV003113
Outline . The
l
mode selection system automatically carries out engine control to match the operating mode selected by the operator, and acts to reduce fuel consumption, extend the life of the track shoes, and reduce the frequency of operation of the deceleration. The engine control modes consist of the economy mode control used when dozing,
D475A-3
l
the shoe slip control used when ripping, and the reverse slow mode control, which can be used for either operation. The lock-up control mode is the same as the conventional lock-up function. It cannot be selected in combination with the above modes.
10-111 0
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
FUNCTIONS OF MODE SELECTION SYSTEM l
The mode selection system consists of the mode selection panel (with built-in microcomputer) which selects the operating mode, the machine controller (with built-in microcomputer) which governs the engine control, the electronic engine throttle controller (with built-in microcomputer) which receives the command from the machine controller and controls the fuel injection pump, the lock-up controller which switches the lock-up of the torque converter ON/OFF according to the torque converter dividing pulse output by the machine controller, and various sensors. The following is an explanation of the functions of each controller.
Functions of engine controller 1. It follows the lower engine
Jr
speed (higher voltage) of the two signals (the manual command input from the throttle potentiometer and the deceleration potentiometer, and the shoe slip control command), and sends an electric current signal to the governor solenoid to control the engine. For details, see STRUCTURE AND FUNCTION, Engine control system with electronic engine throttle controller.
Functions of machine controller 1.
2.
3.
4.
5.
The shoe slip controller uses the input signal from the acceleration sensor to calculate the travel speed of the machine in relation to the ground. In addition, it inputs the torque converter speed sensor system and calculates the shoe speed. From these data, it detects the shoe slip ratio. Next, it inputs the engine speed sensor signal and torque converter speed sensor signal, and calculates the drawbar pull. It uses the results of the calculation in Steps 1 and 2 above together with the mode selector signal from the monitor panel and the transmission oil pressure sensor signal to calculate the optimum engine speed. It then sends a signal to the engine controller as the shoe slip control command. It has a function which divides the torque converter output shaft speed pulse of 20 pulses/rev to 4 pulses/rev, and when the monitor panel lock-up mode is input, it sends the divided torque converter pulse signal to the lock-up controller. The machine controller judges from the input torque converter dividing pulse and the transmission oil pressure signal, and sends the lock-up to the lock-up solenoid valve. * For details, see STRUCTURE AND FUNCTION, Operation of torque converter lockup control system.
10412 0
D475A-3
STRUCTURE
AND
FUNCTION
MODE
OPERATION OF MODE SELECTION SYSTEM . It is possible to select the five modes individually optimum conditions for the type of work.
T
Opera Ition
IMode switch
IdeIomlendent lound election ,electior
Mode actuation conditions
Actuation,
2
SYSTEM
to carry out work under the
features of mode
b Automatically switches ON/OFF according to the load
1. When torque converter approaches stall range or when gear is shifted, lock-up is turned OFF; when there is light load, lock-up is turned ON. 2. Possible to use at all speed ranges 3. Impossible to select combined operation with other mode 4. Suitable for dozing operations where there is comparatively little change in load.
Nhen transmission is at -1 with economy mode switch (I) or (2) ON
When economy mode ((1) or (2)) and shoe slip control are set in combination, economy control is carried out when the transmission is shifted to Fl, and slip control is carried out when the ripper lever is operated and the switch is turned ON. The engine output can be controlled to 2 levels without operating the engine deceleration. Mode (1): 90% (at 1.5 km/h) Mode (2): 65% (at 1.5 km/h) At neutral, the engine speed is reduced to partial speed.
a
L 8
or in combination
SELECTION
0
-I
0
When transmission ?I, R2, R3
is at
1. The engine output can be controlled to partial without operating the engine deceleration. Engine speed when in traveling reverse: 1400-1600 rpm 2. Set speed when traveling in reverse RI, R2, R3: 70% of full throttle
Nhen the following conditions are fulfilled I. When transmission is at Fl 2. After ripper DOWN, ripper TILT lever is operated and limit switch is turned ON
To prevent the machine from starting suddenly when it moves off, modulation is carried out. When this happens, if ripper DOWN signal enters shoe slip controller, drawbar pull characteristics are reduced by approx. 40% and engine output is controlled. The SSC controller controls the engine output according to the drawbar pull characteristics (see Rockbed selection below) selected by the operator from the drawbar pull characteristics (set to 5 levels), and prevents the occurrence of slippage. The SSC controller takes the drawbar pull immediately before slippage occurs when the shoe slip ratio is 30% or more as the maximum and carries out control of the engine output. When this happens, if the ripper TILT or ripper UP signal are input, the SSC controller increases the drawbar pull characteristic by approx. 30 - 80% and controls the engine output. At neutral, the engine speed is reduced to partial speed.
1 Interconnected with shoe slip control and is turned ON.
1. When the SSC control is turned ON, selection mode [31 lights up. 2. The selection is made 1 ti 3 t) 5 according to the load and condition of the bedrock.
0
F ._ B z
Ir
*
0
When the above modes are set, it is possible to operate the fuel control lever and decelerator pedal. In such cases, the engine output control is carried out according to the minimum value command from the controller command, throttle command, and deceleration command. For the superdozer only, it is possible to select the lock-up and REVERSE slow at the same time.
D475A-3
10-113 0
MODE SELECTION SYSTEM
STRUCTURE AND FUNCTION
SENSORS ENGINE SPEED SENSOR
c
0. 76fG
0.75fE
Structure
2
of
circuit sxrJ03114
1. Magnet 2. Terminal 3. Case 5. Boot 6. Connector
TORQUE CONVERTER SPEED SENSOR
o 83 -2
1
F= I
1. 2. 3.
c Structure
2
3
of
circuit
SXD03115
Connector Flange Sensor
10-114 0
D475A-3
STRUCTURE AND FUNCTION
TRANSMISSION
MODE SELECTION SYSTEM
OIL PRESSURE SENSOR
Structure
of
circuit SXD031 I6
1.
2. 3. 5. 6.
Plug Diaphragm Switch Wire Connector
D475A-3
10-115 0
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
ACCELERATION SENSOR
Acceleration
Deceleration c
m
Power
Amp
Structure
1. 2. 3. 4.
of
circuit
Plate Sensor portion Wire Connector
Outline l
l
l
SXD031 17
The acceleration sensor is installed under the front of the operator’s cab. With the acceleration sensor, the position of the ball inside the sensor changes according to the acceleration. Inside the sensor, there is a coil that detects the position of the ball. This is amplified by the amp and is sent as a voltage change to the SSC controller. The input and output characteristics of the sensor are shown in the diagram on the right.
5
-2 -1.5
I
0 Acceleration
1.5 2 [G) SXD03118
lo-116 0
D475A-3
ELECTRICAL EQUIPMENT
STRUCTURE AND FUNCTION
ELECTRICAL EQUIPMENT RELAY BOX
RELAY BOX CIRCUIT
_________-__ ?.P ::
SVDOJI
D475A-3
19
10-117 0
ELECTRICAL EQUIPMENT
STRUCTURE AND FUNCTION
OPERATION OF LAMP SYSTEM
Panel
,’
,’
I’
switch
,’
I’
‘\
..
Monitor Panel ii I luminat ion) Relay
box
SVD03120
LAMP SYSTEM CIRCUIT DIAGRAM Relay
box Safety
relay
1 I
-&
I
+Lz24V
Panel r----
switch _-__ Head lamp switch
1I
Head
I
Head
lamp
fuse
lamo
I I
relay
>
Head
lamp
El L
+
D4 um Diode
Monitor
illumination
T I SVD03121
lo-118 0
D475A-3
STRUCTURE AND FUNCTION
ELECTRICAL EQUIPMENT
PREHEAT (ELECTRICAL INTAKE AIR HEATER) CONTROL
Panel
Intake
switch
mani fold
__________--_____--__---__-----___---____---__-.~~‘~
Monitor
Panel
II II
‘.
..
.\
A
..
II I II I II I
‘.
Heater
relay
I
____---_---__----_-._I
,I I I
p
l.
0\
_i
I
i ~._____________________-----___-__----___---_____~. Relay
box SVD03122
PREHEAT CIRCUIT
Relay
box
Start 0 0
Preheat
Preheat
pi lot
(Monitor)
timer
l!zl
Heater relay
Battery
Battery
relay
Heater
Panel snitch (Preheat)
SVD03123
D475A-3
10-119 0
STRUCTURE
AND
FUNCTION
Order of operation for preheating 1) When -the PREHEAT switch (1) of panel switch is turned ON, the preheating timer starts to operate, and in cold weather, the preheating relay inside the relay box is turned ON. 2) The output current of the relay box passes through the heater relay and flows to the electrical intake air heater inside the intake manifold to start preheating. 3) When preheating starts, the preheating pilot lamp on the monitor panel lights up for 36 seconds to give the display. 4) The pilot lamp then flashes for 16 seconds to show that the preheating is completed.
10-120 0
ELECTRICAL
CONTROL
SVD03026
D475A-3
STRUCTURE AND FUNCTION
TORQUE System
CONVERTER
ELECTRICAL CONTROL
LOCK-UP
CONTROL
SYSTEM
diagram
,*-. ,’
,’
,’ ,J
,’
,’
-\
‘.
‘\
‘. ‘. -.
I’
*’
,’
c’
,’
‘. --\
I’ I’
‘. ‘\
,’ I’
-\ ‘\
,J
C’
‘\
-\
‘. ‘\
,’
‘. ‘. ‘. ‘.
,’
Monitor
‘..
Panel Relay Solenoid
drive
Machine controller
box
sisna
Transmission oil Pressure sensor
Steerins
Transmission
_____
clutch
Torque converter output shaft speed sensor (20 pulse/rev)
SVD03124
Operation With the torque converter lock-up control system, the torque converter lock-up is operated automatically according to the load on the machine by the controller and signal from the two sensors. When the torque converter is locked up, the display lamp inside the monitor panel lights up. The torque converter speed sensor is connected to the machine controller, and inputs a pulse signal to the machine controller. The machine controller power source is always ON. The setting of the lock-up mode is carried out using the mode selection panel. The lock-up controller receives the torque converter speed signal from the SSC controller and transmission oil pressure sensor, and connects or disconnects the connection of the lock-up solenoid and display lamp to
D475A-3
the ground to turn the lock-up ON or OFF. The lock-up is turned ON or OFF when it fulfills the following conditions for the two sensors. l
l
When lock-up is ON (solenoid “activated”) When both of the following conditions are fulfilled (AND circuit): Torque converter output shaft speed: 1,360 rpm or more Transmission oil pressure: 1.95 MPa 120 kg/cm? or more When lock-up is OFF (solenoid “deactivated”) When either of the following conditions are fulfilled (OR circuit): Torque converter output shaft speed: 1,330 rpm or less Transmission oil pressure: 1.5 MPa (15 kg/cm*) or less
10-121 0
20
TESTING AND ADJUSTING
Standard value table for engine related parts .................................................................................... 20- 2 Standard value table for chassis related parts .................................................................................... 20- 3 Standard value table for electrical related parts ................................................................................. 20- 9 Testing and adjusting ............................................................................................................................. 20-101 Troubleshooting ...................................................................................................................................... 20-201
fl
Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.
1.
The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs.
2.
The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.
3.
These standard values are not the standards used in dealing with claims.
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt or other rotating parts.
D475A-3
20-1 6
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Machine model
D475A-3
Engine
SDA12V140-1
Item
Measurement conditions
Standard value for new machine
Service limit value
2,100 – 2,200
—
600 – 700
—
2,000
—
kPa {mmHg}
Min. 120 {900}
Min. 107 {800}
°C
Max. 650
Max. 750
Bosch index
Max. 4.0
7.0
Max. 1.0
2.5
0.43
—
0.80
—
Unit
High idling Engine speed
Low idling
rpm
Rated speed Air supply pressure (boost pressure)
At rated output
Exhaust temperature
Whole speed range (ambient temperature: 20°C) At sudden acceleration
Exhaust gas color At high idling Valve clearance (normal temperature)
Intake valve mm Exhaust valve
Compression pressure (SAE15W-40 or SAE30 oil)
Engine oil temperature: 40 – 60°C (Engine speed)
MPa 2 {kg/cm } (rpm)
Min. 3.63 {37}
Min. 2.65 {27}
(160 – 200)
(160 – 200)
Blow-by pressure (SAE15W-40 or SAE30 oil)
At rated output (SAE15W-40 or SAE30) (SAE10)
kPa {mmH2O}
Max. 1.47 {Max. 150}
Max. 2.94 {Max. 300}
0.39 – 0.54 {4.0 – 5.5} 0.29 – 0.44 {3.0 – 4.5}
Min. 0.25 {2.5} Min. 0.20 {2.0}
(SAE10)
Min. 0.12 {1.2} Min. 0.10 {1.0}
Min. 0.10 {1.0} Min. 0.08 {0.8}
°C
80 – 110
120
°
12 ± 1
—
20 ± 2
—
20 ± 2
—
Oil pressure (Water temperature: Min. 80°C)
At high idling (SAE15W-40 or SAE30) (SAE10) At low idling (SAE15W-40 or SAE30)
Oil temperature
Whole speed range (oil pan)
Fuel injection timing
Before top dead center
Alternator belt tension Air conditioner compressor belt tension
20-2 4
Deflection when pressed with finger force of approx. 58.8 N {6kg}
MPa {kg/cm2}
mm
D475A-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Model Category
Item
Engine speed
Deceleration low idling speed Deceleration high idling speed Torque converter stall speed Torque converter stall + work equipment relief speed
Measurement conditions • Engine water temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C • Deceleration Lo: Decelerator pedal depressed • Deceleration Hi: Directional lever at N + work equipment control levers at HOLD • Torque converter stall: F3 stall • Torque converter stall + work equipment relief: F3 stall + pitch back relief
• Engine stopped • Center of pedal • Engine stopped • Center of lever knob
1st – 2nd
Directional
• Engine stopped • Center of lever knob
N-FORWARD
Steering
• Engine at low idling • Center of lever knob
Full stroke (N – Left, right) Until clutch is completely disengaged
• Engine at low idling • Center of pedal
Total travel
Brake pedal
Blade lever
Ripper lever
Operating effort of control lever, pedal Joystick
Decelerator pedal
• Engine at low idling • Hydralic oil temperature: 45 – 55°C • Center of lever knob • Engine at low idling • Hydralic oil temperature: 45 – 55°C • Center of lever knob
2nd – 3rd
Position until brake oil pressure becomes O MPa{0 kg/cm2} HOLD – RAISE, FLOAT HOLD – Left, right tilt HOLD – RAISE, LOWER
°
mm
mm
mm
mm
mm
HOLD – TILT N {kg} 1st → 2nd 2nd → 3rd
Speed range 3rd → 2nd
Nm {kgm}
2nd → 1st Directional
• Engine stopped • Center of lever knob
N – FORWARD N – REVERSE
D475A-3
Standard value
Permissible value
850 – 950
850 – 950
2,000 ± 50
2,000 ± 50
1,630 – 1,730
Min. 1,590
1,480 – 1,600
Min. 1,420
50 ± 5
50 ± 5
13 ± 5
13 ± 5
13 ± 5
13 ± 5
40 ± 10
40 ± 10
40 ± 10
40 ± 10
74 ± 25
74 ± 25
rpm
N-REVERSE
• Engine stopped • Center of pedal • Engine stopped • Center of lever knob
Unit
mm
Speed range
Joystick
Operating effort of control lever, pedal
Decelerator pedal
D475A-3
N {kg}
28 ± 5 28 ± 5 (Play: Max. 10 mm) (Play: Max. 10 mm) 75 ± 8
75 ± 8
61 ± 10
61 ± 10
80 ± 10
80 ± 10
60 ± 10
60 ± 10
85 ± 10
85 ± 10
85 ± 10
85 ± 10
53.9 ± 4.9 {5.5 ± 0.5} 2.94 ± 0.78 {0.30 ± 0.08} 4.90 ± 0.78 {0.50 ± 0.08} 2.75 ± 0.78 {0.28 ± 0.08} 3.92 ± 0.78 {0.40 ± 0.08} 68.6 ± 14.7 {7.0 ± 1.5} 68.6 ± 14.7 {7.0 ± 1.5}
53.9 ± 4.9 {5.5 ± 0.5} 2.94 ± 0.78 {0.30 ± 0.08} 4.90 ± 0.78 {0.50 ± 0.08} 2.75 ± 0.78 {0.28 ± 0.08} 3.92 ± 0.78 {0.40 ± 0.08} 68.6 ± 14.7 {7.0 ± 1.5} 68.6 ± 14.7 {7.0 ± 1.5}
20-3 4
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Item Joystick
Operating effort of control lever, pedal
Category
Steering
Blade lever
Ripper lever
Power train oil pressure
Torque converter inlet port pressure Torque converter outlet port pressure Torque converter lockup clutch pressure Torque converter stator clutch pressure Transmission main relief pressure Transmission modulating pressure Transmission reducing pressure Transmission lubricating pressure Steering clutch actuating pressure
Steering brake actuating pressure Ripper pin-puller pressure
20-4 4
Measurement conditions • Engine at low idling • Center of pedal
Brake pedal
D475A-3
Until clutch is completely disengaged Until machine turns when bracke is applied
• Engine at low idling • Center of pedal
Unit
N {kg}
N {kg}
• Engine at low idling • Hydraulic oil temperature: 45 – 55°C • Center of lever knob
HOLD – RAISE
• Engine at low idling • Hydraulic oil temperature: 45 – 55°C • Center of lever knob
HOLD – RAISE, LOWER
HOLD – FROAT
N {kg}
HOLD – Left, right tilt N {kg}
HOLD – TILT IN, TILT BACK
• Power train oil tempe rature: Within operaing range
Engine at high idling MPa {kg/ cm2}
Engine idling Engine idling Engine idling Engine idling Engine idling
at low at high at low at high at low
Standard value
Permissible value
8.83 ± 2.94 {0.9 ± 0.3}
8.83 ± 2.94 {0.9 ± 0.3}
38.2 ± 2.94 {3.9 ± 0.3}
38.2 ± 2.94 {3.9 ± 0.3}
490.3 ± 49.0 {50.0 ± 5.0} 29.4 ± 4.9 {3.0 ± 0.5} 72.6 ± 3.9 {7.4 ± 0.4} 24.5 ± 9.8 {2.5 ± 1.0}
490.3 ± 49.0 {50.0 ± 5.0} 29.4 ± 4.9 {3.0 ± 0.5} 72.6 ± 3.9 {7.4 ± 0.4} 24.5 ± 9.8 {2.5 ± 1.0}
17.7 ± 4.9 {1.8 ± 0.5}
17.7 ± 4.9 {1.8 ± 0.5}
17.7 ± 4.9 {1.8 ± 0.5}
17.7 ± 4.9 {1.8 ± 0.5}
0.78 – 0.98 {8.0 – 10.0} 0.29 – 0.59 {3.0 – 6.0} 1.12 – 1.42 {11.5 – 14.5} 2.55 – 2.94 {26.0 – 30.0} 2.55 – 2.94 {26.0 – 30.0} 2.55 – 2.94 {26.0 – 30.0} 2.06 – 2.45 {21.0 – 25.0} 0.20 – 0.37 {2.0 – 3.8} 2.35 – 2.75 {24.0 – 28.0} 2.55 – 2.94 {26.0 – 30.0} 2.35 – 2.75 {24.0 – 28.0} 2.45 – 2.84 {25.0 – 29.0} 2.64 – 2.94 {26.4 – 29.8}
0.78 – 0.98 {8.0 – 10.0} 0.29 – 0.59 {3.0 – 6.0} Min. 1.08 {Min. 11.0} Min. 2.35 {Min. 24.0} Min. 2.35 {Min. 24.0} Min. 2.35 {Min. 24.0} Min. 1.96 {Min. 20.0} 0.20 – 0.37 {2.0 – 3.8} Min. 2.16 {Min. 22.0} Min. 2.35 {Min. 24.0} Min. 2.16 {Min. 22.0} Min. 2.26 {Min. 23.0} 2.30 – 2.94 {23.5 – 30.0}
D475A-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model
Travel speed
• Level road surface • Engine at high idling • Engine water temperature: Within operating range • Economy mode: OFF • REVERSE slow mode: OFF • Run-up distance: 10 – 30 m • Measurement distance: 20 m
• Hydraulic oil temperature: 45 – 55°C • Relieve only circuit that is being measured
Rear pump relief pressure
Work equipment control pressure PPC valve pressure outlet port pressure Blade tilt cylinder Blade pitch cylinder Ripper lift cylinder
Permissible value
3.4 ± 0.2
3.4 ± 0.2
6.3 ± 0.3
6.3 ± 0.3
10.9 ± 0.5
10.9 ± 0.5
4.3 ± 0.2
4.3 ± 0.2
7.9 ± 0.4
7.9 ± 0.4
13.9 ± 0.7
13.9 ± 0.7
3.5 ± 0.2
3.5 ± 0.2
6.4 ± 0.3
6.4 ± 0.3
11.4 ± 0.6
11.4 ± 0.6
4.7 ± 0.2
4.7 ± 0.2
8.2 ± 0.4
8.2 ± 0.4
14.5 ± 0.7
14.5 ± 0.7
Engine at low idling
18.6 – 20.6 {190 – 210}
Min. 18.1 {Min. 185}
Engine at high idling
20.1 – 21.6 {205 – 220}
Min. 19.6 {Min. 200}
Engine at low idling
18.6 – 20.6 {190 – 210}
Min. 18.1 {Min. 185}
Engine at high idling
20.1 – 21.6 {205 – 220}
Min. 19.6 {Min. 200}
18.6 – 20.6 {190 – 210}
Min. 18.1 {Min. 185}
Engine at high idling
20.1 – 21.6 {205 – 220}
Min. 19.6 {Min. 200}
Engine at low idling
3.73 – 4.41 {38.0 – 45.0}
Min. 3.53 {Min. 36.0}
Engine at high idling
4.02 – 4.71 {41.0 – 48.0}
Min. 3.92 {Min. 40.0}
Engine at high idling
4.02 – 4.71 {41.0 – 48.0}
Min. 3.92 {Min. 40.0}
FORWARD 1st FORWARD 2nd FORWARD 3rd REVERSE 1st REVERSE 2nd REVERSE 3rd FORWARD 1st FORWARD 2nd FORWARD 3rd REVERSE 1st REVERSE 2nd REVERSE 3rd
Engine at low idling
Assist pump relief pressure
Oil leakage from cylinder
Work equipment
Work equipment pressure
Front pump relief pressure
Standard value
Measurement conditions
Lock-up switch OFF
Item
Lock-up switch ON
Power trainl
Category
D475A-3
• Hydraulic oil temperature: 45 – 55°C • All work equipment control levers at HOLD • Hydraulic oil temperature: 45 – 55°C • Lever, stroke end
• Hydraulic oil temperature: 45 – 55°C • Engine at high idling • Measure oil leakage during 1 minute when cylinder is relieved
Unit
km/h
MPa {kg/ cm2}
cc/ min
Ripper tilt cylinder
D475A-3
20-5 4
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Category
Item
D475A-3
RAISE
Measurement posture
Blade lift (Single tiltdozer specification) (Dual tiltdozer specification)
LOWER RAISE
Measurement posture
Low idling
13.0 – 18.0
Max. 20.0
High idling
3.6 – 4.6
Max. 5.0
Low idling
1.0 – 1.5
Max. 2.0
High idling
1.0 – 1.5
Max. 2.0
Low idling
18.0 – 25.0
Max. 28
High idling
5.5 – 6.5
Max. 8.0
Low idling
1.2 – 1.8
Max. 2.8
High idling
1.2 – 1.8
Max. 2.0
Low idling
14.1 – 17.3
Max. 19.0
High idling
4.3 – 5.3
Max. 7.0
Low idling
9.7 – 11.9
Max. 14.0
High idling
3.0 – 3.6
Max. 5.0
LOWER
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Blade in contact with ground – Raised to max. height
Blade speed
Measurement posture
Left tilt
Work equipment
Blade lift (Superdozer specification)
Blade tilt (Single tiltdozer specification)
Right tilt
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Full left tilt – Full right tilt
Left tilt
Measurement posture
Blade tilt (Dual tiltdozer specification)
Low idling High idling
Right tilt
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Full left tilt – Full right tilt
4
Permissible value
Unit
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Blade in contact with ground – Raised to max. height
20-6
Standard value
Measurement conditions
Low idling High idling
D475A-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Category
Item
D475A-3
Left tilt
Measurement posture
Blade tilt (Superdozer specification)
Blade pitch (Dual tiltdozer specification) Serial No.: 10601 to •
Low idling
—
—
High idling
4.0 – 5.0
Max. 7.0
Low idling
—
—
High idling
3.0 – 3.6
Max. 6.0
Low idling
8.0 – 12.0
Max. 14.0
High idling
2.7 – 3.7
Max. 4.5
Low idling
10.0 – 13.0
Max. 15.0
High idling
3.8 – 4.8
Max. 5.5
Low idling
—
—
High idling
7.0 – 9.0
Max. 10.0
Low idling
20.0 – 30.0
Max. 35.0
High idling
8.3 – 9.3
Max. 10.5
Low idling High idling
Blade pitch (Dual tiltdozer specification) Serial No.: • and up
Right tilt Pitch dump
Measurement posture
Pitch back
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Full pitch back – full pitch dump
Low idling High idling
Measurement posture
Blade pitch (Superdozer specification)
Pitch dump
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Full pitch back – full pitch dump
Pitch back
sec
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Full pitch back – full pitch dump
Pitch back
Blade speed
Pitch dump
Measurement posture
Work equipment
Permissible value
Unit
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Full left tilt – Full right tilt
D475A-3
Standard value
Measurement conditions
20-7 4
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Category
Item
D475A-3 Standard value
Permissible value
Low idling
7.4 – 9.0
Max. 12.0
High idling
2.2 – 2.8
Max. 4.0
2.2 – 3.2
Max. 5.0
High idling
2.0 – 3.0
Max. 4.0
Low idling
15.7 – 19.1
Max. 24.0
High idling
4.8 – 5.8
Max. 7.0
10.0 – 15.0
Max. 18.0
High idling
3.5 – 4.5
Max. 5.0
Low idling
Max. 10.0
Max. 10.0
High idling
Max. 1.8
2.5
Low idling
Max. 12.0
Max. 12.0
Max. 2.0
3.0
sec
Max. 0.5
1.5
mm/ min
Max. 150/15
Max. 300/15
Measurement conditions RAISE
Measurement posture
Unit
Ripper speed
• Hydraulic oil temperature: 45 – 55°C • Lowest shank hole • Ripper in contact with ground – Raised to max. height
LOWER
Ripper lift
Tilt in
Measurement posture
Low idling
Blade (Single tiltdozer specification) (Dual tiltdozer specification)
Time lag
Work equipment
Tilt out
Ripper tilt • Hydraulic oil temperature: 45 – 55°C • Lowest shank hole • Ripper in contact with ground – Raised to max. height • Hydraulic oil temperature: 45 – 55°C • Raise blade to maximum height, then lower blade and measure time taken from point where blade contacts ground to point where idler comes off ground
Low idling
sec
sec
sec
Blade (super dozer specificaiton)
• Hydraulic oil temperature: 45 – 55°C • Raise blade to maximum height, then lower blade and measure time taken from point where blade contacts ground to point where idler comes off ground
Ripper
• Hydraulic oil temperature: 45 – 55°C • Raise ripper to maximum height, then High lower ripper and measure time taken from idling point where ripper contacts ground to point where final drive comes off ground
sec High idling
Hydraulic drift
Measurement posture
Blade lif
• Hydraulic oil temperature: 45 – 55°C • Engine stopped • Raise blade to maximum height, then measure hydraulic drift for 15 minutes at bottom edge of blade (change in height h)
20-8 4
D475A-3
TESTING
AND ADJUSTING
STANDARD Systerr
STANDARD
:onnector No.
;pectiol lethoc
Judgement If the below.
Fuel control dial
Deceleration potentiometer
Neutral limit switch
cancel
Right bank engine speed sensor
Left bank engine speed sensor
FCD female)
D475A-3
PARTS
condition is as shown it is normal.
/
Measurement conditions in the
table
4.0 - 6.0 kR
(1) - (3)
Between
(I) - (2)
0.25 - 7.0 kQ
Between
(2) - (3)
0.25 - 7.0 kR
I
condition is as shown it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
If the below.
condition is as shown it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
If the below,
condition is as shown it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
If the below,
condition is as shown it is normal.
FCS (male)
TL2 (male)
212 (male)
El6 (male)
I
GCR (male)
GCL (male)
I
IBetween
If the below, El2 (male)
1) Turn starting switch OFF. 2) Disconnect connector.
If the below,
(1) - (2)
I
condition is as shown it is normal. (1) - (2)
Between
(3) - (5)
Between
(3) - (6)
I
in the
table
I
in the
1
in the
table
200 - 400 R Min.
I
1) Turn starting switch OFF. 2) Disconnect connector.
1 MQ
Max.
condition is as shown it is normal.
1) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
table
500 - 1,000 R
(I) - (2)
1 Between
I
500 - 1,000 R
condition is as shown it is normal.
Between
If the below. LH governor cut relay
RELATED
table
1 Between
If the below, RH governor cut relay
TABLE FOR ELECTRICAL
VALUE TABLE FOR ELECTRICAL RELATED PARTS
Name of component
Buzzer switch
VALUE
1 R
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
20-9
STANDARD
TESTING AND ADJUSTING
T
Syster n
Name of component
Rack position sensor
r
(Zonnector
lspectiol
No.
nethoc
VALUE TABLE FOR ELECTRICAL RELATED PARTS
Judgement
If the condition is as shown below, it is normal. El3
Pre-stroke solenoid
Rack position sensor
Governor solenoid
El5 (male)
El4 (male)
Between
(3) - (2)
o-o.1
v
Between
(4) - (2)
o-o.1
v
1
Between
(I) -
(2)
(1) - (2)
in the
I
in the
1) Turn starting switch OFF. 2) Disconnect connector.
table
1) Turn starting switch OFF. 2) Disconnect connector.
10 - 21 n
1
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
table
I) Turn starting switch OFF. 2) Disconnect connector.
table
I) Insert Tadapter. 2) Turn starting switch OFF.
E9
El1 (male)
ElO’ (male)
Between
(1) - (2)
10 - 21 R
Between
(1) - (2)
1 Between
(7) - (8) (16)1
in the
IO - 21 52
If the condition is as shown below, it is normal.
Back-up power source
1) Insert Tadapter. 2) Turn starting switch ON.
table
10 - 21 R
If the condition is as shown below, it is normal. Between
table
0.1 - 4.4 v
(1) - (2)
If the condition is as shown below, it is normal. Pre-stroke solenoid
in the
1 Between
If the condition is as shown below, it is normal. Governor solenoid
Measurement conditions
table
in the
20 - 30 v
I
El1 Switch power source
20-l0
If the condition is as shown below, it is normal. Between (9)(17) - (8)(16)
in the
20 - 30 v
table
1) Insert Tadapter. 2) Turn starting switch ON.
D475A-3
TESTING
Systen
STANDARD
AND ADJUSTING
r
Name of component
CIonnector
3pEdiO~
No.
lethod
VALUE
TABLE
Judgement
FOR ELECTRICAL
condition is as shown it is normal.
If the below,
condition is as shown it is normal.
PARTS
Measurement conditions
table
If the below,
RELATED
in the
table
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
Governor cut relay Fi
El1
I
Governor cut relay L
I
Between (5) - (14)
If the below,
Solenoid power source R
When
normal
When abnormality occurs
(1) - (21)
I 20 - 30 v Max.
condition is as shown it is normal.
Between
/
in the
1) Insert Tadapter. 2) Turn starting switch ON.
1 V
table
20 - 30 v
1
1) Insert Tadapter. 2) Turn starting switch ON.
E21 If the below.
Solenoid power source
L
Between If the below,
Governor solenoid
R
L
E21 (female)
If the below,
Engine speed sensor
Engine speed sensor
Potentiometer power
source
D475A-3
E21
If the below,
A
E31 B
(2) - (14)
(3) - (14)
(6) - (16)
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
in the
table
1) Insert Tadapter. 2) Start engine. t Use AC range of tester.
table
1) Insert Tadapter. 2) Start engine. * Use AC range of tester.
table
1) Insert Tadapter. 2) Turn starting switch ON.
0.5 - 3.0 v
in the
0.5 - 3.0 v
condition is as shown it is normal.
Between
1) Turn starting switch OFF. 2) Disconnect connector.
4.5 - 5.4 v
condition is as shown it is normal.
Between
If the below,
(16) - (21)
table
10 - 21 R
condition is as shown it is normal.
Between
If the below,
(IO) - (20)
in the
10 - 21 R
condition is as shown it is normal.
Between If the below,
(9) - (19)
1) Insert Tadapter. 2) Turn starting switch ON.
10 - 21 R
condition is as shown it is normal.
Between Rack position sensor power source
(8) - (18)
table
10 - 21 R
condition is as shown it is normal.
Between
Pre-stroke solenoid L
(7) - (17)
in the
20 - 30 v
condition is as shown it is normal.
Between If the below,
Pre-stroke solenoid R
(12) - (21)
condition is as shown it is normal.
Between If the below,
Governor solenoid
condition is as shown it is normal.
in the
4.6 - 5.4 V
20-11
TESTING
T
Systern
AND ADJUSTING
STANDARD
T
Name of component
Connector No.
SPeCti
TABLE FOR ELECTRICAL
Judgement
iethc
position sensor R
1 Between
(7) - (16)
1
1 Between
(17) - (6)
1
in the
E31 L
Between
(8) - (16)
Between
(18) - (6)
o-o.1
I
I
I) Insert T-
I table
1) Insert Tadapter. 2) Start engine.
table
1) Insert Tadapter. 2) Start engine. 3) Fuel control dial at MAX.
0.1 - 4.4 v o-o.1
L
v
in the
I
I
If the condition is as shown below. it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
Fuel control dial
Deceleration potentiometer
E31 E32
Engine water temperature sensor
S-NET
Between
E41
E32 (5) - E31 (16)
If the condition is as shown below, it is normal. Between
(6) (12) - (IO)
10.3 - 5.0 V 1 in the
table
4.0 - 10.0 v
Transmission R switch
20-12
I) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter. 2) Start engine.
Service switch
Transmission F switch
PARTS
adapter. 2) Start engine.
v
in the
If the condition is as shown below, it is normal.
Machine controller command
table
0.1 - 4.4 VI
If the condition is as shown below, it is normal.
Rack position
RELATED
Measurement conditions
table
If the condition is as shown below, it is normal.
Rack
sensor
VALUE
E51
D475A-3
TESTING
T
Systen 1
STANDARD
AND ADJUSTING
Name of component
--i Zonnector No.
VALUE
lspectiol nethoc
TABLE FOR ELECTRICAL
Judgement
RELATED
PARTS
Measurement conditions
table
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
I) insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter. 2) Turn starting switch ON.
Transmission 1 switch
Transmission 2 switch E51
Transmission 3 switch
Super dozer specification selection signal
1 Between
(15) - (1)
1
If the condition is as shown below, it is normal.
Starting switch START signal
Startiartigo;witch Between (18) - (11
St”,:i ;T;;tc
1V
Max.
h
in the Max.
I
1) Insert Tadapter.
table 1 V
20 - 30 v
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter. 2) Turn starting switch ON.
Buzzer cancel switch
E52
Model selection signal
D475A-3
i,f.i,lt
20-30V
1
20-l 3
TESTING
Systerr
STANDARD
AND ADJUSTING
Name of componer 1t
lonnector No.
;pectior lethoc
condition
is as shown Direction
If the below,
in the
table
Max.
1 L2
at N
Operated to FORWARD
Min.
1 MR
-
Min.
1 MR
Between (l)(2) - chassis
in the
Transmissic In 2 oil pressu Ire switch
I
I
I
I
If the below,
condition is as shown it is normal.
in the
table
I) Disconnect connector. 2) Start engine.
If the below,
condition is as shown it is normal.
in the
table
I) Disconnect connector.
TM1 (male)
TM2 (male)
Between (1) - (2)
If the below,
Torque converter speed sen! sor
Min.
1 MR
2nd selected
Min.
1 MR
Max.
-
condition is as shown it is normal.
in the
engine.
1 R table
1) Disconnect connector. 2) Start engine.
TM3 (male) Max.
-
If the below,
condition is as shown it is normal.
in the
Note:
During gear-shifting, the resistance rise above 1 R temporarily.
If the below,
condition is as shown it is normal.
1 R table
1) Disconnect connector. 2) Start engine.
TMM (male)
TCI (male)
1 Between
(1) - (2)
Between (l)(2) -chassis
20-14
2) Start
1st or 3rd selected
Between (l)(2) - chassis
Transmissic 3n oil modulating pressure svvitch
1) Disconnect connector. 2) Start engine.
TMR (male)
Between (l)(2) -chassis
Transmissic In 3 oil pressL Ire switch
1) Disconnect connector. 2) Start engine.
table
I
Transmissic In 1 oil pressu Ire switch
PARTS
,
condition is as shown it is normal.
I
RELATED
Measurement conditions
table
it is normal.
Between (1) - (2)
TMF (male)
I
Transmissic )n R oil press1 Ire switch
TABLE FOR ELECTRICAL
Judgement If the below,
Transmissic In F oil pressu Ire switch
VALUE
1
in the
may
table
500 - 1,000 R Max.
I) Turn starting switch OFF.
1
2) Disconnect connector.
1 MR
D475A-3
TESTING AND ADJUSTING
Blade left tilt oil pressure switch
Blade right tilt oil pressure switch
Ripper RAISE oil pressure switch
Ripper LOWER oil pressure switch
Ripper TILT IN oil pressure switch
D475A-3
TLS (male)
TRS (male)
RPU (male)
RPD (male)
RTI (male)
Measure voltage Measure resistance Measure resistance
BLD (male)
Measure resistance
Machine controller system
Blade LOWER oil pressure switch
BLU (male)
Measure resistance
Blade RAISE oil pressure switch
SS3
Measure resistance
Acceleration sensor
Connector Inspection No. method
Measure resistance
Name of component
Measure resistance
System
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
Measurement conditions
Judgement table If the condition is as shown in the table below, it is normal. Between (1) – (2)
7.0 – 9.0 V
Between (2) – (3)
1.25 – 3.75 V
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Blade lever at HOLD Min. 1 MΩ Blade lever at RAISE
Max. 1 Ω
—
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Blade lever at HOLD Min. 1 MΩ Blade lever at LOWER
Max. 1 Ω
—
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Blade lever at HOLD Min. 1 MΩ Blade lever at left tilt
Max. 1 Ω
—
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Blade lever at HOLD Min. 1 MΩ Blade lever at right tilt
Max. 1 Ω
—
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Ripper lever at HOLD Min. 1 MΩ Ripper lever at RAISE
Max. 1 Ω
—
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Ripper lever at HOLD Min. 1 MΩ Ripper lever at LOWER
Max. 1 Ω
—
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2) Between (1)(2) – chassis
Ripper lever at HOLD Min. 1 MΩ Ripper lever at TILT IN
Max. 1 Ω
—
Min. 1 MΩ
1) Insert Tadapter. 2) Turn starting switch ON.
1) Disconnect connector. 2) Start engine.
1) Disconnect connector. 2) Start engine.
1) Disconnect connector. 2) Start engine.
1) Disconnect connector. 2) Start engine.
1) Disconnect connector. 2) Start engine.
1) Disconnect connector. 2) Start engine.
1) Disconnect connector. 2) Start engine.
20-15 4
TESTING AND ADJUSTING
Left blade cylinder angle sensor
CSL (male)
Measure resistance
Measurement conditions
Judgement table If the condition is as shown in the table below, it is normal. Between (1) – (2)
Ripper lever at HOLD Min. 1 MΩ Ripper lever at TILT BACK
Max. 1 Ω
—
Min. 1 MΩ
Between (1)(2) – chassis
Blade lever top button switch
Torque converter lockup solenoid
Backup alarm relay
P01 (female) P03 (male)
P02 (female) P03 (male)
LU2 (male)
BB5 (male)
Measure voltage Measure resistance
CSR (male)
Measure resistance
Right blade cylinder angle sensor
1) Disconnect connector. 2) Start engine.
If the condition is as shown in the table below, it is normal. Between — 2.0 – 3.0 V (2) – (1) All work equipment Between control levers at HOLD 0.8 – 1.2 V (3) – (1) At ripper RAISE 1.5 – 2.0 V relief
1) Insert Tadapter. 2) Start engine.
If the condition is as shown in the table below, it is normal.
1) Turn starting switch OFF. 2) Disconnect connector.
Between (1) – (3)
4.0 – 6.0 V
Between (1) – (2)
0.25 – 7.0 V
Between (2) – (3)
0.25 – 7.0 V
If the condition is as shown in the table below, it is normal.
Blade lever front button switch
20-16
HPS
Measure resistance
Machine controller system
Work equipment circuit oil pressure sensor
RTB (male)
Measure voltage
Ripper TILT BACK oil pressure switch
Connector Inspection No. method
Measure voltage
Name of component
Measure resistance
System
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
Between (1) – (3)
4.0 – 6.0 V
Between (1) – (2)
0.25 – 7.0 V
Between (2) – (3)
0.25 – 7.0 V
If the condition is as shown in the table below, it is normal. Between P03 – P01
Switch released
Min. 1 MΩ
Switch pressed
Max. 1 Ω
If the condition is as shown in the table below, it is normal. Between P03 – P02
Switch released
Min. 1 MΩ
Switch pressed
Max. 1 Ω
If the condition is as shown in the table below, it is normal. Between (1) – (2)
40 – 80 Ω
Between (1) (2) – chassis
Min. 1 MΩ
If the condition is as shown in the table below, it is normal. Between (1) – (2)
200 – 400 Ω
Between (3) – (5)
Min. 1 MΩ
Between (3) – (6)
Max. 1 Ω
1) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
D475A-3 20-16 4
TESTING
System
STANDARD
AND ADJUSTING
Name of component
Zonnector No.
spectior iethoc
VALUE
TABLE
Judgement
FOR
UNL (male)
Between Between
(1) - (2) (I) (2) - chassis
If the condition is as shown below, it is normal. Demand solenoid
PCV (male)
Pitch back solenoid
PPB (male)
PPD (male)
TLL (male)
TLR (male)
Pitch back assist solenoid
PBA (male)
PDA (male)
Dual tilt selection solenoid
D475A-3
PST (male)
table
20 - 60 R
Between
(1) (2) - chassis
Min. in the
table
(1) - (2)
20 - 60 a
Between
(1) (2) - chassis
Min. in the
table
(I) - (2)
20 - 60 R
Between
(1) (2) - chassis
Min. in the
table
(I) - (2)
20 - 60 R
Between
(1) (2) - chassis
Min.
(1) (2) - chassis
Between
(1) - (2)
Between
(1) (2) - chassis
Between
(I) - (2)
Between
(1) (2) - chassis
Between
(1) - (2)
Between
(1) (2) - chassis
table
10 - 40 n
table
IO-40R
table
IO-40n
I) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
in the
table
IO-40R Min.
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
in the
Min.
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
in the
Min.
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
in the
Min.
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
Between
Between
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
Between
(I) - (2)
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
Between
If the condition is as shown below, it is normal. DST (male)
in the
(I) - (2)
Between
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
Between
If the condition is as shown below, it is normal. Pitch selection solenoid
table
Min.
If the condition is as shown below, it is normal. Pitch dump assist solenoid
in the
(I) (2) - chassis
If the condition is as shown below, it is normal.
PARTS
1 MR
Between
If the condition is as shown below, it is normal. Right tilt limit solenoid
40 - 80 R Min.
40 - 80 R
If the condition is as shown below, it is normal. Left tilt limit solenoid
table
(I) - (2)
If the condition is as shown below, it is normal. Pitch dump solenoid
in the
Between
If the condition is as shown below, it is normal.
RELATED
Measurement conditions
table
If the condition is as shown below, it is normal. Unload solenoid
ELECTRICAL
1) Turn starting switch OFF. 2) Disconnect connector.
1 MR
20-17
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Systen
Name of component
T
C:onnector
Judgement
No.
If the condition is as shown below, it is normal.
Controller power source
Between
(7) (13) - (6) (12)
If the condition is as shown below, it is normal.
Torque converter lock-up solenoid
1
Between
(1) - (6)(12)
Measurement conditions
table in the
table
20 - 30 v in the
table
~%i~~na’~Max’Iv 1
1) Insert Tadapter. 2) Start engine.
High idling, drrectronal 2. _ 3. v
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter. 2) Start engine.
If the condition is as shown below. it is normal.
in the
table
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
Pitch back solenoid
Pitch dump solenoid
I) Insert Tadapter. 2) Turn starting switch ON.
Ml1
Left tilt limit solenoid
Right tilt limit solenoid
Pitch dump assist solenoid
Pitch back assist solenoid
Solenoid power source
1 Between M21
Demand solenoid
20-18
(I) (12) - (11) (21)
If the condition is as shown below. it is normal.
t”“ir,;
1 20 - 30 V 1 in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
D475A-3
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Systen
Name of component
Unload solenoid
Pitch selection solenoid
T Clonnector No.
7
Judgement
khod
If the condition is as shown in the table below, it is normal.
Dual tilt selection solenoid
Transmission R switch
D475A-3
Max. 1 V
Pitch ooerated
20 - 30 v I
2!) Start engine.
,
1I) Insert T-
If the condition is as shown in the table below, it is normal.
.Blade lever at HOLD
Max. 1 V
Dual tilt operated
20 - 30 V
Economymode OFF Between (I’) - (11)(21) Economy mode 2
adapter.
;?) Start engine.
I) Insert Tadapter. d2) Turn starting switch ON. 3) Fuel control dial at MAX.
00 - 00 V 00 - 00 v
If the condition is as shown in the table below, it is normal. Between (2) - (17)
Rock selection mode switch
Transmission F switch
Blade lever at HOLD
)gndsaep:e~-
1
I
If the condition is as shown in the table below, it is normal.
Acceleration sensor
Kser power source
I
Between tg) - (lg)
Engine command signal
zer power source
) ~~~~e~~
2!) Start engine.
Blade lever at RAISE 20 - 30 V
If the condition is as shown in the table below, it is normal.
I
1
Max. 1 V
Blade lever at HOLD
Between 14) - (15)
Between (8) - (18) M21
Measurement conditions
table
1.25 - 3.75 V
I
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
I) Insert T-
Between (6) - (16)
20 - 30 v
1
adapter. 2) Turn starting switch ON.
M31 If the condition is as shown in the table below, it is normal. Between (7) - (16)
4.25 - 5.75 V
If the condition is as shown in the table below, it is normal. Between (8) chassis
Direction at Neutral
Max. 1 V
chassis
1) Insert Tadapter. 2) Start engine.
Operated to FORWARD 20 - 30 V
If the condition is as shown in the table below, it is normal. B7;y-r
1) Insert Tadapter. 2) Turn starting switch ON.
Direction at Neutral
Max. 1 V
1) Insert Tadapter. 2) Start engine.
Operated to REVERSE 20 - 30 V
20-19 0
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Systen
Name of component
Connector No.
Measurement conditions
Judgement table If the condition is as shown in the table below, it is normal.
Transmission 1 switch
Between (9) chassis
2nd or 3rd selected
Max. 1 V
1st selected
20 - 30 v
I) Insert T-
adapter. 2) Stat-t engine.
If the condition is as shown in the table below, it is normal.
Transmission 2 switch
Between (19) chassis
1st or 3rd selected
Max. 1 V
2nd selected
20 - 30 v
I) Insert Tadapter. 2) Start engine.
If the condition is as shown in the table below, it is normal.
Transmission 3 switch
Between (IO) chassis
1st or 2nd selected
Max. 1 V
3rd selected
20 - 30 v
I) Insert Tadapter. 2) Start engine.
If the condition is as shown in the table below, it is normal. Transmission modulating switch
M31
Between (20) chassis Note:
20 - 30 v
Engine running
Max. lV(Note)
Left blade cylinder angle sensor
If the condition is as shown below, it is normal.
Right blade cylinder angle sensor
If the condition is as shown below, it is normal.
Blade RAISE oil pressure
Blade LOWER oil pressure switch
Blade left tilt oil pressure switch
(11) - (16)
1 Between (12) - (16) 1
Work equipment circuit pressure sensor
20-20
Engine stopped
During gear-shifting, the voltage rise to 20 - 30 V temporarily.
Between
M32
1) Insert Tadapter.
may
in the table
1) Insert Tadapter. 2) Start engine.
1.5 - 3.5 v in the table
1.5 - 3.5 v
I
1) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the table
1) InsertTadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the table
I) Insert Tadapter. 2) Start engine.
If the condition is as shown below, it is normal.
in the table
I) Insert Tadapter. 2) Start engine.
Between (6) chassis
Blade lever at HOLD
Blade lever at LOWER Max. 1 V
If the condition is as shown below, it is normal. Between (15) chassis
20 - 30 V
in the table
Blade lever at HOLD
20 - 30 V
Blade lever at left tilt
Max. 1 V
I) Insert Tadapter. 2) Stat-t engine.
D475A-3
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Systen
Name of component
lonnector No.
SpCliOI
Judgement
iethod
If the condition is as shown below, it is normal.
Blade right tilt oil pressure switch
Between (8) chassis
Between (2) chassis
Between (IO) chassis
Bemean
(3) chassis M32
Ripper TILT BACK oil pressure switch
(16) chassis
at
Between (7) chassis
Ripper lever at LOWER
Ripper lever
Between
Rippe;F;r
at
Between (14) chassis
M4
TILT BACK
(4) (12) - chassis
M51
in the table
v
in the table
in the table 4.0 - 10.0 v in the table
Max. 1 V in the table 7.0 - 9.0 v in the table
Oil level normal
20 - 30 v
Oil level abnormal
Max. 1 V
(1) - chassis
(2) - (IO)
I) Insert Tadapter. 2) Start engine.
Max. 1 V
When switch is ON
(9) - chassis
I
I) Insert Tadapter. 2) Start engine.
Max. 1 V
20 - 30 V
If the condition is as shown below, it is normal. Between
1) Insert Tadapter. 2) Start engine.
Max. 1 V
When switch is OFF
If the condition is as shown below, it is normal. Between
in the table
Ripper lever at HOLD 20 - 30 V
- Ripper lever at
If the condition is as shown below, it is normal.
Hydraulic oil level sensor
1) Insert Tadapter. 2) Start engine.
Max. 1 V
at HOLD 20 - 30
If the condition is as shown below, it is normal.
Sensor 8 V power source
in the table
Ripper lever at HOLD 20 - 30 V
If the condition is as shown below, it is normal.
Buzzer cancel switch
D475A-3
Ripp;;irEer
If the condition is as shown below, it is normal. Between
1) insert Tadapter. 2) Start engine.
Ripper lever at HOLD 20 - 30 V
If the condition is as shown below, it is normal. Between
S-NET
Torque converter speed sensor
Max. 1 V
If the condition is as shown below, it is normal.
Ripper TILT IN oil pressure switch
Engine speed sensor
20 - 30 V
Blade lever at right tilt
If the condition is as shown below, it is normal.
Ripper LOWER oil pressure switch
in the table
Blade lever at HOLD
If the condition is as shown below, it is normal.
Ripper RAISE oil pressure switch
Measurement conditions
table
in the table 0.5 - 3.0 v in the table 0.5 - 3.0 v
1) Insert Tadapter. 2) Turn starting switch ON. 1) Insert Tadapter. 2) Turn starting switch ON.
1) Insert Tadapter. 2) Turn starting switch ON. 1) Insert Tadapter. 2) Turn starting switch ON.
1) Insert Tadapter. 2) Start engine. Ir Use AC range of tester. 1) Insert Tadapter. 2) Start engine. k Use AC range of tester.
20-21
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Name of component
r
C' onnector No.
Judgement
Measurement conditions
table
I) Insert Tadapter. !) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
t$,“,“eJP switch
REVERSE slow mode switch
zi
If the condition is as shown in the table below, it is normal.
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
1) Insert Tadapter. 2) Turn starting switch ON.
M51 1-1
If the condition is as shown in the table below, it is normal.
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
1) InsertTadapter. 2) Turn starting switch ON.
If the condition is as shown in the table below, it is normal.
1) Insert Tadapter. 2) Turn starting switch ON.
Pitch back switch
Pitch dump switch
7
20-Z 0
D475A-3
TESTING
Systerf
STANDARD
AND ADJUSTING
Name of component
onnector No.
VALUE
ipectior
Judgement
ethod If the below,
Power train (torque converter) oil temperature sensor
Fuel level sensor
Radiator water level sensor (main)
Radiator water level sensor (dual)
Between (1) - (2)
table
Water
t;?;erature 0
A12proo.
Water
tT;gerature
A8ppr00.
1) Turn starting switch OFF. !) Disconnect connector.
A4p;;p,x. A;;~oo.
condition is as shown it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
If the below,
condition is as shown it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
condition is as shown it is normal.
in the
table
Max.
1 Q
1) Turn starting switch OFF. 2) Disconnect connector.
453 (male)
422 (male)
;I
If the below, 405 (male)
Between (1) - (2)
If the below, DRT (male)
404 (male)
ANB
Float at upper limit Float at lower limit
condition is as shown it is normal.
Between (1) - (2)
Float at upper limit Float at lower limit
condition is as shown it is normal.
Between (1) - (2) If the below,
Alternator
PARTS
If the below,
If the below, Engine oil level sensor
in the
A3y;roo.
Water
RELATED
Measurement conditions
table
temperature 1oo”c temperature 90°C temperature 35°C
Water 402 (male)
FOR ELECTRICAL
condition is as shown it is normal. Water
Engine water temperature sensor
TABLE
Float at upper limit Float at lower limit
condition is as shown it is normal.
1 Between terminal
R and chassis
Min. in the
Max.
1 MR table
1 Q
Min.
1 MR
in the
table
Max.
1 Q
Min.
1 MQ
in the
table
127.5 - 29.5 VI
1) Turn starting switch OFF. 2) Disconnect connector.
1) Turn starting switch OFF. 2) Disconnect connector.
1) Start engine. (Run at above mid-range speed)
*If the batten/ is old, or after starting in cold areas, the voltage may not rise for some time. If the below, Engine oil pressure sensor
D475A-3
condition is as shown it is normal.
in the
table
I) Turn starting switch OFF. 2) Disconnect connector.
20-23
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Syster
Name of component
Zonnector No.
Air cleaner clogging sensor
lspediol nethoc
Judgement
Measurement conditions
table
If the condition is as shown below. it is normal.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
If the condition is as shown below, it is normal.
in the
table
I) Turn starting switch OFF. 2) Disconnect connector.
AFI AF2
Hydraulic oil temperature sensor
452 (male)
Between (I) - body
Oil temperature below 105°C
Max.
Oil temperature 105°C or above
Min 1 MD
If the condition is as shown below, it is normal.
I Service switch
S24
Front right lamp relay Front left lamp relay Working lamp relay Electrical intake air heater relay
BBI %:“’ %13e) (male) BB4 (male)
Switch
I
OFF
Alternator
CNI
1 Max. 1 R
1 Min. 1 MR -1
I Between (2) - (3)
I Min. I MD
/ Max. I R
1
I Between (4) - (5)
1 Max. I R
I Min. I MR
I
1 Between (5) - (6)
1 Min. 1 MD
1 Max. 1 R
1
If the condition is as shown below, it is normal. I Between
(11 - (2)
I
1 Between
(3) - (5)
1
1 Between
(3) - (6)
I
(I) - (2)
in the
table
200 - 400 R Min.
I
I
1 MR
Max.
in the
20-24
oil
I) Turn starting switch OFF. 2) Disconnect connector.
I
1 Q table
1) Insert Tadapter. 2) Turn starting
20 - 30 v
switch
ON.
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter.
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter.
Between (4) - (2)
Engine
stopped
Engine
running
Max.
1 V
27.5 - 29.5 V
If the condition is as shown below, it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the condition is as shown below, it is normal.
in the
table
I) Insert Tadapter. 2) Turn starting switch ON.
Radiator water leve sensor
Engine level sensor
1) Turn starting switch OFF. 2) Disconnect connector.
1 Between (1) - (2)
Between
Starting switch START signal
table
ON
1
If the condition is as shown below, it is normal.
Power source
in the
1 R
)
D475A-3
TESTING
Syster
AND
STANDARD
ADJUSTING
Name of component
T
Connector No.
VALUE
spectic lethot
TABLE
Judgement If the below,
FOR ELECTRICAL
in the
table
1) Insert
T-
adapter. 2) Turn
Engine oil pressure sensor
switch
below 0.05’MPa (0.5
PARTS
Measurement conditions
table
condition is as shown it is normal.
RELATED
Max.
starting ON.
1 V
kg/cm? If the below, Hydraulic oil temperature sensor
CNI
Between (8) - (2)
If the below,
Air cleaner Clogging sensor
condition is as shown it is normal.
If the below,
S-NET
Max.
Oil temperature 105°C or above
20 - 30 v
When air cleaner is normal
in the
Max.
1 V
table
1V
1) InsertTadapter. 2) Turn starting switch
1) Insert Tadapter. 2) Turn starting switch
(11) (12) - (IO)
in the
table
Engine water temperature sensor
If the below,
Power train (torque converter) oi temperature sensor
4.0 - 10.0 v
D475A-3
Water temperature 70°C (level 1) Water temperature 83°C (level 2) Water temperature 94°C (level 3) Water temperature 98°C (level 4) Water temperature 102°C (level 5) Water temperature 108°C (level 6)
condition is as shown it is normal.
in the
table
Approx. 8.8 kR Approx. 6 kR
ON.
1) Turn starting switch OFF. 2) Disconnect connector.
Approx. 4.4 kR Approx. 4.0 kR Approx. 3.5 kQ Approx. 3.1 kR in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
in the
table
1) Turn starting switch OFF. 2) Disconnect connector.
CNl (female) CN2 (female) Between CN2 (2) CNI (2)
If the below, Fuel level sensor
condition is as shown it is normal.
Between CN2 (I) CNI (2)
ON.
1) Insert Tadapter. 2) Turn starting switch
If the below,
ON.
26 - 36 V
condition is as shown it is normal.
Between
table
Oil temperature below 105°C
condition is as shown it is normal.
Between (9) - (2)
in the
condition is as shown it is normal.
20-25
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
Systen
Name of component
C:onnector No.
;pectio1 rethoc
Judgement
Measurement conditions
table
If the below.
condition is as shown it is normal.
in the
table
I) Insert Tadapter. 2) Turn starting switch ON.
If the below,
condition is as shown it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the below,
condition is as shown it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
Preheatins signal
Caution lamp
CNI CN2
Alarm buzzer I
Lighting signal
I
I
stoooed
I
If the below,
condition is as shown it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch ON.
If the below,
condition is as shown it is normal.
in the
table
1) Insert Tadapter. 2) Turn starting switch OFF.
CN4
Backup power source
Eween If the below,
Starting switch ON signal
(7) - (2)
20 - 30 V
condition is as shown it is normal.
Between
z&?gy
I
(I) - (2)
in the
I table
1) Insert Tadapter. 2) Turn starting switch ON.
20 - 30 V
If the below,
condition is as shown it is normal.
in the
table
1) Insert Tadapter.
If the below,
condition is as shown it is normal.
in the
table
I) Insert Tadapter.
condition is as shown it is normal.
in the
table
1) InsertTadapter. 2) Turn starting switch ON.
START signal TO1
Alternator )I
If the below, Service switch
When switch is OFF
Between (5) - (2) I
I
If the below,
When switch is ON
condition is as shown it is normal.
20 - 30 V Max.
1 V
1
in the
I
table
1) Insert Tadapter. 2) Turn start_ing switch ON.
table
1) Insert Tadapter. 2) Turn starting switch ON.
S-NET Between
Power source
so1
If the below,
4.0 - 10.0 v
condition is as shown it is normal.
Between
20-26
(9HlO) - (8)
(I) - (2)
in the
20 - 30 v
I
D475A-3
TESTING AND ADJUSTING Table of tools for testing, adjusting, and troubleshooting .................................................................................. 20-102 Measuring engine speed .......................................................................................................................................... 20-103 Measuring air supply pressure (boost pressure) .................................................................................................. 20-105 Measuring exhaust temperature ............................................................................................................................. 20-106 Measuring exhaust color ......................................................................................................................................... 20-107 Adjusting valve clearance ........................................................................................................................................ 20-108 Measuring compression pressure ........................................................................................................................... 20-109 Measuring blow-by pressure ................................................................................................................................... 20-110 Measuring engine oil pressure ............................................................................................................................... 20-111 Testing and adjusting fuel injection timing ........................................................................................................... 20-112 Testing and adjusting alternator belt tension ....................................................................................................... 20-113 Testing and adjusting belt tension for air conditioner compressor ................................................................... 20-113 Adjusting engine speed sensor ............................................................................................................................... 20-114 Adjusting fuel control dial and decelerator pedal ................................................................................................ 20-115 Measuring torque converter stall speed ................................................................................................................ 20-117 Measuring torque converter stall + hydraulic pump relief (full stall) speed ..................................................... 20-118 Measuring power train oil pressure ....................................................................................................................... 20-119 Simple procedure for testing brake performance ................................................................................................. 20-124 Adjusting full monolever and parking lever .......................................................................................................... 20-125 Adjusting brake pedal linkage ................................................................................................................................. 20-129 Adjusting clearance of idler ..................................................................................................................................... 20-131 Testing and adjusting track shoe tension .............................................................................................................. 20-132 Measuring and adjusting work equipment oil pressure ...................................................................................... 20-133 Testing and adjusting work equipment control circuit pressure ........................................................................ 20-136 Measuring PPC valve and pitch • tilt control valve output pressure .................................................................. 20-138 Adjusting PPC valve ................................................................................................................................................. 20-142 Measuring output pressure of demand solenoid valve ....................................................................................... 20-143 Measuring output pressure of ripper pin-puller solenoid valve ......................................................................... 20-144 Checking location of cause of hydraulic drift of blade and ripper ..................................................................... 20-145 Measuring leakage inside hydraulic cylinder ........................................................................................................ 20-146 Releasing remaining pressure in hydraulic circuit ............................................................................................... 20-147 Bleeding air from hydraulic cylinders .................................................................................................................... 20-147 Adjusting work equipment safety lever ................................................................................................................. 20-148 Procedure for selecting model ................................................................................................................................ 20-149 Procedure for adjusting blade tilt limit angle (dual tilt dozer specification) ..................................................... 20-150 Procedure for adjusting blade tilt limit angle (super dozer specification) ......................................................... 20-152
D475A-3
20-101 4
TABLE OF TOOLS TESTING
TABLE OF TOOLS FOR TESTING, TROUBLESHOOTING Check
or measurement
iterr
Symbol 1
ADJUSTING,
Part Name
Part No.
Air supply pressure (boost oressure)
A
799-201-2202
Boost
Water temperature, oil temperature, exhaust temperature
B
799-101-1512
Digital
temperature
1
799-201-9000
Handy
smoke
2
Commercially available
Smoke
meter
Exhaust
Valve
color
Compression
Remarks
I
-101 - 199.9 kPa I-760 - 1,500 mmHgI Negative pressure measurement type
kit gauge
-99.9
- 1.299”C
Discoloration: 0 - 70% (with standard color) i$s..;;oration x l/IO + Bosch
checker
1Feeler gauge
-2;1210 795-502-1205
Compression
gauge
AND
C
clearance
Intake: 0.43 mm, exhaust: 0.80 mm gauge
0 - 6.9 MPa (0 - 70 kg/c21
pressure E
Blow-by
FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
AND ADJUSTING
F
pressure
1
G
Oil pressure
For 140 Engine
q
799-201-1604
Blow-by
checker
799-101-5002
Hydraulic
790-261-1203
Digital
799-101-5220
Nipple
0 - 4.9 kPa {O - 500 mmHzOI
tester
hydraulic
Series
Pressuregauge: 2.5, 5.9, 39.2, 58.8 MPa (25, 60, 400, 600 kg/cm*} Pressure
tester
gauge: 58.8 MPa I600
kg/cm*1
For 10 x 1.25 plug 07002-I 2 Blade
tilt control
Operating
angle
J
1023
O-ring
799-401-2320
Hydraulic
799-402-3800
Angle
79A-264-0021
Push-pull
Work
hydraulic equipment
Voltage,
resistance
Troubleshooting harness, sensor
Push-pull
drift
L
Commercially available
speed
M
Commercially available
N
79A-264-0211
Tester
799-601-8000
T-adapter
value
of wiring
P
0 - 294 N IO - 30 kg}
scale
0 - 490 N IO - 50 kg}
Scale
Stopwatch
I / 799-601-7360
20- 102
scale
/ 79A-264-0091
Stroke,
gauge: 0.98 MPa {IO kg/cm*}
gauge
K
effort
Pressure
gauge
/ Adapter
assembly
I For relay (5 pin)
D475A-3
TESTING AND ADJUSTING
MEASURING
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) careful not to touch any hot parts when A Be moving or installing the measuring tools. Ir *
re-
Measure the air supply pressure separately for the left and right banks. Measure the air supply pressure under the following conditions. . Coolant temperature: Within operating range . Power train oil temperature: Within operating range . Hydraulic temperature: 45 - 55°C
1.
Remove air supply pressure measurement (I) or (2) (PT1/8). . Plug (1): For right bank . Plug (2): For left bank
2.
Fit nipple @ (PT l/8) and hose @ of oil pressure gauge kit HI, then connect boost gauge A.
3.
Run the engine at a mid-range speed or above to bleed the oil from the hose. * Insert the connection of the hose and pressure gauge about half way, repeat the action to open the self-seal portion at the hose end, and bleed the oil. jr If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be
plugs
used. *
4.
If there is oil inside the hose, the gauge will not work, so always bleed the oil.
Run the engine at high idling to stall the torque converter, and read the air supply pressure (boost pressure). * For details of the procedure for stalling the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED. * The air supply pressure (boost pressure) should be measured with rhe engine running at rated output. However,when measuring in the field, a similar value can be obtained at torque converter stall speed.
D475A-3
AIR SUPPLY PRESSURE (BOOST PRESSURE)
TESTING AND ADJUSTING
MEASURING
EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE Await for the mainfold temperature to go down before removing or installing the sensor. * Measure the exhaust temperature under the following conditions. . Coolant temperature: Within operating range . Power train oil temperature: Within operating range . Hydraulic temperature: 45 - 55°C 1.
Remove
2.
Remove exhaust temperature (I) or (2) (PT l/8). l Plug (I): For right bank l Plug (2): For left bank
3.
Fit sensor @ of digital temperature gauge B, then connect digital temperature gauge B. * Clamp the wiring harness of the temperature gauge to prevent it from touching any hot part during measurement.
4.
Carry out actual work at engine high idling and measure the maximum value for the exhaust temperature during operation. * Use the PEAK mode of the digital temperature gauge. + The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation using the following formula. . Compensation value [“Cl = Measured value + 2 x (20 - ambient temperature)
20- 106
the engine
right bank adiabatic measurement
cover. plug
D475A-3
MEASURING
TESTING AND ADJUSTING
EXHAUST COLOR
MEASURING EXHAUST COLOR Be careful not to touch any hot parts when A moving or installing the measuring tools. .
*
re-
When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker Cl; when recording formal data, use Smoke Meter C2. Measure the exhaust color under the following conditions. Engine water temperature: Within operating range l
1. Measuring with Handy Smoke Checker Cl.
1)
Install fillter paper to Handy Smoke Checker Cl. 2) Insert the exhaust gas suction port into the exhaust pipe. 3) Accelerate the engine suddenly, and operate the handle of Handy Smoke Checker Cl at the same time to collect the exhaust gas on the filter paper. 4) Remove the filter paper and compare it with the scale supplied to judge the condition. 2.
Measuring with Smoke Meter C2 1) Insert-probe @ of Smoke Meter C2 into the outlet port of exhaust pipe, and tighten the clip to secure it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose and accelerator switch to Smoke Meter C2. * Keep the pressure of the air supply below 1.5 MPa {I5 kg/cm*}. 3) Connect the power cord to the AC socket. Sr When connecting the cord, check that the power switch of the Smoke Meter is OFF. 4) Loosen the cap nut of the suction pump and fit the filter paper. * Fit the filter paper securely so that the exhaust gas cannot leak. 5) Turn the power switch of Smoke Meter C2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of Smoke Meter C2 at the same time to collect the exhaust gas color on the filter. 7) Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of unused filter paper inside the filter paper holder, and read the value shown. I,
D475A-3
BVD00701
20-107 0
TESTING
AND ADJUSTING
ADJUSTING
VALVE
CLEARANCE
ADJUSTING VALVE CLEARANCE 1. Remove the cylinder head cover. * For details, see TESTING AND ADJUSTING, REMOVAL OF CYLINDER HEAD ASSEMBLY. 2.
Rotate the crankshaft in the normal direction to align the Rl.GTOP line on crankshaft pulley (I) with pointer (2) and set the RI cylinder to compression top dead center. * At the compression top dead center, the rocker arms for both the intake and exhaust move. If the rocker arms do not move, the cylinder is not at compression top dead center, so rotate the crankshaft one more turn and align the lines again. * Use the hexagonal shaft of the alternator drive pulley when cranking.
3.
Inset-t feeler gauge D between crosshead (4) and rocker arm (3) of the RI cylinder, adjust with adjustment screw (5) until the clearance is a sliding fit, then tighten locknut (6) to hold adjustment screw (5) in position. m Locknut: 58.8 + 5.9 Nm {S f 0.6 kgml +- After tightening the locknut, check the valve clearance again.
4.
After adjusting the RI cylinder at compression top dead center, turn the crankshaft 120” each time, align each TOP line on crankshaft pulley (1) with pointer (2), and adjust the clearance of the valves of each cylinder according to the firing order. * Firing order : RI - Ll - R5 - L5 - R3 - L3 - R6 - L6 - R2 L2 - R4 - L4
-__
71 --7
BVLOl316
@@@@@@ Ll
L2
L3
L4
LS
L6
BVD00704
20-l 08
D475A-3
TESTING
AND ADJUSTING
MEASURING PRESSURE
a
MEASURING
COMPRESSION
PRESSURE
COMPRESSION
When measuring the extremely careful not fold or any other hot fan belt or any other
compression pressure, be to touch the exhaust maniparts or get caught in the rotating parts.
1. Adjust the valve clearance. * For details, see ADJUSTING ANCE.
VALVE
2.
Warm up the engine so that the engine perature is 40 - 60°C.
3.
Remove nozzle holder assembly cylinder which is to be measured. * For details, see DISASSEMBLY BLY, REMOVAL OF NOZZLE SEMBLY.
(I)
CLEAR-
oil tem-
from
the
AND ASSEMHOLDER AS-
4.
Fit adapter 0 of compression connect compression gauge E.
5.
Disconnect governor solenoid connector El5 (1) of the right fuel injection pump and governor solenoid connector El1 (2) of the left fuel injection pump.
6.
Turn the starting switch on and set the monitor panel to monitoring code 1991. Ir For details, see MEASURING ENGINE SPEED.
7.
Crank the engine with the starting motor and measure the compression pressure. * Measure the compression pressure at the point where the pressure gauge indicator remains steady. * When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range.
gauge
E, then
2
BVD00708
D475A-3
20- 109
TESTING AND ADJUSTING
MEASURING PRESSURE *
MEASURING
BLOW-BY PRESSURE
BLOW-BY
Measure the blow-by pressure under the following conditions. . Coolant temperature: Within operating range . Power train oil temperature: Within operating range . Hydraulic temperature: 45 - 55°C
1. Install nozzle (I) of blow-by checker F to blowby hose @ of the left bank, then block the hose connection. * Connect the short hose and throttle the outlet port.
2.
Install nozzle @ and hose (2) of blow-by checker hose (2) of the right bank, then connect blow-by checker F.
F to blow-by
3.
Run the engine at engine high idling and measure the value on the gauge when the torque converter is stalled. For details of the procedure for torque converter stall, see MEASURING TORQUE CONVERTER STALL SPEED. The blow-by should be measured with the engine running at rated output. However, when measuring in the field, a similar value can be obtained at torque converter stall. If it is impossible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output. Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby 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.
20-110
D475A-3
TESTING
AND ADJUSTING
MEASURING PRESSURE *
MEASURING
ENGINE
OIL PRESSURE
ENGINE OIL
Measure the engine oil pressure under the following conditions. . Coolant temperature: Within operating range
1. Remove engine pressure pickup plug (I) (PT l/8).
2.
Fit nipple @ and hose @ of oil pressure gauge Gl, then connect to oil pressure gauge G2 (0.98 MPa {IO kg/cm21).
3.
Start the engine, and measure at low idling and high idling.
D475A-3
the oil pressure
20-111
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
FUEL INJECTION
TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING *
Carry out testing and adjusting fuel injection timing for the left and right banks at the same time.
Testing 1. Remove
the fuel injection
pump cover.
2.
Crank the engine to rotate the crankshaft in the normal direction and align 12” line (I) on the crankshaft pulley with pointer (2). Sr When doing this, check that line (3) on the coupling of the fuel injection pump is close to line (4) on the body. If line (3) on the coupling cannot be seen, rotate the crankshaft one more turn. * Use the hexagonal shaft of the alternator drive pulley when cranking.
3.
Check that line (3) on the coupling of the fuel injection pump is aligned with line (4) on the body.
Adjusting If the fuel injection timing is not correct, adjust as follows. 1. Loosen 2 sets of mounting bolts and nuts (5) in the oblong hole of the coupling and lock bolt (6) to make the coupling free.
*
2.
Rotate the coupling and align line (3) on the coupling with line (4) on the body.
3.
Tighten lock bolt (6) bolts and nuts (5). w Lock bolt: 157 Mounting bolt, 98.0 -
20-112
and 2 sets of mounting
n 0
- 196 Nm {IS - 20 kgm} nut: 122.6 Nm 18.5 - 9.5 kgm1
n
BVD00717
D475A-3
TESTING TESTING
AND ADJUSTING
AND ADJUSTING ALTERNATOR TESTING AND ADJUSTING FOR AIR CONDITIONER
BELT TENSION BELT TENSION COMPRESSOR
TESTING AND ADJUSTING ALTERNATOR BELT TENSION Testing . Measure deflection a of the belt when it is pushed with a finger force of approx. 58.8 N Iapprox. 6 kg1 at a point midway between the alternator pulley and the drive pulley. . Deflection a of belt: 20 + 2 mm Adjusting t If the belt tension is not correct, adjust as follows. 1. Loosen the mounting bolt and nut, mounting bolt (I), and locknut (2). 2.
Turn adjustment nut (3) and move alternator to adjust the tension of the belt.
3.
Tighten locknut (2), mounting mounting bolt and nut.
svooo71a
(4)
bolt (1) and the
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR Testing . Measure deflection a of the belt when it is pushed with a finger force of approx. 58.8 N {approx. 6 kg1 at a point midway between the compressor pulley and the engine drive pulley. . Deflection a of belt: 20 f 2 mm Adjusting If the belt tension lows. Loosen 3 mounting
is not correct,
adjust
as fol-
bolts and nuts (I) and locknut
(2). Turn the adjustment nut and move air conditioner compressor (3) together with the bracket to adjust the tension of the belt. Tighten locknut nuts (I).
D475A-3
(2) and 3 mounting
bolts and
BVDOO720
TESTING
AND ADJUSTING
ADJUSTING SENSOR Ir
ADJUSTING
ENGINE
SPEED SENSOR
ENGINE SPEED
Adjust both left bank speed sensor (I) and right bank speed sensor (2) in the same way.
1. Screw in sensor body (3) so that the tip contacts ring gear (2). Ir Be careful not to damage the sensor tip or let iron particles stick to it. & Sensor thread: Gasket sealant (LG-6) 2.
After sensor body (3) contacts ring gear (4), turn it back 3/4 - 1 turn to adjust clearance a. . Clearance a: 1.2 - 1.5 mm
3.
Tighten locknut (5). m Locknut : 49.0 - 68.6 Nm (5.0 - 7.0 kgm}
*
When fixing the wiring in position, be careful that no excessive force is brought to bear on the sensor wiring.
BVD00723
20-114
D475A-3
TESTING AND ADJUSTING
ADJUSTING
ADJUSTING
FUEL CONTROL DIAL AND DECELERATOR PEDAL
FUEL CONTROL DIAL AND DECELERATOR PEDAL
BVD00739
1.
Outline of fuel control system . The speed signals from the fuel control dial
.
2.
and the decelerator pedal potentiometers are each input to the engine controller. The engine controller gives priority to the lower speed of the two input signals and sends a command to the fuel injection pump. Adjustment of the engine speed is all carried out by the decelerator pedal linkage.
Preparatory work 1)
2)
TV001043
Turn the starting switch on and set the monitor panel to monitoring code 1991. * For details, see MEASURING ENGINE SPEED. Start the engine, set the fuel control dial to the FULL position, and check that the engine speed is at least 1000 rpm. * If the engine speed is below 1000 rpm, adjust by extending installation dimension a of rod (I) to make the engine speed more than 1000 rpm.
D475A- 3
20-l 15
TESTING
AND ADJUSTING
ADJUSTING
3.
Adjusting decelerator pedal speed Set the fuel control dial at the high idling position, depress decelerator pedal (2) until it contacts the stopper, and check that the decelerator pedal speed is normal. . Decelerator pedal speed: 800 - 850 rpm * If the engine speed is not correct, adjust installation dimension a of rod 11). . Installation dimension a: 122 mm
4.
Adjusting high idling speed Set the fuel control dial to the high idling position and check that the high idling speed is correct. . High idling speed: 2000 f 50 rpm * If engine speed is too high: To remove the play in the decelerator pedal, set the engine speed to less than 1900 rpm with stopper bolt (3), then adjust it to the high idling speed. Ir If engine speed is too low: Adjust the high idling speed with stopper bolt (3).
20-116
FUEL CONTROL
DIAL AND
DECELERATOR
PEDAL
D475A-3
TESTING
MEASURING CONVERTER
A +
MEASURING
AND ADJUSTING
TORQUE STALL SPEED
TORQUE
CONVERTER
STALL SPEED
r
Make sure that the area around the machine is safe before starting the operation. Measure the torque converter stall speed under the following conditions. . Coolant temperature: Within operating range . Power train oil temperature: Within operating range . Hydraulic oil temperature: 45 - 55°C
1. Turn the starting switch ON and set the monitor panel to monitoring code [991. * For details, see MEASURING ENGINE SPEED. 2.
Start the engine low idling.
and set the fuel control
dial to
3.
Depress the brake pedal firmly, move the full monolever to 3 and the directional lever to F.
4.
Depress the decelerator pedal and set the fuel control dial to high idling.
5.
Let the decelerator pedal back slowly, run the engine at high idling, and stall the torque converter. Depress the brake pedal firmly during operation. For safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.
A 6.
When the power train oil temperature gauge enters the red gauge, immediately return the full monolever to neutral.
7.
Repeat Steps 3 - 6 three times.
8.
Repeat Steps 3 - 5 again and measure the engine speed immediately the power train oil temperature gauge enters the red range. Ir After completion of the measurement, return the full monolever swiftly to neutral, and run the engine at high idling to lower the power train oil temperature.
D475A-3
20-l 17
TESTING
MEASURING
AND ADJUSTING
POWER TRAIN
OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE AStop the machine on level ground, lower the work equipment completely to ground, then set the parking lever and safety lever to the LOCK position. Measure the power train oil pressure under the following condition. . Power train oil pressure: Within operating range Table of centralized pressure tions and gauges to use 40.
pick-up
port posi-
Gauge MPa {kg/cm*}
Measurement location
,
Torque converter port pressure
inlet
(IN)
2
Torque converter port pressure
outlet
(OCm
9
Torque converter clutch pressure
lock-up
(LU)
5.9 1601
4
Torque converter clutch pressure
stator
WJ
5.9
1601
5
Transmission pressure
main
5.9
1601
6
Transmission pressure
modulating
(TM)
5.9
{601
7
Transmission pressure
reducing
WI)
5.9
I601
8
Transmission pressure
lubrication
0.98
{IO)
9
Left steering
clutch pressure
(LC)
5.9 1601
10
Left steering
brake
(LB)
5.9
1601
11
Right
steering
clutch
pressure
(RC)
5.9
I601
12
Right
steering
brake
pressure
(RB)
5.9
I601
*
Installed
relief
pressure
2.5 {251 0.98
II01
inside the right cover of the floor.
1. Measuring
torque converter inlet oil pressure (IN) 1) Fit hose @ of oil pressure gauge Gl to pressure measurement nipple (I), then connect oil pressure gauge Gl (2.5 MPa {25 kg/cm?). 2) Start the engine and set all the functions of the full monolever to neutral. * Any position can be used for the speed range. 3) Measure the oil pressure at engine high idling.
D475A-3
20-119
TESTING
2.
MEASURING
AND ADJUSTING
Measuring
torque
converter
outlet
POWER TRAIN
OIL PRESSURE
oil pressure
(OUT) I) Fit hose @ of oil pressure gauge Gl to pressure measurement nipple (21, then connect oil pressure gauge Gl (0.98 MPa {IO kg/cm*)). 2) Start the engine and set all the functions of the full monolever to neutral. + Any position can be used for the speed range. the oil pressure at engine high 3) Measure idling.
3.
Measuring torque converter lock-up clutch pressure (LU) 1) Using the blade and ripper, raise the chassis to a height where the track can rotate freely.
A After lever 2)
3) 4)
raising the chassis, set the safety to the LOCK position. Fit hose 0 of oil pressure gauge Gl to pressure measurement nipple (3), then connect oil pressure gauge Gl (5.9 MPa I60 kg/cm2)). Start the engine and turn the lock-up mode switch ON. Run the engine at high idling, set the full monolever speed to Fl, rotate the track under no load, gradually raise the engine speed, and measure the oil pressure when the lockup display lamp lights up.
extremely careful A Be in the track or other
BVDOO741
not to get caught rotating parts dur-
ing the measurement.
4.
Measuring torque converter stator clutch pressure (SC) I) Fit hose @ of oil pressure gauge Gl to pressure measurement nipple (4), then connect oil pressure gauge Gl (5.9 MPa I60 kg/cm*}). 2) Start the engine and set all the functions of the full monolever to neutral. Sr Any position can be used for the speed range. 3) Measure the oil pressure at engine high idling.
20-120
D475A-3
TESTING
5.
6.
MEASURING
AND ADJUSTING
Measuring transmission main relief pressure 1) Remove oil pressure measurement plug (5) (PT1/8). 2) Fit nipple @ and hose @ of oil pressure gauge Gl, then connect oil pressure gauge Gl (5.9 MPa {SO kg/cm21). 3) Start the engine and set all the functions of the full monolever to neutral. -k Any position can be used for the speed range. 4) Measure the oil pressure at engine high idling. Measuring
transmission
modulating
I
POWER TRAIN
I
I
OIL PRESSURE
\ BVD00731
pressure
(TM)
1) Fit hose @ of oil pressure gauge Gl to pres-
2) 3)
7.
sure measurement nipple (6), then connect oil pressure gauge Gl (5.9 MPa 160 kg/cm*}). Start the engine. Measure the oil pressure when the full monolever is operated as follows at engine high idling. The torque converter is stalled during a Steps iv) - v), so depress the brake pedal firmly during operation. For safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation. Measure the pressure with the i) monolever set to 1st (speed range) + Neutral (direction). the pressure with the ii) Measure monolever set to 2nd (speed range) + Neutral (direction). the pressure with the iii) Measure monolever set to 3rd (speed range) + Neutral (direction). the pressure with the iv) Measure monolever set to 3rd (speed range) + FORWARD (direction). the pressure with the VI Measure monolever set to 3rd (speed range) + REVERSE (direction).
Measuring transmission reducing pressure (Fl) 1) Fit hose @ of oil pressure gauge Gl to pressure measurement nipple (7), then connect oil pressure gauge Gl (5.9 MPa {60 kg/cm?). 2) Start the engine and set the full monolever to 1st speed. Sr Set the directional lever and steering lever to the NEUTRAL position. 3) Measure the oil pressure at engine high idling.
D475A-3
20-121
TESTING
8.
9.
AND ADJUSTING
Measuring transmission reducing pressure 1) Remove oil pressure measurement plug (8) (PT1/8). 2) Fit nipple @ and hose @ of oil pressure gauge Gl, then connect oil pressure gauge G2 (0.98 MPa {IO kg/cm*}) . 3) Start the engine and set all the functions of the full monolever to neutral. * Any position can be used for the speed range. 4) Measure the oil pressure at engine high idling.
MEASURING
I
POWER TRAIN
I
I
OIL PRESSURE
\ "BVD067i4
Measuring left steering clutch pressure (LC) 1) Fit hose @ of oil pressure gauge Gl to pressure measurement nipple (9), then connect oil pressure gauge Gl (5.9 MPa 160 kg/cm*}). 2) Start the engine and operate the full monolever steering fully to the left. * Set the directional lever to the neutral position; any position can be used for the speed range. 3) Measure the oil pressure with the engine at low idling and high idling.
10. Measuring left steering brake pressure (LB) 1) Fit hose @ of oil pressure gauge Gl to pressure measurement nipple (IO), then connect oil pressure gauge Gl (5.9 MPa {60 kg/cm*}). 2) Start the engine and set all the functions of the full monolever to neutral. * Any position can be used for the speed range. 3) Measure the oil pressure with the engine at low idling and high idling.
11. Measuring right steering clutch pressure (RC) 1) Fit hose 0 of oil pressure gauge Gl to pressure measurement nipple (I I), then connect oil pressure gauge Gl (5.9 MPa (60 kg/cm*}). 2) Start the engine and operate the full monolever steering fully to the right. * Set the directional lever to the neutral position; any position can be used for the speed range. 3) Measure the oil pressure with the engine at low idling and high idling.
zo- 122
D475A-3
TESTING AND ADJUSTING
MEASURING
POWER TRAIN OIL PRESSURE
12. Measuring right steering brake pressure (RB) 1) Fit hose @ of oil pressure gauge Gl to pres-
2)
3)
sure measurement nipple (12), then connect oil pressure gauge Gl (5.9 MPa {SO kg/cm?). Start the engine and operate the full monolever steering fully to the right. * Any position can be used for the speed range. Measure the oil pressure with the engine at low idling and high idling.
D475A-3
20-123
TESTING
AND ADJUSTING
SIMPLE
PROCEDURE
FOR TESTING
BRAKE PERFORMANCE
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE *
Carry out the simple test of the brake performance under the following conditions. . Coolant temperature: Within operating range . Power train oil temperature: Within operating range
1. Stop the machine on a level surface and set the blade and ripper to the travel posture. BVD00742
2.
Set the full monolever speed range to 2. A If it is set to 1, there will be excess load on the brakes, so always carry out this test in position 2.
3.
Run the engine at low idling, depress the brake pedal securely, then set the monolever direction to F. * Set the steering to the neutral position.
4.
Depress the decelerator pedal control dial to high idling.
5.
Release the decelerator pedal gradually and raise the engine speed to high idling. Check that the machine does not start to move. AThe torque converter is stalled, so depress the brake pedal firmly during operation. For safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.
20-124
and set the fuel
D475A-3
TESTING AND ADJUSTING
ADJUSTING
ADJUSTING
FULL MONOLEVER
FULL MONOLEVER AND PARKING LEVER
AND PARKING LEVER
-..-..-__ -_-__-___
14
~‘Jt-___JlL’,
_/
BVD00743
D475A-3
20- 125
TESTING
AND ADJUSTING
ADJUSTING
t
Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely.
1.
Adjustment of full monolever direction position 1) Remove lever knob (I) and boot (2). 2) Set parking lever (3) to the LOCK position, then set full monolever (4) direction to the neutral position. * If parking lever (3) is not installed, use a screwdriver to pull up lock (5) to the LOCK position (top position). 3) Adjust dimension a between the pins of rod (6), then connect to full monolever (4) and directional lever (7). . Dimention a between pins: 96.5 mm 4) Use rod (6) to adjust installation dimension b between the center of the tip of full monolever (4) and the tip of the steering boss. . Installation dimension b: 30 mm 5) Set directional lever (8) at the transmission end to the neutral position. 6) Connect cable (9) to directional lever (7) at the lever stand end and directional lever (8) at the transmission end. 7) Install boot (2) and lever knob (I).
2.
FULL MONOLEVER
AND PARKING
LEVER
EVDOO744
Adjustment of full monolever speed range 1) Adjust dimention c between the pins of rod (IO), then connect to full monolever (4) and speed lever (7). . Dimention c between pins: 95.5 mm 2) Set speed lever (12) at the transmission end to position 1. 3) Connect cable (13) to speed lever (I I) at the lever stand end and speed lever (12) at the transmission end. BVDOO74!
20-126
D475A-3
TESTING
3.
AND ADJUSTING
ADJUSTING
Adjustment 1 of full monolever steering (steering valve portion) 1) Adjust dimension d between the pins of left rod (13), then connect to steering valve (14) and intermediate lever (15). . Dimension d between pins: 437.5 mm 2) Adjust dimension e between the pins of right rod (161, then connect to steering valve (14) and intermediate lever (15). . Dimension e between pins: 431 mm 3) Check front-to-rear play f of intermediate lever (15). . Front-to-rear play f: 0.1 - 0.2 mm
4.
Adjustment 2 of full monolever steering (servo valve portion) 1) Insert cotter pin @ of servo valve (17) into adjustment hole g. + When adjusting the linkage, insert cotter pin @I into the adjustment hole g to lock the output spool of servo valve (17) at the neutral position. 2) Adjust dimension h between the pins of rod (18), then connect to intermediate lever (16) and servo valve (17). . Dimention h between pins: 84 mm j, Adjust with rod (18) so that cotter pin @ of servo valve (17) can be inserted smoothly. 3) Insert cotter pin @ of servo valve (17) into actuation hole j. * After adjusting the linkage, insert cotter pin @ into actuation hole j to set to a condition where the output spool of servo valve (17) can be actuated.
5.
Adjustment 3 of full monolever steering (full monolever portion) 1) Using pin 0, fix steering boss (19) and intermediate lever (20) in position, and set the steering of full monolever (4) to the neutral position. Sr For pin 0, use the part specified below or a 08 pin. Pin 0: 04205-10825
D475A-3
FULL MONOLEVER
dl
AND PARKING
‘.l,’
LEVER
!
I3
BVDOO746
TESTING AND ADJUSTING
ADJUSTING
FULL MONOLEVER AND PARKING LEVER
Ir
2)
3)
4) 6.
For pin 0, use the part (Part No.:0420510825) or a 08 pin. Adjust dimension k between the pins of rod (211, then connect to intermediate lever (20) and steering lever (22). . Dimention k between pins: 490 mm Adjust dimension m between the pins of rod (23), then connect to steering lever (22) and intermediate lever (24). . Dimention m between pins: 390 mm * Connect so that there is no slack in the input spool of servo valve (17). Remove pin (3).
Adjustment
of parking lever
I) Adjust dimension n between the pins of rod (25), then connect to parking lever (3) and lock (5). . Dimention n between pins: 211 mm Set parking lever (3) to the FREE position, 2) then adjust with rod (25) so that height p from the tip of parking lever (3) to mounting face of lever stand is dimension given below. . Lever height p: 285 f 5 mm 3) Set parking lever (3) to the LOCK position. 4) Connect cable (26) to lock (5) and brake valve lever (27). * Be careful that brake valve lever (27) is not being pulled. 5) Operate parking lever (3) between the FREE position and LOCK position several times and check that it moves smoothly. 6) Operate parking lever (3) between the FREE position and LOCK position and check that full monolever (4) is locked or released at the correct position. 7) Set parking lever (3) to the LOCK position. 8) Adjust so that neutral safety switch (28) is pushed in by amount q and is switched ON. . Pushing in amount q: 2.8 mm
20-128
BVD00749
D475A-3
TESTING AND ADJUSTING
ADJUSTING
BRAKE PEDAL LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely. 1.
Adjust installation dimension a of rod (I), then connect to valve lever (2) and intermediate lever (3). . Rod installation
dimension
a: 500.5 mm
BVD00752
2.
Adjust installation dimension c of damper (5) so that the travel of brake pedal (4) is dimension b. . Brake pedal travel b: 73 mm Damper installation dimension c: 42.5 mm l
D475A-3
20-129 0
TESTING
ADJUSTING
AND ADJUSTING
3.
Adjust installation dimension d of rod (6) at valve end, then connect to intermediate lever (3). . Rod installation dimension c: 1,125 mm * Screw joint (7) fully into the valve.
4.
Adjust installation dimension e of rod (8) at pedal end, then connect to brake pedal (4). . Rod installation dimension e: 198 mm
5.
Push rod (6) at valve end lightly towards the rear of the machine, then turn only joint (9) and connect rod (6) and rod (8).
6.
With brake pedal (4) at the brake RELEASED position, adjust dimension f between pins of rod assembly (IO) to adjust play of the brake pedal. . Pedal play: 1 - 5 mm (center of pedal) . Dimension f between pins of rod assembly: 1,301 mm * Turn joints (7) and (9) in the same direction at the same time when adjusting.
7.
With brake pedal (4) at the RELEASED
BRAKE PEDAL LINKAGE
10
BVD00754
position,
check that brake pedal (4) is in contact with damper (5).
20- 130 0
D475A-3
ADJUSTING
TESTING AND ADJUSTING
ADJUSTING IDLER
CLEARANCE
CLEARANCE OF IDLER
OF
The idler moves forward and backward under external pressure. When this happens, side guide (I) and guide plate (2) become worn. As they become worn, there is side play in the idler, or the idler turns at an angle, causing the track to come off or resulting in uneven wear, so adjust as follows.
Adjustment 1. Drive the machine for 1 - 2 m on flat ground, then measure clearance a (4 places: left, right, inside, outside) between the track frame and side guide (I). 2.
If clearance a is more than 3 mm, remove bolt (3), then take out shim (4), and adjust so that the clearance on one side is less than 0.5 mm. *
There are two types of shim (thickness: mm and 1.0 mm).
0.5 i
.-
I
I
BVDOO755
D475A-3
20-l 31
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Drive the machine forward and stop on a horizontal surface. Jr Stop the machine without using the brake. 2.
Pull steel rod (I) between the idler and carrier roller, and measure clearance a from the bottom of the rod to the track shoe grouser. . Standard clearance a: 20 - 30 mm EVD00757
Adjusting * If the-track shoe tension follows. 1. Remove cover (2).
is not normal,
adjust as
2.
If tension is too high: Loosen plug (3) and release some of the grease. AThere 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.
If tension Pump in Ir If the chine
*
After complection of the adjustment, repeat the above procedure to check the tension again.
BVDOO758
is too low: grease through grease fitting (4). track tension is poor, move the mabackwards or forwards slowly.
EVD00759
ZO-132
D475A-3
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE Installing oil pressure gauges ¤ Stop the machine on level ground, lower the work equipment completely to the ground, then set the parking lever and safety lever to the LOCK position. 1. Installing oil pressure gauge to front pump 1) Remove the control valve cover. 2) Remove oil pressure measurement plug (1) (PT 1/8). 3) Fit nipple 1 and hose 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (39.2 MPa {400 kg/cm2}).
2. Installing oil pressure gauge to rear pump 1) Remove the control valve cover. 2) Remove oil pressure measurement plug (2) (PT 1/8). 3) Fit nipple 1 and hose 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (39.2 MPa {400 kg/cm2}).
3. Installing oil pressure gauge to assist pump 1) Remove the control valve cover. 2) Remove oil pressure measurement plug (3) (PT 1/8). 3) Fit nipple 1 and hose 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (39.2 MPa {400 kg/cm2}).
D475A-3
20-133 4
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Measuring (single tiltdozer specification) fl Hydraulic pump combination chart : Pump is actuated, relief pressure can be measured : Pump is actuated, but relief pressure cannot be measured : Flow merges if lever is operated fully ▲: Cylinder is drained at end of stroke (but it is possible to measure relief pressure by switching panel to monitoring mode [99]) 1. Measuring front pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the ripper lever to the end of the stroke to relieve the ripper lift cylinder or ripper tilt cylinder, and measure the oil pressure with the engine at low idling and high idling.
Lever operation Blade lift Blade single tilt Blade dual tilt Blade pitch Ripper lift Ripper tilt
Pump Front RAISE LOWER Right Left Right Left DUMP BACK RAISE LOWER IN BACK
Rear
Assist
—
—
—
▲
▲
2. Measuring rear pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the blade lever to the end of the stroke to relieve the blade tilt cylinder, and measure the oil pressure with the engine at low idling and high idling. 3. Measuring assist pump relief pressure 1) Turn the starting switch ON. 2) Turn service switch (4) ON and economy mode switch (5) OFF. fl The service switch is installed inside the cover. 3) Turn buzzer cancel switch (6) to the ON position and hold for at least 7 seconds to display [99] on display (7) at the top of the panel. 4) Start the engine and set the safety lever to the FREE position. 5) Operate the ripper lever to the end of the stroke to relieve the ripper lift cylinder or ripper tilt cylinder, and measure the oil pressure with the engine at low idling and high idling.
20-134 4
D475A-3
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Measuring (dual tiltdozer specification) fl Hydraulic pump combination chart : Pump is actuated, relief pressure can be measured : Pump is actuated, but relief pressure cannot be measured : Flow merges if lever is operated fully : Cylinder is drained at end of stroke 1. Measuring front pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the ripper lever to the end of the stroke to relieve the ripper lift cylinder or ripper tilt cylinder, and measure the oil pressure with the engine at low idling and high idling.
Lever operation Blade lift Blade single tilt Blade dual tilt Blade pitch Ripper lift Ripper tilt
Pump Front RAISE LOWER Right Left Right Left DUMP BACK RAISE LOWER IN BACK
Rear
Assist
2. Measuring rear pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the blade lever to the end of the pitch back stroke to relieve the blade pitch cylinder, and measure the oil pressure with the engine at low idling and high idling. 3. Measuring assist pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the blade lever to the end of the pitch back stroke to relieve the blade pitch cylinder, and measure the oil pressure with the engine at low idling and high idling.
D475A-3
20-135 4
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Measuring (super dozer specification) fl Hydraulic pump combination chart : Pump is actuated, relief pressure can be measured : Pump is actuated, but relief pressure cannot be measured : Flow merges if lever is operated fully : Cylinder is drained at end of stroke. 1. Measuring front pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the blade lever to the end of the pitch dump stroke to relieve the blade pitch cylinder, and measure the oil pressure with the engine at low idling and high idling.
Lever operation Blade lift Blade single tilt Blade dual tilt Blade pitch Ripper lift Ripper tilt
Pump Front RAISE LOWER Right Left Right Left DUMP BACK RAISE LOWER IN BACK
Rear
Assist
—
—
—
2. Measuring rear pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the blade lever to the end of the pitch back stroke to relieve the blade pitch cylinder, and measure the oil pressure with the engine at low idling and high idling. 3. Measuring assist pump relief pressure 1) Start the engine and set the safety lever to the FREE position. 2) Operate the blade lever to the end of the pitch back stroke to relieve the blade pitch cylinder, and measure the oil pressure with the engine at low idling and high idling.
20-135-1 4
D475A-3
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Adjusting 1. Adjusting main relief valve for blade lift valve fl If the front pump relief pressure is not correct, adjust main relief valve (8) of the blade lift valve as follows. 1) Remove cover (9), then loosen locknut (10). 2) Turn adjustment screw (11) to adjust. fl Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw: 2.43 MPa {24.8 kg/cm2} 3 Locknut: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} Cover: 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
2. Adjusting main relief valve for blade tilt, ripper Lo valve fl If the rear pump relief pressure is not correct, adjust main relief valve (12) of the blade tilt and ripper Lo valve as follows. 1) Remove cover (13), then loosen locknut (14). 2) Turn adjustment screw (15) to adjust. fl Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw: 2.43 MPa {24.8 kg/cm2} 3 Locknut: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} Cover: 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
D475A-3
20-135-2 4
TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
3. Adjusting main relief valve for assist valve fl If the assist pump relief pressure is not correct, adjust main relief valve (16) of the assist valve as follows. 1) Remove cover (17), then loosen locknut (18). 2) Turn adjustment screw (19) to adjust. fl Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw: 2.43 MPa {24.8 kg/cm2} 3 Locknut: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} Cover: 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
20-135-3 4
D475A-3
TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE Measuring ¤ Stop the machine on level ground, lower the work equipment completely to the ground, then set the parking lever and safety lever to the LOCK position. fl Measure the work equipment hydraulic pressure under the following conditions. • Hydraulic oil temperature: 45 – 55°C 1. Remove the control valve cover. 2. Remove oil pressure measurement plug (1) (10 x 1.25). 3. Fit nipple 1 and hose 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (5.9 MPa {60 kg/cm2}).
4. Start the engine, then measure the oil pressure with the engine at low idling and high idling.
Adjusting fl If the oil pressure is not correct, adjust PPC relief valve (2) as follows.
20-136 4
D475A-3
TESTING AND ADJUSTING
1. Loosen
2.
locknut
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE
(3).
Turn adjustment screw (4) to adjust. * Turn the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE . To DECREASE pressure, turn COUNTERCLOCKWISE w Locknut: 9.8 Nm Il.0 kgm1 l
*
After complection above procedure
of the adjustment, repeat the to check the oil pressure again. EVD00772
D475A-3
20-137
TESTING
AND ADJUSTING
MEASURING PPC VALVE AND PITCH . TILT CONTROL VALVE OUTPUT PRESSURE
MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE AStop the machine on level ground, lower the work equipment completely to the ground, then set the parking lever and safety lever to the LOCK position. * Measure the PPC valve output pressure under the following conditions. . Hydraulic oil temperature: 45 - 55°C 1.
Method of measuring PPC valve portion * Measure the following circuits at the PPC valve. i) Blade lift RAISE circuit which does not pass through the relay block. ii) Blade tilt circuit before it enters the pitch, tilt control valve 1) Disconnect hose (1) from the circuit to be measured. * See the circuit drawing on the next page 2) Fit adapter @ and nipple @ of oil pressure gauge Gl, then connect oil pressure gauge Gl (5.9 MPa (60 kg/cm*11 with hose 0. 3) Start the engine and set the safety lever to the FREE position. 4) Operate the control lever of the circuit to be measured, and measure the oil pressure at engine high idling. Sr Operate the control lever fully when measuring. * For blade LOWER, operate to the FLOAT position.
2.
Method of measuring relay block portion * Measure the following circuits at the PPC valve. i) Blade lift LOWER circuit ii) Blade tilt circuit after it passes through the pitch, tilt control valve iii) Ripper lift circuit iv) Ripper tilt circuit 1) Disconnect hose (2) from the circuit to be measured. * See the circuit drawing on the next page.
20-138
D475A-3
MEASURING PPC VALVE AND PITCH TILT CONTROL VALVE OUTPUT PRESSURE l
TESTING
AND ADJUSTING
2) Fit adapter @ and nipple @ of oil pressure
3) 4)
D475A-3
gauge Gl, then connect oil pressure gauge Gl (5.9 MPa I60 kg/cm*}) with hose 0. Start the engine and set the safety lever to the FREE position. Operate the control lever or knob switch of the circuit to be measured, and measure the oil pressure at engine high idling. Operate the control lever fully when measuring. When measuring the output pressure of the pitch dump solenoid valve or pitch back solenoid valve, set the blade lever at HOLD and operate the knob switch. When measuring the output pressure of the tilt limit solenoid valve, operate the blade lever in the tilt direction. When the blade reaches the tilt limit angle, shut off the output pressure from the PPC valve.
20-139
MEASURING PPC VALVE AND PITCH TILT CONTROL VALVE OUTPUT PRESSURE l
TESTING
AND ADJUSTING
Blade
I
PPC valve
I
I
(Blade
lower)
(Blade
tiltsRIGHT)
(Ripper
I I I
IIIII, ! IIII II !
lift1
(Ripper
lower)
[Ripper
tilt
back)
[Ripper
tilt
in)
I
RioPer
PPC valve
I1
L-___-___-_-_.___._-___------.-._._.-_~
Pitch,tiIt
control
valve
TVDO1045
20-140
MEASURING PPC VALVE AND PITCH TILT CONTROL VALVE OUTPUT PRESSURE l
TESTING AND ADJUSTING
1
(Blade
Relay
block
\CB ---I Blade
-------_________
1
lower)
2 _,_________-------,_
valve
7
3
-I----------------I_
4
_}__________------I_
;
---_I_________-------~~,
B
-I_---____---____-r
O0
-
lo” ,
(Blade
(Ripper (Ripper (Blade
L
Lift)
tilt lift) t i It,
PAkT
back) LEFT),
11
12 13
~
1 To S/D
solenoid
(Blade (Ripper (Ripper
t i It.
RIGHT) lower1 tilt 1n1
j
Blade
I 1 tilt.rioper
I LO valve
valve
TVDOlO46
20-14:
TESTING
ADJUSTING *
.
*
ADJUSTING
AND ADJUSTING
PPC VALVE
If there is excessive play at the tip of the blade lever and ripper lever, adjust the PPC valve as follows. Standard play dimension a: 1 - 5 mm at point 250 mm from center of lever (both front-to-rear and left-right) The diagram shows the ripper PPC valve.
1. Remove
boot (I).
2.
Loosen locknut (2), then turn disc (3) to adjust the play. * When doing this, do not move the piston.
3.
Secure
disc (3) in position
(2). w
Locknut: 98.07 - 127.49 Nm {IO - 13 kgm1
4.
PPC VALVE
and tighten
locknut
Install boot (1).
BVD00514
20-142
D475A-3
TESTING
AND ADJUSTING
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE
a Ir
Stop the machine on level ground, lower the work equipment completely to the ground, then set the parking lever and safety lever to the LOCK position. Measure the solenoid valve output pressure under the following conditions. . Hydraulic temperature: 45 - 55C l
1.
Disconnect
2.
Fit adapter 0 and nipple @ of oil pressure gauge Gl, then connect oil pressure gauge Gl (39.2 MPa {400 kg/cm2}) with hose 0. * The blade Lo circuit is used for the basic pressure of the solenoid valve of the demand valve.
3.
Start the engine FREE position.
4.
Run the engine at full throttle and measure the oil pressure when the blade lever is returned to HOLD and when it is operated in the lift direction. * The pressure should be as follows. When lever is at HOLD: Approx. 0 MPa (0 kg/cm21 When lever is operated to lift: Almost same as blade lift circuit pressure
D475A-3
hose (I).
and set the safety lever to the
20-l 43
TESTING
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID
A *
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE
AND ADJUSTING
VALVE
Stop the machine on level ground, lower the work equipment completely to the ground, then set the parking lever and safety lever to the LOCK position. Measure the output pressure of the ripper pin puller solenoid valve under the following conditions. . Power train oil temperature: 45 - 55°C
1.
Disconnect
2.
Fit adapter @ and nipple @ of oil pressure gauge Gl, then connect oil pressure gauge Gl (5.9 MPa (60 kg/cm*}) with hose 0. Ir The power train circuit is used for the basic pressure of the ripper pin puller solenoid valve.
3.
Start the engine
4.
Operate the pin-puller switch and measure the oil pressure when the ripper pin-puller cylinder is operated fully.
20-144
output
hoses (1) and (2).
and run at low idling.
D475A-3
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER
TESTING AND ADJUSTING
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER +
If hydraulic drift occurs in the blade and 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 inspection posture, then stop the engine. 1) Blade lift cylinder Push the blade against the ground to raise the front of the chassis. Ir 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 (maximum right tilt), 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.
2.
Operate the control lever in the direction to extend the cylinder rod, and check the movement of the cylinder. . If the downward movement becomes faster, the packing is defective. . If there is no change, the control valve is defective. * If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to charge the accumulator before carrying out the operation.
TVD00958
I
TVD00959
I
TVD00960
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. in the posture 1) With the work equipment given above, (holding pressure applied to the bottom end), the 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.
D475A-3
3)
In this condition, if the lever is operated as shown above, the circuit at the head end is connected to the drain circuit (the bottom end is closed by a check valve), and the oil at the head end flows to the drain circuit. As a result, the balance is lost and the speed of downward movement increases.
20- 145
TESTING
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER
AND ADJUSTING
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER *
Measure the oil leakage inside the hydraulic inder under the following conditions. . Hydraulic oil temperature: 45 - 55°C
Ir
The blade lift cylinder has a built-in piston valve, so the internal leakage cannot be measured.
1.
Fully extend the cylinder to be measured, and set to the measurement posture. I) Blade tilt cylinder: Tilt the blade fully to the right. 2) Ripper lift cylinder: Remove the shank pin and lower the ripper fully. 3) Ripper tilt cylinder: Tilt the ripper fully to the front.
2.
Disconnect the piping at the head end of the cylinder and block the piping at the chassis end with a blind plug. * Remove the cover when disconnecting the blade tilt cylinder hose. g
3.
4.
Be careful not to disconnect the bottom end.
the piping
cyl-
at
Run the engine at high idling and apply the relief pressure to the bottom end of the cylinder. * Blade tilt cylinder: Tilt blade to right Ripper lift cylinder: Lower ripper Ripper tilt cylinder: Tilt ripper to front Wait for 30 seconds, then measure of leakage over the next 1 minute.
Disconnect Stroke
end
hose %a()
the amount
TWDOIOIB
20- 146
D475A-3
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT BLEEDING AIR FROM HYDRAULIC CYLINDERS
TESTING AND ADJUSTING
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT Ir
When disconnecting the piping between the hydraulic cylinder and control valve, first release the remaining pressure inside the piping as follows.
1.
Loosen the oil filler cap slowly to release pressure inside the hydraulic tank.
2.
Operate the work equipment control levers to the front, rear, left, and right. * When the levers are operated 2 - 3 times, the pressure inside the accumulator is released.
3.
Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the work equipment control levers to the front, rear, left, and right. J, If the above operation is repeated 2 - 3 times, the remaining pressure will be completely released. * For the ripper cylinder, the remaining pressure is released through the ripper Hi valve, so repeat the above procedure several times.
the
BLEEDING AIR FROM HYDRAULIC CYLINDERS Ir After replacing or installing hydraulic
cylinders or disconnecting and connecting hydraulic piping, bleed the air from the circuit as follows.
1.
Start the engine 5 minutes.
2.
Run the engine at low idling, and extend and retract the hydraulic cylinders 4 - 5 times. * Stop the position rod about 100 mm from the end of the stroke. Never operate it to the relief position.
3.
Run the engine at high procedure in Step 2.
4.
Then run the engine at low idling and operate the pistpn rod to the end of the stroke to relieve the circuit.
D475A-3
and run at low idling for about
idling
and
repeat
the
20-147
TESTING
AND ADJUSTING
ADJUSTING EQUIPMENT 1.
ADJUSTING
WORK EQUIPMENT
SAFETY
LEVER
WORK SAFETY LEVER
Adjust dimension a between the pins of rod (I), then connect to safety lever (2) and PPC lock valve (3). . Dimension a between pins: 330 mm
20-148
D475A-3
TESTING AND ADJUSTING
PROCEDURE FOR SELECTING MODEL
PROCEDURE FOR SELECTING MODEL fl If the monitor panel, engine controller, and machine controller have been replaced, or if the machine specifications have been changed, select the model as follows. If the monitor panel, engine controller, and machine controller have been replaced, or if the machine specifications have been changed, select the model as follows. fl If the machine specification and the controller model code are different, the system may not work properly or errors may occur. To prevent such problems, always select the correct model. 1. Turn the starting switch ON. 2. Turn service switch (1) ON, set economy mode switch (2) to 1, and display [– –] or [20] on display (3) at the top of the panel. fl The service switch is installed inside the cover. fl On the straight tilt dozer specification, display [– –], and on the dual tilt dozer specification and super dozer specification, display [20]. 3. Hold buzzer cancel switch (4) at the ON position for at least 7 seconds and display [CH] on display (3) at the top of the panel. 4. Operate REVERSE slow mode switch (5) and display [30] on display (3) at the top of the panel. fl [30] is the model selection code. 5. Operate buzzer cancel switch (4) and display the model code for the appropriate specification on display (6) at the bottom of the panel. 6. Operate REVERSE slow mode switch (5) and display [CR] on display (3) at the top of the panel. 7. Operate buzzer cancel switch again and check that the buzzer sounds once. 8. Operate the reverse slow mode switch (5) to display [OP] in upper display unit (3).
D475A-3
Machine specification and model code Specification of machine
Model code
Single tiltdozer
body 00
Single tiltdozer + SSC
body 01
Dual tiltdozer
body 10 or 30
Dual tiltdozer + SSC
body 11 or 31
Superdozer
body 20
20-149 8
TESTING AND ADJUSTING
9. Operate buzzer cancel switch (4) to display the code of the corresponding specification in lower display unit (6). fl The hydraulic oil level sensor is optional. If error code E0370 is displayed, check the model code.
PROCEDURE FOR SELECTING MODEL
Machine specification and model code Specification of machine
Model code
Standard
Code 00
With hydraulic oil level sensor
Code 01
10. Turn service switch (1) OFF.
fl The automatic deceleration control interlocked with the brake is a special specification. If error code E0736, E0776, or E0777 is displayed, perform 1 – 8 of PROCEDURE FOR SELECTING MODEL CODE above, and then perform the following operation. 9. Operate buzzer cancel switch (4) to display the code of the corresponding specification in lower display unit (6). 10. Operate the reverse slow mode switch (5) to display [LP] in upper display unit (3). Then, each time reverse slow mode switch (5) is operated, [AU], [FC], [dE], and [bP] are displayed in order. 11. While [dE] is displayed, operate buzzer cancel switch (4) to display [dECL00] in lower display unit (6). 12. Turn service switch (1) OFF.
20-149-1 8
D475A-3
TESTING AND ADJUSTING
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION)
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION) *
Ir
*
If the blade and blade cylinder potentiometer have been removed and installed again, or the machine controller has been replaced, adjust the blade tilt limit angle as follows. If this adjustment is not carried out, the amount of tilt will be reduced, or will become too large and will interfere with the track, so always carry out this adjustment. Carry out the adjustment on a level ground surface.
1.
Start the engine, run at low idling, and set the blade at the following basic posture. 1) Set the tilt angle to horizontal (0’). 2) Set the pitch angle to the maximum pitch back. 3) Lower the blade to the ground.
2.
Adjust installation dimension a of rod (I), and connect to potentiometer lever (2) and yoke (3). . Installation dimension a: 376.5 mm
3.
Turn service switch (4) ON, turn economy mode switch (5) to 1, and display (6) or 1201 on display (6) at the top of the panel. Ir The service switch is installed inside the cover.
4.
Press top button (7) on the blade lever to save the blade horizontal condition to the system. * When the buzzer sounds once, the saving is completed.
5.
Raise the tip of the blade approx. ground surface.
6.
Operate the blade lever to left tilt and set the left tilt annle to 12”. If top button (7) of the blade lever is pressed while the blade is being operated, the horizontal position will change, so do not press top switch (7). The tilt limit function will not work, so operate slowly and be careful not to let the tilt angle become too large. Use angle gauge J to adjust the tilt angle correctly.
EVtlOO795
I
1 m above the
-
-4 BVD00636
20- 150
D475A-3
PROCEDURE TESTING
FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION)
AND ADJUSTING
7.
Press front button (8) on the blade lever to save the left tilt limit value to the system. Sr When the buzzer sounds once, the saving is completed.
8.
Turn service switch (4) OFF. Sr To set the blade to the adjustment posture, switch the monitor panel to the normal mode.
9.
Set the blade to the maximum ture.
pitch dump
pos-
I
[@j&iii&) ElVDOO788
10. Turn service switch (4) ON again and display [201 on display (6) at the top of the panel. 11. Operate the blade lever to right tilt and set the right tilt angle to 12”. * If top button (7) of the blade lever is pressed while the blade is being operated, the horizontal position will change, so do not press top switch (7). * The tilt limit function will not work, so operate slowly and be careful not to let the tilt angle become too large. Ir Use angle gauge J to adjust the tilt angle correctly.
I
FiVD00796
12. Press front button (8) on the blade lever to save the right tilt limit value to the system. * When the buzzer sounds once, the saving is completed. 13. Turn service switch (4) OFF and stop the engine. 14. Start the engine again, operate the left and right tilt, and check that the blade does not interfere with the track when the blade is raised to any height. BVD00797
DA75A-3
20-151
PROCEDURE TESTING
FOR ADJUSTING BLADE TILT LIMIT ANGLE (SUPER DOZER SPECIFICATION)
AND ADJUSTING
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (SUPER DOZER SPECIFICATION) Ir
Ir
If the blade and blade cylinder potentiometer have been removed and installed again, or the machine controller has been replaced, adjust the blade tilt limit angle as follows. If this adjustment is not carried out, the amount of tilt will be reduced, or will become too large and will interfere with the track, so always carry out this adjustment. Carry out the adjustment on a level ground surface.
BVDOO79
I
1. Start the engine, run at low idling, and set the blade at the following basic posture. 1) Set the tilt angle to horizontal (0”). 2) Set the pitch angle to the maximum pitch back. 3) Lower the blade to the ground. 2.
Adjust installation dimension a of rod (I), and connect to potentiometer lever (2) and yoke (3). . Installation dimension a: 376.5 mm
I 3.
Turn service switch (4) ON, turn economy mode switch (5) to 1, and display (6) or 1201 on display (6) at the top of the panel. * The service switch is installed inside the cover.
4.
Press top button (7) on the blade lever to save the blade horizontal condition to the system. * When the buzzer sounds once, the saving is completed.
5.
Turn service switch (4) OFF. Ir To set the blade to the adjustment posture, switch the monitor panel to the normal mode.
6.
Operate the blade as follows as preparation to make it possible to operate the tilt. 1) Raise the tip 200 - 300 mm from the ground. 2) Set the angle of the edge to 52”. j, Use angle gauge J to adjust the angle of the edge correctly. 3) Raise the tip of the blade approx. a further 1 m above the ground surface.
I
\ BVDO0792
I
I
v--
‘4 BVD00636
20-152
D475A-3
PROCEDURE TESTING
FOR ADJUSTING BLADE TILT LIMIT ANGLE (SUPER DOZER SPECIFICATION)
AND ADJUSTING
7.
Turn service switch (4) ON again and display [201 on display (6) at the top of the panel.
8.
Operate the blade lever to left tilt and set the left tilt angle to 7”. * The tilt limit function will not work, so operate slowly and be careful not to let the tilt angle become too large. * Use angle gauge J to adjust the tilt angle correctly.
9.
Press front button (8) on the blade lever to save the left tilt limit value to the system. Ir When the buzzer sounds once, the saving is completed.
10 Operate the blade lever to right tilt and set the right tilt angle to 7”. * The tilt limit function will not work, so operate slowly and be careful not to let the tilt angle become too large. Ir Use angle gauge J to adjust the tilt angle correctly. 11
Press front button (8) on the blade lever to save the right tilt limit value to the system. * When the buzzer sounds once, the saving is completed.
I
BVD00793
I
BVD00794
12. Turn service switch (4) OFF and stop the engine. 13. Start the engine again, operate the left and right tilt, and check that the blade does not interfere with the track when the blade is raised to any height. . Automatic stop angle for tilt: 7 + I0
D475A-3
20-153
TROUBLESHOOTING Points to remember when troubleshooting ........................................................................................ 20-202 Sequence of events in troubleshooting .............................................................................................. 20-203 Points to remember when carrying out maintenance ....................................................................... 20-204 Checks before troubleshooting ............................................................................................................ 20-212 Connector types and mounting locations ........................................................................................... 20-213 Connection table for connector pin numbers .................................................................................... 20-221 Explanation of functions of control mechanism of electrical system ............................................. 20-232 Display method and special functions of monitor panel .................................................................. 20-236 Method of using troubleshooting charts ............................................................................................ 20-249 Troubleshooting of network system (N mode) .................................................................................. 20-301 Troubleshooting of engine controller system (E mode) ................................................................... 20-401 Troubleshooting of machine controller system (C mode) ................................................................ 20-501 Troubleshooting of hydraulic and mechanical systems (H mode) .................................................. 20-601 Troubleshooting of monitor panel and electrical system (M mode) ............................................... 20-701 Troubleshooting of air conditioner system ........................................................................................ 20-801
D475A-3
20-201 3 7
POINTS
TROUBLESHOOTING
POINTS TO REMEMBER
TO REMEMBER
WHEN
TROUBLESHOOTING
WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. A When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water A the engine to cool down before starting troubleshooting.
may spurt out and cause burns, so wait for
A
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When
removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.
20-202 0
4) 5)
4.
5.
6.
Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure . Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. t When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting . Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure . Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
D475A-3
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop
IExamination, When
confirmation
a request
of symptoms
for repairs
is received,
first
I,
-------
ask the following points. . Name of customer * . 2)
Jobsite
>
step 1
1)
TEW00181
TEW00180
Type,
serial
Details
number
of jobsite,
Ask questions
Ring!
-------
Ring!
of machine
etc.
to gain an outline
of the prob-
lem. *
Condition
*
Work being carried out at the time of the
of failure TEW00182
failure .
Operating
.
Past history,
environment details of maintenance,
etc.
Step 2
TEPOl348
[Determining 1)
location
of causel
Look at the troubleshooting
section
shop
probable
manual
to find
locations
of the
of possible
causes.
TEP01350
Step 3 ]Preparation 1)
of troubleshooting
tools.1
Look at the table of troubleshooting the shop manual
and prepare
tools in
the necessary
tools. . T-adapter . 2)
Hydraulic
pressure
gauge
kit, etc.
Look in the parts book and prepare essary
replacement
the nec-
parts.
that
Drive
matches
and
the symptoms,
operate
the condition
the
and judge
and carry
machine if there
out
to confirm is really
a
TEP01351
Was there chine
anything
Did the failure Had any repairs
D475A-3
strange
before the failure
about the ma-
occurred?
occur suddenly? been carried out before the
20-203 0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT 1)
Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
Improver
insertion
TEP01352
I Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
Improper
comPression
TEP01353
20-204 0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
TEW00194
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. Ir When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. * 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.
D475A-3
TEW00195
TEW00196
20-205 0
21 Removing, installing, and drying connectors and wiring harnesses l
Disconnecting connectors
0
Q
Press lightly when removing
Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. * Never pull with one hand.
TEP01354
When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. * If the connector is twisted up and down or to the left or right, the housing may break.
TBW00484
I 0
TBP01355
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. * If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
TEW00198
20-206 0
D475A-3
TROUBLESHOOTING
0
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors Check the connector visually. I) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to * the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. If there is any damage or breakage, re* place the connector.
Cliks into position
I
I I
TEP01356
Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. * If the connector cannot be corrected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
D475A-3
I
II
TEWOOZOO
TBW00487
20-207 0
TROUBLESHOOTING
l
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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. @ Disconnect the connector and wipe off the water with a dry cloth. * If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
TEW00196
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
TEWOOZOZ
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassemble.
20-208 Co
D475A-3
TROUBLESHOOTING
3)
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Handling control box The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
TEW00204
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
TEW00205
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2.
,,@!J/x
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. * if the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 41 When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. * If there is any change, there is probably defective contact in that circuit.
D475A-3
20-209 0
TROUBLESHOOTING
3.
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1)
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, repairing the machine in rain or high winds, places where there is a lot of dust.
or or
21
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.
3)
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
L
I 4)
TEW00207
TEW00208
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.
TEW00209
20-210 0
TROUBLESHOOTING
POINTS
TO REMEMBER
5) Change hydraulic oil when the temperature
WHEN
CARRYING
OUT MAINTENANCE
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.
oi
I
TEP01358
71
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
TEW00211
D475A-3
20-211 0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING Item
.JJijeement
Action
Check fuel level, type of fuel
-
Add fuel
Check for impurities in fuel
-
Clean, drain
Check hydraulic oil level
-
Add oil
4.
Check hydraulic strainer
-
Clean, drain
5.
Check swing machinery oil level
-
Add oil
Check engine oil level (oil pan oil level), type of oil
-
Add oil
Check coolant level
-
Add water
B.
Check dust indicator for clogging
-
Clean or replace
9.
Check hydraulic filter
-
Replace
1.
Check for looseness, corrosion of battery terminal, wiring
-
Tighten or replace
2.
Check for looseness, corrosion of alternator terminal, wiring
-
Tighten or replace
3.
Check for looseness, corrosion of starting motor terminal, wiring
-
Tighten or replace
1.
Check for abnormal noise, smell
-
Repair
Check for oil leakage
-
Repair
3.
Carry out air bleeding
-
Bleed air
1.
Check battery voltage (engine stopped)
1. 2. 3.
6. 7.
2.
20 - 3ov
Replace
Check battery electrolyte level
-
Add or replace
3.
Check for discolored, burnt, exposed wiring
-
Replace
4.
Check for missing wiring clamps, hanging wiring
-
Repair
Check for water leaking on wiring (be particularly careful attention
-
Disconnect
2.
5.
connector and dry
to water leaking on connectors or terminals) 6.
Check for blown, corroded fuses
7.
Check alternator voltage (engine running at l/2 throttle or above)
8.
Check operating sound of battery (when switch is turned ON/OFF)
20-2 12 0
Wter running for several minutes: 27.5 - 29.5V -
Replace Replace
Replace
DA75A-3
TROUBLESHOOTING
CONNECTOR Conrector No. 101
location
Address
Connectar No.
Intermediate
connector
K-2
260
1
2 I Intermediate
connector
I l-l
1 1 262 I
1
2 1Intermediate
connector
I I-l
I
x
104 1X
TYPES AND MOUNTING
No. of pins
Type
103 1X
CONNECTOR TYPES AND MOUNTING
16
Mounting
LOCATIONS Type
I
I’
No. of Dins
I
Intermediate
connector
K-2
264
SWP
112
x
4
Intermediate
connector
J-2
270
Terminal 1
122
SWP
12
Intermediate
connector
x-3
1 28u
137 I Terminal I 1 I Electricalintakeair heater(rightbank) I C-8 I
371
1M
153
L-3
372
M
connector
B-2
373
M
connector
C-l
374
IM
I
I A-7 I I 375 I M
I
4 I Caution lamp
I-
I A-5 I I 402 IX
I
2 I Engine water temperature sensor! Z-l
I
204
IM
I
I I Left front lamp
I Right front Iamp
I 403
209
x
4
Intermediate
212
M
4
Buzzer cancel switch
213
IM
M
4 I Preheating 14
2
connector
Alarm buzzer
4 I Rear lamp switch 4
-
IM
I
2
I I Left working
223
IM
I
1
I Left
lamp
rear lamp
241
SWP
4
Intermediate
241
l-pin connector
1
Backup alarm
242
SWP
6
Intermediate
connector
connector
-
( -
I Enoine
oil pressure sensor
I B-7 b-l
405
x
2
Radiatorwater level sensor (main)
B-7
414
Terminal 1
431
Electricalintakeair heater(left bank) A-3
I SWP I 14 I Intermediate 1X
IX
connector
I w-3
I 2 I Fuel level sensor I 2 I Intermediate connector
I v-2
16
Intermediate
I J-9
451
SWP
connector
K-3
452
X
1
Hydraulic oil temperature sensor
2
Torqueconverteroil temperature sensor L-3
Q-l
x
506
SWP
14
Intermediate
connector
w-3
I O-7 I
577
SWP
12
Intermediate
connector
w-2
578
SWP
6
Intermediate
connector
u-2
connector
I w-3
I K-2 I
992
SWP
16
Intermediate
connector
v-2
I L-6 I
993
SWP
16
Intermediate
connector
w-3
o-3
994
SWP
14
Intermediate
connector
d-7
I 599
I SWP I 12 I Intermediate
1SWP I 14 I Intermediate
F-9
r&5-
P-2
I ADH I
I
4 I Additional
connector
I d-7
heater switch
I M-7
I L-9I
I
1 I Right rear lamp
244
IX
(
2 I Ripper pin-puller solenoid valve1 l-9 I
250
I Terminal I 1 I Starting switch (terminal
D475A-3
washer motor
453
IM
Starting switch (terminal
Window
2 I Window washer motor
1M-6
243
Terminal 1
2
I
-
Engine oil level sensor
421
-
Diode
washer motor
2
1 422
Front lamp &working lamp switch O-7
221
Window
x
O-6
connector
I Terminal I
2
404
A-6
I P-7 I I
switch
Intermediate
220
255
I-
1 2 1Window washer motor
Intermediate
I
219
I A-4
Intermediate
IM
I
I-
3
203
IM
1 I-I
compressor
12
SWP
218
C) I P-9
connector
An conditioner
Q-7
connector
x
l-pin connector
Starting switch (terminal ACC)
Intermediate
202
217
w-7
4
201
:::I
1
w-7
connector
1 4 ( Intermediate
I
1354x
SWP
switch
I Terminal I I I Starting switch (terminal IX
BR)I P-8
I V-7
6
Intermediate
214
I
Ripper pin-puller
4
I
I
2
x
136 I Terminal I 1 I Electricalintakeair heater(left bank) I B-7 I
Address
location
2 I Horn switch
111
x
Mounting
Terminal 1 1 1 Starting switch (terminal
263
135 I Terminal 1 1 I Electricalintakeair heater(rightbank) I B-7 1 I 301
LOCATIONS
B) I Q-9 I RI)
P-9
20-2 13 co
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
LOCATIONS
Mounting location
20-214 0
D475A-3
TROUBLESHOOTING
D475A-3
CONNECTOR TYPES AND MOUNTING
LOCATldNS
20-215 0
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
LOCATIONS
241
DRT 2 206 HRN 209 207 406 206 204 CSR 351 ANE ANR
ANB 206 4 402
-
/
/
SR3 iSL[///
,
201 404 202
//
/
//
SR5
20-216 0
D475A-3
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
UNL
+
I
D475A-3
LU2
TMM
243
244
431
LOCATIONS
GNDP
BVDOO819
20-217 0
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
\
270
LOCATIONS
CN-10
/I
w
\ i’y
BLU \ RPU \
//-
I \
-._ 'f
20-218
\
'BBt'
D475A-3
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
CN-8
+ ’
LOCATIONS
1 lCN-l~N-L,
,262
E21. E41.
E61. E62. El 1. E31.
E32
1. M51 1. M31.
M32
.* GCR
l\ +
D475A-3
\ 461 GND3
\ CN-17
/
//I
221 BVD0082 1
20-219 0
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
996
LOCATIONS
984
AF2
AF'\
402
20-220 0
\
D475A-3
CONNECTION
TROUBLESHOOTING
CONNECTION j,
TABLE FOR CONNECTOR
The terms male and female refer to the pins, while refer to the mating portion of the housing.
No. of pins
TABLE FOR CONNECTOR
T
the terms
PIN NUMBERS
PIN NUMBERS male housing
and female
Female
housing)
housing
X type connector Male (female
housing)
(male
at=
2
0
TEwoo222
1
3
3 : 2 TEW00223
TEW00224
4
TEW00225
D475A-3
20-22 1 co
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
SWP type connector Female (male housing)
Male (female housing) 4
1
6
Kid
8 8
4
m i
12
TEW00237
TEW00236
1
_--.__ ______
5
0 0
9
1
4
5
8
9
12 BLtwO35
BLwoo34
1 4
8
11
3
10 i4
11
8
4
1
14 7
TEW00239
b
1
16
1
4
5
8
9
2
ELF%036
20-222 0
D475A-3
CONNECTION
TROUBLESHOOTING
No. of pins
r
TABLE FOR CONNECTOR
PIN NUMBERS
M type connector Male (female
Female
housing)
(male
housing)
. 2
I i
i
Em38
BLW0039
3
El
2
@ Y 1 TEW00244
TEwoo243
3
1
@% 4
2 TEW00246
4
1
@ 3’
‘6
TEW00247
TEWC0248
BLPmO41
D475A-3
20-223 0
CONNECTION
TROUBLESHOOTING
No. of pins
T
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector Male (female
Female
housing)
(male
housing)
8
‘8
4
TEW00249
TEwoo250
10
io
5
TEW00251
I
12 (White
BEL00113
12
5
6
I
EEL001 14
16 (White
7
20-224 0
I6
EEL00115
BEL00116
D475A-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
S type connector Male (female
Female
housing)
(male
housing)
10 (Blue)
s
10 1
BEL00117
BELO
6
6
1
12 (Blue:
TEWOO254
16 (Blue
BLpooo44
D475A-3
20-225 0
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
MIC connector Female (male housing)
Male (female housing)
BLPOO046
BLFiXW47
8
BLtWO46
13
13
BLFU0049
17
1
1
BLFUOO52
BLFUoO51
11
21
21 / i
20-226 0
j
TEN'00259
D475A-3
CONNECTION
TROUBLESHOOTING
No. of pins
r
AMP040 Male
(female
type
TABLE
FOR CONNECTOR
PIN NUMBERS
connector Female
housing)
(male
housing)
4
8
8
BLPcoO54
12
12
6
7
i
3L 8
BLFmm
16
16
1
9 BLWOO57
10
TEW00232
20
SEEI I 20
s
1 1 mFuoo5a
D475A-3
20-227 0
CONNECTION
TROUBLESHOOTING
No. of pins
T
AMP070 Male (female
PIN NUMBERS
type connector Female
housing) 1
TABLE FOR CONNECTOR
(male
housing)
7
8
6
4 BLPWOS
12
8 BLFOOO61
20-228 0
D475A-3
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
2
L type type connector Male (female
&I
Female
housing)
(male housing)
1
q
m
2
m
TEW00258
D475A-3
20-229 0
CONNECTION
TROUBLESHOOTING
No. of pins
T
Automobile Male (female
TABLE FOR CONNECTOR
connector Female
housing)
PIN NUMBERS
FB B
(male
housing)
I
2
3
BV'LO1141
BVLO1140
2
1
4
3’
4
20-230 0
‘4
BVL01142
BVLO1143
ELMlO
BLKW70
ELF03371
BLFWO72
1
D475A-3
No. of pins
TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION
TROUBLESHOOTING
T
Relay connector Male (female
Female
housing)
Y
5
3
1
5
6
6
(male
housing)
3
BLFQOO73
BLFUW74
6
5
6 U
5
2
1
BLP00075
D475A-3
J
ELF%076
20-231 0
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
TROUBLESHOOTING
EXPLANATION
OF FUNCTIONS
OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
I
(@
SSC initial
setting
connector
I
,
oil
level
sensor (iJ
Monitor
@Fwitch
Dane1
erter oil tewerature sensor (Lock-up
mode switch
signal)
!Economu
mode switch
sienal)
(Reverse slow mode switch (Shoe slip
mode switch
(Rockbed selection
aode switch sitnat)
(S-NET)
----a--
I
signal) signal)
a
IO
@Engine
speed sensor
(rioht
Rioht
bank)
@Engine
controller
bank
fuel
injection
PUITIP
0
@Rishmnor
cut relay
@Left sovernor
cat relay
I @Buzzer
cancel
Left
bank
fuel
injection
PUMP
@-l7;k-&-s:---~
snitch -c
I
13 14 TVDOll63
20-232 0
D475A-3
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
TROUBLESHOOTING
@Blade
RAISE
oil
Pressure
switch
@Blade
LOWER oil
Pressure
switch
@Blade @Blade
RIGHT
TILT
oil
@Ripper
UP oil
@Ripper
DOWN oil
@Ripper
TILT
IN oil
ORinner
TILT
BACK oil
oressure
Pressure
switch
@Pitch
@DabI
c
Pressure
selection solenoid
@Pitch
duan assist solenoid
@Pitch
back assist solenoid
@Pitch
dump solenoid
@Pitch
back
switch
Pressure
switch c
@Left
a EVERSE oil
Pressure
switch
@Machine
9
lever -
tilt
switch
c
@Blade
solenoid
switch
oressure
1st
selection
oil
Pressure
switch
nd oil
Pressure
switch
controller
tilt
solenoid
linit
solenoid
limit
solenoid
@Rinht
tilt
@Pitch
independent solenoid
@Left
battoa drain solenoid
@Backup
alarm
relay
FRONT switch
@TornueGerter
speed
sensor
@Work
@I enuknent
oil
Pressure
sensorfl401
@Work
enuEment
oi I pressure
sensorf1001
c
TVDOl164
D475A-3
20-233 0
TROUBLESHOOTING
Functions of machine monitor system . Monitor panel (I) receives the signals from
. .
.
.
.
.
.
.
.
.
.
.
.
each switch and sensor and the S-NET data from the engine controller and machine controller. It then calculates these and drives or displays the lamps, gauges, tachometer, and service meter, displays codes when an abnormality occurs, and also carries out monitoring of the functions and machine condition. The voltage generated by alternator (2) is input to the monitor panel. Radiator water level sensor (3) detects the water level in the radiator sub tank and inputs an ON/OFF signal to the monitor panel. Engine oil level sensor (4) detects the level of the oil in the engine oil pan and inputs an ON/OFF signal to the monitor panel. Engine oil pressure sensor (5) detects the engine oil pressure when the engine is running and inputs an ON/OFF signal to the monitor panel. Hydraulic oil level sensor (6) detects the level of the oil in the hydraulic tank and inputs an ON/OFF signal to the monitor panel. Air cleaner clogging sensor (7) detects clogging of the air cleaner from negative intake air pressure between the air cleaner and turbocharger, and inputs an ON/OFF signal to the monitor panel. Torque converter oil temperature sensor (8) detects the temperature of the oil in the power train and inputs an analog signal to the monitor panel. Fuel level sensor (9) detects the level of the fuel in the fuel tank and inputs an analog signal to the monitor panel. Engine water temperature sensor (10) detects the temperature of the engine cooling water and sends an analog signal to the monitor panel and engine controller. SSC initial setting connector (11) inputs an ON/OFF signal to the monitor panel to switch the initial setting of the SSC switch on the panel. Service switch (12) inputs an ON/OFF signal to the monitor panel to switch the display on the monitor panel and engine controller. Caution lamp (13) receives the ON/OFF signal output from the monitor panel and turns the lamp on or off. Alarm buzzer (14) receives the ON/OFF signal output from the monitor panel and turns the buzzer on or off.
20-234 0
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
Functions of engine throttle, pump controller control system Engine controller (15) receives the signals from the sensors, the S-NET data from the monitor panel, the S-NET data from the machine controller, and the SSC throttle command. It then calculates these and sends signals to the solenoid valves or relays to control the engine. Fuel control dial (16) detects the amount of opening of the throttle and inputs an analog signal to the engine controller. Deceleration potentiometer (17) detects when the decelerator pedal is depressed and inputs an analog signal to the engine controller. Engine speed sensors (18) and (19) detect the speed of the engine flywheel and input a pulse signal to the engine controller. The signal from left bank engine speed sensor (19) is also input to the machine controller. Governor cut relays (20) and (21) receive the ON/OFF signals output from the engine controller and supply or stop the power for the solenoids. Buzzer cancel switch (22).inputs the ON/OFF signal to the engine controller and machine controller to stop the buzzer when an abnormality occurs. Rack sensors (23) and (24) detect the position of the fuel injection pump rack and input an analog signal to the engine controller Pre-stroke solenoids (25) and (26) receive the analog signal output from the engine controller, and control the pre-stroke of the fuel injection pump. Governor solenoids (27) and (28) receive the analog signal output from the engine controller and control the functions of the fuel injection pump governor.
D475A-3
TROUBLESHOOTING
Functions of machine control system . Machine controller (29) receives the signals
.
.
.
.
.
.
.
.
.
.
from each switch and sensor, the switch signals from the monitor panel, and the SNET data from the monitor panel and engine controller. It then calculates these and outputs signals to the solenoid valves, relays, or engine controller to control the movement of the machine. Oil pressure switches (30), (311, (321, and (33) of the blade lever detect the operating condition of the blade lever and input an ON/OFF signal to the machine controller. Oil pressure switches (341, (35), (361, and (37) of the ripper lever detect the operating condition of the ripper lever and input an ON/OFF signal to the machine controller. Oil pressure switches (381, (391, (401, (411, and (42) of the transmission detect the gearshifting condition of the transmission and input an ON/OFF signal to the machine controller and engine controller. Transmission modulating oil pressure sensor (43) detects the modulating oil pressure and inputs an ON/OFF signal to the machine controller. Blade lever switches (44) and (45) detect the operating condition of the switches and input an ON/OFF signal to the machine controller. Torque converter speed sensor (46) detects the rotating speed of the torque converter output shaft and inputs a pulse signal to the machine controller. Work equipment oil pressure sensor [I401 (47) detects the discharge pressure of the main pump for the work equipment and inputs an analog signal to the machine controller. Work equipment oil pressure sensor [IO01 (48) detects the discharge pressure of the work equipment assist pump and inputs an analog signal to the machine controller. The acceleration sensor detects the position of the internal ball that moves when the machine travels, and inputs an analog signal to the machine controller. Torque converter lock-up solenoid (50) receives the ON/OFF signal output from the machine controller and engages or disengages the lock-up clutch and stator clutch.
D475A-3
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
Demand solenoid (51) receives the ON/OFF signal output from the machine controller and switches the demand valve. Unload solenoid (52) receives the ON/OFF signal output from the machine controller and switches the unload valve. Pitch selection solenoid (53) and dual tilt selection solenoid (54) receive the ON/OFF signal output from the machine controller and switch the main circuit of tilt cylinder. Pitch dump assist solenoid (55) and pitch back assist solenoid (56) receive the ON/OFF signal output from the machine controller and switch the assistance to the pitch main circuit. Pitch dump solenoid (57) and pitch back solenoid (58) receive the ON/OFF signal output from the machine controller and switch the pitch PPC circuit. Left tilt limit solenoid (59) and right tilt limit solenoid (60) receive the ON/OFF signal output from the machine controller and switch the tilt PPC circuit. Pitch independent solenoid (61) receives the ON/OFF signal output from the machine controller and switches the assist/ independent valve. Left bottom drain solenoid (62) receives the ON/OFF signal output from the machine controller and switches the left bottom drain valve. Backup alarm relay (63) receives the ON/ OFF signal output from the machine controller and switches the backup alarm circuit.
20-235 0
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING
DISPLAY METHOD
AND SPECIAL FUNCTIONS
OF MONITOR
PANEL Economy
mode switch
Reverse switch
slow
TOP display
/
mode
Bottom
Caution
Buzzer
cancel
lamp
switch
/
Service
%I:Monitorinp mode To go to next item-press reverse slow mode switch:to so back to previous *2:Adjustment mode To so to next item, press reverse slow mode swit C h:to go back to previous t3:Service code display mode E:Code for existing problem.P:Code for problem hat occurred in past;Code displayed in turn on service meter To go to next item. press reverse slow mode SW tch;to go back to previous to clear code. press buzzer cancel switch(P on Y)
20-236 0
display
item.
press
itemtnot and
time
itemtnot
switch
buzzer
cancel
switch
available) of
occurrence
available); TVD01065
D475A-3
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Procedure for switching to each mode
1
1 Serviciitch
m , 1
Economy
m;de
switch
1
rl
v
Tilt
adjustment
mode
____-__--------
lual tilt SuPerdozer ____-__--------
Buzzer (Press
cancel switch far 7 seconds)
Monitoring
mode
1
A1
Adjustment
mode
k’2
only
t Buzzer (Press
7
cancel switch for 7 seconds)
a jervice
code
display
mode
ki
TVD01066
D475A-3
20-237 0
TROUBLESHOOTING
1.
DISPLAY
METHOD
AND SPECIAL
FUNCTIONS
Normal display functions During normal operations, the speed range is shown on the top panel and the service meter is displayed on the bottom panel.
OF MONITOR
Speed
range
PANEL
display
0
[_T
!jervice
/ meter
display Tvoolo67
2.
User code display function when abnormality occurs If an abnormality occurs during operations and it is necessary to inform the operator, the user code and service meter are displayed in turn on the bottom panel. In the case of user codes with a high emergency level, the caution lamp flashes and the alarm buzzer sounds at the same time. The user codes are displayed only when an abnormality with a high emergency level occurs. This means that an abnormality may have occurred even when there is no user code display. If any problem is felt, always use the service code display mode to check if there is any service code.
User
code
q
[TT
Service
meter
[Displayed
in
turn]
TVDOI 068
20-238 0
D475A-3
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
User codes and type of abnormality User codes l
. . .
EOl
Action taken by machine
Type of abnormality
l
l
l
l
Torque converter lock-up does not come ON Blade is not automatically reset Blade speed is slow Pitch speed is slow Abnormality in engine water temperature monitor Abnormality in power train oil temperature monitor Abnormality in hydraulic oil temperature monitor Tilt limit has no effect
l
l
.
l
.
E02
. . l
CALL03
. . .
. CALL
D475A-3
Pitch is actuated when tilt is operated Pitch actuation stops Torque converter lock-up is not switched ON or is not switched OFF Engine runs on one bank (output is reduced) Engine speed cannot be controlled Abnormality in engine water temperature monitor
.
Engine cannot
.
be controlled
l
.
Stops automatic stop function When automatic stop function is not actuated, work is possible, but be careful
Flashes caution lamp, sounds alarm buzzer Stops tilt limit function If engine is stopped and then started again, tilt limit function, automatic stop function are not actuated, so work is possible, but be careful Flashes caution lamp, sounds alarm buzzer It is only possible to move machine to a safe place
Flashes caution lamp, sounds alarm buzzer Engine must be stopped immediately
20-239 0
TROUBLESHOOTING
3.
DISPLAY
METHOD
AND SPECIAL
FUNCTIONS
OF MONITOR
PANEL
Tilt adjustment mode display and function + This mode applies to the dual tilt dozer specification machine and superdozer specification machine. Ir For details of the method of using this mode, see TESTING AND ADJUSTING, Procedure for adjusting blade tilt control angle.
BVD00827
4.
Monitoring mode display function The condition of all parts of the machine can be checked on the monitor panel through the signals from the sensors installed to various parts of the machine. The method for displaying the monitoring data consists of values such as the engine speed, voltage, and current that are displayed as numerals, and the operating condition of the oil pressure switches and solenoid valves that are displayed as bits.
Monitoring
Monitoring
mode
data TVD01069
20-240 0
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Monitoring code No. and display item + For details of items where the display unit is displayed Monitoring item
Code No.
I
as a bit, see Details of bit display
Engine speed
1 rpm
Machine controller
7R
Torque converter speed
1 rpm
Machine controller
bU
I
7H
Actuation status of transmission oil pressure switch
bh
I
Component
99
I
I
Display unit
items.
1 Travel speed (theoretically calculated value)
1
0.1 km/h
1 Machine controller
1 Bit display
1 Machine controller
Actuation status of blade lever oil pressure switch
Bit display
Machine controller
RH
Actuation status of ripper lever oil pressure switch
Bit display
Machine controller
55
Actuation status of solenoid valve
Bit display
Machine controller
5N
I S-NET connection status
l
I
Bit display
I
1 rpm
Engine controller
I I
FO
Engine control command speed
Fd
Fuel control dial voltage
10 mV
Engine controller
dd
Deceleration command speed
1 rpm
Engine controller
dU
Deceleration potentiometer voltage
I ~~10 mV
5d
Shoe slip control command voltage
10 mV
Machine controller
1R
Voltage of R.H. fuel injection pump rack position sensor
10 mV
Engine controller
I
2R
Voltage of L.H. fuel injection pump rack position sensor
IO mV
Engine controller
I
I
15
1 Current of R.H. fuel injection pump governor solenoid
10 mA
1 Engine controller
I
25
Current of L.H. fuel injection pump governor solenoid
10 mA
Engine controller
1P
Current of R.H. fuel injection pump pre-stroke solenoid
10 mA
Engine controller
2P
Current of L.H. fuel injection pump pre-stroke solenoid
10 mA
Engine controller
75
Engine water temperature sensor voltage
I
10 mV
Engine controller
1E
Engine speed A
I
1 rpm
Engine controller
2E
I Engine speed B
I
1 rpm
I Engine controller
I
I I I
I I I
HE
Actuation status of transmission oil pressure switch
HP
Work equipment circuit oil pressure (main 140 pump)
A5
Acceleration sensor voltager
5E
Shoe slip control command voltager
5R
Shoe slip control command speed
Lb
Left tilt angle sensor voltage
Rb
Right tilt angle sensor voltage
LA
Blade lift cylinder angle
HA
Work equipment circuit oil pressure (assist 100 pump)
D475A-3
1
Bit display
-7
Engine~~controller
7
I
Engine controller
1 kg/cm2
Machine controller
10 mV
Machine controller
10 mV
Engine controller
I
1 rpm
Engine controller
I
10 mV
Machine controller
IO mV
Machine controller
0.1”
Machine controller
1 kg/cm*
Machine controller
I
I I
I
I
20-241 0
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Details of bit display items Ir The diagram on the right is an example
Sr
of the bit display (iJ 0, and @ display OFF condition 0, 0, and @ display ON condition Except for code 55, all data are displayed on the lower panel. Code 55 displays the actuation status of 10 solenoids on the top and bottom panels.
OFF
I
ON
OFF
ON
BVO00835
7H: Actuation status of transmission oil pressure switch HE: Actuation status of transmission oil pressure switch 0: FORWARD oil pressure switch 0: REVERSE oil pressure switch 0: 1st oil pressure switch 0: 2nd oil pressure switch 0: 3rd oil pressure switch @: Modulating * Item @ is displayed only at the instant the sensor *
is switched OFF when shifting gear. The display example in the diagram on the right shows the condition when FORWARD 1st is operated.
Bv000829
bH:Actuation condition of blade lever oil pressure switch RAISE oil pressure switch LOWER oil pressure switch (Not used) (Not used) Left tilt oil pressure switch Right tilt oil pressure switch The display example in the diagram on the right shows the condition when RAISE + left tilt are operated at the same time.
I
6V000830
I
BVO00830
RH:Actuation condition of ripper lever oil pressure switch 0: UP oil pressure switch 0: DOWN oil pressure switch 0: (Not used) 0: (Not used) 0: TILT BACK oil pressure switch @: TILT IN oil pressure switch * The display example in the diagram on the right shows the condition when UP + TILT BACK are operated at the same time.
20-242 0
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
55: Actuation status of super solenoid Single tilt specification and dual tilt specification 0: Left tilt limit solenoid 0: Demand solenoid 0: Pitch selection solenoid 0: Pitch dump assist solenoid 0: Pitch back assist solenoid @: Right tilt limit solenoid 0: (Not used) @: Unload solenoid @: Dual tilt selection solenoid @: Pitch dump solenoid @I: Pitch back solenoid 0: (Not used) * The display example in the diagram on the right shows the condition when the demand solenoid and pitch dump solenoid are ON.
Superdozer specification Left tilt limit solenoid Demand solenoid Pitch selection solenoid Pitch dump assist solenoid Pitch independent solenoid Right tilt limit solenoid (Not used) Unload solenoid Left bottom drain selection solenoid Pitch dump solenoid Pitch back solenoid (Not used) The display example in the diagram on the right shows the condition when the demand solenoid and pitch dump solenoid are ON.
5N: 0: 0: 0: 0: 0: @: Ir
BVD00831
S-NET connection status Engine controller Monitor panel (tachometer module) (Not used) Machine controller Monitor panel (caution module) (Not used) The diagram on the right shows the display conditions when normal (all items are ON)
BVD00832
D475A-3
20-243 0
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
5. Adjustment mode display and function This is used to check or change the model settings saved to memory inside the controller or to measure the engine high idling speed (engine controller control).
Adjustment code No. and adjustment item Code No.
Adjustment item
Content
High idling speed
The deceleration control is canceled by the machine controller and it becomes possible to measure the high idling speed by the engine controller control. fl For details of the method of operation, see TESTING AND ADJUSTING, Measuring engine speed.
30
Machine model setting
Used to check or change model code set inside controller fl For details of the method of operation, see TESTING AND ADJUSTING, Procedure for selecting machine model.
CR
Exclusive mode for factory
fl This mode is for the exclusive use of the factory, so it must not be touched.
CH
20-244 3 4
D475A-3
TROUBLESHOOTING
6.
DISPLAY
METHOD
AND SPECIAL
Service code display mode display and function If any abnormality is detected in the electrical system of the engine controller, machine controller, or monitor panel, the nature of the abnormality and the time of occurrence are saved to memory inside the monitor panel in the order of occurrence. When this mode is selected, the service codes saved to memory and the time of occurrence of the codes are displayed in turn on the service meter. The letter at the left side indicates the following: E: Problem still existing P: Problem that has returned to normal A maximum of 20 service codes can be saved in memory. If there is no service code saved in memory, I- -1 is displayed on the top panel.
FUNCTIONS
OF MONITOR
PANEL
Order of occurrence
Service
'0
code
mhih
\
o/u/)
E
[
J
I Service meter when problem
reading occurred
1
[Displayed
in
turn]
123JS.6 h/ TV1301071
Service
codes and abnormal
system Method of Troukk$ting User code re-enaction
Abnormal system EOIOI
1 Abnormality in network system (engine controller system)
I
S
1 N mode 1 CALL03 1
E0104
Abnormality in network system (monitor panel system)
s
N mode
CALL03
E0105
Abnormality in network system (machine controller system)
S
N mode
CALL03
S
I C mode I
-
EOlll
1 Abnormality in machine controller power source voltage
I
E0120
Short circuit in monitor caution lamp system
S
M mode
CALL03
E0121
Short circuit in monitor alarm buzzer system
S
M mode
CALL03
E0150
I Abnormality in machine controller EPPROM
I
S
I C mode I CALL03 I
E0151
Abnormality in specification selection
S
C mode
CALL03
E0152
Abnormality in network system
S
N mode
CALL03
Disconnection in torque converter speed sensor system
E
C mode
EOI
Short circuit in toraue converter speed sensor system
E
C mode
EOI
E0201 E0202 E0203 E0204
I Disconnection in transmission FORWARD & REVERSE oil pressure switch system I Short circuit in transmission
E0205 xhort E0206
circuit in transmission
FORWARDclutch oil pressure REVERSEclutch oil pressure
I Disconnectionin transmission1st & 2nd & 3rd oil pressure
switch switch switch
system
( 1
E+
I C mode 1
E+
I c mode I
EOl
1
EOI
1
E01
1
system
I
E+
1 C mode I
system
I
E+
I C mode I
EOI
1
EOI
)
E0207
I Short circuit in transmission 1st clutch oil pressure switch system I
E+
I C mode I
E0208
Short circuit in transmission 2nd clutch oil pressure switch system
E+
C mode
EOI
E0209
Short circuit in transmission 3rd clutch oil pressure switch system
E+
C mode
EOI
D475A-3
1
20-245 0
TROUBLESHOOTING
Service code
DISPLAY
METHOD
AND
SPECIAL
FUNCTIONS
Abnormal system
OF MONITOR
PANEL
Method Of kxIbksting User codc re-enaction
I
I
E0210
1 Disconnection in transmission modulating oil Dressure sensor svsteme
1
E0211
1 Abnormality in power train (torque converter) oil temperature
I
I
E
1 C mode 1
E
1 M mode )
EOl
Short circuit in torque converter lock-up solenoid system
E+
C mode
CALL03
E0213
Disconnection in torque converter lock-up solenoid system
E+
C mode
CALL03
E0220
Short circuit in transmission modulating oil pressure sensor system
E
C mode
S
1 C mode I
E02
E0212
E0301
1 Short circuit in left blade tilt angle sensor system
I
-
-
E0302
Disconnection in left blade tilt angle sensor system
S
C mode
E02
E0303
Short circuit in right blade tilt angle sensor system
S
C mode
E02
E0304
I Disconnection in right blade tilt angle sensor system
S
I C mode I
E02
C mode
-
C mode
-
I
E0305
Short circuit in blade RAISE oil pressure switch system
E+
E0306
Short circuit in blade right tilt oil pressure switch system
E+
E0307
I Short circuit in blade left tilt oil pressure switch system
1
E+
E0308
Short circuit in ripper UP oil pressure switch system
E+
E0309
Short circuit in ripper DOWN oil pressure switch system
E0310
I Short circuit in ripper TILT IN oil pressure switch system
E0311
Short circuit in front button switch system
E0312
1
1 C mode 1
-
C mode
-
E+
C mode
-
E+
I C mode I
-
E+
C mode
-
Short circuit in top button switch system
E+
C mode
E0313
Short circuit in pitch back solenoid system
E+
C mode
CALL03
E0314
Disconnection in pitch back solenoid system
S
C mode
CALL03
E0315
Short circuit in pitch dump solenoid system
E+
C mode
CALL03
E0316
I Disconnection in pitch dump solenoid system
E0317
Short circuit in left tilt limit solenoid system
I
S
I C mode I CALL03
E+
C mode
E02
E0318
Disconnection in left tilt limit solenoid system
S
C mode
E02
E0319
Short circuit in right tilt limit solenoid system
E+
C mode
E02
E0320
Disconnection in right tilt limit solenoid system
S
C mode
E02
E0321
Short circuit in dual selection solenoid system
E+
C mode
CALL03
E0322
Disconnection in dual selection solenoid system
S
C mode
CALL03
Short circuit in pitch selection solenoid system
E+
C mode
CALL03
E0324
Disconnection in pitch selection solenoid system
S
C mode
CALL03
E0325
Short circuit in pitch back assist solenoid system
E+
C mode
EOl
E0326
Disconnection in pitch back assist solenoid svstem
S
C mode
EOI
E0327
I Short circuit in pitch dump assist solenoid system
E+
I c mode I
EOl
E0323
1
E0328
Disconnection in pitch dump assist solenoid system
S
C mode
EOl
E0329
Abnormality in hvdraulic oil temperature
E
M mode
E01
E0330
Short circuit in blade LOWER oil pressure switch
E+
Cmode
E0332
Short circuit in unload valve solenoid system
E+
C mode
EOI
E0333
Disconnection in unload valve solenoid system
S
C mode
EOl
20-246 0
-
D475A-3
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Service code E0334
Short circuit in demand valve solenoid
E0335
Disconnection
E0336
Short circuit in ripper TILT BACK oil pressure switch system
E0337
Short circuit in pitch independent
S
C mode
E0338
Disconnection
E0339
Short circuit in left bottom
E0340
Disconnection
system
in demand valve solenoid
system
solenoid
in pitch independent
system
solenoid
drain solenoid
in left bottom
1 Abnormality
E0352
Abnormality
E0360
Short circuit in work equipment
E0361
Disconnection in work equipment
E0362
Short circuit in work equipment
E0363
Disconnection in work equipment
E0401
Abnormality
in engine controller
E0402
Abnormality
in engine controller
E0403
Mistaken
E0405
Abnormality
in fuel control
E0406
Abnormality
in deceleration
E0407
Abnormality
in shoe slip control
E0409
1 Abnormality
system
system
drain solenoid
1 E0351
I
Method of Troublesting User code re-enaction
Abnormal system
system
in standard value of blade tilt angle sensor in compensated
connection
I
E+
C mode
E01
S
C mode
EOl
E+
C mode
CALL03
E+
C mode
CALL03
S
C mode
CALL03
E+
C mode
CALL03
S
1 C mode 1
EOl
value of blade tilt angle sensor
S
C mode
E01
oil pressure sensor (140 DumD) system
E
C mode
EOI
E
C mode
EOI
E
C mode
EOl
E
C mode
EOl
S
E mode
CALL
S
E mode
CALL
S
E mode
CALL
oil pressure sensor (140 pump) system oil pressure sensor (140 pump) system oil pressure sensor (140 pump) system power source voltage
in engine controller
S
E mode
CALL03
system
S
E mode
CALL03
value
S
E mode
CALL03
dial system potentiometer command
in engine speed sensor A system
I
E
I E mode I CALL03 I
E0410
Abnormality in engine speed sensor B system
E
E mode
CALL03
E0411
Abnormality
in right rack sensor system
S
E mode
CALL03
E0412
Abnormality
in left rack sensor system
S
E mode
CALL03
E0413
Abnormality
in rack sensor power source system
S
E mode
CALL03
E0421
Short circuit in right governor
S
E mode
CALL
S
E mode
CALL
S
E mode
CALL
system
S
E mode
CALL
cut relay system
S
E mode
EOl
S
E mode
EOl
S
E mode
EOI
S
E mode
EOl
E0422
Disconnection
E0423
Short circuit in left governor
E0424
Disconnection
E0425
Short circuit in right governor
solenoid
in right governor
E0426
Disconnection
E0427
Short circuit in left governor
E0428
Disconnection
solenoid
solenoid
in left governor
system
system
solenoid
in right governor
system
cut relay system
cut relay system
in left governor
cut relay system
E0430
Abnormalitv
in enoine oil pressure
E
M mode
CALL
E0431
Abnormality
in radiator
S
M mode
CALL
E0432
Abnormality
in engine water temperature
E
M mode
01
E0433
Short circuit in left ore-stroke
S
E mode
CALL03
E0434
1 Disconnection in left pre-stroke
D475A-3
water level
solenoid solenoid
svstem system
I
S
1
I E mode I CALL03 I
20-247 0
TROUBLESHOOTING
Service code 1 E0435
Ir
*
AND SPECIAL
FUNCTIONS
PANEL
Method of Tro&Itting User code re-enaction
Abnormal system
1 Abnormality in engine water temperature sensor system
OF MONITOR
I
E
1 E mode 1 CALL03 1
Abnormality in network system
S
E mode
CALL03
E0437
Abnormalitv in riaht aovernor servo
S
E mode
CALL
s
1E mode
I Abnormality in left governor servo
I
I
CALL
1
E0440
Disconnection in solenoid power source 1 system
S
E mode
CALL
E0441
Disconnection in solenoid Dower source 2 system
S
E mode
CALL
E0442
Abnormality in engine controller backup power source system
S
E mode
CALL03
E0443
Abnormality in engine controller switch power source system
S
E mode
CALL03
E0455
Engine overheating
E
E mode
E0456
Short circuit in riaht ore-stroke solenoid svstem
S
E mode
CALL03
E0457
Disconnection in right pre-stroke solenoid system
S
E mode
CALL03
E0501
Short circuit in acceleration sensor system
S
C mode
EOI
E0502
Disconnection in acceleration sensor svstem
S
C mode
EOl
S
I C mode
s+
C mode
EOI EOI
1 E0601
Ir
METHOD
E0436
1 ~0436
I
DISPLAY
I Short circuit in buzzer cancel switch system
I
-
I
-
E0610
Short circuit in backup alarm relay system
E0611
Disconnection in backup alarm relay system
S
C mode
E0632
Short circuit in bedrock selection mode switch system
S
C mode
-
E0633
Disconnection in bedrock selection mode switch system
S
C mode
-
E
I C mode I
-
E0930
I Disconnectionin engine speed sensor system (machine controllersystem) I
Method of re-enaction S: Service code that can be re-enacted when starting switch is turned ON S+: Service code that can be re-enacted when starting switch is turned ON and applicable switch lever is operated E: Service code that can be re-enacted when engine is started E+: Service code that can be re-enacted when engine is started and applicable switch or lever operated Troubleshooting mode N mode: Troubleshooting of network system (N mode) E mode: Troubleshooting of engine controller system (E mode) C mode: Troubleshooting of machine controller system (C mode) M mode:Troubleshooting of monitor panel and electrical equipment system (M mode) Re-enaction of service code and method of confirming return to normal The procedure for re-enacting the service code and checking that the condition has returned normal after repair is as follows. 1) Switch to the service code display mode and check the service code that is displayed. Ir Make a note of all the service codes. 2) Delete the service codes. 3) Carry out the re-enaction of all the service codes that were displayed. * For details of the method of re-enaction, see the above table or the section troubleshooting. 4) Check if the service codes on the service code display are displayed or not displayed.
20-248 0
I
I
or
is
to
on
D475A-3
METHOD
TROUBLESHOOTING
OF USING
METHOD OF USING TROUBLESHOOTING 1. Category of troubleshooting code number Troubleshooting
2.
TROUBLESHOOTING
CHARTS
CHARTS
Contents
Code No.
N-00
Troubleshooting
of network
system
E-00
Troubleshooting
of engine
c-00
Troubleshooting
of machine
H-00
Troubleshooting
of hydraulic,
M-00
Troubleshooting
of monitor
controller controller
system system
mechanical
system
panel and electrical
system
Method of using troubleshooting table for each troubleshooting mode code number and problem 1) Troubleshooting The title of the troubleshooting chart gives the troubleshooting code, and problem with the machine. 2) General precautions When carrying out troubleshooting for the problem, precautions that apply to all items are given at the top of the page and marked with *. The precautions marked * are not given in the I, but must always be followed when carrying out the check inside the /. conditions 3) Distinguishing Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the problem is further divided into sections marked with small letters (for example, a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. chart (See Example 0) 4) Method of following troubleshooting Check or measure the item inside 0, and according to the answer follow either the YES line or the NO line to go to the next I. (Note: The number written at the top right corner of the I is an index number; it does not indicate the order to follow.) . Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. . Below the I there are the methods for inspection or measurement, and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. . Below the I is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item I). tools 5) Troubleshooting When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. 6) Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each problem. l
D475A-3
20-249 0
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
@ M-8 When starting switch is turned on, monitor panel gives no display @ Ir Before carrying out troubleshooting, check that all the related connectors are properly inset-ted. * Always connect any disconnected connectors before going on to the next step. @
a)
Caution
module
(Gauge/lamp
unit) gives no display
Cause
YES
Defective monitor panel (caution module)
1 Is voltage between CNI (I) and (2) normal?
-
2
Is voltage between CNl (1) NO and chassis ground normal?
* Turn starting switch ON. *20-30V
* Turn starting switch ON. *20-30V
M-8 Related
Defective contact or disconnection in wiring harness between CNl (female) (2) -chassis ground Defective contact or disconnection in wiring harness between CNl (female) (1) -fuse 12
YES
electrical
Monitor
NO
Remedy
Replace
Repair or replace
Repair or replace
circuit diagram
Panel
CNl Power
source
(d2)
215
(16)
421
(14)
(24V)
Bl 1 (14)
Fuse
box
$J
GND
214
(14)
GND5 77%
20-250 0
TV001 139
D475A-3
TROUBLESHOOTING OF NETWORK SYSTEM (N MODE)
Action taken by controller Electrical
circuit diagram
when
abnormality
occurs and problems
on machine..
.......................
.20-302
of N mode system .....................................................................................
.20-304
Service codes of network
system ... . ....................................................................................................
.20-305
N-l
[EOIOII
Abnormality
in network
system
(engine
N-2
iE01041 Abnormality
in network
system
(monitor
panel system)
N-3
fE01051 Abnormality
in network
system
(machine
controller
N-4
[EOIOII,
[E01041, and [E01051 are displayed
(Abnormality
in network
system
controller
system)
is displayed..
is displayed..
system)
............. ..20-30 6
...................
is displayed..
.20-307
.......... ..20-30 8
at same time
is displayed)
..........................................................................
.20-309
N-5
IE01521 Abnormality
in network
system
is displayed..
.............................................................
.20-310
N-5
IE04361 Abnormality
in network
system
is displayed..
.............................................................
.20-310
D475A-3
20-301 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code
Service code
Abnormal
Nature
system
of abnormality
% When the monitor l
EOlOl
Abnormality in network system (engine controller system)
-
z l
E0104
Abnormality in network system (monitor panel system)
CALL 03
l
panel detects an abnormality in the network of the engine controller system When service code EOIOI is generated independently 1. Defective contact or disconnection in wiring harness between monitor panel TO1 (9)(10) and engine controller E41 (6) 2. Defective engine controller When service codes E0104 and E0105 are generated at same time 1. Short circuit with ground, defective contact, disconnection in wiring harness or hot short between monitor panel TO1 (9HlO) - monitor panel CNI (11)(12) - engine controller E41 (6) - machine controller M32 (4) 2. Defective monitor panel (tachometer module) When the monitor panel detects an abnormality in the network of the monitor panel (caution module) system When service code E0104 is generated independently 1. Defective contact or disconnection in wiring harness between monitor panel TO1 (9)(10) and monitor panel CNl (11)(12) 2. Defective monitor panel (caution module) When service codes EOIOI and E0105 are generated at same time 1. Short circuit with ground, defective contact, disconnection in wiring harness or hot short between monitor panel TO1 (9HlO) - monitor panel CNI (11)(12)-engine controller E41 (6) -machine controller M32 (4) 2. Defective monitor panel (tachometer module)
.% When the monitor panel detects an abnormality in the network of the machine controller system When service code E0105 is generated independently 1. Defective contact or disconnection in wiring harness between monitor panel TO1 (9)(10) and machine controller M32 (4) 2. Defective machine controller When service codes EOlOl and E0104 are generated at same time 1. Short circuit with ground, defective contact, disconnection in wiring harness or hot short between monitor panel TO1 (9)(10) - monitor panel CNI (11)(12) - engine controller E41 (6) - machine controller M32 (4) 2. Defective monitor panel (tachometer module) l
E0105
Abnormality in network system (machine controller system)
l
I l
E0152
Abnormality in network system
l
When the machine controller detects an abnormality in the network When service code E0152 is generated independently 1. Defective machine controller When service codes EOIOI, E0104, and E0105 are generated at same time Sr Same as for each service code
% When the engine controller detects an abnormality in the network When service code E0436 is generated independently 1. Defective engine controller When service codes EOlOl, E0104, and E0105 are generated at same time Ir Same as for each service code l
E0436
20-302 0
Abnormality in network system
l
D475A-3
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. Flashes caution lamp. 2. Sounds alarm buzzer.
1. Flashes caution lamp. 2. Sounds alarm buzzer.
1. Flashes caution lamp. 2. Sounds alarm buzzer.
1. Speed range display is not given. 2. Tachometer display is not given. 3. Lock-up lamp goes out.
1. Speed range display is not given. 2. Tachometer display is not given. 3. Lock-up lamp goes out.
D475A-3
20-303 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
OF N MODE SYSTEM
ENGINE CONTROLLER SYSTEM
Engine
Monitor
controller
S-NET S-NET S-NET
(+I (-) (+) CNI
Machine
controller
Panel
S-NET S-NET S-NET
(-) (+) (+)
S-NET S-NET S-NET
C-1 (+I (+I
(AMPI~)
TXD01072
20-304 0
D475A-3
TROUBLESHOOTING
SERVICE CODES OF NETWORK
SERVICE CODES OF NETWORK SYSTEM
SYSTEM
The monitor panel, engine controller, and machine controller make up a network having the circuit shown in “Electrical circuit diagram of N mode system”. The monitor panel, engine controller, and machine controller monitor the communicating condition of the network respectively. If any abnormality occurs, they display the corresponding service code. I) Monitor panel The monitor panel monitors the communicating condition of each network component device. If any abnormality occurs in a device, the monitor panel displays one of the following service codes. (1) EOIOI: An abnormality has occurred in the engine controller system. (2) E0104: An abnormality has occurred in the monitor panel (caution module) system. (3) E0105: An abnormality has occurred in the machine controller system. 2) Engine controller The engine controller monitors the communicating condition of the whole network. If any abnormality occurs in the communicating condition, the engine controller displays the following service code. (4) E0152: An abnormality has occurred in a system of the whole network. (The name of the troubled system is not displayed.) 3) Machine controller The machine controller monitors the communicating condition of the whole network. If any abnormality occurs in the communicating condition, the machine controller displays the following service code. (4) E0436: An abnormality has occurred in a system of the whole network. (The name of the troubled system is not displayed.) Since the network is monitors by the above three devices, if any abnormality occurs in the network system, multiple service codes are displayed at the same time. For quick troubleshooting, it is important to know by using the monitoring mode, etc. what system each service code indicates.
D475A-3
20-305 0
N-l
TROUBLESHOOTING
N-l *
[EOIOI] Abnormality is displayed
in network
system (engine controller
system)
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P“ is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
+ *
Cause
YES
- Goto N-4.
~
II
WXl7Y~l?
* Turn
starting switch OFF. * Disconnect TO1 and E41. * Max. 1 R
N-l
Related
electrical
NO
Defective engine controller
Replace
Defective contact or disconnection in wiring harness between TO1 (female) (9) (10) - E41 (female) (6)
Repair or replace
circuit diagram Monitor
Engine
controller
Panel
TO; (16) E41 (12) S-NET
S-NET
(-1
S-NET
(+I
(+I
:NI (AMPEX)
t
3g-g
!--
Machine
controller
S-NET
(+I
S-NET
(+I
TXDOlO57
20-306 0
D475A-3
N-2
TROUBLESHOOTING
N-2 [E0104] Abnormality displayed * Ir *
in network
system (monitor
panel system) is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carving out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
YES
Go to N-4.
1 Are service codes lEOlOll, [E01051 _ displayed at same time? * Turn starting switch ON. NO
2 YES Is resistance between TO1 (female) (91 (10) and CNl (female) (11) (12) normal? NO
* Turn starting switch OFF. * Disconnect TO1 and CNl. * Max. 1 n
N-2 Related
electrical
Defective monitor panel (caution module)
Replace
Defective contact or disconnection in wiring harness between TO1 (female) (9) (10) - NC1 (female) (ll), (12)
Repair or replace
circuit diagram Monitor
Engine
controller
I
E41 (12)
TO1 (16) 214 (14)
S-NET
(+I
3
S-NET
(-1
3
S-NET
(+I
S-NET
(-)
-1 I-
1
I
CNl (AMP12) I I S-NET
Machine
Panel
I
I (+I
controller
I
M32 (16)
TXDOl057
D475A-3
20-307 0
N-3
TROUBLESHOOTING
N-3 [E0105] Abnormality in network system) is displayed
system (machine controller
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Remedy
Cause
YES 1
l
N-3 Related
Go to N-4.
I
Are service codes IEOlOll, IE01041 _ displayed at same time? ~ Turn starting switch ON. NO
2 YES Is resistance between TO1 (female) (9) (10) and M32 (female) (4) normal? NO * Turn starting switch OFF. * Disconnect TO1 and M32. * Max. 1 R
electrical
Defective machine controller
Replace
Defective contact or disconnection in wiring harness between TO1 (female) (9) (10) - M32 (female) (4)
Repair or replace
circuit diagram
Monitor Engine
Panel
r
controller
TO1 (16)
I E41 (12) S-NET
(+I
S-NET
(-1
S-NET
(+I
I CN~ (AMPEX) @
Machine
1
S-NET
(-1
1-n
S-NET
(+I
---a
S-NET
(+I
controller
S-NET
(+I
S-NET
(+)
TXDOl057
20-308 0
D475A-3
N-4
TROUBLESHOOTING
N-4 [EOIOI], [E0104], and [E0105] are displayed at same time (Abnormality in network system is displayed) If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Do all service
YES
- Disconnect CNl. *Turn starting switch ON.
Do all service codes go off’?
I\
YES 3
* Disconnect M32. Do all service + Turn starting NG codesgooff7 switch ON. * Disconnect E41. * Turn starting switch ON.
4 YE! Is voltage between _ TO1 (female) (9) NO (10) and chassis ground normal? * DisconnectTOl. -Turn starting switch ON. * Min. 7.5 V
NC
Defective monitor panel (caution module)
Replace
Defective machine controller
Replace
Defective engine controller
Replace
Defective monitor panel (tachometer module)
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between TO1 (female) (9) (10) - CNl (11) (12)- E41 (female) (6) - M32 (female) (4) or between E41 (female) (12) - M32 (female) (12)
Repair or replace
N-4 Related electrical circuit diagram Monitor Engine
controller
Panel
TO1 (16) E41 (i2)
S-NET
(+I
@-
S-NET
(-1
@-
S-NET
(+I
@-
Machine
-a
S-NET
(+I
controller
I
I
M32 (16) S-NET
(+I
S-NET
(+I
TXD01057
D475A-3
20-309 0
N-5
TROUBLESHOOTING
N-5 [E0152] Abnormality *
in network
system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
Go to N-4.
[E01041,and [El051 * Turn starting switch ON.
Is any one of [EOlOll, IE01041, and [El051 disr9aved. too?
h
L l
I urn startmg switch ON.
H NV
N-5 [E0436] Abnormality *
in network
Go to N-l, 2, or 3 according to displayed service code.
Defective machine controller
?eplace
system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.)
Cause
YES
Go to N-4.
1
all of service IAre codes [EOlOll,
I
[E01041,and tE1051 _ displayed, too? * Turn starting switch ON.
2
YES
Is any one of [EOIOII, LE01041, NO and [El051 displayed, too? * Turn starting switch ON.
20-310 0
Remedy
NO
Go to N-l, 2, or 3 according to displayed service code.
Defective engine controller
Replace
D475A-3
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)
Action taken by controller Electrical
circuit diagram
when
abnormality
occurs and problems
on machine..
........................
20-402 20-408
of E mode system .......................................................................................
E- 1
IE04011 Abnormality
in engine
controller
power
E- 2
[E04021 Abnormality
in engine
controller
is displayed
E- 3
[E04031 Mistaken
connection
in engine
source voltage
controller
.................. .20-410 20-410
........................................................... ............................................
.20-411
................................................
20-412
is displayed
dial system
is displayed..
E- 4
[E04051 Abnormality
in fuel control
is displayed
E- 5
[E04061 Abnormality
in deceleration
E- 6
[E04071 Abnormality
in shoe slip control
E- 7
IE04091 Abnormality
in engine
speed sensor A system
is displayed
..................................
.20-415
E- 8
IE04101 Abnormality
in engine
speed sensor 8 system
is displayed..
..................................
20-416
E- 9
[E04111 Abnormality
in right rack sensor system
E-10
IE04121 Abnormality
in left rack sensor system
E-11
IE04131 Abnormality
in rack sensor power
potentiometer
E-12
lE04211 Short circuit in right governor
E-13
IE04221 Disconnection
E-14
[E04231 Short circuit in left governor
E-15
IE04241 Disconnection
E-16 E-17 E-18
[E04271 Short circuit in left governor
E-19
IE04281 Disconnection
E-20
[E04331 Short circuit in left pre-stroke
command
is displayed..
solenoid
system
.20-417
...............................................
20-418
............................
.20-419
..................................
20-420
...............................
20-421
is displayed
system
20-414
.............................................
is displayed
system
20-413
...............................
is displayed..
source system
solenoid
..........................................
value is displayed
is displayed
solenoid
in right governor
is displayed
is displayed
....................................
.20-422
system
is displayed
.................................
.20-423
IE04251 Short circuit in right governor
cut relay system
is displayed
.................................
.20-424
LEO4261 Disconnection
cut relay system
is displayed..
...............................
.20-425
...................................
20-426
................................
20-427
in left governor
solenoid
in left governor
cut relay system
in left governor
E-21
IE04341 Disconnection fE04351 Abnormality
in engine
E-23
IE04371 Abnormality
in right governor
E-24
[E04381 Abnormality
in left governor
in left pre-stroke
system
solenoid
...................................
20-428
...............................
.20-429
is displayed
sensor system
is displayed..
............... .20-430
servo is displayed
....................................................
.20-431
servo is displayed..
.....................................................
.20-431
E-25
[E04401 Disconnection
solenoid
power
E-26
[E04411 Disconnection
in power
supply system
E-27
(E04421 Abnormality
in engine
controller
backup power
E-28
[E04431 Abnormality
in engine
controller
switch
E-29
[E04551 Engine overheating
E-30
IE04561 Short circuit in right pre-stroke
E-31
[E04571 Disconnection
E-32
Engine does not revolve when
E-33
Engine does not stop when
D475A-3
is displayed
system
water temperature
source
is displayed
in right pre-stroke starting
starting
is displayed..
cut relay system solenoid
E-22
is displayed..
1 system
is displayed
2 of solenoid
power
.................................
is displayed..
source system source system
.20-432
.......................
..... .20-433
is displayed.. is displayed..
...... -20-434
................................................................................. solenoid solenoid switch
switch
is displayed
system
.20-435 .20-436
............................
20-437
to ON position.. ...........................
20-438
system
is turned
................................
is displayed..
20-432
is turned to OFF position.. ..............................
.20-441
20-401 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code
Service code Abnormal
system
Nature
E0401
Abnormality in engine controller power source voltage
% When controller power source voltage is less than 36 V 1. Defective controller
E0402
Abnormality in engine controller
% Data written to RAM inside controller do not match read data 1. Defective controller
E0403
Mistaken connection in engine controller
engine controller connector E31 and connector E51 are mistakenly connected 1. Mistaken connection of connector E31 and connector E51 2. Controller E31 (1) short circuiting with ground 3. Defective contact or disconnection in wiring harness between controller E51 (1) and chassis ground 4. Defective controller
Abnormality in fuel control dial system
X When input voltage from fuel control dial is less than 0.3 V or more than 4.55 V 1. Defective fuel control dial 2. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between controller E31 (6) and fuel control dial FCS (1) 3. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between controller E32 (1) and fuel control dial FCS (2) 4. Defective contact or disconnection in wiring harness between controller E31 (16) and fuel control dial FCS (3)
CALL
sx When
E0405
I When input voltage from deceleration potentiometer is less than 0.3 V or more than 4.55 V 1. Defective deceleration potentiometer 2. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between controller E31 (61 and fuel control dial FCD (1) 3. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between controller E32 (11) and fuel control dial FCD (2) 4. Defective contact or disconnection in wiring harness between controller E31 (16) and fuel control dial FCD (3)
E0406
Abnormality in deceleration potentiometer system
E0407
Abnormality in shoe slip control command value
% When input voltage from machine controller is less than 0.3 V or more than 4.55 V 1. Defective machine controller 2. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between controller E31 (9) and SSC controller M21 (17) 3. Defective controller
Abnormality in engine speed sensor A system
+X When input from engine speed sensor A becomes less than 300 rpm after engine is started 1. Defective left engine speed sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E31 (3) and speed sensor El6 (1) 3. Defective contact or disconnection in wiring harness between controller E31 (14) and speed sensor El6 (2) 4. Defective controller
E0409 CALL 03
I E0410
Abnormality in engine speed sensor B system
1. 2. 3. 4.
E0411
E0412
20-402 0
of abnormality
Abnormality in right rack sensor system
Abnormality in left rack sensor system
When input from engine speed sensor B becomes less than 300 rpm after engine is started Defective right engine speed sensor Short circuit with ground, defective contact, or disconnection in wiring harness between controller E31 (2) and speed sensor El2 (1) Defective contact or disconnection in wiring harness between controller E31 (14) and speed sensor El2 (2) Defective controller
+Z When input voltage from rack sensor is less than 0.1 V or more than 4.4 V 1. Defective right rack sensor 2. Short circuit with ground, short circuit with power source, defective contact, or disconnection in wiring harness between controller E21 (16) and rack sensor El3 (1) 3. Defective contact or disconnection in wiring harness between controller E51 (1) and rack sensor El3 (2) 4. Short circuit with ground, short circuit with power source, defective contact, or disconnection in wiring harness between controller E31 (7) and rack sensor El3 (3) 5. Short circuit with ground, short circuit with power source, defective contact, or disconnection in wiring harness between controller E31 (17) and rack sensor El3 (4) 6. Defective controller f When input from rack sensor is less than 0.1 V or more than 4.4 V 1. Defective left rack sensor 2. Short circuit with ground, short circuit with power source, defective contact, or disconnection in wiring harness between controller E21 (16) and rack sensor E9 (1) 3. Defective contact or disconnection in wiring harness between controller E51 (1) and rack sensor E9 (2) 4. Short circuit with ground, short circuit with power source, defective contact, or disconnection in wiring harness between controller E31 (81 and rack sensor E9 (3) 5. Short circuit with ground, short circuit with power source, defective contact, or disconnection in wiring harness between controller E31 (18) and rack sensor E9 (4) 6. Defective controller
D475A-3
TROUBLESHOOTING
Condition when normal (voltage, current, resistance) * Voltage
between El1 (7) - (8)(16): 20 - 30 V * Voltage between El1 (9K17) - (8Kl6): 20 - 30 V
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1. Lights up caution lamp, sounds alarm buzzer 2. Stops engine
1. Engine cannot be controlled
1. Stops engine
1. Engine cannot be controlled
* Voltage between E31 (1) - chassis: 20 - 30 V * Voltage between E51 (1) - chassis: Max. 1 V
1. Lights up caution lamp, sounds alarm buzzer
- Voltage between E31 (6) - (16): 4.6 - 5.4 V * Voltage between E32 (1) - E31 (16): 0.3 - 4.55 V
1. Lights up caution lamp, sounds alarm buzzer 2. Controls with deceleration potentiometer signal 3. After machine is stopped (neutral). fixes engine speed at 1300 rpm
1. Engine speed cannot be controlled
* Voltage between E31 (6) - (16): 4.6 - 5.4 V . Voltage between E32 (11) - E31 (16): 0.3 - 4.55 V
1. Lights up caution lamp, sounds alarm buzzer 2. Controls with fuel control dial signal 3. After machine is stopped (neutral), fixes engine speed at 1300 rpm
1. Engine speed cannot be controlled
. Voltage between E31 (9) - chassis: 0.3 - 4.55 V
1. Lights up caution lamp, sounds alarm buzzer 2. Controls with fuel control dial signal 3. After machine is stopped, stops shoe slip control function
1. Shoe slip control is not actuated
* Resistance of speed sensor: 500 - 1000 R * Voltage between E31 (3) - (14): 0.5 - 3.0 V (AC range)
1. Lights up caution lamp, sounds alarm buzzer 2. Controls with signal from engine speed sensor 6
* Resistance of speed sensor: 500 - 1000 R * Voltage between E31 (2) - (14): 0.5 - 3.0 V (AC range)
1. Lights up caution lamp, sounds alarm buzzer 2. Controls with signal from engine speed sensor A
* Voltage - Voltage
between E31 (7) - E51 (1): 0.1 - 4.4 V between E31 (17) - E51 (1): 0.1 - 4.4 V
1. Lights up caution lamp, sounds alarm buzzer 2. Sets right fuel injection pump to NO INJECTION condition
1. Engine runs on one bank
* Voltage between E31 (8) - E51 (1): 0.1 - 4.4 V . Voltage between E31 (18) - E51 (1): 0.1 - 4.4 V
1. Lights up caution lamp, sounds alarm buzzer 2. Sets left fuel injection pump to NO INJECTION condition
1. Engine runs on one bank
D475A-3
20-403 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
Service code Abnormal system
Nature of abnormality ?% When
‘;y
Abnormality in rack sensor power source system
power source voltage of rack sensor is less than 4.6 V 1. Defective right rack sensor or left rack sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (16) and right rack sensor El3 (1) or left rack sensor E9 (1) 3. Defective contact or disconnection in wiring harness between right rack sensor El3 (2) or left rack sensor E9 (2) and chassis 4. Defective controller
E0421
Short circuit in right governor solenoid system
%%When output current to governor solenoid is more than 2.1 A 1. Defective right governor solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller E21 (7) and governor solenoid El5 (11 3. Short circuit with power source in wiring harness between controller E21 (17) and governor solenoid El5 (2) 4. Defective controller
E0422
Disconnaction in right governor solenoid system
Z When output current to governor solenoid is less than 0.1 A 1. Defective right governor solenoid 2. Defective contact or disconnection in wiring harness between controller E21 (7) and governor solenoid El5 (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (17) and governor solenoid El5 (2) 4. Defective controller
E0423
Short circuit in left governor solenoid system
% When output current to governor solenoid is more than 2.1 A 1. Defective left governor solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller E21 (8) and governor solenoid El1 (1) 3. Short circuit with power source in wiring harness between controller E21 (18) and governor solenoid El 1 (2) 4. Defective controller
E0424
Disconnection in left governor solenoid system
% When output current to governor solenoid is less than 0.1 A 1. Defective left governor solenoid 2. Defective contact or disconnection in wiring harness between controller E21 (8) and governor solenoid El 1 (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (18) and governor solenoid El1 (2) 4. Defective controller
E0425
Short circuit in right governor cut relay system
I When output voltage to right governor cut relay is more than 5 - 15 V 1. Defective right governor cut relay 2. Short circuit with power source in wiring harness between controller El1 (4) and relay GCR (2) 3. Defective controller
E0426
Disconnection in right governor cut relay system
%%When output voltage to right governor cut relay is less than 5 - 15 V 1. Defective right governor cut relay 2. Defective contact or disconnection in wiring harness between starting switch ACC terminal and relay GCL (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller El1 (4) and relay GCR (2) 4. Defective controller
E0427
Short circuit in left governor cut relay system
% When output voltage to left governor cut relay is more than 5 - 15 V 1. Defective left governor cut relay 2. Short circuit with power source in wiring harness between controller El1 (5) and relay GCL (2) 3. Defective controller
Disconnection in left governor cut relay system
% When output voltage to left governor cut relay is less than 5 - 15 V 1. Defective left governor cut relay 2. Defective contact or disconnection in wiring harness between starting switch ACC termi nal and relay GCL (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller El1 (5) and relay GCL (2) 4. Defective controller
Short circuit in left pre-stroke solenoid system
% When output current to pm-stroke solenoid is more than 2.1 A 1. Defective left pra-stroke solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller E21 (10) and pre-stroke solenoid El0 (1) 3. Short circuit with power source in wiring harness between controller E21 (20) and prestroke solenoid El0 (2) 4. Defective controller
E0413
CALL
EOI
E0428
‘;y
E0433
20-404 0
D475A-3
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
-
Voltage between E21 (6) - chassis: 5 V
Action by controller when abnormality is detected
Problem that appears on machine? when there is abnormality
1. Lights up caution lamp, sounds alarm buzzer 2. Reduces engine output by 20%
1. Lacks power
- Resistance of solenoid: 10 - 21 Q
1. Lights up caution lamp, sounds alarm buzzer
1. Engine runs on one bank
. Resistance of solenoid: 10 - 21 Q
1. Lights up caution lamp, sounds alarm buzzer
1. Engine runs on one bank
* Resistance of solenoid: 10 - 21 R
1. Lights up caution lamp, sounds alarm buzzer
1. Engine runs on one bank
. Resistance of solenoid: 10 - 21 R
1. Lights up caution lamp, sounds alarm buzzer
1. Engine runs on one bank
1. Lights up caution lamp, sounds alarm buzzer 2. Reduces engine output by 20%
1. Lacks power
* Resistance of relay: 200 - 900 Q + Voltage between El1 (4) and (13): 20 - 30 V
- Resistance of relay: 200 - 900 R - Voltage between El1 (4) and (13): 20 -
30 V
. Resistance of relay: 200 - 900 Q . Voltage between El1 (5) and (14): 20 - 30 V
. Resistance of relay: 200 - 900 fi * Voltage between El 1 (5) and (14): 20 - 30 V
- Resistance of solenoid: 10 - 21 Q
D475A-3
20-405 0
ACTION TROUBLESHOOTING
User code
Service code
Abnormal
TAKEN
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Nature
system
of abnormality
% When E0434
Disconnection in left pm-stroke solenoid system
CALL 03
CALL
a
E0435
Abnormality in engine water temperature sensor system
When input voltage from engine water temperature sensor is less than 0.3 V or more than 0.5 V 1. Defective engine water temperature sensor 2. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between controller E32 (5). monitor panel CN2 (1) - engine water temperature sensor 402 (1) 3. Defective contact or disconnection in wiring harness between engine water temperature sensor 402 (2) and chassis ground 4. Defective controller or monitor panel
E0437
Abnormality in right governor servo
1. Defective right governor solenoid system or rack sensor system (governor command value and rack sensor signal do not match) 2. Abnormality in solenoid power source R system 3. Defective controller
E0438
Abnormality in left governor servo
1. Defective left governor solenoid system or rack sensor system (governor command value and rack sensor signal do not match) 2. Abnormality in solenoid power source L system 3. Defective controller
Disconnection in solenoid power source 1 system
% When controller switch power source is more than 24 V but solenoid power source R is less than 5 V 1. Defective right governor cut relay 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (1) and relay GCR (6) 3. Defective contact or disconnection in wiring harness between E21 (21) and chassis ground 4. Defective controller
Disconnection in solenoid power source 2 system
% When controller switch power source is more than 24 V but solenoid power source L is less than 5 V 1. Defective left governor cut relay 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (12) and relay GCL (6) 3. Defective contact or disconnection in wiring harness between E21 (21) and chassis ground 4. Defective controller
E0440
E0441
E0442
Abnormality in engine controller backup power source system
E044.3
Abnormality in engine controller switch power source system
E6455
Engine overheating
CALL 03
-
% When backup power source voltage is more than 5 V lower than switch power source voltage 1. Blown fuse 1 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller El 1 (7) and fuse 1 3. Defective controller
% When
E0456
switch power source voltage is more than 5 V lower than backup power source voltage 1. Defective starting switch 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller El1 (9K17) and starting switch ACC terminal 3. Defective controller
% When engine water temperature is more than 105°C
Short circuit in right pm-stroke solenoid system
CALL 03
I When output current to pre-stroke solenoid is more than 2.1 A 1. Defective right pre-stroke solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller E21 (9) and pre- stroke solenoid El4 (1) 3. Short circuit with power source in wiring harness between controller E21 (19) and prestroke solenoid El4 (2) 4. Defective controller
I
E0457
20-406 0
output current to pre-stroke solenoid is less than 0.1 A 1. Defective left pre-stroke solenoid 2. Defective contact or disconnection in wiring harness between controller E21 (10) and prestroke solenoid El0 (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (20) and pre-stroke solenoid El0 (2) 4. Defective controller
Disconnection in right pre-stroke solenoid system
When output current to pm-stroke solenoid is less than 0.1 A 1. Defective right pre-stroke solenoid 2. Defective contact or disconnection in wiring harness between controller E21 (9) and pre stroke solenoid El4 (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller E21 (19) and pre-stroke solenoid El4 (2) 4. Defective controller
D475A-3
ACTION TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
* Resistance
TAKEN
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
of solenoid: 10 - 21 R
1. Lights up caution lamp, sounds alarm buzzer 2. Reduces engine output by 20%
- Resistance of sensor: 3.8 - 80 kQ
1. Lights up caution lamp, sounds alarm buzzer 2. Controls with with engine water temperature taken as 90°C
Problem that appears on machint when there is abnormality 1. Lacks power
1. Lights up caution lamp, sounds alarm buzzer 2. Sets right fuel injection pump to NO INJECTION condition
1. Engine runs on one bank
1. Lights up caution lamp, sounds alarm buzzer 2. Sets left fuel injection pump to NO INJECTION condition
1. Engine runs on one bank
* Voltage between E21 (1) and (21): 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Engine runs on one bank
- Voltage
1. Lights up caution lamp, sounds alarm buzzer
1. Engine runs on one bank
between E21 (12) and (21): 20 - 30 V
* Voltage between El 1 (7) and (8X16): 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Drives with switch power source
* Voltage between El1 (9)(17) and (8)(16): 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Drives with backup power source
1. Lights up caution lamp, sounds alarm buzzer 2. Runs engine at low idling
1. Engine speed does not go up from low idling
. Resistance of solenoid: 10 - 21 R
1. Lights up caution lamp, sounds alarm buzzer 2. Reduces engine output by 20%
1. Lacks power
* Resistance of solenoid: 10 - 21 R
1. Lights up caution lamp, sounds alarm buzzer 2. Reduces engine output by 20%
1. Lacks power
D475A-3
20-407 0
TROUBLESHOOTING
ELECTRICAL CIRCUITAL DIAGRAM OF E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
OF E MODE SYSTEM
t
TV001058
20-408 0
D475A-3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
TVD01059
D475A-3
20-409 0
E-l, E-2
TROUBLESHOOTING
E-l *
[E0401] Abnormality displayed
in engine controller
power source voltage
is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Cause
YES
Go to E-27.
1 Is service code [E04421 displayed, too? l
Turn starting switch ON.
2 -
YES
l
Turn starting switch ON.
* *
Defective engine controller
NO
E-2 [E0402] Abnormality *
Go to E-28.
Is service code - LEO4431 NO displayed, too?
in engine controller
is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the Cause Remedy related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
1
Replace
Starting
E-2 Related Ensine
electrical
switch
circuit diagram
controller
~~~
I
I
TXDOl073
20-410 0
D475A-3
E-3
TROUBLESHOOTING
E-3 [E0403] Mistaken
connection
in engine controller
is displayed
Check that connectors E31, E32, E51, and E52 on the chassis side are properly connected to the engine controller. If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
* *
* *
Cause
1 YES Is voltage between E51 (1) and chassis ground normal? *Turn stkting switch ON. Max. 1 V
NO
Defective engine controller
Replace
Defective contact or disconnection in wiring harness between E51 (female) (1) -chassis ground
Repair or replace
l
E-3 Related
electrical
circuit diagram
Engine
controller
vy$+--_&
TXD01074
D475A-3
20-411 0
E-4
TROUBLESHOOTING
E-4 [E0405] Abnormality * * *
in fuel control dial system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Remedy
Cause
YES 2 Is voltage between E32 (1) and chassis ground normal? ~ * Turn starting switch ON. * 0.7 - 4.3 v
YE
1
between E31 (6) and (16) normal?
_
YES 3
Is voltage between FCS (2) NO and chassis 4 YE! ground normal? lSreSiStance ~ between E32 * Turn starting - (female) 11) and switch ON. NO chassis ground * 0.7 - 4.3 v normal? *To”;;.starting switch N( * Disconnect * Min. 1 MR
-Turn starting switch ON. - 4.6 - 5.4 V
FCS and E32
YES
1 I
NO h
ground normal? * Turn starting switch ON. - 4.6 - 5.4 V
1 I *4.0-6.0kc2 Is voltage between E31 (6) NO and chassis ground normal? P * Turn starting switch ON. - 4.6 - 5.4 V
.1 ‘I
YES
EYE! Is resistance between
electrical
Engine
Replace
Defective contact or disconnection in wiring harness between E32 (female) (1) - FCS (female) (2)
Repair or replace
Defective fuel control dial
Replace
Short circuit with chassis ground in wiring harness between E32 (female) (1) - FCS (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between E31 (female) (16) - FCS (female) (3)
Repair or replace
Defective fuel control dial
Replace
Defective contact or disconnection in wiring harness between E31 (female) (6) - FCS (female) (1)
Repair or replace
Defective fuel control dial
Replace
Short circuit with chassis ground in wiring harness between E31 (female) (6) snd FCS (female) (I)
Repair or replace
E31
- (female) (6) and NO chassis ground normal? * Turn starting switch OFF. - Disconnect FCS and E31. - Min. 1 MR
E-4 Related
Defective engine controller
-
N(
circuit diagram
controller
F31 ti0)
Analog
(3)
Fuel
GND E32
FCS
dial
i (1 6)
TXDOl075
20-412 0
D475A-3
TROUBLESHOOTING
E-5
E-5 [E0406] Abnormality +
* *
in deceleration
potentiometer
is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Cause
YFS 2 YE
1
between E31 (6) and (16) normal? * Turn starting switch ON. * 4.6 - 5.4 V
s voltage between E32 (I 1) YES and chassis 3 ground normal? ~ Is voltage * Turn starting between FCD (2) switch ON. NO and chassis 4YE . 0.7 - 4.3 v ground normal? -lSreSiStancer P between E32 * Turn starting - (female!) (11) and u switch ON. NO chassis _ * 0.7 - 4.3 v ll0rlllei? -Turnstarting switch NI OFF. * DisconnectFCD and E3: . Min. 1 MR 6 YES
NO h
ground normal? * Turn starting switch ON. * 4.6 - 5.4 V
1 I a4.0-6.0kQ Is voltage between E31 (6) NO and chassis ground normal? -Turn starting switch ON. -4.6 - 5.4 V
.1
YES
8YE Is resistance between E31 - (female) (6) and NO chassis ground normal? *Turn starting switch OFF. - Disconnect FCD and E31. * Min. 1 MR
E-5 Related
electrical gine
II
Nj
Defective engine controller
Replace
Defective contact or disconnection in wiring harness between E32 (female) fll)-FCD (female) (2)
Repair or replace
Defective deceleration potentiometer
Replace
Short circuit with chassis ground in wiring harness between E32 (female) (11) - FCD (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between E31 (female) (16) - FCD (female) (3)
Repair or replace
Defective deceleration potentiometer
Replace
Defective contact or disconnection in wiring harness between E31 (female) (6) - FCD (female) (1)
Repair or replace
Defective deceleration potentiometer
Replace
Short circuit with chassis ground in wiring harness between E31 (female) (6) - FCD (female) (1)
Repair or replace
circuit diagram
controller
Analog
FCD
(3)
W 3
GND
3
---Lx
Decele Potent
Decelerator Potentiometer L
-
Remedy
rator iometer
I
TXD01076
D475A-3
20-413 0
E-6
TROUBLESHOOTING
E-6 [E0407] Abnormality in shoe slip control command value is displayed Ir If the starting switch was turned off after the abnormality occurred, turn the starting switch * *
on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
YES 1 Is voltage between E31 (9) and (16) normal? * Turn starting switch ON. al-4v
3 -
NO
Is voltage between M21 (17) and (11) normal?
Is resistance YES between E31 2 7 (female) (9) and M21 (female) (17) , normal?
YES
-
NO * Turn starting switch OFF. * Disconnect E31 and M21. * Max. 1 Q
* Turn starting switch ON. al-4v
I
NO
Defective engine controller
Replace
Short circuit with chassis ground in wiring harness between E31 (female) (9) - M21 (female) (17)
Repair or replace
Defective contact or disconnection in wiring harness between E31 (female) (9) - M21 (female) (17)
Repair or replace
Defective machine controller
1 Replace
E-6 Related electrical circuit diagram
Engine
I
controller
M21 (21)
I E31 (20)
n
GND
D
Ens ine
command
GND5 TXD01077
20-414 0
D475A-3
E-7
TROUBLESHOOTING
E-7 [E0409] Abnormality * + +
in engine speed sensor A system is displayed
If the starting switch was turned off after the abnormality occurred, start engine and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
2 YES
Wrong adjustment of engine speed sensor A
Adjust
Defective engine controller
Replace
;(-ZHl
AND ADJUSTING. * Start engine.
(female) (2) and
Defective contact, disconnection or short circuit with chassis ground in wiring
4 YES
harness between E31 (female) (2)- El6 (female)
Is resistance * Turn starting switch OFF. . Disconnect E31. ~500-1,000n
Engine
between
3
(female) (2) and El6
resistance El6 I\ ) (male) (1) and (2) normal? - starting s Turn Is
between
switch OFF. * Disconnect E16. ~500-1,000n
E-7 Related
YES
electrical
(female)
E31
Defective contact or disconnection in wiring
(1) normal?
harness between E31 (female) (14) - El6 (female)
* Turn starting NO switch OFF. * Disconnect E31 and E16. *Max. 1 D
Repair or replace
(1)
Repair or replace
(2)
Defective engine speed sensor A
NO
circuit diagram
controller 992
Engine
speed
A
(16)
995
(14)
E
E
a
8
El 6 (2)
Right speed
engine sensor
3 3
TXDOI 078
D475A-3
20-4 15 0
E-8
TROUBLESHOOTING
E-8 [E0410] Abnormality
in engine speed sensor B system is displayed
*
If the starting switch was turned off after the abnormality occurred, start engine and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on to the next step.
Cause
2 YES If speed sensor B is adjusted, is service code P u displayed? II
YE
1
(female) (3) and * Turn starting switch OFF. - Disconnect E31. * 500 - 1,000 n
* See TESTING AND ADJUSTING. * Start engine.
between El2 (male) (I) and (2) normal?
h
*Turn starting switch OFF. * Disconnect E12. *500-1,OOOR
E-8 Related
Engine
electrical
NO
I
4 YES
-Turn H
I
starting NO switch OFF. - Disconnect E31 and E12. * Max. 1 Q
NO
Remedy
Wrong adjustment of engine speed sensor B
Adjust
Defective engine controller
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between E31 (female) (3) - El2 (female) (1) - M41 (female) (1) Defective contact or disconnection in wiring harness between E31 (female) (14) - El2 (female) (2)
Defective engine speed sensor B
Repair or replace
Repair or replace
Replace
circuit diagram
controller
TXD01079
20-416 0
D475A-3
TROUBLESHOOTING
E-9
E-9 [E0411] Abnormality in right rack sensor system is displayed fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) fl If the operation can be continued, perform the checks in Steps 1 and 2 under the operating condition where a trouble occurs. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.
YES 1 Is voltage between E31 (7) and (17) normal? • Turn starting switch ON. • 0.1 – 4.5 V
YES 2 Is voltage between E13 (3) NO and (4) normal? • Turn starting switch ON. • 0.1 – 4.5 V
3 YES
NO
Is resistance between E13 (female) (3) and (2) and between (4) and (2) normal?
• Turn starting switch OFF. • Disconnect E31 and E13. • 50 kΩ – 1 MΩ
NO
Cause
Remedy
Defective engine controller
Replace with new part
Defective contact or disconnection in wiring harness between E31 (female) (7) – E13 (female) (3) or between E31 (female) (17) – E13 (female) (4)
Repair or replace
Defective right rack sensor
Replace rack sensor
Short circuit with chassis ground in wiring harness between E31 (female) (7) – E13 (female) (3) or between E31 (female) (17) – E13 (female) (4)
Repair wiring harness or replace
E-9 Related electrical circuit diagram
D475A-3
20-417 3 4
TROUBLESHOOTING
E-10
E-10 [E0412] Abnormality in left rack sensor system is displayed fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) fl If the operation can be continued, perform the checks in Steps 1 and 2 under the operating condition where a trouble occurs. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.
YES 1 Is voltage between E31 (8) and (18) normal? • Turn starting switch ON. • 0.1 – 4.5 V
YES 2 Is voltage between E9 (3) NO and (4) normal? • Turn starting switch ON. • 0.1 – 4.5 V
3 YES
NO
Is resistance between E9 (female) (3) and (2) and between (4) and (2) normal?
• Turn starting switch OFF. • Disconnect E31 and E9. • 50 kΩ – 1 MΩ
NO
Cause
Remedy
Defective engine controller
Replace with new part
Defective contact or disconnection in wiring harness between E31 (female) (8) – E9 (female) (3) or between E31 (female) (18) – E9 (female) (4)
Repair or replace
Defective left rack sensor
Replace rack sensor
Short circuit with chassis ground in wiring harness between E31 (female) (8) – E9 (female) (3) or between E31 (female) (18) – E9 (female) (4)
Repair wiring harness or replace
E-10 Related electrical circuit diagram
20-418 3 4
D475A-3
E-l 1
TROUBLESHOOTING
E-II *
* *
[E0413] Abnormality displayed
in rack sensor power source system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
F
I
Defective engine controller
Y‘ES
Defective contact, disconnectionor short circuit with chassis ground in wiring harness between E21 (female) (16l- El3 (female) (1) - E9 (female) (1)
1
(female) (16) and E-51 (female) (11 *Turn starting switch OFF. * Disconnect E21 and E51. - Min. 500 kn
Cause
I Is resistance ing 1.
hIO
-Turn starting switch OFF. - Disconnect E21 and E51. - Min. 500 M
NO
Remedy
Replace
Repair or replace
Defective contact or disconnection in wiring harness between El3 (female) (2) - E9 (female) (2) -chassis ground
Repair or replace
Defective rack sensor having abnormal resistance
Replace
2
E-l 1 Related electrical circuit diagram Engine
controller E21 till
Right sensor Rack sensor
(+)
rack
L
E51 (20) Left rack sensor
v
nw
GND5 TXDOl082
D475A-3
20-419 0
TROUBLESHOOTING
E-12
E-12 [E04211 Short circuit in right governor solenoid system is displayed *
Sr Ir
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
3 YES Is voltage YES between E21 - (female) (17) and 2 . chassis ground Turn starting -s reskance 7 w=~vJ*~~ FIF, (male) normal. :_...__.. _._, switch OFF. _ -Disconnect El5 NO j tze$ (2) ant * Disconnect E21. (1) (2) and and E21. NC chassis‘n grouna -Turn starting switch ON. shown in Table _“2s - Max. 1 V * Turn starting switch OFF. NO * Disconnect E15. (17) and between (7) (17) and chassis ground as shown in
l
Table
1
Remedy
Defective engine controller
Replace
Short circuit with chassis ground or power source in wiring harness between E21 (female) (7) - El5 (female) (1)
Repair or replace
Short circuit with power source in wiring harness between E21 (female) (17) - El5 (female) (2)
Repair or replace
Defective right governor solenoid
Replace
Table 2
E-12 Related Engine
electrical
circuit diagram
controller
I
E21 (2 1)
992 (1 6)
995 (14)
E 15 (2)
Govenor
solenoid
I+)
R
@
@
3
Govenor
solenoid
(-1
R
@
(IJ
3
Govenor solenoid (R. H)
TVDOI 165
20-420 0
D475A-3
E-13
TROUBLESHOOTING
E-13 [E0422] Disconnection displayed
in right governor solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective engine controller
YE
Defective contact, disconnection or short circuit with chassis ground in wiring harness between E21 (female) (17) - El5 (female) (2)
1 (17) and between (7) (17) and chassis ground as shown in *Turn starting switch OFF. * Disconnect E21.
(1) and (2) and between (1) (2) and NC 1 chassis ground as i L
Turn starting switch OFF. * Disconnect E15.
l
Table
I
NO
Remedy
Replace
Repair or replace
Short circuit with power source in wiring harness between E21 (female) (7) - El5 (female) (I)
Repair or replace
Defective right governor solenoid
Replace
Table 2
1
fll
E-13 Related electrical circuit diagram Engine
controller
992 ,\, (16) Govenor
solenoid
(4
R
Govenor
solenoid
(-1
R
995 (14)
El 5 (2)
@
@
3
@
@
3
Govenor solenoid (R. H)
I
TVDOI 165
D475A-3
20-421 0
E-14
TROUBLESHOOTING
E-14 [E0423] Shot-t circuit in left governor solenoid system is displayed If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
Defective controller
YES
11 voltage between E21 (female) (8) and (18) and between (8) (18) and chassis ground as shown in Table l? Is
3 YES YES
2
* Turn starting Is between El1 (male) switch OFF. (1) and (2) and * Disconnect E21. Nc between (1) (2) and chassrs ground as shown in Table 2? * Turn starting switch OFF. * Disconnect El 1.
Table
Is voltage between E21 (female) (18) and chassis ground normal? p p NO - Disconnect El 1 and E21. *Turn starting switch ON. * Max. 1 V
NO
Replace
Short circuit with chassis ground or power supply in wiring harness between E21 (female) (8) - El1 (female) (1)
Repair or replace
Short circuit with power source in wiring harness between E21 (female) (18) - El1 (female) (2)
Repair or replace
Defective solenoid
Replace
left governor
Table 2
1
E-14 Related
Engine
engine
Remedy
electrical
controller
circuit diagram
L. H. governor solenoid
TXD01083
20-422 0
D475A-3
E-15
TROUBLESHOOTING
E-15 [E0424] Disconnection displayed
in left governor solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
Defective engine controller 1
I
voltage
Is between E21 (female) (8) and
3
(18) and between (8) _ (18) and chassis ground as shown in Table l?
YES
* Turn starting Ps resistance between El1 (male) switch OFF. and (2) and * Disconnect E21. NO- (1) between (1) (2) and chassis ground as shown in Table 2?
2
Is voltage between El1 (1) and chassis ground normal?
p *Turn starting switch ON. *20-30V
*Turn starting switch OFF. * Disconnect El 1.
Table
Defective contact, disconnection or short circuit with chassis ground in wiring harness between E21 (female) (18) -El 1 (female) (2)
YES
Short circuit with power source in wiring harness between E21 (female) (8) - El1 (female) (1)
p NO
Defective solenoid
NO
Remedy
Replace
Repair or replace
Repair or replace
left governor
Table 2
1
-1
)I
E-15 Related
Engine
electrical
circuit diagram
controller
I,
993 (16)
E21 (;l) \
Governor
solenoid
(+I
L
Governor
solenoid
C-1 L
I
I
I
994 (14)
El 1 (2)
L. H. governor solenoid
I
8
Q
3
.D
18
3
3
3
TXD01083
D475A-3
20-423 0
E-16
TROUBLESHOOTING
E-16 [E0425] Short circuit in right governor cut relay system is _ _ displayed *
* *
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
_i 2 YES
Defective engine controller
Is voltage between
YES El1 (female) (4) 1 Is resistance between GCR _ (male) (1) and (2) normal? * Turn starting switch OFF. mDisconnect GCR. ~200-900a
E-16 Related
and chassis ground normal?
Short circuit with power source in wiring harness between El1 (female) (4) - BCR (female) (2)
*Disconnect GCR NO and Eli. Turn starting switch ON. * Max. 1 V l
Defective right governor cut relay
NO
electrical
circuit diagram
R. H. governor cut relay Engine
Repair or replace
controller
I
El I (17)
Starting
switch
GCR (6)
TXD01084
20-424 0
D475A-3
E-17
TROUBLESHOOTING
E-17 [E0426] Disconnection displayed * * Ir
in left governor cut relay system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES 3
I
-a I
I 3
ground normal? _
(male) (1) and (2) normal?
* Turn starting switch ON. *20-30V
E-17 Related
Is voltage between GCR (1) and chassis ground normal? * Turn starting switch ON. *20-30V
I
-Turn starting switch OFF. * &connect GCR. ~200-900n
NO
NO
Remedy
Defective engine controller
Replace
Defective contact or disconnection in wiring harness between El 1 (female) (4) - GCR (female) (2)
Repair or replace
Defective contact, disconnectionor short circuit with chassis ground in wiring harness between GCR (female) (1) -ACC terminal 01 starting switch Defective right governor cut relay
’ NO
electrical
YES
Cause
Repair or replace
Replace
circuit diagram
R. H. governor cut relay Engine
1
D475A-3
controller
I
TXD01084
20-425 0
E-18
TROUBLESHOOTING
E-18
[E0427]
Short circuit in left governor
cut relay system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
2 YES 1 r
normal?
- Turn
I
starting switch OFF. * Disconnect GCL. *200-g00R
E-18 Related
YES
Is voltage between El1 (female) (5) andchassis
and Ell. * Turn starting switch ON. Max. 1 V l
NO
electrical
Replace
Short circuit with power source in wiring harness between El 1 (female) (5) - GCL (female) (2)
Repair or replace
Defective left governor cut relay
Replace
circuit diagram
Starting
L. H. governor cut relay Engine
Defective engine controller
controller
I
El 1 (17)
E21 till
switch
GCL (6) (i)@@(Q(q
I
TXD01085
20-426 0
D475A-3
E-19
TROUBLESHOOTING
E-19 [E0428] Disconnection displayed * * Jr
in left governor
cut relay system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES 2 Is voltage YES
lp Is resistance between GCL _ (male) (I) and (2) normal? . Turn starting switch OFF. * Disconnect GCL. .200-900R
E-19 Related
between
El 1 (5) and chassis ground normal? * Turn starting switch ON. *20-30V
3 P YES
~0
* Turn starting switch ON. *20-30V
electrical
NO
I
Remedy
Defective engine controller
Replace
Defective contact or disconnection in wiring harness between El 1 (female) (5) - GCL (female) (2)
Repair or replace
Defective contact, diyxmnection or short circuit w$;;“.si;7em;;d$ wiring
Repairor replace
(female) (1)- ACC terminal of starting switch Defective left governor cut relay
NO
Replace
circuit diagram
L. H.
Engine
Is voltage between GCL (1) and chassis ground normal?
Cause
governor
controller
TXDOl085
D475A-3
20-427 0
E-20
TROUBLESHOOTING
E-20 sr * *
[E0433] Short circuit in left pre-stroke displayed
solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
11
IS resistance baween E21 (female)(10)and (2)and between (10) (201and chassis
groundas shown in Table 17
3 YES Is voltage between E21 (female) (20) and chassis ground normal?
-
YES 2 * Turn starting Is rasrstance between El0 (male) switch OFF. (1)and 12)and NO * Disconnect E21. NG between (1) (2) and - * Disconnect El0 and E21. chassrsground as * Turn starting switch ON. shown in Table 27 * Max. 1 V . Turn starting l
Table
switch OFF. Disconnect EIO.
NO
Remedy
Defective engine controller
Replace
Short circuit with chassis ground or power supply in wiring harness between E21 (female) (10) - El0 (female) (I)
Repair or replace
Short circuit with power source in wiring harness between E21 (female) (20) - El0 (female) (2)
Repair or replace
Defective left pre-stroke solenoid
Replace
Table 2
1
c
E-20 Related Engine
electrical
circuit diagram
controller
E21 Prestroke solenoid (+I Prest roke solenoid (-1
L L
th 1)
993 I
(1 6) I I
994
(14)
El0
@
g)
-g)
3
@
$J
3
3
(3)
,_,
Left Prest solenoid
roke
TXDOlOi36
20-428 0
D475A-3
E-21
TROUBLESHOOTING
E-21 [E0434] Disconnection displayed *
* *
in left pre-stroke
solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
IJ
Is resistancebetween E21 (female)(10) and (2) and between (10) _ (20) and chassis groundas shown in ITable 17
*Turn starting switch OFF. * Disconnect E21. NO-
3 YES YES
2
Is resistance between El0 (male) _ (‘) a”d (2)(1) and between (2) and chassis ground as , shown in Table 27 I Turn starting switch OFF. * Disconnect EIO.
Is voltage between El0 (female) (I) and chassis ground normal? * Turn starting
switch
Remedy
Defective engine controller
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between E21 (female) (20) - El0 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness batween E21 (female) (IO) - El0 (female) (1)
NO
ON.
*20-30V
Defective left pre-stroke solenoid
l
NO
Replace
Table 2
Table 1
Resistance
El0 (male)
I
Between (I) - (2) Between (I) (2) - chassis
E-21 Related
Engine
Repair or replace
electrical
IO-21Q
1
Min. 1 MSZ
circuit diagram
controller
Prestroke solenoid Prest roke solenoid
1
Left
E21 thl, \ (+)
L
(-1
L
993 (1 6) I
I
@
3
@-
3
Prest id
roke
/l
TXD01086
D475A-3
20-429 0
E-22
TROUBLESHOOTING
E-22 [E04351 Abnormality is displayed *
* *
in engine water temperature
sensor system
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective engine controller
YES
I 3 YES
E32
(female) 5 and
Is resistance
chassis ground as shown in following table?
*Turn starting switch OFF. * Disconnect E32.
YES 2
PIs resistance NO
Replace
Defective contact,
1 Is resistance between
Remedy
between 402 (female) (1) and 2 shown
in
as
-
between 402
-CNZ
(female) and chassis ground normal? eTurn
switch OFF. - Disconnect 402. * Max. 1 Q
following
table? * Turn starting switch OFF. . Disconnect 402.
(female)
Repair or replace
(1)
Defective contact or disconnection in wiring
NO
starting
disconnection or short circuit with chassis ground in wiring harness between E32 (female) (5) - 402 (female) (1)
Repair or replace
harness between CN2 (female) (2) -chassis ground
Defective engine water temperature sensor
NO
Replace
Table Resistance
Engine water temperature 10 - 100°C
E-22 Related
Engine
Approx.
electrical
80 - 3.8 k&2
circuit diagram
Monitor
controller E32
Panel
I
I
(I 6)
215
(16)
CN2 (8) temperature
temp. sensor
Engine 214
(14)
7ja
20-430 0
water
temp. sensor
GND5
TXD01087
D475A-3
TROUBLESHOOTING
E-23 [E0437] Abnormality Jr
E-23, E-24
in right governor servo is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
Remedy
Go to Troubleshooting for fuel injection pump.
E-24 [E0438] Abnormality j,
in left governor servo is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
Remedy
Go to Troubleshooting for fuel injection pump.
D475A-3
20-431 0
E-25, E-26
TROUBLESHOOTING
E-25 [E0440] Disconnection displayed *
solenoid power source 1 system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
Remedy
Go to E-17.
E-26 [E0441] Disconnection displayed *
in power supply system 2 of solenoid is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
Remedy
Go to E-19.
20-432 0
D475A-3
TROUBLESHOOTING
E-27
E-27 [E0442] Abnormality system is displayed *
li * *
in engine controller -
backup power source
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that fuse 1 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES
Defective engine controller
1 I Is voltage between El1 (7) and (8) (16) normal? * Turn starting switch OFF. l20-30V
Cause
Replace
Defective contact or disconnection in wiring harness between El 1 (female) (8) (16) -chassis ground
Repair or replace
NO
Defective contact or disconnection in wiring harness between El 1 (female) (7) -fuse 1
Repair or replace
Is voltage between El 1 (7) ND and chassis ground normal? . Turn starting switch OFF. *20-30V
I
YES u
_ 2
Remedy
E-27 Related electrical circuit diagram
Engine
controller
El 1 (i7)
Fuse
box
A
TXDOlO66
D475A-3
20-433 0
1
E-28
TROUBLESHOOTING
E-28 [E0443] Abnormality system is displayed
in engine controller
switch power source
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that fuse 1 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between El1 (9) (17) and (8) (16) normal?
_ 2 Is voltage between El 1 (9) NO (17) and chassis ground normal?
* Turn starting switch ON. *20-30V
Turn starting switch ON. *20-30V l
E-28 Related
YES
electrical
NO
Replace
Defective contact or disconnection in wiring harness between E11 (female) (8) (16) -chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between El1 (female) (9) (17) - ACC terminal of starting switch
Repair or replace
switch
controller
I
Fuse
Defective engine controller
circuit diagram Starting
Engine
Remedy
\
El 1 (171
POWER
(24V)
POWER
(24V)
box
GND5 81
1 (14)
421
(14)
215
(16)
TXD01089
20-434 0
D475A-3
E-29
TROUBLESHOOTING
E-29 [E0455] Engine overheating *
is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
1 YES Is any other service code displayed, too? - Turn starting switch ON.
0475A-3
NO
Remedy
Problem probably caused by other abnormality occurring at same time.
Check according to displayed service code.
Problem probably caused by abnormality in engine.
Go to troubleshooting for engine.
20-435 0
E-30
TROUBLESHOOTING
E-30 [E0456] Short circuit in right pre-stroke displayed *
* *
solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
1
I
. Turn starting switch OFF. Disconnect E21.
El4 hale) Wand
(2)
and between (1)(2) and chassisground
l
switch OFF. . Disconnect E14.
Table
-
3 YES Is voltage between
Disconnect El4
NO
Replace
Short circuit with chassis ground or power supply in wiring harness between E21 (female) (9) - El4 (female) (1)
Repair or replace
Short circuit with power source in wiring harness between E21 (female) (19) - El4 (female) (2)
Repair or replace
Defective right pre-stroke solenoid
Replace
*Turn starting switch ON.
NO
Table 2
1
E-30 Related
tneine
Defective engine controller
electrical
circuit diagram
controller
E2 1 (2 1)
I Prestroke
solenoid
C-1
992 (1 6)
995 (14)
El4
GJ
3
@
3
(2)
I Right Prest roke solenoid
TXD01090
20-436 0
D475A-3
E-31
TROUBLESHOOTING
E-31 [E0457] Disconnection displayed Jr * Ir
in right pre-stroke
solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I
Remedy
Defective engine controller
3
I
.. - I urn startmg l
switch OFF. Disconnect E21.
YES
EH_ between El4
knale)
* Turn starting switch OFF. * Disconnect E14.
Defective contact or disconnection in wiring harness between E21 (female) (9) - El4 (female) (I)
NO
*Turn starting switch ON. .20-30V
Defective right pre-stroke solenoid
JO
Repair or replace
Repair or replace
Replace
Table 2
Table 1
Between (9) - (19) Between (9) (19) - chassis
E-31 Related
electrical
El4 (male)
Resistance
Between (I) - (2)
10 - 21 a
Resistance
E21 (female)
tnaine
Defective contact, disconnection or short circuit with chassis ground in wiring harness between E21 (female) (19) - El4 (female) (2)
YE
1table 17
Replace
IO-21sz
I
1 Min. 1 MQ
1
I
I- Between
(1) (2) - chassis
) Min. 1 MR
1
circuit diagram
controller
992 (1 6)
995 (14) QJ
@
Right Prestroke solenoid
TXDOtO90
D475A-3
20-437 0
TROUBLESHOOTING
E-32
E-32 Engine does not revolve when starting switch is turned to ON position * * * * *
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Check that fuse 1 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis ground.) When performing any part of troubleshooting, turn the parking lever to the LOCK position. Before carrying out troubleshooting, check that all the related connectors are properly inserted. 5 YES Always connect any disconnected connectors before goI Isconnection of II ing on to the next step.
H N~~~~~ * Check visually. NO *Check both sides.
4
YEiS Is voltage between 103 (2). 104 (2) and chassis ground
YES
normal?
103 (1),104(l)
A------
. Disconnect ANR. NO chassis ground normal? *Turn starting Ilswitch ON. - Disconnect220. * Max. 1 V *Turnstarting switch ON. * Max. 1 V
and
* Turn starting switch to START position. -2O-30V
9 YES
NO -Turn starting switch OFF. - Disconnect TL2. * Max. 1 D 10 YES Is voltage between *Turn starting terminal C of switch to START - starting switch and position. NO chassis ground *20-30V normal?
Is voltage between TL2 (3) hIO and chassis ground normal?
sound of battery
*Turn starting switch ON and OFF. *20-30V *Check both sides.
-Turn starting switch to START position. *20-30V
YES
specific gravity of
r
battery relay and
YES
Is voltage between -Turn starting terminal 6R of switch ON. - starting switch and NO chassis ground *20-30V *Check both sides. . normal? -
* Voltage: Min. 24 V * Specific gravity: Min. 1.26
. Turn starting switch ON. *20-30V
-
13 YES
Is resistance between terminals _ NO 6 and 6R Of starting switch normal? NO - Disconnect terminals B and BR of starting switch. - Turn starting switch ON. -Max.lOCl
NO
20-438 0
D475A-3
TROUBLESHOOTING
E-32
Cause
Defective starting motor
Remedy
Xeplace
iepair or .eplace
Defective alternator
qeplace
Defective diode (220)
qeplace
Short circuit with power source in wiring harness between 103 (female) (2) 104 (female) (2) - CNR or 220 (male) (2)
qepair or peplace
Defective contact or disconnection in wiring harness between TL2 (female) (1) - 103 (female) (I) - 104 (female) (I)
Repair or replace
Defective neutral safety switch Defective contact or disconnection in wiring harness between terminal C (280) of starting switch - TL2 (female) (3)
Repair or replace
3eplace
{eplace
qepair or ,eplace
3epair or ,eplace
- Defective starting switch
Defective battery
D475A-3
qeplace
qeplace
20-439 0
E-32
TROUBLESHOOTING
E-32 Related electrical circuit diagram
Travel switch
Start
lock
in9
switch
TL2 (X3)
Alternator 301
(4)
104
(2)
-IX-
Starting
motor
2
Starting
motor 103
(2) 2
3
421
Battery
811
v------
(14)
3 D--
Fuse
(14) _
f
box
TXDOlO91
20-440 0
D475A-3
E-33
TROUBLESHOOTING
E-33 Engine does not stop when starting switch is turned to OFF position Ir Ir j,
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
F--F=
YES 1
I
. Turn starting switch OFF. - Disconnect terminals B and ACC. - Min. 1 MQ
E-33 Related
electrical
Replace
Short circuit with power source in wiring harness between El 1 (female) (9) (17) -terminal ACC of starting switch
Repair or replace
Defective starting switch
Replace
NO
circuit diagram
Starting
Engine
Defective engine controller
switch
controller
El 1 (17) s13
Fuse 320A o/8
POWER
(24V)
POWER
(24V)
(12)
GND5 box
81 1 (14)
421
(14)
215
(16)
-D TXD01089
D475A-3
20-441 0
TROUBLESHOOTING OF MACHINE CONTROLLER SYSTEM (C MODE)
Action taken by controller Electrical
c-
1
circuit diagram
when
abnormality
in machine
controller
power
controller
EPROM is displayed
[E01501 Abnormality
in machine
c- 3
[E01511 Abnormality
in specification
c- 4
[E02011 Disconnection
c- 5
[E02021 Short circuit in torque
C- 6
[E02031 Disconnection
in torque
pressure C-IO
switch & 3rd oil pressure
c-12 c-13
..........................................
2nd clutch oil pressure 3rd clutch oil pressure
in transmission
modulating
20-531
switch system 20-532
switch system
oil pressure
20-533
sensor system 20-534
..................................................................................................................................
iE02121 Short circuit in torque
c-15
IE02131 Disconnection
C-l 6
fE02201 Short circuit in transmission
in torque
converter
lock-up solenoid
converter
system
lock-up solenoid
modulating
system
oil pressure
............. .20-535
is displayed.. is displayed..
.......... .20-536
sensor system 20-537
..................................................................................................................................
c-17
[E03011 Short circuit in left blade tilt angle sensor system
C-18
[E0302]
.20-529
switch system
..................................................................................................................................
C-l 4
is displayed
20-528
..................................................................................................................................
fE02101 Disconnection is displayed
20-527
switch system
switch & 2nd oil
is displayed
1st oil clutch pressure
[E02091 Short circuit in transmission is displayed
.20-526
..................................................................................................................................
[E02081 Short circuit in transmission is displayed
1st clutch oil pressure
switch system
IE02071 Short circuit in transmission is displayed
C-II
REVERSE clutch oil pressure
in transmission
.20-525
switch system
..................................................................................................................................
[E02061 Disconnection
.20-523
switch system
............................................................
clutch oil pressure
.20-523
................. .20-524 ....................
..................................................................................................................................
[E02051 Short circuit in transmission is displayed
c- 9
is displayed
clutch oil pressure
is displayed
FORWARD
.20-516
................................................. is displayed
.20-504
.............. -20-522
........................................
speed sensor system FORWARD
switch system
fE02041 Short circuit in transmission is displayed
......................
is displayed..
speed sensor system
converter converter
source voltage
is displayed
selection
in transmission
& REVERSE oil pressure
C- 8
on machine..
of C mode system .....................................................................................
[EOI 1 II Abnormality
c- 2
c- 7
occurs and problems
............................
.20-538
is displayed
.........................
.20-539
c-19
[ E03031 Short circuit in right blade tilt angle sensor system is displayed
.........................
.20-540
c-20
[ E03041 Disconnection
......................
.20-541
c-21
[E0305]
Disconnection
is displayed
in left blade tilt angle sensor system in right blade tilt angle sensor system
Short circuit in blade RAISE oil pressure
is displayed
switch system
is displayed
switch system
.................. .20-542 ............... .20-543
c-22
[E03061 Short circuit in blade right tilt oil pressure
C-23
[E03071 Short circuit in blade left tilt oil pressure
switch system
is displayed..
................ .20-544
C-24
[E03081 Short circuit in ripper RAISE oil pressure
switch system
is displayed
................. .20-545
C-25
[E0309]
Short circuit in ripper LOWER oil pressure
switch system
is displayed..
switch system
is displayed
C-26
[E03101 Short circuit in ripper TILT IN oil pressure
C-27
[E031 I] Short circuit in blade lever front button switch system
C-28
[E03121 Short circuit in blade lever upper button switch system
c-29
[E03131 Short circuit in pitch back solenoid
c-30
[E03141 Disconnection
c-31
[E03151 Short circuit in pitch dump
C-32
fE03161 Disconnection
D475A-3
is displayed
system
in pitch back solenoid solenoid
in pitch dump solenoid
is displayed
system system
.............. ..20-54 7
....................
.20-548
.................. .20-549
........................................
.20-550
is displayed
.....................................
.20-551
is displayed..
....................................
.20-552
.................................
.20-553
is displayed
system
is displayed
............. .20-546
is displayed..
20-501 0
c-33 c-34 c-35 C-36 c-37 C-38 c-39 c-40 c-41 C-42 c-43 c-44 c-45 C-46 c-47 C-48 c-49 c-50 c-51 C-52
[E03171 Short circuit in left tilt limit solenoid system is displayed ..................................... .20-554 [E03181 Disconnection in left tilt limit solenoid system is displayed ................................... 20-555 [E03191 Short circuit in right tilt limit solenoid system is displayed.. ................................. .20-556 [E03201 Disconnection in right tilt limit solenoid system is displayed.. .............................. .20-557 [E03211 Short circuit in dual tilt selection solenoid system is displayed.. .......................... .20-558 [E03221 Disconnection in dual tilt selection solenoid system is displayed.. ....................... .20-559 [E03231 Short circuit in pitch selection solenoid system is displayed ................................ .20-560 [E03241 Disconnection in pitch selection solenoid system is displayed ............................. .20-561 [E03251 Short circuit in pitch back assist solenoid system is displayed ............................. .20-562 [E03261 Disconnection in pitch back assist solenoid system is displayed .......................... .20-563 IE03271 Short circuit in pitch dump assist solenoid system is displayed.. ......................... .20-564 [E03281 Disconnection in pitch dump assist solenoid system is displayed.. ...................... .20-565 [E03301 Short circuit in blade LOWER oil pressure switch system is displayed.. .............. .20-566 IE03321 Short circuit in unload valve solenoid system is displayed ................................... .20-567 [E03331 Disconnection in unload valve solenoid system is displayed ................................ .20-568 [E03341 Short circuit in demand valve solenoid system is displayed ................................. .20-569 [E03351 Disconnection in demand valve solenoid system is displayed .............................. .20-570 [E03361 Short circuit in ripper TILT BACK oil pressure switch system is displayed ......... .20-571 [E03371 Short circuit in pitch independent solenoid system is displayed .......................... .20-572 (E03381 Disconnection in pitch independent solenoid system is displayed ....................... .20-573
c-54
fE03391 Short circuit in left bottom drain solenoid system is displayed ............................ .20-574 [E03401 Disconnection in left bottom drain solenoid system is displayed ......................... .20-575
c-55
[E03511 Abnormality
C-56
IE03521 Abnormality
c-53
c-57
in standard value of blade tilt angle sensor is displayed.. ............... .20-576 in compensated value of blade tilt angle sensor is displayed.. ....... .20-576
[E03601 Short circuit in work equipment oil pressure sensor (140 pump) system is displayed ..................................................................................................................................
20-577
C-58
[E03611 Disconnection in work equipment oil pressure sensor (140 pump) system is displayed ..................................................................................................................................
20-578
c-59
[E03621 Short circuit in work equipment oil pressure sensor (100 pump) system
C-60
is displayed .................................................................................................................................. [E03631 Disconnection in work equipment oil pressure sensor (100 pump) system is displayed ..................................................................................................................................
C-61 C-62 C-63 C-64 C-65 C-66 C-67 C-68 C-69 c-70 c-71 C-72
20-579 20-580
[E05011 Short circuit in acceleration sensor system is displayed ........................................ .20-581 [E05021 Disconnection in acceleration sensor system is displayed ..................................... .20-582 [E06011 Short circuit in buzzer cancel switch system is displayed ...................................... .20-583 [E06101 Short circuit in backup alarm relay system is displayed ........................................ .20-584 [E06111 Disconnection in backup alarm relay system is displayed ..................................... .20-585 [E06321 Short circuit in rockbed selection mode switch system is displayed.. .................. .20-586 [E06331 Disconnection in rockbed selection mode switch system is displayed.. ............... -20-587 [E09301 Disconnection in engine speed sensor system is displayed .................................. .20-588 Lock-up device does not operate when lock-up mode switch is turned ON.. .................... .20-589 Engine output does not change when economy mode switch is turned ON .................... .20-590 Reverse travel speed does not change when reverse slow mode switch is turned ON ...20-591 Shoe slip control device does not operate when shoe slip control switch is turned ON or shoe slip level does not change when rockbed selection mode switch is changed .......................................................................................................................
c-73 c-74 c-75
Any solenoid related to machine controller does not operate.. ........................................... Backup alarm does not sound or keeps sounding ................................................................ Ripper pin puller cylinder does not operate ...........................................................................
20-502 0
20-592 .20-593 .20-594 .20-596
D475A-3
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code
Service code
Abnormal
Nature
system
of abnormality
?i?When -
CALL 03
EOlll
Abnormality in machine controller power source voltage
~0150
Abnormality in machine controller EZPROM
~0151
Abnormality in specificanon selection
the controller power source voltage is less than 17 V 1. Defective contact or disconnection in wiring harness between controller Ml1 (7)(13), M21 (12) -fuse 12 2. Defective contact or disconnection in wiring harness between controller Ml1 (6)(12), M21 (11) -chassis ground 3. Drop in battery voltage or defective fuse 12 4. Defective controller 3ibWhen an abnormality is detected in the controller non- volatile ROM
u
When an abnormality is detected in the specification selection data in the program
Disconnection in torque converter speed sensor system
% When input voltage from torque converter speed sensor is more than 3.0 V 1. Defective torque converter speed sensor or defective installation 2. Defective contact or disconnection in wiring harness between controller M51 (2) and speed sensor TCl (1) 3. Defective contact or disconnection in wiring harness between controller M51 (11) and speed sensor TCl (2) 4. Defective controller
Short circuit in torque converter speed sensor system
I 1. 2. 3.
~0203
Disconnection in transmission FORWARD & REVERSE oil pressure switch system
% When the engine speed is more than 300 rpm and the FORWARD clutch oil pressure switch and REVERSE clutch oil pressure switch are both OFF at the same time 1. Defective FORWARD clutch oil pressure switch or REVERSE clutch oil pressure switch 2. Defective contact or disconnection in wiring harness between controller M31 (8) and oil pressure switch TMF (1) 3. Defective contact or disconnection in wiring harness between oil pressure switch TMF (2) and chassis ground 4. Defective contact or disconnection in wiring harness between controller M31 (18) and oil pressure switch TMR (1) 5. Defective contact or disconnection in wiring harness between oil pressure switch TMR (2) and chassis ground 6. Defective controller
E0204
Short circuit in transmission FORWARD clutch oil pressure switch system
+X When the engine speed is less than 300 rpm and the FORWARD clutch oil pressure switch is ON 1. Defective FORWARD clutch oil pressure switch 2. Short circuit with ground in wiring harness between controller M31 (8) and oil pressure switch TMF (1) 3. Defective controller
E0205
Short circuit in transmission REVERSE clutch oil pressure switch system
E0201
E0202
When torque converter speed is more than 500 rpm higher than engine speed Defective torque converter speed sensor Short circuit with ground in wiring harness between controller M51 (2) and speed sensor TCl (1) Defective controller
EOI f
When the engine speed is less than 300 rpm and the REVERSE clutch oil pressure switch is ON 1. Defective REVERSE clutch oil pressure switch 2. Short circuit with ground in wiring harness between controller M31 (18) and oil pressure switch TMR (1) 3. Defective controller
I
20-504 0
E0206
Disconnection in transmission 1st & 2nd & 3rd oil pressure switch system
E0207
Short circuit in transmission 1st clutch oil pressure switch system
When the engine speed is more than 300 rpm and the 1st clutch oil pressure switch, 2nd clutch oil pressure switch, and 3rd clutch oil pressure switch are all OFF at the same time 1. Defective 1st clutch oil pressure switch, 2nd clutch oil pressure switch, or 3rd clutch oil pressure switch 2. Defective contact or disconnection in wiring harness between controller M31 (9) and oil pressure switch TM1 (1) 3. Defective contact or disconnection in wiring harness between oil pressure switch TM1 (2) and chassis ground 4. Defective contact or disconnection in wiring harness between controller M31 (19) and oil pressure switch TM2 (1) 5. Defective contact or disconnection in wiring harness between oil pressure switch TM2 (2) and chassis ground 6. Defective contact or disconnection in wiring harness between controller M31 (10) and oil pressure switch TM3 (1) 7. Defective contact or disconnection in wiring harness between oil pressure switch TM3 (2) and chassis ground 8. Defective controller % When the engine speed is less than 300 rpm and the 1st clutch oil pressure switch is ON 1. Defective 1st clutch oil pressure switch 2. Short circuit with ground in wiring harness between controller M31 (9) and oil pressure switch TM1 (1) 3. Defective controller
D475A-3
ACTION TROUBLESHOOTING
TAKEN
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Condition when normal (voltage, current, resistance)
Action by controller when abnormality is detected
Voltage between Ml1 (7h13) and (6)(12): 20 - 30 v * Voltage between M21 (12) and (11): 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
-
Problem that appears on machine when there is abnormality 1. In some cases, system does not work normally and it is impossible for solenoid and relay to drive
1. Lights up caution lamp, sounds alarm buzzer 1. Sets by default to straight tiltdozer specification 2. Lights up caution lamp, sounds alarm buzzer
1. Superdozer functions are not actuated 2. Shoe slip control functions are not actuated 3. Dual tiltdozer functions are not actuated
- Sensor resistance: 500 - 1000 R - Voltage between M51 (2) and (10): 0.5 - 3.0 V (engine started, AC range)
1. Travel speed cannot be detected, so lockup is not actuated
- Sensor resistance: 500 - 1000 R - Voltage between M51 (2) and (10): 0.5 - 3.0 V (engine started, AC range)
1. Travel speed cannot be detected, so lockup is not actuated
. Resistance of switch (engine running) Full monolever at Neutral: Min. 1 MC Full monolever at FORWARD: Max. 1 R (TMF) Full monolever at REVERSE: Max. 1 Q (TMR) * Voltage between M31 (8) and chassis (engine running) Full monolever at Neutral: 20 - 30 V Full monolever at FORWARD: Max. 1 V * Voltage between M31 (18) and chassis (engine running) Full monolever at Neutral: 20 - 30 V Full monolever at REVERSE: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
* Resistance of switch (engine running) Full monolever at Neutral: Min. 1 MD Full monolever at FORWARD: Max. 1 R * Voltage between M31 (8) and chassis (engine running) Full monolever at Neutral: 20 - 30 V Full monolever at FORWARD: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
* Resistance of switch (engine running) Full monolever at Neutral: Min. 1 MR Full monolever at REVERSE: Max. 1 R * Voltage between M31 (18) and chassis (engine running) Full monolever at Neutral: 20 - 30 V Full monolever at REVERSE: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
. Resistance of switch (engine running) Full monolever at other speed range: Min. 1 MD Full monolever at applicable speed range: Max. 1 C * Voltage between M31 (9) and chassis (engine running) Full monolever at 2nd or 3rd: 20 - 30 V Full monolever at 1st: Max. 1 V * Voltage between M31 (19) and chassis (engine running) Full monolever at 1st or 3rd: 20 - 30 V Full monolever at 2nd: Max. 1 V - Voltage between M31 (10) and chassis (engine running) Full monolever at 1st or 2nd: 20 - 30 V Full monolever at 3rd: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
* Resistance of switch (engine running) Full monolever at 2nd or 3rd: Min. 1 MR Full monolever at 1st: Max. 1 R * Voltage between M31 (10) and chassis (engine running) Full monolever at 2nd or 3rd: 20 - 30 V Full monolever at 1st: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
D475A-3
20-505 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
Service code
Abnormal
Nature
system
of abnormality
H E0208
Short circuit in transmission 2nd clutch oil pressure switch system
EOI
-
x Short circuit in transmission 3rd clutch oil pressure switch system
E0210
Disconnection in transmission modulating oil pressure sensor system
% When modulating oil pressure sensor remains OFF after shifting gear 1. Defective modulating oil pressure sensor 2. Defective contact or disconnection in wiring harness between M31 (20) and oil pressure sensor TMM (I) 3. Defective contact or disconnection in wiring harness between oil pressure sensor TMM (2) and chassis ground 4. Defective controller
E0212
Short circuit in torque converter lock-up solenoid system
% When output voltage to lock-up solenoid has become high 1. Defective lock-up solenoid 2. Short circuit with ground in wiring harness between controller Ml1 (1) and solenoid LU2 (1) 3. Defective controller
% When E0213
Disconnection in torque converter lock-up solenoid system
output voltage to lock-up solenoid has become low 1. Defective lock-up solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (1) and solenoid LU2 (1) 3. Defective contact or disconnection in wiring harness between solenoid LU2 (2) and chassis ground 4. Defective controller
E0220
Short circuit in transmission modulating oil pressure sensor system
% When the engine speed is less than 300 rpm and the modulating oil pressure sensor is ON 1. Defective modulating oil pressure switch 2. Short circuit with ground in wiring harness between controller M31 (20) and oil pressure sensor TMM (1) 3. Defective controller
E0301
Short circuit in left blade tilt angle sensor system
E0302
Disconnection in left blade tilt angle sensor system
E02
EO303
EO304
20-506 0
When the engine speed is less than 300 rpm and the 3rd clutch oil pressure switch is ON 1. Defective 3rd clutch oil pressure switch 2. Short circuit with ground in wiring harness between controller M31 (10) and oil pressure switch TM3 (1) 3. Defective controller
E0209
CALL 03
-
When the engine speed is less than 300 rpm and the 2nd clutch oil pressure switch is ON 1. Defective 2nd clutch oil pressure switch 2. Short circuit with ground in wiring harness between controller M31 (19) and oil pressure switch TM2 (1) 3. Defective controller
Short circuit in right ;;bt;ilt angle sensor
Disconnection in right Qz;;ilt angle sensor
% When input voltage from left blade tilt angle sensor is more than 4.688 V 1. Defective left blade tilt angle sensor 2. Short circuit with power source in wiring harness between controller M31 (11) and tilt angle sensor CSL (2) 3. Defective contact or disconnection in wiring harness between controller M31 (16) and tilt angle sensor CSL (3) 4. Defective controller % When input voltage from left blade tilt angle sensor is less than 0.293 V 1. Defective left blade tilt angle sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (7) and tilt angle sensor CSL (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (11) and tilt angle sensor CSL (2) 4. Defective controller % When input voltage from right blade tilt angle sensor is more than 4.688 V 1. Defective right blade tilt angle sensor 2. Short circuit with power source in wiring harness between controller M31 (12) and tilt angle sensor CSR 12) 3. Defective contact or disconnection in wiring harness between controller M31 (16) and tilt angle sensor CSR (3) 4. Defective controller +%When input voltage from right blade tilt angle sensor is less than 0.293 V 1. Defective right blade tilt angle sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (7) and tilt angle sensor CSR (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (12) and tilt angle sensor CSR (2) 4. Defective controller
D475A-3
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
-
Resistance of switch (engine running) Full monolever at 1st or 3rd: Min. 1 MR Full monolever at 2nd: Max. 1 R - Voltage between M31 (19) and chassis (engine running) Full monolever at 1st or 3rd: 20 - 30 V Full monolever at 2nd: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
. Resistance of switch (engine running) Full monolever at 1st or 2nd: Min. 1 MR Full monolever at 3rd: Max. 1 R . Voltage between M31 (10) and chassis (engine running) Full monolever at 1st or 2nd: 20 - 30 V Full monolever at 3rd: Max. 1 V
1. Stops speed range display function
1. Speed range display is not given.
* Resistance of sensor Engine stopped: Min. 1 MR Engine running: Max. 1 R . Voltage between M31 (20) and chassis Engine stopped: 20 - 30 V Engine running: Max. 1 V
1. Estimates and actuates speed range from other normal oil pressure switch signals
1. Takes longer for lock-up to be actuate< after shifting gear
. Resistance of solenoid: 20 - 66 R - Voltage between Ml1 (1) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to lock-up solenoid
1. Lock-up is not actuated
* Resistance of solenoid: 20 - 60 R * Voltage between Ml1 (1) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Lock-up is not actuated
* Resistance of sensor Engine stopped: Min. 1 MR Engine running: Max. 1 R - Voltage between M31 (20) and chassis Engine stopped: 20 - 30 V Engine running: Max. 1 V
1. Estimates and actuates speed range from other normal oil pressure switch signals
1. Takes longer for lock-up to be actuate< after shifting gear
* Voltage between M31 (11) and (16) When blade is raised (pitch dump): 3.19 V When blade is lowered to ground (pitch back): 1.80 V
1. Lights up caution lamp, sounds alarm buzzer
1. When blade is tilted fully, there is dan ger that blade may contact other par and break
* Voltage between M31 (11) and 116) When blade is raised (pitch dump): 3.19 V When blade is lowered to ground (pitch back): 1.80 V
1. Lights up caution lamp, sounds alarm buzzer
1. When blade is tilted fully, there is dan ger that blade may contact other par and break
. Voltage between M31 (111 and (16) When blade is raised (pitch dump): 1.80 V When blade is lowered to ground (pitch dump): 3.20 V
1. Lights up caution lamp, sounds alarm buzzer
1. When blade is tilted fully, there is dan ger that blade may contact other par and break
- Voltage between M31 (11) and (16) When blade is raised (pitch dump): 1.80 V When blade is lowered to ground (pitch back): 3.20 V
1. Lights up caution lamp, sounds alarm buzzer
1. When blade is tilted fully, there is dan ger that blade may contact other pan and break
D475A-3
20-507 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User :ode
Service code
Abnormal
Nature
system
of abnormality
-x-When E0305 Short circuit in blade RAISE oil pressure switch system
blade RAISE oil pressure switch is continuously ON 1. Defective blade RAISE oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (11) and oil pressure switch BLU (I) 3. Defective controller
Short circuit in blade right tilt oil pressure switch system
I When blade right tilt oil pressure switch is continuously ON 1. Defective blade right tilt oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (8) and oil pressure switch TRS (1) 3. Defective controller
Short circuit in blade left tilt oil pressure switch system
% When blade left tilt oil pressure switch is continuously ON 1. Defective blade left tilt oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (15) and oil pressure switch TLS (1) 3. Defective controller
E0308
Short circuit in ripper RAISE oil pressure switch system
% When ripper RAISE oil pressure switch is continuously ON 1. Defective ripper RAISE oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (2) and oil pressure switch RPU (1) 3. Defective controller
E0309
Short circuit in ripper LOWER oil pressure switch system
% When ripper LOWER oil pressure switch is continuously ON 1. Defective ripper LOWER oil pressure switch 2. Shon circuit with ground in wiring harness between controller M32 (10) and oil pressure switch RPD (1) 3. Defective controller
EO310
Short circuit in ripper TILT IN oil pressure switch system
I When ripper TILT IN oil pressure switch is continuously ON 1. Defective ripper TILT IN oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (3) and oil pressure switch RTI (1) 3. Defective controller
E0311
Short circuit in pitch dump knob switch system
% 1. 2. 3.
When pitch dump oil pressure switch is continuously ON Defective pitch dump oil pressure switch Short circuit with ground in wiring harness between controller M51 (12) and switch PO1 Defective controller
El)312
Short circuit in pitch back knob switch system
I 1. 2. 3.
When pitch back switch is continuously ON Defective pitch back switch Short circuit with ground in wiring harness between controller M51 (11) and switch PO2 Defective controller
E0313
Short circuit in pitch back solenoid system
% When output voltage to pitch back solenoid has become high 1. Defective pitch back solenoid 2. Short circuit with ground in wiring harness between controller Ml1 (2) and solenoid PPB (1) 3. Defective controller
E0314
Disconnection in pitch back solenoid system
% When output voltage to pitch back solenoid has become low 1. Defective pitch back solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (2) and solenoid PPB (1) 3. Defective contact or disconnection in wiring harness between solenoid PPB (2) and chassis ground 4. Defective controller
E0315
Short circuit in pitch dump solenoid system
I When output voltage to pitch dump solenoid has become high 1. Defective pitch dump solenoid 2. Short circuit with ground in wiring harness between controller Ml1 (8) and solenoid PPD (1) 3. Defective controller
E0305
E0306
E0307
-
CALL 03
20-508 0
D475A-3
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Condition when normal (voltage, current, resistance)
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
Resistance of switch (engine running) Blade lever at HOLD: Min. 1 MR Blade lever operated to RAISE: Max. 1 f.2 . Voltage between M32 (11) and chassis (engine running) Blade lever at HOLD: 20 - 30 V Blade lever operated to RAISE: Max. 1 V
1. Stops automatic resetting function of blade when lift is operated
1. Automatic resetting function of blade is not actuated (superdozer specification) 2. Unload control is not actuated, so blade RAISE speed is slow
-
* Resistance of switch (engine running) Blade lever at HOLD: Min. 1 Mf2 Blade lever operated to right tilt: Max. 1 $2 - Voltage between M32 (8) and chassis (engine running) Blade lever at HOLD: 20 - 30 V Blade lever operated to right tilt: Max. 1 V
1. Dual tilt may be operated even when pitch button is ON and blade lever is not operated 2. Dual tilt is not actuated
- Resistance of switch (engine running) Blade lever at HOLD: Min. 1 MD Blade lever operated to left tilt: Max. 1 D . Voltage between M32 (15) and chassis (engine running) Blade lever at HOLD: 20 - 30 V Blade lever operated to left tilt: Max. 1 V
1. Dual tilt may be operated even when pitch button is ON and blade lever is not operated 2. Dual tilt is not actuated
. Resistance of switch (engine running) Ripper lever at HOLD: Min. 1 MD Ripper lever operated to UP: Max. 1 R * Voltage between M32 (2) and chassis (engine running) Ripper lever at HOLD: 20 - 30 V Ripper lever operated to UP: Max. 1 V
1. Part of shoe slip control function is not actuated 2. Engine speed does not rise when ripper UP is operated when traveling in REVERSE 3. Unload controller is not actuated, so ripper UP speed is slow
. Resistance of switch (engine running) Ripper lever at HOLD: Min. 1 MD Ripper lever operated to DOWN: Max. 1 D . Voltage between M32 (10) and chassis (engine running) Ripper lever at HOLD: 20 - 30 V Ripper lever operated to DOWN: Max. 1 V
1. Part of shoe slip control function is not actuated 2. Unload controller is not actuated, so ripper DOWN speed is slow
- Resistance of switch (engine running) Ripper lever at HOLD: Min. 1 MD Ripper lever operated to TlLT IN: Max. 1 D * Voltage between M32 (3) and chassis (engine running) Ripper lever at HOLD: 20 - 30 V Ripper lever operated to TILT IN: Max. 1 V
1. Part of shoe slip control function is not actuated 2. Unload controller is not actuated, so ripper TILT IN speed is slow
. Resistance of switch (between COM and NO) Switch released: Min. 1 MD Switch pressed: Max. 1 D * Voltage between M51 (12) and chassis Switch released: 20 - 30 V Switch pressed: Max. 1 V
1. Switch ON flag is cleared
1. Cannot operate pitch dump (superdozer specification) 2. Cannot operate pitch dump or pitch back (dual tilt specification)
* Resistance of switch (between COM and NO) Switch released: Min. 1 MD Switch pressed: Max. 1 R . Voltage between M51 (11) and chassis Switch released: 20 - 30 V Switch pressed: Max. 1 V
1. Switch ON flag is cleared
1. Cannot operate pitch back (superdozer specification) 2. Cannot operate dual tilt (dual tilt specification)
-
Resistance of solenoid: 20 - 60 D * Voltage between Ml1 (2) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to pitch back solenoid
1. Pitch back is not actuated
* Resistance of solenoid: 20 - 60 D * Voltage between Ml1 (2) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Pitch back is not actuated
* Resistance of solenoid: 20 - 60 D . Voltage between Ml1 (8) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to pitch dump solenoid
1. Pitch dump is not actuated
D475A-3
20-509 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
Service code
Abnormal
Nature
system
of abnormality
% When CALL 03
E02
E0316
E0317
Short circuit in left tilt limit solenoid system
% 1. 2. 3.
E0318
Disconnection in left tilt limit solenoid system
% When output voltage to left tilt limit solenoid has become low 1. Defective left tilt solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (3) and solenoid TLL (1) 3. Defectivecontact or disconnectionin wiring harness between solenoidTLL (2) and chassisground 4. Defective controller
E0319
Short circuit in right tilt limit solenoid system
_
When output voltage to left tilt limit solenoid has become high Defective left tilt limit solenoid Short circuit with ground in wiring harness between controller Ml1 (3) and solenoid TLL (1) Defective controller
%
When output voltage to right tilt limit solenoid has become high 1. Defective right tilt limit solenoid 2. Short circuit with ground in wiring harness between controller Ml1 (10) and solenoid TLR (1) 3. Defective controller
E0320
Disconnection in right tilt limit solenoid system
% When output voltage to right tilt limit solenoid has become low 1. Defective right tilt solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (10) and solenoid TLR (1) 3. Defectivecontact or disconnectionin wiring harnessbetween solenoidTLR (2) and chassisground 4. Defective controller
E0321
Short circuit in dual selection solenoid system
% When output voltage to dual selection solenoid has become high 1. Defective dual selection solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller M21 (9) and solenoid DST (1) 3. Short circuitwith power source in wiring harnessbetween controllerM21 (19) and solenoidDST (2) 4. Defective controller
E0322
Disconnection in dual selection solenoid system
E0323
Short circuit in pitch selection solenoid system
E0324
Disconnection in pitch selection solenoid system
E0325
Short circuit in pitch back assist solenoid system
R 1. 2. 3.
E0326
Disconnection in pitch back assist solenoid system
% When output voltage to pitch back assist solenoid has become low 1. Defective pitch back assist solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (11) and solenoid PBA (1) 3. Defective contact or disconnection in wiring harness between solenoid PEA (2) and chassis 4. Defective controller
E0327
Short circuit in pitch dump assist solenoid system
% 1. 2. 3.
E0328
Disconnection in pitch d ump assist solenoid system
% When output voltage to pitch dump assist solenoid has become low 1. Defective pitch dump assist solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (5) and solenoid PDA (1) 3. Defective contact or disconnection in wiring harness between solenoid PDA (2) and chassis 4. Defective controller
CALL 03
I 1. 2. 3.
When output voltage to dual selection solenoid has become low Defective dual selection solenoid Defectivecontactor disconnectionin wiring harness betweencontrollerM21 (9) and solenoidDST 11) Short circuit with ground, defective contact, or disconnection in wiring harness between between controller M21 (19) and solenoid DST (2) 4. Defective controller
f
EOl
20-510 0
output voltage to pitch dump solenoid has become low 1. Defective pitch dump solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (8) and solenoid PPD (1) 3. Defectivecontact or disconnectionin wiring harnessbetween solenoid PPD(2) and chassisground 4. Defective controller
Disconnection in pitch dump solenoid system
When output voltage to pitch selection solenoid has become high 1. Defective pitch selection solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller M21 (8) and solenoid PST (1) 3. Short circuitwith power source in wiring harnessbetween controllerM21 (18) and solenoidPST (2) 4. Defective controller % 1. 2. 3.
When output voltage to pitch selection solenoid has become low Defective pitch selection solenoid Defectivecontactor disconnectionin wiring harnessbetween controllerM21 (8) and solenoidPST (1) Short circuit with ground, defective contact, or disconnection in wiring harness between controller M21 (18) and solenoid PST (2) 4. Defective controller When output voltage to pitch back assist solenoid has become high Defective pitch back assist solenoid Short circuit with ground in wiring harness between controller Ml1 (11) and solenoid PSA (1) Defective controller
When output voltage to pitch dump assist solenoid has become high Defective pitch dump assist solenoid Short circuit with ground in wiring harness between controller Ml1 (5) and solenoid PDA (1) Defective controller
D475A-3
ACTION TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
TAKEN
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
-
Resistance of solenoid: 20 - 60 z1 - Voltage between Ml1 (8) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
Problem that appears on machine when there is abnormality
1. Lights up caution lamp, sounds alarm buzzer
1. Pitch dump is not actuated
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to left tilt limit solenoid
1. Left tilt limit is not actuated
* Resistance of solenoid: 20 - 60 R * Voltage between Ml1 (3) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Left tilt limit is not actuated
- Resistance of solenoid: 20 - 60 a * Voltage between Ml1 (IO) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. lbi;z$j;rup caution lamp, sounds alarm
1. Right tilt limit is not actuated
- Resistance of solenoid: 20 - 60 C2 - Voltage between Ml1 (3) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
’
2. Stops output to right tilt limit solenoid
* Resistance of switch : 20 - 60 0 * Voltage between Ml1 (10) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Right tilt limit is not actuated
* Resistance of solenoid: 10 - 20 Q * Voltage between M21 (9) and (19) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to dual selection solenoid
1. Tilts when pitch is operated 2. Pitch when dual is operated
* Resistance of solenoid: 10 - 20 Q * Voltage between M21 (9) and (19) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Tilts when pitch is operated 2. Pitch when dual is operated
. Resistance of solenoid: 10 - 20 C2 * Voltage between M21 (8) and (18) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to pitch selection solenoid
1. Pitch is not actuated
* Resistance of solenoid: 10 - 20 Q * Voltage between M21 (8) and (18) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
1. Pitch is not actuated
* Resistance of solenoid: 10 - 20 Q . Voltage between Ml1 (11) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Stops output to pitch back assist solenoid
1. Pitch back becomes slower
1. Pitch back becomes slower
* Resistance of solenoid: 10 - 20 R . Voltage between Ml1 (11) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
* Resistance of solenoid: 10 - 20 C2 * Voltage between Ml1 (5) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V * Resistance of solenoid: 10 - 20 Q . Voltage between Ml1 (5) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
D475A-3
1. Stops output to pitch dump assist solenoid
l. Pitch dump becomes slower
1. Pitch dump becomes slower
20-511 0
TROUBLESHOOTING
User code
Service code
Abnormal
Nature
system
of abnormality
% When -
Short circuit in blade
E0330
E0332
E0333
;.rhR
oil Pressure
Short circuit in unload valve solenoid system
f When output voltage to unload valve solenoid has become high 1. Defective unload valve solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller M21 (4) and solenoid UNL (1) 3. Short circuit with power source in wiring harness between controller M21 (15) and solenoid UNL (2) 4. Defective controller
Disconnection in unload valve solenoid system
% When output voltage to unload valve solenoid has become low 1. Defective unload valve solenoid 2. Defective contact or disconnection in wiring harness between controller M21 (4) and solenoid UNL (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M21 (15) and solenoid UNL (2) 4. Defective controller
EOl
-
% When output voltage to demand valve solenoid has become high
1. Defective demand valve solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller M21 (2) and solenoid PVC (1) 3. Short circuit with power source in wiring harness between controller M21 (13) and solenoid PVC (2) 4. Defective controller
E0334
Short circuit in demand valve solenoid system
E0335
Disconnection in &z;;d valve solenoid
E0336
Short circuit in ripper TILT BACK oil pressure switch system
% When ripper TlLT BACK oil pressure switch is continuously ON 1. Defective ripper TILT BACK oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (6) and oil pressure switch RTB (1) 3. Defective controller
E0337
Short circuit in pitch independent solenoid system
I 1. 2. 3.
E0338
Disconnection in pitch independent solenoid system
% When output voltage to pitch independent solenoid has become low 1. Defective pitch independent solenoid 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (11) and solenoid PIT (1) 3. Defective contact or disconnection in wiring harness between solenoid PIT (2) and chassis 4. Defective controller
% When output voltage to demand valve solenoid has become low 1. Defective demand valve solenoid 2. Defective contact or disconnection in wiring harness between controller M21 (2) and solenoid PVC (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M21 (13) and solenoid PVC (2) 4. Defective controller
When output voltage to pitch independent solenoid has become high Defective pitch independent solenoid Short circuit with ground in wiring harness between controller Ml 1 (11) and solenoid PIT (1) Defective controller
% When
CALL 03
Short circuit in left bottom drain solenoid system
output voltage to left bottom drain solenoid has become high 1. Defective left bottom drain solenoid 2. Short circuit with ground or short circuit with power source in wiring harness between controller M21 (9) and solenoid LBD (1) 3. Short circuit with power source in wiring harness between controller M21 (19) and solenoid LBD (2) 4. Defective controller
E0340
Disconnection in left bottom drain solenoid system
H When output voltage to left bottom drain solenoid has become low 1. Defective left bottom drain solenoid 2. Defective contact or disconnection in wiring harness between controller M21 (9) and solenoid LBD (1) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M21 (19) and solenoid LBD (2) 4. Defective controller
E0351
Abnormality in standard value of blade tilt angle potentiometer
ilc When tilt limit adjusted value is outside range 1. Defective adjustment of tilt limit 2. Defective controller
E0352
Abnormality in compensated value of blade tilt angle potentiometer
I When tilt limit adjusted value is outside range 1. Defective adjustment of tilt limit 2. Defective controller
E0339
EOI
20-512 0
blade LOWER oil pressure switch is continuously ON 1. Defective blade LOWER oil pressure switch 2. Short circuit with ground in wiring harness between controller M32 (6) and oil pressure switch BLD (1) 3. Defective controller
D475A-3
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
Action by controller when abnormality is detected
Problem that appears on machim when there is abnormality
-
Resistance of switch (engine running) Blade lever at HOLD: Min. 1 MD Blade lever operated to LOWER: Max. 1 0 - Voltage between M32 (6) and chassis (engine running) Blade lever at HOLD: 20 - 30 V Blade lever operated to LOWER: Max. 1 V
1. Stops automatic resetting function of blade when lift is operated
1. Automatic resetting function of blade i! not actuated (superdozer specification) 2. Unload controller is not actuated, SC blade LOWER speed is slow
- Resistance of solenoid: 10 - 20 42 * Voltage between M21 (4) and (15) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Stops pump assist function
1. Pump assist function does not work, SC work equipment speed becomes slower
* Resistance of solenoid: 10 - 20 D * Voltage between M21 (4) and (15) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
* Resistance of solenoid: 10 - 20 42 - Voltage between M21 (2) and (13) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Pump assist function does not work, SC work equipment speed becomes slower
1. Stops output to demand valve solenoid
1. Pitch speed becomes slower
- Resistance of solenoid: 10 - 20 Q . Voltage between M21 (2) and (13) When solenoid is OFF: Max, 1 V When solenoid is ON: 20 - 30 V
1. Pitch speed becomes slower
* Resistance of switch (engine running1 Ripper lever at HOLD: Min. 1 MD Ripper lever operated to TILT BACK: Max. 1 Q - Voltage between M32 (16) and chassis (engine running) Ripper lever at HOLD: 20 - 30 V Ripper lever operated to TILT BACK: Max. 1 V
1. Engine speed varies greatly during doz ing operations when SSC switch is ON 2. Shoes slip frequently during ripping op erations 3. Unload control is not actuated
. Resistance of solenoid: 20 - 60 D * Voltage between Ml1 (I I) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to pitch independent solenoid
* Resistance of solenoid: 20 - 60 Q * Voltage between Ml1 (II) and chassis When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
. Resistance of solenoid: 10 - 20 Q * Voltage between M21 (9) and (19) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer 2. Stops output to left bottom drain solenoid
* Resistance of solenoid: 10 - 20 Q * Voltage between M21 (9) and (19) When solenoid is OFF: Max. 1 V When solenoid is ON: 20 - 30 V
1. Lights up caution lamp, sounds alarm buzzer
D475A-3
20-513 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
Service code
Abnormal
system
of abnormality
X4When
input voltage from work equipment oil pressure sensor is more than 4.688 V 1. Defective work equipment oil pressure sensor 2. Defective contact or disconnection in wiring harness between controller M31 (16) and oil pressure sensor HP1 (I) 3. Short circuit with power source in wiring harness between controller M31 (13) and oil pressure sensor HP1 (3)
E0360
Short circuit in work equipment oil pressure sensor (140 pump) system
E0361
Disconnection in work equipment oil pressure sensor (140 pump) system
% When input voltage from work equipment oil pressure sensor is less than 0.3 V 1. Defective work equipment oil pressure sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (6) and oil pressure sensor HP1 (2) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (13) and oil pressure sensor HP1 (3)
Short circuit in work equipment oil pressure sensor (I 00 pump) system
X+ When input voltage from work equipment oil pressure sensor is more than 4.688 V 1. Defective work equipment oil pressure sensor 2. Defective contact or disconnection in wiring harness between controller M31 (16) and oil pressure sensor HP2 (1) 3. Short circuit with power source in wiring harness between controller M31 (14) and oil pressure sensor HP2 (3)
E0363
Disconnection in work equipment oil pressure sensor (100 pump1 system
% When input voltage from work equipment oil pressure sensor is less than 0.3 V 1. Defective work equipment oil pressure sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (6) and oil pressure sensor HP2 (2) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (14) and oil pressure sensor HP2 (3)
E501
Short circuit in acceleration sensor system
% When acceleration sensor power source voltage is less than 0.3 V 1. Defective acceleration sensor 2. Short circuit with power source in wiring harness between controller M31 (2) and acceleration sensor SS3 (2) 3. Defective contact or disconnection in wiring harness between controller M31 (17) and acceleration sensor SS3 (3)
Disconnection in acceleration sensor system
% When input voltage from acceleration sensor is more than 4.7 V 1. Defective acceleration sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M32 (9) and acceleration sensor SS3 (I) 3. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (2) and acceleration sensor SS3 (2)
EOI
~0362
-
EOI E0502
-
Nature
E0601
Short circuit in buzzer cancel switch system
E0610
Short circuit in backup alarm relay system
E0611
Disconnection in backup alarm relay system
E632
Short circuit in bedrock selection mode switch system
EO633
Disconnection in bedrock selection mode switch system
EOl
% 1. 2. 3.
When buzzer cancel switch is continuously ON Defective buzzer cancel switch Short circuit with ground in wiring harness between controller M32 (7) and switch 212 (3) Defective controller
% 1. 2. 3.
When output voltage to backup alarm relay has become low Defective backup alarm relay Short circuit with ground in wiring harness between controller Ml1 (9) and relay 885 (I) Defective controller
% When
output voltage to backup alarm relay has become high 1. Defective backup alarm relay 2. Short circuit with power source, defective contact, or disconnection in wiring harness between controller Ml1 (9) and relay 885 (I) 3. Defective contact or disconnection in wiring harness between relay BB5 (2) and chassis
4. Defective controller
-
E0930
20-514 0
Disconnection in engine speed sensor system
% When
input voltage from signal of bedrock selection mode switch is more than 4.688 V 1. Defective monitor panel 2. Short circuit with power source in wiring harness between controller M31 (3) and monitor panel SO1 (9) 3. Defective controller % When input voltage from signal of bedrock selection mode switch is less than 0.293 V 1. Defective monitor panel 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M31 (3) and monitor panel SO1 (9) 3. Defective controller f When input voltage from engine speed sensor is more than 3.0 V 1. Defective left engine speed sensor 2. Short circuit with ground, defective contact, or disconnection in wiring harness between controller M41 (I) and speed sensor El2 (1) 2. Defective contact or disconnection in wiring harness between controller M41 (91 and speed sensor El2 (2) 4. Defective controller
D475A-3
ACTION
TAKEN
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
- Voltage - Voltage
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
between M31 (6) and (16): 20 - 30 V between M31 (13) and (16): 0.3 - 4.666 v
1. Stops unload function at relief 2. Stops auto pitch back function
1. Auto pitch back function is not actuated
- Voltage between M31 (6) and (16): 20 - 30 V * Voltage between M31 (13) and (16): 0.3 - 4.666 v
I. Stops unload function at relief 2. Stops auto pitch back function
1. Auto pitch back function is not actuated
* Voltage between M31 (6) and (16): 20 - 30 V . Voltage between M31 (14) and (16): 0.3 - 4.666 v
I. Stops unload function at relief 2. Stops auto pitch back function
1. Auto pitch back function is not actuated
- Voltage between M31 (6) and (16): 20 - 30 V . Voltage between M31 (14) and (16): 0.3 - 4.688 v
1. Stops unload function at relief 2. Stops auto pitch back function
1. Auto pitch back function is not actuated
- Voltage between M32 (9) - M31 (17):
1. Shoe slip control is not carried out
1. Part of shoe slip control function is not actuated
1. Shoe slip control is not carried out
1. Part of shoe slip control function is not actuated
7.0 - 9.0 v
* Voltage between M31 (I) - 17: 0.75 - 4.25 V
1. Buzzer cannot be turned OFB.
* Resistance of switch When switch is OFF: Min. 1 MR When switch is ON: Max. 1 a * Voltage between M32 (7) and chassis When switch is OFF: 20 - 30 V When switch is ON: Max. 1 V
* Resistance of relay: 200 - 900 a * Voltage between El1 (4) and (13)
1. Stops output to relay
1. Backup alarm does not sound
Full monolever at Neutral: Max. 1 V Full monolever at REVERSE: 20 - 30 V
pResistance of relay: 200 - 900 L2 - Voltage between El1 (4) and (13)
1. Backup alarm does not sound
Full monolever at Neutral: Max. 1 V Full monolever at REVERSE: 20 - 30 V
- Voltage
1. Fixes rockbed selection mode to 3
1. Rockbed switched
selection
mode
cannot
be
- Voltage
1. Fixes rockbed selection mode to 3
1. Rockbed switched
selection
mode
cannot
be
* Sensor resistance: 500 - 1,000 Q . Voltage between M41 (I) and (9): 0.5 - 3.0 V (AC range)
1. Stops auto pitch back function
1. Auto pitch back function is not actuated (superdozer specification) 2. Tachometer display is not given.
between M31 (3) and chassis At mode 1: Approx. 4.4 V At mode 2: Approx. 2.5 V At mode 3: Approx. 1.3 V
between M31 (3) and chassis At mode 1: Approx. 4.4 V At mode 2: Approx. 2.5 V At mode 3: Approx. 1.3 V
D475A-3
20-515 0
ELECTRICAL
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM Single-tilt
specification
model
and dual-tilt
CIRCUITAL
DIAGRAM
OF C MODE
SYSTEM
OF C MODE SYSTEM
specification
model
TVD01060
20-516 0
D475A-3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
TVDOIOGI
D475A-3
20-517 0
TROUBLESHOOTING
ELECTRICAL CIRCUITAL DIAGRAM OF C MODE SYSTEM
TV001062
20-518 0
D475A-3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
Super-dozer specification model
--
-..
** 21
TVD01157
D475A-3
20-519 0
TROUBLESHOOTING
ELECTRICAL CIRCUITAL DIAGRAM OF C MODE SYSTEM
(2/3)
TVD01158
20-520 0
D475A-3
TROUBLESHOOTING
D475A-3
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM
20-521 0
C-l
TROUBLESHOOTING
C-l
[EOII I] Abnormality displayed
in machine controller
power source voltage
is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that fuse 12 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES 1
Defective machine controller
I
Replace
Defective contact or disconnection in wiring
Repair or replace
harness between Ml 1 (female) (6) (12) -chassis ground Defective contact or disconnection in wiring
Turn starting switch ON. *20-30V l
C-l Related Main
electrical controller Ml
harness between Ml1 (female) (7) (13) -fuse
NO
Repair or replace 12
circuit diagram
I 1 (13) 421 (14)
611 (14)
Fuse
box
GND5 TXD01092
20-522 0
D475A-3
TROUBLESHOOTING
C-2 [E0150] Abnormality Ir
c-2, c-3
in machine controller
E2ROM is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause
Defective machine controller
I
C-3 [E0151] Abnormality Ir
in specification
Remedy
Replace
selection is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.)
Cause
1 YES Is specification set in controller conformed to machine? - Check with adjustment mode “30” of monitor panel.
D475A-3
Remedy
Defective machine controller
Replace
Setting of wrong specification in controller
Set specification correctlv
_
NO
20-523 Co
c-4
TROUBLESHOOTING
C-4 [EOZOII Disconnection displayed * * *
in torque converter
speed sensor system is
If the starting switch was turned off after the abnormality occurred, start the engine and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
1 Is resistance between M51 (female) (2) and (10) normal? l
3 YES Is resistance
-
Turn starting switch OFF.
: ~~oc~~“,o~ nM5” NO
YES 2 Is resistance between TCI (female) (1) and (2) normal?
Turn starting switch OFF. * Disconnect TCI. ~500-1,000a
l
c-4 Related
Main
I
electrical
-
between M51
(female) (21and TCl (female) (1) normal?
Remedy
Defective machine controller
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between M51 (female) (10) - TCl (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between M51 (female) (2) - TCl (female) (1)
*Turn starting NO switch OFF. Disconnect M51 and TCI. * Max. 1 a l
Defective torque converter speed sensor
NO
Repair or replace
Replace
circuit diagram
Torque speed
controller
I M51 (17)
(16)
TCl
a
@
I
3
@
3
506
(14)
451
converter sensor
(2)
I
TXDOIOQ3
20-524 0
D475A-3
c-5
TROUBLESHOOTING
C-5 [E0202] Short circuit in torque converter displayed Ir
speed sensor system is
If the starting switch was turned off after the abnormality occurred, run the engine for 5 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
* *
Cause
YES
1 Is resistance between M51 (female) (2) and (10) normal?
3
P Turn starting Is resistance switch OFF. between TCl Disconnect M51. ND (female) (1) and * 500 - 1,000 R (2) normal?
l
l
‘Turn starting switch OFF. * Disconnect TCl. ~500-1,000n
YES
Is resistance YES between M51 3 r (female) (2) and TCl (female) (1) normal? P * Turn starting NO switch OFF. * Disconnect M51 and TCI. * Max. 1 R NO
inserted.
Remedy
Defective machine controller
Replace
Defective contact, disconnectionor short circuit with chassis ground in wiring harness between M51 (female) ItO) -TCl (female)(2)
~e~~reor
Defective contact or disconnection in wiring harness between M51 (female) (2) -TCl (female) (1)
Repair or replace
Defective torque converter speed sensor
Replace
I
C-5 Related
Main
electrical
circuit diagram
lorque speed
controller
M51 (i7) Torque speed Torque sDeed I
D475A-3
I
converter (+I converter (-1
506 (14) 2
@
I
451 (16)
converter sensor
TCl (2)
$g
@
3
$)
a
3
TXDOlO93
20-525 0
C-6
TROUBLESHOOTING
C-6 [E0203] Disconnection in transmission FORWARD clutch oil pressure switch system & REVERSE oil pressure switch system is displayed * * Ir
If the starting switch was turned off after the abnormality occurred, run the engine and hold the joystick in the forward and reverse positions for 10 seconds respectively and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
F
Remedy
Cause
I
YES
‘2 Is voltage between Yl IS M31 (18) and chassis ground normal? Start engine. Direction: N * Max. 1 V
l
l
1 Is voltage between
4 YE: Is resistance YES between TMR - (female) (2) and 3 chassis ground normal? Is resistance N( _ * Turn starting _ between TMR switch OFF. NO (male) (1) and (2) * Disconnect TMR. normal? * Max. 1 C2 Disconnect TMR. * Start engine. NO Direction: N * Max. 1 R l
l
Start engine. * Direction: N * Max. 1 V l
1 Is resistance
Start engine. * Direction: N Max. 1 Q l
NO
Defective machine controller
Replace
Defective contact or disconnection in wiring harness between M31 (female) (18) -TMR (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between TMR (female) (2) -chassis ground
Repair or replace
Defective transmission reverse clutch oil pressure switch
Replace
Defective contact or disconnection in wiring harness between M31 (female) (8) -TMF (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between TMF (female) (2) -chassis ground
Repair or replace
Defective transmission forward clutch oil pressure switch
Replace
l
C-6 Related Main
electrical
circuit diagram
controller M31 Transmission FORWARD switch Transmission RFVFRSF switch
Transmission oil Pressure TMR (2)
(;O) 506
I
451
(14)
I
I
I
(16)
\
@
I
REVERSE switch
3
(ij-
-3
599 (16) TMF
(2)
3 +--3 GND2
20-526 0
fi
Transmission oil Pressure
FORWARD switch TXD01094
D475A-3
c-7
TROUBLESHOOTING
C-7 [E0204] Short circuit in transmission switch system is displayed
FORWARD
clutch oil pressure
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 30 seconds and check that the service code displays “E” at the head. (If “P” is
*
* *
displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES
Defective machine controller
1 Is voltage between M31 (8) _ and chassis ground normal? _ * Turn starting switch ON. *20-30V
2
Is resistance between TMF _ NO (male) (I) and (2) normal? *Turn starting switch OFF. * Disconnect TMF. Min 1 MD
Defective contact or disconnection in wiring harness between M31 (female) (8) -TMF (female) (1) - E51 (female) (5)
YES
. NO
inserted.
Replace
Repair or rep’ace
Defective transmission for-ward clutch oil pressure switch
Replace
oil
switch
l
C-7 Related Main
electrical
circuit diagram
controller
Pressure
TXD01095
D475A-3
20-527 0
C-8
TROUBLESHOOTING
C-8 [E0205] Short circuit in transmission switch system is displayed *
Ir *
REVERSE clutch oil pressure
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 30 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Defective machine controller Is voltage between M31 (18) and chassis ground normal? _ Turn starting switch ON. *20-30V l
Defective contact or disconnection in wiring harness between M31 (female) (18) - TMR (female) (I) - E51 (female) (6) Defective transmission reverse clutch oil pressure switch
_ 2
YES
Is resistance between TMR NO (male) (1) and (2) normal? * Turn starting switch OFF. Disconnect TMR. * Min 1 MR
NO
Repair or replace
Replace
l
C-8 Related
electrical
Main
circuit diagram
controller
I M31
(20)
506
(1 6)
451
(16)
TMR
(2)
TXD01096
20-528 0
D475A-3
TROUBLESHOOTING
c-9
C-9 [E0206] Disconnection in transmission 1st clutch oil pressure switch & 2nd oil pressure switch & 3rd oil pressure switch system is displayed Ir
If the starting switch was turned off after the abnormality occurred, run the engine and hold the joystick in the Ist, 2nd, and 3rd positions for IO seconds respectively and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) * Before carrying out troubleshooting, check that all the related connectors are properly inserted. Ilr Always connect any disconnected connectors before going on to the next step.
Cause
3 Is voltage ES between M31 (10) and chassis ground normal? Start engine. * Gear speed: Other than 3rd Max. 1 V l
YES
-
4YEZ
Is resistance between TM3 NO (male) (1) and (2) normal?
l
NO * DisconnectTM3. * sralt engine. * Gear speed: Other than 3rd . Max. 1R 6 YE:
‘ES Iground normal?
Defective machine controller
1
* Start engine. Gear speed: Other than 2nd * Max. 1 V l
b
I
* Start engine. Gear speed: Other than 1st * Max. 1 V l
_
Is r&Stance YES between TM1 - (female) (2) and 7 chassis ground n0rlIlal?
Is resistance _ between TM1 _ NO (male) (1) and (2) normal? * DisconnectTMl. *Stan engine. * Gear speed: Other than 1st * Max. 10 9
A
(female) (2) and
Turn starting switch OFF. * Disconnect TM3. * Max. 1 Q l
D475A-3
- Max.
* Disconnect TMZ. * Start engine. * Gear speed: Other than 2nd * Max. 1Q 8
and chassis ground normal?
YES
Turn starting switch OFF. * Disconnect TMl. * Max. 1 R l
NO
NO
YES
-
NO
1 L2
Remedy
Replace
GotoA
Defective transmission 3rd clutch oil pressure switch Defective contact or disconnection in wiring harness between M31 (female) (19) -TM2 (female) (I) Defective contact or disconnection in wiring harness between TM2 (female) (2) -chassis ground Defective transmission 2nd clutch oil pressure switch Defective contact or disconnection in wiring harness between M31 (female) (9) -TM1 (female) (1) Defective contact or disconnection in wiring harness between TM1 (female) (2) -chassis ground Defective transmission 1st clutch oil pressure switch Defective contact or disconnection in wiring harness between M31 (female) (10) - TM3 (female) (1) Defective contact or disconnection in wiring harness between TM3 (female) (2) -chassis ground
Repair or replace
Repair or replace
Replace
Repair or replace
Repair or replace
Replace
Repair or replace
Repair or replace
20-529 0
c-9
TROUBLESHOOTING
C-9 Related
Main
electrical
circuit diagram
controller
M31 (i0) =36 (14) Transmission Transmission
451
(16)
1st
TM1 (2)
Transmission oil Pressure -
switch
TM2 (2)
Transmission oil Pressure
2nd switch
Transmission oil Pressure
3rd switch
Ii!_!2 13 14 15
3
-3
TM3 (2) 3 4-3
GND2 TX001097
20-530 0
D475A-3
c-10
TROUBLESHOOTING
C-10 [E0207] Short circuit in transmission switch system is displayed
1st oil clutch pressure
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 10 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES
.I Is voltage between M31 (9) and chassis ground normal? * Turn starting switch ON. l20-30V
I
_ 2
YES
Is resistance between TM1 NO (male) (1) and (2) normal? *Turn starting switch OFF. Disconnect TMI. * Min. 1 MQ
NO
Cause
Remedy
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (9) TM1 (female) (1) - E51 (female) (7)
Repair or replace
Defective transmission 1st clutch oil pressure switch
Replace
l
C-IO Related Main
electrical
circuit diagram
controller
TX001098
D475A-3
20-531 0
C-l 1
TROUBLESHOOTING
C-11 [E0208] Short circuit in transmission switch system is displayed * Ir *
2nd clutch oil pressure
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 10 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
Defective machine controller
Replace
YES ~
Short circuit with chassis ground in wiring harness between M31 (female) (19) - TM2 (female) (1) - E51 (female) (6)
Repair or replace
NO
2nd clutch switch
1 Is voltage between M31 (19) and chassis ground normal? * Turn starting switch ON. *20-30V
2 Is resistance between TM2 NO (male) (1) and (2) normal?
* Turn starting switch OFF. * Disconnect TM2.
Remedy
Defective transmission
oil pressure
Replace
* Min. 1 MR
C-l 1 Related
electrical
Main
circuit diagram
controller
M31 (;O, Transmission 2nd switch
Engine
506 (14)
451 (16)
TM2 (2)
3 3
I
Transmission oil Pressure
controller
2nd switch
GtiD2
TXDOlO99
20-532 0
D475A-3
c-12
TROUBLESHOOTING
C-12 [E0209] Short circuit in transmission switch system is displayed * Jr Jr
3rd clutch oil pressure
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 10 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I
2
YES
_
Is resistance between TM3 _ NO (male)(1) and (2) normal?
*Turn starting switch ON. l20-30V
1
Remedy
Defective machine controller
YES 1 Is voltage between M31 (IO) and chassis ground normal?
Cause
* Turn starting switch OFF. * Disconnect TM3. Min. 1 ML2
NO
Short circuit with chassis ground in wiring harness between M31 (female) (10) - TM3 (female) (1) - E51 (female) (9)
Repair or replace
Defective transmission 3rd clutch oil pressure switch
Replace
l
C-12 Related
electrical
circuit diagram
controller
Main
M31 (20) 3rd
Engine
,
506 (14)
TM3 (2)
451 (16)
switch
controller
psqy
Transmission oil Pressure
I
3rd switch
GND2
TXDOllOO
D475A-3
20-533 0
1
c-13
TROUBLESHOOTING
C-13 [E0210] Disconnection in transmission sensor system is displayed * Ir Ir
modulating
oil pressure
If the starting switch was turned off after the abnormality occurred, run the engine without applying any load for 10 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
YES 1 Is voltage between M31 (20) and chassis ground normal? Start engine. * Max. 1 V l
3
YES
Is resiSTance YES between TMM - (female) (2) and 2 ~ chassis ground normal? Is resistance between TMM * Turn starting NO switch OFF. NO (male) (1) and (2) normal? . Disconnect TMM. * Max. 1 fi Disconnect TMM. Start engine. NO * Max. 1 Q
Defective machine controller
Replace
Defective contact or disconnectionin wiring harness between M31 (female) (20) - TMM (female)
Repair or replace
(1)
Defective contact or disconnectionin wiring harness between TMM (female) (2) -chassis ground
Repair or replace
Defective transmission modulating oil pressure sensor
l
l
C-13 Related electrical circuit diagram
Main
controller
c
cmiccinn Tran,,,,,,,,,,, modu’lat ” Ins
L
I M31 (20) \
-I
\ I7OWl swl ”tcijv y
506 (14) I, II i c =I -.A +-
45 l(16)
TMM (2)
7=
Transmission modulating oil Pressure sensor
77%
GND2
TXDOI 101
20-534 0
D475A-3
c-14
TROUBLESHOOTING
C-14 [E0212] Short circuit in torque converter is displayed * Ir Ir
lock-up solenoid system
If the starting switch was turned off after the abnormality occurred, run the engine and drive so that the lock-up solenoid will work, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
‘ES
between
M 11
(female)
(1) and
I
3 YES
Turn starting switch OFF. * Disconnect Mll. *40-80R
(female)
(1) and
l-l
*
N
switch OFF. * Disconnect LU2.
YES
II
Is resistance between M 11
NO
Defective machine controller
Replace
Defective diode (LUG)
Replace
Short circuit with chassis ground in wiring harness between Ml1 (female) (1) - LU2 (female) (1) - LUG (female) (1)
Repair or replace
Defective torque converter lock-up solenoid
Replace
Table
I
LU2 (male) Between Between
Resistance
(I) - (2)
40 - 80 Q
(I) (2) - chassis
Min. 1 MR
C-14 Related
Main
I
I
electrical
controller
I
circuit diagram
I LOCK-UP solenoid
TXDOl 102
D475A-3
20-535 0
c-15
TROUBLESHOOTING
C-15 [E0213] Disconnection system is displayed * * *
in torque converter
lock-up solenoid
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
Defective machine controller
Replace
Defective diode (LUG)
Replace
Short circuit with chassis ground in wiring harness between Ml 1 (female) (1) - LU2 (female) (1) - LUG (female) (1)
Repair or replace
Defective torque converter lock-up solenoid
Replace
1 between Ml1 (1)
* Turn starting switch ON. * Max. 1 V
3 YES Is resistance YES between LU2 - (female) (2) and 2 chassis ground spcmal, Is resistance -Turn starting . between LU2 switch OFF. h10 (male) (1) and (2) * Disconnect LU2. normal? * Max. 1 R Turn starting switch OFF. NO . Disconnect LU2. *40-80R
-
NO
l
C-15 Related
Main
electrical
circuit diagram
controller
1
Ml1 (13)
506 (14)
451
LU2 (2)
(16)
LOCK-UP solenoid
LOCK-UP solenoid LUG (2)
GND2
20-536 0
+h-
TXDOllO2
D475A-3
C-16
TROUBLESHOOTING
C-16 [E0220] Short circuit in transmission sensor system is displayed Ir Jr *
modulating
oil pressure
If the starting switch was turned off after the abnormality occurred, hold the starting switch at the ON position for 30 seconds and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between M31 (20) and chassis ground normal? _
2
Is resistance between TMM _ NO (male) (1) and (2) normal?
*Turn starting switch ON. *20-30V
Turn starting switch OFF. * Disconnect TMM. . Min 1 MR
l
C-16 Related
Main
YES
electrical
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (20) -TMM (female) (I)
Repair or replace
Defective transmission modulating oil pressure sensor
NO
circuit diagram
controller M31 (20,
wz+
Remedy
506 ---Kl-
451
(14)
TMM (2)
(16)
Transmission oi I modulating Pressure s ensor
3
-cH-
3
GND2 TXDOI I01
D475A-3
20-537 0
c-17
TROUBLESHOOTING
C-17 Ir
* * *
[E0301] Short circuit in left blade tilt angle sensor system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that the left blade tilt angle sensor is installed normally. (If not, adjust.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES 1 Is voltage between M31 (11) and (16) normal? l
l
Set blade in standard position. Turn starting switch ON.
_ 2 _ No
* 1.8 * 0.5 V
YES
Is reistance between CSL(male) (1) and (3) normal? l
Turn starting switch OFF.
Cause
Remedy
I
Defective machine controller
Replace
Defective contact or disconnection in wiring harness between M31 (female) (16) - CSL (female) (3)
Repair or replace
Defective left blade tilt angle sensor
NO
Disconnect CSL. * 4.0 - 6.0 kQ l
C-17 Related electrical circuit diagram
Main
I
controller
Left stroke
I
M31 (20) Sensor Power
599
(16)
El11 (14)
810 (12)
20-538 0
I
201 (121
inder
sensor
CSL (X3)
.a
a
3
3
a
gJ
3
($ ,
,3 ,,
@ , \,
,, I
101 (16)
CYI
3
,
\,
TXD01103
D475A-3
C-18
TROUBLESHOOTING
C-18 [E0302] Disconnection displayed Ir
in left blade tilt angle sensor system is
Ir
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that the left blade tilt angle sensor is installed normally. (If not, adjust.)
* *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
Remedy
ES
Yt * Set blade in standard position. * Turn starting switch ON. *1.8+0.5V
7
switch OFF. * Disconnect CSL and M31. Min. 1 MQ
between M31 (7)
NO
6YE
l
t *Turn starting switch ON. * 4.75 - 5.25 V
F
Is resistance between M31 (female) (7) and chassis ground normal? . Turn starting switch OFF. Disconnect CSL and M31. - Min. 1 Ma l
C-18 Related
Main
electrical
I
D475A-3
-
* Turn starting switch OFF. * Disconnect CSL. . 4.6 - 6.0 kR NO
N
Replace
Defective contact or disconnection in wiring harness between M31 (female) (II) - CSL (female) (2)
Repair or replace
Defective left blade tilt angle sensor
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (1 I) - CSL (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between M31 (female) (7) - CSL (female) (1)
Repair or replace
Defective left blade tilt angle sensor
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (7) - CSL (female) (I)
Repair or replace
circuit diagram
Left
controller ensor
Is resistance YES between CSL 5 - (male) (I) and (3) normal?
Defective machine controller
stroke
cylinder
sensor
Dower
I
TX001103
20-539 0
c-19
TROUBLESHOOTING
C-19 [E0303] Short circuit in right blade tilt angle sensor system is displayed If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that the right blade tilt angle sensor is installed normally. (If not, adjust.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES
1 Is voltage between M31 (12) and (16) normal? _
2
Set blade in standard position. Turn starting switch ON. * 1.8 + 0.5 V l
* Turn starting switch OFF. * Disconnect CSR. * 4.0 - 6.0 kQ
l
C-19 Related
Main
YES
Is reistance between NO CSRfmale) (1) and (3) normal?
electrical
controller
, M31 (20)
NO
I
Remedy
Defective machine controller
Replace
Defective contact or disconnection in wiring harness between M31 (female) (16) - CSR (female) (3)
Repair or replace
Defective right blade tilt angle sensor
Replace
circuit diagram
599 (I 6)
El1 1 (14)
910 (12)
101
I I
Cause
(16)
201
(12)
Right stroke CSR (X3)
cylinder sensor
-L---lTXDOl104
20-540 0
D475A-3
c-20
TROUBLESHOOTING
C-20 [E0304] Disconnection displayed *
* * *
in right blade tilt angle sensor system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Check that the right blade tilt angle sensor is installed normally. (If not, adjust.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
4YEI 1 YES
Set blade in standard position. Turn starting switch ON. *1.8+0.5V
Is resistance YES between M31 - (female) (12) and chassis ground normal?
l
Is voltage - between M31 (7) NO and (16) normal? * Turn starting switch ON. 04.75 - 5.25 V
-
electrical
-
. Set blade in NC standard positiqn. * :I: startmg swatch . 1.8 + 0.5 V
Turn starting switch OFF. * Disconnect CSR l
NO
and M31’ Min. 1 MR
6YE! Is resistance YES between CSR 5 (male) (I) and (3) normal?
Is resistance between M31 - (female) (7) and NO chassis ground normal?
-
* Turn starting switch OFF. * Disconnect CSR and M31. * Min. 1 MD
C-20 Related
Is voltage between CSR (2) and (3) normal?
l
2
l
-
3
*Turn starting switch OFF. * Disconnect CSR. -4.6 - 6.0 kD NO
NC
Defective machine controller
Replace
Defective contact or disconnection in wiring harness between M31 (female) (12) - CSR (female) (2)
Repair or replace
Defective right blade tilt angle sensor
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (12) - CSR (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between M31 (female) (7) - CSR (female) (I)
Repair or replace
Defective right blade tilt angle sensor
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (71 - CSR (female) (I)
Repair or replace
circuit diagram Right
Main controller
stroke 599 (I 6)
I
Remedy
Bll
(14)
BlO (12)
101 (161
201 (12)
cylinder sensor
CSR (X3)
I
TXDOllO4
D475A-3
20-541 0
c-21
TROUBLESHOOTING
C-21 [E0305] Short circuit in blade RAISE oil pressure switch system is displayed Sr * *
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between M32 (11) and chassis ground normal? * Turn starting switch ON. l20-30V
2
YES
Is resistance between BLU NO
Remedy
Defective machine controller (See Note)
Replace
Short circuit with chassis ground in wiring harness between M32 (female) (11) - BLU (female) (1)
Repair or replace
(male)(1) and (2) normal? * Turn starting switch OFF. * Disconnect BLU. * Min 1 MR
NO
Defective blade raise oil pressure switch
Note: This service code is saved as an error when the blade lever is held in the RAISE position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-21 Related
Main
electrical
circuit diagram
controller ise oil switch
TX1301
20-542 0
105
D475A-3
c-22
TROUBLESHOOTING
C-22 LEO3061Short circuit in blade right tilt oil pressure switch system is displayed * If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Jr Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on to the next step.
YES
Defective machine controller
1 Isvoltage between M32 (8) _ and chassis ground normal? _
2
Short circuit with chassis ground in wiring harness
YES
between M32 (female) - TRS (female) (1)
Is resistance between TRS NO (male) 11) and 12) normal?
Turn starting switch ON. .20-30V l
* Turn starting switch OFF. . Disconnect TRS. Min 1 MQ
Replace
(8)
Defective blade right tilt oil pressure switch
NO
Repair or replace
Replace
l
Note: This service code is saved as an error when the blade lever is held in the right tilt position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-22 Related Main r
electrical
circuit diagram
controller
I
TRS (2)
M32 (i6) Pressure
Blade right tilt oil Pressure switch
switch
GND5 TXDOIIOG
D475A-3
20-543 0
TROUBLESHOOTING
C-23 * j, Ir
C-23
[E0307] Short circuit in blade left tilt oil pressure switch system is displayed
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES Is voltage between M32 (15) and chassis ground normal? . Turn starting switch ON. l20-30V
Defective machine controller
I
1
Remedy
Short circuit with chassis ground in wiring harness between M32 (female) (15) -TLS (female) (1)
_ 2
YES
Is resistance between TLS ND (male) (1) and (2) normal? *Turn starting switch OFF. . Disconnect TLS. lMinlMR
Repair or replace
Defective blade left tilt oil pressure switch
NO
Note: This service code is saved as an error when the blade lever is held in the left tilt position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-23
Related
Main
electrical
circuit diagram
controller
I
M32 (16) Left tilt Pressure
TLS (2)
Blade left tilt oil Dressure switch
oil switch
GND5 TXDOl 107
20-544 0
D475A-3
C-24
TROUBLESHOOTING
C-24 [E0308] Short circuit in ripper RAISE oil pressure switch system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
YES
Defective machine controller
1 Is voltage between M32 (2) and chassis ground normal?
_ 2
YES
Is resistance between RPU
* Turn starting switch ON. *20-30V
NO (male) (1) and (2) normal? *Turn starting switch OFF. * Disconnect RPU. * Min 1 MD
NO
Short circuit with chassis ground in wiring harness between M32 (female) (2) - RPU (female) (1)
Repair or replace
Defective ripper raise oil pressure switch
Replace
Note: This service code is saved as an error when the ripper lever is held in the RAISE position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-24 Related Main
electrical
circuit diagram
controller
RPU (2)
M32 ti6, Vll
switch
El
I I
I
I
I
I
---r2)\IF-J\
I
Ripper Pressure
L-G--h
-
raise oil switch
I TVVA) t----c+ Y I
77%
GND5
TXDOIIOB
D475A-3
20-545 0
c-25
TROUBLESHOOTING
C-25 [E0309] Short circuit in ripper LOWER oil pressure switch system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I YES
Defective controller
1 Is voltage between M32 (IO) and chassis ground normal? * Turn starting switch ON. *20-30V
Cause
2
YES
Is resistance NO (male) (1) and (2) normal? * Turn starting switch OFF. * Disconnect RPD. * Min 1 MR
NO
I
machine
I
Remedy
Replace
Short circuit with chassis ground in wiring harness between M32 (female) (10) - RPD (female) (1)
Repair or replace
Defective ripper lower oil pressure switch
Replace
Note: This service code is saved as an error when the ripper lever is held in the LOWER position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-25 Related Main
electrical
circuit diagram
controller
M32 (i6)
RPD (2)
Ripper Pressure
lower oil switch
3
switch
3
GND5
20-546 0
TXDOI 109
D475A-3
C-26
TROUBLESHOOTING
C-26 [E0310] Short circuit in ripper TILT IN oil pressure switch system is displayed * Ir Ir
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
YES 1 Is voltage between M32 (3) and chassis ground normal? * Turn starting switch ON. l20-30V
_ 2
YES
Is resistance between RTI NO (male) (I) and (2) normal? * Turn starting switch OFF. * Disconnect RTI. * Min 1 Ma
NO
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between M32 (female) (3) - RTI (female) (1)
Repair or replace
Defective ripper tilt in oil pressure switch
Replace
Note: This service code is saved as an error when the ripper lever is held in the TILT IN position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-26 Related electrical circuit diagram Main
controller
RTI (2)
M32 (i6) Ripper
tilt
switch
Ripper tilt IN oil Pressure switch
3
GND5 TXDOlllO
D475A-3
20-547 0
C-27
TROUBLESHOOTING
C-27 [E0311] Short circuit in blade lever front button switch system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES 1
I
* Turn starting switch OFF. * Disconnect PO1 and P03. * Min 1 MQ
NO
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between M51 (female) (12) - PO1 (male)
Repair or replace
Defective blade lever knob switch
Replace
Note: This service code is saved as an error when the blade lever front button is pressed and held for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-27 Related
electrical
circuit diagram Blade
Main
GND5
20-548 0
lever
switch
controller
TXDOllll
D475A-3
C-28
TROUBLESHOOTING
C-28 [E0312] Short circuit in blade lever upper button switch system is displayed * * Ir
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between M51 (11) and chassis ground normal? * Turn starting switch ON. .20-30V
2 Is resistance between PO2 - (female) (1) and NO ~03 (male) normal? * Turn starting switch OFF. * Disconnect PO2 and P03. * Min 1 MD
YES
-
NO
Remedy
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between M51 (female) (11) - PO2 (male)
Repair or replace
Defective blade lever knob switch
Replace
Note: This service code is saved as an error when the blade lever upper button is pressed and held for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-28 Related
electrical
circuit diagram Blade
Main
lever
switch
controller
I
M51 (17) Upper
button
switch
11
GND5
D475A-3
TXDOllli’
20-549 0
c-29
TROUBLESHOOTING
C-29
[E0313]
Short circuit in pitch back solenoid system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and perform pitch back operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
between (female)
3
Ml 1 (2) and
YES , r
Turn starting switch OFF. * Disconnect Mll. l20-60R l
1, .____.-____ .___.._Z. I
4
IS res1sIa”Ge
“UWVBWI
PPB(male) (1) and
,^ N
._.._ ____ rg table?
. Turn
starting switch OFF. * Disconnect PPB.
YES
Is resistance between Ml 1 (female)
(2) and
-
I chassisground
normal? II’ * Turn startina switch OFF.* Disconnect G3 and Mll. *20-60R NO
I
Remedy
Defective machine controller
Replace
Defective diode (G3)
Replace
Short circuit with chassis ground in wiring harness between Ml 1 (female) (2) - PPB (female) (1) - G3 (female) (I)
~e~$eor
Defective pitch back solenoid
Replace
Table
I
PPB (male)
Resistance
(I) - (2)
20 - 60 Q
(I) (2) - chassis
Min. 1 MQ
Between Between
I
1
C-29 Related electrical circuit diagram
Main
controller PPB (2) 3 3
I I
GND5 fi
20-550 0
Pitch back solenoid
G3 (2)
TXD01113
D475A-3
c-30
TROUBLESHOOTING
C-30 [E0314] Disconnection
in pitch back solenoid system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
1 Is voltage
3
between Ml 1 (2) and chassis around normal? l
l
Turn starting switch ON. Max. 1 V
1Isresistance
YES
II
Defective machine controller
Replace
Defective contact, disconnectionor short circuit with power socrce in wiring harness between Ml 1 (female) (2) - PPB(female) (11
Repair or replace
Defective contact or disconnection in wiring harness between PPB (female) (2) -chassis ground
n * Turn starting switch OFF. * Disconnect PPB. .20-60Q
* Max. 1 D
Defective pitch back solenoid
NO
Remedy
Repair or replace
Replace
C-30 Related electrical circuit diagram
Main
controller
PPB (2) 3 3
GND5 n@-
D475A-3
Pitch back solenoid
TXDOl113
20-551 0
c-31
TROUBLESHOOTING
C-31 [E0315] Short circuit in pitch dump solenoid system is displayed *
* *
If the starting switch was turned off afterthe abnormality occurred, turn the starting switch on and press the pitch dump switch of the blade lever, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES
Defective machine controller
Replace
Defective diode (G4)
Replace
Short circuit with chassis ground in wiring harness between Ml 1 (female) (8) - PPD (female) (I) - G4 (female) (I)
Repair or replace
Defective pitch dump solenoid
Replace
11 Is resistance between Ml 1
3 YES Is resistance YES between Ml 1 - (female) 18) and _ 2 chassis ground * Turn starting Is reslsxancebetween normal? PPD(male) (11and switch OFF. * Turn starting (2) and between (1) NO * Disconnect Ml 1. switch OFF. NO ~{$%J%&n in l20-60R Disconnect G4 and Ml 1. *20-6on *Turn starting switch OFF. NO Disconnect PPD. (female) (8) and chassis ground normal?
-
l
l
Table Resistance
PPD (male)
I
(I) - (2)
20 - 60 Q
(1) (2) - chassis
Min. 1 MQ
Between Between
C-31 Related electrical circuit diagram Main
controller Ml 1 (13)
PPD (2)
_ Pitch dump solenoid
G4 (2)
GND5 Tfii
20-552 0
TXDOlIl4
D475A-3
C-32
TROUBLESHOOTING
C-32 [E0316] Disconnection *
* *
in pitch dump solenoid system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
Defective machine controller
YES
between
3
Ml 1 (8)
-Turn starting switch ON. * Max. 1 V
I Isresistance
I I
harness between Ml 1 (female) (8) - PPB (female)
Repair or replace
(1
Repair or replace
PPD (female) (2) -chassis ground harness
F -Turn starting switch OFF. * Disconnect PPD. .20-60R
Main
Defective contact, disconnection or short circuit with power source in wiring
YES
Defective contact or disconnection in wiring
I
C-32 Related
Replace
electrical
* Max. 1 R
between
Defective pitch dump solenoid
NO
Replace
circuit diagram
controller
Ml 1 (i3)
PPD
(2) Pi SO
ch dump enoid
G4 (2) 0 GND5
D475A-3
&+
TXDOll14
20-553 0
TROUBLESHOOTING
c-33
C-33 [E0317] Short circuit in left tilt limit solenoid system is displayed If the starting switch was turned off after the abnormality occurred, start the engine and slowly tilt the blade to the left end, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
F
Remedy
Cause
ES
I Defective
machine
Replace
controller
1
(female) (31and
* Turn starting switch OFF. * Disconnect Mll. l20-60R
3 Is resistance YES between Ml1 - (female) (3) and _ 2 chassis ground Is resrstancebetween normal? TLL (male) (1) and (2) and between (1) (2) Turn starting ’ and chassisground switch OFF. as shown in * Disconnect G5 and followingtable? l20-60R * Turn starting switch OFF. NO * Disconnect TLL. l
h
YES
NO Ml 1.
Defective diode fG5)
Replace
Short circuit with chassis ground in wiring harness between Ml 1 (female) (3) -TLL (female) (1) - G5 (female) (1)
Repair or replace
Defective let? tilt limit solenoid
Replace
Table
I
TLL (male)
I
Resistance
(
Between (I) - (2)
I
20 - 60 Sz
I
Between (I) (2) - chassis
Min. 1 MQ
C-33 Related electrical circuit diagram
TLL
GND5
20-554 0
‘I
(2)
Left ti It solenoid _control
G5 (2)
I 2
TXDOl115
D475A-3
c-34
TROUBLESHOOTING
C-34 [E03_18]Disconnection in left tilt limit solenoid system is displayed Ir If the starting switch was turned off after the abnormality occurred, turn the starting switch Ir Ir
on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
3
between Ml 1 (3) YE
around normal? *Turn starting switch ON. * Max. 1 V
Is resistance between TLL (male) (1) and (2) normal? CA
Turn starting switch OFF. * Disconnect TLL. *20-60R l
C-34 Related
electrical
YES
jeHP
. Turn starting switch OFF. Disconnect TLL. * Max. 1 CA
Defective machine controller
Replace
Defective contact, disconnectionor short circuit with power source in wiring harness between Ml1 (female) (3) - TLL (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between TLL (female) (2) -chassis ground
NO
Repair or replace
l
Defective left tilt limit solenoid
NO
Replace
circuit diagram
ilt I solenoid
I I
GND5 &-
D475A-3
G5 (2)
TXDOlIlS
20-555 0
c-35
TROUBLESHOOTING
C-35
[E0319] Short circuit in right tilt limit solenoid system is displayed
If the starting switch was turned off after the abnormality occurred, start the engine and slowly tilt the blade to the right end, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
Remedy
Defective machine controller
YES
1
Replace
1 resistance between Ml1 (female) (10) and chassis ground normal? Is
Turn starting switch OFF. * Disconnect Mll. *20-6OD l
3 Is resistance YES between Ml1 - (female) (10) and 2 chassis ground 1S normal? TLR (male) (1) and (2) p Turn starting and between(11(Z) - and chassisground switch OFF. NO as shown in Disconnect G6 and followingtable? *20-60R - Turn starting switch OFF. NO * Disconnect TLR.
YES
Defective diode (G6)
-
l
l
p NO Ml 1.
Short circuit with chassis ground in wiring harness between M 11 (female) (10) - TLR (female) (1) G6 (female) (1)
Repair or replace
Defective right tilt limit solenoid
Replace
Table
C-35 Related
Main
electrical
circuit diagram
controller
I
TLR (2)
Ml 1 (13) control
Right control
t i It solenoid
3
solenoid
3
I
I I
GNDS
20-556 0
h+
G6 (2)
TXDOlllG
D475A-3
C-36
TROUBLESHOOTING
C-36 [E0320] Disconnection displayed * * Ir
in right tilt limit solenoid system is
If the starting switch was turned off after the abnormality occurred, start the engine and slowly tilt the blade to the right end, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that ail the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
Defective machine controller
1 Is voltage between M 11 (10) and chassis ground normal? * Turn starting switch ON. * Max. 1 V
3 Yf 2 Is resistance between TLR NO
(male)(1) and (2) normal7 * Turn starting switch OFF. * Disconnect TLR. *20-60R
C-36 Related
Main
electrical
Defective contact, disconnection or short circuit with power source in wiring harness between Ml 1 ;;male) (10) - TLR (female1
YES
EHP
* Turn starting switch OFF. * Disconnect TLR. * Max. 1 R
Replace
Repair or replace
Defective contact or disconnection in wiring harness between TLR (female) (2) -chassis ground
NO
Repair or replace
Defective right tilt limit solenoid
IO
Replace
circuit diagram
controller
Right
tilt
I solenoid
~~~
GNDS k+
D475A-3
TXDOIIIG
20-557 0
c-37
TROUBLESHOOTING
C-37 [E0321] Short circuit in dual tilt selection solenoid system is displayed *
If the starting switch was turned
Ir *
press the back button of the blade lever, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
off after the abnormality
occurred,
turn the starting switch on and
Cause
YES
1J resistancebetween M21 (female)(9) and (19) and between(9) _ (19) and chassis groundas shown in Table 17 Is
3
* Turn starting Is DST (male) (I) and switch OFF. (2) and bahyen (11 Disconnect M21. NG (2) and chaws ground as shown in Table 27
Is voltage between M21 (female) (19) and chassis ground normal?
YES 2
l
Turn starting switch OFF. * Disconnect DST. l
_
* Disconnect DST NO and M21. -Turn starting switch ON. Max. 1 V l
NO
C-37 Related
electrical
Replace
Short circuit with chassis ground or power source in wiring harness between M21 (female) (9) - DST (female) (I)
Repair or replace
Short circuit with power source in wiring harness between M21 (female) (19) - DST (female) (2)
Repair or replace
Defective dual tilt selection solenoid
Replace
circuit diagram
controller
506 (14)
pmmM21 (21)
Dual tilt
20-558 0
Defective machine controller
Table 2
Table 1
Main
YES
Remedy
451 (16)
Dual tilt select solenoid
__.__
D475A-3
C-38
TROUBLESHOOTING
C-38 [E0322] Disconnection displayed *
+ Ir
in dual tilt selection solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective machine controller
YES
II
Defective contact, disconnectionor short circuit with chassis ground in wiring harness between M21 (female) (19) - DST (female) (2) Defective contact or disconnectionin wiring harness between M21 (female) (9) - DST (female) (1)
switch OFF. * Disconnect M21.
* Turn
st switch OFF. n-r+ nCT * Disconb,,,, yvI.
Table
Defective dual tilt selection solenoid
NO
Remedy
Replace
Repair or replace
Repair or replace
Replace
Table 2
1
C-38 Related electrical circuit diagram
Main
506 (14)
controller
242 (6)
M21 (21) Dual tilt solenoid
select (+I
;;;k,;ilt
451 (16) I
)d=3
DST (2)
4
I
6
2
solenoid
TXDOlI17
D475A-3
20-559 0
c-39
TROUBLESHOOTING
C-39 [E0323] Short circuit in pitch selection solenoid system is displayed Ir Ir *
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and press the dump button of the blade lever, and check that the service code displays “E” at the head. ilf “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective controller 1 Is resistance between M21 (female) (8) and (18) and between (8) _ (18) and chassis ground as shown in Table l?
17
1
Replace
wiring M21
harness (female)
between (8) - DST
Repair or replace
(female) (1) Short circuit with power source in wiring harness between M21 (female) (18) - DST (female) (2)
Repair or replace
Defective solenoid
Replace
pitch selection
Table 2
C-39 Related
Main
machine
Short circuit with chassis ground or power source in
3 YES
Is voltage between YES M21 (female) (18) and chassis 2 * Turn starting b ground normal? PST (male) (1) and (2) ~ p switch OFF. and between (1) (21 * Disconnect PST NO * Disconnect M21. NO- and chassis ground and M21. as shown in Table 2? * Turn starting switch ON. * Max. 1 V *Turn starting switch OFF. NO * Disconnect PST.
Table
Remedy
electrical
controll
circuit diagram
451
(16) rlCT
Pitch
lO\
Pitch solenoid
select
selL_.
TXDOlll8
20-560 0
D475A-3
c-40
TROUBLESHOOTING
C-40 [E0324] Disconnection displayed *
* *
in pitch selection solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective machine controller
YES
I
I
1 Is resstance
between
3
M21 (female)(8) and (18) and between(8) _ (18) and chassis ground as shown in Table 17
Is voltage between YES PST (female) (1) and chassis 2 * Turn starting m ground normal? PST (male) (1) and (2) p switch OFF. * Disconnect PST. and between(1) (2) * Disconnect M21. - and chassis ground * Turn starting NO as shown in Table 2? switch ON. * Turn starting switch OFF. * Disconnect PST.
Table
II I
Defective contact, disconnectionor short circuit with chassis ground in wiring harness between M21 (female) (18) - PST (female) (2) Defective contact or disconnectionin wiring harness between M21 (female) (81-PST (female) (1)
YES
NO
Defective pitch selection solenoid
Repair or replace
Repair or replace
Replace
_-
Table 2
1 M21 (female) Between
Between
Main
II
I
(8) - (18)
electrical
controller
Pitch
select
Pitch
select
Resistance IO-40R
I
(8) (18) - chassis
C-40 Related
DA75A-3
Replace
Min. 1 MQ
1
1
I
I
l
I
PST (male)
I
Resistance
I
Between Between
(I) - (2)
(I) (2) - chassis
/
10 - 40 R
1 I
I
Min. 1 ML2
circuit diagram
Pitch
select
20-561 0
c-41
TROUBLESHOOTING
C-41 [E03251 Short circuit in pitch back assist solenoid svstem is displayed sr * *
If the starting switch was turned off after the abnormality occurred, start the engine and perform pitch back operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is resistance between Ml 1 (11) and chassis ground normal?
_ starting NO switch OFF. * Disconnect Ml 1. *IO-4021 - Turn
2 YES Is resistancebeWeen
PBA (male)(lland (2)andbetween
(2) and chassis groundas shown in followinctable? * Turn starting switch OFF. Disconnect PBA.
_
NO
Remedy
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between Ml 1 (female) (11) - PBA (female) (1)
Repair or replace
Defective pitch back assist solenoid
Replace
l
Table
;
C-41 Related electrical circuit diagram
Main
controller
Pitch assist PBA (2)
I Ml I (13)
506 (14)
451
(16)
242 (6)
back solenoid
I 2
GNDl TX1301
20-562 0
119
D475A-3
1
C-42
TROUBLESHOOTING
C-42 [E0326] Disconnection displayed *
Ir *
in pitch back assist solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
Defective machine controller
3
1Isresistance
(11) and chassis * Turn starting switch ON. * Max. 1 V
YES
II
Defective contact or disconnection in wiring harness between PBA (female) (2) -chassis ground L
I
* Turn starting switch OFF. * Disconnect PBA. *lo-4OQ
Main
Defective contact, disconnectionor short circuit with power source in wiring harness between Ml1 ;zmale) (11) - PBA (female)
h
C-42 Related
Replace
electrical
Repair or replace
Defective pitch back assist solenoid
Replace
circuit diagram
controller
Pitch assist
I Ml 1 (13)
Pitch back solenoid
* Max. 1 Q NO
Repair or replace
506 (14)
451
(16)
back solenoid
PEA (2)
242 (6)
assist
I 2
GNDl TXDO1119
D475A-3
20-563 0
TROUBLESHOOTING
C-43
C-43
[E03271 Short circuit in pitch dump assist solenoid system is displayed
If the starting switch was turned off after the abnormality occurred, start the engine and perform pitch dump operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is resistance between Ml 1 (5) and chassis 2 YES ground normal? Is resistsncebetween p PDA Hoyle) (1) and * Turn starting _ (2) and between(1) _ NO (2) and chassis switch OFF. groundas shown in * Disconnect Mll. followinntable? *lo-4on Turn starting NO switch OFF. * Disconnect PDA. l
Remedy
Defective machine controller
Replace
Short circuit with chassis ground in wiring harness between Ml 1 (female) (5) - PDA (female) (1)
Repair or replace
Defective pitch dump assist solenoid
Replace
Table
I
PDA (male)
1
10 - 40 zz
(I) (2) - chassis
Min. 1 MCI
C-43 Related
Main
Resistance
(1) - (2)
Between Between
I
electrical
controller
circuit diagram
Pitch assist
I Ml 1 (13)
506
(14)
dump solenoid
451 (16)
GNDI TXDOl120
20-564 0
D475A-3
c-44
TROUBLESHOOTING
C-44 [E0328] Disconnection displayed
in pitch dump assist solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Remedy
Replace
I
Is voltage between Ml 1 (5) and chassis ground normal?
* Turn starting switch ON. - Max. 1 V
3
I
F
YES -
2 _ Is resistance between PDA (male) (1) and (2) normal?
: l
C-44 Related
Main
I
Defective contact, disconnection or short circuit with dower source in wirina ham&s between Ml 1 (female) (5) - PDA (female)
YES
II
I Is resistance between PDA
(1)
(female) (2) and chassis ground normal? * Turn starting NO switch OFF. * Disconnect PDA.
Defective contact or disconnection in wiring harness between PDA (female) (2) -chassis ground Defective pitch dump assist solenoid
Turn starting
electrical
Repair or replace
Repair or replace
Replace
circuit diagram
controller
Pitch assist PDA (2)
I Ml I (‘13)
Pitch dump assist solenoid
506 (I 4)
451
(1 6)
242
(6)
dump solenoid
I
GNDl TX001 120
D475A-3
20-565 0
TROUBLESHOOTING
c-45
C-45 [E0330] Short circuit in blade LOWER oil pressure switch system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
between M32 (6)
2 YES between BLD
switch ON. l20-30V Turn starting switch OFF. Disconnect BLD. * Min 1 MD
l
NO
Remedy
Defective machine controller (See Note)
Replace
Short circuit with chassis ground in wiring harness between M32 (female) (61 - BLD (female) (1)
Repair or replace
Defective blade lower oil pressure switch
Replace
l
Note: This service code is saved as an error when the blade lever is held in the LOWER position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-45 Related Main
electrical
circuit diagram
controller
M32 (i6)
BLD (2)
Blade lower oi I Pressure swi tch
3 3
GND5 TXDOl121
20-566 0
D475A-3
C-46
TROUBLESHOOTING
C-46 [E0332] Short circuit in unload valve solenoid system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, start the engine and raise the blade to relieve at the stroke end, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3 YES
(15) and between (4)
Is voltage between YES M21 (female) (15) 2 and chassis
n
*Turn starting switch OFF. * Disconnect M21.
* Disconnect UNL.
Table
Defective machine controller
Replace
Short circuit with chassis ground or power source in wiring harness between M21 (female) (4) - UNL (female) (1)
Repair or replace
Short circuit with power source in wiring harness between M21 (female) (15) - UNL (female) (2)
Repair or replace
Defective unload valve solenoid
Replace
._-
Table 2
1
C-46 Related
Main
I
D475A-3
Remedy
electrical
controller
circuit diagram
Unload
TXDOl122
20-567 0
c-47
TROUBLESHOOTING
C-47 [E0333] Disconnection displayed + * *
in unload valve solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective controller
YES
1 Isreslsfance between M21 (female) (4) and (15) and between (41 _ (15) and chassis y&as shown in * Turn starting Is UNL (male) (1) and switch OFF. (2) and betwqen (1) * Disconnect M21. NG (2) and chassis ground as shown in Table 2?
* Turn starting switch OFF. * Disconnect UNL.
Table
Is voltage between UNL (female) (1) and chassis ground normal? Disconnect UNL. * Turn starting switch ON. *20-30V
NO
l
machine
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between M21 (female) (15) - UNL (female) (2) Defective contact or disconnection in wiring harness between M21 (female) (4) - UNL (female) (1)
3 YES YES 2
Remedy
Defective solenoid
NO
unload valve
Repair or replace
Repair or replace
Replace
Table 2
1
C-47 Related
electrical
circuit diagram
-ai n controller
I M21
(21)
577
(12)
578
(8)
3
3
4
4
UNL
(2)
Unload solenoid
I 3
TXDOl122
20-568 0
D475A-3
C-48
TROUBLESHOOTING
C-48 [E0334] Short circuit in demand valve solenoid system is displayed If the starting switch was turned off after the abnormality occurred, start the engine and perform pitch dump operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
YES
II Is resistancebetween M21 (female)(2) and (13) and between (21 (13) and chassis groundes shown in Table 17
H
3 YES Is voltage between YES M21 (female) (13) 2 r and chassis 1ground normal?
-Turn starting switch OFF. Disconnect M21.
(2) and between (1)
l
* Turn starting switch OFF. Disconnect PCV.
11
* Disconnect PCV NO and M21. *Turn starting switch ON. * Max. 1 V NO
Remedy
Defective machine controller
Replace
Short circuit with chassis ground or power source in wiring harness between M21 (female) (2) - PCV (female) (1)
Repair or replace
Short circuit with power source in wiring harness between M21 (female) (13) - PCV (female) (2)
Repair or replace
Defective demand valve solenoid
Replace
l
Table
1
Table 2 M21 (female)
Between Between
(2) - (13)
40 - 80 R
(2) (13) - chassis
Min. 1 MQ
C-48 Related Main
electrical
PCBV (male)
Resistance
(I) - (2)
40 - 80 R
(I) (2) - chassis
Min. 1 MR
Between Between
Resistance
circuit diagram
controller I
M21
(21)
577
(12)
570
(8)
241
1
I
3
2
2
4
(4)
PCV (2)
Demand solenoid
TXDOl 123
D475A-3
20-569 0
c-49
TROUBLESHOOTING
C-49 [E0335] Disconnection displayed
in demand valve solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Remedy
Cause
Defective machine controller
YES
Defective contact, disconnectionor short circuit with chassis ground in wiring harness between M21 ;;male) (13) - PCV (female)
ground Table l?
Defective contact or disconnectionin wiring harness between M21 (female) (2) - PCV (female) (1)
* Turn starting switch OFF. Disconnect M21. l
. Turn starting switch OFF. * Disconnect PCV.
Table
switch ON. *20-30V
Repair or replace
Repair or replace
Defective demand valve solenoid
NO
Table 2
1
C-49 Related
Main
Replace
electrical
circuit diagram
controller 1
M21 Demand
solenoid
Demand solenoid
(21)
577
(12)
578
(8)
241
(4)
PCV (2)
(+
1
3
1
(-
2
4
2
Demand solenoid
TXDOl123
20-570 0
D475A-3
TROUBLESHOOTING
c-50
C-50 [E0336] Short circuit in ripper TILT BACK oil pressure switch system is displayed If the starting switch was turned off after the abnormality occurred, hold the starting switch in the
*
ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is
* *
displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between M32 (16) and chassis ground normal? _ *Turn starting switch ON. *20-30V
_ 2 Is resistance between RTB NO (male) (I) and (2) normal? *Turn starting switch OFF. * Disconnect RTB. * Min 1 MR
YES s
NO
Remedy
Defective machine controller (See Note)
Replace
Short circuit with chassis ground in wiring harness between M32 (female) (16) - RTB (female) (1)
Repair or replace
Defective ripper tilt back oil pressure switch
Replace
Note: This service code is saved as an error when the ripper lever is held in the TILT BACK position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-50 Related electrical circuit diagram Main
controller
1
RTB (2)
M32 (16) Tilt back oil Pressure switch
Ripper tilt back oil Pressure switch
3
@
3
GND5 TXDOl1.24
D475A-3
20-571 0
c-51
TROUBLESHOOTING
C-51 [E0337] Shot-t circuit in pitch independent displayed
solenoid system is
If the starting switch was turned off after the abnormality occurred, start the engine and perform pitch operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* +
I YES
1
Remedy
Defective machine controller
I
1
Cause
resistance between Ml 1 Is
(female) Ill) and chassis ground
-
normal? ~ * Turn starting switch OFF. * Disconnect Mll. *lo-400
Short circuit with chassis ground in wiring harness between Ml 1 (female) (11) -PIT (female) (1)
2 YES
Is resistancebetween PIT (male) (1) and (2) _ and between (1) (2) _ NO and chassisground as shown in followinatable? * Turn starting NO switch OFF. Disconnect PIT.
Repair or replace
Defective pitch independent solenoid
l
Table
I I
PIT (male) Between Between
C-51
(I)- (2)
IO-40R
1
(I) (2) - chassis
Related
Main
Resistance
I
electrical
I 1
Min. 1 MQ
)
circuit diagram
controller
I
Ml1 (13)
506 (14) 3
PIT (2)
451 (16)
Pitch independent solenoid
.a
@
3
GND2 TVDOI 160
20-572 0
D475A-3
1
TROUBLESHOOTING
c-52
C-52 [E0338] Disconnection displayed *
* *
in pitch independent
solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Defective machine controller
YES
I 1
Is voltage between Ml 1 (11) and chassis ground normal? * Turn starting switch ON. * Max. 1 V
YES
Defective contact, disconnectionor short circuit with power source in wiring harness beween Ml1 $ymale) (11) -PIT (female)
NO
Defective contact or disconnection in wiring harness between PIT (female) (2) -chassis ground
,I 3
Is resistance YES between PIT 2 7 (female) 12)and -1 chassis ground rNXmsl? Is resistance _ between PIT * Turn starting switch OFF. NO (male) (1) and (21 normal? . Disconnect PIT. I I * Max. 1 R Turn starting switch OFF. NO * Disconnect PIT. .lO-40R
-
I
Main
electrical
controller
Replace
Repair or replace
Repair or replace
Defective pitch independent solenoid
l
C-52 Related
I
circuit diagram
I
Ml1 (i3)
506 (14)
451 (16)
PIT (2)
Pitch independent solenoid _
pzJEyj+
GND2 TVDOllGO
D475A-3
20-573 0
c-53
TROUBLESHOOTING
C-53 [E0339] Short circuit in left bottom displayed *
* *
drain solenoid system is
If the starting switch was turned off after the abnormality occurred, start the engine and perform pitch operation, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
1J Is resistance between M21 (female) (9) and (19) _ and between (9) (19) and chassis round as shown ina_able 17
I
voltage between ‘ES M21 (female) (19) I Is
* Turn starting between LBD (male) switch OFF. (1) and (2) and * Disconnect M21. NG between(lj(2)and chassis around as B 27
l
lull, ~&cX,W.g switch OFF. Disconnect LBD.
* Disconnect LBD NO and M21. *Turn starting switch ON. - Max. 1 V NO
Defective machine controller
Replace
Short circuit with chassis ground or power source in wiring harness between M21 (female) (9) - LBD (female) (1)
Repair or replace
Short circuit with power source in wiring harness between M21 (female) (19) - LBD (female) (2)
Repair or replace
Defective left bottom drain solenoid
Replace
Table 2
Table 1
C-53 Related
Main
3 YES
Remedy
electrical
circuit diagram
Left drain
controller
Left drain
bottom solenoid
bottom
(-1
TV001161
20-574 0
D475A-3
c-54
TROUBLESHOOTING
C-54 [E0340] Disconnection displayed *
* *
in left bottom
drain solenoid system is
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Defective machine controller 1 Is resistancebetween M21 (female)(9) and (19) and between (9) A (19) and chassis Bzbu;;l,asshown in
I2
* Turn starting Ts res8stancebetween LBD(male) (1) and switch OFF. (2) and between (1) * Disconnect M21. N& (2) and chaws groundas shown in Table 2? Turn starting switch OFF. . Disconnect LBD.
l
Table
* Disconnect LBD. Turn starting switch ON. *20-30V
NO
l
Defective left bottom drain solenoid
NO
Repair or replace
Repair or replace
Replace
Table 2
1 M21 (female) Between
rEletween I
Main
bottom solenoid
I
Min. 1 MR
1 I
1 Between I
Resistance 10 - 40 R
(I) - (2)
(I) (2) - chassis
1
Min. 1 MQ
circuit diagram
Left bottom drain solenoid
controller
Left drain
Between
IO-40R
(9) - (19)
electrical
LBD (male)
Resistance
(9) (19) - chassis
C-54 Related
D475A-3
Defective contact, disconnectionor shorl circuit with chassis ground in wiring harness between M21 (female) (19) - LBD (female) (21 Defective contact or disconnectionin wiring harness between M21 (female) (9) - LBD (female) (1)
3 YES
Is voltage between LBD (female) (1) and chassis ground normal?
YES
Replace
(-1
20-575 0
1 1 1
C-55, C-56
TROUBLESHOOTING
C-55 [E0351] Abnormality is displayed
in standard
value of blade tilt angle sensor
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.)
*
Cause
1 YES Is any other service code displayed, too? - Turn starting switch ON.
NO
C-56 [E0352] Abnormality sensor is displayed
in compensated
-)r If the starting switch was turned off after the abnormality check that the service returned to normal.)
code
displays
“E” at the
head.
Remedy
Check according to displayed service code.
Replace
Wrong adjustment limit
Adjust
of tilt
value of blade tilt angle occurred, turn the starting switch on and (If “P” is displayed, the condition has
Cause
Is any other service code displayed, too? l
Turn starting switch ON.
20-576 0
h
NO
Remedy
Check according to displayed service code.
Replace
Wrong adjustment of tilt limit
Adjust
D475A-3
TROUBLESHOOTING
c-57
C-57 [E03601 Short circuit in work equipment pump) system is displayed * * Ir
oil pressure sensor (140
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
YES
l
Raise ripper to
NO
. 1.5-2.OV * Disconnect HPl. * Turn starting switch ON. * Max. 1 V
C-57 Related
electrical
l
Max. 1 R
NO
Remedy
Defective machine controller
Replace
Defective work equipment oil pressure sensor (140 pump)
Replace
Defective contact or disconnection in wiring harness between M31 (female) (13) - HP1 (female) (3)
Repair or replace
Short circuit with power source in wiring harness between M31 (female) (13) - HP1 (female) (3)
Repair or replace
circuit diagram
Work equipment Pressure sensor (140) Sensor oil
oil
Power
Pressure
TXDOI 125
D475A-3
20-577 CD
C-58
TROUBLESHOOTING
C-58 IE03611 Disconnection in work equipment pump) system is displayed
oil pressure sensor (140
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Cause
Remedy
Defective machine controller
Replace
IDefective contact or
5
,disconnection in wiring harness between M31 (13) - HP1 I[female) (3) I[female)
between M31 (13) and (16)
IDefective work equipment oil pressure 1 jsensor (140 pump)
YE Start engine. * Raise ripper to relieve. . 1.5-2.OV l
1&z&ground 2
I
I
Short circuit with chassis ground in wiring harness between M31 (female) (13) - HP1 (female) (3)
- Turn l
l
* Turn starting switch ON. l20-3ov
1
starting switch OFF. Disconnect HP1 and M31. Min. 1 MR
YES
(female) (6) and
n
* Turn starting switch OFF. Disconnect HP1 and M31. * Min. 1 MD
NO
Defective contact or disconnection in wiring harness between M31 (female) (61- HP1 (female) (2) Short circuit with chassis ground in wiring harness between M31 (female) (6) HP1 (female) (2)
Repair or replace
Replace
Repair or replace
Repair or replace
Repair or replace
l
C-58 Related
Main
electrical
circuit diagram
Work equipment oi I Pressure sense r (140)
controller
oil
Pressure
1
20-578 0
TXDOI 125
D475A-3
c-59
TROUBLESHOOTING
C-59
[E0362] Short circuit in work equipment pump) system is displayed
oil pressure sensor (100
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
Defective machine controller
Replace
Defective work equipment oil pressure sensor (100 pump)
Replace
Defective contact or disconnection in wiring harness between M31 (female) (16) - HP2 (female) (1)
Repair or replace
Short circuit with power source in wiring harness between M31 (female) (14) - HP2 (female) (3)
Repair or replace
1 Is voltage between M31 (14) and (16) normal? - Start engine. * Raise ripper to relieve. *1.5-2.OV
C-59 Related
Main
3 YES Is resistance YES between HP2 - (female) 11) and 2 _ chassis ground nOrmal? Is voltage between M31 * Turn starting switch OFF. N , (14) and chassis ground normal? * Disconnect HP2. * Max. 1 Q * Disconnect HP2. * Turn starting NO switch ON. * Max. 1 V
electrical
-
NO
circuit diagram
Controller Work equipmen oi I Pressure
TVDOll62
D475A-3
20-579 0
C-60
TROUBLESHOOTING
C-60 [E0363] Disconnection in work equipment pump) system is displayed
oil pressure sensor (100
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
4YEf
between M31 YE ~
* Start engine. * Raise ripper to relieve. l1.5-2.ov
I
. Disconnect HP2
between M31 (6)
NO
between M31 N
chassis ground normal? *Turn startina switch OFF.* Disconnect HP2 and M31. *Min. 1 MR
Replace
Defective contact or disconnection in wiring harness between M31 (female) (14) - HP2 (female) (3)
Repair or replace
Defective work equipment oil pressure sensor (100 pump)
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (14) - HP2 (female) (3)
Repair or replace
Defective contact or disconnection in wiring harness between M31 (female) (6) - HP2 (female) (2) Short circuit with chassis ground in wiring harness between M31 (female) (6) HP2 (female) (2)
YES
*Turn starting switch ON. .20-30V
Defective machine controller
I
NO
Repair or replace
Repair or replace
C-60 Related electrical circuit diagram
I
Main
I
Contro
ler
I
M31 (20) I
-
Sensorwzr source(24Vl ~~;~,~;~‘~~~&f’ Sensor
’
GND
577
(‘2)
578
HP2 (3)
(8)
g
g
3
@
@
3
@
a
Work equipment oi I Pressure (100)
-3
I TVDO1I62
20-580 0
D475A-3
C-61
TROUBLESHOOTING
C-61 [E0501] Short circuit in acceleration Sr * *
sensor system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
3 between M31 (2) and (17) normal? * Turn starting switch ON. * 1.25 - 3.75 V
C-61 Related
Main
Is resistance YES between SS3 - (female) (3) and 2 _ chassis ground normal? Is voltage between M31 (2) Turn starting NO and chassis switch OFF. ground normal? * Disconnect SS3. * Max. 1 R * Disconnect SS3. * Turn starting NO switch ON. * Max. 1 V
YES II -
l
electrical
controller
NO
Defective controller
machine
Defective sensor
acceleration
Replace
Replace
Defective contact or disconnection in wiring harness between M31 (female) (17) - SS3 (female) (3)
Repair or replace
Short circuit with power source in wiring harness between M31 (female) (2) SS3 (female) (2)
Repair or replace
circuit diagram
421
(14)
ss3
(4)
Accelerat sensor
ion
3 3
3
TVD01126
D475A-3
20-581 0
C-62
TROUBLESHOOTING
C-62 [E0502] Disconnection Ir * *
in acceleration
sensor system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES
QYE!
:E&%LJ land (3) normal?
between M31 (2) and (17) normal? Turn starting switch ON. l1.25-3.75V
1 I
* Turn
starting switch ON. * 1.25-3.75V
(female) (2) and
l
I
1 normal?
Turn startina switch OFF.* Disconnect SS3 and M31. * Min. 1 MR
11 N(
l
between M32 (9) M31 (17)
NC and
-Turn starting switch ON. 7.0 - 8.0 V
NO
5 YES
between M32
l
h Turn starting switch OFF. * Disconnect SS3 and M31. Min. 1 Ma l
NO
Defective machine controller
Replace
Defective contact or disconnection in wiring harness between M31 (female) (2) - SS3 (female) (2)
Repair or replace
Defective acceleration sensor
Replace
Short circuit with chassis ground in wiring harness between M31 (female) (2) - SS3 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between M32 (female) (9) - SS3 (female) (1)
Repair or replace
Short circuit with chassis ground in wiring harness between M32 (female) (9) SS3 (female) (1)
Repair or replace
l
C-62 Related electrical circuit diagram
hlain
controller
Sensor
I M31 (20)
GND
421 (14)
ss3 (4)
@
3
g
3
a
3
Accelerat sensor
ion
I
M32
L
20-582 0
(i 6)
TVDOll.26
D475A-3
C-63
TROUBLESHOOTING
C-63 [E0601] Short circuit in buzzer cancel switch system is displayed If the starting switch was turned off after the abnormality occurred, hold the starting switch in the ON position for 60 seconds, and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Remedy
Cause
YES 1
I
~~ . Turn startina switch OFF.* Disconnect 212. * Min 1 MR
NO
Defective machine controller (See Note)
Replace
Short circuit with chassis ground in wiring harness between M32 (female) (7) -212 (female) (I)
Repair or replace
Defective buzzer cancel switch
Replace
Note: This service code is saved as an error when the buzzer cancel switch is held in the ON position for 60 seconds while the engine is running. When finding out the cause of abnormality, check that the above operation has not been performed during work.
C-63 Related
Main
electrical
circuit diagram
controller Buzzer switch
214 (14)
cance ‘I
M\W
77%
GND5
D475A-3
TVDOl127
20-583 0
TROUBLESHOOTING
C-64
C-64 [E0610] Short circuit in backup alarm relay system is displayed * * Ir
If the starting switch was turned off after the abnormality occurred, start joystick to the REVERSE position, and check that the service code displays is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors Always connect any disconnected connectors before going on to the next
the engine and tun the “E” at the head. (If “P” are properly step.
Remedy
Cause
YES
Defective controller
1
inserted.
machine
Replace
Is resiStance between
Ml 1
(female) (9) and chassis ground
-
normal? Turn starting switch OFF. . Disconnect Mll. l200-400Q
l
2
Is resistance between 885 NO (male) (1) and (2) (3) normal? * Turn starting switch OFF. Disconnect 885. *200-400Q
YES k
NO
Short circuit with chassis ground in wiring harness between Ml 1 (female) (9) - 885 (female) (1)
Repair or replace
Defective relay
Replace
backup alarm
l
C-64 Related Main
electrical
circuit diagram
controller Backup
1
1 Backup
Backup
alarm
Kg_
>(~P-----K1~/
alarm
re I ray
t
alarm
I
I
GND4 7797 (ReI ay
box) TVDOl128
20-584 0
D475A-3
TROUBLESHOOTING
C-65
C-65 [E0611] Disconnection * * *
in backup alarm relay system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3
between Ml 1 (9) YE 2
s Turn starting switch ON. - Max. 1 V
between 885 (male) (1) and (2)
N
*Turn starting switch OFF. * Disconnect 885. .200-400R
C-65 Related Main
electrical
YES
EHP
* Turn starting switch OFF. * Disconnect 885. - Max. 1 L2
NO
Remedy
Defective machine controller
Replace
Defective contact, disconnection or short circuit with power source in wiring harness between Ml1 (female) (9) - BB5 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between 885 (female) (2) -chassis ground
Repair or replace
Defective backup alarm relay
Replace
circuit diagram
controller
Backup
BlO (12)
alarm
relrau
BB5 (6) 1 -3 3
Backup
alarm
431 (2)
Fuse
box
3
I
3
(Re I ay
box) TVDOI 128
D475A-3
20-585 0
C-66
TROUBLESHOOTING
C-66 *
* *
[E0632] Short circuit in rockbed selection mode switch system is displayed
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1
I
M31 (3) and M51 (3) as shown in
2 YES
Remedy
Defective machine controller
Replace
Defective monitor panel
Replace
Short circuit with power source in wiring harness between M31 (female) (3) - SO1 (female) (9)
Repair or replace
between M31f3) switch ON. * Disconnect Sol. * Turn starting switch ON. - Max. 1 V
NO
Table Between
M31 (3) - M51 (31, (4) In mode
C-66 Related
Voltage
1
Approx.
4.4 V
In mode 3
Approx.
2.5 V
In mode 5
Approx.
1.3 V
electrical
circuit diagram
Main controller
M31 (20) SSC mode
~-J=g._j
3 4
I
GND5
20-586 0
I
TVDOll29
D475A-3
C-67
TROUBLESHOOTING
C-67 [E0633] Disconnection is displayed *
* *
in rockbed selection mode switch system
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
YES
Defective machine controller
Replace
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between M31 (female) (3) - SO1 (female) (9)
Repair or replace
Short circuit with chassis ground in wiring harness between M31 (female) (3) SO1 (female) (9)
Repair or replace
I M31 (3) and M51 (3) as shown in
‘1 -1
* Turn starting switch ON. NO , and chassis I ground normal? I
I 1
*Turn starting switch OFF. * Disconnect SO1 and M31. ‘Min. 1 MQ
; between M31 - (female) (3) and SO1 (female) (9) normal? . Turn starting NO switch OFF. * Disconnect SO1 and M31. * Max. 1 R u-l
Table 1 Between
M31 (3) - M51 (31, (4)
1
Voltage
1
1
Approx.
4.4 V
1
In mode 3
1
Approx.
2.5 V
1
In mode 5
1
Approx.
1.3 V
I
In mode
C-67 Related
Main
electrical
circuit diagram
controller
214 (14)
Monitor
Panel
GND5
D475A-3
20-587 0
C-68
TROUBLESHOOTING
C-68 [E0930] Disconnection
in engine speed sensor system is displayed
If the starting switch was turned off after the abnormality occurred, start the engine and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
*
* *
Remedy
Cause
Is resistance
II
Defective machine controller
II
lit%:ind H ;;FH-
3
YES
i!
*Turn starting switch OFF. Disconnect M41. ~500-1.000R
I I ‘!27!-”
l
I-----..---
srrrrand(2) Ial?
*Turn starting switch OFF. * Disconnect E12. .500-1,GGon
C-68 Related Main
electrical
I
I
*Turn starting NO switch OFF. * Disconnect M41 and E12. Max. 1 R l
NO
Replace
disconnection or ihort circuit with chassis ground in wiring harness between M41 (female) (9) - El2 (female) (2) Defective contact or disconnection in wiring harness between (female) (1) -El2
M41 (female)
Defective left-bank engine speed sensor
Repair or replace
Repair or replace (1)
Replace
circuit diagram
controller
993 (I 6)
El2 (2) Left engine speed sensor
Enoine controller
E31 (20) Engine speed 5
3
Pulse GND
14
r TVDO1130
20-588 0
D475A-3
C-69
TROUBLESHOOTING
C-69 Lock-up device does not operate when lock-up mode switch is turned- ON Ir * *
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
Defective controller
YES
1 Is voltage between M51 (6) and (3) as shown in Table I?
3 YES Is voltage between SO1 (3) and (2) as shown in Tabl 2?
YES 2
* Turn starting switch ON.
Is resistance between M51 - (female) (6) and NO chassis ground
-
* Turn starting switch OFF. Disconnect SO1 and M51. Min. 1 MR
l
Turn starting switch ON.
_
machine
Replace
Defective contact or disconnection in wiring harness between M51 (female) (6) - SO1 (female) (3)
Repair or replace
Defective
Replace
monitor
1
panel
NO Short circuit with chassis ground in wiring harness between M51 (female) (6) - SO1 (female) (3)
NO
l
Repair or replace
l
Table 2
Table 1
C-69 Related
Main
electrical
circuit diagram
controller
M51 67)
Monitor
GND
@
GND
(g
Rock-up
switch
@
GND5&
D475A-3
Panel
I
so1 (12)
Rock-up
switch
TVDOI 135
20-589 0
c-70
TROUBLESHOOTING
C-70 Engine output turned ON * + *
does not change when economy
mode switch is
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
M51 (14) and (3) and between (7) and (3) as shown in * Turn starting switch ON.
4 YES YES 3
Is voltage between SO1 (4) and (2) and between (5) and (2) as shown in Table 2?
Is resvstance between M51 - (female) (14) and (3) - . Turn starting switch ON. NO and between (7) and (3) normal? Turn startina switch OFF.NO * Disconnect SO1 and M51. * Min. 1 MO
NO
l
Economy mode switch
Between
Between
M51 (14) - (3) (4)
M51 (7) - (31, (4)
Economy mode switch
Defective machine controller
Replace
Defective transmission oil pressure switch system
Recheck service code
Defective contact or disconnectionin wiring harness between M51 (female) (14) - SO1 (female) (4) or between M51 (female) (7) - SO1 (female) (5)
Repair or replace
Defective monitor panel
Replace
Short circuit with chassis ground in wiring harness between M51 (female) (14) - SO1 (female) (4) or between M51 (female) (7) - SO1 (female) (5)
Repair or replace
Between so1 (4) - (2)
Between so1 (5) - (2)
When
OFF
20 - 30 u
20 - 30 u
When
OFF
20 - 30 u
20 - 30 u
When
at 1
20 - 30 u
Max.
1 U
When
at 1
20 - 30 u
Max. 1 U
When
at 2
Max. 1 U
20 - 30 u
When
at 2
Max.
20 - 30 u
C-70 Related
I
Main
electrical controller
1 U
circuit diagram Monitor
I M51 (17)
Panel
I
so1
(12)
TV001 131
20-590 0
D475A-3
c-71
TROUBLESHOOTING
C-71 Reverse travel speed does not change when reverse slow mode switch is turned ON * Ir Ir
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
2 YES YE
1
Is monitoring code [7Hl displayed normally? * Start engine.
NO
Is voltage
YES_ between SO1 (6)
* Turn starting switch ON.
3
N
Is resistance between M51 (female) (15) and (3) normal? ‘Turn starting switch OFF. * Disconnect SO1 and M51. * Min. 1 MQ
Table
and (2) as shown in Table 2? _
*Turn starting switch ON.
Main
_ P NO
NO
Replace
Defective transmission oil pressure switch system
Recheck service code
I Repair or replace
Defective monitor panel
Replace
Short circuit with chassis ground in wiring harness between M51 (female) (15) - SO1 (female) (6)
Repair or replace
Table 2
1
c-71 Related
Defective machine controller
Defective contact or disconnection in wiring harness between M51 (female) (15) - SO1 (female) (6)
4 YES
M51 (15) and (3) as shown in Table l?
Remedy
electrical
circuit diagram
controller Monitor
Panel
REVERSEslow switch
GND5
D475A-3
TVDOI 13.7
20-591 0
C-72
TROUBLESHOOTING
C-72 Shoe slip control device does not operate when shoe slip control switch is turned ON or shoe slip level does not change when rockbed selection mode switch is changed * Ir Ir
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
3 YES 2Is monitoring code [7H1 displayed normally?
YI
1
_
I
YES
Is monitoring code IRHI displayed normally? * Start engine.
NO
* Start engine.
NO
between M51 (8) and (3) as shown * Turn starting switch ON.
(3) normal? * Turn starting switch OFF.* Disconnect SO1 and M51. * Min. 1 MR
Table
II
I NO
1
Remedy
Cause
Defective machine controller
Replace
Defective transmission oil pressure switch system
Recheck service code
Defective ripper relay oil pressure switch system
Recheck service code
Defective contact or disconnection in wiring harness between M51 (female) (8) - SO1 (female) (7)
Repair or replace
Defective monitor panel
Replace
Short circuit with chassis ground in wiring harness between M51 (female) (81 - SO1 (female) (7)
Repair or replace
Table 2
Shoe slip control switch
Between
Between so1 (7) - (2)
Shoe slip control switch
M51 (8) - (3) (4)
I
When
OFF
I
20 - 30 U
I
I
When
OFF
I
20 - 30 u
I
I
When
ON
I
Max.
I
I
When
ON
I
Max. 1 U
I
C-72 Related Main
electrical
1 U
circuit diagram
controller Monitor
1
l-F?% GND
@
SSC switch
@
so;
Panel
(12)
TVDOI 133
20-592 0
D475A-3
c-73
TROUBLESHOOTING
C-73 Any solenoid related to machine controller * * Ir
does not operate
Check that fuse 12 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Defective machine controller
1 YES Is voltage between M21 (I) and (11) normal?
-
Turn starting switch ON. l20-30V
NO
C-73 Related
electrical
l
Main
controller
Remedy
Replace
Defective contact or disconnection in wiring harness between M21 (female) (1) -fuse 12
Repair or replace
circuit diagram
I
421 (14) @
Bl 1 (14) 3
Fuse
box
---ET! 20A
12
TVDOl 134
D475A-3
20-593 0
c-74
TROUBLESHOOTING
C-74 Backup alarm does not sound or keeps sounding * * Ir
a) Ir
Check that any service code is not displayed. (If any service code is displayed, check according to it.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Backup buzzer does not sound Check that fuse 3 is not broken. chassis ground.)
(If it is broken, check the circuit related to it for short circuit with
Remedy
Cause
ground normal? Start engine. * Travel in reverse. 20 - 30 V (See note) 1I YES l
between 885 (3)
l
1Is voltage between switch ON. *20-30V * Turn starting switch ON. *20-30V
Note: The voltage
b)
fluctuates
Backup buzzer
at the interval
H NO
of about
1 second
1 YES 885 is disconnected, does buzzer sound normally?
* Turn starting switch ON.
20-594 0
t
NO
Replace
Defective backup alarm
Replace
Defective contact or disconnection in wiring harness between BB5 (female) (5) - 431 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between fuse 3 outlet - BB5 (female) (3)
Repair or replace
Defective fuse power source system
Repair or replace
between
20 - 30V and IV.
keeps sounding
I 1If relay
Defective backup alarm relay
Cause
Defective backup buzzer relay Short circuit with power source in wiring harness between 885 (female) (51 -431 (female) (1)
I
Remedy
Replace
Repair or replace
D475A-3
c-74
TROUBLESHOOTING
C-74 Related electrical circuit diagram
Main
controller
Ml1 (i3)
1 22 (12) m-
n Backup
alarm
431 (2)
Backup
BlO (12)
alarm
re I ray
885 (6)
3 3 buse
Dox
GND4* (Re I ay
box) TVD01128
D475A-3
20-595 0
TROUBLESHOOTING
c-75
C-75 Ripper pin puller cylinder does not operate *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
*
a) *
inserted.
Pin cannot be pulled out Check that fuse 12 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis ground.)
I
Cause
7
YES
resistancebetween _ 244 (male) (1) and (2) YE 1. and between (1) (2) and chassisground as shown in If
1 between 244
NO
* Turn starting switch OFF. * Disconnect 244.
(1)
4 YES Is resistance YES between 263 (male) (1) and (2) normal? 3
*Turn starting switch ON. - Switch: PULL *20-30V h
Is voltage between 263 (I) and chassis ground normal?
_
+ Turn starting switch OFF. * Disconnect 263. * Max. 1 $2 5
NO
YES
Is voltage between fuse 12 outlet and NO chassis ground normal?
* Turn starting switch ON. *20-30V
* Turn starting switch ON. *20-30V
NO
Remedy
Defective pin puller solenoid
Replace
Defective contact or disconnection in wiring harness between 244 (female) (2) -chassis ground
Repair or replace
Defective contact or disconnection in wiring harnessbetween (female) (2) - 244 (female) (1)
Repair or replace
Defective pin puller solenoid
Replace
Defective contact or disconnection in wiring harness between fuse 12 outlet - 263 (female) (1)
Repair or replace
Defective fuse power source system
Repair or replace
Table
I
224 (male)
1 Between
b)
(I) (2) - chassis
Pin cannot
be pushed
I
Resistance
1
Min. 1 MR
in
I 1 YES Is resistance between 263 (male) (1) and (2) normal? -Turn starting switch OFF. * Disconnect 263. * Min 1 MR
20-596 0
NO
Cause
I
I
Remedy
Short circuit with power source in wiring harness between 263 (female) (2) - 244 (female) (I)
Repair or replace
Defective pin puller switch
Replace
D475A-3
TROUBLESHOOTING
c-75
C-75 Related electrical circuit diagram
Pin
Duller
TVD01136
D475A-3
20-597 0
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
modes
Table of failure
and causes . . . . . .. . . . . . .. . . . . . . .. .. . . . . . . .. . . . . . .. . . . . . .. . .. . . . . . .. . . . . .. . . . .. . . . . . .. . . . . . .. . . . . .. . .. . .. . .. . . .. . . 20-602 (lacks drawbar
pull). ...............................................................................
20-604
H- 1
Machine
lacks power
H- 2
Machine
does not move (at 2nd or 3rd gear speed) ..............................................................
.20-606
H- 3
Machine
does not move at any gear speed .............................................................................
20-608
H- 4
Machine
travels
or in reverse ............................................................................
.20-610
H- 5
Time lag is excessive
H- 6
Machine
does not turn in either direction
H- 7
Machine
turns only in one direction
H- 8
Machine
turns too far .................................................................................................................
.20-613
H- 9
Brakes do not work.. ...................................................................................................................
.20-613
H-10
Torque
H-l 1
Power train oil overheats
H-12
All work equipment
H-13
Work equipment
H-14
Blade lift speed is slow or lacks power
...................................................................................
.20-617
H-15
Blade tilt speed is slow or lacks power
....................................................................................
20-618
H-16
Blade pitch does not work ..........................................................................................................
20-618
H-17
Ripper lift speed is slow or lacks power ...................................................................................
20-619
H-18
Ripper tilt speed is slow or lacks power.. ................................................................................
.20-619
H-19
Excessive
hydraulic
drift of blade lift .......................................................................................
.20-620
H-20
Excessive
hydraulic
drift of blade tilt .......................................................................................
.20-620
H-21
Excessive
hydraulic
drift of ripper lift ......................................................................................
.20-620
H-22
Ripper pin-puller
H-23
Abnormal
D475A-3
only forward
when gear is shifted
or travel direction
is changed..
.......................
................................................................................
.........................................................................................
lock-up does not work.. ................................................................................
converter
............................................................................................................
.20-610 20-611 20-612
20-614 20-615
speeds are low.. .......................................................................................
.20-616
does not move at all.. ...................................................................................
.20-617
cylinder
does not work ................................................................................
noise from around
hydraulic
pump
........................................................................
.20-621 20-621
20-601 0
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
Failure
mode
Machine
turns only in one direction
0
Machine
turns too far
0.0..
Brakes do not work Torque
converter
00
lock-up
does not work
Work
equipment
0
speeds
H-7 H-E 0
H-S
0.0.
Power train oil overheats All work equipment
0.0
are low
does not move at all
0
H-11 00
0
00
0
H-l
0
0.00..
0
00
.
H-l
0
Blade lift speed is slow or lacks power
00
Blade tilt speed is slow or lacks power
0
Blade pitch does not work
H-l 0
H-l
0
0
H-l
0
.
.
Ripper lift speed is slow or lacks power
0
0.0
H-l
Ripper tilt speed is slow or lacks power
0
0.0
H-l
Excessive
hydraulic
drift of blade lift
Excessive
hydraulic
drift of blade tilt
0
Excessive
hydraulic
drift of ripper
0.0
Ripper
pin-puller
Abnormal
20-602 0
cylinder
0
lift
does not work
noise from around
hydraulic
0
H-l
0
H-l
0
H-2 H-2
. pump
.
.
H-2 .
H-2:
D475A-3
TROUBLESHOOTING
H-1
H-1 Machine lacks power (lacks drawbar pull) fl Check that the power train oil level is normal. (If insufficient, supply new oil.)
YES
6 YES YES Is engine speed at F3 stall 5 normal?
Is steering clutch, YES brake oil pressure as shown in 4 following table?
1 Is brake dragging?
Is inlet and outlet
YES pressure of • See Note.
3 YES Is transmission
modulating pressure normal?
2 Is transmission main relief NO pressure normal? • Engine at high idling • Min. 2.35 MPa {Min. 24.0 kg/cm2}
NO
• Torque converter stall speed: Min. 1,590 rpm • Full stall speed: Min. 1,420 rpm
NO
NO
torque converter normal?
• Engine at high NO idling • Inlet pressure: 0.78 – 0.98 MPa {8.0 – 10.0 kg/cm2} • Outlet pressure: 0.29 – 0.59 MPa {3.0 – 6.0 kg/cm2}
• Engine at high idling • Min. 2.35 MPa NO {Min. 24.0 kg/cm2}
7 YES Is free length of main relieve valve spring normal and does spool move smoothly?
NO • Free length of spring: 120.3 mm
Note: Set the machine on a level ground and run the engine at low idling. Shift the joystick to F2. If the machine starts traveling, the brake is not dragging. Table
Measuring condition
Joystick
At neutral
Steering to left
Steering to right
20-604 3 4
Clutch oil pressure (MPa {kg/cm2})
Brake oil pressure (MPa {kg/cm2})
Left
Right
Left
Right
Engine at low idling
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
Min. 2.16 {Min. 22.0}
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.35 {Min. 24.0}
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
0 {0}
Engine at high idling
0 {0}
Min. 2.35 {Min. 24.0}
Min. 2.26 {Min. 23.0}
0 {0}
D475A-3
H-l
TROUBLESHOOTING
Cause
-
Brake dragging
Go to H-9
Defective engine
Check engine
Defect in transmission
Repair or replace
Defective steering clutch
Go to H6
Defect in torque converter
Repair or replace
Defective transmission valve
Repair or replace
Defective power train pump Defective main relief valve spring, spool catching, or clogging with dirt
D475A-3
Remedy
Replace
Replace, repair, or clean
20-605 0
TROUBLESHOOTING
H-2
H-2 Machine does not move (at 2nd or 3rd gear speed) fl Check that the power train oil level is normal. (If insufficient not, supply new oil.) YES ª Criteria for Item 6 • Engine at high idling • Inlet pressure: 0.78 – 0.98 MPa {8.0 – 10.0 kg/cm2} • Outlet pressure: 0.29 – 0.59 MPa {3.0 – 6.0 kg/cm2}
YES
3
6 Is inlet and outlet
YES Is brake dragging
YES pressure of
at F1 or R1?
YES 4 2 Is transmission main relief NO pressure normal?
Does speed gear
YES lever of transmission valve shift normally?
• Engine at high idling • Min. 2.35 MPa {Min. 24.0 kg/cm2}
• Operate joystick.
1
NO
Is parking brake released?
5
torque converter normal?
Is transmission modulating pressure normal?
ª See criteria at left upper part.
NO
• Engine at high idling NO • Min. 2.35 MPa {Min. 24.0 kg/cm2}
8 YES Is free length of main relieve valve spring normal and does spool move smoothly?
NO • Free length of spring: 120.3 mm
• Operate parking brake.
NO
NO
20-606 3 4
D475A-3
TROUBLESHOOTING
H-2
Cause
7 YES Is steering clutch oil pressure as shown in following table?
Remedy
Brake dragging
Go to H-9
Defect in transmission
Repair or replace
Defective steering clutch
Go to H-6
Defect inside torque converter
Repair or replace
Defective transmission valve
Repair or replace
Defective power train pump
Replace
Defective main relief valve spring, spool catching, or clogging with dirt
Replace, repair, or clean
Defective adjustment of gear speed linkage
Adjust
Defective adjustment of parking brake linkage
Adjust
NO
Table
Measuring condition
Joystick
At neutral
Steering to left
Steering to right
D475A-3
Clutch oil pressure (MPa {kg/cm2})
Brake oil pressure (MPa {kg/cm2})
Left
Right
Left
Right
Engine at low idling
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
Min. 2.16 {Min. 22.0}
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.35 {Min. 24.0}
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
0 {0}
Engine at high idling
0 {0}
Min. 2.35 {Min. 24.0}
Min. 2.26 {Min. 23.0}
0 {0}
20-607 3 4
TROUBLESHOOTING
H-3
H-3 Machine does not move at any gear speed fl Check that the power train oil level is normal. (If insufficient, supply new oil.) YES 6 Is steering clutch
YES oil pressure as ª Criteria for Item 4 • Engine at high idling • Inlet pressure: 0.78 – 0.98 MPa {8.0 – 10.0 kg/cm2} • Outlet pressure: 0.29 – 0.59 MPa {3.0 – 6.0 kg/cm2}
5 YES
shown in Table 2?
Is transmission modulating pressure normal?
NO
4 • Engine at high idling • Min. 2.35 MPa {Min. 24.0 kg/cm2}
Is inlet and outlet YES pressure of torque converter normal?
3
ª See criteria at left upper part.
YES Is transmission
NO
main relief pressure normal?
• Engine at high idling • Min. 2.35 MPa {Min. 24.0 kg/cm2}
2 Does directional
YES lever transmission
NO
valve shift normally?
1
8 YES Is free length of main relieve valve spring normal and does spool move smoothly?
NO • Free length of spring: 120.3 mm
• Operate joystick.
Is brake oil pressure as shown in Table?
NO
NO
NO
Table 1
Brake pedal
Measuring condition
Released
Depressed
20-608 3 4
Brake oil pressure (MPa {kg/cm2}) Left
Right
Engine at low idling
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
0 {0}
Engine at high idling
0 {0}
0 {0}
D475A-3
TROUBLESHOOTING
H-3
Cause
7 YES Does steering valve lever move normally? • Operate joystick.
NO
Remedy
Defect in steering clutch or transmission
Repair or replace
Defective steering clutch seal or steering valve
Repair or replace
Defective adjustment of steering linkage
Adjust
Defective transmission valve
Repair or replace
Defect inside torque converter
Repair or replace
Defective power train pump
Replace
Defective main relief valve spring, spool catching, or clogging with dirt
Replace, repair, or clean
Defective adjustment of directional lever linkage
Adjust
Defective brake
Go to H-9
Table 2
Measuring condition
Joystick
At neutral
Steering to left
Steering to right
D475A-3
Clutch oil pressure (MPa {kg/cm2})
Brake oil pressure (MPa {kg/cm2})
Left
Right
Left
Right
Engine at low idling
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
Min. 2.16 {Min. 22.0}
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.35 {Min. 24.0}
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
0 {0}
Engine at high idling
0 {0}
Min. 2.35 {Min. 24.0}
Min. 2.26 {Min. 23.0}
0 {0}
20-609 3 4
TROUBLESHOOTING
H-4, H-5
H-4 Machine travels only forward or in reverse fl Check that the gear speed changes normally in the direction where travel is normal. (If not, perform check of H-3.)
Cause
1 YES Is directional lever of transmission shifts normally? • Operate joystick.
NO
Remedy
Slippage of clutch in direction where machine does not start (Forward or reverse)
Repair or replace
Defective adjustment of directional lever linkage
Adjust
H-5 Time lag is excessive when gear is shifted or travel direction is changed Cause
YES
YES
1 3 Is brake dragging?
YES
• See Note.
2
NO
Do gear speed lever and directional lever of transmission valve shift normally?
Is transmission main relief pressure normal? • Engine at high idling NO • Min. 2.35 MPa {Min. 24.0 kg/cm2}
• Operate joystick.
NO
Brake dragging
Go to H-9
Defective transmission valve (Defective operation of spool)
Repair or replace
4 YES Defective power train Is free length of main relieve valve spring normal and does spool move smoothly?
• Free length of spring: 120.3 mm
Remedy
pump Defective main relief valve spring or clogging NO with dirt Defective adjustment of gear speed linkage or directional lever linkage
Replace
Replace or clean
Adjust
Note: Use the blade and ripper to raise the chassis, then run the engine at low idling. Shift the joystick to F3 or R3. If the track shoe moves at this time, the brake is not dragging.
20-610 3 4
D475A-3
TROUBLESHOOTING
H-6
H-6 Machine does not turn in either direction fl Check that the power train oil level is normal. (If insufficient, supply new oil.)
Cause
YES
Remedy
Defective operation of brake
Go to H-9
Seizure of clutch disc, plate
Replace
1 Is clutch disengaged?
YES 2
• See Note. Is steering clutch, brake oil pressure NO as shown in following table?
4 YES Defective clutch piston Does clutch valve YES spool move 3 normally? Does steering valve lever move NO normally?
seal
Defective operation of steering valve clutch NO spool
Defective adjustment of steering linkage
• Operate joystick.
NO
Replace
Repair or replace
Adjust
Note: Travel in F1 or R1 on a level ground with the engine at low idling, then operate the joystick to the left or right to the position where the clutch should be disengaged (about a half stroke). If the machine stops or turns slowly at this time, the clutch is disengaged.
Table
Measuring condition
Joystick
At neutral
Steering to left
Steering to right
D475A-3
Clutch oil pressure (MPa {kg/cm2})
Brake oil pressure (MPa {kg/cm2})
Left
Right
Left
Right
Engine at low idling
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
Min. 2.16 {Min. 22.0}
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.35 {Min. 24.0}
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
0 {0}
Engine at high idling
0 {0}
Min. 2.35 {Min. 24.0}
Min. 2.26 {Min. 23.0}
0 {0}
20-611 3 4
TROUBLESHOOTING
H-7
H-7 Machine turns only in one direction
Cause
3 YES YES 2
Is clutch oil pressure on steerable side as shown in following table?
NO
Is clutch, brake oil YES pressure on unsteerable side normal?
1
4 YES Do clutch valve spool and brake NO valve spool move smoothly?
Does steering valve lever move normally?
NO
NO
Remedy
Wear, scuffing of brake disc, plate
Replace
Slippage of clutch on steerable side
Repair or replace
Defective clutch chamber seal or defective seal ring
Repair or replace
Development operation of clutch valve spool or brake valve spool
Repair or replace
Defective steering linkage
Adjust
Table
Measuring condition
Joystick
At neutral
Steering to left
Steering to right
20-612 3 4
Clutch oil pressure (MPa {kg/cm2})
Brake oil pressure (MPa {kg/cm2})
Left
Right
Left
Right
Engine at low idling
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
Min. 2.16 {Min. 22.0}
0 {0}
0 {0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.35 {Min. 24.0}
0 {0}
0 {0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
0 {0}
Engine at high idling
0 {0}
Min. 2.35 {Min. 24.0}
Min. 2.26 {Min. 23.0}
0 {0}
D475A-3
TROUBLESHOOTING
H-8, H-9
H-8 Machine turns too far Cause
1 YES
Remedy
Defective operation of brake
Go to H-9
Defective disengagement of clutch
Go to H-6
Is clutch disengaged? • See Note.
NO
Note: Travel in F1 or R1 on a level ground with the engine at low idling, then operate the joystick to the left or right to the position where the clutch should be disengaged (about a half stroke). If the machine stops or turns slowly at this time, the clutch is disengaged.
H-9 Brakes do not work fl Check that the power train oil level is normal. (If insufficient, supply new oil.) Cause
YES 2
Remedy
Wear of brake disc, plate
Replace
Defective brake piston seal
Replace
Defective operation of brake valve spool
Adjust
Defective adjustment of brake linkage
Adjust
Is brake oil
YES pressure as shown in following table?
1
3 YES Does brake valve spool move NO smoothly?
Is brake linkage adjusted normally?
NO
NO
Table 1
Brake pedal
Measuring condition
Released
Depressed
D475A-3
Brake oil pressure (MPa {kg/cm2}) Left
Right
Engine at low idling
Min. 2.16 {Min. 22.0}
Min. 2.16 {Min. 22.0}
Engine at high idling
Min. 2.26 {Min. 23.0}
Min. 2.26 {Min. 23.0}
Engine at low idling
0 {0}
0 {0}
Engine at high idling
0 {0}
0 {0}
20-613 3 4
TROUBLESHOOTING
H-10
H-10 Torque converter lock-up does not work fl Check that any service code is not displayed. (If any service code is displayed, check according to it.)
Cause
2 YES Is torque YES converter stall speed at F3 normal?
1 Is torque converter lock-up oil presssure normal?
NO
• Engine at high idling • Min. 1,590 rpm
4 YES
• Engine at high idling • Min. 1.08 MPa {Min. 11.0 kg/cm2}
Does lock-up YES solenoid valve spool move smoothly? 3
NO
Is transmission main relief NO pressure normal? • Engine at high idling • Min. 2.35 MPa NO {Min. 24.0 kg/cm2}
5 YES Is free length of main relieve valve spring normal and does spool move smoothly?
NO • Free length of spring: 120.3 mm
20-614 3 4
Remedy
Defective lock-up clutch
Repair or replace
Defect inside torque converter
Repair or replace
Defective torque converter lock-up valve
Repair or replace
Defective torque converter loc-up solenoid valve
Repair or replace
Defective power train pump
Replace
Defective main relief valve spring, spool catching, or clogging with dirt
Replace, repair, or clean
D475A-3
TROUBLESHOOTING
H-11
H-11 Power train oil overheats fl Check that the power train oil is actually at high temperature. (If it is normal, check the panel in M mode.) fl Check that the power train oil level is normal. (If insufficient, supply new oil.)
Cause
YES
YES
1
3
Brake dragging
Go to H-9
Defective engine cooling system
Check engine cooling system
Is torque
Is brake dragging?
YES converter stall speed at F3 normal?
• See Note.
2 Is transmission main relief NO pressure normal?
• Engine at high idling • Min. 1,590 rpm
4 YES
Go to A
Does machine stop when Item 3 NO is checked? Slippage of brake disc,
NO plate
• Engine at high idling • Min. 2.35 MPa {Min. 24.0 kg/cm2}
NO
5 YES Is free length of main relieve valve spring normal and does spool move smoothly?
• Free length of NO spring: 120.3 mm
6 YES A
Remedy
Is inlet and outlet pressure of torque converter normal? • Engine at high NO idling • Inlet pressure: 0.78 – 0.98 MPa {8.0 – 10.0 kg/cm2} • Outlet pressure: 0.29 – 0.59 MPa {3.0 – 6.0 kg/cm2}
Repair or replace
Defective power train pump (Air entering through suction circuit)
Repair or replace
Defective main relief valve spring, spool catching, or clogging with dirt
Replace, repair, or clean
Slippage of transmission clutch, excessive engine output, or slippage of steering clutch
Repair or replace
Defect inside torque converter
Repair or replace
Note: Use the blade and ripper to raise the chassis, then run the engine at low idling. Shift the joystick to F3 or R3. If the track shoe moves at this time, the brake is not dragging.
D475A-3
20-615 3 4
TROUBLESHOOTING
H-12
H-12 All work equipment speeds are low fl Check that the hydraulic oil level is normal. (If insufficient, supply new oil.)
Cause
4 YES Defective work YES 3
equipment pump assembly
Does condition become normal when work equipment pump assembly is replaced?
NO
YES Is rear pump
relief pressure normal?
• Engine at high idling • 19.6MPa {200kg/cm2}
2 YES Is front pump
relief pressure normal?
1
5 YES
NO
Does condition become normal in Item 3 when main relief valve of blade tilt/ripper Lo valve is adjusted?
NO
• Engine at high idling • Min. 19.6 MPa {Min. 200 kg/cm2}
Is work equipment control oil pressure normal?
6 YES
NO
Does condition become normal in Item 2 when main relief valve of blade lift valve is adjusted?
NO
• Engine at high idling • Release safety lever. • Min. 3.92 MPa {Min. 40.0 kg/cm2}
YES 7
Is work equipment control oil pressure normal NO when safety lever is locked?
• Engine at high idling • Lock safety lever.NO • Min. 3.92 MPa {Min. 40.0 kg/cm2}
YES 8 Does condition become normal in Item 7 when PPC relief valve is adjusted?
20-616 3 4
Repair or replace
Defective adjustment of main relief valve of blade tilt/ripper Lo valve
Replace
Defective main relief valve of blade tilt/ripper Lo valve
Repair or replace
Defective adjustment of main relief valve of blade lift valve
Replace
Defective main relief valve of blade lift valve
Repair or replace
Internal leakage in PPC valve or tilt limit solenoid valve
Repair or replace
Defective adjustment of PPC relief valve
Adjust
pump
NO
Replace
Defective PTO
9 YES Defective PPC charge Is any foreign material found in NO strainer of PPC relief valve?
Remedy
Defective PPC relief valve
Replace
Repair or replace
D475A-3
TROUBLESHOOTING
H-13, H-14
H-13 Work equipment does not move at all fl Check that the hydraulic oil level is normal. (If insufficient, supply new oil.)
Cause
2 YES YES 1
Does condition become normal when work equipment pump assembly is replaced?
Defective work equipment pump assembly
Replace
Defective PTO
Repair or replace
Defective PPC charge pump
Replace
Defective PPC relief valve
Repair or replace
NO
Is work equipment control oil pressure normal?
3 YES
• Engine at high idling • Min. 3.92 MPa NO {Min. 40.0 kg/cm2}
Is any foreign material found in strainer of PPC relief valve?
NO
Remedy
H-14 Blade lift speed is slow or lacks power fl Check that the hydraulic oil level is normal. (If insufficient, supply new oil.) fl Check that the hydraulic drift of the blade lift is normal. (If not, go to H-19.) fl Check that the blade has not been modified.
Cause
3 YES YES 2 Is PPC valve
Does condition become normal when suction valve on blade RAISE side of blade lift valve is replaced?
YES output pressure 1 Does cylinder operate smoothly?
Defective suction valve of blade lift valve
Repair or replace
Defective operation of blade lift valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in cylinder
Bleed air
on blade RAISE side normal? • Engine at high idling NO • Operate lever through all stroke. • Min. 3.92 MPa {Min. 40.0 kg/cm2}
NO
D475A-3
NO
Remedy
20-617 3 4
TROUBLESHOOTING
H-15, H-16
H-15 Blade tilt speed is slow or lacks power fl Check that the hydraulic oil level is normal. (If insufficient, supply new oil.) fl Check that the hydraulic drift of the blade tilt is normal. (If not, go to H-20.) fl Check that the blade has not been modified. Cause
2 YES Is PPC valve
Remedy
Defective operation of blade tilt valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in cylinder
Bleed air
YES output pressure 1 normal?
Does cylinder operate smoothly?
• Engine at high NO idling • Operate lever through all stroke. • Min. 3.92 MPa {Min. 40.0 kg/cm2}
NO
H-16 Blade pitch does not work Dual tilt specification Cause
1 YES Is blade tilt operation normal?
NO
Remedy
Defective pitch selector solenoid valve
Repair or replace
Defective blade tilt circuit
Go to H-15
Superdozer specification Cause
1 YES Is blade tilt operation normal?
NO
20-618 3 4
Remedy
Defective pitch dump solenoid valve or pitch back solenoid valve
Repair or replace
Defective blade tilt circuit
Go to H-15
D475A-3
TROUBLESHOOTING
H-17, H-18
H-17 Ripper lift speed is slow or lacks power fl Check that the hydraulic oil level is normal. (If insufficient, supply new oil.) fl Check that the hydraulic drift of the ripper lift is normal. (If not, go to H-21.) fl Check that the ripper has not been modified.
Cause
3 YES YES 2 Is PPC valve YES output pressure on ripper RAISE 1 side normal? Does cylinder operate smoothly?
Does condition become normal when suction valve on ripper RAISE side of ripper Hi valve is replaced?
NO
• Engine at high idling NO • Operate lever through all stroke. • Min. 3.92 MPa {Min. 40.0 kg/cm2}
NO
Remedy
Defective suction valve of ripper Hi valve
Repair or replace
Defective operation of ripper Lo or Hi valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in cylinder
Bleed air
H-18 Ripper tilt speed is slow or lacks power fl Check that the hydraulic oil level is normal. (If insufficient, supply new oil.) fl Check that the ripper has not been modified.
Cause
2 YES YES Is PPC valve output pressure 1
Defective operation of ripper Lo or Hi valve spool
Repair or replace
Defective PPC valve
Repair or replace
Air in cylinder
Bleed air
normal?
Does cylinder operate smoothly?
• Engine at high NO idling • Operate lever through all stroke. • Min. 3.92 MPa {Min. 40.0 kg/cm2}
NO
D475A-3
Remedy
20-619 3 4
TROUBLESHOOTING
H-19, H-20, H-21
H-19 Excessive hydraulic drift of blade lift fl Check that there is no leakage of oil in the blade lift cylinder circuit. fl Check that the blade has not been modified. Cause
1 YES Is hydraulic drift speed heightened when lever is shifted down with front part of chassis raised?
• Stop engine. • See TESTING AND ADJUSTING.
NO
Remedy
Excessive internal leakage in blade cylinder (Defective piston seal)
Repair or replace
Excessive internal leakage in blade lift valve (Defective oil seal)
Repair or replace
H-20 Excessive hydraulic drift of blade tilt fl Check that there is no leakage of oil in the blade tilt cylinder circuit. fl Check that the blade has not been modified. Cause
1 YES Is leakage in blade tilt cylinder normal?
NO
• Engine at full throttle • 12 cc/min
Remedy
Excessive internal leakage in blade tilt/ripper Lo valve (Defective oil seal)
Repair or replace
Excessive internal leakage in blade tilt cylinder (Defective piston seal)
Repair or replace
H-21 Excessive hydraulic drift of ripper lift fl Check that there is no leakage of oil in the ripper lift cylinder circuit. fl Check that the ripper has not been modified. Cause
1 YES Is leakage in ripper lift cylinder normal? • Engine at full throttle • 12 cc/min
20-620 3
NO
Remedy
Excessive internal leakage in blade tilt/ripper Lo valve or ripper Hi valve (Defective oil seal)
Repair or replace
Excessive internal leakage in ripper lift cylinder (Defective piston seal)
Repair or replace
D475A-3
TROUBLESHOOTING
H-22 Ir
H-22, H-23
Ripper pin-puller
cylinder does not work
Check that the power train oil pressure
is normal.
(If not, check the power train.)
1 YES Is output
H-23 Abnormal *
Defective pin-puller cylinder
II
oil level is normal.
(If insufficient,
supply new oil.)
Cause
1
I N0
D475A-3
Repair or replace
noise from around hydraulic pump
Check that the hydraulic
ES Is air
I
Remedy
Defective seal in pump suction circuit
Repair
Clogged hydraulic tank strainer
Clean
Defective work equipment pump
Replace
Operate for a while and check for change of condition.
Check again according to change of condition.
Improper oil
Replace
sucked in .3
YES
I
) NC
20-621 0
TROUBLESHOOTING OF MONITOR PANEL AND ELECTRICAL SYSTEM (M MODE)
Action taken by controller Electrical
when
circuit diagram
occurs and problems
abnormality
on machine . . . . . .. . . . . .. . .. .. . . .. . .. . 20-702
of M mode system . . .. . . . . . . . .. .. . . . . .. . . . . . .. .. . . . . . . .. . . . . .. . . . . .. . . .. .. .. . . . .. . .. . . .. .. . . .. .. . . . . . .. . 20-704
M- 1 [E0120] Short circuit in caution
lamp output system
M- 2 [E0121] Abnormality
in network
system
M- 3 [E021 I] Abnormality
in power train (torque
M- 4 [EO3291 Abnormality
in hydraulic
M- 5 [E0430] Abnormality
in engine
M- 6 [E04311 Abnormality
in radiator
M- 7 [E0432] Abnormality
in engine
(monitor
converter
oil temperature
oil pressure water
is displayed
....................................... is displayed..
panel system)
oil temperature
is displayed
................. .20-707
is displayed..
...... ..20-70 8
.............................................
is displayed
......................................................
.20-709
.......................................................
20-709
water temperature
is displayed
...........................................
starting
switch is turned
on, monitor
panel gives no display ...................................
M- 9 When
starting
switch is turned
on, monitor
panel lamps all stay lighted
starting
switch
is turned
on (engine
stopped),
When
starting
switch
(but battery charge, M-12
When
starting
is turned engine
on (engine
oil pressure
switch is turned
stopped],
caution
on (engine
caution
20-714
items flash 20-716
items flash
do not flash) ..............................................
20-718
engine
M-13
Preheating
does not light up or go out ......................................................................
20-724
M-14
Abnormality
in caution
buzzer ...................................................................................................
20-725
M-15
Abnormality
in caution
lamp ......................................................................................................
20-727
M-16
Abnormality
in engine
M-17
Abnormality
in power train (torque
M-18
Abnormality
in fuel level gauge .................................................................................................
M-19
Speed
M-20
Service
M-21
Abnormality
M-22
caution
20-713
(but battery charge, monitor
oil pressure
caution
do not flash) ..............................................
stopped),
.20-711
check before starting
items flash .................................................................................................................................... M-II
.20-710
up and
do not go out ............................................................................................................................... When
20-708
level is displayed
M- 8 When
M-10
.20-706
water temperature
range display shows
converter]
“- -“, engine
meter does not advance
gauge.. .................................................................
when
oil temperature
gauge ................................
speed is not displayed
engine
is running
.......................................
.....................................................
in service mode .....................................................................................................
Night lighting
on monitor
(front lamp, working
lamps do not light up .....................................................................
Front lamps and working
M-24
Rear lamps do not light up.. ....................................................................................................... Automatic
M-26
Windshield
D475A-3
preheater wiper
20-731 20-733 20-735 20-735 20-736
panel does not light up
lamp are normal) .....................................................................................
M-23
M-25
.20-729
does not work ..........................................................................................
and window
washer
do not work.. .............................................................
20-738 20-740 20-743 20-744 20-747
20-701 0
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code
Service code Abnormal system
Nature of abnormality % When GND output voltage to caution lamp has become high
E0120
Short circuit in monitor caution lamp system
E0121
Short circuit in monitor alarm buzzer system
E0211
Abnormality in power train (torque converter) oil temperature
CALL 03
EOI
E0329
E0430
Abnormality in hydraulic oil temperature
Abnormality in radiator water level
1. Defective caution lamp 2. Short circuit with power source in wiring harness between monitor panel CN2 (7) and caution lamp 375 (2) 3. Defective monitor panel % When alarm buzzer GND output voltage has become high 1. Defective alarm buzzer 2. Short circuit with power source in wiring harness between monitor panel CN2 (8) and alarm buzzer 217 (2) 3. Defective monitor panel % When torque converter oil temperature caution lamp on monitor panel flashes 1. Rise of torque converter oil temperature to about 130°C 2. Defective torque converter oil temperature sensor
% When hydraulic oil temperature caution lamp on monitor panel flashes 1. Rise of hydraulic oil temperature to about 108°C 2. Defective contact or disconnection in wiring harness between monitor panel CNI (8) - sensor 452 (I 1 3. Defective hydraulic oil temperature sensor
I When engine oil pressure caution lamp on monitor panel flashes 1. Lowering of engine oil pressure 2. Short circuit with chassis ground in wiring harness between monitor panel CNI (7) - sensor 301 (3) 3. Defective engine oil pressure sensor
CALL
E0431
EOI
E0432
20-702 0
Abnormality in engine oil pressure
Abnormality in engine water temperature
X+ When radiator water level caution lamp on monitor panel flashes 1. Lowering of radiator water level (Main or dual) 2. Defective contact or disconnection in wiring harness between monitor panel CNI (5) - sensor DRT (2) 3. Defective contact or disconnection in wiring harness between sensor DRT (1) - sensor 405 (1) 4. Defective contact or disconnection in wiring harness between sensor 405 (2) - GND 5. Defective radiator water level sensor % When engine water temperature caution lamp on monitor panel flashes 1. Rise of engine water temperature to about 108°C 2. Defective engine water temperature sensor
D475A-3
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal (voltage,
current,
resistance)
Action by controller when abnormality
is detected
Problem that appears on machine when there is abnormality
Voltage between CN2 (7) and chassis : Max. 6 V (when caution lamp lights up)
1. Sounds alarm buzzer
1. Caution lamp does not light up
Voltage
1. Lights up caution
1. Alarm buzzer does not sound
between
CN2 (8) and chassis
lamp
: Max. 3 V (when alarm buzzer sounds)
l
l
l
l
1. Lights up caution sounds alarm buzzer
lamp,
Voltage between 452 (1) (CNI (8)) chassis ground When sensor is turned ON (hydraulic oil temperature is about 104°C or lower): 1 V max. When sensor is turned OFF (hydraulic oil temperature is about 108°C or higher): 20 - 30 V
1. Lights up caution sounds alarm buzzer
lamp,
Voltage between 301 (3) (CNI (7)) chassis ground When sensor is turned ON (engine is stopped but starting switch is at ON position): 1 V max. When sensor is turned OFF (engine is started): 20 - 30 V
1. Lights UP caution sounds alarm buzzer
lamp,
Voltage between DRT (2) KNI (5)) - chassis ground When sensor is turned ON (radiator water level is above LOW mark) : 1 V max. When sensor is turned OFF (radiator water level is below LOW mark): 20 - 30 V
1. Lights up caution sounds alarm buzzer
lamp,
Resistance At 100°C At 90°C At 35°C At 20°C At 10°C
1. Lights up caution sounds alarm buzzer
lamp,
Resistance At 100°C At 90°C At 35°C At 20°C At 10°C
D475A-3
: : : : :
: : : : :
between Approx. Approx. Approx. Approx. Approx.
between Approx. Approx. Approx. Approx. Approx.
453 (I) - (2) 3.8 k!.2 5 kD 29 kD 52 M 80 kQ
402 (I) - (2) 3.8 kQ 5 kQ 29 M 52 kD 80 kD
20-703 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF M MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
OF M MODE SYSTEM
Right battery
E lectrical a ir heater
Rirht lamp
relay
,161 (8,
intake timer
head relay
-
Engine ten9eratre
=a
Radiator
rater
wate
Radiator rater level sensor
TVD01063
20-704 0
D475A-3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF M MODE SYSTEM
Starting
D475A-3
switch
20-705 0
M-l
TROUBLESHOOTING
M-l [E0120] Short circuit in caution lamp output system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I 2 YES YES 1 P Is resistance between 375 _ (male) (1) and (2) normal? * Turn starting switch OFF. * Disconnect 375. - loo-400R
M-l
Related
Is voltage between CN2 (female) (7) and chassis ground normal? NO * Disconnect 375, CN2. * Turn starting switch ON. * Max. 1 V
NO
electrical
Cause
1
Remedy
Defective monitor panel (caution module)
Replace
Short circuit with power source in wiring harness between CN2 (female) (7) and 375 (female) (2)
Repair or replace
Defective caution lamp
Replace
circuit diagram
Caution I amp
375 Monitor
I
Panel
I
x.
(4) I
215
(16)
TVDOI 137
20-706 0
D475A-3
M-2
TROUBLESHOOTING
M-2 [E0121] Short circuit in caution buzzer system is displayed *
* *
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and has check that the service code displays “E” at the head. (If “P” is displayed, the condition returned to normal.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
2 YES YEA
normal? *Turn starting switch OFF. - Disconnect 217. -Min. 200 Q
M-2 Related
i Isvoltaoebetween1 CN2 (female) (8)
t
Defective monitor panel (caution module)
Replace
Short circuit with power source in wiring harness between CN2 (female) (8) and 217
Repair or replace
Defective caution buzzer
Replace
1
- Turn starting switch ON. - Max. 1 V NO
electrical
Remedy
circuit diagram
Caution buzzer
Monitor
217
Panel 1
CN2 (81
215
(16)
421
(14)
Bl 1 (14)
Fuse box lOA
Caution buzzer TVD01138
D475A-3
20-707 0
M-3, M-4
TROUBLESHOOTING
M-3 [E0211] Abnormality in power train (torque converter temperature is displayed
oil
Cause
YES
Remedy
-
Go to Ml2 e).
Defective monitor panel (caution module)
Replace
Defective power train
See note
Note: The display on the monitor panel has returned to normal, but it shows that the power train oil temperature sensor has detected abnormal oil temperature in the past. Check the power train and remove the cause of the abnormality.
M-4 LEO3291 Abnormality
in hydraulic oil temperature
is displayed
Cause
YES
Go to Ml2 f).
1 Is hydraulic oil temperature caution lamp on monitor flashing?
2
YES
head of service code? NO
-
Defective monitor panel (caution module)
Replace
Defective hydraulic equipment
See note
Note: The display on the monitor panel has returned to normal, but it shows that the hydraulic oil temperature sensor has detected abnormal oil temperature in the past. Check the hydraulic equipment and remove the cause of the abnormality.
20-708 0
D475A-3
M-5,
TROUBLESHOOTING
M-5 [E0430] Abnormality
in engine oil pressure is displayed
Cause
YES
r
I
Remedy
Go to Ml2 b).
pressure caution lamp on monitor
YES
Nq k&of
M-6
Defective monitor panel (caution module)
-Replace
se&ice Defective engine
See note
Note: The display on the monitor panel has returned to normal, but it shows that the engine oil pressure sensor has detected a drop in the oil pressure in the past. Check the engine and remove the cause of the abnormality.
M-6 [E0431] Abnormality
in radiator water level is displayed
Cause
YES
Go to Ml2 CL
1 Is radiator water level caution lamp on monitor flashing? P
2
YES
Remedy
-
Defective monitor panel (caution module)
Replace
Defective engine
See note
Is [El displayed at head of service code?
No I
I I
NO
Note: The display on the monitor panel has returned to normal, but it shows that the radiator water level sensor has detected a drop in the water level in the past. Check the engine and remove the cause of the abnormality.
0475A-3
20-709 0
M-7
TROUBLESHOOTING
M-7 [E0432] Abnormality
in engine water temperature
is displayed
Cause
YES
Go to Ml2 d).
NO
Note: The display on the monitor panel has returned to normal, temperature sensor has detected abnormal oil temperature remove the cause of the abnormality.
20-710 0
Remedy
-
Defective monitor panel (caution module)
Replace
Defective engine
See note
but it shows that the engine water in the past. Check the engine and
D475A-3
M-8
TROUBLESHOOTING
M-8 When starting switch is turned on, monitor * *
panel gives no display
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
unit) gives no display a) Caution module (Gauge/lamp * Check that fuse 12 is normal before starting troubleshooting. (If it is blown,
check for a short circuit with the ground
in the wiring
harness
related to it.)
Cause
YES 1
Defective monitor panel (caution module)
I
* Turn starting switch ON. *20-30V
M-8 a) Related
Monitor
electrical
Panel
Defective contact or disconnection in wiring harness between CNl (female) (2) - chassis ground Defective contact or disconnection in wiring harness between CNl (female) (1) -fuse 12
NO
(12)
215
(16)
421
(14)
611
($
8
GND5
D475A-3
Replace
Repair or replace
Repair or replace
circuit diagram
I
CNl
Remedy
(14)
Fuse
box
TV001139
20-711 0
M-8
TROUBLESHOOTING
b) Jr
Tachometer module (Tachometer/service meter unit) gives no display Check that fuse 1 and 12 are normal before starting troubleshooting. (If they are blown, check for a short circuit with the ground in the wiring
2 YES Is voltage - between TO1 (1) and (2) normal? 1 Is voltage between TO1 (7) and (2) normal? * Turn starting switch ON. *20-30V
-
YES -
* Turn starting switch ON. *20-30V
NO
3 YES Is voltage between TO1 (7) NO and chassis ground normal? NO
s Turn starting switch ON. *20-30V
M-8 b) Related
electrical
related to them.)
Defective monitor panel (caution module)
Replace
Defective contact or disconnection in wiring harness between TO1 (female) (1) -fuse 12
Repair or replace
Defective contact or disconnection in wiring harness between TO1 (female) (2) -chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between TO1 (female) (7) -fuse 1
Repair or replace
circuit diagram
215 Monitor
harness
(16)
Panel 1
TO1
GND Power source when normal
(1 6)
(24)
TVDOI 140
20-712 0
D475A-3
M-9
TROUBLESHOOTING
M-9 When starting switch is turned on, monitor lighted up and do not go out a1
Caution
module
(Gauge/lamp
unit) displays
all stay lighted
panel lamps all stay
up and do not go out
Remedy
Cause
Defective monitor panel (caution module)
b1 Tachometer out
module
(Tachometer/service
meter
unit) displays
all stay lighted
up and do not go
Defective monitor panel (tachometer module)
D475A-3
Replace
20-713 0
M-10
TROUBLESHOOTING
M-10 When starting switch is turned on (engine stopped), _ starting items flash *
check before
*
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
a) Ir
[Radiator water level1 flashes Check that the radiator water level is normal
before starting
inserted.
troubleshooting.
Cause
water level caution lamp go
YES
* Connect short connector to 405. *Turn starting switch ON.
!I
mp90
1
* Connect short connector to DRT (female). * Turn starting switch ON.
,
(female) (2) and
-Turn starting switch OFF. * Disconnect 405. * Max. 1 R 5 YES Is resiStance between DRT A- (female) (1) and chassis ground normal? * Turn starting switch OFF. Max. 1 fD
-
NO
l
M-10 a1 Related
Monitor
electrical
4 YE5 YE 3
Defective radiator water level sensor (main) system
Check sensor according to STANDARD VALUE TABLE, then replace
Defective radiator water level sensor (dual) system
Check sensor according to STANDARD VALUE TABLE. then replace
Defective monitor panel (caution module)
Replace
(female) (5) and
*Turn starting switch OFF. -Disconnect CNl. * Max. 1 42 NO
NC
ToA Defective contact or disconnection in wiring harness between 405 (female) (2) and chassis ground Defective contact or disconnection in wiring harness between CNl (female) (5) - DRT (female) (2) Defective contact or disconnection in wiring harness between DRT (female) (1) and 405 (female) (1)
Repair or replace
Repair or replace
Repair or replace
circuit diagram
Panel
TVDOll41
20-714 0
D475A-3
M-10
TROUBLESHOOTING
b) Jr
[Engine oil level1 flashes Check that the engine oil level is normal
before starting
YES
troubleshooting.
Cause
Remedy
Defective engine oil level sensor system
Checksense! accordingto STANDARD VALUETABLE, then replace
Defective monitor panel (caution module)
Replace
1 I Does enoine oil level caution lamp go out?
3
II
I_~
* Connect short Is resistance connector to 404 between 404 - (female) (2) and (female). NO chassis ground * Turn starting normal? switch ON. . Turn starting switch OFF. - Disconnect 404. - Max. 1 R
M-10 b) Related
Monitor
electrical
YES 2 ~_ -
YES
Is resistance between ChK--III (female) (6) and chassis ground n0rlllZ3l7 *Turn starting switch OFF. * Disconnect CNl. * Max. 1 5:
NO
NO
Defective contact or disconnection in wiring harness between CNl (female) (6) - 404 (female) (1) Defective contact or disconnection in wiring harness between 404 (female) (2) -chassis ground
Replace
Repair or replace
circuit diagram
Panel
Engine
oil
level
TVDOI 142
D475A-3
20-715 0
M-II
TROUBLESHOOTING
M-II When starting switch is turned on (engine stopped), caution items flash (but battery charge, engine oil pressure caution do not flash) * * *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. Check both the engine oil pressure system and alternator system.
a)
Engine oil pressure
sensor system Remedy
Cause
2 YES
1
I
Is resistance
(female)
M-II
a) Related
Monitor
Defective monitor (caution module)
17) and
1;hasssjlsground starting switch OFF. - Disconnect CNI. * Min. 1 R
NO
Defective engine pressure sensor
IO
electrical
Check sensor according to STANDARD VALUE TABLE, then replace
Engine
1
(12)
oil
Repair or replace
circuit diagram
Panel
CNl
panel
Defective contact or disconnection in wiring harness between CNl (female) (7) - 403
1 I
- Turn
-Turn starting switch OFF. * Disconnect 403. * Min. 1 Q
inserted.
215
(16)
421
(14)
112
(4)
301
(4)
oil Pressure sensor
TVDOI 143
20-716 0
D475A-3
TROUBLESHOOTING
b)
Alternator
M-l 1
system
Cause
2 YE
1 Is voltage between ANR (alternator)
Is voltage between CNl (female) (4) and chassis ground normal? - Disconnect CNI. * Turn starting N~ switch ON. * Max. 1 V
* Disconnect ANR. * Turn starting switch ON. * Max. 1 V
3 Is voltage between TO1 (female) (4) and chassis ground normal? * Disconnect TOI. *Turn starting switch ON. * Max. 1 V
4 YES CNl (female) (4) p * Disconnect CNl, NC 220. . Turn starting switch ON.
. Mar.
NO
M-II
b) Related
Monitor
electrical
1 ”
Remedy
Defective monitor panel (caution module)
Replace
Defective monitor panel (tachometer module)
Replace
Defective diode (220)
Replace
Short circuit with power source in wiring harness between CNl (female) (4) TO1 (female) (4) - ANR 103 (female) (2) - 104 (female) (2) - 220 (male) (2)
Repair or replace
Defective alternator
Replace
circuit diagram
Panel
812 (8) 215 (16)
TO1 (16)
---Et
220 (6)
122 (12) +%I-
m
Starting p$-J.__ti
motor
I
l-L.3 103 (2)
101 (16)
-
TVDOl 144
D475A-3
20-717 0
M-12
TROUBLESHOOTING
M-12 When starting switch is turned on (engine stopped), caution items flash (but there is no abnormality in checks before starting items or engine) * *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
a)
[Battery
inserted.
charge1 flashes
Remedy
YES 2
I
Is voltage between YES CNl (female) (4) and chassis 3 YES ground normal? , Isvoltage between , CNl (female) (1) * Disconnect CNl. Is voltage between ND and chassis * Start engine. ANR (alternator ground normal? - * Run at half side) and chassis throttle or above. * Disconnect CNl, NO ground normal? TOl. *20-30V . Start engine. * Disconnect ANR. : ;;! ;ah$f throttle or above. * Start engine. * Run at half throttle or above. NO -2O-30V
M-12 a) Related Monitor
electrical
Replace
Defective monitor panel (tachometer module)
Replace
Defective contact or disconnection in wiring harness between CNl (female) (4) - ANR
Repair or replace
Defective alternator
Replace
circuit diagram
Panel
El2 215
TO1 (16)
Starting
Defective monitor panel (caution module)
(16)
122
(8)
220
(6)
(12)
Y
motor
3
153 (4)
Battery
@J?$-fy
103
(2)
101
(16)
TVDOI 144
20-718 0
D475A-3
M-12
TROUBLESHOOTING
b) Sr
[Engine oil pressure] flashes Check that the engine oil pressure
is normal
before starting
troubleshooting.
Cause
Defective engine oil pressure sensor
2
h
Is resistance between CNl . (female1(7) and chassis ground normal?
YES
Defective monitor panel (caution module)
-
Short circuit with chassis ground in wiring harness between CNl (female) (7) - 403
* Turn starting NO switch OFF. - Disconnect CNI, 403. * Min. 1 MR
M-12 b) Related
Monitor
3heck sensor xcording to
STANDARD 4ALUE TABLE,
:hen replace
Does engine oil pressure caution lamp go out? * Disconnect 403. * Start engine.
Remedy
electrical
Panel
Repair or replace
circuit diagram
I CNl
Replace
(12)
Engine
_ .-
215
,. _I
I1 ti)
^ I r. ,\
421
(141
. .^ I,\
112
(41
^^.
301
I,\
(41
oil
Pressure
sensor
TV001
cl
[Radiator
water
143
level1 flashes
Cause
Remedy
Go to M-10 a)
D475A-3
20-719 0
M-12
TROUBLESHOOTING
d) *
[Engine water
temperature]
flashes
Check that the engine water temperature
is normal before starting troubleshooting.
* YES 2
-
Is engine water temperature gauge in level 7 range (Max.)?
Defective engine controller
I
Does engine water YES temperature caution lamp go out? , * Disconnect E32. ~0 - Start engine.
3 Does engine water temperature caution lamp go out? * Connect short connector to 402 (female). * Start enaine.
* Start engine. 1
Monitor
electrical
Panel
CNl
Check sensor according to STANDARD VALUE TABLE,
Defective monitor panel (caution module)
Repair or replace
circuit diagram
I
(12) I
CN2
Defective engine water temperature sensor
Defective monitor panel (caution module)
NO
M-12 d) Related
Replace
(8)
214
(14)
599
(12)
215
(16)
122
(12)
111
(4)
402
g
-3
@
3
(2)
Engine water temperature sensor
temperature
I
I
Engine
controller
E32
I
(20)
Engine water temperature sensor
TVDOI 145
20-720 0
D475A-3
M-12
TROUBLESHOOTING
e) *
[Power
train (torque
converter)
oil temperature]
Check that the power train (torque converter) shooting.
flashes
oil temperature
is normal before starting trouble-
Remedy
Check sensor
2
Is engine water temperature gauge in level 7 range (Max.)?
YES
Does power train YES oil temperature caution lamp go 1 out? -
* Start engine.
* Connect short connector to 453 (female). - Start engine.
NO
NO
M-12 e) Related
Monitor
electrical
Defective power train oil temperature sensor
accordingto
STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Defective monitor panel (caution module)
Replace
circuit diagram
Panel Tome
453
(2)
converter
oil temperature
.a
-3 oil
temperature
TV001
D475A-3
146
20-721 0
M-12
TROUBLESHOOTING
f) *
[Hydraulic oil temperature] flashes Check that the hydraulic oil temperature
is normal
before starting
YES 1 Does hydraulic oil temperature caution lamp go out?
2 Is resistance between CNl (female) (8) and
* Connect CN452 (female) (1) to chassis ground. * Start engine.
M-12 f) Related
Monitor
-
NO
YES
-
normal?
electrical
Panel
CNl
Defective hydraulic oil temperature sensor
accordingto STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Defective contact or disconnection in wiring harness between CNl (female) (8) - 452 (female) (1)
chassis ground
*Turn starting switch OFF. * Disconnect CN 1. - Max. 1 R
troubleshooting.
NO
Repair or
circuit diagram
I
(12)
s13
(12)
506
(14)
451
(16)
452
(1)
Hydraulic temperature sensor
o i
temperature
TVDOI I
20-722 0
D475A-3
I
TROUBLESHOOTING
g) *
[Air cleaner
M-12
clogging]
flashes
Check that the air cleaner is not clogged before starting troubleshooting.
Cause
YES
Defective air cleaner clogging sensor
1 3 YES
Does air cleaner clogging caution lamp go out? * Disconnect AFl and AFL!, then connect wiring harness end. * Start engine.
Is resistance YES between CNl 2 I- (female) (9) and chassis ground
-
Is resistance
-
between AF2 (wiring harness
NO end) and chassis ground normal? . Turn starting switch OFF. * Disconnect AF2. * Max. 1 R
M-12 g) Related
Monitor
electrical
normal? -
mTurn
starting
switch OFF. * Disconnect CNl. - Max. 1 Q NO
-
. NO
Remedy
Check sansor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module) Defective contact or disconnection in wiring harness between CNI (female) (9) - AFl Defective contact or disconnection in wiring harness between AF2 chassis ground
Repair or replace
circuit diagram
Panel
TVDOI 148
D475A-3
20-723 0
M-13
TROUBLESHOOTING
M-13 Preheating Ir
monitor
does not light up or go out
* *
Check that the automatic preheating operation is normal before starting troubleshooting. (If not, go to M-25) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Preheating
monitor
does not light up during
preheating
operation Remedy
Cause
1 YES Is voltage between CN2 (female) (5) and chassis ground normal? * Disconnect CN2. NO *Turn starting switch to HEAT. (See Note) .20-30V
Note: Turn the starting
switch
b1
lights up when
Preheating
monitor
in the opposite
direction
preheating
Defective monitor panel (caution module)
Replace
Defective contact or disconnection in wiring harness between CN2 (female) (5) -electrical intake air heater
Repair or replace
from ON.
operation
is stopped Remedy
Cause
CN2 (female) (5)
* Disconnect CN2. *Turn starting switch ON. * Max. 1 V
M-13 Related
1
Defective monitor panel (caution module) Short circuit with power source in wiring harness between CN2 (female) (5) electrical intake air heater
NO
electrical
circuit diagram
Electrical
air
I
20-724 0
Replace
I
ReDair or
heater
intake
TVDOI 149
D475A-3
M-14
TROUBLESHOOTING
M-14 Abnormality
in caution buzzer
Check that any service code is not displayed. (If any one is displayed, check according to it.) The alarm buzzer sounds for all caution items except the battery charge. Even if there is an abnormality in the battery charge, the alarm buzzer does not sound. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
* * * *
Caution item flashes but buzzer does not sound, or buzzer does not sound for 1 second after starting switch is turned ON Check that fuse 10 is normal before starting troubleshooting. (If it is blown, check for short circuit with the ground in the wiring harness related to it.)
a) *
Remedy
Cause
YES
Defective monitor panel (caution module)
Replace
Defective caution buzzer
Replace
Defective contact or disconnection in wiring harness between CN2 (female) (8) and 217
Repair or replace
Defective contact or disconnection in wiring harness between 217 fuse 10
Repair or replace
II 3
1Isresistance
YES
I I
~~
;;E;;z’,‘,“d;,“d. NO
-. . meet 217, CN2. IQ
*Turn starting switch ON. *20-30V
b)
No abnormality
NO
is displayed
on monitor
but buzzer
sounds
I YES 1 Does buzzer stop when CN2 is disconnected?
2
Is resistance P between CN2 * Disconnect CN2. - (female) (8) and -Turn starting NO chassisground switch ON. normal?
YES
-
*Turn starting NO switch OFF. . Disconnect 217, CN2. . Min. 1 MR
D475A-3
I I
Remedy
Cause
Defective monitor panel (caution module)
Replace
Defective caution buzzer
Replace
Short circuit with chassis ground in wiring harness between 217 and CN2 (female) (8)
Repair or replace
I
20-725 0
M-14
TROUBLESHOOTING
M-14 Related
electrical
circuit diagram
Caution buzzer
Monitor
Panel
217 215
(16)
421
(14)
Bl 1 (14)
Fuse
box
TVDOI 138
20-726 0
D475A-3
M-15
TROUBLESHOOTING
M-15 Abnormality
in caution lamp
*
to it.) inserted.
a)
Caution item flashes but caution lamp does not flash, or caution lamp does not light up for 2 seconds after starting switch is turned ON Check that fuse 10 is normal before starting troubleshooting. (If it is blown, check for short circuit with the ground in the wiring harness related to it.)
Check that any service code is not displayed. (If any one is displayed, check according Sr Before carrying out troubleshooting, check that all the related connectors are properly Ir Always connect any disconnected connectors before going on to the next step.
Ir
Remedy
Cause
YES
Defective monitor panel (caution module)
Replace
Defective caution lamp
Replace
Defective contact or disconnection in wiring harness between CN2 (female) (7) and 375 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between 375 (female) (1) -fuse 10
Repair or replace
1
3 YES
light up when CN2 (female) (7) and chassis ground are
YES -
- 2 . Disconnect CN2, Is voltage between then connect 375 (female) (1) (female) (8) to NO and chassis chassis ground. ground normal? . Turn starting * Disconnect 375. switch ON. * Turn starting switch ON. *20-30V
b)
Is resistance between 375 (female) 12)and CN2 (female) (7) normal?
No abnormality
-
NO *Turn starting switch OFF. * Disconnect 375, CN2. * Max. 1 R NO
is displayed
on monitor
but caution
lamp lights up
I YES 1
I
2 resiStance between CN2 * Disconnect CN2. - (female) (7) and h ) chassis ground * Turn starting normal? switch ON.
YES
Cause
I
Remedy
Defective monitor panel (caution module)
Replace
Defective caution lamp
Replace
Short circuit with chassis ground in wiring harness between 375 (female) (2) and CN2 (female) (7)
Repair or replace
Is
-
* Turn starting NO switch OFF. * Disconnect 375, CN2. * Min. 1 MQ
D475A-3
I
I
20-727 0
TROUBLESHOOTING
M-15 Related
electrical
M-15
circuit diagram
Iid
375
Monitor
Panel
2
1
(4)
TVD01137
20-728 0
D475A-3
M-16
TROUBLESHOOTING
M-16 Abnormality Jr
in engine water temperature
gauge
* Ir
Check that the engine water temperature is normal before starting troubleshooting. (If not check the engine.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Engine water
temperature
gauge shows
abnormally
low temperature Remedy
Cause
Defective engine controller
Does gauge display become 1normal? - Disconnect E32. * Turn starting switch ON.
II
4 YE! Is resistance
R
(female)
(2) and
I
tl0rlTlal?
-Turn starting switch OFF. * Disconnect CNl and 402. - Max. 1 D
temperature
Check sensor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Defective contact or disconnection in wiring
* Connect short connector to 402. *Turn starting switch ON.
b1 Engine water
lr
Defective engine water temperature sensor
- Disconnect 402, CN2
harness between
CN2
(female)
(female)
(1) -402
Defective contact or disconnection in wiring harness between
NO
(1)
(female)
CNl
(2) - 402 (female)
gauge gives no display
YES
I
2
Does gauge display appear?
3
- Disconnect 402. NO * Turn starting switch ON.
between CN2 (female) (1) and chassis ground normal?
starting switch OFF. * Disconnect 402 and CN2. - Min. 1 MD
*Turn
D475A-3
YES
Is resistance -
Repair or replace
(2)
(gauge
does not even display one level)
Cause
- Disconnect E32. *Turn starting N switch ON.
Repair or replace
-
NO
Remedy
Defective engine controller
Replace
Defective engine water temperature sensor
Check sensor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Short circuit with chassis ground in wiring harness between CN2 (female) (I) - E32 (female) (5) - 402 (female) (1)
Repair or replace
20-729 0
M-16
TROUBLESHOOTING
M-16 Related
Monitor
electrical
circuit diagram
Panel
CNl
(i2)
214 i
CN2
I
(8)
215
>cl (14)
599
(12)
122
(12)
9
(16)
1 I 1 (4)
402
g
-3
@
3
(2) -
Engine water sensor temperature
Engine water temperature
Engine
controller
E32
I
(20)
TVDOI
20-730 0
145
D475A-3
M-17
TROUBLESHOOTING
M-17 Abnormality in power train (torque converter) oil temperature gauge Ir Check that the power train (torque converter) oil temperature is normal before starting troubleIr *
shooting. (If not check the power line.) Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
a)
Power
train oil temperature
gauge shows
abnormally
YES
low temperature
Cause
Remedy
Defective power train oil temperature sensor
Check sensor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
1 3
Does gauge display go out?
1Is resistance
YES
II
YE Defective contact, disconnection, or short circuit with power source in
* Lonnecr snort connector to 453. * Turn starting switch ON.
NO * Turn starting switch OFF. * Disconnect 453. CN2. * Max. 1 R
(female) (2) and
Turn starting switch OFF. IO s Disconnect 453, CNI. - Max. 1 R -
b)
Power train (torque display one level)
converter)
1
hIO
i
I.5 resistance between CN2 (female) (2) and chassis ground .. normaIr
I
I
I NO
. Turn starting switch OFF. * Disconnect 453, CN2. * Min. 1 MR
D475A-3
between CN2 (female) 12)- 453 (female) 11)
wiring
harness
Defective contact or disconnectionin wiring harness between CNl (female) (2) - 453 (female)
oil temperature
YE
* Disconnect 453. -Turn starting switch ON.
connected.
gauge
gives no display
(gauge
Repair or replace
Repair or replace (2)
does not even
Cause
Remedy
Defective power train oil temperature sensor
Check sensor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Short circuit with chassis ground in wiring harness between CN2 (female) (2 - 453 (female) (1)
Repair or replace
20-731 0
M-17
TROUBLESHOOTING
M-l 7 Related electrical circuit diagram
I
Monitor
Panel
I CNl ti2)
214 (14)
Torque
converter
TVDOl146
20-732 0
D475A-3
M-18
TROUBLESHOOTING
M-18 Abnormality *
in fuel level gauge
Ir *
Check that there is ample fuel before starting troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
a)
Fuel level gauge always
display
FULL
YES 1 I-
- Turn starting NO switch OFF. . Disconnect 422, CN2. * Min. 1 MD
b)
connected.
Defective fuel level sensor
Check sensor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Short circuit with chassis ground in wiring harness between CN2 (female) (3) - 422 (female) (1)
Repair or replace
Fuel level gauge gives no display (gauge does not even display one level)
Remedy
Cause
I
1
Does gauge display show FULL?
- Connect
short
3
-
YES 2
_
Is resistance connector to 422. between 422 * Turn starting - (female) (2) and NO CNl (female) (2) switch ON. normal?
-
NO + Turn starting switch OFF. * Disconnect 422, CN2. * Max. 1 R
* Turn starting switch OFF. NO * Disconnect 422, CNl. . Max. 1 R
D475A-3
YES
Is resistance between 422 (female) (1) and CN2 (female) (3) normal?
Defective fuel level sensor
Check sensor according to STANDARD VALUE TABLE, then replace
Defective monitor panel (caution module)
Replace
Defenive contact, disconnection,or short circuit with power source in wiring (female)
harness between (3) - 422
CN2
(female) (1)
Defective contact or disconnectionin wiring harness between (female)
Repair or replace
Repair or replace
CNl
(2) - 422 (female)
(2)
20-733 0
M-18
TROUBLESHOOTING
M-18 Related electrical circuit diagram
Monitor
Panel
CNl
I
(12)
214
(14)
599
(12) 422
GND
CN2 Fuel
I
(8)
215
(16)
122
(2)
Fuel
level
gauge
(12)
level
I 1
20-734 0
TVDOIl50
D475A-3
M-19,
TROUBLESHOOTING
M20
M-19 Speed range display shows ‘- -‘, engine speed is not displayed
Remedy
Cause
Abnormality system
in network
Go to N-3
M-20 Service meter does not advance when engine is running * *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
I 1 YES Is sand timer mark dsplayed on service meter module? * Start engine.
D475A-3
NO
Cause
Defective monitor panel (tachometer module)
Go to M-12 a)
inserted.
Remedy
Replace
-
20-735 0
M-21
TROUBLESHOOTING
M-21 Abnormality Ir
in service mode
Ir
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
a)
Does not switch
to service mode even when
service switch
inserted.
is operated
Cause
YES
3 YES YES 2r
Is resistance between S24 (3) and TO1 (female)
switch OFF. NO * Turn service switch ON. * Max. 1 R
b)
Defective monitor panel (caution module)
Replace
Defective contact or disconnection in wiring harness between S24 (2) chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between S24 (3) and TO1 (female) (51
Repair or replace
Defective service switch
Replace
Stays in service mode
Cause
Y‘ES
~~
switch OFF. - Min. 1 MR
20-736 0
-Turn starting NO switch OFF. -Turn service switch ON. * Min. 1 MR
Remedy
Defective monitor panel (caution module)
Replace
Short circuit with chassis ground in wiring harness between S24 (female) (3) and TO1 (female) (5)
Repair or replace
Defective service switch
Replace
D475A-3
M-21
TROUBLESHOOTING
M-21 Related
Monitor
electrical
circuit diagram
Panel
214 (14)
GND5
s24
l
W
0
o---o
Service
D475A-3
switch
TVDOIISI
20-737 0
M-22
TROUBLESHOOTING
M-22 Night lighting on monitor panel does not light up (front lamp, working lamp are normal)
* *
Check the lamps visually to confirm that there is no disconnection before starting troubleshooting. (If any lamp is broken, replace it.) Check that fuse 10 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Panel lighting
* *
on tachometer
module
does not light up
1 YES Is voltage between TO1 (female) (6) and chassis ground normal?
NO
- Disconnect TOl.
-Turn starting
Cause
Remedy
Defective monitor panel (tachometer module)
Replace
Defective contact or disconnection in wiring harness between 219 (female) (3) and TO1 (female) (6)
Repair or replace
switch ON. * Turn front lamp and working lamp switch ON. .20-3ov
b)
Panel lighting
on caution
module
does not light up
P
* Disconnect TOl. * Turn starting switch ON. * Turn front lamp and working lamp switch ON. *20-30V
c)
Is resistance between CN4 - (female) (2) and NO chassis ground normal?
(female)
I
rls voltage
between
SO1 (female) SO2 (female)
(10). (1) and
-
chassis grouind normal) * Disconnect
Sol,
so2. * Turn
starting
switch
ON.
* Turn front lamp and working lamp switch ON. *20-30V
20-738 0
_ NO
2 Is resistance between SO1 (female) (2). SO2 (female) (2) and chassis ground normal?
YES k _
Turn starting NO switch OFF. * Disconnect Sol, S02. * Max. 1 R
*
Replace
I Repair or replace
Repair or
harness between CN4 (female) (2) -chassis ground
NO
module
Remedy
(1)
Defective contact or disconnection in wiring
YES 1
harness between 219 (female) (3) and CN4
-
* Turn starting switch OFF. . Disconnect CN4. * Min. 1 R
on switch
Defective contact or disconnectionin wiring
YES
2
Panel lighting
I
Defective lamp or defective contact of lamp
YES 1 Is voltage between CN4 (female) (1) and chassis ground normal?
Cause
Remedy
does not light up
When SO1 is defective: Defective monitor panel (switch module) When SO2 is defective: Defective lamp or defective contact of lamp
Repair or replace
Defective contact c: disconnection in wiring harness between 219 (female) (3) - SO1 (female) (10) or SO2 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between SO1
(female) (2) or SO2 (female) (2) -chassis ground
Repair or replace
D475A-3
TROUBLESHOOTING
M-22 Related Mon itor
M-22
electrical Panel
circuit diagram
I so1 (12) relay
I
TO1 (16)
a
I I I
219 (4)
TVDOl152
D475A-3
20-739 0
TROUBLESHOOTING
M-23
M-23 Front lamps and working + Ir
lamps do not light up
* *
Check that all bulbs are normal. (If any one is broken, replace it.) Check that fuse 10, 11, and 14 are normal. (If any one is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a1
Any one of front lamps and working
lamps does not light up
Defective contact or disconnectionin wiring harness between RBl (female) (2). RB2 (female) (2). RB3 (female) (2) - chassis ground Defective contact or disconnectionin wiring harness between 219 (female) (3) - RBl (female) (1). RB2 (female) (1) and RB3 (female) (1) -chassis ground
2 YES
, Is
voltagebetween
YES ~61 (1). RB2 (1). RB3 (1) and chassis ground normal? 1 Does night lighting on monitor panel light up?
*Turn starting NO switch ON. *Turn front lamp and working lamp switch ON. -2O-30V 3 YES
* Turn starting Is resistance switch ON. between 219 -Turn front lamp NO (female) (2) and and working (3) normal? lamp switch ON. *Turn starting NO switch ON. * Disconnect 219. *Turn front lamp and working lamp switch ON. *20-30V
b)
Repair or replace
Repair or replace
Defective contact or disconnection in wiring harness between fuse 10 219 (female) (2)
Repair or replace
Defective front lamps/working lamps
Repair or replace
Left front lamp does not light up Cause
YES
4YEI
1 If relay RB2 is
*Turn starting switch ON. *Turn front lamp and working lamp switch ON.
Is voltage between RB2 (1) NO and chassis 4 ground normal? I-
* Turn starting switch ON. -Turn front lamp and working lamp switch ON. .20-30V
20-740 0
Is resistance YES between RB2 - (female) (2) and chassis ground 2 normal?
I I
* Turn starting switch OFF. * Disconnect RB2. * Max. 1 R
IO
Is voltage YES between RB2 (3) and chassis 3 ground normal? -
* Turn starting switch ON. *20-30V
NC
Remedy
Defective left front lamp relay (RB2)
Replace
Defective contact or disconnectionin wiring harness between RB2 (female) (5) - 204 (female) (1). 207 (female) (l), or breakage of bulb
Repair or replace
Defective contact or disconnection in wiring harness between RB2 (female) (3) - fuse1 4
Repair or replace
Defective contact or disconnectionin wiring harness between RB2 (female) (2) -chassis ground
Repair or replace
Defective contact or disconnectionin wiring harness between RB2 (female)(l)-811 hnale)(lll
Repair or replace
D475A-3
M-23
TROUBLESHOOTING
c)
Right front lamp does not light up Cause
i 4 YES
YE ;~~
-Turn starting switch ON. *Turn front lamp and working lamo switch ON.
2 between RBl (1)
. Turn starting switch ON. * Turn front lamp and working lamp switch ON. *20-30V
d)
Working
switch OFF. * Disconnect RBl. . Max. 1 R
NO
JO
Defective right front lamp relay (RBl)
Replace
Defective contact or disconnectionin wiring harness between RBl (female) (5) - 203 tfemale) (1). 206 (female) (1). or breakage of bulb
Repair or replace
Defective contact or disconnection in wiring harness between RBl (female) (3) - fuse14
Repair or replace
Defective contact or disconnectionin wiring harness between RBl (female) (2) -chassis ground
Repair or replace
Defective contact or disconnectionin wiring harness between FIB1 (female) (1) - Bll (male) (111
Repair or replace
1
lamp does not light up Cause
‘ES
4YEL
1 1If relav RB3 is
1 Is resistance YES between RB3 _ (female) (2) and chassis ground normal?
*Turn starting switch ON. *Turn front lamp between RB3 (1)
-Turn starting switch ON. *Turn front lamp and working lamp switch ON. *20-30V
D475A-3
Remedy
-Turn starting switch OFF. - Disconnect RB3. * Max. 1 R
0
Is voltage YES between RB3 (3) and chassis 3 ground normal? -
I
STurn starting switch ON. *20-30V
I
NO
NC
Remedy
Defective working lamp relay (RB3)
Replace
Defective contact or disconnectionin wiring harness between RB3 (female) (5) - 221 (female) (1). WRD (female) (11,or breakage of bulb
Repair or replace
Defective contact or disconnection in wiring harness between RB3 (female) (3) - fuse11
Repair or replace
Defective contact or disconnectionin wiring harness between RB3 (female) (2) -chassis ground
Repair or replace
Defective contact or disconnectionin wiring harness between RB3 (female) (l)- Bll (male) (11)
Repair or replace
20-741 Co
TROUBLESHOOTING
M-23 Related
Head
electrical
M-23
circuit diagram Left relaY
lamp.
:;;::y Iamp219 (4)
Fuse
box
215 (16)
421 (14)
RB3 (6)
Bt I (14)
a-
D-
B
TiJ-
head
lama
iB2 (6)
Rioht relar
head
Iamb
RBl (6)
I
@lOA 3lOA 1420A
I
I
-
t
-812
GND5ih Floor frame) Left
workins
TVDO1153
20-742 0
D475A-3
M-24
TROUBLESHOOTING
M-24 Rear lamps do not light up Ir * * *
Check that all bulbs are normal. (If any one is broken, replace it.) Check that fuse 10 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3 YES 2
YES 1 _ Is resistance between 218 (male) (2) and (3) normal?
Is voltage between 218 (2) and chassis ground normal? *Turn starting switch ON. *20-30V
_
YES
Is voltage between 223 (1). 243 (1) and chassis ground normal? * Turn starting NO switch ON. *Turn rear lamp switch ON. .20-3OV
NO
* Turn starting switch OFF. * Disconnect 218. No * Turn rear lamp switch ON. * Max. 1 R
Remedy
Breakage of bulb
Replace
Defective contact or disconnection in wiring harness between 218 (female) (3) - 223 (female) (1). 243 (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between fuse10 218 (female) (2)
Repair or replace
Defective rear lamp switch
Replace
M-24 Related electrical circuit diagram
Fuse
Right rear
Left
box
lamp
A77
TVDOI I54
D475A-3
20-743 0
M-25
TROUBLESHOOTING
M-25 Automatic Ir Sr * Ir
preheater
does not work
Check that the outside temperature is in the operation range of the automatic preheater. Check that fuse 15 is normal. (If it is broken, check the circuit related to it for short circuit with chassis ground.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
IS
6
IIsresistance
I
IES i *Turn starting switch OFF. * Disconnect RB4. . Max. 1 R
YES between RB4 (I) LzC Iground normal? * Turn starting switch ON. -Turn preheater switch ON.
*Turn starting switch ON. * Turn preheater switch ON. .20-30V
YE 1ground normal?
3 Is
resistance
(female) (3) and
1&ss;gro”nd
I 1
*Turn starting switch ON. *Turn preheater switch ON. .20-30V
starting YE switch OFF. 9 -Turn preheater switch ON. . Disconnect RH 1. - Max. 1 R hJO (male) (2) and (3)
1
*Turn starting switch ON. *20-30V
t
N0
I NO
10
* Turn
between RHl (2)
1
I Is resistance (female) (2) and
*Turn starting switch OFF. - Disconnect 213. - Max. 1 Q
YES
II
H
J I NO
+ Turn starting switch OFF. NO * Disconnect 213. . Turn preheater switch ON. . Max. 1 R
IO
20-744 0
D475A-3
M-25
TROUBLESHOOTING
Cause
8
- Is voltage between RB4 (3) and chassis ground normal? * Turn starting switch ON. *20-30V
YES
Is voltage YES between 137,138 and chassis 7 ground normal? * Turn starting NO switch ON. -Turn preheater switch ON. -2O-30V NO
Remedy
Defective electrical intake air heater relay (RB41
Replace
Defective electrical intake air heater
Replace
Defective contact or disconnection in wiring harness between RB4 (female) (5) - 137, 138
Repair or replace
Defective contact or disconnection in wiring harness between RB4 (female) (3) -fuse 15
Repair or replace
Defective contact or disconnection in wiring harness between RB4 (female) (2) and chassis ground
Repair or replace
Defective contact or Repair or replace
Replace
Repair or replace
I
(female) (3) and 213 (female (3)
/ C%Fc;ive preheater
Replace
I.._..._-_
Repair or replace
Defective contact or disconnection in wiring “_...__..
(female) (2) -fuse 15
D475A-3
Repair or replace
20-745 0
TROUBLESHOOTING
M-25 Related
Starting
M-25
electrical
circuit diagram
switch D’)
I
lAPPI
Electrical
intake
air
heater
relay
Electrical intake heater timer
612 (8) Preheat
switch
2
air
RHI (3)
13 (4)
I ,
lectrical
intake
,
air
atterr
relay
tterv
relav(L
(R. H.)
H.)
heater TVDOl155
20-746 0
D475A-3
TROUBLESHOOTING
M-26
M-26 Windshield *
wiper and window
washer do not work
*
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
al
Any one of windshield
wiper
and window
washers
does not work
Remedy
Cause
Defective contact or disconnection in wiring harness between battery relay terminal M -fuse box inlet
bl *
Front windshield wiper does not work Check that fuse 5 is normal. (If it is broken, chassis ground.)
check the circuit
related
YES
YE
. Turn starting switch ON.
between CN-9 (5)
* Turn starting switch ON. *20-30V
D475A-3
4YEI Is resiStance YES between CN-12 - (female) (41and CN 3 -9 Ifemale) (2) _ Is voltage between normal? CN-12 (female) (3) * Td;‘. starting switch N( and chassis . DisconnectCN-12 ground normal? and CN-9. * Max. 1 R * Turn starting switch OFF. * Disconnect CN12. * Max. 1 R 0
NO
Repair or replace
to it for short circuit with
Remedy
Cause
replaced, does front windshield wiper
inserted.
Defective front windshield wiper switch
Replace
Defective front windshield wiper motor
Replace
Defective contact or disconnectionin wiring harness between (female)
CN-12
(4) - CN-9 (female)
Repair or replace
(2) Defective contact or disconnection in wiring harness between (female)
CN-12
(3) -chassis
ground
Defective contact or disconnectionin wiring harness between -9 (female) (5)
fuse 5 - CN
Repair or replace
Repair or replace
20-747 0
M-26
TROUBLESHOOTING
c) Sr
Left windshield wiper, right windshield wiper and rear windshield wiper do not work Check that fuse 3, 4, and 6 are normal. (If any one is broken, check the circuit related to it for short circuit with chassis ground.)
Remedy
Cause
YES
windshield wiper -Turn starting switch ON.
ground normal?
starting switch ON. -2O-30V
washer
Replace
Defective contact or disconnectionin wiring harness between switch connector (female) (4) motor connector (female) (2)
Repair or replace
connector
Repair or replace
switch
(3) -fuse
Defective contact or disconnectionin wiring
Turn startina switch OFF.* Disconnect connector. * Max. 1 R
Window
Defective windshield wiper motor
harness between
NO
l
d)
Replace
Defective contact or disconnectionin wiring
I - Turn
between motor connector (3) and
Defective windshield wiper switch
harness between connector (female) chassis ground
does not spout washer
fluid (although
windshield
wiper
Repair or replace
motor 13) -
works
normally)
Cause
Insufficient window washer fluid, clogging of nozzle, or defective piping
‘ES
sound of motor
YES 3
washerswitch
20-748 0
Supply fluid, repair or replace
Replace
. Turn starting switch ON. * Turn window ON.
Remedy
* Turn starting switch ON. -Turn window washer switch ON.
-
If switch is replaced, does NO window washer works normally? P * Turn starting switch ON. *Turn window washer switch ON.
-
-
4 YES -
Is resistance between motor - connector (female) NO 12) and chassis ground normal? * Turn starting switch OFF. * Disconnect connector. * Max. 1 R
-
NO
Defective windshield wiper switch
Replace
Defective contact or disconnectionin wiring harness between switch connector (female) (1) motor connector (female) (1)
Repair or replace
Defective contact or disconnection in wiring harness between motor connector (female) (2) and chassis ground
Repair or replace
D475A-3
TROUBLESHOOTING
M-26 Related
electrical
M-26
circuit diagram
I Wiper
CND2
Window
washer
motor
Window
washer
motor
Window
washer
motor
Window
washer
motor
C-0
Door
wiper
C.*nl I IU~II motor
.*iper .
Door motor
uiper (R. H.
1
switch&H.) CN-I
3 (6)
CN-1
-
7 (4)
Battery
TVDOll56
D475A-3
20-749 0
1 I
TROUBLESHOOTING OF AIR CONDITIONER SYSTEM
Electrical circuit diagram of air conditioner system ...........................................................................20-802 Troubleshooting of air conditioner which does not work .................................................................20-803
D475A-3
20-801 7
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF AIR CONDITIONER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF AIR CONDITIONER SYSTEM
20-802 7
D475A-3
TROUBLESHOOTING
TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK
Troubleshooting of air conditioner which does not work fl fl fl fl
Carry out the following troubleshooting when the battery and battery relay are normal. Before carrying out the troubleshooting, check that the fuse is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
A. Air does not blow out • 20 – 30 V • Turn blower “Lo” switch ON. • Turn starting switch ON.
• 240 ± 40 Ω • Turn starting switch OFF. • Disconnect CN-R1.
• 20 – 30 V • Turn starting switch ON. • Turn blower OFF.
Cause 1 ✩ Is voltage between CN-AC1 (13C), CN-R1 (13D), CN-R1 (6C) and chassis ground normal? YES
NO
2 Is resistance between CN-R1 (male) (13D) and (14A) normal? YES
NO
3 ✩ Is voltage between CN-AC1 (14B) and chassis ground normal? YES
NO
4 ✩ • Max. 1 Ω • Turn starting switch OFF.
• 20 – 30 V • Turn blower “Lo” switch ON. • Turn starting switch ON. • 20 – 30 V • Turn starting switch ON. • Turn blower “Lo” switch ON.
Is resistance between CN-AC1 (OC) and chassis ground normal? YES
NO
• Turn starting switch OFF. • Disconnect CN86. : 2.0 Ω ± 7% : 0.8 Ω ± 7%
Defective blower main relay
Replace
Disconnection or defective contact in wiring harness between CN-R1 (14A) – CNAC1 (14B)
Repair or replace
Disconnection or defective contact in wiring harness between CN-AC1 (OC) – chassis ground
Repair or replace
Defective blower main relay
Replace
Disconnection or defective contact in wiring harness between CN-R1 (10B) – CN-B (10A)
Repair or replace
Disconnection or defective contact in wiring harness between CN-R (OD) – chassis ground
Repair or replace
Defective blower resistor
Replace
Disconnection or defective contact in wiring harness between CN-B (11A) – CN-R (11C)
Repair or replace
YES 6 Is voltage between CN-B (10A) NO and chassis ground normal? YES
Is resistance between CN-R (OD) and chassis ground normal? YES
NO
8 Is resistance between CN-R (11C) and (OD) and between CN-R (11C) and (12A) normal? YES
NO
9 • Max. 1 Ω • Turn starting switch OFF.
Repair or replace
5 Is voltage between CN-R1 (6C) NO and chassis ground normal?
7 • Max. 1 Ω • Turn starting switch OFF.
Disconnection or defective contact in wiring harness between; • Fuse – CN-M26 (13A) – CNAC1 (13C) • Fuse – CN-M26 (13A) – CNR1 (13D) • Fuse – CN-M26 (6A) – CN-R1 (6C)
Remedy
Is resistance between CN-B (11A) and CN-R (11C) normal? YES
NO
Go to 10 on next page
D475A-3
20-803 7
TROUBLESHOOTING
TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK
Cause From 9 on previous page • Turn starting switch ON. • Turn blower “Lo” switch ON.
Remedy
10 NO
Does blower motor rotate?
Defective blower motor
Replace
Go to “B. Air is not cooled”
—
Disconnection or defective contact in wiring harness between fuse – CN-M26 (13A) – CN-R2 (13E)
Repair or replace
Defective blower Hi relay
Replace
Disconnection or defective contact in wiring harness between CN-R2 (18A) – CNAC1 (18B)
Repair or replace
Disconnection or defective contact in wiring harness between fuse – CN-M26 (13A) – CN-R3 (13H)
Repair or replace
Defective blower Me relay
Replace
Disconnection or defective contact in wiring harness between CN-R3 (17A) – CNAC1 (17B)
Repair or replace
Disconnection or defective contact in wiring harness between CN-B (11A) – CN-R2 (11B)
Repair or replace
YES 11
• Change control panel switch.
NO
Is Hi and Me selected normally? YES
• 20 – 30 V • Turn starting switch OFF. • Turn blower “Hi” switch ON.
• 240 ± 40 Ω • Disconnect CN-R2. • Turn starting switch OFF.
• 20 – 30 V • Turn starting switch ON. • Turn blower OFF.
• 20 – 30 V • Turn starting switch ON. • Turn blower “Me” switch ON.
• 240 ± 40 Ω • Disconnect CN-R3. • Turn starting switch OFF.
• 20 – 30 V • Turn starting switch ON. • Turn blower OFF.
12 ✩ Is voltage between CN-R2 (13E) and chassis ground normal? YES
NO
13 Is resistance between CN-R2 (13E) and (18A) normal?
NO
YES 14 ✩ Is voltage between CN-AC1 (18B) and chassis ground normal? YES
NO
15 ✩ Is voltage between CN-R3 (13H) and chassis ground normal? YES
NO
16 NO
Is resistance between CN-R3 (13H) and (17A) normal? YES
17 ✩ Is voltage between CN-AC1 (17B) and chassis ground normal? YES
NO
18 • Max. 1 Ω • Turn starting switch OFF.
Is resistance between CN-B (11A) and CN-R2 (11B) normal? YES
NO
Go to 19 on next page
20-804 7
D475A-3
TROUBLESHOOTING
TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK
Cause From 18 on previous page • Max. 1 Ω • Turn starting switch OFF.
• Turn starting switch ON. • Turn blower “Hi” switch ON.
19
Is resistance between CN-R2 (OE) and chassis ground normal? YES
NO
Disconnection or defective contact in wiring harness Repair or between CN-R2 (OE) – chassis replace ground
20 NO
Does blower rotate at Hi?
Defective blower Hi relay
Replace
Disconnection or defective contact in wiring harness between CN-R (12A) – CN-R3 (12B)
Repair or replace
YES 21
• Max. 1 Ω • Turn starting switch OFF.
Is resistance between CN-R (12A) and CN-R3 (12B) normal? YES
• Max. 1 Ω • Turn starting switch OFF.
Is resistance between CN-R3 (OB) and chassis ground normal? YES
NO
22
• Turn starting switch ON. • Turn blower “Me” switch ON.
Remedy
NO
Disconnection or defective contact in wiring harness Repair or between CN-R3 (OB) – chassis replace ground
23 Does blower rotate at Me?
NO
Defective blower Me relay
Replace
Go to “B. Air is not cooled”
—
YES
If trouble is not repaired by taking remedy against causes marked with ✩, control panel may be defective.
D475A-3
20-805 7
TROUBLESHOOTING
TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK
B. Air is not cooled • Max. 1 Ω • Turn starting switch OFF. • Disconnect CN80.
• Max. 3500 Ω • Turn starting switch OFF. • Disconnect CN-AC1.
Cause 1 Is resistance between CN-AC1 (15B) NO and CN-T (15A) and between CNAC1 (16C) and CN-T (16B) normal?
YES 2 ✩ NO
Is resistance between CN-AC1 (15B) and (16C) normal?
3 ✩ Is voltage between CN-R4 (13I) NO and chassis ground normal?
• 240 ± 40 Ω • Turn starting switch OFF. • Disconnect CN-R4.
NO Is resistance between CN-R4 (male) (13I) and (19C) normal?
• Max. 1 Ω • Turn starting switch OFF. • Disconnect CN-R4.
Is resistance between CN-R4 (19C) and CN-P (19A) normal?
• 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON.
Is voltage between CN-P (19A) NO and chassis ground normal?
• 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON. • 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON.
Disconnection or defective contact in wiring harness Repair or between CN-AC1 (15B) – CN-T replace (15A)
Defective frost thermistor ª Check sensed temperature for abnormality.
Replace
Disconnection or defective contact in wiring harness between fuse – CN-M26 (13A) – CN-R4 (13I)
Repair or replace
Defective compressor clutch relay
Replace
Disconnection or defective contact in wiring harness between CN-R4 (19C) – CN-P (19A)
Repair or replace
Disconnection or defective contact in wiring harness between CN-R4 (19C) – CN-P (19A)
Repair or replace
Defective pressure switch Note) Check pressure for abnormality.
Replace
YES
• 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON.
• 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON.
Remedy
YES 4 ✩
YES 5 NO
YES 6 ✩
YES 7 Is voltage between CN-P (26A) NO and chassis ground normal? YES 8 Is voltage between CN-AC1 (26B) and chassis ground normal? YES
NO
9 Is voltage between CN-R4 (6D) NO and chassis ground normal? YES
Disconnection or defective contact in wiring harness Repair or between CN-P (26A) – CN-AC1 replace (26B)
Disconnection or defective Repair or contact in wiring harness between fuse – CN-M26 (6A) – replace CN-R4 (6D)
Go to 10 on next page
20-806 7
D475A-3
TROUBLESHOOTING
TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK
Cause • 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON. • 20 – 30 V • Turn air conditioner switch ON. • Turn starting switch ON. • Turn blower ON.
From 9 on previous page
Remedy
10
Is voltage between CN-R4 (9B) NO and chassis ground normal?
Defective compressor clutch relay
Replace
YES 11 Is voltage between CN-M26 (9A) and chassis ground normal? YES
NO
Disconnection or defective contact in wiring harness Repair or between CN-R4 (9B) – CN-M26 replace (9A)
12 • Turn air conditioner switch ON.
Does magnetic clutch operate normally?
NO
Defective magnetic clutch
Replace
Defective compressor
Replace
Defective control panel
Replace
YES 13 • Turn air conditioner switch ON.
Does compressor operate normally?
NO
YES
If trouble is not repaired by taking remedy against causes marked with ✩, control panel may be defective.
D475A-3
20-807 7
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. ............... PRECAUTIONS WHEN CARRYING OUT OPERATION .......................................... SPECIAL TOOL LIST .................................. SKETCHES OF SPECIAL TOOLS.. ............. ENGINE OIL COOLER ASSEMBLY Removal and Installation .................... FUEL INJECTION PUMP ASSEMBLY Removal and Installation .................... AFTERCOOLER CORE ASSEMBLY Removal and Installation .................... NOZZLE HOLDER ASSEMBLY Removal and Installation .................... ENGINE FRONT SEAL Removal and Installation .................... ENGINE REAR SEAL Removal and Installation .................... CYLINDER HEAD ASSEMBLY Removal and Installation .................... FUEL TANK ASSEMBLY Removal and Installation .................... MAIN RADIATOR ASSEMBLY Removal and Installation .................... SUB RADIATOR ASSEMBLY Removal and Installation .................... RADIATOR GUARD ASSEMBLY Removal and Installation .................... ENGINE ASSEMBLY Removal and Installation .................... DAMPER ASSEMBLY Removal and Installation .................... Disassembly and Assembly ............... POWER TRAIN UNIT ASSEMBLY Removal and Installation .................... PTO, TORQUE CONVERTER ASSEMBLY Removal and Installation .................... Disconnection and connection.. ......... TORQUE CONVERTER ASSEMBLY Disassembly and Assembly ............... PTO ASSEMBLY Disassembly and Assembly ...............
D475A-3
30- 3 30- 6 30- 8 30-15 30-23 30-24 30-25 30-27 30-28 30-30 30-33 30-37 30-38 30-40 30-41 30-43 30-47 30-49 30-52
30-56 30-59 30-61
TORQFLOW TRANSMISSION ASSEMBLY Removal and Installation . . . . . .. . . . . . .. . . . . 30- 79 Disassembly and Assembly . .. . . . . . .. . .. 30- 80 STEERING CASE ASSEMBLY Disassembly and Assembly . . . . .. .. . . . .. 30-100 STEERING CLUTCH, BRAKE ASSEMBLY Disassembly and Assembly . . . . . . . .. . . . . 30-108 TRANSFER GEAR HOUSING ASSEMBLY Disassembly and Assembly . . . . . . . .. . . . . 30-I 16 POWER TRAIN PUMP ASSEMBLY Removal and Installation . . . . . .. . . . . . . .. . . . 30-120 SCAVENGING PUMP ASSEMBLY Removal and Installation .. . . . .. .. . . . . . .. . . 30-121 TORQUE CONVERTER OIL COOLER Removal and Installation . . . . .. . . . . . .. . .. . . 30-122 TORQUE CONVERTER VALVE ASSEMBLY Removal and Installation .. . . . . . . .. .. . . .. . . 30-123 Disassembly and Assembly . . . . . ..__.... 30-124 TRANSMISSION CONTROL VALVE ASSEMBLY Removal and Installation .. . . . .. . . . . . . .. . . . .. 30-127 Disassembly and Assembly . .. . . .. . . . .. . 30-130 STEERING CONTROL VALVE ASSEMBLY Removal and Installation .. . . . . .. . . . . .. . . . . .. 30-135 Disassembly and Assembly . . .. . .. . .. .. . 30-136 FINAL DRIVE ASSEMBLY Removal and Installation . . .. .. . . . . . . .. . . . . 30-140 Disassembly and Assembly . .. . .. . . .. .. . 30-141 TRACK FRAME ASSEMBLY Removal and Installation . .. . .. . . .. .. . . . . . . 30-158 IDLER ASSEMBLY Disassembly and Assembly . . . . . . . .. . . . . 30-161 RECOIL SPRING ASSEMBLY Removal and Installation _................. 30-165 Disassembly and Assembly . . . . . . . .. . . . . 30-171
30-72
30-l 0
TRACK ROLLER ASSEMBLY Removal and Installation .................... 30-173 Disassembly and Assembly ............... 30-175 CARRIER ROLLER ASSEMBLY Removal and Installation ................. 30-177-4 Disassembly and Assembly ............ 30-177-5 BOGIE ASSEMBLY Removal and Installation .................... 30-178 Disassembly and Assembly ............... 30-180 NO.1 BOGIE ASSEMBLY Removal and Installation .................... 30-189 TRACK SHOE ASSEMBLY Removal and Installation .................... 30-195 Overall disassembly ......................... 30-197-4 Overall assembly .............................. 30-197-8 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS ............... 30-197-23 FIELD DISASSEMBLY OF ONE LINK ... 30-197-24 FIELD ASSEMBLY OF ONE LINK ......... 30-197-27 MASTER LINK Disassembly and Assembly .......... 30-197-30 PIVOT SHAFT ASSEMBLY Removal and Installation .................... 30-198 EQUALIZER BAR Removal and Installation .................... 30-199 EQUALIZER BAR BUSHING Disassembly and Assembly ............... 30-202 HYDRAULIC PUMP ASSEMBLY Removal and Installation .................... 30-204 BLADE LIFT VALVE ASSEMBLY Removal and Installation .................... 30-205 Disassembly and Assembly ............... 30-206 BLADE TILT, RIPPER LO VALVE ASSEMBLY Removal and Installation .................... 30-208 Disassembly and Assembly ............... 30-210
30-2 2 6
RIPPER HI VALVE ASSEMBLY Removal and Installation .................... 30-212 Disassembly and Assembly ............... 30-214 PPC RELIEF VALVE ASSEMBLY Removal and Installation .................... 30-216 HYDRAULIC CYLINDER ASSEMBLY Disassembly and Assembly ............... 30-217 RIPPER PIN-PULLER CYLINDER ASSEMBLY Disassembly and Assembly ............... 30-223 BLADE ASSEMBLY Removal and Installation .................... 30-226 GIANT RIPPER ASSEMBLY Disassembly and Assembly ............... 30-228 ROPS GUARD Removal and Installation .................... 30-232 OPERATOR’S CAB ASSEMBLY Removal and Installation .................... 30-233 FLOOR FRAME ASSEMBLY Removal and Installation .................... 30-235 DASHBOARD ASSEMBLY Removal and Installation .................... 30-240 CONTROLLER ASSEMBLY Removal and Installation .................... 30-242 AIR CONDITIONER COMPRESSOR ASSEMBLY Removal and Installation .................... 30-243 AIR CONDITIONER CONDENSER ASSEMBLY Removal and Installation .................... 30-245 AIR CONDITIONER UNIT ASSEMBLY Removal and Installation .................... 30-246 HOOD ASSEMBLY Removal and Installation .................... 30-250
D475A-3
DISASSEMBLY
AND ASSEMBLY
METHOD
OF USING MANUAL
1.
METHOD
OF USING
MANUAL
When removing or installing unit assemblies @ When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. @ Any special techniques applying only to the installation procedure are marked m, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 0 0 0 0 ASSEMBLY .. . . . . . . .. .. Title of operation a .. . . . . . .. . .. . . . . . . .. . . . . .. . . .. . . . . . . .. . . . . . .. . . .. . . . . .. . . . . . . . . . .. . . . . Precautions related to safety when carrying out the operation . .. . .. . .. . .. . . . . . . .. . . . . . . .. . .. . . . . . .. . . . . . . . . . .. . . . . Step in operation 1. XXXX(1) * . .. . .. . . . . . . .. . . . . . . .. . . . . .. . . .. . . . . . .. . . .. . . . . .. . . . . . .. . . . .. . . . . . Technique or important point to remember when removing XXXX (I). Indicates that a technique is listed for use 2. a a a a (2).. .. . . . . .. . . . . . . . . . .. . . . . . . .. . . . . . .. . .. . . . . .. . . . . m during installation 3. 0 0 0 0 assembly (3)
..... ..... ...... ............ ...... .................. ........ Quantity
of oil or water
drained
INSTALLATION OF 0 0 0 0 ASSEMBLY .. ..Title of operation l Carry out installation in the reverse order to removal. . .. . .. . . .. . . .. . . . . .. . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .. . . . . . Technique used during installation p . .. . . . . . .. . . .. . . . .. . . . . . . . . . .. . . . . . . . .. . . . . .. . .. . . . . . .. . . . . . . .. . .. Technique or important point to remember when installing a a a a (2). l Adding water, oil .. . . . . . . .. .. .. . . . . .. . . . . . . .. .. . . . Step in operation * . . . . . . .. . . . . .. .. . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . .. . . .. . . . . .. Point to remember when adding water or oil %z . . . . . . . . .. . . . . .. .. . . . . . . .. . . . . . . .. . .. . . . . . .. . . . . . . .. . . . . . Quantity
when filling with oil and water
2.
General precautions when carrying out installation or removal (disassembly are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, these precautions when carrying out the operation.
3.
Listing of special tools @ For details of the description, part number, and quantity of any tools (Al, etc.) that appear the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
D475A-3
or assembly) of units so be sure to follow
in
30-3 0
DISASSEMBLY
4.
Standard
AND ASSEMBLY
tightening
Use these torques Thread diameter of bolt
torques
bolts and nuts. (Always
use torque
wrench).
7
Nm
mm
mm
6 8 10 12 14
10 13 17 19 22
13.2~ 1.4 3123 66k7 113+10 177z19
1.35TO.15 3.2~0.3 6.7 20.7 11.52 1 1822
16 18 20 22 24
24 27 30 32 36
279k30 382k39 549259 745e83 9272103
28.5~3 3924 56e6 7658.5 94.52 10.5
27 30 33 36 39
41 46 50 55 60
13202140 172Oe190 2210~240 275Ok290 32902340
Thread diameter of bolt
Width across flats
Tightening
mm
I
torque
No.
torque
Use these torques Thread
30-4 0
diameter
bm
135*15 175r20 225+25 280230 335235
kgm
I
7.8521.95 18.62 4.9 40.2~ 5.9 82.35~7.85
0.8~ 0.2 1.9kO.5 4.1 ~0.6 8.42 0.8
of hose nuts for hose nuts. Thread
03 04 05 06 10 12 14
Tightening
Nm
I
IO 13 14 27
Use these torques Nominal
MANUAL
Width across flats
6 8 10 12
6.
OF USING
of bolts and nuts
for metric
mm
5.
METHOD
diameter
Tightening
across flat
torque
mm
Nm
kam
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.52 4.9 492 19.6 78.5r 19.6 137.3229.4 176.5529.4 196.12 49 245.22 49 294.2* 49
2.5t0.5 5+2 822 14+3 1823 2025 25+5 3025
of split flange for split flange Width
Width
mm
bolts bolts. Tightening
across flat
mm
mm
10 12 16
14 17 22
Nm 65.726.8 11229.8 279t29
torque k9m 6.7 + 0.7 II.52 1 28.5~3
D475A-3
DISASSEMBLY
AND ASSEMBLY
7.
torque
Tightening
Use these torques Nominal
No.
of O-ring
Thread
Tightening
torque
Nominal 08 10 12 14 16 18 20 24 30 33 36 42 52
D475A-3
No.
diameter
Width
mm
of O-ring
Tightening
across flat mm
Varies depending on type of connector.
torque
Nm
kgm
34.3% 4.9 93.129.8 142.12 19.6 421.4~ 58.8 877.1* 132.3
3.550.5 9.5el 14.5*2 4326 89.5~ 13.5
boss connector
for O-ring Thread
MANUAL
boss connector
14 20 24 33 42
Use these torques
OF USING
boss connector
for O-ring
02 03,04 05,06 10.12 14
8.
METHOD
boss connector diameter
Width
Tightening
across flat
mm
mm
8 IO 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 36 -
Nm 7.355 1.47 11.27k1.47 17.6421.96 22.542 1.96 29.4k4.9 39.2~~4.9 49k 4.9 68.6~ 9.8 107.8* 14.7 127.4~ 19.6 151.9224.5 210.7e29.4 323.4& 44.1
torque bm 0.7520.15 1.15iro.15 1.8~0.2 2.3~0.2 3kO.5 420.5 520.5 721 1121.5 1322 15.5k2.5 21.5~3 33+ 4.5
30-5 0
DISASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
AND ASSEMBLY
PRECAUTIONS
WHEN CARRYING
OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) general precautions given below when carrying out the operation.1
1. . . . . . . . . . . Ir
of units, be sure to follow
the
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number
2)
I
Plug (nut end)
I
Sleeve nut (elbow end)
Use the two items below as a set
Split flange type hoses and tubes
Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
0737 I-30400
05
07379-00500
07378-10500
07371-30500
3)
If the part is not under hydraulic
pressure,
the following
corks can be used.
I= 27
07049-02734
L
27
22.534
30-6 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
PRECAUTIONS
WHEN
CARRYING
OUT OPERATION
2. . . . . .
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
*
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. * When using the machine for the first time after repair or long storage, follow the same procedure.
3. .
Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. * For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
. .
.
D475A-3
30-7 0
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST Serial No.: 10601 – 10684 fl Tools with part number 79OT-fififi-fifififi cannot be supplied (they are items to be locally manufactured). fl New/remodel: N: Tools with new part numbers, newly developed for this model fl R: Tools with upgraded part numbers, remodeled from items already available for other models. fl Blank: Tools already available for other models, used without any modification fl Tools marked fi in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component
Disassembly and assembly of engine
Symbol
Installer kit
■
1
Press fitting of front seal, sleeve
2
795-602-2300
Installer kit
■
1
Press fitting of rear seal, sleeve
3
790-331-1110
Wrench
■
1
Installation of cylinder head
790-431-1120
Adapter
■
1
791-520-4140
Screw
■
1
791-181-1020
Sleeve
■
1
791-765-1150
Plate
■
1
791-112-1180
Nut
■
1
790-101-2540
Washer
■
1
790-101-2102
Puller(294kN{30ton})
■
1
790-101-1102
Pump
■
1
790-413-1010
Bracket
■
1
790-501-5000
Repair stand
■
1
790-413-1010
Bracket
■
1
790-501-5000
Repair stand
■
1
799-301-1600
Oil leak tester
■
1
791-622-1110
Bracket
■
1
01016-51690
Bolt
■
1
01011-81600
Bolt
■
1
791T-822-1810
Push tool
■
1
N
791T-822-1820
Push tool
■
1
N
791-822-1830
Wrench
■
1
N
Removal, installation of bearing round nut
790-337-1032
Lifting tool
■
1
791-827-1910
Plate
■
1
N
Removal, installation of final drive assembly
01011-83015
Bolt
■
3
790-431-1081
Guide
■
1
790-431-1031
Block
■
1
790-101-2350
Leg
■
2
C
D
1 Disassembly and assembly of steering
E 2 3
1 Disassembly and assembly of final drive
J 2
30-8 2 6
NeceNew/ Q’ty Sketch Nature of work, remarks ssity remodel
795-602-2200
4
Disassembly and assembly of transmission
Part Name
1
A
Disassembly and assembly of torque converter
Part No.
Pulling out pin or radiator guard
Disassembly, assembly of torque converter Disassembly, assembly of transmission Checking actuation of piston Removal, installation of clutch, brake assembly
fi fi
Press fitting of bearing
Pulling out sprocket bearing
D475A-3
DISASSEMBLY AND ASSEMBLY
Component
Symbol
■
2
790-101-2360
Plate
■
4
02215-11622
Nut
■
2
790-101-2102
Puller(294kN{30ton})
■
1
790-101-1102
Pump
■
1
790-431-1101
Installer assembly
■
1
790-101-2102
Puller(294kN{30ton})
■
1
790-101-1102
Pump
■
1
791-585-1510
Installer
■
1
790-431-1220
Remover assembly
■
1
790-101-2102
Puller(294kN{30ton})
■
1
790-101-1102
Pump
■
1
790-431-1210
Installer assembly
■
1
790-101-2102
Puller(294kN{30ton})
■
1
790-101-1102
Pump
■
1
790-431-1230
Remover & installer
■
1
790-101-2102
Puller(294kN{30ton})
■
1
790-101-1102
Pump
■
1
790-431-1240
Guide
■
1
791-830-1470
Plate
■
1
791-830-1320
Rod
■
2
790-101-2510
Block
■
1
790-101-2570
Plate
■
2
01580-01613
Nut
■
2
01643-31645
Washer
■
2
2
791-560-1520
Installer
■
1
3
791-830-1480
Push tool
■
1
4
791-601-1000
Oil pump
■
1
Filling with oil
5
791-515-1520
Installer
■
1
Installation of floating seal
6
790-434-1490
Push tool
■
1
7
791-630-1270
Wrench
■
1
Removal, installation of round nut
8
791-630-1210
Plate
■
1
Press fitting of bushing
9
791-530-1510
Installer
■
1
Installation of floating seal
4 J 5
6
7
8
1 Assembly of Idler
Disassembly and assembly of carrier roller Assembly of track roller
D475A-3
NeceNew/ Q’ty Sketch Nature of work, remarks remodel ssity
Adapter
3
L
Part Name
790-101-2430
2
Disassembly and assembly of final drive assembly
Part No.
SPECIAL TOOL LIST
Pulling out sprocket bearing
Press fitting of sprocket bearing Installation of floating seal
Pulling out center hub
Press fitting of center hub
Pulling out, press fitting of carrier pin Assembly of No. 1 pinion N
Press fitting of idler bushing
Installation of floating seal N
R
Press fitting of seal guide
Press fitting of floating seal collar
30-9 2 6
DISASSEMBLY
AND ASSEMBLY
Component
SPECIAL TOOL LIST
Part No.
Symbol I
Assembly roller
1790-434-1480 1Push
11
I 791-601-1000
12
30-l 0 0
I oil pump Lifting tool
I
Press fitting of seal ring
1 n
1 1
n
1
790-401-1761
Adapter
W
1
Shackle
W
2
790-401-1770
T-bolt
W
2
1
I Filling with oil
Removal, installation track roller assembly
1Rod
1~111 1~111 I=111
I I I
I I I
1Adapter
lrnlll
I
I
1 Frame
3 I 791-685-9520
( Frame
4
1 791-685-9530
,
1W11I
790-401-1540
11 1 791-126-0150
13
tool
790-401-1700
~~791-685-9510
Disassembly and assembly of bogie
,
10 of track
r~~O~~, SketchNature of work, remarks
Part Name I
12
791-685-9620
Extension
W
1
13 14
791-830-1550 791-830-1560
Adapter Sleeve
W W
1 1
15
04530-I 1080
Eyebolt
n
2
24
01017-52010
Bolt
n
4
25
791-830-1590
Spacer
n
1
N
26
N
N N
Pulling out, press fitting of shaft assembly
791-830-1580
Push tool
n
1
14
01017-31650
Bolt
4
3
Pulling out cage
15
790-201-2310
Plate
w
1
Pulling out collar
16
1 791-830-1520
I Installer
I H
I
I
I
N
of
I
I Press fitting of floating seal
D475A-3
DISASSEMBLY
Component
AND
ASSEMBLY
Part No.
Symbol
17
20
21
SPECIAL
Part Name
ry,cyi, Sketch Nature
790-101-5201
Push tool kit
790-101-5341
. Plate
1
790-101-5221
* Grip
1
01010-51225
* Bolt
790-601-1000
Oil pump
ml
H
TOOL
of work,
LIST
remarks
1 Press fitting of bushing
1 W
1
Filling with oil
FaWi;$of
No. 1 bogie
Removal of No. 1 bogie
Disassembly and assembly of bogie
Removal of No. 1 bogie
D475A-3
30-11 0
DISASSEMBLY
SPECIAL TOOL LIST
AND ASSEMBLY
Component
T
Symbol
T
Part No.
791T-830-1500
Disassembly and assembly of bogie
26
1
Disassembly and assembly of recoil spring
Disassembly and assembly of equalizer bar
2
n
Lifting tool
1
791T-830-1530
1- Tube
1
ili”lO
1- Plate
I
11
. Clip
1
01852-01210
l
Nut
2
SketchNature of work, remarks
N
IN
07283-31193
10 Removal, installation of No. 1 bogie track roller
01643-31232
1- Washer
I
I21
I
01643-31645
1* Washer
I
Ill
I
04530-l 1628
1Evebolt
I
Ill
I Pulling out idler cushion guide pin
ii,,i,,
791-635-3160
I Extension
790-201-2790
I Spacer
1~111 ImId
790-101-1300
Cylinder (980kNIlOO
’
’
790-101-1102
Pump
n
1
791-730-l
Bolt
n
6
Nut
W
6
120
01643-33380
1Washer
792-900-1610
I Adapter
ton))
I I
n
1
791-775-1110
Sleeve
n
1
791T-850-1150
Plate
n
1
1Nut
01643-33080
1Washer
790-101-2102
I Puller(294kN{3Oton}) I n
790-101-1102
I Pump
I I
N
0
I I
1~111
I
Bracket
n
1
N
0
791T-850-1170
Bracket
n
1
N
0
790-438-l
Screw
n
1
790-101-2540
I Washer Nut
1~121 1~121
790-101-2102
I Puller(294kNQOton)) I
790-101-l
I Pump
102
w I I
ID111
Pulling out center pin
I
791T-850-1160
110
of
I
I=111 I=111
01582-53024
assembly
I
1~111
Screw
Disassembly, recoil spring
Removal of recoil cylinder assembly
1m161
792-900-l 530
791-112-1180
30-12 0
I,$;
791T-830-1540
01580-13326
1
Part Name
I I
Pulling out side pin bushing
/
I
D475A-3
DISASSEMBLY
Component
Disassembly and assembly of pivot shaft
AND
ASSEMBLY
Symbol
P
SPECIAL
Part No.
Part Name
Necessity O’ty
rfZcZ
Sketch Nature
791T-850-1180
Sleeve
n
1
N
0
791T-850-1190
Plate
n
1
N
0
791-730-I
Bolt
n
2
791-101-3310
Block
l
1
01643-32060
Washer
l
2
130
01580-02016 790-105-2300
( Nut
n
1
of work,
LIST
remarks
Press fitting of seal
I
(ml21
Jack assembly
TOOL
I
Pump
n
1
1
791-646-7531
Plug remover
H
1
Knocking out small plug
2
791-660-7460
Pin brush
n
1
Cleaning of pin
3
79 l-646-7900
Push tool
n
1
Knocking in large plug
4
791-932-1110
Push tool
n
1
Knocking in all plugs
790-101-l
102
Filling with oil and checking air tightness Disassembly and assembly of track shoe
Disassembly,
assembly of
790-502-1003
Cylinder repair stand 0
1
Disassembly, assembly of cylinder
790-201-1702
Push tool kit
1
Press fitting of coil bushing
1
* Blade lift Blade tilt (standard specification) * Blade pitch (superdozer specification) Ripper tilt
790-201-1861
l
Push tool
m
l
Disassembly and assembly of hydraulic cylinder
D475A-3
790-201-1881
. Push tool
1
790-201-1871
. Push tool
1
790-201-1721
. Push tool
1
790-101-5021
l
Grip
1
01010-50816
. Bolt
1
l
l
l
Ripper lift Ripper puller
30-13 0
DISASSEMBLY
Component
AND ASSEMBLY
SPECIAL TOOL LIST
Part No.
Symbol I
Part Name
r:iOyi Sketch Nature
of work,
remarks
I
790-201-1500 1 790-201-1670
Push tool kit 1 Plate
1m111
I
l
Press fitting of dust seal
I 1 I
I
I - Blade lift l
Ripper lift
Blade tilt (standard specification) . Blade pitch (superdozer specification) . Ripper tilt l
3
I 790-201-1530
j
790-101-5021 I
Disassembly, assembly of hydraulic cylinder
4
5
6
Air conditioner related
X
01010-50816
Plate
/
I 1
. Grip l
I
1
I
I- Pin puller
I
I
1
1
Bolt
1
I
I
790-720-1000
Expander
n
1
796-720-I690
Ring
n
1
07281-01919
Clamp
n
1
Installationof all cylinder piston rings
Blade lift (standard specification)
796-720-l690
Ring
n
1
07281-02169
Clamo
I
1
796-720-1710
Ring
n
1
07281-02709
Clamp
n
1
796-720-I 630
Ring
n
1
07281-00709
Clamp
1
790-102-2303
Wrench
n n
1
Removal and installation of pin puller cylinder head
799-703-1200
Service tool kit
n
1
Charging with freon gas
799-703-I
100
Vacuum
pump
n
1
(100 V specification)
799-703-I
110
Vacuum
pump
n
1
(220 V specification)
799-703-l
120
Vacuum
pump
n
1
(240 V specification)
n
1
799-703-I 400
30-14 0
l
Gas leak detector
Blade lift (superdozer specification) Ripper tilt, lift Blade tilt (standard specification) Blade pitch (sucerdozer soecification) Pin puller
D475A-3
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
Serial No.: 10685 and up fl Tools with part number 79OT-fififi-fifififi cannot be supplied (they are items to be locally manufactured). fl New/remodel: N: Tools with new part numbers, newly developed for this model fl R: Tools with upgraded part numbers, remodeled from items already available for other models. fl Blank: Tools already available for other models, used without any modification fl Tools marked fi in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component
Disassembly, assembly of engine
Symbol
Installer kit
■
1
2
795-602-2300
Installer kit
■
1
3
790-331-1110
Wrench
■
1
790-431-1120
Adapter
■
1
791-520-4140
Screw
■
1
791-181-1020
Sleeve
■
1
791-765-1150
Plate
■
1
791-112-1180
Nut
■
1
790-101-2540
Washer
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
790-413-1010
Bracket
■
1
790-501-5000
Repair stand
■
1
790-413-1010
Bracket
■
1
790-501-5000
Repair stand
■
1
799-301-1600
Oil leak tester
■
1
791-622-1110
Bracket
■
1
01016-51690
Bolt
■
1
01011-81600
Bolt
■
1
791T-822-1810
Push tool
■
1
791T-822-1820
Push tool
■
1
791-822-1830
Wrench
■
1
790-337-1032
Lifting tool
■
1
791-827-1910
Plate
■
1
01011-83015
Bolt
■
3
790-431-1081
Guide
■
1
790-431-1031
Block
■
1
790-101-2350
Leg
■
2
C
D
1 Disassembly, assembly of steering system
E 2 3
1 Disassembly, assembly of final drive
J 2
D475A-3
NeceNew/ Q’ty Sketch Nature of work, remarks ssity remodel
795-602-2200
4
Disassembly, assembly of transmission
Part Name
1
A
Disassembly, assembly of torque converter
Part No.
Press fitting of front seal and sleeve Press fitting of rear seal and sleeve Removal, installation of cylinder head
Pulling out of radiator guard
Disassembly, assembly of torque converter Disassembly, assembly of transmission Operation check of piston
Removal, installation of clutch and brake assembly
fi fi
Press fitting of bearing Removal, installation of bearing round nut
Removal, installation of final drive assembly
Pulling out of sprocket bearing
30-14-1 6
DISASSEMBLY AND ASSEMBLY
Component
Symbol
Part Name Adapter
■
2
790-101-2360
Plate
■
4
02215-11622
Nut
■
2
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
790-431-1101
Installer assembly
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
791-585-1510
Installer
■
1
790-431-1220
Remover assembly
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
790-431-1210
Installer assembly
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
790-431-1230
Remover and installer
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
790-431-1240
Guide
■
1
791-830-1760
Plate
■
1
791-830-1320
Rod
■
2
790-101-2510
Block
■
1
790-101-2570
Washer
■
2
01580-01613
Nut
■
2
01643-31645
Washer
■
2
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
2
791-560-1520
Installer
■
1
Installation of floating seal
3
791-830-1480
Push tool
■
1
Press fitting of seal guide
4
791-601-1000
Oil pump
■
1
Supply of oil
5
791-515-1520
Installer
■
1
Installation of floating seal
6
791-830-1770
Push tool
■
1
3
4 J 5
6
7
8
1 Assembly of idler
L
Disassembly, assembly of carrier roller
Disassembly, assembly of track roller
6
Pulling out of sprocket bearing
Press fitting of sprocket bearing Installation of floating seal
Pulling out of center hub
Press fitting of center hub
Pulling out and press fitting of carrier pin Installation of 1st pinion N
Press fitting of idler bushing
N
Press fitting of seal guide
7
791-630-1270
Wrench
■
1
8
791-830-1740
Plate
■
1
9
791-515-1520
Installer
■
1
10
791-830-1730
Push tool
■
1
11
791-601-1000
Oil pump
■
1
Supply of oil
790-401-1700
Lifting tool
■
1
790-401-1761
Adapter
■
1
Removal, installation of track roller assembly
12
30-14-2
NeceNew/ Q’ty Sketch Nature of work, remarks remodel ssity
790-101-2430
2
Disassembly, assembly of final drive
Part No.
SPECIAL TOOL LIST
Removal, installation of round nut
N
Press fitting of bushing Installation of floating seal
N
Press fitting of seal guide
D475A-3
DISASSEMBLY AND ASSEMBLY
Component
Symbol
Disassembly, assembly of track roller
Part No.
SPECIAL TOOL LIST
Part Name
790-401-1540
Shackle
■
2
790-401-1770
T-bolt
■
2
791T-830-1780
Plate
■
3
01011-62700
Bolt
■
6
01673-32780
Washer
■
6
1
791-830-1620
Plate
■
1
N
2
791-830-1630
Spacer
■
1
N
3
791-830-1640
Screw
■
3
N
4
01580-12722
Nut
■
3
5
01630-32780
Washer
■
3
6
790-101-4000
Puller (490 kN {50 tons})
■
1
7
790-101-1102
Pump
■
1
1
791-830-1650
Plate
■
1
N
2
791-830-1660
Spacer
■
1
N
3
796-670-1120
Plate
■
1
4
790-434-1070
Screw
■
1
5
01580-13629
Nut
■
2
6
01643-33690
Washer
■
1
7
790-101-4000
Puller (490 kN {50 tons})
■
1
8
790-101-1102
Pump
■
1
1
791-830-1620
Plate
■
1
N
2
791-830-1640
Screw
■
3
N
3
01580-12722
Nut
■
3
4
01643-32780
Washer
■
3
5
790-101-4000
Puller (490 kN {50 tons})
■
1
6
790-101-1102
Pump
■
1
17
791T-830-1670
Guide
■
2
18
791-530-1510
Installer
■
1
Installation of floating seal
19
791-601-1000
Oil pump
■
1
Supply of oil
791-630-1860
Bracket
■
1
791-630-1870
Bracket
■
1
791T-830-1510
Spacer
■
2
19M-09-12850
Bolt
■
2
01643-33380
Washer
■
2
791T-830-1700
Lifting tool
■
1
N
791T-830-1710
• Bar
1
N
791T-830-1720
• Plate
1
N
07283-31079
• Clip
1
01582-01210
• Nut
2
12
Disassembly, assembly of bogie and track roller
13
14
15
Disassembly, assembly of bogie
L
16
20
21
D475A-3
NeceNew/ Q’ty Sketch Nature of work, remarks remodel ssity Removal, installation of track roller assembly N
fi Securing of bogie
Pulling out of ring and shaft
N Pulling out of ring
Press fitting of pin assembly
N
fi
fi
Removal of 1st bogie assembly
fi fi
Removal, installation of 1st bogie track roller
30-14-3 6
DISASSEMBLY AND ASSEMBLY
Component Disassembly, assembly of bogie
Symbol L
Part Name
01643-31232
• Washer
2
04530-11628
• Eyebolt
1
790-434-1401
Remover assembly
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
791-685-8502
Compressor
■
1
791-635-3160
Extension
■
1
790-201-2790
Spacer
■
1
790-101-1300
Cylinder (980 kN {100 tons})
■
1
790-101-1102
Pump
■
1
791-730-1120
Bolt
■
6
01580-13326
Nut
■
6
01643-33380
Washer
■
6
792-900-1610
Adapter
■
1
792-900-1530
Screw
■
1
791-775-1110
Sleeve
■
1
791T-850-1150
Plate
■
1
01582-53024
Nut
■
1
01643-33080
Washer
■
1
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
791T-850-1160
Bracket
■
1
791T-850-1170
Bracket
■
1
790-438-1110
Screw
■
1
790-101-2540
Washer
■
2
791-112-1180
Nut
■
2
790-101-2102
Puller (294 kN {30 tons})
■
1
790-101-1102
Pump
■
1
791T-850-1180
Sleeve
■
1
791T-850-1190
Plate
■
1
791-730-1130
Bolt
■
2
790-101-3310
Plate
■
1
01643-32060
Washer
■
2
01580-02016
Nut
■
2
790-105-2300
Jack assembly
■
1
790-101-1102
Pump
■
1
1
791-646-7531
Push tool
■
1
Removal of small plug
2
791-660-7460
Pin brush
■
1
Cleaning of pin
3
791-646-7900
Push tool
■
1
Fitting of large plug
2
M
3
1
Disassembly, assembly of equalizer bar
N
2
Disassembly, assembly of pivot shaft
Disassembly, assembly of track shoe
30-14-4 6
P
R
NeceNew/ Q’ty Sketch Nature of work, remarks remodel ssity Removal, installation of 1st bogie track roller
21
1
Disassembly, assembly of recoil spring
Part No.
SPECIAL TOOL LIST
Pulling out of idler cushion guide pin
Disassembly, assembly of recoil spring
Removal of recoil spring assembly
fi
Pulling out of center pin
fi fi Pulling out of pin and bushing
fi fi Press fitting of seal
D475A-3
DISASSEMBLY AND ASSEMBLY
Component
4
5
R
8
D475A-3
Part Name
NeceNew/ Q’ty Sketch Nature of work, remarks remodel ssity
791-932-1110
Push tool
■
1
790-701-3000
Seal checker
■
1
Fitting of small plug Supply of oil and airtightness check
or 791-601-1000
Oil pump
791-632-1010
Installer
■
1
1
791-832-1610
Plate
■
1
2
791-832-1270
Bracket
■
1
3
01010-81495
Bolt
■
1
4
791-832-1250
Bracket
■
1
5
01010-62050
Bolt
■
2
6
791-832-1220
Plate
■
1
7
791-832-1230
Shaft
■
2
8
791-832-1210
Frame
■
1
9
791-832-1240
Nut
■
2
10
04530-11628
Eyebolt
■
2
11
791-832-1310
Adapter
■
1
12
791-832-1280
Adapter
■
1
13
791-832-1320
Guide
■
1
14
01320-41030
Screw
■
5
15
791-832-1640
Pusher
■
1
16
791-832-1340
Extension
■
2
17
791-832-1650
Adapter
■
1
18
791-832-1480
Adapter
■
1
19
791-832-1670
Guide
■
1
20
791-832-1330
Guide
■
1
21
791-832-1660
Adapter
■
1
22
791-832-1630
Guide
■
1
23
791-832-1470
Guide
■
1
24
791-832-1410
Extension
■
1
25
791-832-1350
Pusher
■
1
26
791-832-1620
Guide
■
1
27
04530-11018
Eyebolt
■
1
28
790-101-4500
Cylinder (1,960 kN {200 tons})
■
1
29
790-101-1102
Pump
■
1
30
790-101-4200
Puller (294 kN {30 tons})
■
1
31
791-685-9230
Spacer
■
1
6
Disassembly, assembly of track shoe
Part No.
Symbol
SPECIAL TOOL LIST
Replacement of link seal
Pulling out and press fitting of pin and bushing N
N
30-14-5 6
DISASSEMBLY AND ASSEMBLY
Component
Part No.
Symbol
SPECIAL TOOL LIST
Part Name
791-685-5600
Push tool assembly
2
791-685-5640
3
N
• Adapter
1
N
791-685-5660
• Ring
1
N
4
791-685-5670
• Plate
1
N
5
791-685-5680
• Ring
1
N
6
791-685-5690
• Push tool
1
N
7
791-685-5710
• Adapter
1
N
8
791-685-5720
• Spring
1
N
9
791-685-5730
• Bar
1
N
10
01252-30655
• Bolt
1
11
01580-01210
• Nut
1
791-685-5740
Push tool
10 Disassembly, assembly of track shoe
R
1
6
1
N Press fitting of ring
1
791-832-1490
Push tool
■
1
N
2
791-832-1510
Push tool
■
1
N
1
791-685-5700
Push tool assembly
■
1
N
2
791-685-5650
• Adapter
1
N
3
791-685-5660
• Ring
1
N
4
791-685-5670
• Plate
1
N
5
791-685-5680
• Ring
1
N
6
791-685-5690
• Push tool
1
N
7
791-685-5710
• Adapter
1
N
8
791-685-5720
• Spring
1
N
9
791-685-5730
• Bar
1
N
10
01252-30655
• Bolt
1
11
01580-01210
• Nut
1
791-685-5750
Push tool
11
13
30-14-6
■
Press fitting of ring (For large plug)
or
12
Disassembly, assembly of hydraulic cylinder
■
1
9
1
NeceNew/ Q’ty Sketch Nature of work, remarks remodel ssity
■
Press fitting of ring
1
N
Press fitting of ring (For small plug)
For pushing of ring Disassembly, assembly of cylinder
790-502-1003
Cylinder repair stand
●
1
790-201-1702
Push tool kit
■
1
Press fitting of roll bushing
790-201-1881
• Push tool
1
• Blade tilt (Standard specification) • Blade pitch (Superdozer specification) • Ripper tilt
790-201-1871
• Push tool
1
• Ripper lift
790-201-1721
• Push tool
1
• Pin puller
790-101-5201
• Grip
1
—
01010-50816
• Bolt
1
—
U 2
D475A-3
DISASSEMBLY AND ASSEMBLY
Component
Symbol
3
Disassembly, U assembly of hydraulic cylinders
4
5
6
Parts related to air conditioner
D475A-3
X
Part No.
SPECIAL TOOL LIST
Part Name
790-201-1500
Push tool kit
790-201-1670 790-201-1680
NeceNew/ Q’ty Sketch Nature of work, remarks ssity remodel ■
1
Press fitting of dust seal
• Plate
1
• Blade lift
• Plate
1
• Ripper lift
790-201-1690
• Plate
1
• Blade tilt (Standard specification) • Blade pitch (Superdozer specification) • Ripper tilt
790-201-1530
• Plate
1
• Pin puller
790-101-5201
• Grip
1
01010-50816
• Bolt
1
—
—
790-720-1000
Expander
■
1
Installation of piston rings of all cylinders
796-720-1690
Ring
■
1
07281-01919
Clamp
■
1
Blade lift (Standard specification)
796-720-1690
Ring
■
1
07281-02169
Clamp
■
1
796-720-1710
Ring
■
1
07281-02709
Clamp
■
1
Ripper tilt, lift Blade tilt (Standard specification) Blade pitch (Superdozer specification)
796-720-1630
Ring
■
1
Pin puller
07281-00709
Clamp
■
1
790-102-2303
Wrench
■
1
Removal, installation of pin puller cylinder head
799-703-1200
Service tool kit
■
1
Charging with refrigerant gas
799-703-1100
Vacuum pump
■
1
(100V specification)
799-703-1110
Vacuum pump
■
1
(200V specification)
799-703-1120
Vacuum pump
■
1
(240V specification)
799-703-1400
Gas leak detector
■
1
Blade lift (Superdozer specification)
—
30-14-7 6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Serial No.: 10601 – 10684 Note:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
E2 Push tool
D475A-3
30-15 2 6
DISASSEMBLY
AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L13-22 Bracket
23
DRILL
2 PLACES
A-A
CDD01246 HEAT TREATMENT ----
02
BOSS
SS4OOB
1
1.76
$40
01
PLATE
SS4OOP
1
0.17
t16
SYM.
PART NAME
MATERIAL
QTY/SET v?:B
PART NAME
BRACKET REMARKES
-
791T-630-1580
MATERIAL
SEE DWG OTY
----
n
L13-23 Stand
PLACES
ClO$+C
A-A
4-c 5
01580-02016 02
LA
2 PLACES
NUT CHANNEL
STD SS4OOA
01
PLATE
SS4OOP
SYM.
PART NAME
MATERIAL
30-16 0
CDD01247
3
--
1
5.58
2
2.63
QTY/SET 7;;;
---Cl5Ox75x6.5 t16 REMARKES
HEAT TREATMENT
MATERIAL
----
SEE DWG
PART NAME
STAND
791T-630-1590
QTY
----
n
0475A-3
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L21 Spacer /I/
/
\ p3
\
/V
I
A
4343 ________-_____-_-_-._-._-
Cl
_
< 6 mm -aa
cl_I
,
Cl CWD03.289 HEAT TREATMENT ----
MATERIAL
PART NAME
QTY
STKM13A
SPACER
791T-830-1510
‘n
L22-3 Plate
D475A-3
30-17 0
DISASSEMBLY
SKETCHES OF SPECIAL TOOLS
AND ASSEMBLY
L-25 Guide
CWD03290 HEAT TREATMENT ----
MATERIAL
PART NAME
QTY
GUIDE
1
1 791T-830-1460
STKM13A
A
L-26 Tube
9-
a0 ~
_____---
--------
60
CWD03292 HEAT TREATMENT
z
1571-01625
SEAT
STD
01
TUBE
STKM13A
SYM.
PART NAME
MATERIAL
30-18 0
----
2 1
0. 118 38. 5
QTYISET :;;y
PART NAME
@114.
3Xt8.
REMARKES
5
MATERIAL
SEE DWG QTY
TUBE
791T-830-1530
'a
D475A-3
DISASSEMBLY
AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L-26 Plate
2-13.5
DRILLS \
t ml c-0
14. 5
126.5 155.5
1 791T-830-1540
Nl
n
Plate
33
DRILL
CWD03.294
D475A-3
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
N2 Bracket
CWD03295 HEAT TREATMENT
MATERIAL
HEAT TREATMENT ----
MATERIAL
PART NAME
QTY
N2 Bracket
CWD03296
02
TUBE
STKM13A
1
3.33
@177.8xt9.
01
PLATE
SS4OOP
1
2.93
t16
SYM.
PART NAME
MATERIAL
OTYhET
30-20 0
"I;;:
REMARKES
5
SEE DWG
BRACKET
791T-850-1170
'A
D475A-3
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
P Sleeve
Q
360
02
I
2-10x1.5
_-.-.-.-
I
665:O. 2
I-
, CWD03.297 I
02
TUBE
STK13A
1
42.2
4273. 1xt12
01
PLATE
SS4OOP
1
5.13
t22
SYM.
PART NAME
MATERIAL
MATERIAL
PART NAME
QTY
SEE
DWG
SLEEVE
791-850-1180
REMARKES
QTY/SET v;;r
HEAT TREATMENT ----
'A
P Plate
2-22
1
DRILLS
=+
CWD03298 HEAT TREATMENT ----
MATERIAL
PART NAME
QTY
SS4OOP
PLATE
791-850-1190
D475A-3
'a
30-21 0
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Serial No.: 10685 and up Note:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
E2 Push tool
30-22 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L13 Plate
L17 Guide
D475A-3
30-22-1 6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L20 Spacer
L21 Bar
30-22-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L21 Plate
N1 Plate
D475A-3
30-22-3 6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
N2 Bracket
N2 Bracket
30-22-4 6
D475A-3
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
P Sleeve
P Plate
D475A-3
30-22-5 6
DISASSEMBLY
AND ASSEMBLY
ENGINE OIL COOLER
REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1. Remove fuel injection pump assembly (right). For details, see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY (RIGHT).
2.
Drain coolant.
3.
Remove
coolant
4.
Remove
oil cooler assembly
5.
Remove
manifold
6.
Remove
oil cooler assembly
bypass tube (I). (front) (2).
(3). (rear) (4).
INSTALLATION OF ENGINE OIL COOLER ASSEMBLY l
l
Carry out removal.
installation
in the
reverse
order
to
Refilling with water Add water to the specified
level, and run the engine to circulate the water through the system. Then check the water level again.
D475A-3
30-23 0
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY (BOTH LEFT AND RIGHT) 1. Open 2. 3.
4. 5. 6. 7. 8. 9. 10. 11. 12.
engine side cover (I) and remove side cover (2). Close fuel supply valve. Remove mounting bolts (4) of fuel strainer (31, and move fuel strainer assembly to side. . Left fuel injection pump only. Remove fuel pump coupling cover. Remove lubrication tube (5). Disconnect hose (6) for field pump. Disconnect tubes (7) and (8). Disconnect fuel hose (9). Disconnect fuel injection tube (IO). Remove injection pump mounting bolts ( Remove coupling lock bolt (12). Remove injection pump (13). * Be careful not to lose the coupling key, and store it in a safe place.
el kg
Fuel injection
pump assembly
I ‘/
’
\
-2
CWD02941
: / /
4
CWD02945
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY (BOTH LEFT AND RIGHT) l
Carry out removal.
installation
m
Sleeve
w
Coupling
in the
reverse
order
to
nut: 23.5 z 1.0 Nm 12.4 2 0.1 kgm}
m
CWD02946
lock bolt: 157 - 196 Nm {IS - 20 kgm1
m l
.
Adjust the injection timing. For details, see TESTING AND ADJUSTING, justing fuel injection timing. Bleed the air from the fuel circuit.
30-24 0
Ad-
D475A-3
DISASSEMBLY
AFTERCOOLER
AND ASSEMBLY
CORE
REMOVAL OF AFTERCOOLER CORE ASSEMBLY 1. 2.
Drain coolant. Remove hood assembly. For details, see REMOVAL
OF HOOD ASSEM-
BLY. 4. 5.
Remove engine side cover. Remove muffler assembly (I) and bracket (2). Remove air cleaner assembly (3). . Remove the air cleaner bracket also.
6.
Remove
7.
Disconnect
8.
Removal of aftercooler bank) 1) Remove aftercooler
3.
intake connector electrical
(4).
intake air heater (5).
core assembly
(for left
tubes (61, (71, and (8).
CUD02949
2)
Remove
connectors
(9) and (IO), and cover
3)
(II). Remove
aftercooler
core assembly
(12).
CUD02950
D475A-3
DISASSEMBLY AND ASSEMBLY
9.
Removal of aftercooler bank) 1) Remove aftercooler
.
core assembly
(for right
tube (13).
2)
Remove
connectors
(14) and (151, and cover
3)
(16). Remove
aftercooler
core assembly
INSTALLATION AFTERCOOLER ASSEMBLY l
AFTERCOOLER CORE
Carry out installation removal.
(17).
OF CORE
in the
reverse
order
to
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
30-26 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY 1.
2. 3. 4. 5. 6. 7.
Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. Remove engine side cover (1). Remove cylinder head cover (2). Disconnect fuel tube (3). m Loosen locknut (41, and remove connection (5). Remove holder (6). H & Remove nozzle holder assembly (7). Jr Using the removed holder and mounting bolts, screw into the head of the nozzle holder, and pull out the nozzle holder. * Check that there is a gasket fitted to the tip of the nozzle holder. * Mark each nozzle holder with the cylinder number, be careful not to damage the tip, and keep in a safe place.
I
CUD02953
INSTALLATION OF NOZZLE HOLDER ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
m
Sleeve
w
m
Connection : 34.3 - 39.2 Nm (3.5 - 4.0 kgm1 Locknut : 29.4 - 34.3 Nm (3.0 - 3.5 kgm}
w
Holder
a
nut : 23.5 +. 0.98 Nm 12.4 + 0.1 kgm1
mounting bolt : 66.2 t. 7.4 Nm 16.75 t 0.75 kgm}
m Align with the connection mount hole of the nozzle holder, then insert the nozzle holder.
D475A-3
30-27 0
DISASSEMBLY AND ASSEMBLY
REMOVAL SEAL
ENGINE FRONT SEAL
OF ENGINE FRONT
1.
Remove radiator guard assembly. For details, see REMOVAL OF RADIATOR GUARD ASSEMBLY.
2.
Remove crankshaft pulley (I).
m
I
J
3.
Remove front seal (2).
INSTALLATION FRONT SEAL l
-IAr+ CWD02956
Carry out installation removal.
OF ENGINE
in the reverse order to
I
v
CWD02957
If Align the dowel pin when installing the crankshaft pulley. Tighten the mounting bolts in the order shown in the diagram on the right. w Crankshaft pulley mounting bolt :
m *
Do as follows according to the wear of the crankshaft seal contact surface. I) When crankshaft is a new part or when there is no wear of oil seal contact surface. i) Fill approx. 50 - 80% of lip portion at top of seal circumference with lithium grease. ii) Insert spacer @ (t=l.8 - 2.8 mm) between tool Al and seal (21, and press fit. iii) After press fitting, check mounting dimension a. Front seal mounting dimension a : 18 - 19 mm
CD001514
I
Al
a
CWD02958
30-28 0
D475A-3
DISASSEMBLY
2)
3) .
ENGINE FRONT SEAL
AND ASSEMBLY
When installing oil seal at different mounting position Fill approx. 50 - 80% of lip portion at top i) of circumference of seal (2) with lithium grease. ii) Using tool Al, press fit seal (2). diiii) After press fitting, check mounting mension b. Front seal mounting dimension b : 16.2 mm
b
When there is wear of crankshaft oil seal contact surface Procedure for assembling front seal with sleeve i) Coat all of inside surface of sleeve (3) with gasket sealant (LG-7). ii) Using tool Al, press fit sleeve (3) to specified position. Sleeve mounting dimension c: 5 mm * Tighten the bolts uniformly. * After press fitting the sleeve, wipe off all the gasket sealant that is forced out. iii) Fill approx. 50 - 80% of lip portion at top of circumference of seal (4) with lithium grease. between iv) Insert washer @ (01640-22232) tool Al and seal (41, and press fit. diVI After press fitting, check mounting mension c. Front seal mounting dimension c : 13 mm
I
D475A-3
4
CWD02961
30-29 0
DISASSEMBLY
REMOVAL SEAL 1.
2.
AND
ASSEMBLY
ENGINE
REAR SEAL
OF ENGINE REAR
Remove damper assembly. For details, see REMOVAL OF DAMPER BLY.
ASSEM-
Sling with eyebolts @ (M16, P=2), remove mounting bolts (I), screw in forcing screws @ (M12, P=1.75), then remove flywheel (2). r+ kg
Flywheel
: 140 kg CWD02962
3.
Remove
rear seal (3).
INSTALLATION REAR SEAL 1.
CWD02963
OF ENGINE
Using guide bolt, and install flywheel
(2).
2
CWD02964
2.
Secure flywheel
(2) and housing
with plate 0.
.
30-30 0
/
CWD02965
D475A-3
DISASSEMBLY
*
ENGINE
AND ASSEMBLY
REAR SEAL
1
Tighten the mounting bolts in the order shown in the diagram on the right. m Flywheel mounting bolt : 1st step: 98 +. 19.6 Nm I10 = 2 kgm} 2nd step: 294 + 19.6 Nm I30 = 2 kgm1 3rd step: 539 + 19.6 Nm I55 = 2 kgm1
CWD02966
3.
After installing flywheel, use dial gauge @I to measure radial and face runout of flywheel. . Face runout: Max. 0.30 mm . Radial runout: Max. 0.30 mm
m *
Do as follows according to the wear of the crankshaft seal contact surface. 1) When crankshaft is a new part or when there is no wear of oil seal contact surface. Fill approx. 50 - 80% of lip portion at top i) of seal circumference with lithium grease. each ii) Insert 2 washers @ (01640-22032) between tool A2 and seal (2), and press fit. iii) After press fitting, check mounting dimension a. Front seal mounting dimension a : 20 mm
D475A-3
J
CWD02968
30-31 0
DISASSEMBLY AND ASSEMBLY
2)
ENGINE REAR SEAL
When installing oil seal at different mounting position i) Fill approx. 50 - 80% of lip portion at top of circumference of seal (3) with lithium grease. ii) Insert spacer @ (t=2.4 mm) between tool A2 and seal (3), and press fit. iii) After press fitting, check mounting dimension b. Front seal mounting dimension b : 25 mm J
3) .
When there is wear of crankshaft oil seal contact surface Procedure for assembling front seal with sleeve i) Coat all of inside surface of sleeve (4) with gasket sealant (LG-7). ii) Using tool A2, press fit sleeve (4) to specified position. Sleeve mounting dimension c : 14 mm Ir Tighten the bolts uniformly. * After press fitting the sleeve, wipe off all the gasket sealant that is forced out. iii) Fill approx. 50 - 80% of lip portion at top of circumference of seal (5) with lithium grease. iv) Insert 2 washers @ (01640-22032) each between tool A2 and seal (5), and press fit. iii) After press fitting, check mounting dimension c. Front seal mounting dimension c : 21 mm
5
30-32 0
CWD03248
CWD02970
D475A-3
DISASSEMBLY
CYLINDER
AND ASSEMBLY
HEAD
REMOVAL OF CYLINDER HEAD ASSEMBLY g 1. 2.
3. 4. 5. 6. 7. 8. 9. 10.
11. 12.
Disconnect the cable from the negative (4 terminal of the -battery. Drain coolant. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. Remove left and right engine side covers. Remove muffler assembly (I) Ir Remove the muffler bracket also. Remove exhaust connector (2). Remove intake connector (3). Remove oil supply tube (4). Remove drain tube (5). Remove hose (6). [w Remove turbocharger assembly (7). * Remove the turbocharger assembly on the opposite side in the same way. Remove air cleaner assembly (8). * Remove the air cleaner bracket also. m Remove exhaust manifold assembly (9).
CWD02972
13. Removal of exhaust manifold assembly (for left bank) 1) Remove aftercooler tubes (IO), (I I), and (12). 2) Remove electrical intake air heater wiring harness (13). 3) Sling intake manifold and aftercooler assembly (141, and remove mounting bolts. j, To prevent the electrical intake air heater from falling, install a guide bar in the bottom intake manifold mounting bolt hole. 4) Remove intake manifold and aftercooler asa sembly (I 4). & kg
5)
D475A-3
Remove
Intake manifold, bly : 50 kg electrical
aftercooler
I
IO
CWD02973
assem-
intake air heater (15).
30-33 0
DISASSEMBLY
AND ASSEMBLY
CYLINDER
14. Removal of intake manifold assembly (for right bank) 1) Remove aftercooler tube (16). 2) Remove electrical intake air heater wiring harness (17). 3) Sling intake manifold and aftercooler assembly (181, and remove mounting bolts. * To prevent the electrical intake air heater from falling, install a guide bar in the bottom intake manifold mounting bolt hole. 4) Remove intake manifold and aftercooler assembly (18). a
HEAD
u@ I
I
CWD0.2974
el
Intake manifold, aftercooler assembly : 50 kg Remove electrical intake air heater (19). kg
5)
15. Remove
fuel
injection
tube
(21). 16. Remove
air vent tube (22).
17. Remove
head cover (23).
(20) and spill tube m
m CWD02975
18. Remove rocker arm (24). m Ir To prevent pressure on the push rod when installing the rocker arm, loosen the locknut and turn the adjustment screw back 2 - 3 turns. 19. Remove
push rod (25) and crosshead
20. Remove nozzle holder assembly. For details, see REMOVAL OF NOZZLE ASSEMBLY. 21. Remove
rocker housing
22. Remove
cylinder
30-34 0
(26I.m
HOLDER
(27).
head (28).
D475A-3
DISASSEMBLY
CYLINDER
AND ASSEMBLY
HEAD
INSTALLATION OF CYLINDER HEAD ASSEMBLY .
Carry out installation removal.
in the
reverse
order
to
a_ m &
Turbocharger
mounting bolt : 49 z 4.9 Nm I5.0 z 0.5 kgm} Bolt thread, seat surface : Anti-friction compound (LM-PI
m m 6 *
Exhaust
manifold mounting bolt : 49 2 4.9 Nm I5.0 f 0.5 kgm} Bolt thread, seat surface: Anti-friction compound (LM-P) Tighten the mounting bolts in the order shown in the diagram.
7 17
w *
20 2
1 13
3
21
23 12
Exhaust manifold mounting bolt : 66.15 r 7.35 Nm i6.75 f; 0.75 kgm} Tighten the mounting bolts in the order shown in the diagram.
a w
Sleeve
nut : 23.5 = 0.98 Nm 12.4 t 0.1 kgm}
m
Head cover mounting bolt : 4.9 = 0.98 Nm IO.5 t 0.1 kgm1
m
m Sr
m * *
CWDO2981
Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. w Rocker arm mounting bolt : 98 z 4.9 Nm {IO 2 0.5 kgm) Check that the push rod is inserted securely in the cam follower. Adjust the crosshead as follows. 1) Loosen the locknut and turn back the adjustment screw. 2) Press down lightly with a finger on the top of the crosshead and screw in the adjustment screw. 3) When the adjustment screw contacts the valve stem, tighten it a further 20”.
D475A-3
30-35 0
DISASSEMBLY
4)
AND ASSEMBLY
CYLINDER
HEAD
Tighten the locknut to hold the adjustment screw in position. w Locknut : 58.8 + 5.9 Nm IS.0 + 0.6 kgm}
11 * Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance. m & Bolt thread, seat surface : Anti-friction compound (LM-PI w Tighten the mounting bolts by hand for at least the first 2 - 3 turns, then tighten as follows. 1) 1st step: 137.2 - 156.8 Nm (14 - 16 kgm1 2) 2nd step: 210.7 - 220.5 Nm 121.5 - 22.5 kgm1 3) 3rd step: Using wrench A3, tighten 90” +:‘I When not using wrench A3, tighten as follows.
CWD02982
l
Order 1st step
Procedure 137.2 - 156.8 Nm (14 - 16 kgm)
I
210.7 - 220.5 Nm (21.5 - 22.5 kgm1
* *
*
Tighten bolt @ to 66.15 + 7.35 Nm 16.75 & 0.75 kgm1 After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt.
Make mark with punch
, l
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
30-36 0
DXD03202
D475A-3
DISASSEMBLY
AND ASSEMBLY
FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY 1. Disconnect hose (I 1.
*
Before disconnecting the hose, close the fuel valve.
2.
Remove bracket (2).
3.
Disconnect wiring connector (for fuel gauge) and remove clamp.
4.
Remove bracket (3) and clamp (4).
5.
Disconnect hoses (5) and (61, and remove clamp.
6.
Lift off fuel tank assembly (7). I&lkg
Fuel tank assembly (when full) :2,lOOkg
INSTALLATION ASSEMBLY l
Carry out installation removal.
OF FUEL TANK
in the reverse order to
DO2967
D475A-3
30-37 0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF MAIN ASSEMBLY
MAIN
RADIATOR
RADIATOR
1. Drain coolant. 2.
Disconnect HRN) (1).
3.
Lift off radiator
front lamp connectors
Radiator
(CN-209,
CN-
top cover (2). top cover assembly
: 85 kg CWD02988
4.
Disconnect hose (4).
5.
Disconnect wiring harness clamps (7 places) at top of radiator, and radiator water level sensor connector KN-405).
6.
Disconnect
7.
Remove
8.
Open guard (71, and remove right: 2 each).
9.
Remove wind breaker plates (9) (top and bottom), and (IO) (left and right).
radiator
inlet hose (3) and aeration
sub tank hose (5).
wind breaker
plate (6).
bolts (8) (left and
10. Sling radiator assembly ( 1 I), then remove mount bolts (12) (left and right: 2 each).
30-38 0
top
D475A-3
DISASSEMBLY
MAIN RADIATOR
AND ASSEMBLY
11. Remove
covers (13) (left and right).
12. Remove
tube (14).
13. Remove
bottom mount bolts (15) (left and right).
14. Lift off radiator assembly (II). Ir Be careful not to damage lifting the radiator off. &I kg
Radiator
assembly
the core
when
: 550 kg CWD02993
INSTALLATION OF MAIN RADIATOR ASSEMBLY l
.
Carry out installation removal.
in the
reverse
order
to
Refilling with water Add water to the specified
level, and run the engine to circulate the water through the system. Then check the water level again.
D475A-3
30-39 0
DISASSEMBLY
AND ASSEMBLY
SUB RADIATOR
REMOVAL OF SUB RADIATOR ASSEMBLY 1. Drain coolant. front lamp connectors HRN) (1). 3. Lift off radiator top cover (2).
2. Disconnect
l+ kg
Radiator
(CN-209,
top cover assembly
CN-
: 85 kg
4. Remove
hood (3) and side cover. For details, see REMOVAL OF HOOD BLY.
5. Disconnect 6. Disconnect
ASSEMCWD0.2994
main radiator hoses (4) and (5). radiator inlet hose (6) and sub tank
hose (7).
7. Disconnect
wiring harness clamps at top of radiator, and radiator water level sensor connector (CN-DRT). 8. Sling radiator assembly (81, and remove top mount bolts (9) (left and right: 2 each).
9. Remove bolt (IO). 10. Open bottom undercover
(11) and remove
tube
(12). 11. Remove bottom mount bolts (13) (left and right). 12. Lift off radiator assembly (8). * Be careful not to damage the core when lifting the radiator off. &I kg
Radiator
assembly
: 170 kg
CWO02996
NSTALLATION
l
.
Carry out installation removal.
OF SUB
in the
reverse
order
to
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
30-40 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
RADIATOR GUARD
REMOVAL OF RADIATOR GUARD ASSEMBLY 1.
Remove cap (I) and shim (2) of blade lift cylinm der. Check the number and thickness of the shims, and keep in a safe place. Star-t the engine and retract the piston rod fully, then tie the piston rod with wire to prevent it from coming out. Tie the piston rod on the opposite side in the same way. CWD02997
2.
3. 4. 5.
6.
7.
8.
Remove covers (3) and tubes (4). (left and right) a Release the remaining pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. * Fit a cover to prevent dirt from entering the piping. Sling blade lift cylinder assembly (51, then fit cylinder holder tool and secure to radiator guard. Drain coolant. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. Disconnect radiator inlet and outlet hoses, aeration hose, and wiring harness clip. For details, see REMOVAL OF MAIN RADIATOR ASSEMBLY. Disconnect hydraulic cooler hoses (6) and (71, and clamp (8). g Release the remaining pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. * Fit a cover to prevent dirt from entering the piping.
-
i-..
ACWD02998
CWD02999
Loosen tension of tension pulley (9), and remove fan belt (IO). + Using a chain block, pull the tension pulley securely in the direction shown in the diagram on the right to loosen the belt tension.
CWD03000
D475A-3
30-41 0
DISASSEMBLY
AND ASSEMBLY
RADIATOR GUARD
9. Sling radiator guard assembly and remove lock bolt, then using tool A4, push rear pin (11) to inside of radiator guard and remove.
IO. Remove lock plate, then using tool A4, pull front pin (12) to outside move.
of radiator
guard
11. Lift off radiator guard assembly (13). Sr Be extremely careful not to damage ing and piping when removing. kg rE?I
Radiator
guard assembly
and
re-
the wir-
: 4,700 kg
INSTALLATION OF RADIATOR GUARD ASSEMBLY l
Carry out installation removal.
+
.
Standard
in the
shim thickness
reverse
order
to
: 4 mm
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
30-42 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
ENGINE
REMOVAL OF ENGINE ASSEMBLY g
Disconnect the cable from the negative (-1 terminal of the battery. 1. Drain coolant. 2. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY. 3. Open underguards (1st and 2nd from front of machine). 4. Disconnect connectors (1) (CN-201, 202).
5. Disconnect
2 starting
motor wires (2).
6. Disconnect
connectors
(3) (CN-101,
111, 112).
7. Close heater valve, disconnect heater hose (41, then remove clamp and move towards rear of engine. 8. Disconnect air conditioner hoses (5) and (6).
‘@-iJ
Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. Fit covers to prevent dirt or moisture from entering the hoses. Disconnect all the clamps for hoses (5) and (6).
9. Disconnect IO. Disconnect
torque radiator
converter
oil cooler tube (7).
outlet tube (8) and bracket
(9). 11. Disconnect
D475A-3
sub radiator
outlet hose (IO).
DISASSEMBLY
AND ASSEMBLY
12. Disconnect
fuel hoses (II),
ENGINE
(121, and (13).
13. Disconnect radiator inlet hose (14). . Disconnect at clamp portion (15) at the radiator end. 14. Disconnect
sub radiator
inlet hose (16).
15. Disconnect aeration hoses (17) and (18). . Disconnect at the radiator end. 16. Remove
fan pulley cover. CWD03010
17. Remove hydraulic oil cooler assembly. . Remove the 2 cooler hoses, then brackets (20).
remove
18. Loosen tension of tension pulley (21) and remove fan belt (22). Ir Using a chain block, pull the tension pulley securely in the direction shown in the diagram on the right to loosen the belt tension.
22 CWDO
30-44 0
D475A-3
DISASSEMBLY
ENGINE
AND ASSEMBLY
19. Sling universal joint (231, then ing bolts and remove. Universal
remove
mountm
joint : 65 kg
20. Remove front mount bolts (25).
bolts (24) and rear mount a
-__-__-__-._-
_--.-
____________-__-__-__-.
21. Remove
el kg
*
D475A-3
engine
assembly
Engine assembly
-
-.-.
1
cw003014
(26).
: 3,400 kg
When removing the engine, check that all the wiring and piping has been disconnected. Operate the lever block so that there is no interference with other parts, set with the front slightly raised, and lift off. Be particularly careful not to let the front mount hit the radiator.
30-45 0
1
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY Carry out removal.
l
installation
ENGINE
OF ENGINE
in the
reverse
order
to
m Ir Ir
*
w
Install the hoses without twisting or inter-ference. When installing the air conditioner circuit hoses, be extremely careful not to let any dirt, dust, or moisture get inside the hoses. Check that there is an O-ring at the piping connection for the air conditioner hose, then tighten the hose. Coat the O-ring thoroughly with compressor oil (Showa Shell Suniso 4G or 5G). Tightening torque of air conditioner gas piping:
Thread
size
1 Tightening
M6 bolt (receiver oortion) M6 bolt (compressor portion)
torque
5.39k1.47 9.8i1.96
(Nm {kgmI)
IO.55+0.15)
0-Ang DBD02985
1
I
(I .0+0.2}
w
Universal joint mounting bolt : 156.8 - 196 Nm I16 - 20 kgm1
w
Engine mount mounting bolt : 1,715 - 1,911 Nm (175 - 195 kgm}
IFTI
.
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
9
Charging with air conditioner gas Using tool X, charge the air conditioner with air conditioner gas (R134a).
30-46 0
circuit
D475A-3
DISASSEMBLY
DAMPER
AND ASSEMBLY
REMOVAL OF DAMPER ASSEMBLY 1. Remove hood assembly. For details, see REMOVAL BLY.
2.
Open underguard
3.
Remove -
:
OF HOOD
ASSEM-
(3rd from front of machine).
drain plug (I) and drain damper Damper
oil.
case : Approx. 2.2 i?
I 4.
Remove
5.
Sling universal joint (31, then remove bolts, and lift off. &I kg
Universal
joint : 65 kg
(4) and coupling
mounting m
m
6.
Remove
holder
7.
Remove
retainer
8.
Sling damper cover (71, then use forcing screw @ (12mm, P=1.75) to remove damper cover. g Install guide bolts (12mm, P=1.75, e=lOO) in 2 mounting bolt holes in the top of the damper cover so that the damper cover does not come out suddenly. &I kg
9.
CUD03016
dipstick and dipstick guide (2).
(5).
(6).
Damper
cover : 50 kg
Sling damper assembly (81, then using guide bolt @ (16mm, P=2.0) and nut 0, loosen nut slowly so that damper assembly does not come out suddenly, then remove. & kg
D475A-3
Damper
assembly
: 85 kg
30-47 0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY l
Carry out removal.
OF DAMPER
installation
m
Universal
&
Holder
DAMPER
in the
reverse
order
to
joint mounting bolt : 156.8 - 196 Nm {IS - 20 kgm}
a
-Holder
.
mounting
bolt thread : Thread tightener (LT-2) mounting bolt : 490 - 607.6 Nm I50 - 62 kgm}
Refilling with oil (damper case) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-48 0
D475A-3
DISASSEMBLY
DAMPER
AND ASSEMBLY
DISASSEMBLY ASSEMBLY
OF DAMPER
Disassembly 1. Remove 2. Remove 3. Remove 4. Remove 5. Remove 6. Remove 7. Remove
of damper assembly bolt (I), then remove flange seal (3). shaft (4). rubber (5). flange (6) from body (7). seal (8). bearing (9).
Disassembly 8. Remove
of damper cover assembly bearing (IO) and seal (11) from
9.
(12). Remove
oil seal (13) from retainer
(2).
cover
(14).
I ASSEMBLY ASSEMBLY
14.
CWD03021
OF DAMPER
Assembly of damper assembly 1. Using push tool, press fit bearing (9). & Flywheel pilot portion : Grease (G2-UI Fill 50% (approx. 55 g) of clearance a. + ‘a CWDO3022
2.
Install seal (8) to flange (6), and seal (3) to flange (2). Ir Install the seal with the lip facing the inside as shown in the diagram.
I I
D475A-3
CWD03023
30-49 0
DISASSEMBLY
3.
AND ASSEMBLY
Align the bolt holes with body (7), then flange (6). & Flange mating surface :
DAMPER
install
Gasket sealant (LG-4) *
*
Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both the flange and body surfaces with gasket sealant. Coat with a thickness of about 0.1 - 0.2 mm, leave to dry for 2 - 3 minutes, then tighten. CWD03025
4. 5.
Set shaft (4) to flange and body assembly in position. Assemble rubber (5). sr When assembling the rubber, coat the whole surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI). * After assembling the rubber, fill approx. 50% (approx. 400 g) of the space (b portion: 16 places) between the shaft and body with grease (G2-LI).
b
I 6.
Install flange (2). & Flange mating
*
*
7.
I
CWD03026
surface
: Gasket sealant (LG-4)
Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both the flange and body surfaces with gasket sealant. Coat with a thickness of about 0.1 - 0.2 mm, leave to dry for 2 - 3 minutes, then tighten.
Tighten
bolt (1). CED01810
30-50 0
D475A-3
DISASSEMBLY
DAMPER
AND ASSEMBLY
Assembly of damper cover assembly 8. Using push tool 0, press fit oil seal (13) to retainer (14). & Oil seal press-fitting surface : Gasket sealant (LG-II Sr Coat the inside surface of the retainer thinly with gasket sealant and wipe off any sealant that is forced out. & Lip of oil seal : Grease (G2-LI)
9.
Using push tool 0, (12).
10. Using push tool 0, (12). 6 *
&
press fit bearing (IO)to cover
I
CWD03029
II
cw003030
press fit oil seal (I 1) to cover
Oil seal press-fitting surface : Gasket sealant (LG-1) Coat the inside surface of the cover thinly with gasket sealant and wipe off any sealant that is forced out. Lip of oil seal : Grease (G2-LI)
D475A-3
30-51 0
POWER TRAIN UNIT
DISASSEMBLY AND ASSEMBLY
REMOVAL OF POWER TRAIN UNIT ASSEMBLY 1. Drain case. -
:
- : 2.
3.
oil from
hydraulic
Hydraulic
tank and power
train
tank : Approx. 140 !?.
Power train case : Approx. 210 4
Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. Remove fuel tank assembly. For details, see REMOVAL OF FUEL TANK ASSEMBLY.
4.
Disconnect
lubrication
5.
Disconnect
pin-puller
6.
Disconnect wiring (4). * Disconnect the hydraulic oil temperature and lock-up solenoid connector, and connector connecting to the left and right fenders.
7.
Disconnect
8.
Remove hydraulic and tube (9).
9.
Disconnect
30-52 0
control
hoses (I) and (3). hose (2).
cables (51, (61, and (7).
pump
hose (IO).
inlet tube coupling
(8)
POWER TRAIN UNIT
DISASSEMBLY AND ASSEMBLY
10. Disconnect ripper hose (II), then disconnect clamp (1 place) on top of steering case.
11. Remove
universal Universal
joint (12). joint : 65 kg
12. Remove front mount bolt (13). 13. Remove rear mount mount cap (15). & kg
14. Remove towards
Mount
bolt
m
(141, then
remove m
cap : 30 kg
housing clip (161, and move flange (17) m final drive end.
15. Using forcing
screws 0,
remove
cover (18).
CUD03038
D475A-3
30-53 0
DISASSEMBLY
POWER TRAIN
AND ASSEMBLY
16. Remove shaft (19). * Pull out the shaft with forcing screws 0. Ir If the shaft will not come out, set jack @ on the ground and push the shoe grouser up, then move the sprocket to the front or rear to a position where the shaft will come out, and remove the shaft.
17. Lift off power train unit assembly Power train unit assembly
30-54 0
(20).
UNIT
-
\
m
: 5,500 kg
D475A-3
DISASSEMBLY AND ASSEMBLY
POWER TRAIN UNIT
INSTALLATION OF POWER TRAIN UNIT ASSEMBLY l
Carry out installation removal.
Universal
in the
reverse
order
to
joint mounting bolt : 156.8 - 196 Nm {IS - 20 kgm}
m m
Front mount bolt : 1,519 - 1,911 Nm I155 - 195 kgm1
w
Rear mount bolt : 823.2 - 1,029 Nm I84 - 105 kgm)
Ir
Check that the housing clip is fitted securely in the flange. Housing clip : 4.9 - 8.8 Nm IO.5 - 0.9 kgm}
)14
w
m *
l
When installing the power train unit assembly, pay attention to the mating surface of the coupling, and be careful not to damage the seal of the rear mount coupling.
Refilling with oil Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
Ia
Power train case : Approx. 210 J?
%a
Hydraulic
D475A-3
tank : Approx. 140 1
30-55 0
DISASSEMBLY AND ASSEMBLY
PTO. TORQUE CONVERTER
REMOVAL OF PTO, TORQUE CONVERTER ASSEMBLY 1.
2.
Remove power train unit assembly. For details, see REMOVAL OF POWER UNIT ASSEMBLY.
TRAIN
Raise power train unit assembly (I) and set on block 0. * Set blocks under the front of the oil pan, transmission rear case, and steering case. CWD03041
3.
Remove
brake rod (2).
E-i-
103042
4.
5. 6.
Disconnect central pressure detection hose (31, then remove together with central pressure detection bracket (4). * Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing. Remove oil filler tube (5). Sling filter assembly (61, then remove. & kg
7.
Power train pump,
Lift off mount II+kg
9.
: 40 kg
Remove power train pump (7) and strainer assembly (8). a Sling the power train pump, then remove together with the strainer. r&lkg
8.
Filter assembly
Mount
strainer
CWD03043
assembly
: 100 kg
bracket (9). bracket : 70 kg
Remove tube (IO) and scavenging pump (11). a Sling the scavenging pump, then remove the mounting bolts. CWD03044
I+ kg
30-56 0
Scavenging
pump
: 24 kg
D475A-3
DISASSEMBLY AND ASSEMBLY
IO. Remove
hose (12).
11. Remove
gauge
PTO, TORQUE CONVERTER
guide (13).
13
CWD03045
12. Removal of hydraulic pump 1) Remove tube (14). 2) Remove tube (15). 3) Lift off right pump assembly & kg 4)
Pump assembly
: 40 kg
Lift off left pump assembly kg IF?l
Pump assembly
(16).
(17).
: 25 kg 6
CWD03046
13. Remove oil pan (18). * Remove the block under the oil pan, sling the oil pan, then remove the mounting bolts and disconnect the oil pan. kg lE?l
Oil pan : 120 kg
1u-
CWDO3047
14. Remove
PTO and torque converter assembly m (19). g Sling the PTO and torque converter assembly, then remove the mounting bolts. Ir Using a lever block, lift off the PTO and torque converter assembly horizontally.
el kg
D475A-3
PTO, torque
converter
assembly : 850 kg
30-57 0
PTO, TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY
INSTALLATION OF PTO, TORQUE CONVERTER ASSEMBLY Carry out installation removal.
l
a
in the
reverse
order
to
Bend the cotter pin securely.
m &
PTO boss rotating
portion
: Grease (G2-LII
113 *
30-58 0
Using a lever block, raise the PTO and torque converter assembly horizontally, align it with the spline of the shaft at the steering case end, then install.
D475A-3
DISASSEMBLY
AND ASSEMBLY
PTO, TORQUE CONVERTER
DISCONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY 1.
Set PTO and torque tool c.
converter
assembly
(I) to
CWD03049
2.
Remove
3.
Remove cap (3). * Remove snap ring (41, then remove
4.
coupling
assembly
(2).
the cap.
m Remove retainer assembly (5). * Using forcing screws, remove the cover, retainer assembly, and shims. Jr Check the number and thickness of the shims, and keep in a safe place. CWD03050
5.
Remove
6.
Remove spacer (7). Ir Remove snap ring spacer.
m
oil seal (6).
(81, then
remove
the
CWD03051
7.
Remove PTO assembly (9) and torque converter assembly (IO). Ir Using eyebolts 0, raise the PTO assembly, then disconnect it from the torque converter assembly. r&lkg
PTO, torque
converter
assembly : 850 kg
CWD03052
D475A-3
30-59 0
DISASSEMBLY
AND ASSEMBLY
PTO, TORQUE CONVERTER
CONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY .
Carry out connection disconnection.
in the
reverse
order
to
Adjust the clearance of the taper roller bearing as follows. 1) Assemble the oil seal to the retainer assembly, then install the cover, and tighten to 9.8 Nm {I kgm}. 2) Using a clearance gauge, measure clearance a between the retainer and the housing. Ir Measure clearance a at four points (A, B, C, D) around the circumference, and take the average as clearance a. 3) Measure shim thickness. . a - (0 to 0.05 mm) * Shim thickness: 0.15 mm, 0.20 mm, 0.50 mm 4) Assemble the selected thickness of shim, and tighten the retainer assembly to the specified torque. w Retainer mounting bolt: 58.8 - 73.5 Nm IS - 7.5 kgm} * Assemble the shim as shown in the diagram on the right so that it does not come at position b of the retainer removal tap.
I]-&-a
‘I CWD03053
b
CWDO3054
Shim shape
6
Outer circumference
of oil seal:
Gasket sealant (LG-5)
DXD03203
30-60 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
TORQUE
CONVERTER
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY Set the torque
converter
assembly
to tool C.
Torque converter valve assembly Remove torque converter valve assembly
(I).
Draining oil Remove 2 drain plugs (21, and drain oil from pump case. Sr After draining the oil, tighten the plugs. Lockup clutch, drive case assembly 1) Leaving 2 mounting bolts (3) in position, remove mounting bolts, then place input shaft side on top and remove remaining mounting bolts. 2)
CED01289
CED01290
CED01291
CED01292
Using eyebolts 0, remove lockup clutch and drive case assembly (4). Ir Disassemble the lockup clutch and drive case assembly as follows. i) Remove seal ring (5), and using forcing screws 0, remove input shaft (6).
ii) iii)
Remove snap ring (71, then remove plate (8). Set clutch housing side at bottom, and using forcing screws 0, remove turbine (9).
CED01293
D475A-3
30-6 1 0
DISASSEMBLY
TORQUE CONVERTER
AND ASSEMBLY
iv) Set clutch housing at top, then using eyebolts 0, remove housing and piston assembly (IO). Ir When the assembly is removed, the piston will fall out, so support it by hand when removing. v) Remove piston (11) from housing (12).
II
8 8 c3 8 Q CED01295
vi) Remove vii) Remove
seal ring (13) from piston. seal ring (14) from housing.
‘13
CED01297
viii)Using push tool 0; from housing.
remove
bearing
CED01296
i4 CED01298
(15)
CED01299
ix) Remove 3 discs (16) and 2 plates (17) from drive case (18). * After removing the discs and plates, keep them in a flat place to prevent them from becoming distorted.
I 30-62 0
CWD03060
DISASSEMBLY
4.
AND ASSEMBLY
TORQUE
Stator assembly 1) Remove snap ring (191, then remove stator assembly (20). 2) Disassemble stator assembly as follows. i) Remove snap ring (211, then remove race (22) from stator (23).
CED01301
ii)
Remove
CEDOl302
snap ring (24) from stator (23).
23
5.
CED01303
Pump assembly I) Remove snap ring (25). 2) Remove pump assembly (26). pump assembly as follows. 3) Disassemble i) Remove retainer (27). ii) Remove bearing and guide assembly (28) from pump (29).
CED01305
CED01304
iii) Remove bearing guide (31). 6.
CONVERTER
Stator clutch housing Set stator clutch housing stator clutch housing (32).
outer
race
at top
(30)
and
from
remove
_ CED01306
D475A-3
CEO01307
DISASSEMBLY
7.
TORQUE CONVERTER
Spring Remove
8.
AND ASSEMBLY
------lI
spring (33).
Springs, discs, plate Remove springs (341, 2 discs (35), and 1 plate (36). Ir After removing the discs and plates, them in a flat place to prevent them becoming distorted.
9.
keep from
Pin Remove
pin (37).
CED01308
CED01309
10. Inner gear Remove
snap ring (38), then remove
inner gear
(39).
11. Piston 1) Remove
piston (40) from case (41).
I 2) 3)
Remove Remove
CED01310
CEDOl311
seal ring (42) from piston. seal ring (43) from case.
CED01312
CED01313
12. Stator shaft assembly I) 2)
Tap stator shaft assembly (44) with a plastic hammer, and remove from case (45). Disassemble stator shaft assembly as follows. i) Using push tool @, remove shaft assembly (46) from stator shaft assembly.
CED01315
30-64 0
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER
Remove snap ring (471, then remove bearing inner race (461, bushing (491, and seal ring (50) from shaft. iii) Remove seal ring (51) from stator shaft ii)
(52). iv) Remove snap plate (54).
ring
(53),
then
remove
50
47
48
CED01316
v)
Using push tool 0, remove then remove plate (56).
bearing
5i
54 CEDC
(551,
CUD03057
D475A-3
30-65 0
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY *
Wash all parts in clean flushing oil (in particular, oil holes, etc.), then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
l
Set case (41) to tool C.
1.
Stator shaft assembly
1) Assemble
2) 3)
4)
5)
plate (56) to stator shaft (52), and using push tool, press fit bearing (55). Ir Put drops (approx. 6 cc) of engine oil (SAEIOW-CD or SAE30-CD) on the bearing and rotate about 10 times. Install plate (54), and secure with snap ring (53). Install seal ring (51) to stator shaft (52). * After installing the seal ring, coat it with grease (G2-LI) to fix it to the shaft securely.
__
47
48
CED01316
7)
ND03059
Install seal ring (50) to-shaft. * After installing the seal ring, coat it with grease (G2-LI) to fix it to the shaft securely. Using push tool @, press fit bushing (49) to shaft. * Be careful not to deform the bushing when press fitting.
50
6)
5i
CED01321
Using push tool @, press fit inner race (48) to shaft. Install snap ring (47), and secure inner race.
CED01322
30-66 0
CEDOl323
DISASSEMBLY
TORQUE
AND ASSEMBLY
CONVERTER
8) Tap stator shaft (52) with a plastic hammer and press fit bearing portion to case. 9) Set shaft (46) to stator shaft, then using push tool, press fit bearing portion. IO) Turn over case and tighten mounting bolts of shaft from case end. 6 Mounting bolt : Thread tightener (LT-21 w Mounting bolt : 58.8 - 73.5 Nm 16 - 7.5 kgml CEO01324
2.
46
CED01325
Piston 1) Install seal ring (43) to case. & Outer circumference of seal ring : Grease (G2-LI) * Be careful to assemble the seal ring facing in the direction shown in the diagram on the right. 2) Install seal ring (42) to piston. & Outer circumference of seal ring : Grease (G2-LI) CED01313
*
CED01312
Be careful to assemble the seal ring facing in the direction shown in the diagram on the right.
DBD02991
3)
3.
Install piston (40) to case (41). & Contact surface of seal ring : Grease (G2-LII
Inner gear Install inner gear (39) and secure with snap ring (38).
CEDO1311
D475A-3
CED01310
DISASSEMBLY
AND ASSEMBLY
4.
Pin Install pin (37).
5.
Plate, discs, springs Install 1 plate (36),2 discs (351, and springs (34).
6.
Spring Install spring (33).
TORQUE
CED01309
7.
Stator clutch housing Install stator clutch housing (32). Check that the springs are fitted securely in * the holes in the housing and piston. s ;oun;in; koi; : Thread tightener (LT-2) kwn oun in 0 : 98 - 122.5 Nm {IO - 12.5 kgm)
8.
Pump assembly I) Assemble pump assembly as follows. i) Using push tool, press fit bearing outer race (30) to guide (31). Ir Put drops (approx. 6 cc) of engine oil (SAEIOW-CD or SAE30-CD) on the bearing and rotate about 10 times. ii) Set bearing and guide assembly (28) to pump (29), then tap with a plastic hammer and press fit bearing portion. iii) Install retainer (27). 6 Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 58.8 - 74.5 Nm {S - 7.5 kgml 2) Install pump assembly (26). * When installing the pump, be careful not to damage the seal ring assembled to the shaft. 3) Install snap ring (25).
9.
11
CONVERTER
CED01308
CED0130/
CE001306
29 CED01305
CED01304
Stator assembly I) Assemble stator assembly as follows. i) Install snap ring (24) to stator (23).
23
30-68 0
:ED01303
D475A-3
DISASSEMBLY
ii) 2)
TORQUE
AND ASSEMBLY
Assemble race (22) to stator (231, and secure with snap ring (21). Install stator assembly (20) to stator shaft, and secure with snap ring (19).
I
I
CONVERTER
I
CE001302 1 1
CED01301
CED01327
CED01328
IO. Lock-up clutch, drive case assembly 1) Assemble lock-up clutch and drive case assembly as follows. i) Set turbine (9) to block 0, and set drive case (18) to turbine.
ii)
Install 3 discs (16) and 2 plates (17).
cw003060
iii) Install seal ring (14) to housing. 6 Outer circumference of seal ring : Grease (G2-LI) iv) Install seal ring (13) to piston. & Outer circumference of seal ring : Grease (G2-LII
CED01298
D475A-3
CEDOl297
DISASSEMBLY
AND ASSEMBLY
v) Install piston (11) to housing (12). 6 Contact surface of seal ring : Grease (G2-LI) Ir When installing, be careful not to damage the seal ring. vi) Using eyebolts 0, install housing and piston assembly (IO). * Support the piston assembly by hand to prevent it from falling out when installing. & Mounting bolt : Thread tightener (LT-2) m Mounting bolt : 98 - 122.5 Nm {IO - 12.5 kgm1 vii) Using push tool, press fit bearing (15). * Put drops (approx. 6 cc) of engine oil (SAEIOW-CD or SAEBO-CD) on the bearing and rotate about 10 times. viii)lnstall plate (81, and secure with snap ring (7). ix) Install input shaft (6). & Mounting bolt : Thread tightener (LT-21 m Mounting bolt : 156.8 - 196 Nm {IS - 20 kgm} x) Install 2 seal rings (5).
2)
TORQUE CONVERTER
li CED01295
CED01296
CED01329
5
CED01330
Using eyebolt 0, install lock-up clutch and drive case assembly (4). * Align the positions of the turbine oil groove (% mark) and drain plug (2) when installing.
CED01331
3) Tighten mounting bolts (3). Jr Check that drain plug (2) is tightened. m Mounting bolt : 49 - 58.8 Nm I5 - 6 kgm1 w Drain plug : 9.8 - 12.7 Nm 11 - 1.3 kgm1
CED01290
30-70 0
CED01289
D475A-3
DISASSEMBLY
AND ASSEMBLY
TORQUE CONVERTER
11. Torque converter valve assembly Install torque converter valve assembly (I). j, Tighten the mounting bolts uniformly in turn and be careful not to tighten them unevenly. w Mounting bolt :
43.1 - 53.9 Nm i4.4 - 5.5 kgm1
D475A-3
30-71 0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY ASSEMBLY 1.
PTO
OF PTO
PTO lubrication tube Sling PTO assembly and remove lubrication
tube
(I). * Remove the 3 lubrication tubes on the opposite side also, set the torque converter end at the bottom, then lower.
2.
Hydraulic pump gear assembly 1) Using forcing screws 0, pull out cover assembly (2) and lift off. 2) Using puller 0, remove gear assembly (3) from cover (4).
J/
3)
Using puller 0, from gear (7).
remove
bearings
i
i CED01256
(5) and (6)
6’ 3.
CED01257 1 1
Power train l PPC pump gear assembly 1) Using forcing screw 0, pull out cover sembly (8) and lift off. 2) Using puller 0, remove bearing (9). 3) Remove gear (IO).
CEO01259
CEO01260
as-
CWD03062
30-72 0
D475A-3
DISASSEMBLY
4) 5)
PTO
AND ASSEMBLY
Using push tool 0, remove boss (II) bearing (12) from cover. Using forcing screw 0, remove bearing from boss (I I).
and (12)
12 CWDO3063
4.
Scavenging drive gear Remove snap ring (13) from bottom of PTO case, then remove gear (14).
5.
Shaft assembly 1) Remove plate (15) of idler gear.
m 2)
3)
6.
Turn over PTO case, then using forcing screw 0, remove shaft assembly (16). * The bearing outer race and key assembly will come out from the bottom of the PTO case, so place a wooden block in position and be careful not to damage the assembly. Remove plug (17), then using forcing screw, push out bearing (18). + After removing the bearing, assemble the plug again in the correct position.
I8
CWD03064
CWD03065
Idler gear assembly 1) Remove idler gear assembly (19) and bearing (20) from bottom of PTO case. 2) Remove outer race (21).
CWD03066
D475A-3
PTO
DISASSEMBLY AND ASSEMBLY
7.
PTO case 1) Remove race assembly (24) together with bearing outer race (25).
CED01272
2)
Remove bearing inner races (26) and (27) from race (28).
17
3) 4)
CEDO 1273
Remove bearing outer.race (29). Remove sleeve (30).
/ CED01274
8.
Bearing 1) Remove snap ring (22). 2) Remove bearing (23).
CWD03067
30-74 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY ASSEMBLY
PTO
OF PTO
* *
Clean all parts, and check for dirt or damage. Check that the snap ring is fitted securely in the groove.
1.
Bearing
I)
Using push tool, press fit bearing (23) to case. Ir Put drops (approx. 6 cc) of engine oil (SAEIOW-CD or SAE30-CD) on the bearing and rotate about 10 times. Install snap ring (22).
2)
2.
CWD03067
PTO case 1) Install sleeve (30) to case. * Install the sleeve with the chamfered inside circumference facing down. * Expand-fit the sleeve. 2) Using push tool, press fit bearing outer race (29).
Using push tool, press fit bearing inner races (27) and (26) to race (28).
3)
27
4)
Install race assembly (24). & Internal surface of race :
5)
Using push tool, press fit bearing outer race (25). * Put drops (approx. 6 cc) of engine oil (SAEIOW-CD or SAE30-CD) on the bearing and rotate about 10 times.
Anti-friction
compound
CED01273
(LM-P)
CEO01272
D475A-3
DISASSEMBLY
3.
AND ASSEMBLY
Idler gear 1) Using push tool 0, press fit bearing race (21) to gear (19). 2) Position idler gear to PTO case.
PTO
outer
CWDO3068
4.
Shaft assembly I) Using push tool @, press fit bearing inner race (18) to shaft. 2) Fit O-ring, align shaft assembly (16) with idler gear, then insert.
5.
Bearing I) Turn over PTO case, and press fitting bearing spacer (31) and bearing inner race (20) to shaft, then tighten mounting bolts of shaft assembly. * Put drops (approx. 6 cc) of engine oil (SAEIOW-CD or SAEBO-CD) on the bearing, then rotate approx. 10 turns.
CWD03070
2)
Install plate (15). & Mounting m
6.
bolt : Thread tightener (LT-2) Mounting bolt : 98 - 123 Nm {IO - 12.5 kgm1
Scavenging drive gear I) Install gear (I 4). 6 Spline portion
30-76 0
: Grease (G2-LI)
D475A-3
DISASSEMBLY
2)
7.
Install case.
AND ASSEMBLY
snap
ring (13) from
PTO
bottom
Power train, PPC pump gear assembly 1) Using push tool 0, press fit bearing boss (II).
of PTO
(12) to
CWD03072
2)
Using push tool 8, press fit boss (I I) and bearing (12) to cover. * Expand fit the bearing. &Boss spline portion : Grease (G2-LII
3)
Install gear (IO). & Gear spline portion & Gear mounting bolt Thread m Gear mounting bolt 98 - 122.6 Nm
: Grease (G2-LI) : tightener (LT-2) : {IO - 12.5 kgml CWD03073
4) 5)
8.
Using push tool 0, press fit bearing (9) to gear (IO). Raise cover assembly (8) and install. * If the cover assembly is stiff and does not enter the case, use a plastic hammer and tap evenly on the side face to install.
Hydraulic pump gear assembly 1) Using push tool 0, press fit bearings and (6) to gear (7).
(5)
CWD03075
0475A-3
30-77 0
DISASSEMBLY AND ASSEMBLY
PTO
2) Using push tool @, press fit gear assembly
3)
9.
(3) to cover (4). + Expand fit the bearing. * Set the end where the bearing end face and gear end face are level so that it faces the cover. 6 Gear spline portion : Grease (G2-LI) Fit O-ring, then raise cover assembly (2) and install to case. * If the cover assembly is stiff and does not enter the case, use a plastic hammer and tap evenly on the side face to install.
CWD03076
Lubrication tube Sling PTO assembly,
then install lubrication
tube
(IL * Install 3 lubrication tubes also on the opposite side. m Mounting bolt :
19.6 - 29.4 Nm I2 - 3 kgm1
30-78 0
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
REMOVAL OF TORQFLOW TRANSMISSION ASSEMBLY .
1.
Remove PTO and torque converter assembly. For details, see REMOVAL OF PTO, TORQUE CONVERTER ASSEMBLY. Remove TORQFLOW A *
transmission
assembly
(1).
m then re-
Sling the transmission assembly, move the mounting bolts. Using a lever block, raise the transmission horizontally, then remove from the steering.
r&lkg
TORQFLOW
transmission
assembly: 1,400 kg
INSTALLATION TRANSMISSION l
Carry out installation removal.
OF TORQFLOW ASSEMBLY in the
reverse
order
to
(I *
D475A-3
Using a lever block, sling transmission assembly (I) horizontally, align with spline of shaft at steering case end, then install.
30-79 0
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
DISASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY Set the transmission
l
1.
Control valve assembly 1) Remove filter assembly (I).
2)
2.
assembly on the block.
Using eyebolts, remove control valve assembly (2) together with seat. * Do not remove the fourteen bolts marked %.
Sleeve
1) Remove plug (8). 2) Using eyebolts @I, pull out sleeve (9).
CWD03080
3.
Transmission case 1) Turn over transmission
2)
assembly, and remove plate (IO). Using eyebolts, remove transmission case (II).
30-80 0
D475A-3
DISASSEMBLY
4.
TORQFLOW
AND ASSEMBLY
TRANSMISSION
Housing 1) Remove 17 tie bolts (12). 2) Using eyebolts, remove housing (13). 3) Remove seal ring (14) from housing.
14 CWOO3082
5.
6.
7.
Spring Remove
spring (15).
Discs, plates, springs Remove discs (161, plates (171, and springs (18) in turn. Ir Keep the discs and plates in a flat place to prevent them from becoming deformed.
18
No. 1 ring gear Remove ring gear (19). CWD03083
8.
No. 1 housing, piston 1) Using eyebolts, remove No. 1 housing piston assembly (20). 2) Remove piston (22) from housing (21).
and
CWD03084
9.
Spring Remove
spring (23).
10. Discs, plates, springs Remove discs (241, plates (251, and springs (26) in turn. * Keep the discs and plates in a flat place to prevent them from becoming deformed. 11. Sleeve, guide pin 1) Remove sleeve (27). 2) Remove guide pin (28).
D475A-3
26 .
25
23
28 “-
CWD03085
30-81 0
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
12. Shaft, No. 1, 2, 3 carrier assembly Using eyebolts, remove No. 1, 2, and 3 carrier assembly (29). &I kg
1)
Shaft, No. 1, 2, 3 carrier assembly : 200 kg
Disassemble the shaft and carrier assembly as follows. i) Remove snap ring (13OL then remove sun gear (30). CWD03086
ii)
2)
Using eyebolts, remove shaft and No. 1 carrier assembly (31) from No. 2 and 3 carrier assembly (32).
Disassemble the shaft and No. 1 carrier assembly as follows. i) Raise the assembly, then using forcing screw 0, remove shaft and cage assembly (33).
31
-CWDO3087
Using plastic hammer, remove cage assembly (341, spacer (351, and bearing (36). iii) Remove seal ring (37) from cage assembly. iv) Remove seal ring (38) from cage. VI Remove seal ring (40) from shaft (39). ii)
u CWDO3088
vi) Remove shaft (421, ball (431, thrust washer (441, gear (451, and bearing (46) from No. 1 carrier assembly (41). vii) Remove seal rings (47) and (131).
41
30-82 0
CWD03089
D475A-3
DISASSEMBLY
3)
TORQFLOW TRANSMISSION
AND ASSEMBLY
Disassemble the No. 2, No.3 carrier assembly as follows. i) Remove sun gear (48). ii) Using eyebolts, remove plate and gear assembly (49).
CWD03090
iii) Remove (51) and iv) Remove assembly v) Remove
ring (50), and disassemble plate gear (52). plate (54) from No. 2, 3 carrier (53). seal ring (55) from plate.
5i
vi)
CWD03091
Remove shaft (56), ball (57), thrust washer (58), gear (59), and bearing (60).
57 :WD03092
vii) Using push tool, remove collar and bearing assembly (61) from carrier. viii)Using push tool, remove bearing (62).
D475A-3
TORQFLOW TRANSMISSION
DISASSEMBLY AND ASSEMBLY
ix) Using puller and push tool, remove bearing (63) and spacer (64) from collar (65). XI Remove seal ring (66).
-
13. No. 2 ring gear Remove
ring gear (67).
14. No. 2 housing, piston 1)
Using eyebolts, remove piston assembly (68).
el 2)
Remove
and
piston : 80 kg
No. 2 housing,
kg
No. 2 housing
piston (70) from housing
(69). CWD03095
-
15. No. 3 piston Remove
No. 3 piston (71).
16. Spring Remove
spring (72). I
17. Discs, plates, springs Remove discs (73), plates (741, and springs (75) in turn. * Keep the discs and plates in a flat place to prevent them from becoming deformed. -
-
18. Seat Remove
seat (76).
19. No. 3 housing Using eyebolts, E?lkg
remove
No. 3 housing
No. 3 housing
(77).
: 55 kg
20. No. 4 piston Remove No. 4 piston (78).
78 CWD03097 -
30-84 0
D475A-3
DISASSEMBLY
21. Spring Remove
AND ASSEMBLY
TORQFLOW
83
spring (79).
84
TRANSMISSION
132
22. Discs, plates, springs Remove discs (801, plates (811, and springs (82) in turn. Ir Keep the discs and plates in a flat place to prevent them from becoming deformed. 23. Guide pin Remove guide pin (83). CWD03098
24. Sun gear Remove snap ring (1321, then remove
sun gear
(84). 25. Plate, bearing 1) Using eyebolts, remove plate and bearing assembly (85). 2) Using push tool 0, remove bearing (87) from plate (86).
87
3) 4)
Using puller @ and push tool 0, remove bearing (88). Using push tool, remove bearing (90) from collar (89).
CWD03099
-
CWD03100
26. No. 3 ring gear 1) Remove ring gear (91). 2) Remove ring (92) from ring gear.
CWD03101
D475A-3
30-85 0
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
27. Plate, ring gear 1) Using forcing screws, remove plate and ring gear assembly (93). 2) Remove ring gear (94). 28. No. 4 carrier, No. 5 clutch assembly Using eyebolts, remove No. 4 carrier and No. 5 clutch assembly (95).
93 1) Disassemble the No. 4 carrier and No. 5 i) ii)
clutch assembly as follows. Remove 2 mounting bolts, then install guide bolts. Remove remaining mounting bolts, then loosen guide bolts @ slowly, and remove No. 4 carrier assembly (96) from No. 5 clutch assembly (97). &I kg
No. 4 carrier assembly, No. 5 clutch assembly : 160 kg
iii) Remove shaft (98), ball (99), thrust washer (IOO), gear (IOI), and bearing (102).
CWDO3104
iv) Remove spring (103) and pin (104). v) Remove discs (105), plates (106), and springs (107). * Keep the discs and plates in a flat place to prevent them from becoming deformed. vi) Remove guide pin (108). vii) Remove inner gear (109). viii)Remove seal ring (110) from inner gear.
Id!
1‘10
iO6
CWD03105
30-86 0
TORQFLOW TRANSMISSION
DISASSEMBLY AND ASSEMBLY
ix) Remove piston (112) from No. 5 housing (111). x) Remove spacer (113) and seal ring (I 14) from No. 5 housing. 29. Shaft Remove
shaft (115).
30. Shaft assembly Set case so that shaft is at bottom, then using eyebolts, remove shaft assembly (117) from case (116). &I kg
Shaft assembly:
80 kg
1) Disassemble i)
the shaft assembly as follows. Remove snap ring, then using eyebolts, sling shaft assembly, knock out bearing portion, and remove shaft assembly (118). CWD03107
ii) Remove cage (I 19). iii) Using stand @, remove
bearing
(120).
CWD03108
snap ring (1341, then iv) Remove bearing (121) from cage (133). VI vi)
remove
123
Remove seal ring (122). Remove
cover (123).
CWD03109
D475A-3
30-87 0
DISASSEMBLY
vii) Remove viii)Remove
AND ASSEMBLY
TORQFLOW TRANSMISSION
bearing (124). seal ring (126).
ix) Remove snap ring (1351, then remove boss and bearing (127). XI Remove snap ring (136), then using push tool, remove bearing (129) from boss (128).
CWD03111
30-88 0
D475A-3
DISASSEMBLY
TORQFLOW TRANSMISSION
AND ASSEMBLY
ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY Wash all parts in clean flushing oil (in particular, oil holes, etc.), then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Set the seal ring with the side taking the pressure facing the housing, then coat with grease (G2-LI) and install uniformly so that it is positioned correctly. Align the notches of the oil groove when installing the discs.
DXD03204
Shaft assembly
F=l
I) Assemble the shaft assembly as follows. Install seal ring (126). ii) Using push tool, install baring (124).
i)
126 CWD03113
iii) Install cover (123). iv) Install seal ring (122). v) Install bearing (121) to cage (133) and secure with snap ring (134).
123
CWD03109
vi) Using push tool, press fit bearing (120). vii) Fit seal ring and install cage (119).
CWD031
D475A-3
30-89 0
TORQFLOW
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
viii)Using eyebolts, sling shaft assembly (I 18), then press fit bearing, and secure with snap ring. 2)
Set the case so that the side for installing the steering assembly is at the top, then using eyebolts, install shaft assembly (117) in the case (I 16).
t-l 2.
CWD03107
No. 4 carrier, No. 5 clutch assembly 1) Assemble the No. 4 carrier and No. 5 clutch assembly as follows. i) Using push tool, install spacer (I 13) to No. 5 housing (I 11). ii) Install seal ring (114). iii) Install piston assembly (112) to No. 5 housing (111).
,113 .I14
CWDO3115
iv) Install seal ring (110) to inner gear. v) Install inner gear (109). vi) Install guide pin (108). vii) Install springs (107), plates (106), and discs (105) in turn. viihlnstall pin (104) and spring (103). Ir Free length of spring : 103.5 mm
Id!
1’10
iO8
CWD03105
ix) Assemble bearing (102) in gear (IOI), and fit thrust washers (100) to both sides, then set in position in carrier. ball (99) to shaft (98), and push x) Assemble shaft into carrier.
99
CWD03104
30-90 0
D475A-3
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
TRANSMISSION
(96) to No. 5 xi) Set No. 4 carrier assembly clutch assembly (97), and using 2 guide bolts 0, compress spring, then tighten mounting bolts. Sr Check that the spring is fitted securely in the hole of the housing, then tighten the mounting bolts. & Mounting bolt : Thread tightener (LT-21 Q~~cI Mounting bolt : 157 - 196 Nm {IS - 20 kgml
2)
3.
Using eyebolts, install No. 4 carrier and No. 5 clutch assembly (95).
Plate, ring gear 1) Using eyebolts, align with dowel pin, then install plate (93). * To ensure that the plate is fitted facing in the correct direction, check the bolt hole, then knock in the dowel pin portion with a plastic hammer until there is no clearance at the mating surface. 2) Install ring gear (94).
4.
No. 3 ring gear 1) Install ring gear (92). 2) Install No. 3 ring gear (91).
5.
Plate, bearing 1) Using push tool, press fit bearing (90) collar (89). 2) Using push tool, press fit bearing (88).
95
CWD03102
-
in
3116
D475A-3
DISASSEMBLY
3)
4)
AND ASSEMBLY
TORQFLOW
TRANSMISSION
Using push tool, press fit bearing (87) in plate (86). * Set the large protrusion of the bearing assembly on top as shown in the diagram right, and install to the plate. Using eyebolts, install plate and bearing assembly (85).
CWD03117
mall
Protrusion
DXD03205
6.
Sun gear Install sun gear (841, and secure with snap ring (132).
7.
Guide pin Install guide pin (83).
8.
Discs, plates, springs Install springs (821, plates (81), and discs (80) in turn.
9.
Spring Install spring (79). * Free length of spring : 81.7 mm
-
CWD03098
10. No. 4 piston Fit seal ring and install No. 4 piston (78). 11. No. 3 housing Using eyebolts, housing (77).
fit seal ring and install
No. 3
12. Seat Install seat (76). CWD03097
30-92 0
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
TRANSMISSION
13. Discs, plates, springs Install springs (751, plates (741, and discs (73) in turn. 14. Spring Install spring (72). + Free length of spring
: 84 mm
15. No. 3 piston Fit seal ring and install No. 3 piston (71). CWD03096
16. No. 2 housing, piston I) Fit seal ring, and install piston (70) to housing (69). 2) Using eyebolts, install No. 2 housing and piston (68). * Check that the spring is fitted securely in the hole of the housing.
67
68
17. No. 2 ring gear Install ring gear (67). CWD03095
18. Shaft, No. 1, 2, 3 carrier assembly 1) Assemble the No. 2, No. 3 carrier as follows. i) Install seal ring (66) to carrier. ii) Using push tool, press fit spacer (64) and bearing (63) in collar (65).
CWD0311!
iii) Using push tool, press fit bearing (62). iv) Using push tool, press fit collar and bearing (61) in carrier.
-
CWD03120
D475A-3
30-93 0
DISASSEMBLY
TORQFLOW TRANSMISSION
AND ASSEMBLY
VI Assemble bearing (60) in gear (591, then fit thrust washers
carrier. vi) Assemble
(58) to both sides, and set in
ball (57) to shaft (561, and push
shaft into carrier.
50 -
CWD03092
-
vii) Install seal ring (55) to plate. viiijlnstall plate (54) to No. 2, 3 carrier assembly (53).
ix) Set plate (51) to gear (521, and install ring (50).
CWD03121
Using eyebolts, install plate and gear assembly (49). xi) Install sun gear (461, and secure with snap ring. xl
CWD03090
2) i) ii)
Assemble the shaft and No. 1 carrier assembly as follows. Install seal ring (471, (131) to carrier. Assemble bearing (46) in gear (451, then fit thrust washers
(44) to both sides, and set in
carrier. iii) Assemble ball (43) to shaft (421, and push shaft into carrier case (41).
43 131
I 30-94 0
41
CWDO3089
D475A-3
TORQFLOW TRANSMISSION
DISASSEMBLY AND ASSEMBLY
iv) Install seal ring (40) to shaft (39). v) Install seal ring (38) to cage.
CWD03122
vi)
Using push tool, press fit bearing cage. vii) Press fit bearing (36) in shaft.
(37)
in
CWD03123
viii)Set spacer (35) to bearing and cage assembly (34), and press fit shaft (39).
ix) Using eyebolts, sembly (33). 3) i)
install
shaft
and cage
as-
Assemble the shaft and carrier assembly as follows. Using eyebolts, install shaft and No. 1 carrier assembly (31) to No. 2, 3 carrier assembly (32). Sr Align the sun gear with the tooth face of the planetary gear, and tap with a plastic hammer to install.
33 CWD03125
D475A-3
DISASSEMBLY
AND ASSEMBLY
TORQFLOW
TRANSMISSION
on its side, then install secure with snap ring
ii)
Set carrier assembly sun gear (301, and (130).
4)
Using eyebolts, install shaft and No. 1, 2, 3 carrier assembly (29) to housing.
19. Sleeve, guide pin I) Install guide pin (28). 2) Install sleeve (27). 20. Discs, plates, springs Install springs (26), plates (251, and discs (24) in turn. 21. Spring Install spring (23). Free length of spring : 112 mm * CWD03126
22. No. 1 housing, piston I) Fit seal ring and install piston (22) to housing (21). eyebolts, install No. 1 housing and Using 2) piston (20). Check that the spring is fitted securely in * the hole of the housing.
CWD03084
23. No. 1 ring gear Install ring gear (19). 24. Discs, plates, springs. Install springs (181, plates (171, and discs (16) in turn. 25. Spring Install spring (15). Free length of spring : 112 mm * CWD03083
30-96 0
D475A-3
DISASSEMBLY
TORQFLOW
AND ASSEMBLY
TRANSMISSION
26. Housing 1) Install seal ring (14) to housing. 2) Using eyebolts, set housing (13) in position. 3) Tighten 17 tie bolts (12) in turn. m Tie bolts: 353 - 392 Nm I 36 - 40 kgm)
14 CWD03082
27. Checking piston stroke Using tool D, check each piston stroke. *
Air pressure
: 0.5 - 0.6 MPa (5 - 6 kg/cm? Unit : mm
Piston
No. 1 (R)
I
1
Standard
stroke
7.4
CWD03127
y--g---
No. 5 (I)
I
7.1
28. Transmission case 1) Using eyebolts, install transmission 2) Install plate (IO).
case
(II).
CWD03081
D475A-3
30-97 0
DISASSEMBLY
AND ASSEMBLY
TORQFLOW
TRANSMISSION
29. Rotation detection shaft 1) Set case so that valve mounting surface is at top, then insert rotation detection shaft (115) from output end. * Check that the tip of the shaft is mated
with the lock portion of its mating boss.
28
2) 3)
Using push tool, install bearing (129) to boss (128), and secure with snap ring (136). Install boss and bearing assembly (127) to output shaft, and secure with snap ring (135). * Install the bearing slowly and be careful that shaft (115) is mated with the lock portion of boss (128).
127
i i CWD03129
30. Sleeve 1) Install sleeve (9). 2) Install plug (8).
CWD03130
31. Control valve assembly 1) Using eyebolts, install control valve assembly (2) together with seat. w Mounting bolt : 44 - 54 Nm I4.5 - 5.5 kgml & 2)
Mounting bolt with marked % (9 PCS): Gasket sealant (LG-5) Install filter assembly (I).
30-98 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
STEERING
CASE
DISASSEMBLY OF STEERING CASE ASSEMBLY 1.
Steering valve I) Remove
steering
valve assembly valve : 25 kg
Steering 2) 2.
Remove
(I).
seat (2).
Clutch, brake assembly Using tool El, sling clutch and brake assembly, then remove mounting bolts, and remove clutch and brake assembly (3). * Remove the clutch and brake assembly on the opposite side in the same way. When pulling out the clutch and brake assembly, be careful not to damage the discs and plates.
3.
left and right shafts (4).
Lubrication tube Remove
5.
CWD03132
Shafts Remove
4.
I
lubrication
tube (5).
Pipes 1) Remove 2) Remove
left and right pipes (6). pipe (7).
7
6.
CWD03134
Input shaft I) 2)
Remove cage assembly (8). Remove snap ring, and pull out input shaft (9) from case.
30- 100 0
DA75A-3
DISASSEMBLY
7.
8.
AND ASSEMBLY
STEERING
Transfer, gear housing assembly Fit guide bolt and screw in forcing screws then remove housing assembly (IO).
CASE
0,
Cage 1) Turn over so that right cage is at top, then remove bearing cage (II). * Check the number and thickness of the shims, and keep in a safe place.
CUD03136
2) 9.
Using eyebolts
0,
remove
Bevel gear, shaft assembly Using eyebolts, remove bevel assembly (13).
1) i) ii)
cage (12).
gear
and shaft
Disassemble the bevel gear and shaft assembly as follows. Pull out reamer bolt, and remove bevel gear (14) from shaft (15). Using puller 0, remove bearings (16) and (17) from shaft.
CUD03138
10. Cage 1) Turn over steering case, and remove bearing cage (18). * Check the number and thickness of the shims, and keep in a safe place. 2) Remove outer race (19) from bearing cage.
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CASE
ASSEMBLY OF STEERING CASE ASSEMBLY *
Wash all parts, then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Cage I) Using push tool, press fit outer race (19) 2) Assemble shim, and install bearing cage (18). Ir Standard shim thickness : 2 mm w Mounting bolt : 245 - 308.7 Nm (25 - 31.5 kgm1
2.
CWD03139
Bevel gear, shaft assembly I) Assemble bevel gear and shaft as follows. i) Using tool E2, press fit bearings (77) and (16). ii) Set bevel gear (14) to shaft (151, and tighten reamer bolt. m Reamer bolt : 490 - 607.6 Nm (50 - 62 kgm)
14 CWDO3140
iii) Using eyebolts, install bevel gear and shaft assembly (13). 3.
Cage 1) Using eyebolts 0, install cage (12). m Mounting bolt : 245 - 308.7 Nm I25 - 31.5 kgm}
_
2)
4.
I
CWD03137
Assemble shim, and install bearing cage (I 1). Ir Standard shim thickness : 2 mm m Mounting bolt : 245 - 308.7 Nm {25 - 31.5 kgm}
Adjusting preload Rotate bevel gear 2 - 3 turns, and fit push-pull scale @I to tip of teeth, then measure rotating torque of bevel gear shaft. * Standard value of rotating torque: 9.8 - 11.8 Nm {I .O - 1.2 kgm) /
30-l 02 0
CWD03141
D475A-3
DISASSEMBLY
5.
STEERING
AND ASSEMBLY
CASE
Transfer, gear housing assembly Fit guide bolt @ to steering case, and install housing assembly (IO). w Mounting bolt : 245 - 308.7 Nm (25 - 31.5 kgm}
:WD03142
6.
Adjusting tooth contact, backlash 1) Adjusting backlash Put the probe of dial gauge @ in contact with the tip of the bevel gear teeth at right angles. Hold the bevel pinion in position, and read the measurement when the bevel gear is moved forward and backward. * Standard value for backlash : 0.3 - 0.4 mm * Measure at a minimum of three points on diagonally opposite sides. Adjusting If the result of the inspection shows that the correct backlash is not being obtained, adjust as follows. 1, If backlash is too small: Adjust the shim thickness at the bevel pinion end to move the bevel pinion in direction A, or adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B.
When
backlash
is small
BI)
3 ii)
*
D475A-3
If backlash is too large: Adjust the shim thickness at the bevel pinion end to move the bevel pinion in direction A (the opposite direction from A above), or adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B (the opposite direction from B above). When adjusting the shim thickness at the bearing cage of the bevel gear shaft, do not change the preload of the bearing. Adjust by moving shims between the bearing cage and the bevel pinion. Always keep the same total thickness of shims.
When
DBD02993
backlash
is large
Q
‘V BC
\
\I
DBD02994
30-103 0
DISASSEMBLY
2)
AND ASSEMBLY
Adjusting tooth contact Testing Coat the tooth face of the bevel pinion i) lightly with red lead (miniurn). Rotate the bevel gear in both the forward and reverse directions, and inspect the pattern left on the teeth. ii) The standard tooth contact should be as follows: (from small end of pinion) a) Width of tooth contact: 30 - 75% b) Center of tooth contact: 20 - 40% c) Position of tooth contact: 20 - 40% It must be within the standard value when preload is given to the taper roller bearing which is supporting the bevel gear, and only the bevel pinion is meshed, with no load. The tooth contact should be in the center of the tooth height and there should be no strong contact at the root of the teeth. The contact should be in about the same position when the gear is rotated in forward or reverse.
STEERING
Dedendum
CASE
(root of tooth) \
Addendum
(tip of tooth)
\ Small end DBD02995
DAD02996
30-104 0
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CASE
Adjustment If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. If bevel pinion is too far from center line i) of bevel gear. Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. [Correct the tooth contact as follows.1 Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Or adjust the thickness of the shims at the bearing cage of the bevel gear shaft to move the bevel gear in direction B, then check the tooth contact pattern and backlash again. ii)
*
D475A-3
If bevel pinion is too close to center line of bevel gear. Contact is at the big end of the convex tooth face of the bevel gear and the small end of the concave tooth face. [Correct the tooth contact as follows.1 Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A (the opposite direction from A above). Or adjust the thickness of the shims at the bearing cage of the bevel gear shaft to move the bevel gear in direction B (the opposite direction from B above), then check the tooth contact pattern and backlash again. When adjusting the movement in or out of the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the bearing cage and the bevel pinion. Always keep the same total thickness of shims.
t A DBDOO161
A DBDOOl62
30-105 0
DISASSEMBLY
STEERING
AND ASSEMBLY
7.
Input shaft 1) Assemble input shaft (9) in case, and secure with snap ring. 2) Install cage assembly (8).
8.
Pipes 1) Install pipe (7). 2) Install left and right pipes (6). * Coat the O-rings thinly with grease (G2LI), and be careful not to damage them when installing.
I 9.
Lubrication tube Install lubrication
tube (5).
10. Clutch, brake assembly Using tool El, install clutch and brake assembly (3). w
Mounting
bolt : 279 t 30 Nm 128.5 + 3 kgm}
11. Shafts Install left and right shafts (4). If it is difficult to insert the shafts with the * bevel locked, release the steering brake before inserting. 1) Remove plugs (201, then remove bolts (21), and tighten them in plug holes to compress clutch spring and release brake.
30-106 0
i
CASE
CWD03134
DISASSEMBLY AND ASSEMBLY
STEERING CASE
12. Steering valve 1) Install seat (2). Install steering valve assembly (1). m Mounting bolt : 44 - 54 Nm 14.5 - 5.5 kgm1
2)
D475A-3
30-107 0
DISASSEMBLY AND ASSEMBLY
STEERING CLUTCH, BRAKE
DISASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY Disconnection 1.
brake assembly
Collar Remove
2.
of clutch,
plate (I), then remove
collar (2).
Sleeve
1) Remove plate (3).
2) 3)
Using forcing screws 0, remove sleeve (4). Using puller 0, pull out bearing (5) from sleeve.
CWD03147
3.
Clutch, brake assembly Turn over clutch and brake assemblies, and using eyebolts 0, disconnect clutch assembly (6) and brake assembly (7).
30- 108 0
D475A-3
DISASSEMBLY
Disassembly 1. Stopper Remove 2.
AND ASSEMBLY
of clutch
stopper
STEERING
CLUTCH,
BRAKE
assembly
(8).
Discs, plates, springs Remove discs (9), springs (IO), and plates (11) in turn. * Keep the discs and plates in a flat place to prevent them from becoming deformed.
0 CWD03149
3.
4.
5.
Torque pin Remove torque
pin (12).
Clutch hub Using eyebolts,
remove
clutch hub (13).
Plate I) Using forcing screws 0,
remove flange (I 4).
12 CWD03150
2) 6.
Remove
outer race (15) from flange.
Bearing cage 1) Remove bearing
cage assembly
(16).
CWDO3151
2)
7.
8.
Remove plate (18) and nut (191, then remove bearings (20) and (21) from cage (17).
Spacer Remove
spacer (22).
Clutch cage, piston I) Using eyebolts, remove 2) Remove piston (24).
D475A-3
clutch cage (23).
DISASSEMBLY AND ASSEMBLY
3) 9.
Remove
STEERING CLUTCH, BRAKE
outer race (25) from clutch cage.
Belleville springs Remove Belleville
springs
(26).
CWD03153
IO. Brake hub I) Using eyebolts 0, remove brake hub (27). 2) Remove bearing (28) from brake hub.
CWD03154
30-110 0
D475A-3
DISASSEMBLY
Disassembly 1.
2.
Stopper Remove
STEERING
AND ASSEMBLY
of brake
stopper
assembly
CLUTCH,
-
(29).
Discs, plates, springs Remove discs (30), springs (31), and plates (32) in turn. * Keep the discs and plates in a flat place to prevent them from becoming deformed. CWD03155
3.
Brake cage I) Using eyebolts @, remove brake cage (33). 2) Remove outer race (34) and seal ring (35) from brake cage.
-
3i
4.
5.
Torque pin Remove torque Piston Remove
CWD03156
pin (36).
piston (37) and seal ring (38).
6.
BRAKE
Belleville springs Remove Belleville
springs
CWD03157
(39).
CWD03158
DA75A-3
DISASSEMBLY
AND ASSEMBLY
STEERING
CLUTCH,
BRAKE
ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY Assembly 1.
of brake assembly
Belleville springs Install Belleville springs (39). * Fit the Belleville springs back to back when installing.
CWD03158
2.
Piston Fit seal ring (38) and install piston (37).
3.
Torque pin Install torque
pin (36).
CWD03157
4.
Brake cage 1) Using push tool, install outer race (34) to brake cage. 2) Install seal ring (35). 3) Using eyebolts 8, install brake cage (33). m Mounting bolt : 245 - 308.7 Nm I25 - 31.5 kgm}
35,
5.
Discs, plates, springs Install plates (32), springs (311, and discs (30) in turn. Ir Check the mating surfaces of the discs and plates for dirt or damage, and coat them thinly with engine oil before assembling.
6.
Stopper Install stopper (29). m Mounting bolt : 245 - 308.7 Nm I35 - 31.5 kgm}
CWD03156
CWD03155
30-l 12 0
DISASSEMBLY AND ASSEMBLY
Assembly 1.
of clutch
STEERING CLUTCH, BRAKE
assembly
Brake hub I) Using push tool, press fit bearing (28) in brake hub. 2) Using eyebolts 0, install brake hub (27) to clutch housing.
7
CWD03154
2.
Belleville springs Install Belleville springs (26). Sr Fit the Belleville springs back to back when installing.
3.
Clutch cage, piston 1) Install outer race (25) to clutch cage.
CWD03153
2) 3)
Install piston (24). Using eyebolts, fit seal ring and install clutch cage (23) to housing.
4.
Spacer Install spacer (22).
5.
Bearing cage 1) Using push tool, press fit bearings (21) and (20) to cage (171, then tighten nut (191, and install plate (18). Ir Hold the cage with press, and using a hook wrench, tighten the nut. m Nut : 490 - 607.6 Nm I50 - 62 kgml 2) Install bearing cage (16).
6.
Plate 1) Using push tool, press fit outer race (15) to flange.
D475A-3
19 23
24
CWD03152
16
DISASSEMBLY
2)
AND ASSEMBLY
STEERING
CLUTCH,
BRAKE
Install flange (14). m Mounting bolt : 245 - 308.7 Nm I25 - 31.5 kgml
7. Clutch hub
Set guide bolts to housing, and using eyebolts, install clutch hub (13). 8. Torque
pin
Install torque pin (12). i2 CWD03159
9. Discs, plates,
springs
Install plates (II), springs (IO), and discs (9) in turn. Ir Check the mating surfaces of the discs and plates for dirt or damage, and coat them thinly with engine oil before assembling. 10. Stopper
Install stopper (8). w Mounting bolt : 245 - 308.7 Nm I25 - 31.5 kgm}
Y
il
IO CWD03149
30-114 0
D475A-3
DISASSEMBLY
Connection 1.
STEERING CLUTCH, BRAKE
AND ASSEMBLY
of clutch,
brake assembly
Clutch, brake assembly Using eyebolts 0, install brake assembly clutch assembly (6).
2.
Sleeve I) Using push tool 0, sleeve.
2)
Set sleeve blies.
press fit bearing
(4) to clutch
and brake
(7) to
(5) in
assem-
CWD03161
3)
3.
Install plate (3). w Mounting bolt : 112 + 9.8 Nm Ill.5
+ 1.0 kgml
Collar Fit collar (2) and install plate (I).
CWD03146
D475A-3
30-115 0
DISASSEMBLY AND ASSEMBLY
TRANSFER
GEAR HOUSING
DISASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY *
Set the transfer
gear
housing
assembly
on a
block. 1. Lubrication tube Remove lubrication
2.
tube (I) together
with block.
Bearing cage I) Remove bearing cage (2). 2) Using push tool, remove bearing (3). 3) Remove snap ring, and using push tool, remove bearing (4)
3.
Transfer gear 1) Remove transfer 2)
Using puller 0, both sides.
gear (5). remove inner
races (6) on
5 CUD03163
4.
Pinion housing 1) Remove lubrication 2)
tube (7). Using eyebolts 0, remove pinion housing assembly (8). Ir Check the number and thickness of the
slims, and keep in a safe place.
8
5.
CUD03164
Pinion assembly
1) Using forcing screws, remove cover (9). 2) Remove holder (IO). 3) 4)
Push pinion shaft with press, then pull out pinion gear (11). Remove holder, and using puller 0, remove inner race (12) from pinion gear (11).
30-116 0
D475A-3
DISASSEMBLY
5) 6)
Remove Remove
AND ASSEMBLY
cage, bearing assembly collar (14) from transfer
TRANSFER GEAR HOUSING
(13). gear (15).
CWD03166
7)
Using push tool 0, remove outer race (16), bearings (17) and (18), collar (191, and outer race (20).
CWDO3167
D475A-3
30-117 0
DISASSEMBLY
AND ASSEMBLY
TRANSFER
GEAR HOUSING
ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY 1.
Pinion assembly I) Using push-tool, press fit outer race (20) in bearing cage. 2) Assemble collar (191, bearing inner races (17) and (18). 3) Using push tool, press fit bearing outer race (16). 18
20 cwrJo3168
4)
5)
6) 7‘1
8)
Using push tool 0, press fit inner race (12) in pinion gear (II), and install holder. w Holder mounting bolt : 245 - 308.7 Nm 125 - 31.5 kgm} Install transfer gear (15) and collar (14) to pinion gear.
Using push tool, press fit cage, bearing assembly (13). Install holder (IO). w Holder mounting bolt : 245 - 308.7 Nm {25 - 31.5 kgm1
Install cover (9) as follows. Tighten cover mounting bolts temporarily in the order shown in diagram on right. (Approx. 49 Nm (5 kgm1) l Check clearance A between cover and cage, and check that it is as follows. Clearance A : 0.53 r 0.47 mm * Check that the variation around the whole circumference is less than 0.05 mm. Check also that the bearing is completely press fitted and is not at an angle. . After checking the above, tighten the mounting bolts of cover (9) in the order shown in the diagram on the right. m Mounting bolt : 58.8 - 73.5 Nm 16 - 7.5 kgm1 l
30-l 18 0
CWD03171
DISASSEMBLY
2.
TRANSFER
AND ASSEMBLY
Pinion housing 1) Assemble shim, and using eyebolts stall pinion housing assembly (8). -f Standard shim thickness: 2 mm 2) Install lubrication tube (7).
0,
GEAR HOUSING
in-
1
8
3.
Transfer gear I) Using push tool 0, press fit inner races (6) on both sides. 2) Set transfer gear (5) in case.
4.
Bearing cage 1) Using push tool, press fit bearing (41, and secure with snap ring. 2) Using push tool, press fit bearing (3). 3) Install bearing cage assembly (2) to case. w Mounting bolt : 245 - 308.7 Nm I25 - 31.5 kgm}
5.
Lubrication tube Install lubrication
D475A-3
tube (I) together
CWD03164
with block.
30-119 0
DISASSEMBLY AND ASSEMBLY
POWER TRAIN PUMP
REMOVAL OF POWER TRAIN PUMP ASSEMBLY 1.
Remove oil strainer inspection of operator’s platform.
cover at front left
2.
Open undercover.
3.
Remove oil strainer (1). Ir Disconnect coupling (2) and remove mounting bolts.
(3rd from front of machine).
4.
Disconnect
5.
Lift off power train pump assembly
strainer
hose (3).
Power train pump assembly
(4).
: 60 kg
INSTALLATION OF POWER TRAIN PUMP ASSEMBLY l
Carry out installation removal.
30-120 0
in the
reverse
order
to
D475A-3
DISASSEMBLY
SCAVENGING
AND ASSEMBLY
PUMP
REMOVAL OF SCAVENGING PUMP ASSEMBLY 1.
Open undercover.
2.
Disconnect inlet tube (I). * Oil will leak out from inside the piping, prepare a container to catch the oil.
3.
Disconnect
4.
Remove
(3rd from front of machine).
so
outlet tube (2).
scavenging Scavenging
pump assembly pump assembly
(3).
: 25 kg
INSTALLATION OF SCAVENGING PUMP ASSEMBLY .
Carry out installation removal.
.
Refilling with oil (power train case) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
D475A-3
in the
reverse
order
to
30-121 0
TORQUE CONVERTER OIL COOLER
DISASSEMBLY AND ASSEMBLY
REMOVAL OF TORQUE CONVERTER OIL COOLER 1.
Remove
2.
Drain coolant.
3.
Open engine cover (2).
engine
undercover.
left side cover (I) and remove
side
\ 4.
Remove
'2
CWD02941
water tubes (3) and (4).
I 5.
Remove
6.
Sling torque converter oil cooler then lower assembly to remove.
CWD02942
oil inlet tube (5) and outlet tube (6).
Torque
converter
assembly
(71,
oil cooler assembly : 170 kg
I
CWD02943
INSTALLATION OF TORQUE CONVERTER OIL COOLER l
.
Carry out installation removal.
in the
reverse
order
to
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
30- 122 0
D475A-3
DISASSEMBLY
TORQUE
AND ASSEMBLY
CONVERTER
VALVE
REMOVAL OF TORQUE CONVERTER VALVE ASSEMBLY 1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S ASSEMBLY.
CAB
2.
Remove operator’s seat and floor frame cover. * Use turnbuckle (I) when disconnecting the brake rod. Check the mounting dimensions m of the rod before disconnecting.
3.
Disconnect
4.
Disconnect central pressure detection hose (3). Sr Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing.
5.
Disconnect
6.
Remove
connector
of solenoid
valve (2).
hose (4).
torque
converter
valve assembly
(5).
pYi2J
el
Torque
kg
converter
valve assembly
: 25 kg
INSTALLATION OF TORQUE CONVERTER VALVE ASSEMBLY l
Carry out installation removal.
j,
reverse
order
to
Adjust the brake pedal linkage. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage. m Turnbuckle locknut : 34.3 - 58.8 Nm 13.5 - 6 kgml
m
D475A-3
in the
Torque converter valve assembly mounting bolt : 43.1 - 53.9 Nm 14.4 - 5.5 kgm1
30-123 0
DISASSEMBLY
DISASSEMBLY 1.
Disassembly I) Remove 2) Remove 3) Remove 4) Pull out
TORQUE
AND ASSEMBLY
OF TORQUE CONVERTER
of lock-up valve solenoid valve (1). cover (21, then remove cover (41, then remove spool (6).
CONVERTER
VALVE
VALVE ASSEMBLY
spring (3). piston (5).
2.
Disassembly of torque converter relief valve 1) Remove cover (71, then remove spring (8). 2) Remove cover (91, then remove valve (IO), spring (II), and valve (12). 3) Pull out spool (13).
3.
Disassembly of main relief valve 1) Remove cover (14L then remove spring (I 5). 2) Remove cover (161, then remove valve (171, spring (181, and valve (19). 3) Pull out spool (20).
4.
Disassembly of stator clutch modulating valve 1) Remove cover (211, then remove piston (22) and spring (23). 2) Remove- ring (24) from body. 3) Remove cover (251, then remove valve (26), spring (271, and valve (28). 4) Pull out spool (29).
5.
Disassembly of lock-up clutch modulating valve I) Remove cover (30), then remove piston (31) and spring (32). 2) Remove ring (33) from body. 3) Remove cover (34), then remove valve (351, spring (361, and valve (37). 4) Pull out spool (38). 5) Remove spool (39) and shim (40) from spool (38).
30-124 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
TORQUE CONVERTER VALVE
4
‘5
7 \
CDD02150
D475A-3
30-125 0
DISASSEMBLY
AND ASSEMBLY
TORQUE
CONVERTER
VALVE
ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY *
Ir
1.
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. When assembling valves (37) and (35L (28) and (26), (19) and (17), and (12) and (IO), assemble as shown in.the diagram so that the end with the hole in the center of the valve is on the inside of the spool. Assembly of lock-up clutch modulating valve 1) Set shim (40) td spool (39) and assemble to spool (38). Ir Standard shim thickness : 2.0 mm 2) Assemble spool (38). 3) Assemble valve (37), spring (361, and valve (35) to spool, then fit O-ring and install cover (34). Assemble ring (33) to body. Assemble spring (32). Assemble piston (31) to cover (30), then fit O-ring and install cover. Assembly of stator clutch modulating valve 1) Assemble spool (29). 2) Assemble valve (281, spring (271, and valve (26) to spool, then fit O-ring and install cover 4) 5) 6)
2.
CED02152
(25). Assemble ring (24) to body. Assemble spring (23). Assemble piston (22) to cover (211, then fit O-ring and install cover. Assembly of main relief valve 1) Assemble spool (20). 2) Assemble valve (191, spring (18), and valve (17) to spool, then fit O-ring and install cover 3) 4) 5)
3.
(16). Assemble spring (15), then fit O-ring and install cover (14). Assembly of torque converter relief valve 1) Assemble spool (13). 2) Assemble valve (121, spring (II), and valve (IO) to spool, then fit O-ring and install cover 3)
4.
(9). Assemble spring (81, then fit O-ring and install cover (7). Assembly of lock-up valve I) Assemble spool (6). 2) Assemble piston (5) to cover (41, then fit Oring and install cover. 3) Assemble spring (31, then fit O-ring and install cover (2). 4) Fit O-ring and install solenoid valve (I). 3)
5.
30- 126 0
D475A-3
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
CONTROL
VALVE
REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY 1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR ASSEMBLY.
CAB’S
2. Remove operator’s seat and floor frame cover. Ir Use turnbuckle (I) when disconnecting the brake rod. Check the mounting dimensions a of the rod before disconnecting.
3. Disconnect
clamps
(2) and (3).
4. Disconnect
rod (4).
5. Disconnect
rod (5) at servo valve output
6. Disconnect
2 hoses (6).
directional control 7. Disconnect speed control cable (8).
cable
end. ,KJ
(7) and
8. Remove bracket assembly (9). . Remove together with the servo valve. 9. Remove
bracket (IO).
IO. Disconnect
wiring
harness
connector
(I 1).
11. Disconnect central pressure detection hose (12). * Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing. control valve (13). 12. Remove transmission Ir Do not remove the 2 bolts marked %. &I kg
D475A-3
Transmission
a
control valve assembly : 80 kg
30-127 0
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
CONTROL VALVE
INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
Ir
Adjust the brake pedal linkage. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage. w Turnbuckle locknut : 34.3 - 58.8 Nm {3.5- 6 kgm}
Ir
Adjust the servo valve output portion. For details, see TESTING AND ADJUSTING, Adjusting steering lever.
w
&
Mounting
bolt : 44 - 54 Nm I4.5 - 5.5 kgm} Mounting bolts marked % (x7):
Gasket sealant (LG-5)
CWD03177
30-128 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL
VALVE
DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY 1.
Remove 3 mounting bolts, then remove speed and direction selector valve assembly (I). a
2.
Remove 2 mounting bolts, then remove upper valve assembly (2) from lower valve assembly m (3).
Upper valve assembly
i7
30- 130 0
CWD03178
D475A-3
DISASSEMBLY AND ASSEMBLY
Lower
valve
TRANSMISSION
CONTROL VALVE
assemble
1st
valve
I ve
REVERSE Speed
and
directional
valve
valve
assembly
a
DXD03206
D475A-3
30-131 0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL
VALVE
Disassembly of upper valve assembly . Disassembly of transmission lubrication valve assembly 1) Remove plug (6), then remove spring (7), and valve assembly (8). 2) Remove plate (91, then remove valve (IO), spring (11) and stopper (12). 3) Remove valve (141, spring (15) and valve (16) from valve assembly (8).
.
Disassembly of modulating valve assembly 1) Remove plate (171, then using forcing screws (Dia. = IO mm, pitch = 1.5 mm), remove stopper (18). 2) Remove valve (191, spring (20) and valve (21), then remove valve (221, and shims (23) and
3) 4)
l
(24). * Check the number and thickness of the shims, and keep in a safe place. Remove plate (251, then remove boss (26) and valve (27). Remove plug (28) from valve. Remove plate (291, then remove piston (301, springs (31) and (32).
Disassembly of pilot valve assembly I) Remove plug (341, and spring (351, then remove valve (36). 2) Remove plate (371, valve (381, spring (39) and valve (40). Remove valve (41), shim (421, springs (43) and (441, and stopper (45). * Check the number and thickness of the shims, and keep in a safe place. 3) Remove valve (471, spring (48) and valve (49) from valve (36).
Disassembly of lower valve assembly I) Remove spring (50). 2) Remove plate (51), then remove and valve (53). Disassembly I) Remove 2) Remove 3) 4) 5) 6) 7) 8)
stopper
(52)
of speed and direction selector valve cover (54). spring (55) and pull out shaft assembly
(56). Remove plug (57), then remove spring (58) and ball (59). Loosen lock nut (601, then remove yoke (61). Remove cover (62), and pull out direction selector valve (63). Remove lever (64) and pull out shaft assembly (651, then remove washers (66) and (67). Loosen lock nut (681, the remove yoke (69). Remove speed selector valve (70).
30-132 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
CONTROL
VALVE
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY *
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Assembly of speed, direction selector valve assembly 1) Assemble speed selector valve (70). 2) Install yoke (69) to valve. 3) Align washer (66) with shaft hole, then align with yoke and install shaft assembly (65). 4) Rotate valve (70) so that length from end face of valve to center of shaft pin is 29.2 mm, then tighten lock nut (68) to hold in position. 5) Assemble direction selector valve assembly
29.1+0.3mm/J
M29.2f0.3mm
CWD03181
(63). Install yoke (61) to valve. Align washer (67) with shaft hole, then align lever (64) with detent of shaft assembly, and set in position. Install shaft assembly (56). 8) Rotate valve (63) so that length from end face of valve to center of shaft pin is 29.1 mm, then tighten lock nut (60) to hold in position. 9) Align groove of valve, then install ball (591, spring (58) and plug (57). Ir After installing, check that the valve works properly. IO) Install spring (55), then fit gaskets and install covers (62) and (54). 6) 7)
2.
3.
Assembly of lower valve assembly 1) Assemble valve (53). 2) Fit O-ring and assemble stopper install plate (51). 3) Assemble spring (50).
(52), then
Assembly of upper valve assembly . Pilot valve 1) Assemble valve (491, spring (48) and valve (47) in valve (46). 2) Assemble stopper (451, spring (44) and spring (43). Fit shim (42) and assemble valve (411, valve (401, spring (39) and valve (38). 3) Fit O-ring and install plate (37). * Shim thickness: Assemble 6 x 0.5 mm shims 4) Assemble valve assembly (36) and spring (351, fit O-ring and install plug (34).
D475A-3
30- 133 0
DISASSEMBLY
.
TRANSMISSION
CONTROL
VALVE
Modulating valve I) Assemble springs (32) and (31) and piston (30), fit O-ring and install plate (29). 2) Fit O-ring and assemble boss (261, then align with dowel pin and install plate 3)
4)
.
AND ASSEMBLY
(25). Screw plug (28) into valve (271, then assemble in valve body, fit O-ring and install stopper (18). Fit shims (24) and (23) and assemble valves (22) and (211, spring (20) and valve (191, then fit O-ring and install plate (17). Ir Shim thickness: 0.5 mm x 6 (Large) 0.5 mm x 2 (Small)
Assembly of transmission lubrication valve assembly 1) Assemble valve (16), spring (15) and valve (14) in valve (13). 2) Assemble stopper (121, spring (11) and valve (IO), then fit O-ring and install plate 3)
(9). Assemble valve assembly (8) and spring (71, then fit O-ring and install plug (6).
4.
Fit gasket and install upper valve assembly (2) to lower valve assembly (3) with 2 mounting bolts. (marked %) m Mounting bolt: 44 - 54 Nm I4.5 - 5.5kgm}
5.
Fit O-ring and install speed and direction selector valve assembly (I) with 3 mounting bolts. (marked A) m Mounting bolt: 44 - 54 Nm (4.5 - 5.5kgm}
2
30-134 0
I
3
2
CWD03180
D475A-3
DISASSEMBLY
STEERING
AND ASSEMBLY
CONTROL
VALVE
REMOVAL OF STEERING CONTROL VALVE ASSEMBLY 1. Remove fuel tank assembly. For details, see REMOVAL OF FUEL TANK SEMBLY.
m
2.
Remove
brake rod (I).
3.
Disconnect
4.
Disconnect parking brake cable (3). Ir Measure the dimension of the bracket portion.
steering
AS-
control
m
rod (2).
‘5
5.
Disconnect
6.
Remove &I kg
m mounting
3182
2 hoses (4).
steering Steering
control valve assembly control valve assembly
(5). a : 25 kg
INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
Bend the cotter pin securely.
Bend the cotter pin securely.
Adjust the installation dimension at the bracket portion to the dimension measured when removing. Bend the cotter pin securely.
w
D475A-3
Steering control valve assembly mounting bolt : 44 - 54 Nm 14.5 - 5.5 kgml
30- 135 0
DISASSEMBLY
DISASSEMBLY 1.
2.
STEERING
AND ASSEMBLY
control assembly steering control assembly
(1).
(2).
3.
Parking brake valve 1) Remove body (3), then remove piston (4). 2) Remove spring (5), then remove valve (6).
4.
Valve cover 1) Remove nuts (7) and (8). 2) Remove cover (9).
5. Clutch valve 1) Remove plug (IO), then remove spring 2) Push in valve from cover mounting face then remove piston (12), valve (13), and assembly (14). 3) Disassemble shaft assembly as follows. i) Remove nut (15), then remove guide ii) Remove shim (17) from guide (16). iii) Remove spring (18) and guide (19) bolt (20). 4) Remove cylinder (21). 6.
Brake valve 1) Remove plug (22), then remove spring 2) Push in valve from cover mounting face then remove piston (24), valve (25), and assembly (26). 3) Disassemble shaft assembly as follows. i) Remove nut (27), then remove guide ii) Remove shim (29) from guide (28). iii) Remove spring (30) and guide (31) bolt (32). 4) Remove cylinder (33).
30-136 0
VALVE
OF STEERING CONTROL VALVE ASSEMBLY
Parking brake control assembly Remove parking brake control assembly Steering Remove
CONTROL
(II). end, shaft
(16). from
(23). end, shaft
(28). from
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CONTROL VALVE
CWD02848
D475A-3
30- 137 0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
STEERING
CONTROL
VALVE
OF STEERING CONTROL VALVE ASSEMBLY
*
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Brake valve I) Install cylinder (33) to valve body (34). 2) Assemble shaft assembly as follows. i) Assemble guide (31) and spring (30) to bolt (32). ii) Assemble shim (29) to guide (28) and install to bolt (32). Ir Shim thickness : 0.5 mm iii) Install nut (27). w Nut: 13.25 + 1.45 Nm Il.35 t 0.15 kgml 3) Insert shaft assembly (26). valve (25), and piston (24) into body (34) from plug mounting surface end. 4) Fit spring (231, then fit O-ring and install
5.
Steering control assembly Install steering control assembly (2). w Mounting bolt : 49.0 t 4.9 Nm I5.0 t. 0.5 kgm}
6.
Parking brake control assembly Install parking brake control assembly (I). m Mounting bolt : 49.0 1 4.9 Nm 15.0 +. 0.5 kgm}
plug Cm w Plug : 68.6 2 9.8 Nm I7 + 1 kgml 2.
Clutch valve 1) Install cylinder (21). 2) Assemble shaft assembly as follows. i) Assemble guide (19) and spring (18) to bolt (20). ii) Assemble shim (17) to guide (16) and install to bolt (20). * Shim thickness : 0.5 mm iii) Install nut (15). -Nut : 13.25 = 1.45 Nm Il.35 L 0.15 kgm} 3) Insert shaft assembly (14), valve (131, and piston (12) into body (34) from plug mounting surface end. 4) Fit spring (1 I), then fit O-ring and install plug (IO). w Plug : 68.6 2 9.8 Nm (7 + 1 kgm}
3.
Valve cover I) Install cover (9). 2) Install nuts (8) and (7). s /u: : Thread tightener (LT-2) Urn u : 13.25 f 1.45 Nm II.35 t 0.15 kgml
4.
Parking brake valve I) Assemble valve (6) and install spring (5). 2) Assemble piston (41, then fit O-ring and install body (3).
30- 138 0
D475A-3
DISASSEMBLY AND ASSEMBLY
io
D475A-3
STEERING CONTROL VALVE
CWDO2848
30-139 0
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
REMOVAL OF FINAL DRIVE ASSEMBLY Serial No.: 10601 – 10684 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Raise chassis with jack or ripper and set stand 1 under frame. 3. Remove covers (1) and (2). 4. Remove cover (3), then using forcing screw, pull out drive shaft (4). 1 fl If the shaft will not come out, set a jack on the ground and push the shoe grouser up, then move the sprocket to the front or rear to a position where the shaft will come out, and remove the shaft. fl Pull the shaft out to a position where it contacts the sprocket. 5. Remove 3 bolts of final drive and install tool J1. 6. Sling final drive assembly (5), then remove mounting bolts, and lift off. 2 4 Final drive assembly : 3,600 kg
INSTALLATION OF FINAL DRIVE ASSEMBLY Serial No.: 10601 – 10684 • Carry out installation in the reverse order to removal. 1 fl If the shaft will not go in, set a jack on the ground and push the shoe grouser up, then move the sprocket to the front or rear to a position where the shaft will go in, and install the shaft. 2 2 Final drive assembly mounting bolt : Thread tightener (LT-2) 3 Final drive assembly mounting bolt : 1,960 – 2,450 Nm (200 – 250 kgm) • Refilling with oil (final drive case) Add oil through the oil filler to the specified level. 5
30-140 2 6
Final drive case : 71 ¬ (GO140)
D475A-3
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
REMOVAL OF FINAL DRIVE ASSEMBLY Serial No.: 10685 and up 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Raise chassis with jack or ripper and set stand 1 under frame. 3. Remove covers (1) and (2). 4. Remove cover (3), then using forcing screw, pull out drive shaft (4). 1 fl If the shaft will not come out, set a jack on the ground and push the shoe grouser up, then move the sprocket to the front or rear to a position where the shaft will come out, and remove the shaft. fl Pull the shaft out to a position where it contacts the sprocket. 5. Remove 3 bolts of final drive and install tool J1. 6. Sling final drive assembly (5), then remove mounting bolts, and lift off. 2 4 Final drive assembly : 3,600 kg
INSTALLATION OF FINAL DRIVE ASSEMBLY Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 fl If the shaft will not go in, set a jack on the ground and push the shoe grouser up, then move the sprocket to the front or rear to a position where the shaft will go in, and install the shaft. 2 2 Final drive assembly mounting bolt : Thread tightener (LT-2) 3 Final drive assembly mounting bolt : 1,960 – 2,450 Nm (200 – 250 kgm) • Refilling with oil (final drive case) Add oil through the oil filler to the specified level. 5
D475A-3
Final drive case : 71 ¬ (GO140)
30-140-1 6
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1.
Draining oil Remove drain plug and drain oil from final drive case. -
2.
3.
:
Final drive case : Approx.
Sprocket 1) Set final drive assembly approx. 50 mm). 2) Remove sprocket (I).
Cover Using eyebolts
0,
remove
71 e
to block
(height:
cover (2).
CED01622
4.
Hub 1) Remove plate (3). 2) Using eyebolts 0,
lift off hub (4).
CED01623
5.
Sprocket hub assembly 1) Remove holder (5). j, Check the number and thickness shims, and keep in a safe place.
CED01624
of the
CED01625
D475A-3
30-l 41 0
DISASSEMBLY
6.
Wear guard Lift off wear guard (13).
7.
Cover assembly 1) Using eyebolts,
2)
FINAL DRIVE
AND ASSEMBLY
lift off cover assembly
(14).
-
Disassemble cover assembly as follows. i) Remove floating seal cover (15). ii) Remove floating seal (16) from floating seal cover. * Keep the floating seal in a safe place to protect it from damage.
CWD03186
iii) Remove space race (18).
(17)
and
bearing
inner
r
I iv) Remove
plate,
then
remove
ring gear
(19). 8.
Carrier assembly 1) Using eyebolts (20).
D475A-3
0,
remove
carrier assembly
CWD03187
DISASSEMBLY
2)
FINAL DRIVE
AND ASSEMBLY
Disassemble carrier assembly as follows. i) Set carrier assembly on block (height: approx. 100mm). ii) Remove holder (21). iii) Using tool 57, remove planetary gear shaft (22).
J7
CED01638
iv) Remove planet gear (231, bearing inner races (24A) and (24B), and spacer (240.
24 B
v)
Remove
bearing
24c
24 A
CED01639
outer race (24D).
CED01640
9.
Sun gear I) Remove plate (25). 2) Remove holder (26). 3) Pull out sun gear shaft assembly
(27).
CWD03189
30-144 0
FINAL DRIVE
DISASSEMBLY AND ASSEMBLY
4)
Remove holder (51) from sun gear shaft assembly, and pull out sun gear (52)
10. Hub, shaft assembly 1)
Remove
plate (28).
3i CWDO3191
2)
Using tool J5, pull out hub assembly (29) and bearing inner race (30) from shaft assembly
(31).
CED01643
3)
D475A-3
Disassemble i) Remove ii) Remove (34B).
hub assembly (29) as follows. gear (32) from hub (33). bearing outer races (34A) and
CED01644
DISASSEMBLY
4) 5)
AND ASSEMBLY
FINAL DRIVE
Using eyebolts @, pull out shaft assembly (31) from case. Disassemble shaft assembly as follows. i) Remove collar (36). ii) Remove bearing inner race (37) and collar (38).
CED01648
CED01647
11. Cage assembly 1) Using eyebolts 2)
0,
remove
cage
assembly
(39). Remove shims (40). * Check the number and thickness shims, and keep in a safe place.
of the
CED0164S
3)
Disassemble cage assembly as follows. i) Using puller 8, remove bearing outer race (41). ii) Remove oil seals (42) and (43).
CEDOl650
4
42
43 CED01652
12. Gear assembly 1) Remove gear assembly (44). 2) Using puller 0, remove bearing (45) and (46) from gear (47).
inner races
CED01653
30-146 0
CED01654
D475A-3
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
13. Outer race, oil seals I) Using puller @, remove bearing outer race (48). 2) Remove oil seals (49) and (50) from cover.
49
* 50 CEDOl655
D475A-3
CED01656
30-147 0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
FINAL DRIVE
OF FINAL DRIVE
*
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Hub, shaft assembly 1) Assemble shaft-assembly as follows. i) Install collar (38). ii) Using push tool 0, press fit bearing ner race (37). iii) Install collar (36).
in-
2) Using eyebolts 8, install shaft assembly (31) 3)
CED01648
CED01668
-
to case. Assemble hub assembly as follows. i) Using push tool, press fit bearing outer races (34A) and (34B) to hub (33).
ii)
4)
5)
Set gear (32) to hub (33). & Mounting bolt : Thread tightener (LT-2) w Mounting bolt : 823 - 1,029 Nm {84 - 105 kgm} Set shaft assembly (31) and hub assembly (29) in position, then using tool J6, press fit bearing (30) portion.
Install plate (28). & Mounting w
bolt : Thread tightener (LT-2) Mounting bolt : 490 - 608 Nm(50 - 62 kgm}
CWD031Sl
30-l 48 0
FINAL DRIVE
DISASSEMBLY AND ASSEMBLY
2.
Carrier assembly I) Assemble carrier assemblv as follows. * The planetary gear bearing forms a set, so align the distinguishing marks on the inner race, outer race, and spacer when assembling.
Distinguishing mark for bearing (for example: y-12B) Distinauishina mark for bearing (for eiample:MZ-12B) , 1 ,
I
DBD02998
i)
install ring and spacer to planet gear, then using push tool @I, press fit top and bottom bearing outer races (24D).
ii)
Assemble spacer (24C) and bearing inner races (24B) and (24A) to planet gear (231, then set to carrier. * Set so that the protruding part at the end face of the planet gear faces the outside of the machine.
248
24c
24A
CED01639
iii) Using tool 57, press fit planetary gear shaft (22). * Align the shaft with the position of the bearing and spacer hole, and press fit gradually. iv) Install holder (21). & Mounting bolt :
Thread tightener w *
D475A-3
(LT-21
Mounting bolt : 490 - 608 Nm 150 - 62 kgm) After tightening the bolts, check that the gear rotates smoothly.
II
CEDO1674
30-149 0
DISASSEMBLY
3.
AND ASSEMBLY
FINAL DRIVE
Sun gear I) Press fit sun gear (52) to sun gear shaft, and install holder (51). & Holder mounting bolt : Thread tightener (LT-21 2) Assemble sun gear shaft assembly (27) to carrier (531, then install holder (26) and spacer (25). 6 Holder mounting bolt : Thread tightener (LT-21 CWD03195
4.
5.
Carrier, sun gear assembly Using eyebolts 0, install carrier assembly (20).
and sun gear
Cover assembly 1) Assemble cover assembly as follows. i) Using push tools @I and 0, install oil seals (50) and (49). Ir Install the bottom oil seal with the part receiving the pressure at the bottom; install the top oil seal with the part receiving the pressure at the top. & Lip of oil seal : Grease (G2-LII & Oil seal press-fitting surface : Gasket sealant (LG-5) * Coat the inside surface of the case thinly with gasket sealant and wipe off any sealant that is forced out.
L
CED01657
i, CED01656
30-150 0
0475A-3
DISASSEMBLY
ii)
FINAL DRIVE
AND ASSEMBLY
Using push tool 0, press fit bearing outer race (48) to cover.
CWD03199
iii) Fit ring gear (19) and install plate. * Fit so that the notched part of the end face of the gear faces the inside of the machine. iv) Install spacer (54), then using tool 53, press fit bearing inner race (18). v) Install spacer (17).
vi)
Using tool J4, press fit floating seal (16) to floating seal cover. * Remove all oil and grease from the O-ring and O-ring contact surface, and dry before installing. Jr After installing the floating seal, check that the angle of the seal is less than 1 mm.
J4
I vii) Install floating seal cover (15). Fit a cork plug in the forcing *
w
CED01677
tap.
CWD03197
D475A-3
30-151 0
DISASSEMBLY
*
AND ASSEMBLY
FINAL DRIVE
Install so that the cut-out portion of the floating seal cover is facing the bottom as shown in the diagram on the right. Front
2)
Using eyebolts, raise cover assembly (14) and install. & Case mating surface: Gasket sealant (Three Bond 1216) Ir Check that there are no dents, rust, oil, grease, or water on the mating surface of the case and cover. * Coat the whole circumference of the mating surface of the case (one side) with gasket sealant without any break. * Install the cover assembly within 20 minutes after coating with gasket sealant. w Mounting bolt : 1,715 - 1,911 Nm I175 - 195 kgm1
CWD03185
Wear guard Raise wear guard (13) and install.
7.
Sprocket hub assembly 1) Using tool 54, install floating seal (12) to floating seal cover. * Remove all oil and grease from the Oring and O-ring contact surface, and dry before installing. * After installing the floating seal, check that the angle of the seal is less than 1 mm.
J4
CEO01680
30-152 0
D475A-3
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
2) Using push tool, press fit bearing outer races 3)
(II) and (IO). Install floating
seal cover (9).
CED01630
4)
Set bearing
(8) to sprocket
hub assembly.
CEO01629
5)
II
Using eyebolts 0, sling sprocket hub assembly (6) and set to cover. Ir Check that there is no dirt on the sliding surface of the floating seal, then coat thinly with engine oil.
CEO01627
6)
53
CEO01661
Using tool 53, press fit bearing (7) portion. * Rotate the sprocket hub assembly when press fitting.
7
CED02160
D475A-3
1
DISASSEMBLY
7)
8.
FINAL DRIVE
AND ASSEMBLY
Install holder (5). * Tighten 6 mounting bolts temporarily at equal distances around the circumference, then adjust with shims so that clearance X between cover (14) and holder (5) is within the standard value. Clearance X : 0.1 - 0.3 mm w Mounting bolt (temporary tightening): Approx. 74 Nm 17.5 kgm} 6 Mounting bolt : Thread tightener (LT-2) m Mounting bolt : 490 - 608 Nm 150 - 62 kgm}
cwD0319a
Hub 1) Using eyebolts 0, raise hub (4) and install. 2) Install plate (3). & Mounting bolt : Thread tightener (LT-2) Q~ZI Mounting bolt : 245 - 309 Nm I25 - 31.5 kgm}
CED01624
9.
Cover Using eyebolts
0,
CED01623
install cover (2).
CED016
10. Sprocket Install sprocket (1). m Mounting bolt : 2,500 - 2,794 Nm I255 - 285 kgm}
30-154 0
DISASSEMBLY
FINAL DRIVE
AND ASSEMBLY
11. Gear assembly 1) Using push tool @, press fit bearing inner races (46) and (45) to gear. 2) Set tool J8 to cover (14), and install gear assembly (44). * Leave tool 58 in position until the cage is installed.
CWD03200
12. Cage assembly 1) Assemble cage assembly as follows. i) Using push tools @ and 0, install oil seals (43) and (42). * Install the bottom oil seal with the part receiving the pressure at the bottom; install the top oil seal with the part receiving the pressure at the top. & Lip of oil seal : Grease (G2-LII & Oil seal press-fitting surface : Gasket sealant (LG-5) * Coat the inside surface of the case thinly with gasket sealant and wipe off any sealant that is forced out.
CED01662
CED01663
ii)
Using push tool 0, race (41).
press fit bearing outer
CED01664
D475A-3
30-155 0
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
2) Using eyebolt 0, set cage assembly case, and remove
3)
4)
5)
6) 7)
(39) to
tool 58.
Tighten mounting bolts C, D, E, and F cage A uniformly to a tightening torque 69 Nm (7 kgm1, then loosen bolts. Tighten mounting bolts C and D of cage uniformly to a tightening torque of 20 Nm
of of A I2
kgm1. In this condition, use feeler gauge @ to measure clearances a and b between cage A and cage B. Determine thickness c of shims to insert according to Table 1 on next page. Assemble set shim thickness, then tighten mounting bolts of cage A uniformly. w Mounting bolts : 319 - 608 Nm 132.5 - 62 kgm}
13. Refilling with oil Tighten drain plug and add engine the oil filler to the specified level. %8
oil through
Final drive case : Approx. 71 e (GO1401
CEDOl666
30-156 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
Table 1 a+b More than
Less than
t = 0.15
3.05
3.15
9
3.15
3.25
6
3.25
3.35
3
3.35
3.45
-
3.45
3.55
7
3.55
3.65
4
3.65
3.75
1
3.75
3.85
8
3.85
3.95
5
3.95
4.05
2
4.05
4.15
9
4.15
4.25
6
4.25
4.35
3
4.35
4.45
-
A. .A!5 ._
4.55
7
4.55 4.65
4.65
4
4.75
4.75 4.85
use
Total shim thickness c (mm)
t= 1.0
t = 0.5 1
-
-
1.85
1
1
1.90
1
1.95
-
2
2.00
-
1
2.05
1
2.10
-
2
2.15
-
1
2.20
1
2.25
-
2
2.30
-
1
2.35
1
2.40
2
2.45
1
2
2.50
1
1
2.55
1
1
1 -
-
2
2.60
1
2
2.65
4.85
8
1
1
2.70
4.95
5
2
2.75
4.95
5.05
2
1
5.05 5.15
5.15 5.25
9 6
I
5.35 5.45
-3
5.55
7
5.55
5.65
4
5.65 5.75
5.75 5.85
1
-
3
8
-
2
5.85
5.95
5
5.95
6.05
2
-
3
3.30
6.05
6.15
9
-
3
3.35
6.15 6.25 6.35
6.25 6.35 6.45
6
2
3.40
3 -
3
3.45
1
3
3.50
6.45 _..fis;F; _.__
6.55
7
1
2
3.55
6.65
4
3
3.60
6.65
6.75
1
1
3
3.65
6.75
6.85
1
2
3.70
6.85
6 .95 7.05
8 5
3
3.75
5.25
1
I
ofshimto
1
5.35 5.45
I
Number
(mm)
b
-
-
1
I
r
2 1 2
2.80 1
2.85
2
2.95
-
3
3.00
-
2
3.05
2
3.10
1
1
1 -
-
-
2
I
3.15
1
3.25
3.20
2
1
3
3.80
7.15
9
1
2
3.85
7.15
7.25
6
3
3.90
7.25
7.35
3
3
3.95
6.95 7.05
D475A-3
1
1
2.90
1
30-157 0
DISASSEMBLY AND ASSEMBLY
TRACK FRAME
REMOVAL OF TRACK FRAME ASSEMBLY Serial No.: 10601 – 10684 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Raise chassis with jack or ripper, then set support 1 under frame to keep rear of chassis off ground. 3. Set hydraulic jack 2 to center of equalizer bar, and raise front of chassis. 4. Sling track frame assembly. 5. Remove cover (1). 6. Remove cover (2).
7. Remove bushing (3). 8. Using eyebolts 3, pull out pin (4) 1 fl It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so adjust the height of the track frame before removing.
9. Remove cover (5) together with cushion (6). 2
30-158 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK FRAME
10. Remove mounting bolts, and disconnect (7) from track frame.
cover
CWD03202
11. Remove
cover (8). With the right track frame, disconnect blade tilt cylinder hoses from the cover.
Ir
12. Remove
seal (9) together
13. Remove
washer
(II),
with washer
then remove
4
(IO). m
spacer (12).
__ _.__-__. w ___-._f i___’
CWD03203
14. Lift off track frame assembly (13). * Oil will flow out from the pivot catch it in an oil container. -
&I kg
D475A-3
:
1141 case, so
Pivot case : 26 .@ Track frame
assembly
: 11,050 kg
30-159 0
DISASSEMBLY AND ASSEMBLY
TRACK FRAME
INSTALLATION OF TRACK FRAME ASSEMBLY Serial No.: 10601 – 10684 • Carry out installation in the reverse order to removal. 1 2 Inside surface of bushing: Grease (G2-LI) fl Before installing the pin, adjust the height of the track frame and align the center of the equalizer bar hole and track frame hole. fl Set the pin with the grease hole facing the outside of the machine. 2 fl Fit pin (4) and bushing (3), install cover (2), then install the cover and cushion. 3 fl After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). fl Be careful not to install with the seal displaced in the direction of twisting.
4 fl Be careful not to install the track frame with seal (14) displaced in the direction of twisting. •
Refilling with oil (pivot case) Add oil through oil filler to the specified level. 5
30-160 2 6
Pivot case : 26 ¬ (SAE30)
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK FRAME
REMOVAL OF TRACK FRAME ASSEMBLY Serial No.: 10685 and up 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Raise chassis with jack or ripper, then set support 1 under frame to keep rear of chassis off ground. 3. Set hydraulic jack 2 to center of equalizer bar, and raise front of chassis. 4. Sling track frame assembly. 5. Remove cover (1). 6. Remove cover (2).
7. Using eyebolts 3, pull out pin (3) 1 fl It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so adjust the height of the track frame before removing.
8. Remove mounting bolts, and disconnect cover (4) from track frame.
D475A-3
30-160-1 6
DISASSEMBLY AND ASSEMBLY
TRACK FRAME
9. Remove cover (5). fl With the right track frame, disconnect 4 blade tilt cylinder hoses from the cover. 10. Remove seal (6) together with washer (7). 2 11. Remove washer (8), then remove spacer (9).
12. Lift off track frame assembly (10). 3 fl Oil will flow out from the pivot case, so catch it in an oil container. 6 Pivot case : 26 ¬ 4 Track frame assembly : 11,050 kg
30-160-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK FRAME
INSTALLATION OF TRACK FRAME ASSEMBLY Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 2 Inside surface of bushing: Grease (G2-LI) fl Before installing the pin, adjust the height of the track frame and align the center of the equalizer bar hole and track frame hole. fl Set the pin with the grease hole facing the outside of the machine. 2 fl After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). fl Be careful not to install with the seal displaced in the direction of twisting.
3 fl Be careful not to install the track frame with seal (11) displaced in the direction of twisting. •
Refilling with oil (pivot case) Add oil through oil filler to the specified level. 5
D475A-3
Pivot case : 26 ¬ (SAE30)
30-160-3 6
DISASSEMBLY AND ASSEMBLY
IDLER
DISASSEMBLY OF IDLER ASSEMBLY Serial No.: 10601 – 10684 1. Remove oil filler plug and drain oil. 6 Idler : 2.0 – 2.2 ¬ (G0140) 2. Set idler assembly (1) on block 1. 3. Remove mounting bolts, then using forcing screws 2, remove seal guide (2) together with retainer (3).
4. Turn over idler assembly. 5. Remove mounting bolts, then using eyebolts 3, remove shaft (4) together with retainer. 6. Using puller 4, remove seal guide (5) and retainer (6).
7. Remove seal guides (2) and (5) from retainers (3) and (6).
8. Remove floating seal (7) from seal guides (2) and (5). fl Keep the floating seal in a safe place to protect it from damage. 9. Remove floating seal (8) from seal guides (3) and (6). fl Keep the floating seal in a safe place to protect it from damage.
D475A-3
30-161 2 6
DISASSEMBLY
10. Remove
AND ASSEMBLY
bushings
IDLER
(9) from idler (IO).
CED01837
30-162 0
D475A-3
DISASSEMBLY AND ASSEMBLY
IDLER
ASSEMBLY OF IDLER ASSEMBLY Serial No.: 10601 – 10684 fl Clean all parts, and check for dirt or damage. 1. Set bushing (9) and tool L1 to idler (10), and press fit bushing (9). fl First, center the bushing with a plastic hammer, then press fit with a puller. fl Press fit so that press-fitting dimension a from the end face of the idler to the top surface of the bushing is the dimension given below. • Press-fitting dimension a : 15 ± 1 mm
2. Using tool L2, install floating seal (8) to retainers (3) and (6). 3. Fit O-ring and install retainer (3) to idler.
4. Using eyebolts 3, set idler (10) to shaft (4). fl Set block (height: approx. 200 mm) under the idler. 5. Turn over idler assembly. fl Tie with wire to prevent the shaft from falling out. 6. Fit O-ring and install retainer (6) to idler.
7. Using tool L2, install floating seal (7) to seal guides (2) and (5). 8. Install O-rings to seal guides (2) and (5).
D475A-3
30-163 2 6
IDLER
DISASSEMBLY AND ASSEMBLY
9.
Set seal guide (2) to shaft, then using tools Ll and L3, press fit seal guide (2). * Seal guide press-fitting force : 83.3 - 137.2 kN (8.5 - 14 ton}
CWD03078
Ir
Press fit the seal guide so that press-fitting dimension a from the end face of the shaft to the top surface of the seal guide is the dimension given below. . Press-fitting dimension a :
*
Turn over the idler assembly and repeat the same procedure to press fit the seal guide (5) on the opposite side.
124.5 e 0.2 mm
CED01845
10. Using tool L4, fill with oil to specified then tighten oil filler plug.
level,
%3
Idler : 2.0 - 2.2 e (GO1401
m
Oil filler plug : 156.8 - 254.8 Nm {IS - 26 kgm}
-To
~
30-164 0
=
vacuum tank
DAD03002
D475A-3
DISASSEMBLY AND ASSEMBLY
IDLER
DISASSEMBLY OF IDLER ASSEMBLY Serial No.: 10685 and up 1. Remove oil filler plug and drain oil. 6 Idler : 1.4 – 2.2 ¬ (G0140) 2. Set idler assembly (1) on block 1. 3. Remove mounting bolts, then using forcing screws 2, remove seal guide (2) together with retainer (3) and plate (4).
4. Turn over idler assembly. 5. Remove mounting bolts, then using eyebolts 3, remove shaft (5) together with retainer. 6. Using puller 4, remove seal guide (6) and retainer (7) and plate (8).
7. Remove seal guides (2) and (6) from retainers (3) and (7).
8. Remove floating seal (9) from seal guides (2) and (6). fl Keep the floating seal in a safe place to protect it from damage. 9. Remove floating seal (10) from seal guides (3) and (7). fl Keep the floating seal in a safe place to protect it from damage.
D475A-3
30-164-1 6
DISASSEMBLY AND ASSEMBLY
IDLER
10. Remove bushings (11) from idler (12).
30-164-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
IDLER
ASSEMBLY OF IDLER ASSEMBLY Serial No.: 10685 and up fl Clean all parts, and check for dirt or damage. 1. Set bushing (11) and tool L1 to idler (12), and press fit bushing (11). fl First, center the bushing with a plastic hammer, then press fit with a puller. fl Press fit so that press-fitting dimension a from the end face of the idler to the top surface of the bushing is the dimension given below. • Press-fitting dimension a : 17 ± 0.5 mm
2. Using tool L2, install floating seal (10) to retainers (3) and (7). 3. Fit O-ring and install retainer (3) and plate (4) to idler. fl Check that the plate can be turned smoothly with the hand.
4. Using eyebolts 3, set idler (12) to shaft (5). fl Set block (height: approx. 200 mm) under the idler. 5. Turn over idler assembly. fl Tie with wire to prevent the shaft from falling out. 6. Fit O-ring and install retainer (7) and plate (8) to idler.
7. Using tool L2, install floating seal (9) to seal guides (2) and (6).
D475A-3
30-164-3 6
DISASSEMBLY AND ASSEMBLY
IDLER
8. Set seal guide (2) to shaft, then using tools L1 and L3, press fit seal guide (2). fl Seal guide press-fitting force : 83.3 – 137.2 kN {8.5 – 14 ton}
fl Press fit the seal guide so that press-fitting dimension a from the end face of the shaft to the top surface of the seal guide is the dimension given below. • Press-fitting dimension a : 124.5 ± 0.2 mm fl 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, fill with oil to specified level, then tighten oil filler plug. 5
Idler : 1.4 – 1.5 ¬ (GO140)
3 Oil filler plug : 156.8 – 254.8 Nm {16 – 26 kgm}
30-164-4 6
D475A-3
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
REMOVAL OF RECOIL SPRING ASSEMBLY Serial No.: 10601 – 10684 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. To prevent danger, never stand in front of the idler yoke assembly. 2. Drain oil from recoil cylinder chamber using oil pump. 6 Recoil cylinder chamber: Approx. 75 ¬ 3. Using eyebolt 1, remove cover (1). 4 Cover : 70 kg 4. Remove cover (2). 5. Lift off trunnion (3). 4 Trunnion : 140 kg
6. Remove covers (4). fl Remove both the inside and outside covers.
7. Using tool M1, remove pins (5). 1 fl Remove both the inside and outside pins.
D475A-3
30-165 2 6
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
8. Lift off idler and recoil spring assembly (6). 2 fl Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at the track frame end. 4 Idler, recoil spring assembly : 3,400 kg
9. Disconnect recoil cylinder assembly (7) from idler yoke assembly (8) as follows. 3 1) Put idler yoke assembly (8) in contact with ground, then raise recoil cylinder assembly (7). fl When doing this, check that there is no damage to the weld of recoil cylinder assembly (7). fl Wrap cloth around the chrome plated bushing to protect it.
2) Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides. 4 To prevent danger, never stand in front of the idler yoke assembly or behind the recoil cylinder assembly. The recoil spring inside the recoil cylinder is applying a pushing force of approx. 725 kN (approx. 74 tons) on the idler yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke is 8 – 12 mm. 3) When the bolts are loosened, the torque will suddenly drop. Check that the installed load of the recoil spring is not applying any pushing force on the mounting bolts, then remove all bolts. fl 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.
30-166 2 6
D475A-3
DISASSEMBLY
a
a
AND ASSEMBLY
RECOIL SPRING
If the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (IO), or nut (II) at the tip of the shaft has fallen off, so there is danger that the idler yoke assembly may fly off to the front. For this reason, disassemble as follows. When disconnecting the idler yoke assembly and recoil cylinder assembly, do not stand in front of the idler yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed. Prepare the following parts. i) . Bolt @ (x6): 791-730-I 120 . Nut @ (x6): 01580-13326 . Washer @ (x6): 01643-33380 (use again) ii) Remove 6 bolts marked %, then install bolts 0, nuts 0, and washers
II
CDD01998
0. *
Check that dimension L is less than 450 mm. * Screw in bolts @ until they contact the bottom of the yoke thread. 12 bolts (those iii) Remove remaining not marked %I. iv) Hold bolts @ with a wrench to prevent them from turning, and loosen 2 nuts @ simultaneously on diagonally opposite sides. * Be careful not to let the load bear on only one bolt. v) When recoil spring is fully extended and torque has completely dropped in loosening direction of nut 0, remove bolt 0. Ir
I
CKD01063
Yoke
II
DKD02952
When clearance b is approx. 280 mm, the spring is fully extended.
CEDOl999
D475A-3
RECOIL SPRING
DISASSEMBLY AND ASSEMBLY
10. Remove
ring (12).
CEDOZOOO
11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15). m
CWD03204
12. Disassemble piston assc?mbly (15) as follows. i) Remove wear ring ( 16) from piston. ii) Remove snap ring (171, then remove packing (18).
18
I7
CWD03205
13. Remove &I kg
recoil spring assembly Recoil spring assembly
(19).
: 780 kg
CED02003
30-168 0
DISASSEMBLY
14. Remove bly.
AND ASSEMBLY
holder
(20) from
recoil spring
RECOIL SPRING
assem-
CED02004
D475A-3
30-169 0
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
INSTALLATION OF RECOIL SPRING ASSEMBLY Serial No.: 10601 – 10684 • Carry out installation in the reverse order to removal. 1 fl Before installing the pin, align the center of the hole in the track frame and the dowel pin at the recoil cylinder end with a bar. 2 fl Using a lever block, keep horizontal and be careful not to damage the oil seal at the track frame end when installing. fl Adjust the clearance. For details, see TESTING AND ADJUSTING, Adjusting clearance of idler. 3 fl If the recoil spring set bolt is broken or the nut at the tip of the shaft has fallen off, see ASSEMBLY OF RECOIL SPRING ASSEMBLY when assembling. 4 2 Idler yoke assembly mounting bolt : Thread tightener (LT-2) 3 Idler yoke assembly mounting bolt : 2,205 – 2,695 Nm {225 – 275 kgm} 5 fl To prevent air from accumulating inside the cylinder, fill with grease as follows. i) Fill the inside of the cylinder with approx. 2.0 ¬ of grease. ii) Set with the cylinder drain hole facing up, then loosen the lubricator. iii) Push the piston until it contacts the stopper. This will push out the air and any extra grease.
30-170 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
REMOVAL OF RECOIL SPRING ASSEMBLY Serial No.: 10685 and up 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. To prevent danger, never stand in front of the idler yoke assembly. 2. Drain oil from recoil cylinder chamber using oil pump. 6 Recoil cylinder chamber: Approx. 75 ¬ 3. Using eyebolt 1, remove cover (1). 4 Cover : 70 kg 4. Remove cover (2). 5. Lift off trunnion (3). 4 Trunnion : 140 kg
6. Remove covers (4). fl Remove both the inside and outside covers.
7. Using tool M1, remove pins (5). 1 fl Remove both the inside and outside pins.
D475A-3
30-170-1 6
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
8. Lift off idler and recoil spring assembly (6).2 fl Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at the track frame end. 4 Idler, recoil spring assembly : 3,500 kg
9. Disconnect recoil cylinder assembly (7) from idler yoke assembly (8) as follows. 3 1) Put idler yoke assembly (8) in contact with ground, then raise recoil cylinder assembly (7). fl When doing this, check that there is no damage to the weld of recoil cylinder assembly (7). fl Wrap cloth around the chrome plated bushing to protect it.
2) Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides. 4 To prevent danger, never stand in front of the idler yoke assembly or behind the recoil cylinder assembly. The recoil spring inside the recoil cylinder is applying a pushing force of approx. 788 kN (approx. 81 tons) on the idler yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke is 8 – 12 mm. 3) When the bolts are loosened, the torque will suddenly drop. Check that the installed load of the recoil spring is not applying any pushing force on the mounting bolts, then remove all bolts. fl 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.
30-170-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
If the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (10), or nut (11) at the tip of the shaft has fallen off, so there is danger that the idler yoke assembly may fly off to the front. For this reason, disassemble as follows. When disconnecting the idler yoke assembly and recoil cylinder assembly, do not stand in front of the idler yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed. i) Prepare the following parts. • Bolt 1 (x6): 791-730-1120 • Nut 2 (x6): 01580-13326 • Washer 3 (x6): 01643-33380 (use again) ii) Remove 6 bolts marked ª, then install bolts 1, nuts 2, and washers 3. fl Check that dimension L is less than 450 mm. fl Screw in bolts 1 until they contact the bottom of the yoke thread. iii) Remove remaining 12 bolts (those not marked ª). iv) Hold bolts 1 with a wrench to prevent them from turning, and loosen 2 nuts 2 simultaneously on diagonally opposite sides. fl Be careful not to let the load bear on only one bolt. v) When recoil spring is fully extended and torque has completely dropped in loosening direction of nut 2, remove bolt 1. fl When clearance b is approx. 280 mm, the spring is fully extended.
D475A-3
30-170-3 6
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
10. Remove ring (12).
11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15). 5
12. Disassemble piston assembly (15) as follows. i) Remove wear ring (16) from piston. ii) Remove snap ring (17), then remove packing (18).
13. Remove recoil spring assembly (19). 4 Recoil spring assembly : 780 kg
30-170-4 6
D475A-3
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
14. Remove holder (20) from recoil spring assembly.
D475A-3
30-170-5 6
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
INSTALLATION OF RECOIL SPRING ASSEMBLY Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 fl Before installing the pin, align the center of the hole in the track frame and the dowel pin at the recoil cylinder end with a bar. 2 fl Using a lever block, keep horizontal and be careful not to damage the oil seal at the track frame end when installing. fl Adjust the clearance. For details, see TESTING AND ADJUSTING, Adjusting clearance of idler. 3 fl If the recoil spring set bolt is broken or the nut at the tip of the shaft has fallen off, see ASSEMBLY OF RECOIL SPRING ASSEMBLY when assembling. 4 2 Idler yoke assembly mounting bolt : Thread tightener (LT-2) 3 Idler yoke assembly mounting bolt : 2,205 – 2,695 Nm {225 – 275 kgm} 5 fl To prevent air from accumulating inside the cylinder, fill with grease as follows. i) Fill the inside of the cylinder with approx. 2.0 ¬ of grease. ii) Set with the cylinder drain hole facing up, then loosen the lubricator. iii) Push the piston until it contacts the stopper. This will push out the air and any extra grease.
30-170-6 6
D475A-3
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No.: 10601 – 10684 1. Remove recoil spring assembly (1) with tool M2. The spring is under high installed load, so be careful to set it correctly. fl Installed load of spring : Approx. 725 kN {approx. 74 ton}
2. Apply hydraulic pressure slowly to compress spring, then remove lock plate (2) and remove nut (3). 3. Release hydraulic pressure gradually and relieve tension of spring. 4. Remove rear pilot (5), spacer (6), bolt (7), and front pilot (8) from spring (4).
ASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No.: 10601 – 10684 1. Assemble front pilot (8), bolt (7), spacer (6), and rear pilot (5) to spring (4), then set in tool M2. The spring is under high installed load, so be careful to set all parts correctly. 2. Apply hydraulic pressure slowly to compress spring, and set so that installed length of spring is specified value. fl Installed length a of spring : 1,425 mm fl Installed load of spring : Approx. 725 kN {approx. 74 ton}
D475A-3
30-171 2 6
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
3. Fit nut (3), then install lock plate (2). fl When securing the recoil spring mounting nut, make a clearance of 0 – 1 mm between lock plate (2) and nut (3), then bring lock plate (2) and bolt (7) into tight contact, and secure in position. 2 Lock plate mounting bolt : Thread tightener (LT-2) 4. Gradually release hydraulic pressure to completely release tension of spring, then remove recoil spring assembly (1) from tool M2.
30-172 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No.: 10685 and up 1. Remove recoil spring assembly (1) with tool M2. The spring is under high installed load, so be careful to set it correctly. fl Installed load of spring : Approx. 788 kN {approx. 81 ton}
2. Apply hydraulic pressure slowly to compress spring, then remove lock plate (2) and remove nut (3). 3. Release hydraulic pressure gradually and relieve tension of spring. 4. Remove rear pilot (5), spacer (6), bolt (7), and front pilot (8) from spring (4).
ASSEMBLY OF RECOIL SPRING ASSEMBLY Serial No.: 10685 and up 1. Assemble front pilot (8), bolt (7), spacer (6), and rear pilot (5) to spring (4), then set in tool M2. The spring is under high installed load, so be careful to set all parts correctly. 2. Apply hydraulic pressure slowly to compress spring, and set so that installed length of spring is specified value. fl Installed length a of spring : 1,461 mm fl Installed load of spring : Approx. 788 kN {approx. 81 ton}
D475A-3
30-172-1 6
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
3. Fit nut (3), then install lock plate (2). fl When securing the recoil spring mounting nut, make a clearance b of 0 – 1 mm between lock plate (2) and nut (3), then bring lock plate (2) and bolt (7) into tight contact, and secure in position. 2 Lock plate mounting bolt : Thread tightener (LT-2) 4. Gradually release hydraulic pressure to completely release tension of spring, then remove recoil spring assembly (1) from tool M2.
30-172-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
REMOVAL OF TRACK ROLLER ASSEMBLY Serial No.: 10601 – 10684 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove guard (1). 1 fl Only when removing the last track roller assembly.
3. Operate blade and ripper to raise chassis to a point where track roller assembly is separated from track shoe. 4. Set steel plate 1 on top of track shoe, operate blade and ripper, and lower chassis until track roller assembly contacts steel plate. fl When operating the blade and ripper, run the engine at low idling and operate slowly.
5. Remove mounting bolts and put track roller assembly (2) on steel board 1. 2
6. Operate blade and ripper, and raise chassis to a position where track roller assembly (2) separates from bogie. 7. Using a bar, pull track roller assembly (2) on top of steel plate to outside of machine. 3 4 Track roller assembly : 220 kg
D475A-3
30-173 2 6
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
INSTALLATION OF TRACK ROLLER ASSEMBLY Serial No.: 10601 – 10684 • Carry out installation in the reverse order to removal. 1 3 Guard mounting bolt : 1,960 – 2,450 Nm {200 – 250 kgm} 2 fl All standard specification machines are equipped with double-flange track roller assemblies. fl The superdozer specification machines are equipped with single-flange track roller assemblies and double-flange track roller assemblies. These are installed in different positions, so check the positions when installing. S: Single flange D: Double flange fl Install the track roller assembly with the oil filler plug facing the outside of the machine. fl After fitting the track roller assembly temporarily, align the position of dowel pin (3). 2 Track roller mounting bolt : Thread tightener (LT-2) 3 Track roller assembly mounting bolt: 2,205 – 2,695 Nm {225 – 275 kgm} 3 When using assembly tools Set tool L12 under the track roller assembly, and raise track roller assembly (2), then set to the track frame.
30-174 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
REMOVAL OF TRACK ROLLER ASSEMBLY Serial No.: 10685 and up 1. Loosen the track shoe. For details, see EXPANDING TRACK SHOE ASSEMBLY. 2. Install tool L13 and secure bogie assembly (1). 1 3. Operate the blade and ripper to lift the machine body until track roller assembly (2) separates from the track shoe.
4. Place steel plate 1 on the track shoe and operate the blade and ripper to lower the machine body until the track roller assembly comes in contact with the steel plate. fl Operate the blade and ripper slowly, running the engine at the low idling speed.
5. Remove the mounting bolts and place track roller assembly (2) on steel plate 1. 2 6. Operate the blade and ripper to lift the machine body until track roller assembly (2) separates from the bogie.
7. Pull track roller assembly (2) out of the machine body from the top of the steel plate with a bar, etc. 3 4 Track roller assembly: 240 kg
D475A-3
30-174-1 6
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
INSTALLATION OF TRACK ROLLER ASSEMBLY Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 After removing tool L13, replace the mounting bolts of cover (3) with the regular parts. 3 Cover mounting bolt: 883 – 1,470 Nm {90 – 150 kgm}
2 Install S to the first and last track rollers and install D to the other track rollers. S: Single flange D: Double flange fl Install the track roller assembly with the oil filler plug out. fl After installing the track roller assembly, set the position of dowel pin (4). 2 Track roller assembly mounting bolt: Adhesive (LT-2) 3 Track roller assembly mounting bolt: 2,205 – 2,695 Nm {222 – 275 kgm}
3 When using the assembling tool Set tool L12 under the track roller assembly (2) and lift up and set track roller assembly (2) to the track frame.
30-174-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
DISASSEMBLY OF TRACK ROLLER ASSEMBLY Serial No.: 10601 – 10684 1. Remove oil filler plug and drain oil. Track roller : 2.2 – 2.4 ¬ 2. Set track roller assembly (1) on block 1. 3. Remove mounting bolts, then using forcing screws 2, remove seal guide (2) together with retainer (3). 4. Turn over track roller assembly. 5. Remove mounting bolts, then using eyebolts 3, remove shaft (4) together with retainer. 6. Using press, remove seal guide (5) together with retainer (6) from shaft. 7. Remove seal guides (2) and (5) from retainers (3) and (6).
8. Remove floating seal (7) from seal guides (2) and (5). fl Keep the floating seal in a safe place to protect it from damage. 9. Remove floating seal (8) from retainers (3) and (6). fl Keep the floating seal in a safe place to protect it from damage.
10. Remove bushing (9) from roller (10).
D475A-3
30-175 2 6
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
ASSEMBLY OF TRACK ROLLER ASSEMBLY Serial No.: 10601 – 10684 fl Clean all parts, and check for dirt or damage. 1. Set roller (10) to press, then using tool L8, press fit bushing (9). fl First, center the bushing with a plastic hammer, then press fit with a press. fl Press fit so that press-fitting dimension a from the end face of the roller to the top surface of the bushing is the dimension given below. • Press-fitting dimension a : 15 ± 1 mm 2. Set shaft (4) to roller. 3. Using tool L9, install floating seal (8) to retainers (3) and (6). 4. Fit O-ring and install retainers (3) and (6) to roller.
5. Using tool L9, install floating seal (7) to seal guides (2) and (5). 6. Fit O-ring, then using tool L10, press fit seal guide (2) to shaft. fl Seal guide press-fitting force : 68.6 – 98 kN {7 – 10 ton}
fl 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 the dimension given below. • Press-fitting dimension b : 90 ± 0.2 mm
30-176 2 6
D475A-3
DISASSEMBLY
7.
AND ASSEMBLY
Using tool Lll, fill with oil to specified then tighten oil filler plug.
TRACK ROLLER
level,
Q
Track roller : 2.2 - 2.4 e (GO1401
w
Oil filler plug : 156.8 - 254.8 Nm (16 - 26 kgm]
CDD02029
D475A-3
30-177 0
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
DISASSEMBLY OF TRACK ROLLER ASSEMBLY Serial No.: 10685 and up 1. Remove oil filler plug and drain oil. 6 Track roller : 1.4 – 1.5 ¬ 2. Set track roller assembly (1) on block 1. 3. Remove mounting bolts, then using forcing screws 2, remove seal guide (2) together with retainer (3) and plate (4). 4. Turn over track roller assembly. 5. Remove mounting bolts, then using eyebolts 3, remove shaft (5) together with retainer. 6. Using press, remove seal guide (6) together with retainer (7) and plate (8) from shaft. 7. Remove seal guides (2) and (6) from retainers (3) and (7).
8. Remove floating seal (9) from seal guides (2) and (6). fl Keep the floating seal in a safe place to protect it from damage. 9. Remove floating seal (9) from retainers (3) and (7). fl Keep the floating seal in a safe place to protect it from damage.
10. Remove bushing (11) from roller (12).
30-177-1 6
D475A-3
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
ASSEMBLY OF TRACK ROLLER ASSEMBLY Serial No.: 10685 and up fl Clean all parts, and check for dirt or damage. 1. Set roller (12) to press, then using tool L8, press fit bushing (11). fl First, center the bushing with a plastic hammer, then press fit with a press. fl Press fit so that press-fitting dimension a from the end face of the roller to the top surface of the bushing is the dimension given below. • Press-fitting dimension a : 17 ± 0.5 mm 2. Set shaft (5) to roller. 3. Using tool L9, install floating seal (10) to retainers (3) and (7). 4. Fit O-ring and install retainers (3), (7) and plate (8) to roller. fl Check that the plate can be turned smoothly with the hand.
5. Using tool L9, install floating seal (9) to seal guides (2) and (6). 6. Using tool L10, press fit seal guide (2) to shaft. fl Seal guide press-fitting force : 49 – 83 kN {5 – 8.5 ton}
fl 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 the dimension given below. • Press-fitting dimension b : 86 ± 0.2 mm fl Turn over the track roller assembly and press fit seal guide (6) on the opposite side according to the above procedure.
D475A-3
30-177-2 6
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
7. Using tool L11, fill with oil to specified level, then tighten oil filler plug. 5
Track roller : 1.4 – 1.5 ¬ (GO140)
3 Oil filler plug : 156.8 – 254.8 Nm {16 – 26 kgm}
30-177-3 6
D475A-3
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
REMOVAL OF CARRIER ROLLER ASSEMBLY Serial No.: 10685 and up 1. Loosen the track shoe. For details, see EXPANDING TRACK SHOE ASSEMBLY. 2. Lift up the track shoe with hydraulic jack 1. 3. Lift off carrier roller assembly (1).
1
4 Carrier roller assembly: 105 kg
INSTALLATION OF CARRIER ROLLER ASSEMBLY Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 fl Make a clearance a of 5 mm between the carrier roller and support as shown at right. 2 Carrier roller assembly mounting bolt: Adhesive (LT-2) 3 Carrier roller assembly mounting bolt: 744.8 ± 83.3 Nm {76 ± 8.5 kgm}
D475A-3
30-177-4 6
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY Serial No.: 10685 and up 1. Remove the oil filler plug and drain the oil. fl Drain the oil, turning the shaft. 6 Carrier roller: Approx. 13 ¬ 2. Set carrier roller assembly (1) to block 1. 3. Remove the mounting bolts and cover (2). 4. Remove ring (3).
5. Using tool L7, remove nut (4). 6. Remove the fitted part of the seal guide with puller 2 and remove bearing (5) and roller (6) as one unit by using eyebolts.
7. Remove bearing outer race (7) from the roller. 8. Remove seal guide (8) and bearing inner race (9) as one unit with puller 3.
9. Remove floating seal (10) from seal guide (8).
30-177-5 6
D475A-3
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
10. Remove seal guide (11) with push tool 4. 11. Remove floating seal (12) from seal guide (11).
D475A-3
30-177-6 6
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
ASSEMBLY OF CARRIER ROLLER ASSEMBLY Serial No.: 10685 and up fl Clean the all parts and check them for dirt. 1. Press fit bearing inner race (9) with push tool 5. 2. Press fit bearing outer race (7) with push tool 6.
3. Set roller (6) and bearing inner race (5) to the shaft. 4. Press fit bearing inner race (5) to the shaft with push tool 7. fl Press fit the bearing inner race, turning the roller, until the roller becomes a little hard to turn.
5. Tighten nut (4) with tool L7. 3 Nut: 98 Nm {10 kgm} fl After the nut is tightened, if its hole is not matched to the hole of the shaft, match its hole by loosening the nut. 6. Install ring (3).
7. Fit the O-ring to cover (2) and install them.
30-177-7 6
D475A-3
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
8. Install floating seal (10) to seal guide (8) with tool L5. 9. Fit the O-ring to seal guide (8) and install them, matching them to the dowel pin.
10. Install floating seal (12) to seal guide (11) with tool L5.
11. Press fit seal guide (11) with tool L6. fl Press fit the seal guide so that dimension a between the shaft end and seal guide top will be 181.25 ± 0.2 mm.
12. Supply specified quantity of oil by using tool L4 and tighten the oil filler plug. 5
Carrier roller: 1.25 – 1.35 ¬ (GO140)
3 Oil filler plug: 157 – 255 Nm {16 – 26 kgm}
D475A-3
30-177-8 6
DISASSEMBLY AND ASSEMBLY
BOGIE
REMOVAL OF BOGIE ASSEMBLY Serial No.: 10601 – 10684 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Operate blade and ripper to raise chassis to a point where track roller assembly is separated from track link. Set a block between the track roller and the track link to prevent the chassis from coming down. 3. Remove guard (1). 1 fl Only when removing the last track roller assembly. 4. Align with height of track link and set block 1 on outside of track shoe. 5. Set steel plate 2 on top of track shoe and block 1. 6. Operate blade and ripper, and lower chassis until bogie assembly (2) contacts steel plate 2. fl When operating the blade and ripper, run the engine at low idling and operate slowly. 7. Remove mounting bolts and put bogie assembly (2) on steel board 2. 2 8. Operate blade and ripper, and raise chassis to a position bogie assembly can be pulled out. Set a block between the track roller and the track link to prevent the chassis from coming down. 9. Raise bogie assembly (2) together with guard, place on top of steel plate 2, and pull to outside. 3 10. After removing, separate bogie assembly and guard. 4 Bogie assembly : 1,200 kg Guard : 50 kg
30-178 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
INSTALLATION OF BOGIE ASSEMBLY Serial No.: 10601 – 10684 1 3 Guard mounting bolt : 1,960 – 2,450 Nm {200 – 250 kgm} 2 2 Bogie assembly mounting bolt : Thread tightener (LT-2) 3 Tightening order of bogie assembly mounting bolts: 1. Tighten the bolts to about 294 Nm {30 kgm} in the following. A→B→C→D 2. Tighten the bolts to specified torque: 2,205 – 2,695 Nm {225 – 275 kgm} in the following. B→D→C→A 3. Roughly even the front and rear gaps marked with ✩.
3 fl Fit lever block 3 between the guard of bogie assembly (2) and the guard of the bogie assembly on the opposite side, then side bogie assembly (2) on top of the steel plate to set it to the mounting position.
D475A-3
30-179 2 6
DISASSEMBLY AND ASSEMBLY
BOGIE
REMOVAL OF BOGIE ASSEMBLY Serial No.: 10685 and up 1. Loosen the track shoe. For details, see EXPANDING TRACK SHOE ASSEMBLY.
2. Install tool L13 and secure the bogie assembly.
3. Operate the blade and ripper to lift the machine body until the track roller assembly separates from the track link. Set a block between the track roller and track link so that the machine body will not lower. 4. Set block 1 out of the track shoe, matching it to the height of the track link. 5. Set steel plate 2 on the track shoe and block 1. 6. Operate the blade and ripper to lower the machine body until the track roller of bogie assembly (1) comes in contact with steel plate 2. fl Operate the blade and ripper slowly, running the engine at the low idling speed.
30-179-1 6
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
7. Remove cover (2).
8. Pulling out shaft and ring 1) Set tool L14. 2) Push out shaft (3) and ring (4) to the opposite side simultaneously. fl Pushing out force: 225.5 – 460.9 kN {13 – 47 tons}
3) Remove floating seals (5) from the end faces of rings (4) and (7). fl Store the floating seals so that they will not be damaged.
4) Set tool L15. 5) Pull out spacer (6) and rings (7) and (8). fl Pulling out force: 225.5 – 460.9 kN {23 – 47 tons}
D475A-3
30-179-2 6
DISASSEMBLY AND ASSEMBLY
BOGIE
6) Remove spacer (6). 7) Remove spacer (9) and floating seals (10) between rings (7) and (8). fl Store the floating seals so that they will not be damaged. 8) Pull out the shaft and rings on the opposite side according to above steps 1) – 7).
9. Remove tool L13. 10. Place bogie assembly (1) on steel plate 2. 11. Operate the blade and ripper to raise the machine body until the bogie assembly can be pulled out. Set a block between the track roller and track link so that the machine body will not lower. 12. Sling bogie assembly (1) and pull it out, sliding it on steel plate (2). 4 Bogie assembly: 1,200 kg
30-179-3 6
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
INSTALLATION OF BOGIE ASSEMBLY Serial No.: 10685 and up 1. Assembly of pin assembly 1) Using tool L18, install floating seals (5) to rings (4) and (7) and install floating seals (10) to the opposite side of ring (7) and ring (8). fl When installing the floating seals, completely degrease the O-rings and O-ring contacting surfaces. fl Check that each floating seal is not inclined more than 1 mm.
2) Press fit shaft (3) to ring (8). 3) Install spacer (9). 4) Press fit ring (7) to shaft (3). 5) Install spacer (6). 6) Press fit ring (4) to shaft (3). 2 Apply lubricant (LM-P) to parts a (about 10 mm) of rings (8) and (4).
2. Apply lever block 3 between the guard of bogie assembly (1) and the bogie assembly on the opposite side. Slide bogie assembly (1) on the steel plate to set it to the mounting position.
D475A-3
30-179-4 6
DISASSEMBLY AND ASSEMBLY
BOGIE
3. Match the pin hole of the track frame to that of the bogie and set guide tool L17.
4. Press fitting of pin assembly 1) Set tool L16 and cover (2).
2) Press fit pin assembly (11). fl Direct arrow a on the end face of the pin assembly up (when the pin assembly is installed to the machine). fl Push in the pin assembly with cover (2). fl Push in the pin assembly to machined face b of the bogie. 2 Apply lubricant (LM-P) all over the side of the pin assembly. fl Total press fitting of force of pin assembly: 294.2 – 490.5 kN {30 – 50 tons}
5. Refilling with oil Supply the specified quantity of oil by using tool L19. fl Oil supplying pressure: 0.49 Mpa {5 kg/cm2} 5
Pin assembly: 180 – 200 cc (GO-140)
30-179-5 6
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
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 places on inside and outside). 3 Cover mounting bolt: 883 – 1,470 Nm {90 – 150 kgm}
8. Adjust the tension of the track shoe. For detail, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
D475A-3
30-179-6 6
DISASSEMBLY AND ASSEMBLY
BOGIE
DISASSEMBLY OF BOGIE ASSEMBLY Serial No.: 10601 – 10684 1. Track roller assembly Turn over bogie assembly (1), and lift off 2 track roller assemblies (2).
2. Installation of fixture Turn over bogie assembly, then use tools L13L17 to L13-19 to secure bogie assembly. fl Install the washer between the fixture and the bogie.
3. Collar 1) Remove pin (3). 2) Remove collar (4).
30-180 2 6
D475A-3
BOGIE
DISASSEMBLY AND ASSEMBLY
3)
Remove
floating
seal (5) from collar.
w 4.
Cage I) Using tool L14, remove
CED01951
cage (6) and spacer
(7). Ir Catch the oil in an oil container.
CWD03254
2)
Remove 2 floating of cage.
seals (8) from both sides
CED01953
5.
Pulling out pin assembly 1) Set bogie assembly to tool L13. * The pin assembly is removed from the cage installation side, so set the bogie assembly correctly in the direction for removal. * For details of the method of setting tool L13, see SETTING CHART FOR PIN ASSEMBLY REMOVAL TOOLS. 2) Pull out pin assembly (9) from bogie assembly (I). Ir Pin assembly removal pressure : 519.4 - 1,107.4 kN (53 - 113 ton1
D475A-3
I
CED01954
CED01955
30-181 0
DISASSEMBLY
3)
6.
AND ASSEMBLY
Lift off pin assembly
BOGIE
(9).
Disassembly of pin assembly
1) Remove spacer (IO) and ring (11) from pin assembly.
2) Remove 2 floating seals (12) from both sides
IO
of ring.
CEDOl958
3) 4)
Remove spacer (13) and ring (14) from pin assembly. Remove 2 floating seals ( 15) from both sides of ring. I3
L._..-J CED01960
5) 6)
Remove floating seal (16) and spacer (17) from pin assembly. Using hydraulic press @I and push tool @ and tool L15, pull out collar (19) from shaft
-
(18). * Collar removal pressure : 117.6 - 264.6 kN I12 - 27 ton)
-
30-182 0
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
7. Disconnection of bogie Remove tools L13-17 to L13-19, disconnect inner bogie (20) and outer bogie (21).
fl SETTING CHART FOR PIN ASSEMBLY REMOVAL TOOL L13
D475A-3
30-183 2 6
DISASSEMBLY AND ASSEMBLY
BOGIE
ASSEMBLY OF BOGIE ASSEMBLY Serial No.: 10601 – 10684 1. Securing bogie Assemble outer bogie (21) and inner bogie (20), and secure with tools L13-17 to L13-19. fl Install the washer between the fixture and the bogie. fl After securing the tools, check that the pin mounting holes of the inner bogie and outer bogie are correctly centered.
2. Assembly of pin assembly fl When assembling each floating seal, coat the mating surface of the seal thinly with oil (EO-30). 1) Using hydraulic press 1 and tool L13-16, press fit shaft (18) to collar (19). fl Before press fitting the shaft, center the shaft with the collar. fl Collar press-fitting pressure : 117.6 – 264.6 kN {12 – 27 ton} fl Check that stepped difference a between the end face of the shaft and collar is the dimension given below. • Stepped difference a : 1.5 ± 1.4 mm 2) Using L16, install floating seal (16) to collar (19). fl Remove all oil and grease from the Oring and O-ring contact surface, and dry before installing. fl After installing the floating seal, check that the angle of the seal is less than 1 mm. fl Check that the protrusion of the sliding surface of the floating seal from the collar is 5 – 7 mm. 3) Install spacer (17).
4) Using tool L16, install floating seal (15) to both ends of ring (14). fl Follow the precautions marked fl for Step 2). 5) Install ring (14) and spacer (13) to shaft.
30-184 2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
6)
7)
Using tool L16, install floating seals (12) to both sides of ring (11). * The precautions are the same as for the items marked * in Step 2). Install ring (II)
BOGIE
I2
Llti
IO
and spacer (IO) to shaft.
II B
8)
Using tool L16, install floating seals (8) to both sides of cage (6). * The precautions are the same as for the items marked Ir in Step 2).
9)
Install cage (6) and spacer (7) to shaft.
*
Misalignment X between the stamped arrow mark on the shaft and the bolt hole in the cage shall be 0 2 5”.
X
OO
0
I
0
0
_-
!
0 0 0
0
0
0
@ CWD03208
IO) Using tool L16, install floating seal (5) to collar (4). * The precautions are the same as for the items marked * in Step 2). 11) Install collar (4) to shaft.
D475A-3
30-185 0
DISASSEMBLY
AND ASSEMBLY
BOGIE
12) Install pin (3).
/3
CWDO
3.
Press fitting of pin assembly I) Raise pin assembly (9) and set to bogie assembly (1). * Set the shaft with the arrow marks facing directly up.
I
I 2)
CED01975
Using tool L13, press fit pin assembly (9) to bogie assembly (I). * For details of the method of setting tool L13, see SETTING CHART FOR PIN ASSEMBLY PRESS-FITTING TOOLS. 6 Outer circumference of pin assembly : Anti-friction compound (Three Bond 1809B or equivalent) * Pin assembly press-fitting force: 519.4 - 1,107.4 kN I53 -113 ton}
I *
*
*
30-186 0
I
CED01955
After press fitting the pin assembly partially, use guide bolt @to align the position of the cage bolt hole. Press fit until the cage flange is in tight contact. To protect the thrust bushing until the cage flange is in tight contact, press fit at a maximum force of 1,440 kN {I47 ton}. To protect the flange after the cage flange is in tight contact, push in with a maximum force of 1,735 kN {I77 ton}.
D475A-3
DISASSEMBLY
4.
5.
BOGIE
AND ASSEMBLY
Removal of fixture Remove tools L13-17 sembly.
- L13-19
from
Refilling with oil Using tool L20, add oil to specified tighten oil filler plug. Bogie assembly
Q *
bogie
as-
level and
: 350 - 390 cc (GO1401
To vacuum
To
oil
tank
PurnP
To settle the floating seal in position, fill with oil, then move the inner bogie and outer bogie up and down 5 times.
DAD03006
6.
Track roller assembly Raise 2 track roller assemblies (2) and install to bogie assembly (1). & Track roller mounting bolt : Adhesive (LT-21 w Track roller mounting bolt : 2,205 - 2,695 Nm I225 - 275 kgm1
D475A-3
30-187 0
DISASSEMBLY AND ASSEMBLY
*
BOGIE
SETTING CHART FOR PIN ASSEMBLY FITTING TOOL L13
Ll3;7
Ll3i2
Ll3-II Ll3,-‘2
LJ13-8
PRESS-
Ll/3-26
L/3-!
Ll\-4
Ll3i25
LI)-I5
Ll)-IO
L)3-6
r CWD03058
30488 0
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
DISASSEMBLY OF BOGIE ASSEMBLY Serial No.: 10685 and up 1. Track roller assembly Turn over bogie assembly (1) and lift off 2 track roller assemblies (2).
2. Remove cover (3).
3. Disassemble the pin assembly according to REMOVAL OF BOGIE ASSEMBLY (Step 8).
4. Disconnection of bogie Disconnect inner bogie (4) and outer bogie (5).
D475A-3
30-188-1 6
DISASSEMBLY AND ASSEMBLY
BOGIE
ASSEMBLY OF BOGIE ASSEMBLY Serial No.: 10685 and up 1. Assembly of pin assembly Assemble the pin assembly according to INSTALLATION OF BOGIE ASSEMBLY (Steps 3 – 6).
2. Set inner bogie (4) to outer bogie (5). 3. Press fitting of pin assembly 1) Set tool L16 and cover (3).
2) Press fit the pin assembly. fl Direct arrow a on the end face of the pin assembly up (when the pin assembly is installed to the machine). fl Push in the pin assembly with cover (2). fl Push in the pin assembly to the machined face b of the bogie and secure the level difference of 5 mm between the bogie and pin assembly. 2 Apply lubricant (LM-P) all over the side of the pin assembly. fl Total press fitting of force of pin assembly: 294.2 – 490.5 kN {30 – 50 tons} 4. Refilling with oil Supply the specified quantity of oil by using tool L19. fl Oil supplying pressure: 0.49 Mpa {5 kg/cm2} 5
Pin assembly: 180 – 200 cc (GO140)
30-188-2 6
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
5. Press fit the pin assembly on the opposite side of the bogie according to above steps 3 and 4. fl After press fitting the pin assembly, rock the small bogie so that it can be moved with light force. 6. Tighten the mounting bolts of pin assembly cover (3) (2 places on inside and outside). 3 Cover mounting bolt: 883 – 1,470 Nm {90 – 150 kgm}
7. Track roller assembly Sling and install 2 track roller assemblies (2) to bogie assembly (1). 2 Track roller mounting bolt: Adhesive (LT-2) 3 Track roller mounting bolt: 2,205 – 2,695 Nm {225 – 275 kgm}
D475A-3
30-188-3 6
DISASSEMBLY AND ASSEMBLY
BOGIE
REMOVAL OF NO. 1 BOGIE ASSEMBLY Serial No.: 10601 – 10684 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Operate blade and ripper, and raise chassis to a position where track roller of No. 2 bogie assembly is separated from track link. Set a block between the track roller and the track link to prevent the chassis from coming down. 3. Fit eyebolts to holes of pad mounting bolt (M10 x 2) portion at rear of No. 1 bogie assembly, and raise No. 1 bogie assembly (1). 4. Put steel plate between track shoe and roller, then loosen roller cap bolts (2) approx. 20 mm. (Both inside and outside) 5. Tap end face of shaft (3) with hammer and remove track roller assembly (4). • There is a dowel pin on the near side of the track roller assembly, so be careful not to break it. (Dowel pin insertion tolerance: 5 – 6 mm) 6. Remove roller cap bolt (2), then put track roller assembly (4) on steel plate, and pull out. 4 Track roller assembly : 220 kg 7. Raise No. 1 bogie (5) with tool L21 and hold in position. 8. Remove cover (6).
9. Pulling out pin and bushing 1) Set tool L22 in position.
D475A-3
30-189 2 6
DISASSEMBLY
2)
BOGIE
AND ASSEMBLY
Pull out pin (7).
1’ 3)
Set tool L23 in position.
4) 5)
Push out bushing (6). Remove O-ring (9) and ring (IO)-
I
Li2-4
CWD0321(
CWD03211
6)
Set tool L23 in position.
30-190 0
D475A-3
DISASSEMBLY
BOGIE
AND ASSEMBLY
7)
Pull out spacer
8)
(13). Repeat Steps 1) through 71, and pull out pins and bushings inside bogie.
(II)
and bushings
(12) and
3-7
II
/ 12
10. Lower bogie outside. f?lkg
D475A-3
(5) on steel plate,
Bogie assembly
/I I3
L23-8 CWD03212
and pull out to
: 200 kg
30-191 0
DISASSEMBLY AND ASSEMBLY
BOGIE
INSTALLATION OF NO. 1 BOGIE ASSEMBLY Serial No.: 10601 – 10684 1. Assembly of pin assembly 1) Using tool L24, press fit floating seal (14) to rings (8) and (12), and cage (13). fl Remove all oil and grease from the Oring and O-ring contact surface before assembling the floating seal. fl After installing the floating seal, check that the angle of the seal is less than 1 mm.
2) Press fit pin (7) to cage (13), and install ring (12). 3) Press fit ring (8) to pin (7). 2 Coat portion a (approx. 10 mm) of ring (8) and cage (13) with anti-friction compound (LM-P).
2. Put bogie (5) on steel plate 1, and slide it to center. 3. Using tool L21, set in mounting position.
fl Align the center of the pin hole of the bogie and the track frame, then insert guide tool L25.
30-192 2 6
D475A-3
DISASSEMBLY
4.
BOGIE
AND ASSEMBLY
Press fitting of pin assembly 1) Set tool L23 in position.
2)
Press fit pin assembly (15). * Set so that the arrow mark at the tip of the pin is at the top, then tap with a hammer to set in position. & Coat portion b (approx. 5 mm) on outside circumference of pin assembly with lubricant (LM-PI.
L#tl
5.
CWD03214
Remove plug, then using tool L20, fill with oil to specified level. Q
Pin assembly
: 240 - 255
CC
(EO-30)
CWD03215
6.
Repeat Steps 4 and 5 to press fit pin assembly on outside of bogie.
7.
Install cover (6). (Inside and outside:
8.
Fit eyebolts to holes of pad mounting bolt (Ml0 x 2) portion of bogie (5), then raise bogie and hold in position.
D475A-3
2 places)
30-193 0
DISASSEMBLY
9.
AND ASSEMBLY
BOGIE
Using tool l26, insert track roller assembly (4) to shaft, then raise, taking care to maintain balance, and set on top of track shoe. &I ks
Track roller assembly
: 220 kg
CWD02878
10. Lower machine slowly, and when clearance between bogie (5) and shaft (3) is approx. 20 mm, install cap (16) and tighten temporarily with bolts (2). 11. Align dowel pin hole and tighten & Cap mounting bolt :
bolt (2).
Thread tightener w
(LT-21
Cap mounting
bolt : 1,960 - 2,450 Nm I200 - 250 kgm1
12. Adjust track shoe tension. For details, see TESTING AND ADJUSTING, ing and adjusting track shoe tension.
30-194 0
Test-
D475A-3
DISASSEMBLY AND ASSEMBLY
BOGIE
REMOVAL OF NO. 1 BOGIE ASSEMBLY Serial No.: 10685 and up 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Operate blade and ripper, and raise chassis to a position where track roller of No. 2 bogie assembly is separated from track link. Set a block between the track roller and the track link to prevent the chassis from coming down. 3. Fit eyebolts to holes of pad mounting bolt (M12 x 2) portion at rear of No. 1 bogie assembly, and raise No. 1 bogie assembly (1). 4. Put steel plate between track shoe and roller, then loosen roller cap bolts (2) approx. 20 mm. (Both inside and outside) 5. Tap end face of shaft (3) with hammer and remove track roller assembly (4). • There is a dowel pin on the near side of the track roller assembly, so be careful not to break it. (Dowel pin insertion tolerance: 5 – 6 mm) 6. Remove roller cap bolt (2), then put track roller assembly (4) on steel plate, and pull out. 4 Track roller assembly : 240 kg 7. Raise No. 1 bogie (5) with tool L20 and hold in position. 8. Remove cover (6).
9. Pulling out shaft and ring 1) Set tool L14. 2) Push out shaft (7) and ring (8) to the opposite side simultaneously. fl Pushing out force: 225.5 – 460.9 kN {13 – 47 tons} fl When the ring is pushed out, it interferes with the idler. Accordingly, supply grease to the track tension adjustment parts in advance and move the idler cushion assembly to the front side of the machine body. D475A-3
30-194-1 6
DISASSEMBLY AND ASSEMBLY
BOGIE
3) Remove floating seals (9) from the end faces of rings (8) and (12). fl Store the floating seals so that they will not be damaged.
4) Set tool L15.
5) Pull out spacer (11) and rings (12) and (13). fl Pulling out force: 225.5 – 460.9 kN {23 – 47 tons} 6) Remove spacer (11). 7) Remove spacer (14) and floating seals (10) between rings (12) and (13). fl Store the floating seals so that they will not be damaged.
10. Lower bogie (5) on the steel plate and pull it out. 4 Bogie assembly : 180 kg
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BOGIE
INSTALLATION OF 1ST BOGIE ASSEMBLY Serial No.: 10685 and up 1. Assembly of pin assembly 1) Using tool L18, install floating seals (9) to rings (8) and (12) and install floating seals (10) to the opposite side of ring (12) and ring (13). fl When installing the floating seals, completely degrease the O-rings and O-ring contacting surfaces. fl Check that each floating seal is not inclined more than 1 mm.
2) Press fit shaft (7) to ring (13). 3) Install spacer (14). 4) Press fit ring (12) to shaft (7). 5) Install spacer (11). 6) Press fit ring (8) to shaft (7). 2 Apply lubricant (LM-P) to parts a (about 10 mm) of rings (13) and (8).
2. Slide bogie (5) on steel plate 1 to the center. 3. Set bogie (5) to the mounting position with tool L20.
4. Match the pin hole of the track frame to that of the bogie and insert guide tool L17.
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BOGIE
5. Press fitting of pin assembly 1) Set tool L16 and cover (6).
2) Press fit the pin assembly. fl Direct arrow a on the end face of the pin assembly up in the mounting state on the machine body. fl Push in the pin assembly with cover (6). fl Push in the pin assembly to machined face b of the bogie and secure the level difference of 5 mm between the bogie and pin assembly. 2 Apply lubricant (LM-P) all over the side of the pin assembly. fl Total press fitting of force of pin assembly: 294.2 – 490.5 kN {30 – 50 tons} 6. Refilling with oil Supply the specified quantity of oil by using tool L19. fl Oil supplying pressure: 0.49 Mpa {5 kg/cm2} 5
Pin assembly: 180 – 200 cc
7. Press fit the pin assembly on the opposite side of the bogie according to above steps 5 and 6. 8. Install covers (2) (2 places on inside and outside). 9. Install eyebolts instead of the pad mounting bolts (M12 x 2 pieces) of bogie (5) and lift and hold the bogie.
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BOGIE
10. Insert tool L21 in the shaft of track roller assembly (4), then lift and balance the track roller assembly and set it on the track shoe. 4 Track roller assembly: 220 kg
11. Lower the machine body slowly. When the clearance between bogie (5) and shaft (3) becomes about 20 mm, install cap (15) and secure it with bolts (2) temporarily. 12. Matching the dowel pin holes, tighten bolts (2). 2 Cap mounting bolt: Adhesive (LT-2) 3 Cap mounting bolt: 2,205 – 2,695 Nm {225 – 275 kgm} 13. Adjust the tension of the track shoe. For detail, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
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DISASSEMBLY AND ASSEMBLY
TRACK SHOE
REMOVAL OF TRACK SHOE ASSEMBLY Serial No.: 10601 – 10684 CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY In some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly. Never loosen the lubricator more than one turn. •
Loosen lubricator (1) at the adjustment cylinder, release the grease, then move the machine backwards and forwards a short distance, and check that the track tension is relieved. fl If the shoe tension is relieved, go to REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL). • If the above procedure does not relieve the track tension and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring case is broken, the recoil spring set bolt is broken, or the nut at the end of shaft has fallen off). fl If the shoe tension is not relieved, go to REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).
REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL) fl If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnormality, do as follows. 1. Set master link in position. fl Set a block (height: approx. 400 mm) so that the master link is approx. 600 mm from the ground at the front. 2. Relieve track shoe tension. 1 Never loosen lubricator (1) more than one turn. fl If the track is not relieved by loosening the lubricator, move the machine backwards and forwards. 3. Remove track shoe (2). 2
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DISASSEMBLY AND ASSEMBLY
4.
Remove
5.
Raise tip of master link, move machine towards rear slowly, and lay out track shoe assembly (4). * Length of track : Approx. 12.5 m To prevent danger, never stand in front of the idler yoke assembly.
a
connection
portion
of master
link (3).
REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) * When CHECKING BEFORE REMOVAL OF TRACK
A
1.
2.
SHOE ASSEMBLY shows any abnormality, do as follows. If there is any abnormality inside the track frame, there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so remove the track shoe assembly as follows. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. Loosen lubricator (11, then move machine backwards and forwards to remove grease. g Never loosen lubricator (I) more than one turn. Ir Check that all the grease has been removed.
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3. Drive slowly forward to put track shoe at idler end in contact with large block 1 or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and slack is formed in track shoe assembly, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link. 4. Remove shoe (4), then disconnect master link (5). 5. Move machine towards rear slowly and lay out track shoe assembly. To prevent danger, never stand in front of the idler yoke assembly.
INSTALLATION OF TRACK SHOE ASSEMBLY Serial No.: 10601 – 10684 • Carry out installation in the reverse order to removal. 1 fl For details of the track shoe tension, see TESTING AND ADJUSTING, Testing and adjusting of track shoe tension. 2 fl Tighten the master link shoe mounting bolts in the order shown in the diagram on the right. 2 Shoe mounting bolt : Seizure prevention compound (Maruzen Molymax No. 2 or equivalent) 3 Shoe mounting bolt : 1st step : 784 ± 78.4 Nm {80 ± 8 kgm} 2nd step: Tighten a further 180 ± 10°
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TRACK SHOE
REMOVAL OF TRACK SHOE ASSEMBLY Serial No.: 10685 and up CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY In some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly. Never loosen the lubricator more than one turn. •
Loosen lubricator (1) at the adjustment cylinder, release the grease, then move the machine backwards and forwards a short distance, and check that the track tension is relieved. fl If the shoe tension is relieved, go to REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL). • If the above procedure does not relieve the track tension and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring case is broken, the recoil spring set bolt is broken, or the nut at the end of shaft has fallen off). fl If the shoe tension is not relieved, go to REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).
REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL) fl If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnormality, do as follows. 1. Set master link in position. fl Bring the master link above the idler (just behind the center). fl Set blocks 1 and 2 at the front end of the idler and between the carrier rollers so that the mating faces of the master link will not open until the master bolt is removed.
2. Relieve track shoe tension. 1 Never loosen lubricator (1) more than one turn. fl If the track is not relieved by loosening the lubricator, move the machine backwards and forwards.
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TRACK SHOE
3. Remove track shoe (2). 2 fl Loosen each of the 4 bolts by 1 – 2 turns. Check that the 4 bolts can be turned lightly, then pull them out. Do not pull out only 1 bolt without loosening the other three. fl If a bolt is turned forcibly while it cannot be turned lightly, the threads of it and master link (3) may be damaged.
4. Raise tip of master link, move machine towards rear slowly, and lay out track shoe assembly (4). fl Length of track : Approx. 12.5 m To prevent danger, never stand in front of the idler yoke assembly.
REMOVAL OF TRACK SHOE ASSEMBLY (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) fl When CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows any abnormality, do as follows. If there is any abnormality inside the track frame, there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so remove the track shoe assembly as follows. 1. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2. Loosen lubricator (1), then move machine backwards and forwards to remove grease. Never loosen lubricator (1) more than one turn. fl Check that all the grease has been removed.
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TRACK SHOE
3. Drive slowly forward to put track shoe at idler end in contact with large block 3 or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and slack is formed in track shoe assembly, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link. 4. Remove shoe (2), then disconnect master link (3). 5. Move machine towards rear slowly and lay out track shoe assembly. To prevent danger, never stand in front of the idler yoke assembly.
INSTALLATION OF TRACK SHOE ASSEMBLY Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 fl For details of the track shoe tension, see TESTING AND ADJUSTING, Testing and adjusting of track shoe tension. fl Tighten all of the 4 bolts with the fingers until the master link contacting faces are fitted to each other. fl If a bolt is tightened forcibly before the master link contacting faces are fitted to each other, the threads of that bolt and the master link may be damaged. 2 fl Tighten the master link shoe mounting bolts in the order shown in the diagram on the right. 2 Shoe mounting bolt : Seizure prevention compound (Maruzen Molymax No. 2 or equivalent) 3 Shoe mounting bolt : 1st step : 980 ± 98 Nm {100 ± 10 kgm} 2nd step: Tighten a further 180 ± 10°
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TRACK SHOE
OVERALL DISASSEMBLY OF TRACK SHOE Serial No.: 10685 and up fl When disassembling the track shoe, see shop manual – GUIDANCE FOR REUSABLE PARTS – LUBRICATED TRACKS (III) (Form No.: SEBG4092).
1. Removal of shoe Sling the shoe assembly and set it on a floor with the shoe up. Remove the shoe with a shoe bolt impact wrench. fl If a shoe bolt is still hard (If its torque is not lowered to 0) after it is unscrewed by 1 turn, loosen the other bolts, and it can be removed easily. fl If a bolt is unscrewed forcibly while its torque is not 0, it will stick to the link and will need to be repaired. fl When moving the shoe assembly, take care not to damage the master link. fl If it is obliged to cut a shoe nut with gas, keep the temperature of the sealing parts below 80°C and prevent the spatters from entering the clearance of the link so that the sealing parts will not be deteriorated by the heat.
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2. Disassembly of link 1) Set the link assembly on the link press and hit it with a hammer so that the bushing will be fitted to the jaw. fl If the link tread, outside of the bushing, etc. are worn, adjust the height of the jaw or guide plate to align the disassembly jig with the pin and bushing so that the link hole will not be damaged during disassembly. fl If the above parts are not aligned perfectly, the link hole may be damaged and the pin and bushing may be broken during disassembly. fl Drive the small plug of the pin inward with tool R1 after disassembly to avoid making the workshop dirty.
2) Operate the left cylinder to pull out the fitted parts of the left link, pin, and bushing simultaneously. fl Check the pulling out force of the pin and bushing to see if the necessary fitting force of the pin and bushing is obtained when they are turned over and assembled. fl When the wedge link is cut, it bangs. This phenomenon is normal.
3) Return the left cylinder and operate the right cylinder to pull out the right link, pin, and bushing simultaneously.
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TRACK SHOE
4) Return the right cylinder and take out the links, pins, bushings, and spacers on both sides, then send the next link assembly to the jaw. fl If the end faces of the bushings and sealing surfaces are damaged, oil will leak. Accordingly, handle them with care. fl Take care not to scratch your hands with the sharp edges of a cut wedge link. 3. Inspection Inspect the following items to see if the parts can be reused for an oil lubricated track or a grease lubricated track, then generally examine whether the link assembly should be recycled as an oil lubricated track or as an grease lubricated track. fl For judgment of recycling of the parts, see shop manual – GUIDANCE FOR REUSABLE PARTS – LUBRICATED TRACKS (III) (Form No.: SEBG4092).
1) Check the parts visually for damage, then apply a dye penetrant test or a magnetic flaw test to the parts which seem to be damaged. Discard a cracked part since it cannot be reused. 2) Measure the outside diameters of the fitting parts of the pin and bushing and those of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the allowable interference is obtained. When reusing the parts for an oil lubricated track, the pin and link must have the standard interference. fl If the allowable interference is not obtained, replace the parts with new ones. fl For the criteria, see “Maintenance standard”.
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TRACK SHOE
fl Precautions for storage 1) Store the seal without removing it from the link to prevent rusting of the counterbore of the link, taking care not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing fitting parts and shoe and master link mating faces of the link. 3) Apply rust-preventive oil all over the pin, bushing, and spacer. In particular, take care not to damage the end faces of the bushing.
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TRACK SHOE
OVERALL ASSEMBLY OF TRACK SHOE Serial No.: 10685 and up fl When assembling the track shoe, see shop manual – GUIDANCE FOR REUSABLE PARTS – LUBRICATED TRACKS (III) (Form No.: SEBG4092).
1. When recycling for oil lubricated track 1. Preparation work 1) Cleaning of seal assembly Take the seal assembly out of the link and divide it into the seal ring and load ring, then clean them. fl Since the seal ring and load ring are deteriorated easily by cleaning liquid (trichloroethylene, etc.), clean them quickly. After cleaning them, wipe off the cleaning liquid.
2) When reusing the pin, chamfer the corners of its end smoothly with a grinder. Remove the projections of the fitting parts with the grinder. fl If the corners of the pin end are worn and sharpened, they may scuff the fitting parts to cause oil leakage.
3) Clean the link, pin, bushing, and spacer, if they are dirty. Remove the projections of the link and bushing with the grinder. fl Since the parts are rusted easily, clean them just before assembling them. fl Do not repair the end faces of the bushing with a grinder, etc. since that can cause oil leakage.
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TRACK SHOE
4) If the large plug has been driven out, drive it with tool R3. Clean the pin hole with tool R2 in advance.
i)
Insert the plug in the hole of the guide through the plug inserting hole. ii) Push the bar with the hand and insert the plug until it stops. iii) Push the plug with the bar to press the guide against the pin. iv) Drive the bar with a hammer. fl Driving distance a from pin end: 10 ± 1 mm fl If the edge of the pin hole is worn and sharpened, chamfer it with a small grinder (wheel tip angle: 45 – 60°) so that the plug will not be damaged. fl Coat the plug with G090 and drive it with the smaller end ahead.
5) Installation of seal assembly Clean the counterbore of the link carefully and push in the seal to the bottom with tool R6. fl If any oil sticks to the counterbore of the link and seal assembly, the seal turns and its sealing performance is lowered. Accordingly, do not apply any oil. Take care that oil will not stick to the seal when the seal is inserted in the counterbore.
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DISASSEMBLY AND ASSEMBLY
TRACK SHOE
6) Adjust the dimensions of the fitting jig of the link press to keep the projection distance of the pin and bushing constant and keep the fitting dimensions of the seal within the limits when those parts are assembled. fl For the standard dimensions, see “Pressfitting jig dimension table for link press” fl If the pin end (Part P) and link sides (Parts Q and R) are worn, count in the quantity of the wear when adjusting the dimensions of the fitting jig so that the pin and bushing will be projected by the same distance on both sides. 7) Adjust the relief pressure of the link press so that the pressing force will not exceed the specified value. fl If the pressing force is too large, the spacer is pressed against the bushing with an excessive force. As a result, the spacer may be broken or it and bushing end may be worn abnormally. fl Press cutting force of pin and bushing: 1,274 kN {130 tons} Press cutting force ≈ 1.8 x Average press fitting force (Set the press cutting force by adjusting the relief pressure of the link press.)
2. Assembly of link 1) Apply oil (G090) between the pin and bushing with a clean brush, then set them on this side of the link press jaw. fl When reusing (turning) the bushing, set its worn side to the shoe fitting face of the link (which is directed up on the link press).
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DISASSEMBLY AND ASSEMBLY
TRACK SHOE
2) Press fit both bushing-side master links to the bushings with the shoe fitting faces up. fl At this time, use the pin-side master links as supports. fl Fitting force of bushing: 245 – 382 kN {25 – 39 tons}
3) Measure the distance between the shoe bolt holes of both links with a shoe bolt hole pitch gauge. Press fit the master link until the specified shoe bolt hole pitch is obtained. fl Remove the all chips made when the bushing is press fitted by blowing air against them.
4) Turn over the master links and check that they are press fitted in parallel.
5) Measure the projections of the bushing on both sides with a depth gauge. fl Adjust the fitting jig of the link press so that the bushing will be projected by the same distance on both sides.
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TRACK SHOE
6) Send out the master link and set the next pin and bushing. fl When reusing the pin, install it with its side hole on the link tread side similarly to a new one. If it is not installed in this direction, its strength may lower. Accordingly, make a mark of the side hole on the end face of the pin.
7) Apply gasket sealant (198-32-19890) to the pin fitting hole of the link to prevent oil from oozing through the scuffs of the pin fitting parts.
8) Set the right link and install the spacer to the pin. fl Check that the sealing surface and bush ends are free from dirt and apply oil (G090) to them with a clean cloth or brush. fl Clean the spacer with a clean cloth before installing it.
9) Set the right jig on the receiving side and the left jig on the pushing side and press fit the pin and bushing simultaneously. fl If the jigs shake while the pin and bushing are press fitted, the seal may come off the link. Accordingly, press fit smoothly. If the seal comes off the link, stop press fitting and install the seal to the link correctly, then start press fitting again. fl Press fitting force of pin and bushing: 578 – 833 kN {59 – 85 tons}
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DISASSEMBLY AND ASSEMBLY
TRACK SHOE
10) Using the spacer for fine adjustment, press fit the pin until it is fitted to the lower part of the pin end receiving jig. fl Adjust the depth of the receiving jig so that the pin will be projected by the same distance on both sides.
11) Set the left link and install the spacer to the pin. fl Apply oil similarly to the right link.
12) Set the left jig on the receiving side and the right jig on the pushing side and press fit the left link. fl When press fitting, take care that the seals and spacers on both sides will not come off. Press fitting force of link: 578 – 833 kN {59 – 85 tons}
13) Press fit until the link, spacer, and bushing are fitted to each other. fl Actually, you cannot see from outside if the above parts are fitted. Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the hydraulic pressure to that level. For setting of the relief pressure, see PREPARATION WORK. fl Check that adjacent 2 links can turn around each other.
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TRACK SHOE
14) Measure the distance between the shoe bolt holes with a shoe bolt hole pitch gauge and check that the result is within the limits. fl If the distance between the shoe bolt holes is longer than the limit, disassemble and check for abnormality, then press fit again. fl If the distance between the shoe bolt holes is shorter than the limit and the shoe cannot be installed, the spacer or bushing end may be worn more than the allowable limit. In this case, disassemble and replace the parts. 15) Install the ring to jig R12.
16) Match the jig to the pin hole and push it in until the ring is inserted in the pin hole. fl A sound is made when the ring is inserted in the pin hole.
17) Similarly, insert the ring in the pin groove on the opposite side with jig R9.
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18) Push in the ring with jig R13. Pushing force of ring: 392 – 490 kN {40 – 50 tons}
19) After each link is assembled, bleed air from the pin with tool R5 and check the sealing performance. fl Keep the degree of vacuum inside the pin at 91 – 95 kPa {680 – 710 mmHg} for 5 seconds and check that the pressure does not change. If the pressure changes, disassemble and check the seal. If the seal is free from abnormality, assemble again.
20) Supply oil (G090) with tool R5 until the oil supply pressure rises to 196 – 294 kPa {2 – 3 kg/cm2}. fl In a cold or very cold district, supply Komatsu genuine oil (150-09-19270 or 195-32-61990) having better low-temperature characteristics instead of G090. fl If the oil pressure is heightened too much, it has bad effects on the seal. Take care. fl Supply oil so that the depth L of the hollow of the pin hole will be in the following range when the link is left with the small plug side up (when the link assembly is placed on its side) for 30 minutes. Dimension L: 40 – 70 mm
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21) After supplying oil, drive in the small plug to the specified position with tool R4. fl Apply G090 around the small plug. fl Drive in the plug to the following depth. Driving depth from end: 7.5 ± 1 mm 22) Assemble the master link on the pin side at last. fl Check that the master links on both sides are press fitted in parallel.
3. Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. 3 Shoe bolt (Regular link) Initial torque: 784 ± 78 Nm {80 ± 8 kgm} Retightening angle: 180 ± 10° 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P)
2) When installing a double track, place the assembled double shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) on the links and check that shoe bolt (4) can be tightened easily until the mating faces of the links are fitted together, then connect the links with the master bolts. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 ± 98 Nm {100 ± 10 kgm} Retightening angle: 180 ± 10° fl Tighten the bolts in the order of 1 – 4.
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2. When recycling for grease lubricated track 1. Preparation work 1) Cleaning of seal assembly Take the seal assembly out of the link and divide it into the seal ring and load ring, then clean them. fl Since the seal ring and load ring are deteriorated easily by cleaning liquid, clean them quickly. After cleaning them, wipe off the cleaning liquid.
2) When reusing the pin, chamfer the corners of its end carefully with a grinder so that it will be press fitted smoothly.
3) Drive the large plug and small plug with tools R3 and R4. i) Insert each plug in the hole of the guide through the plug inserting hole. (Apply oil to the plug.) ii) Push the bar with the hand and insert the plug until it stops. iii) Push the plug with the bar to press the guide against the pin. iv) Drive the bar with a hammer. fl Driving distance a from pin end: Small plug: 7.5 ± 1 mm Large plug: 10 ± 1 mm fl If the plugs were not pull out of the pin when disassembled, use them as they are. 4) Clean the outside of the pin, surfaces of the spacer, and end faces and inside of the bushing, if they are dirty. 5) Apply grease to the outside of the pin and surfaces of the spacer.
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TRACK SHOE
6) Installation of seal assembly Clean the counterbore of the link carefully and push in the seal to the bottom with tool R6. fl If any grease sticks to the counterbore of the link and seal assembly, the seal turns and its sealing performance is lowered. Accordingly, do not apply any grease.
7) Adjust the dimensions of the fitting jig of the link press to keep the projection distance of the pin and bushing constant and keep the fitting dimensions of the seal within the limits when those parts are assembled. fl For the standard dimensions, see “Pressfitting jig dimension table for link press” fl If the pin end (Part P) and link sides (Parts Q and R) are worn, count in the quantity of the wear when adjusting the dimensions of the fitting jig so that the pin and bushing will be projected by the same distance on both sides.
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TRACK SHOE
2. Assembly of link 1) Apply lithium grease (G2-LI) between the pin and bushing, then set them on this side of the link press jaw. fl When reusing (turning) the bushing, set its worn side to the shoe fitting face of the link (which is directed up on the link press). 2) Press fit both bushing-side master links to the bushings with the shoe fitting faces up. fl At this time, use the pin-side master links as supports. fl Fitting force of bushing: 245 – 382 kN {25 – 39 tons}
3) Measure the distance between the shoe bolt holes of both links with a shoe bolt hole pitch gauge. Press fit the master link until the specified shoe bolt hole pitch is obtained. fl Remove the all chips made when the bushing is press fitted by blowing air against them. 4) Turn over the master links and check that they are press fitted in parallel.
5) Measure the projections of the bushing on both sides with a depth gauge. fl Adjust the fitting jig of the link press so that the bushing will be projected by the same distance on both sides.
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TRACK SHOE
6) Send out the master link and set the next pin and bushing. fl When reusing the pin, install it with its side hole on the link tread side similarly to a new one. If it is not installed in this direction, its strength may lower. Accordingly, make a mark of the side hole on the end face of the pin. fl If the outside of the pin is worn, set it with the un-worn part on the traction side. In this case, install it with its side hole on the link tread side, too. 7) Set both links and operate both pushing jigs to press fit the pin and bushing simultaneously. fl If the jigs shake while the pin and bushing are press fitted, the seal may come off the link. Accordingly, press fit smoothly. If the seal comes off the link, stop press fitting and install the seal to the link correctly, then start press fitting again. fl Press cutting force of pin and bushing: 1,274 kN {130 tons} Press cutting force ≈ 1.8 x Average press fitting force (Set the press cutting force by adjusting the relief pressure of the link press.) 8) Measure the distance between the shoe bolt holes with a shoe bolt hole pitch gauge. If the result is within the limits, stop press fitting.
9) Install the ring to jig R12.
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10) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove. Similarly, insert the ring on the opposite side with jig R9. fl A sound is made when the ring is inserted in the pin.
11) Push in the ring with jig R13. Pushing force of ring: 392 – 490 kN {40 – 50 tons}
12) Assemble the master link on the pin side at last. fl Check that the master links on both sides are press fitted in parallel.
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TRACK SHOE
3. Shoe (Regular link) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Regular link) Initial torque: 784 ± 78 Nm {80 ± 8 kgm} Retightening angle: 180 ± 10°
4. Assembly of 1/2 track Place the assembled 2 shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) on the links and check that shoe bolt (4) can be tightened easily until the mating faces of the links are fitted together, then connect the links with the master bolts. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 ± 98 Nm {100 ± 10 kgm} Retightening angle: 180 ± 10° fl Tighten the bolts in the order of 1 – 4.
D475A-3
30-197-22 6
DISASSEMBLY AND ASSEMBLY
LINK PRESS
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS Serial No.: 10685 and up
Jig dimension (mm) a
4.6
b
2.0
c
59.1
30-197-23 6
D475A-3
DISASSEMBLY AND ASSEMBLY
ONE LINK
FIELD DISASSEMBLY OF ONE LINK Serial No.: 10685 and up 1. Install tools R8-4, R8-1, and R8-5 to link (1) with 2 bolts (2). fl Use 2 track bolts as 2 bolts (2).
2. Install tool R8-12 to tool R8-4. fl Check that the hole of R8-12 is aligned. If it is not aligned, retighten R8-5 and adjust the position of R8-12. Install tool R8-10 to tool R8-8. Install a rope to R8-10, then sling and install R8-10 to R8-12. Install tools R8-2 and R8-3 to tool R8-1. fl Hitch and install R8-2 to the rib of R8-8 so that R8-8 will not lean.
3. Install tools R8-6, R8-10, R8-7, and R8-11 to tool R8-28. Install ropes to the eyebolt of R8-28 and R8-10, then sling them so that R8-7 will be horizontal. 4. Insert R8-7 in the hole of R8-8 installed to the track, then clamp it with R8-9.
D475A-3
30-197-24 6
DISASSEMBLY AND ASSEMBLY
ONE LINK
5. Pulling out of pin 1) Set tools R8-13, R8-14, and R8-15 to R8-11, then apply hydraulic pressure to push pin (3). 2) After the cylinder reaches the stroke end, connect tools R8-16 and R8-14 and repeat the work. 3) Repeat step 5.2). 4) After the cylinder reaches the stroke end again, remove tools R8-13 and R8-14 and add R8-25 and R8-14 to pull out pin (3).
6. Set tools R8-30 and R8-31 to the roller tread side of the link to be disassembled, then connect tool R8-29 and apply hydraulic pressure to open the link by 5 – 6 mm and disconnect the link.
7. Repeat steps 1 – 5 to remove pin (4) on the opposite side.
30-197-25 6
D475A-3
DISASSEMBLY AND ASSEMBLY
ONE LINK
8. Repeat step 6 to remove link (5).
D475A-3
30-197-26 6
DISASSEMBLY AND ASSEMBLY
ONE LINK
FIELD ASSEMBLY OF ONE LINK Serial No.: 10685 and up 1. Assemble the link sub-assembly according to the following procedure. 1) Set tool R8-17 to the bushing-side end of link (6) and press fit bushing (7). fl Press fitting force of bushing: 245 – 382 kN {25 – 39 tons} 2) Set tool R8-18 to the pin-side end of the link and press fit pin (8). fl Set the pin with its side hole on the link tread side. fl Press fitting force of pin: 333 – 451 kN {34 – 46 tons}
2. Set link sub-assembly (9) to the link to be connected.
3. Set link (10) on the opposite side and support it with tool R8-19.
30-197-27 6
D475A-3
DISASSEMBLY AND ASSEMBLY
ONE LINK
4. Similarly to the disassembly procedure, set tools R8-29, R8-6 – R8-11, and R8-24 to the link. 5. Use R8-18 and R8-23 to press fit the pin. Use tools R8-21, R8-17, R8-20, and R8-14 to press fit the bushing. Press fit the pin and bushing alternately. fl Press fit the pin first. After the bushing is engaged with the link, remove tool R8-19 installed in step 3, then press fit the bushing. fl Press fitting force of pin: 333 – 451 kN {34 – 46 tons} fl Press fitting force of bushing: 245 – 382 kN {25 – 39 tons} 6. Similarly to the disassembly procedure, push open link (11) to be connected by using tools R8-30 and R8-31.
7. Set link (12) to be connected to link (11) and connect them with tool R8-22, then remove tools R8-30 and R8-31.
D475A-3
30-197-28 6
DISASSEMBLY AND ASSEMBLY
ONE LINK
8. Press fitting of pin 1) Set tools R8-28, R8-6 – R8-12, R8-26, R8-27, R8-14, and R8-22 and apply hydraulic pressure to press fit pin (13). 2) After the cylinder reaches the stroke end, remove tools R8-26, R8-27, and R8-14 and repeat the work with tools R8-16, R8-14, R825, and R8-14. 3) After the cylinder reaches the stroke end again, remove tools R8-12, R8-16, R8-25, R814, and R8-22 and press fit the pin with tools R8-18, R8-23, and R8-24. 2 Pin fitting hole of link: Gasket sealant (198-32-19890) fl Set the pin with its side hole on the link tread side. fl Press fitting force of pin: 666 – 902 kN {68 – 92 tons}
8. Install the ring with tools R7, R9, R11, R12, and R13. fl For the method of using the tools, see OVERALL ASSEMBLY OF TRACK SHOE.
30-197-29 6
D475A-3
DISASSEMBLY AND ASSEMBLY
MASTER LINK
DISASSEMBLY OF MASTER LINK Serial No.: 10685 and up fl For the method of using tool R8, see FIELD DISASSEMBLY OF ONE LINK. 1. Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see EXPANDING TRACK SHOE ASSEMBLY. 2. Disassembly of shoe Disconnect the all master links and divide the shoes into 4 parts. 3. Removal of master link • Master pin type 1) Cutting of regular link with gas Cut the parts marked with gas and remove the parts marked . • Necessary special tool: Gus cutting machine
2) Removal of regular link Push pin (1) in the direction of h with a press to remove it from link (2), then pull pin (1) and link (3) together out of bushing (4).
• Master link type 1) Cutting and removal of master link on bushing side with gas Cut the parts marked with gas and remove the parts marked . Move master links (5) and (6) in the direction of h and g to pull them out. Then, push pins (8) and (9) out of regular link (7) in the directions of h and g with a press. • Necessary special tools: 1. Gus cutting machine 2. Tool R8
D475A-3
30-197-30 6
DISASSEMBLY AND ASSEMBLY
MASTER LINK
2) Removal of master link on pin side Cut the parts marked with gas and remove the parts marked . Push pin (10) out of link (11) in the direction of h with a press. Then, pull pin (10) and link (12) together out of bushing (13). • Necessary special tools: 1. Gus cutting machine 2. Tool R8
30-197-31 6
D475A-3
DISASSEMBLY AND ASSEMBLY
MASTER LINK
ASSEMBLY OF MASTER LINK Serial No.: 10685 and up fl For the method of using tool R8, see FIELD DISASSEMBLY OF ONE LINK. 1. Assembly of bushing-side link 1) Press fit bushing-side master link (1) to bushing (2) with a press. fl When press fitting both master links, take care that they will be in parallel with each other. fl Do not damage the mating surfaces of the master links and end faces of the bushing. Unit: mm L1
226 ± 0.7
L2
276 ± 0.7
D1
36 drill hole
D2
33 x 2.0
2. Installation of bushing-side link 1) Expand the center of the link tread with tool R8 as shown in the figure. (Expand the link end by 10 mm.)
2) Set spacer (3) and seal assembly (4) to the counterbore of the link of the connecting part.
D475A-3
30-197-32 6
DISASSEMBLY AND ASSEMBLY
MASTER LINK
3) Match the pin hole and bushing hole to each other and connect the pin and bushing with guide pin 1.
4) Press fit pin (5) with tool R8 and install bushing-side master link (1). 2 Apply gasket sealant (198-32-19890) to the pin hole of the link. fl Set the pin with its side hole on the link tread side.
5) Install ring (6) with tools R8, R9, R11, R12, and R13. 6) Install the shoe to the link of the connecting part.
7) Drive large plug (7) with tool R3 and supply oil with tool R5, then drive small plug (8) with tool R4. fl When press fitting both master links, take care that they will be in parallel with each other (Bushing side and pin side). fl Do not damage the mating surfaces of the master links and end faces of the bushing. fl Take care that dirt and sand will not stick to the seal, spacer, end of bushing, and tap-hole mating face of the master link.
30-197-33 6
D475A-3
DISASSEMBLY AND ASSEMBLY
MASTER LINK
3. Assembly of link on pin side 1) Set spacer (3) and seal assembly (4) to the counterbore of the master link.
2) Pass pin (10) through bushing (9) and set and press fit pin-side master links (11) from both sides with tool R8. 3) Install the ring with tools R8, R9, R11, R12, and R13. 4) Drive large plug (13) with tool R3 and supply oil with tool R5, then drive small plug (14) with tool R4.
4. Connection of master links Place the assembled 2 shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (15) and bushing-side master link (16) together and set them to each other by the mating faces. Place the shoe on the links and check that the shoe bolt can be tightened easily until the mating faces of the links are fitted together, then connect the links with the master bolts. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 ± 98 Nm {100 ± 10 kgm} Retightening angle: 180 ± 10°
D475A-3
30-197-34 6
DISASSEMBLY
PIVOT SHAFT
AND ASSEMBLY
REMOVAL OF PIVOT SHAFT ASSEMBLY 1. Remove track frame assembly. For details, see REMOVAL OF TRACK ASSEMBLY. 2.
Sling pivot shaft assembly (I) and remove mounting bolts, then using forcing screw 0, m pull out pivot shaft assembly. & kg
3.
FRAME
Remove
Pivot shaft assembly
: 390 kg -
seal (21, then remove
cover (3).
CED02111
m
INSTALLATION OF PIVOT SHAFT ASSEMBLY l
Carry out removal.
&
m
installation
in the
reverse
order
to
Pivot shaft press-fitting surface : Anti-friction compound (LM-P)
a CED02192
* * .
Using tool P, press fit seal (2) to the pivot shaft. 6 Seal press-fitting surface : Gasket sealant (LG-6) Check that press-fitting dimension a of the seal from the end face of the shaft is the specified dimension. Press-fitting dimension a : 665 t 1.0 mm
30- 198 0
D475A-3
DISASSEMBLY AND ASSEMBLY
EQUALIZER BAR
REMOVAL OF EQUALIZER BAR Serial No.: 10601 – 10684 1. Remove engine underguard and power train underguard (front). 4 Engine underguard : 330 kg 4 Power train underguard (front) : 340 kg 2. Remove cover (1). fl At the right track frame, disconnect 4 blade tilt cylinder hoses from the cover. fl The front of the machine is raised using the blade, so install a blind plug securely in the hose at the tilt cylinder end. 3. Remove seal (2) together with washer (3). 1 4. Remove washer (4), then remove spacer (5). fl Oil will flow out from the pivot case, so catch it in an oil container. 6 Pivot case : 26 ¬ 5. Set stand and hydraulic jack 1 (294 kN {30 ton}) under radiator guard.
6. Remove cover (6). 7. Remove cover (7).
8. Remove bushing (8). 9. Using eyebolt 2, remove side pin (9). 2 fl It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so use hydraulic jack 1 to adjust the height at the equalizer bar end before removing.
D475A-3
30-199 2 6
DISASSEMBLY AND ASSEMBLY
10. Remove cover (IO) together *
EQUALIZER BAR
with cushion
Repeat Steps 6 to IO to remove on the opposite side.
(II).
1131 the side pin
11. Operate hydraulic jack @ slowly and lower chassis to point where equalizer and right track frames.
bar contacts
left
CED01916
12. Disconnect 13. Remove
lubrication
tube (12).
lock plate (13).
I
CWD03220
14. Using tool Nl, *
remove center pin (14). 1151 It is difficult to remove the pin if the centers of the equalizer bar hole and main frame hole are not aligned, so use hydraulic jack @ to adjust the height at the main frame end before removing.
CWD03221
15. Operate
blade and raise front of chassis, set hydraulic jack under radiator guard.
and
16. Raise equalizer bar (151, move it past main frame and track frame, and remove. g After removing the equalizer lower the chassis. C?lkg
30-200 0
Equalizer
bar assembly
bar,
do not
: 600 kg
D475A-3
DISASSEMBLY AND ASSEMBLY
EQUALIZER BAR
INSTALLATION OF EQUALIZER BAR Serial No.: 10601 – 10684 • Carry out installation in the reverse order to removal. 1 fl After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). fl Be careful not to install with the seal displaced in the direction of twisting. 2 2 Inside surface of bushing : Grease (G2-LI) fl Before installing the pin, operate hydraulic jack 1 to adjust the height of the main frame and align the center of the equalizer bar hole and track frame hole. fl Set the pin with the grease hole facing the outside of the machine. 3 fl Fit pin (9) and bushing (8), install cover (7), then install the cover and cushion. 4 2 Lock plate mounting bolt : Tread tightener (LT-2) 3 Lock plate mounting bolt : 1,519 – 1,911 Nm {155 – 195 kgm} 5 2 Equalizer bar bushing and main frame bushing: Grease (G2-LI) fl Before installing the pin, operate the crane to align the center of the main frame hole and the equalizer bar hole. •
Refilling with oil (pivot case) Add oil through oil filler to the specified level. 5
D475A-3
Pivot case : 26 ¬ (SAE30)
30-201 2 6
DISASSEMBLY AND ASSEMBLY
EQUALIZER BAR
REMOVAL OF EQUALIZER BAR Serial No.: 10685 and up 1. Remove engine underguard and power train underguard (front). 4 Engine underguard : 330 kg 4 Power train underguard (front) : 340 kg 2. Remove cover (1). fl At the right track frame, disconnect 4 blade tilt cylinder hoses from the cover. fl The front of the machine is raised using the blade, so install a blind plug securely in the hose at the tilt cylinder end. 3. Remove seal (2) together with washer (3). 1 4. Remove washer (4), then remove spacer (5). fl Oil will flow out from the pivot case, so catch it in an oil container. 6 Pivot case : 26 ¬ 5. Set stand and hydraulic jack 1 (294 kN {30 ton}) under radiator guard.
6. Remove cover (6). 7. Remove cover (7). 8. Remove main bolt (8) of side pin.
9. Using eyebolt 2, remove side pin (9). 3 fl It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so use hydraulic jack 1 to adjust the height at the equalizer bar end before removing. fl Repeat Steps 6 to 9 to remove the side pin on the opposite side.
30-201-1 6
D475A-3
DISASSEMBLY AND ASSEMBLY
EQUALIZER BAR
10. Operate hydraulic jack 1 slowly and lower chassis to point where equalizer bar contacts left and right track frames. 11. Disconnect lubrication tube (10). 12. Remove lock plate (11).
4
13. Using tool N1, remove center pin (12). 5 fl It is difficult to remove the pin if the centers of the equalizer bar hole and main frame hole are not aligned, so use hydraulic jack 1 to adjust the height at the main frame end before removing.
14. Operate blade and raise front of chassis, and set hydraulic jack under radiator guard. 15. Raise equalizer bar (13), move it past main frame and track frame, and remove. After removing the equalizer bar, do not lower the chassis. 4 Equalizer bar assembly : 600 kg
D475A-3
30-201-2 6
DISASSEMBLY AND ASSEMBLY
EQUALIZER BAR
INSTALLATION OF EQUALIZER BAR Serial No.: 10685 and up • Carry out installation in the reverse order to removal. 1 fl After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). fl Be careful not to install with the seal displaced in the direction of twisting. 2 3 Main mounting bolt of side pin: 2,450 – 2,695 Nm {250 – 275 kgm} fl After tightening main mounting bolts (8) of the side pin, tighten the mounting bolts of covers (6) and (7). fl Take care of the tightening order of min mounting bolts (8) of the side pin and the mounting bolts of covers (6) and (7). 3 2 Inside surface of bushing : Grease (G2-LI) fl Before installing the pin, operate hydraulic jack 1 to adjust the height of the main frame and align the center of the equalizer bar hole and track frame hole. fl Set the pin with the grease hole facing the outside of the machine. 4 2 Lock plate mounting bolt : Tread tightener (LT-2) 3 Lock plate mounting bolt : 1,519 – 1,911 Nm {155 – 195 kgm} 5 2 Equalizer bar bushing and main frame bushing: Grease (G2-LI) fl Before installing the pin, operate the crane to align the center of the main frame hole and the equalizer bar hole. •
Refilling with oil (pivot case) Add oil through oil filler to the specified level. 5
Pivot case : 26 ¬ (SAE30)
30-201-3 6
D475A-3
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY BAR BUSHING 1.
EQUALIZER
BAR BUSHING
OF EQUALIZER
Center bushing Remove center bushings
(I).
J CDD01922
2.
Side bushing 1) Remove seals (2). 2) Remove snap ring (3).
2
2
CDD01923
3)
Set tool N2 in position and remove bushing (4) from equalizer bar (5).
CDD01924
side
CED01925
30-202 0
D475A-3
DISASSEMBLY AND ASSEMBLY
EQUALIZER BAR BUSHING
ASSEMBLY OF EQUALIZER BAR BUSHING 1. Side bushing 1) Set side bushing (4) and tool N2 in position, then press fit side bushing (4) to equalizer bar (5). 2 Outer circumference of bushing : Anti-friction compound (LM-P) fl Align the direction of installation of the side bushing as shown in the diagram on the right. i) Make split surface (mating surface) a of outer bushing horizontal. ii) Set inner bushing and outer bushing grease hole b at an angle. fl Side bushing press-fitting force : 47 – 96 kN {4.8 – 9.8 ton}
2) Install snap ring (3). fl After installing the snap ring, fill front and rear portion c of side bushing with grease (G2-LI). 2 Amount of grease to fill side bushing: 0.45 ¬ 3) Using press, press fit seal (2). fl Seal press-fitting force : 9.8 – 29.4 kN {1 – 3 ton} fl Press fit so that the mouthpiece of the seal does not extend from the end face of the equalizer bar. 2 Lip of oil seal : Grease (G2-LI) 2. Center bushing Using press, press fit bushing (1). 2 Outer circumference of center bushing : Anti-friction compound (LM-P) fl Center bushing press-fitting force : 68.6 – 233.2 kN {7 – 23.8 ton}
D475A-3
30-203 2 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
REMOVAL OF HYDRAULIC PUMP ASSEMBLY a
g 1.
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (-1 terminal of the battery. Drain oil from hydraulic tank. -
2.
3. 4. 5. 6.
:
Hydraulic
tank : 340 e
Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. Disconnect hydraulic oil temperature sensor connector KN452)(1). Disconnect hoses (21, (31, (41, (51, (61, and (7). Disconnect suction tubes (8) and (9). m Sling hydraulic assembly (IO), then remove mounting bolts, and remove. & kg
Hydraulic
pump assembly
: 80 kg
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY l
Carry out installation removal.
w
w
l
in the
reverse
order
to
Coupling
clamp bolt of tube (8): 27.1 - 29.4 Nm I2.76 - 3.0 kgm} Coupling clamp bolt of tube (9): 14.7 - 18.6 Nm {I.5 - 1.9 kgm}
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-204 0
D475A-3
DISASSEMBLY
BLADE LIFT VALVE
AND ASSEMBLY
REMOVAL OF BLADE LIFT VALVE ASSEMBLY a
A
1.
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (-) terminal of the battery. Drain oil from hydraulic tank. -
2. 3. 4.
5. 6. 7. 6.
:
Hydraulic
tank : 340 e
Remove operator’s cab right cover. Disconnect connector (I 1. Disconnect 2 PPC hoses (2). Ir The PPC hoses are distinguished by color m bands. Disconnect 3 main hoses (3). Disconnect PPC relief valve (4) and move towards front of chassis. Disconnect hoses (5) and (6). Sling blade lift valve (71, then remove mounting bolts, and lift off. &I kg
Blade lift valve assembly
CWD03224
: 70 kg
INSTALLATION OF BLADE LIFT VALVE ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
Band DBD03015
w *
.
The connecting position of the PPC hoses is distinguished by the band color at the quick coupler portion, so check the colors when installing.
Transparent ram
Opel
.ator's cad)
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
.
Bleeding air Bleed the air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.
D475A-3
+
Red/White
DAD03016
30-205 0
DISASSEMBLY
AND ASSEMBLY
BLADE LIFT VALVE
DISASSEMBLY OF BLADE LIFT VALVE ASSEMBLY
ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY
1. Disassembly of main spool assembly I) Remove case (I), then remove bolt (2). * Loosen the bolt with the spool assembled inside the body. 2) Remove washer (31, retainer (41, spring (51, spacer (61, retainer (7) and spacer (8). 3) Remove case (91, then remove spring (IO), retainer (11) and spacer (12). 4) Remove case (13) and spacer (14), then remove spool (15). * If the result of disassembly shows that there is any abnormality in the spool or body, replace the whole assembly.
*
2.
Disassembly 1) Remove 2)
3.
4.
5.
6.
1.
2.
3.
of demand valve assembly case (161, then remove spring
(17). Remove case (181, then remove spool (19) and seal (20).
Disassembly of main relief, shuttle valve assembly Remove main relief and shuttle valve assembly (21). Ir If the adjustment screw of the main relief valve is turned, the set pressure will change, so do not disassemble unless necessary. Disassembly of suction valve assembly 1) Remove plug (221, then remove spring (23) and valve (24). 2) Remove plate (25), then remove seat (261, spring (27) and valve (28). Disassembly of check valve assembly Remove plug (291, then remove spring and valve (31).
(30)
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Assembly of shuttle valve assembly Assemble ball (33), then fit O-ring and install plug (32). m Plug : 34.3 + 4.9 Nm 13.5 = 0.5 kgm1 Assembly of check valve assembly Assemble valve (31) and spring (301, then fit O-ring and install plug (29). w Plug : 367.5 + 24.5 Nm I37.5 + 2.5 kgm1 Assembly of suction valve assembly 1) Assemble valve (28) and spring (271, then fit O-ring and seat (261, then fix by plate
2)
4.
*
(25). w Mounting bolt : 276.85 + 31.85 Nm 128.25 f 3.25 kgm} Assemble valve (24) and spring (231, then fit O-ring and install plug (22). m Plug : 514.5 + 24.5 Nm i52.5 f 2.5 kgm}
Assembly of main relief, shuttle valve assembly Fit O-ring and install main relief and shuttle valve assembly (211. * Tighten the mounting bolts in the order @ - 0. w Mounting bolt : 1st step 34.3 + 4.9 Nm 13.5 + 0.5 kgm1 2nd step 66.15 t. 7.35 Nm (6.75 f 0.75 kgml If the main relief valve was disassembled, carry out adjustments after installing the valve assembly to the chassis. For details, see TESTING AND ADJUSTING, Measuring and adjusting work equipment hydraulic pressure.
Disassembly of shuttle valve assembly Remove plug (321, then remove ball (33).
CDD02t56
30-206 0
D475A-3
DISASSEMBLY
BLADE LIFT VALVE
AND ASSEMBLY
a
CWDO3225
5.
Assembly of demand valve assembly 1) Assemble seal (20) and spool (19), then fit O-ring and install case (18). w Mounting bolt : 276.85 = 31.85 Nm (28.25 t: 3.25 kgm} 2) Assemble spring (17) and install case (16). w Mounting bolt : 276.85 f 31.85 Nm I28.25
6.
4) t. 3.25 kgml
Assembly of main spool assembly 1) Assemble spool (15) and spacer (141, then fit O-ring and install case (13). 2) Assemble spacer (12), retainer (II) and spring (IO), then fit O-ring and install case (9).
D475A-3
3)
Assemble spacer (8), retainer (71, spacer (6), spring (51, retainer (41, and washer (31, and install bolt (2). w Mounting bolt : 110.25 z 12.25 Nm 111.25 = 1.25 kgml * Tighten the bolt with the spool assembled inside the body. Fit O-ring and install case (I). * When tightening the bolts of cases (I), (91, and (131, tighten the bolts gradually in turn and be careful not to let any case become misaligned with the center of the spool.
30-207 0
DISASSEMBLY AND ASSEMBLY
BLADE TILT, RIPPER LO VALVE
REMOVAL OF BLADE TILT, RIPPER LO VALVE ASSEMBLY a
a 1.
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (-1 terminal of the battery. Drain oil from hydraulic tank. - :
2. 3. 4. 5. 6. 7.
8.
Hydraulic tank : 340 e
Remove operator’s cab right cover. Disconnect connector (1). Remove bracket (2). Disconnect hose (3) and clamp (4). Disconnect block (5) and move towards center of chassis. Disconnect 6 PPC hoses (61, 5 rear main hoses (71, and 3 front main hoses (8). * The PPC hoses are distinguished by color bands. a Sling blade tilt and ripper Lo valve assembly (91, then remove mounting bolts, and lift off. & kg
Blade tilt, ripper Lo valve assembly : 50 kg
ASSEMBLY OF BLADE TILT, RIPPER LO VALVE ASSEMBLY l
Carry out installation removal.
I Band
in the reverse order to
DBD03015
u *
The connecting position of the PPC hoses is distinguished by the band color at the quick coupler portion, so check the colors when installing.
.
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
.
Bleeding air Bleed the air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.
30-208 0
Distinguishing color bands
Blue/ Black Black White 4
4
t t t
Yellow
Green
(:~~~,o~~~a-
4
Brown
DXD03208
D475A-3
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY OF BLADE TILT, RIPPER LO VALVE ASSEMBLY 1.
Disassembly
of spool assembly
BLADE TILT, RIPPER LO VALVE
ASSEMBLY OF BLADE TILT, RIPPER LO VALVE ASSEMBLY *
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Assembly
1) Remove case-(l) and flange (2). 2) Remove case (3). 3)
4)
2.
Remove bolt (4), then remove washer (5), retainer (61, spring (71, spacers (81, and retainer (9). * When loosening the bolt, always loosen with the spool assembled inside the valve. Pull out spool (IO) from body (II). Ir If the result of disassembly shows that there is any abnormality in the spool or body, replace the whole assembly.
2.
2)
Disassembly
3.
Disassembly
of check valve assembly
of shuttle
valve assembly
Fit O-ring and assemble seat (15), then install bar (14) and tighten bolt (13). w Mounting bolt : 110.25 + 12.25 Nm ill.25 t 1.25 kgm}
Assembly
of main relief valve assembly
Fit O-ring and install main relief valve assembly (12). w Main relief valve assembly : 93.1 + 4.9 Nm 19.5 t 0.5 kgm1 * If the main relief valve was disassembled, carry out adjustments after installing the valve assembly to the chassis. For details, see TESTING AND ADJUSTING, Measuring and adjusting work equipment hydraulic pressure.
Remove mounting bolts (131, then remove bar (141, seat (151, spring (161, and valve (17). 4.
of shuttle
Assemble ball (19). Fit O-ring and install plug (18). m Plug : 34.3 t. 4.9 Nm 13.5 + 0.5 kgml
Assembly of check valve assembly 1) Assemble valve (17) and spring (16).
Main relief valve assembly
Remove main relief valve assembly (12). Ir If the adjustment screw is turned, the set pressure will change, so do not disassemble unless necessary. 3.
I) 2)
valve assembly
Remove plug (18), then remove ball (19). 4.
Assembly of spool assembly 1) Assemble spool (IO) to body (II).
2)
Set retainer (91, spacers (8), spring (71, retainer (61, and washer (5) in position, then tighten bolt (4). Ir Tighten the bolt with the spool assembled inside the body. m Mounting bolt : 30.9 t 3.4 Nm f3.15 + 0.35 kgm} 3) Fit O-ring and install case (3). 4) Fit O-ring, then install flange (2) and case (I).
30-210 0
D475A-3
DISASSEMBLY
BLADE TILT, RIPPER LO VALVE
AND ASSEMBLY
a
/ 4
17
0
IEiv
s2 0
(7
8 --a A
15
0
0
0
14
134
D475A-3
CWD03229
30-211 0
DISASSEMBLY
AND ASSEMBLY
RIPPER HI VALVE
REMOVAL OF RIPPER HI VALVE ASSEMBLY a
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Drain oil from hydraulic tank.
- : 2. 3. 4. 5. 6. 7.
Hydraulic tank : 340 e
Disconnect 4 left hoses (1). Disconnect 4 right hoses (2). Disconnect 2 top hoses (3). Disconnect 3 hoses (4) at center portion of valve. Disconnect hose (5). Lift off ripper Hi valve assembly (6). & kg
Ripper Hi valve assembly : 95 kg
INSTALLATION OF RIPPER HI VALVE ASSEMBLY l
.
Carry out installation removal. Refilling
with
in the reverse order to
oil (hydraulic
tank)
Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. l
Bleeding
air
Bleed the air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.
30-212 0
D475A-3
DISASSEMBLY
DISASSEMBLY OF RIPPER HI VALVE ASSEMBLY 1. 2. 3.
4.
5.
6. 7.
RIPPER HI VALVE
AND ASSEMBLY
Remove blocks (1) and (2). Remove plug (31, then remove ball (4). Disassembly of fixed pressure difference valve assembly 1) Remove plug (51, then remove retainer (61, spring (71, and retainer (8). 2) Pull out spool (9). * When loosening the plug, always loosen with the spool assembled inside the valve. Main relief valve assembly 1) Remove spring (IO), then remove retainer (11) and plug (12). 2) Remove spring (131, then remove retainer (14) and plug (15). 3) Remove spool (16). Ir When loosening the plug, always loosen with the spool assembled inside the valve. Disassembly of ripper tilt Hi valve assembly Disassemble in same way as for disassembly of ripper lift Hi valve. Remove plug (171, then remove spring (18) and check valve (19). Remove plug (201, then remove seat (211, spring (221, and valve (23).
ASSEMBLY OF RIPPER HI VALVE ASSEMBLY Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Assemble valve (231, spring (221, and seat (21), then fit O-ring and install plug (20). w Plug : 514.5 + 24.5 Nm 152.5 + 2.5 kgm} 2. Assemble check valve (19) and spring (181, then fit O-ring and install plug (17). m Plug : 210.8 + 29.4 Nm I21.5 + 3 kgm} 3. Assembly of ripper lift Hi valve assembly I) Assemble spool (16). 2) Fit O-ring and tighten plug (151, then set retainer (14) and spring (13) to spool. w Plug : 66.15 z 7.35 Nm (6.75 t 0.75 kgml 3) Fit O-ring and tighten plug (121, then set retainer (11) and spring (IO) to spool. m Plug : 66.15 + 7.35 Nm (6.75 t. 0.75 kgm} * When tightening the plug, always tighten with the spool assembled inside the valve. 4. Assembly of ripper tilt Hi valve assembly Assemble in same way as for assembly of ripper lift Hi valve assembly. of constant pressure difference 5. Assembly valve assembly 1) Assemble spool (9). 2) Set retainer (81, spring (71, and retainer (6) to spool, and install plug (5). Ir When tighten the plug, always tighten with the spool assembled inside the valve. 6. Assemble ball (41, then fit O-ring and install
*
7.
30-214 0
plug (3). w Plug : 34.3 + 4.9 Nm I3.5 + 0.5 kgm} Fit O-ring and install blocks (2) and (1).
D475A-3
DISASSEMBLY
D475A-3
AND ASSEMBLY
RIPPER HI VALVE
30-215 0
PPC RELIEF VALVE
DISASSEMBLY AND ASSEMBLY
REMOVAL OF PPC RELIEF VALVE ASSEMBLY g
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Remove
operator’s
2.
Remove
hoses (I), (2), (31, and (4).
3.
Remove
PPC relief valve assembly
cab right cover.
(5).
INSTALLATION OF PPC RELIEF VALVE ASSEMBLY l
Carry out installation removal.
30-216 0
in the
reverse
order
to
DA75A-3
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
CYLINDER
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1.
2.
Cylinder Remove
tube cylinder
tube.
Quick drop valve assembly * Blade lift cylinder only. I) Remove quick drop valve assembly
2)
(1).
Disassemble quick drop valve assembly as follows. i) Remove elbow (2). ii) Remove spring (31, washer (41, and valves (5) and (61, and pull out collar (7).
CWDO3233
3.
Piston rod assembly 1) Set cylinder assembly (8) to tool Ul. 2) Remove head assembly (9). 3) Pull out piston rod assembly (IO). * Put an oil container under the cylinder catch the oil.
I
4.
Piston assembly I) Set piston rod assembly
CWDb3234
(IO) to tool Ul.
UI
D475A-3
CWD03.235
30-217 0
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY
2) 3) 4) 5)
6)
Remove Remove Remove ring (15). Remove
spacer (I I). piston assembly (12). backup rings (13) and (14, retainer
Disassemble i) Remove ii) Remove
and O-
(16).
piston assembly wear ring (17). piston ring (18).
as follows.
17
I8
5.
Head assembly 1)
Remove head assembly
Blade
Blade ripper
lift
(19) from piston rod.
CWD03.237
tilt, lift.tilt
DXD03210
2)
Disassemble head assembly as follows. i) Remove O-ring (20) and backup ring (21).
21
30-218 0
20
CWD03239
D475A-3
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC CYLINDER
Remove snap ring (221, then remove seal (23). iii) Remove packing (24), then remove bushing (25). ii)
CWD03240
D475A-3
30-2 19 0
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Ir
Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the packings, dust seals, and O-rings when installing.
1.
Head assembly I) Assemble
i)
Using head. ii) Install iii) Using iv) Install
head assembly
as follows.
tool U2, press fit bushing
(25) to
packing (24). tool U3, press fit seal (23). snap ring (22).
CED02091
v)
Install backup
ring (21) and O-ring
CED02092
(20).
CWD03239
2)
Install head assembly
(19) to piston rod.
Blade
lift
I Tl-
El'lade tilt. r ipper lift,tilt
30-220 0
DXDO3210
DISASSEMBLY
2.
AND ASSEMBLY
HYDRAULIC
CYLINDER
Piston assemblv 1) Assemble o&ton assemblv as follows. i) Using tool U4, expand piston ring (18). * Set the piston ring on the expander and turn the handle 8 - 10 times to expand the ring. ii) Remove piston ring (18) from tool U4, then install to piston. iii) Set tool U5 in position and compress piston ring (18). CED02093
iv) Install wear
CED02094
ring (17) to piston.
CWD03237
2) 3)
4) 5)
3.
Install retainer (16). Install O-ring (15) and backup rings (14) and
-
(13). * Coat the O-ring and backup ring portion with grease, and secure the backup ring to prevent it from opening. Install piston assembly (12). Assemble spacer (II) and tighten mounting bolts. 6 Mounting bolt : Thread tightener (LT-2) m Mounting bolt : Blade lift : 98 - 123 Nm I10 - 12.5 kgml Blade lift, ripper lift, ripper tilt : 157 - 196 Nm {IS - 20 kgm}
CWD03236
Piston rod assembly I) Set cylinder (8) to tool Ul.
I
D475A-3
CWD03241
30-221 0
DISASSEMBLY
2)
3)
4.
HYDRAULIC
AND ASSEMBLY
Assemble piston rod (IO) to cylinder (8). * Coat the seal portion of the piston with grease. * Push in the piston rod fully. Push head assembly to cylinder and tighten mounting bolts. -k Coat the backup ring with grease. m Mounting bolt : Blade lift : 490 2 49 Nm I50 + 5 kgm1 Blade tilt, ripper lift, ripper tilt : 1,320 1: 140 Nm (135 t 15 kgm1
I
CYLINDER
CWDb3234
Quick drop valve assembly Ir Blade lift cylinder only. 1) Assemble quick drop valve assembly as follows. i) Assemble collar (7), and install valves (6) and (51, washer (41, and spring (3). ii) Install elbow (2).
CWD03233
2) 5.
Install quick drop valve assembly
Cylinder tube Install cylinder
(I).
tube.
CWD03232
30-222 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
RIPPER PIN-PULLER
CYLINDER
DISASSEMBLY OF RIPPER PINPULLER CYLINDER ASSEMBLY 1.
Cylinder assembly 1) Set pin-puller cylinder assembly (I) to tool Ul. 2) Using tool U6, loosen cylinder head assem3)
2.
bly (2). Remove piston rod (3) together with cylinder head assembly (2). * Put an oil container under the cylinder to catch the oil.
Cylinder head assembly I) Remove cylinder head piston rod (3).
assembly
(2) from
CD002194
2) 3) 4) 5)
Remove O-ring (5) and backup ring (6). Remove O-ring (7). Remove snap ring (81, then remove dust seal (9). Remove rod packing (IO), then remove bushing (II).
CED02184
3.
Piston rod assembly Remove piston ring (12) from piston rod (3).
CED02185
D475A-3
DISASSEMBLY
AND ASSEMBLY
RIPPER PIN-PULLER
CYLINDER
ASSEMBLY OF RIPPER PINPULLER CYLINDER ASSEMBLY U5 f
Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the packings, dust seals, and O-rings when installing.
1.
Piston rod assembly 1) Using tool U4, expand piston ring (12). Ir Set the piston ring on the expander and turn the handle 8 - 10 time to expand the ring.
2) 3)
h 0 I2 Q
CEO02186
CDD02187
Remove piston ring (12) from tool, then install to piston rod (3). Using tool U5, compress piston ring (12).
CED02185
2.
Cylinder head assembly 1) Using tool U2, press fit bushing inder head (4).
(I I) to cyl-
CDD02188
2)
30-224 0
Using tool U3, press fit dust seal (9) to cylinder head (4).
DISASSEMBLY
3) 4) 5)
AND ASSEMBLY
RIPPER PIN-PULLER
CYLINDER
Install snap ring (8) and rod packing (IO). Install O-ring (7). Install backup ring (6) and O-ring (4).
CED02184
6)
3.
Install cylinder rod (3).
head assembly
(2) to piston
Cylinder assemblv 1) Set cylinder ;o tool Ul and support with block 0. 2) Install piston rod (3) together with cylinder head assembly (2). * Coat the seal portion of the piston with grease. * Coat the backup ring with grease. * Push in the piston fully. 3) Using tool U6, tighten cylinder head assembly (2). w Cylinder head assembly : 441 t. 44.1 Nm I45 + 4.5 kgm}
D475A-3
30-225 0
DISASSEMBLY
AND ASSEMBLY
BLADE
REMOVAL OF BLADE ASSEMBLY a
Lower the work equipment to the ground in a horizontal place, and set blocks @ securely under the left and right straight frames.
1.
Remove cap (I) of lift cylinder. * Check the number and thickness (21, and keep in a safe place.
2.
Sling lift cylinder assembly (3), then start engine and retract piston rod fully, fit cylinder lock tool and secure to radiator guard. Ir Tie the piston rod with wire to prevent it from coming out. . Repeat the same procedure to disconnect the cylinder from the blade on the opposite side.
g
m of shims
CWD03242
Release the remaining pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
3.
Remove
4.
Disconnect hoses (5). Ir Mark the hoses before disconnecting. Ir Fit blind plugs to prevent dirt or dust from entering the piping.
5.
Remove
6.
Remove blade assembly (7). Ir Start the engine, drive the machine slowly in reverse, and disconnect the blade assembly from the trunnions.
CWD03243
left and right covers (4).
left and right trunnion
caps (6).
v
30-226 0
CWD03245
D475A-3
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY l
Carry out installation removal.
BLADE
OF BLADE
in the
reverse
order
to
Adjust so that play a in the axial direction within 0.5 mm and so that the rotation smooth. * Standard shim thickness: 4 mm
is is
m *
pJ *
Adjust with block @ so that height b and width c of the left and right straight frames are the dimensions given below. . Height b of trunnion portion : .
l
Brace width
Refilling Add oil Run the system.
D475A-3
c : Approx.
Approx. 3,840 mm
981 mm
with oil (hydraulic tank) through oil filler to the specified level. engine to circulate the oil through the Then check the oil level again.
30-227 0
DISASSEMBLY
GIANT RIPPER
AND ASSEMBLY
DISASSEMBLY OF GIANT RIPPER ASSEMBLY 1.
2. 3.
Mount machine on block @ and lower blade to ground. g Lock the brake securely. Sling shank, then operate pin-puller switch and pull out shank pin. Raise ripper fully, and lower shank (I) to remove. &I kg
Shank : 1,050 kg
4.
Set stand @ under arm and beam.
5.
Sling lift cylinder assembly and remove pin (2). * Start the engine, retract the piston rod fully, and lower on top of the arm. Sling lift cylinder assembly and remove pin (3). * Start the engine, retract the piston rod fully, and lower on top of the lift cylinder. A Release the remaining pressure from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit.
6.
7.
D
CED02128
CED02129
CED02130
CEO02131
Disconnect 4 lift cylinder hoses (41, 4 tilt cylinder hoses (51, and 2 pin-puller cylinder hoses (6).
8.
Sling tilt cylinder assembly (7), then remove pin (8) and lift off tilt cylinder assembly (7). &I kg
Tilt
cylinder
assembly
: 410 kg
I 30-228 0
CED02133
GIANT RIPPER
DISASSEMBLY AND ASSEMBLY
9.
Sling lift cylinder assembly (91, then remove pin (IO) and lift off lift cylinder assembly (9). &I kg
Lif? cylinder
assembly
: 400 kg
CED02134
IO. Sling beam (II), then remove (12) and lit? off beam (11). l+I kg
left and right pins
Beam : 2,450 kg
CED02135
11. Sling arm (131, then remove
left and right pins
i14) and lift off arm (13). PI kg
D475A-3
Arm : 1,800 kg
30-229 0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY ASSEMBLY
GIANT
RIPPER
OF GIANT RIPPER
1. Raise arm (13) and set in mounting position, then fit left and right pins (14) and secure with lock plate. kg lF?l
*
2.
Arm : 1,800 kg
Set a stand under the arm.
Raise beam (11) and set in mounting position, then fit left and right pins (12) and secure with lock plate. kg CF?l *
Arm : 2,450 kg
Set a stand under the beam.
CED02135
3.
Raise lift cylinder assembly (9) and set in mounting position, then fit pin (IO) and secure with lock plate. &I kg
4.
Lift cylinder
assembly
: 400 kg
I
CED02134
I
CED02133
Raise tilt cylinder assembly (7) and set in mounting position, then fit pin (8) and secure with
lock plate. r+ kg
30-230 0
Tilt cylinder assembly : 410 kg
D475A-3
DISASSEMBLY
GIANT RIPPER
AND ASSEMBLY
5.
Connect 2 pin -puller cylinder hoses (61, 4 tilt cylinder hoses (51, and 4 lift cylinder hoses (4).
6.
Sling tilt cylinder assembly, start engine, extend piston rod and align with pin hole, then install pin (3) and secure with lock plate.
7.
Sling lift cylinder assembly, start engine, extend piston rod and align with pin hole, then install pin (2) and secure with lock plate.
8.
9.
CED02131
CED02130
CED02129
CED02128
Mount machine on block @ and lower blade to ground. a Lock the brake securely. Operate
ripper and raise slightly to remove stand
0. 10. Raise ripper fully, pass wire through shank holder, then raise shank (I) slowly, align with pin hole, and operate pin-puller switch to insert shank pin.
11. Raise blade and lower machine
from block 0.
12. Bleed air from cylinder. For details, see TESTING AND Bleed air from hydraulic cylinder.
D475A-3
I
ADJUSTING,
30-231 0
DISASSEMBLY
REMOVAL
AND ASSEMBLY
ROPS GUARD
OF ROPS GUARD
1. Sling ROPS guard (I) and remove bolts (2).
2.
16 mounting If
Lift off ROPS guard (I). I3 kg
ROPS guard : 1,000
kg
CWDO3246
INSTALLATION GUARD l
Carry out removal.
m
installation
OF ROPS
in the
reverse
order
ROPS guard mounting bolt : 1,960 - 2,450 Nm I200 - 250
to
kgm} CWD03247
30-232 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
OPERATOR’S CAB
REMOVAL OF OPERATOR’S CAB ASSEMBLY a
Disconnect the cable from the negative (-1 terminal of the battery. 1. Remove ROPS guard. For details, see REMOVAL OF ROPS GUARD. 2. Open left cover (I) of operator’s cab. 3. Disconnect wiring connectors (CN-19) (2) and (CN-20, CN-21) (3). Pull out the wiring from inside of the opera* tor’s cab. 4. Disconnect 4 washer hoses (4). m Pull out the hoses from inside of the opera* tor’s cab. 5. Remove step (51, then remove cover (6).
6.
Remove garnishes
7.
Remove covers
or/
-
CWOO3256
(71, (81, and (9).
(IO) on both sides, and cover
(II).
D475A-3
30-233
DISASSEMBLY
AND ASSEMBLY
OPERATOR’S
8.
Remove
9.
Remove 19 mounting bolts, then lift off operator’s cab assembly (16). r&Ikg
CAB
angle (14) and angle (15) inside cab.
Operator’s
cab assembly
: 150 kg
INSTALLATION OF OPERATOR’S CAB ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
m *
30-234 0
When connect the washer colors of their bands.
hoses, match the
D475A-3
FLOOR FRAME
DISASSEMBLY AND ASSEMBLY
REMOVAL OF FLOOR FRAME ASSEMBLY 1.
2.
Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S ASSEMBLY. Remove
CAB
covers (11, (2) and (3).
3
3.
Remove
4.
Lift off operator’s seat (6). * Remove the seat together with the undercover. I+ kg
5.
CWDO3259
step cover (5).
Operator’s seat : 85 kg
Disconnect 2 air conditioner hoses (7).
a
Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. Disconnect at the air conditioner end, then
move the hoses towards the engine. Fit blind plugs to prevent dirt or moisture from entering the hoses. Be careful not to damage or drop the Orings. 6.
7.
Disconnect 2 heater hoses (8). +r Close the heater valve at the engine
CWDO3260
end.
Remove 2 side covers (9).
D475A-3
30-235 0
DISASSEMBLY
8.
Disconnect
AND ASSEMBLY
FLOOR FRAME
blade PPC hose (IO) and hose clamp
(II). 9.
Disconnect blade PPC hoses (121, (131, and (14). Single tilt specification machine only. m
l
I4
10. Disconnect
CWD03261
ripper PPC hoses (151, (161, (171, and
(18).
a
16
11. Disconnect
accumulator
12. Disconnect
tank return hoses (20) and (21).
CWD03262
hose (19).
13263
13. Disconnect clamps (22) (2 places) for wiring ness and washer tank hose. 14. Disconnect
ground
wiring
har-
(23) (SX-8).
15. Disconnect wiring connectors (24) (CN-1221, (25) (CN-4211, (26) (CN-5991, (27) (CN-5061, (28) (CN5771, (29) KN-992), and (30) (CN-993).
30-236 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
FLOOR FRAME
16. Disconnect directional control cable (311, speed control cable (321, and parking brake cable (33) at lever end, then remove from bracket. * Before disconnecting, check the mounting dimensions of the cables. m
CWD03.265
17. Disconnect Ir *
brake pedal linkage (34) at turnbuckle.
If Before disconnecting, check the mounting dimension of the brake rod. The turnbuckle has a reverse thread.
18. Disconnect steering linkage (35) at lever end of servo valve. * After disconnecting, secure the steering rod to the floor frame with rope.
19. Remove
arm rest (36).
I
20. Remove right console (37). * Disconnect the wiring connectors (CN-262, CN-263) inside the console. Ir Remove the lever boot from the console, then remove the console. 21. Remove left console (38). * Remove the lever boot from then remove the console.
the console, CWD03266
D475A-3
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
Serial No.: 10601 – 10732, 10736 22. Remove rear mount bolts (39) (left and right: 4 each). 23. Remove front mount bolts (40) (left and right: 4 each).
Serial No.: 10733 and up
24. Lift off floor frame assembly (41). 4 Floor frame assembly : 500 kg fl Use a chain block to adjust the balance in all directions (front, rear, left, and right), and lift off slowly.
30-238 8
DISASSEMBLY
AND ASSEMBLY
FLOOR FRAME
INSTALLATION OF FLOOR FRAME ASSEMBLY .
Carry out installation removal.
in the
reverse
order
to
m Ir Ir
*
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G). m Tighten the air conditioner gas piping to the following tightening torques.
0-hng DBD02985
Tightening torque (Nm {kgmI)
I Band DE003015
Adjust the directional, parking brake linkage.
speed
control,
and
For details, see TESTING AND ADJUSTING, Adjusting joystick (steering, directional, gear shift lever) parking brake linkage. Adjust the brake pedal linkage. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage. m Brake pedal linkage turnbuckle : 34.3 - 58.8 Nm (3.5 - 6 kgml l
.
Charging with air conditioner gas Using tool X, charge the air conditioner with air conditioner gas (R134a).
circuit
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
D475A-3
30-239 0
DISASSEMBLY AND ASSEMBLY
DASHBOARD
REMOVAL OF DASHBOARD ASSEMBLY 1.
Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY.
2.
m Disconnect 2 air conditioner hoses (1). Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. Disconnect at the air conditioner end, then move the hoses towards the engine. Fit blind plugs to prevent dirt or moisture from entering the hoses. Be careful not to damage or drop the Orings.
3.
Disconnect 2 heater hoses (2). Ir Close the heater valve at the engine end.
4.
Disconnect wiring connectors (3) (CN-S13), (4) (CN-2141, (5) KN-2161, and (6) (CN-2151, and ground connection (CN-206).
5.
Lift off dashboard assembly (7). r+ kg
30-240 0
Dashboard assembly : 120 kg
D475A-3
DISASSEMBLY
DASHBOARD
AND ASSEMBLY
INSTALLATION OF DASHBOARD ASSEMBLY l
Carry out removal.
m
installation
in the
reverse
order
to
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G). Tighten the air conditioner gas piping to the following tightening torques.
Thread
size
O-ring DEW2985
Tightening torque (Nm IkgmI)
16 x 1.5
13.23k1.47 {1.35?0.15}
22 x 1.5
22.05k2.45 (2.2520.251
24 x 1.5
31.85k2.45 (3.25-cO.251
Charging with air conditioner gas Using tool X, charge the air conditioner with air conditioner gas (R134a).
circuit
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
D475A-3
30-241 0
DISASSEMBLY
CONTROLLER
AND ASSEMBLY
REMOVAL OF CONTROLLER ASSEMBLY A
Disconnect the cable from the negative (-1 terminal of the battery.
1.
Remove cover (I).
2.
Disconnect wiring connectors of main controller (2). (CN- S40, Mll, M21, M31, M41, M51)
3.
Disconnect wiring connectors of engine controller (3). (CN-Eli, E21, E31, E32, E41, E51, E52)
4.
Remove main controller (2) and engine controller (3).
I
INSTALLATION OF CONTROLLER ASSEMBLY l
Carry out installation removal.
30-242 0
in the reverse order to
D475A-3
AIR CONDITIONER COMPRESSOR
DISASSEMBLY AND ASSEMBLY
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY (g
Disconnect the cable from the negative minal of the battery
1.
Open engine right side cover side covers (2) and (3).
2.
Disconnect air conditioner connector KN-351) (4).
3.
m Disconnect 2 compressor hoses (5). Ir Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. Ir Fit blind plugs to prevent dirt or moisture from entering the hoses. Ir Be careful not to damage or drop the Orings.
4.
Loosen 4 mount
bolts (6).
5.
Loosen locknut, (7), then remove
and remove adjustment belt from pulley.
6.
Remove 4 mount bolts (61, then remove ditioner compressor assembly (8).
D475A-3
(I)
(-1 ter-
and remove
compressor
clutch
bolt m
air con-
30-243 0
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY l
Carry out installation removal.
in the reverse order to
/FJ Ir
*
w
*
l
Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G). Air conditioner hose mounting bolt : IO + 2 Nm Il.0 + 0.2 kgm}
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting tension of air conditioner compressor belt.
Charging with air conditioner gas Using tool X, charge the air conditioner circuit with air conditioner gas (R134a).
30-244 0
D475A-3
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER CONDENSER
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY 1.
Open engine right side cover side cover (2) and (3).
2.
Disconnect hoses (4). m * Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. Ir Fit blind plugs to prevent dirt or moisture from entering the hoses. * Be careful not to damage or drop the Orings.
3.
(I)
Remove air conditioner condenser from right side of chassis.
and remove
assembly
I
CWD03275
(5)
CWD03278
INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
m Ir
*
w
l
Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G). Air conditioner hose sleeve nut: Outside : 22.05 t 2.45 Nm (2.25 t. 0.25 kgm1 Inside : 1325 t 1.47 Nm II.35 t. 0.15 kgm)
Charging with air conditioner gas Using tool X, charge the air conditioner with air conditioner gas (R134a).
D475A-3
circuit
30-245 0
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER
UNIT
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY 1.
Remove left and right covers (I) and cover (2).
2.
m Disconnect 2 air conditioner hoses (3). Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. Disconnect at the air conditioner end, then move the hoses towards the engine. Fit blind plugs to prevent dirt or moisture from entering the hoses. Be careful not to damage or drop the Orings.
3.
Disconnect 2 heater hoses (4). * Close the heater valve at the engine end.
4.
Disconnect wiring connectors (5) (CN-SIB), (6) (CN-2141, (7) (CN-2161, and (8) (CN-2151, and ground connection (CN-206).
CWD03280
CPDO3281
5.
Remove covers (12) and (13).
30-246 0
D475A-3
DISASSEMBLY
AIR CONDITIONER
AND ASSEMBLY
6.
Remove
step (141, then remove
7.
Remove
panel (161, then remove
8.
Remove
ducts (18) and (19).
9.
Remove
monitor
UNIT
covers (15). cover (17).
(20) and cover (21).
10. Remove RECIRC air filter (22) and FRESH air filter (23). * There is 1 mounting bolt for the air conditioner unit beyond the FRESH air filter bracket.
D475A-3
30-247 0
DISASSEMBLY
AND ASSEMBLY
11. Disconnect
bracket (24) and clamp (25).
AIR CONDITIONER
UNIT
12. Disconnect relays (26) (CN-RI ), (27) (CN-RS), (28) (CN- R3) and connector (29) (CN-M26) inside right side of dashboard.
13. Remove air conditioner 14. Remove blower
30-248 0
unit (30).
motor (31).
D475A-3
DISASSEMBLY
INSTALLATION CONDITIONER l
Carry out removal.
w
AIR CONDITIONER
AND ASSEMBLY
installation
OF AIR UNIT in the
reverse
order
to
i I
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G). Tighten the air conditioner gas piping to the following tightening torques.
22 x 1.5
22.05k2.45
(2.2520.25)
24 x 1.5
31.85k2.45
{3.25*0.25)
M6 bolt (receiver portion)
5.3921.47
{0.55*0.151
M6 bolt (compressor portion)
UNIT
9.821.96
0-iing
DEW2985
{I .0+0.2)
Charging with air conditioner gas Using tool X, charge the air conditioner with air conditioner gas (R134a).
circuit
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
D475A-3
30-249 0
DISASSEMBLY
AND ASSEMBLY
HOOD
REMOVAL OF HOOD ASSEMBLY a
Disconnect the cable from the negative minal of the battery.
1. Remove
radiator
sub tank hose (I)
(-) ter-
and clamp
(2).
I 2.
Remove
precleaner
3.
Remove
exhaust
4.
Disconnect CN-HRN).
5.
Lift off radiator
CWD03283
tubes (3) and (4).
pipe (5).
front
Radiator
u
lamp
connectors
(6) (CN-209,
top cover (7). top cover assembly
: 85 kg
CWDO3285
6.
Lift off hood (8). &I kg l
Hood assembly
Open the side cover and raise.
INSTALLATION ASSEMBLY l
: 210 kg
Carry out removal.
30-250 0
installation
OF HOOD in the
reverse
order
to
40
MAINTENANCE STANDARD
Engine mount ............................................... 40- 2 Damper, universal joint .............................. 40- 3 Torque converter ........................................ 40- 4 Torque converter valve ............................... 40- 6 TORQFLOW transmission ........................... 40- 8 Transmission control valve ......................... 40-10 Power train, hydraulic, lubrication pump ................................... 40-13 Transfer, bevel pinion ................................. 40-14 Bevel gear shaft, steering clutch, brake ...................................................... 40-16 Steering control valve ................................ 40-18 Final drive ..................................................... 40-20 Main frame ................................................... 40-22 Track frame ................................................... 40-24 Recoil spring .............................................. 40-25-1 Idler ................................................................ 40-26 Track roller bogie ......................................... 40-28 Track roller .................................................... 40-30 Carrier roller ................................................ 40-32 Track shoe ................................................... 40-34 Equalizer bar ................................................ 40-38 Pivot shaft ..................................................... 40-40 Hydraulic pump ........................................... 40-41 Work equipment control pump ................. 40-42 Main control valve ...................................... 40-43 PPC valve ..................................................... 40-47 Work equipment cylinder ........................... 40-50 Cylinder stay ................................................ 40-52 Blade ............................................................. 40-54 Ripper equipment ....................................... 40-60
D475A-3
40-1 1 5
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT
Unit: mm
Check item
,
Clearance between and cushion
Clearance between
2
Remedy
bracket
bracket
and bushing
Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
78
-0.030 -0.060
+0.006 -0.048
-0.018 0.066
0.1
200
-0.043 -0.083
+0.072 0
0.043 0.155
0.1
I
Repair
Standard 3
Free height mount
40-2 0
of rubber 118
size
I
116
limit
Replace
I I
D475A-3
MAINTENANCE
STANDARD
DAMPER,
UNIVERSAL
DAMPER, UNIVERSAL JOINT
JOINT
SJOO3043
Unit: mm
NO
1
Check item
Criteria Tolerance
Standard size
Clearance between flywheel housing and cover
Shaft
Hole
Standard clearance
Clearance limit
647.7
-0.224 -0.105
+0.080 0
0.024 0.185
0.2
571.5
-0.022 -0.092
+0.070 0
0.022 0.162
2
Clearance between flywheel and damper
1
Standard 3
4
Outer diameter of oil seal contact face on coupling
Remedy
I
size
I
0.2 Replace
I
Repair limit I 119.9
Outer diameter of bearing contact face on output shaft
f
D475A-3
-
40-3 0
MAINTENANCE
TORQUE CONVERTER
STANDARD
TORQUE CONVERTER
i /
/3 -----4
A-A
SJDO3044
40-4 0
D475A-3
MAINTENANCE
TORQUE CONVERTER
STANDARD
Unit: mm No. -
Remedy
Check item Standard
1
3utside diameter of oil seal contact surface of coupling
size
Repair limit
Tolerance
125
0 -0.100
-
124.8 Repair hard chrome plating or replace
2
Inside diameter of seal ring contact surface of seat
115
+0.035 0
3
Inside diameter of seal ring contact surface of retainer
190
+0.046 0
190.5
4
Inside diameter of seal ring contact surface of sleeve
120
+0.035 0
120.2
5
Backlash of input shaft gear and scavenging pump drive gear
-
Standard
0.204 - 0.516
Backlash of input shaft gear and driven gear
0.204 - 0.516 Standard
Wear of stator shaft seal ring
8
5 ‘; 0 g & 2
=
Width: 5.35 Height: 5.85
Thickness of disc
5.4
5.0
Thickness of plate
5.0
4.5
Thickness of total assembly
26.2
24.0
Replace
Thickness of disc
5.1
5.4
I
I
G
g Z5
-
Thickness of plate
5.0
4.5
Thickness of total assembly
15.8
14.7
Standard
IO
Stator clutch spring
I D475A-3
Repair limit
size
Width: 5.95 Height: 6.50
5 9
Clearance limit
clearance
size
Free length
Installation length
54.1
37.0
Repair limit Installation load
Free length
Installation load
25.5N {12.8 kg)
50.9
106.9N (10.9 kg}
40-5 0
MAINTENANCE
STANDARD
TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
r
-1
\--
i 10
4 D-D
E-E
40-6 0
SAD01225
D475A-3
MAINTENANCE
TORQUE CONVERTER VALVE
STANDARD
Unit: mm
Clearance between main relief valve and valve
converter
relief valve
Clearance between
lock-up
8
Stator clutch valve spring modulating
103.5
92.7
197.1 N (20.1 kg)
100.4
117.5 N (18.1 kg)
9
clutch Lock-upspring (outer) modulating valve
141.4
88.7
158.6 N (16.18 kg)
137.16
150.7 N (15.37 kg)
lo
Lock-up clutch modulating valve spring (inner)
80.5
78.09
675.7 N I68.9 kg)
II
Lock-up valve spring
97
27.9 N 12.85 kg)
D475A-3
110.07
41.8 N 72.5 (4.26 kg) (Normalhsight) (Normal load) 100.0
29.4 N (3.0 kg)
40-7 0
MAINTENANCE
TORQFLOW 13
\
TORQFLOW TRANSMISSION
STANDARD
TRANSMISSION
m
373+19. 6Nm (38f2kaml
16 ,
\
SVD03045
Unit: mm
No
_I
Criteria
Check item Standard size Free length
No. 1 clutch spring (12 PCS)
1
Installation length
100.0 No. 2 clutch spring (12 PCS)
2
1
3 clutch spring PCS)
4
No. 4 clutch spring (12 PCS)
6
No. 5 clutch spring (12 PCS)
40-8 0
I 1
loo.0
90.0
1
84.0
81.7
103.5
94.0 72.0
1
63.0
76.0
Remedy
I
Repair limit
Installation load
Free length
Installation load
40.2 N 114.3 kg}
94.0
119.6 N (12.2 kg}
1 E;k;]
1
150 N (15.3 kg}
1 :1;926k;I 238.3 N (24.3 kg}
94.0 79.0
1
76.5 97.0
1 T&;)
Replace
127.4 N I13 kg}
1 {::4Ok;j 203 N 120.7 kg1
D475A-3
MAINTENANCE
STANDARD
TORQFLOW TRANSMISSION
Unit: mm
NC -
I
Check item I
Standard 6
I
7
Thickness of total assembly for No. 2 clutch
I
8
Thickness of total assembly for No. 3 clutch
I
9
Thickness of total assembly for No. 4 clutch
I
IO
Thickness of total assembly for No. 5 clutch
11
Thickness of a clutch disc
12
Thickness of a clutch plate
-
-
size
I
72.6
72.6
50.2
Repair limit
Tolerance
I
Thickness of total assembly for No. 1 clutch
Remedy
I
I
I I
I
I
0.36
i
68.9
0.36
I
68.9
0.30
I
47.5
39.0
0.26
36.9
61.4
0.33
58.2
5.4
I
kO.1
I
5.8
4.9
I
I I I
I
5.2
-
13
14
15
Wear of seal ring on transmission input shaft
Wear of seal ring on transmission output shaft
t-Thickness Width
Wear of seal rina for No. 5
-
-
Width
I
Thickness I
4.0
-0.01 -0.03
3.5
5.0
20.15
4.85
6.0
-0.01 -0.03
5.65
II
+0.15
I
16
Backlash between each sun gear and planetary pinion
0.16 - 0.35
17
Backlash between each planetary pinion and inner gear on ring gear
0.18 - 0.38
D475A-3
40-9 0
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
CONTROL VALVE
CONTROL VALVE
UPPER VALVE 15
6
7
16
.I
LOWER VALVE
SJD03046
40-l 0 0
D475A-3
MAINTENANCE
TRANSMISSION
STANDARD
CONTROL VALVE
Unit: mm
No
1
Clearance between pilot reducing valve, priority valve and body
2 3 4 5 -
6
Priority valve spring (large)
7 8 -
100.0
76.0
688.4 N (70.2 kg1
97.0
654.1 N 166.7 kg}
80.0
71.5
266.7 N (27.2 kg}
77.6
253.0 N {25.8 kg}
Reducing valve spring
70.5
56.0
283.4 N (28.9 kg}
68.4
269.7 N f27.5 kg}
12
Lubrication
valve spring
78.0
48.0
169.6 N 117.3 kg}
75.7
160.8 N 116.4 kg}
I?
Directional, spring
speed valve
78.0
45.0
113.7 N Ill.6 kg}
75.7
107.9 N {I 1.O kg)
14
Thickness of modulating valve shim
9
Modulating (large)
valve spring
10
Modulating (small)
valve spring
11
-
-
-
-
Large
3 mm (One shim changes pressure by 37.3 kPa IO.38 kg/cm?
Small
I mm (One shim changes
pressure by 41.2 kPa IO.42 kg/cm*1
15
Thickness of priority shim
16
Pilot reducing valve shim adjustment
(One shim changes pressure by 31.4 kPa 10.32kg/cmzI
17
Reducing valve shim adjustment
(One shim changes pressure by 54.9 kPa (0.56 kg/cm*}
18
Lubrication adjustment
(One shim changes pressure by 3.92 kPa jO.04 kg/cr+I
-
3 mm (One shim changes pressure by 136 kPa (1.39 kg/cm*) Adjust
-
-
-
valve
D475A-3
valve shim
40-11 a
MAINTENANCE
TRANSMISSION
STANDARD
SPEED AND DIRECTIONAL SELECTOR VALVE SPOOL
CONTROL VALVE
I-
LI-LI
LUJ
SWD03048
Unit: mm
No
Check item
Clearance between selector valve spool and body
1
-
Repair limit
Standard size 2
Detent spring
3
Installation length of directional selector valve spool yoke
4 5
-
Installation length
Installation load
Free length
Installation load
Standard size
Repair limit
29.1
20.3
Installation length of speed selector spool yoke
29.2
20.3
Installation length of speed selector lever stoooer
34.0
+l.O
40-12 0
Free length
Replace
Adjust
D475A-3
MAINTENANCE
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP
STANDARD
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP (BALI60
+ 112 + 112)
BAL112+112
IA-A
A -I
SJD03073
Unit: mm
No.
TvDe
1
2
Clearance between gear case and side plate, gear
Clearance between plain bearing inner diameter and gear shaft outer diameter
Pin insertion depth
1
Standard
Clearance limit
1
clearance
BALI60
0.04 - 0.10
0.13
BALI12
0.04 - 0.10
0.13
0.060 - 0.145
0.20
BALI60 ?eplace
BALI12
Type 3
Remedy
Criteria
Check item
Standard
size
I
Repair limit
Tolerance
I
I
BALlGO 0 -0.5
14
-
BALI12 4
Rotating torque of spline shaft
BALI60
II
II
2.94 I301
288 I
II
266
I
BALI 12 I
D475A-3
2,000
Delivery limit (Q/min.)
Standard delivery (Q/min.)
Delivery pressure MPa Ikg/cm*I
Speed (rpm)
Type Delivery EOIO - CD 45 - 55°C
5.88 Nm IO.6 kgm1
I
2,000
I
2.94 1301
I
205
I
188
40-13 0
MAINTENANCE
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
STANDARD
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
_/
-------
40-l 6 0
\ ‘\
SWD03050
D475A-3
MAINTENANCE
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
STANDARD
Unit: mm
Check item
No -
Remedy
Criteria
Thickness of brake, clutch plate
Replace &
Warping of brake, clutch plate
Correct or replace Standard
l--rsi;kness of brake, clutch
size
5.4 Tolerance
Warping of brake, clutch disc 3
Thickness of total brake plate and disc assembly
4
Thickness of total brake plate and disc assembly
5
Backlash of brake, clutch disc, and brake hub
6
Backlash between gear and pinion
less than 0.3
Standard
I
Repair limit
I
5.1
I
Repair limit
I
0.4
78.5
76.8
I 1
clearance
Repair limit 1.o
0.3 - 0.4
0.75
seal ring seal ring groove
0.5 - 0.8
0.8
8
Clearance between seal ring and cage seal ring groove
0.5 - 0.8
9
Inside diameter of seal ring contact surface of cage
7
IO
Clearance between and piston
-0.5 -0.7
350
Inside diameter of seal ring contact surface of piston
1
300
::;;‘:
/
Standard 11
12
13
Brake belleville
Clutch belleville
Free length
spring
spring
Interference between bevel I gear and reamer bolt
Hole
Standard clearance
+0.089 0
0.5 0.789
Shaft
+:-052
( “y,,,
Clearance limit
Replace
/ Repair limit
size
Installation length
Adjust or replace
0.8
I Tolerance
Standard size
Replace
74.1
0.4 - 07
bevel
Correct or replace
Repair limit
size
82.2
Standard
Replace
Installation load
Free length
Installation load
19.7
12.9
46.97 kN (4,790 kg1
19.1
44.62 kN 14,550 kg}
20.4
12.9
55.7 kN 15,680 kg1
20.0
53.35 kN 15,440 kg}
Tolerance
Standard size
Shaft
Hole
20
+0.023 +0.002
+0.033 0
Standard interference
Interference limit
Replace -0.032 0.019
0.02
Service limit: 0.05 (measure after installing to bevel gear shaft)
14
Runout of rear face of bevel gear
15
Preload of bevel gear shaRt taper roller bearing
16
Standard shim thickness of bearing cage
1
Correct or replace
Standard rotating torque: 9.8 - 11.8 Nm Il.0 - 1.2 kgm1 (When bevel pinion and gear are not meshed, at tip of bevel gear: 51.0 - 61.8 N (5.2 - 6.3 kg1
Adjust
2.0
Adjust shim
&
D475A-3
40-17 0
MAINTENANCE
STANDARD
STEERING CONTROL VALVE
STEERING CONTROL VALVE
__II__ts!?>
-r-I
4
I
I
\
\
\
3
CL=
13.23*1.47Nm (1.35*0.15kom)
SAD01231
40-18 0
D475A-3
MAINTENANCE
STEERING CONTROL VALVE
STANDARD
Unit: mm
Criteria
No
Check item
1
Clearance between clutch, brake valve and valve body
5
Tolerance Shaft
Hole
Standard clearance
Clearance limit
19
-0.020 -0.030
+0.013 0
0.020 0.043
0.06
Clearance between clutch, brake valve sleeve and guide
18.35
-0.034 -0.043
+0.013 0
0.034 0.056
0.08
Clearance between clutch, brake valve sleeve and guide
16
-0.034 -0.043
+O.Ol 1
0.034 0.054
0.07
Clearance between clutch, brake valve and piston
9
-0.03 -0.04
+0.015 0
0.030 0.055
0.08
Clearance between parking brake valve and body
16
-0.016 -0.034
+0.043 0
0.016 0.077
0.10
Standard size
Standard 6
Remedy
Clutch modulating
spring
Free length
0
Repair limit
size
Installation length
Installation load
Free length
Installation load
57.3
19.0 88.3 kg} N
59
I
1
60.1
1
38
/ r:k;]
/
58.3
/ :$k;I
1
77.2
1
39.5
1 :;k;]
1
74.9
1 $i;l
I
38
19.46 92.77kg} N
Replace
7
Brake modulating
8
Clutch valve return spring
9
Brake valve return spring
10
Parking brake valve spring
D475A-3
spring
62.4
40.5
148.1 N i15.1 kg)
60.5
141.2 N I14.4 kg)
28
15.0
1.67 N IO.17 kg}
27.2
1.57 N iO.16 kg}
40-19 0
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE m,549.?*5+8Nm
3
-\
I
I
I
SJD03051
40-20 0
D475A-3
MAINTENANCE
STANDARD
FINAL DRIVE
Unit: mm
No -
Check item
Criteria
Remedy
Standard clearance
Clearance limit
1
Backlash between No. 1 pinion and No. 1 gear
0.26 - 0.96
1.5
2
Backlash between sun gear and planet pinion
0.25 - 0.70
1.5
3
Backlash between planet pinion and ring gear
0.26 - 0.83
1.5
Outside diameter of No. 1 pinion oil seal contact surface
Standard size
Repair limit
4
120.0
119.9
-
5 6 7
Replace
Thickness of thrust collar of inner body roller bearing Thickness of thrust collar of No. 1 gear boss roller bearing Dimension from mounting face of cover to head of
24.8
24.6
14.0
13.5
72.0
70.5
-
8
Clearance between pinion shaft and carrier
Standard size 110
9 10 -
Tolerance Shaft
Hole
Standard clearance
Clearance limit
-0.035 -0.054
-0.024 -0.059
-0.024 0.030
0.1
Standard shim thickness for No. 1 pinion bearing cage Dimension of end face of final drive cover and end face of bearing
11
Clearance of floating seal guard
12
Wear of sprocket teeth bottom
13
Wear of sprocket teeth tip
2 7.3 - 8.3
Adjust
3.1 - 4.7 Standard size
Repair limit
30
24
486
470
-
Rebuild or replace
-
DA75A-3
40-21 0
MAINTENANCE
STANDARD
MAIN FRAME
MAIN FRAME
F
C
C
a
a
/----------
A-A
13
_-
5
_-
-_
WC! F-F
IY I2
D-D
_
4
_
_-_
G-G
E-E
40-22 0
SWD03052
D475A-3
MAINTENANCE
MAIN FRAME
STANDARD
Unit: mm
No -
Remedy
Criteria
Check item Standard
Repair limit
size
I 1
2
3
Interference between steering case and bushing
Clearance between steering frame and final drive cage learance between
Tolerance
I Standard clearance
Standard size
Shaft
Hole
315
+0.108 +0.056
+0.052 0
(Std. interference) 0.004 0.108
390
-0.018 -0.075
+0.057 0
0.018 0.132
Clearance limit
Above 0
0.2
bracket
4
5 Replace 6 7
radiator
guard mounting
Protrusion of rubber at end face of seal I IO
Free height of front mount rubber
11
Free height of rear mount rubber
-
Ii
16
Press-fitting force for ripper arm mounting bushing Press-fitting force for ripper cylinder mounting bushing Press-fitting force for radiator guard mounting bushing Press-fitting force for .radiator . guard mounting busnmg Press-fitting force for equalizer bar shaft mounting bushing
D475A-3
II
1
0.5
118
116
56
58 I
126.5 - 253 kN 112.9 - 25.8
tOnI
111.8 - 267.7 kN {I 1.4 - 27.3 ton1
62.8 - 142.2 kN (6.4 - 14.5 tOnI
I
Adjust
53.9 - 106.9 kN 15.5 - 10.9 ton1
65.7 - 153 kN 16.7 - 15.6 ton1
40-23 0
MAINTENANCE STANDARD
TRACK FRAME
TRACK FRAME Serial No.: 10601 – 10684
Unit: mm
No.
Check item
Criteria Item
Deformation of track frame outer pipe
1
Clearance between inner pipe and adjustment cylinder protrusion
2
Repair limit
Curvature
7 (for length of 3,000)
Twisting
3 (for level length of 3,000)
Dents (pipe portion)
12
Tolerance
Standard size
Shaft
70
–0.15 –0.35
Standard clearance Clearance between idler bogie and guide
3
Press-fitting force for cartridge
4
40-24 1 5
Remedy
Hole +0.3 0
Standard clearance
Repair or Replace
Clearance limit Replace
0.15 – 0.65
2.0
Clearance limit Adjust
0 – 0.5 323 – 529 kN {33 – 54 ton}
3.0 —
D475A-3
MAINTENANCE STANDARD
TRACK FRAME
Serial No.: 10685 and up
Unit: mm
No.
Check item
Criteria Item
1
2
Deformation of track frame outer pipe
Clearance between inner pipe and adjustment cylinder protrusion
Repair limit
Curvature
7 (for length of 3,000)
Twisting
3 (for level length of 3,000)
Dents (pipe portion)
12
Tolerance
Standard size
Shaft
70
–0.15 –0.35
Standard clearance 3
4
Clearance between idler bogie and guide Press-fitting force for cartridge
D475A-3
Remedy
Hole +0.3 0
Standard clearance
Repair or Replace
Clearance limit Replace
0.15 – 0.65
2.0
Clearance limit Adjust
0 – 0.5 275 – 510 kN {28 – 52 ton}
3.0 —
40-25 1 5
MAINTENANCE STANDARD
RECOIL SPRING
RECOIL SPRING Serial No.: 10601 – 10684
Unit: mm
No.
Check item
Criteria Standard size
Recoil spring
1
Free length 1,713
Clearance between inner cylinder and outer cylinder of outer cylinder bushing
2
Clearance between adjustment cylinder and bushing Press-fitting force for outer cylinder bushing (outer cylinder side) Press-fitting force for outer cylinder bushing (inner cylinder side) Clearance between recoil spring mount nut and lock plate
3 4 5 6
40-25-1 5
Remedy Repair limit
Installation Installation length load
Free length
Installation load
725.2 N {74,000 kg}
1,687
659.5 N {67,300 kg} Clearance limit 0.8
1,425
Tolerance
Standard size
Shaft
Hole
Standard clearance
445
–0.068 –0.165
+0.323 +0.060
0.128 – 0.488
165
–0.100 –0.550
+0.063 0
0.100 – 0.613
Replace
51.0 – 99 kN {5.2 – 10.1 ton} 129.4 – 389.1 kN {13.2 – 39.7 ton}
Adjust
0 – 1.0
D475A-3
MAINTENANCE STANDARD
RECOIL SPRING
Serial No.: 10685 and up
Unit: mm
No.
Check item
Criteria Standard size
1
Recoil spring
Free length 1,731
2
3 4 5 6
Clearance between inner cylinder and outer cylinder of outer cylinder bushing
Clearance between adjustment cylinder and bushing Press-fitting force for outer cylinder bushing (outer cylinder side) Press-fitting force for outer cylinder bushing (inner cylinder side) Clearance between recoil spring mount nut and lock plate
D475A-3
Remedy Repair limit
Installation Installation length load
Free length
Installation load
788.3 N {80,435 kg}
1,705
715.4 N {73,000 kg} Clearance limit
1,455
Tolerance
Standard size
Shaft
Hole
Standard clearance
445
–0.068 –0.165
+0.323 +0.060
0.128 – 0.488
0.8
165
–0.100 –0.550
+0.063 0
0.100 – 0.613
—
Replace
51.0 – 99 kN {5.2 – 10.1 ton} 129.4 – 389.1 kN {13.2 – 39.7 ton}
Adjust
0 – 1.0
40-25-2 5
MAINTENANCE STANDARD
IDLER
IDLER Serial No.: 10601 – 10684
40-26 1 5
D475A-3
MAINTENANCE
IDLER
STANDARD
Unit: mm
No
Remedy
Criteria
Check item Standard size
Repair limit
1,043
-
1
Outside diameter of protruding part
2
Outside diameter of tread surface
990
3
Depth of tread
26.5
-
4
Overall width
325
-
5
Width of tread
85
-
6
7
Clearance between shaft and bushing
Interference between idler and bushing
959
Tolerance Hole
Standard clearance
+0.168 +0.003
0.353 0.581
Standard size
Shaft
180
-0.350 -0.413
Standard size
Shaft
Hole
190
+0.194 +0.122
+0.046 0
1
Tolerance
Width of shaft flange
-
D475A-3
335.0
Clearance limit
I
-
Standard Interference limit interference 0.076 0.194 Repair limit
Standard size 8
Rebuild or replace
-
Replace bushing
Rebuild or replace
40-27 0
MAINTENANCE STANDARD
IDLER
Serial No.: 10685 and up
40-27-1 5
D475A-3
MAINTENANCE STANDARD
IDLER
Unit: mm
No.
1
Check item
Criteria
Remedy
Standard size
Repair limit
1,043
—
Outside diameter of protruding part
2
Outside diameter of tread surface
990
959
3
Depth of tread
26.5
42
4
Thickness of tread
36
20.5
5
Overall width
347
—
6
Width of tread
96
105
7
Clearance between shaft and bushing
Tolerance
Standard size
Shaft
180
–0.350 –0.413
Hole
Standard clearance
Clearance limit
+0.168 +0.003
0.353 – 0.581
—
Standard size 8
9
Width of shaft flange
Interference between ring and shaft
Repair limit
335.0 Tolerance
Standard size
Shaft
Hole
115
+0.046 0
–0.15 –0.20
Standard Interference interference limit Replace ring 0.15 – 0.246
—
Repair limit
End play
Replace ring 0.52 – 0.98
D475A-3
Replace bushing
Rebuild or replace
—
Standard size 10
Rebuild or replace
—
40-27-2 5
MAINTENANCE STANDARD
TRACK ROLLER BOGIE
TRACK ROLLER BOGIE Serial No.: 10601 – 10684
40-28 1 8
D475A-3
MAINTENANCE
TRACK ROLLER BOGIE
STANDARD
Unit: mm Check item
No.
Clearance between and bushing
1
Clearance between
Criteria
shaft
Tolerance
Remedy
Standard size
Shaft
Hole
Standard clearance
Clearance limit
110
-0.195 -0.230
+0.092 +O.OlO
0.205 0.322
0.8
collar
2
fitted) and outer bogie (press-
175
+O.llO +0.075
+0.048 0
-0.027 -0.110
-
3
Clearance between collar and outer bogie (pressfitted)
177
+0.043 +0.003
+0.048 0
0.045 -0.043
-
4
fitted) and inner bogie (press-
176
+0.196 +0.161
+0.048 0
-0.113 -0.196
-
5
Clearance between shaft and collar (press-fitted)
110
-0.195 -0.230
-0.288 -0.323
-0.058 -0.128
-
6
Clearance between shaft and collar (press-fitted)
110
-0.195 -0.230
-0.130 -0.165
-0.003 -0.10
-
7
Clearance of collar
8
Press-fitting bushing
9
Press-fitting washer
force for
Press-fitting
force for
Clearance between
1o
collar
11
Press-fitting
0.3
force for
I collar
6.9 - 39.2 kN IO.7 - 4.0 ton}
1.0 - 3.9 kN IO.1 - 0.4 ton}
I force for outer
II bogie -
I
117.6 - 264.6 kN I12 - 27 ton}
Press-fitting I bogie
force for inner
Press-fitting bogie
force for outer
I
13
II
-
D475A-3
I
Adjust
61.7 - 194.0 kN f6.3 - 19.8 ton1
I
I
I
12
Replace
447.9 - 725.2 kN ( 45.7 - 74.0 ton1 I 0 - 62.7 kN 1 0 - 6.4 ton)
40-29 0
MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER Serial No.: 10601 – 10684
40-30 1 5
D475A-3
MAINTENANCE
TRACK ROLLER
STANDARD
Unit: mm
No. -
Criteria
Check item
Remedy
Standard size
Repair limit
344
-
Outside diameter of flange (inside)
335
-
3
Outside diameter of tread
300
250
4
Thickness of tread
67.5
42.5
5
Overall width
394
-
(Single flange)
155
-
(Double flange)
100
-
1
Outside diameter of flange (outside)
2
-
6
Inside width
Rebuild or replace
7
Width of tread (single flange)
8 9 10 11
Width of shaft flange
12
13
Clearance between shaft and bushing
Replace bushing
14
Interference between bushing and roller
Replace
-
D475A-3
40-31 0
MAINTENANCE STANDARD
TRACK ROLLER
Serial No.: 10685 and up
40-31-1 5
D475A-3
MAINTENANCE STANDARD
TRACK ROLLER
Unit: mm
No.
Check item
Remedy
Standard size
Repair limit
344
—
332
—
(Single flange)
300
230
(Double flange)
300
246
(Single flange)
71.5
36.5
(Double flange)
7.15
44.5
1
Outside diameter of flange (outside)
2
Outside diameter of flange (inside)
3
Outside diameter of tread
4
Criteria
Thickness of tread
5
Overall width
423
—
6
Width of tread (single flange)
99.5
—
7
Width of tread (double flange)
99.5
—
8
Width of flange (Outside of double flange)
34.5
19.5
9
Width of flange (Inside of double flange)
27.5
12.5
10
Width of shaft flange
379
—
11
Clearance between shaft and bushing
Standard size 147
12
13
Interference between shaft and ring
End play
D475A-3
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
–0.350 –0.413
+0.170 0
0.350 – 0.583
—
Tolerance
Standard size
Shaft
Hole
84
+0.046 0
–0.15 –0.20
0.44 – 0.91
Replace bushing
Standard Interference interference limit Replace 0.150 – 0.246 —
— Adjust or replace
40-31-2 5
MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER Serial No.: 10601 – 10684
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Outside diameter of flange
275
—
2
Outside diameter of carrier roller tread
240
215
3
Width of carrier roller tread
85
93
4
Thickness of tread
50
37.5
5
Width of flange
25
17
1
Interference between bearing and roller
6
7
Interference between bearing and shaft
8
Play in axial direction of roller
Tolerance
Standard size
Shaft
Hole
140
0 –0.018
–0.028 –0.068
0.010 – 0.068
—
80
0 –0.019
0 –0.015
–0.019 – 0.015
—
Standard clearance
40-32 1 5
Rebuild or replace
0 – 0.22
Standard Interference interference limit
Replace
Clearance limit 0.3
D475A-3
MAINTENANCE STANDARD
CARRIER ROLLER
Serial No.: 10685 and up
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Outside diameter of flange
275
—
2
Outside diameter of carrier roller tread
240
215
3
Width of carrier roller tread
4
Thickness of tread
5
Width of flange
1
6
Interference between shaft and ring
7
Clearance between shaft and support
8
Play in axial direction of roller
Standard size
96
—
49.5
37
25
14 Tolerance
Standard Interference interference limit
Shaft
Hole
95
+0.046 0
–0.15 –0.20
0.150 – 0.246
—
90
0 –0.2
+0.35 0
0 – 0.55
—
Standard clearance
D475A-3
Rebuild or replace
0 – 0.22
Replace
Clearance limit 0.3
40-33 1 5
MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE Serial No.: 10601 – 10684
fl Portion P shows the link on the side where the bushing is pressed fitted.
40-34 1 5
D475A-3
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm
No.
1
Check item
Criteria Standard size
Repair limit
317.8
—
Link pitch
Bushing outside diameter 116
Normal load
Impact load
107.5
110
Standard size 3
Repair limit
Link height 199
4
Thickness of link metal (bushing press-fitting portion)
Reverse or replace
When turned
Standard size 2
Remedy
181
Rebuild or replace
53.5 276
5
Replace 6
Shoe bolt pitch
84
7 8 9
226
Link
10
Inside width
162
Overall width
83
Tread width
78
11
Protrusion of pin
2.9
12
Protrusion of regular bushing
1.6
13
Overall length of pin
367
Repair or replace
Adjust or replace 14
Overall length of bushing
244
15
Thickness of bushing metal
21.5
16
Thickness of spacer
17
Press-fitting force
18
D475A-3
Bushing
13 225 – 392 kN {23 – 40 ton} —
Regular pin
490 – 686 kN {50 – 70 ton}
40-35 1 4
MAINTENANCE
TRACK SHOE
STANDARD
NO -
Check
Tightening
Additional angle
torque
(Nm IkgmI) a. Regular
180 2 10
Shoe bolt Tightening torque (Nm {kgmII
19
Additional angle
No. of shoes (each side)
Interference between bushing and link
-
2:
Interference between regular pin and link
Clearance between regular pin and bushing
Standard size
40-36 0
Tolerance
Standard interference
Shaft
Hole
113
+0.652 +0.522
+0.087 0
0.465 - 0.652
70
+0.496 +0.396
-0.126 -0.200
0.522 - 0.696
Standard size
Retighten
-
40
70 -
Lower limit torque (reference value) (Nm {kgrnl) 2,940 {3001
180 + 10
I
21
tightening (deg.)
link 785 + 78 180 f 8)
20
tightening (deg.)
link 785 f 78 {80 + 81
b. Master
r
Remedy
Criteria
item
Unit: mm
Tolerance Shaft
Hole
+0.496 +0.396
+I.236 +0.736
Adjust or replace
Standard clearance 0.240 - 0.840
D475A-3
MAINTENANCE STANDARD
TRACK SHOE
Serial No.: 10685 and up
fl Portion P shows the link on the side where the bushing is pressed fitted.
40-36-2 5
D475A-3
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm
No.
Check item
Criteria Standard size
Repair limit
317.8
320.8
Height of grouser
105
35
Overall height of shoe
133
63
1
Link pitch
2 3
5
6
116
107.5
110
22.5
14
16.5 Repair limit
109
181 (ª Note 1)
53.5
35.5 (ª Note 2)
One side
1.6
—
Both sides
3.2
—
Height of link
Thickness of link (bushing press-fitting portion)
8
Clearance between links
10
Heavy load
Standard size
7
9
Weld lug, rebuild, or replace
Load
Outside diameter of bushing
Thickness of bushing
Turn or replace
Turning
Standard size 4
Remedy
Interference between bushing and link
Interference between regular pin and link
Standard size
Tolerance
Standard interference
Shaft
Hole
113
+0.652 +0.522
+0.087 0
0.465 – 0.652
70
+0.496 +0.436
+0.124 +0.050
0.312 – 0.446
Tightening torque (Nm {kgm})
Tightening angle (deg)
785 ± 78 {80 ± 8}
180 ± 10
980 ± 98 {100 ± 10}
180 ± 10
Turn or replace
Rebuild or replace
Adjust or replace
a. Regular link 11
Shoe bolt b. Master link
Retighten
ª Note 1: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit is 183 mm. ª Note 2: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit is 37.5 mm. D475A-3
40-36-3 5
MAINTENANCE
SHINGLE
STANDARD
TRACK SHOE
SHOE
Unit: mm
Check item
NO.
Criteria Standard
Repair
size
1
Height
2
Thickness
28
3
Length of base
52
4
Length
36
D475A-3
105
at tip
Remedy limit
35 Repair by build-up welding or replace
40-37 0
MAINTENANCE
STANDARD
EQUALIZER
EQUALIZER BAR
BAR
n I
I
-_-__-__
h-7
c-c
SJD03060
40-38 0
D475A-3
MAINTENANCE STANDARD
EQUALIZER BAR ª1: For Serial No.: 10684 and up
Unit: mm
No.
1
Check item
Clearance between center pin and bushing
2
Clearance between side pin and bushing
3
Clearance between side pin and spherical surface of bushing
4
Interference between side pin boss and bushing
Criteria Tolerance
Remedy
Standard size
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.083
+0.225 +0.143
0.186 – 0.308
1.0
115
–0.048 –0.078
+0.015 –0.015
0.033 – 0.093
1.0
130
–0.1 –0.3
+0.3 +0.1
0.2 – 0.6
1.0
Tolerance
Standard size
Shaft
Hole
200
+0.051 +0.031
–0.033 –0.079
Standard Interference interference limit 0.064 – 0.130
5
Press-fitting force for side pin bushing
121.5 – 294 kN {12.4 – 30 ton}
6
Press-fitting force for center pin bushing
68.6 – 232.2 kN {7 – 23.8 ton}
7
Press-fitting force for side pin bushing
47.0 – 96.0 kN {4.8 – 9.8 ton}
D475A-3
Replace bushing
—
—
40-39 1 5
MAINTENANCE STANDARD
PIVOT SHAFT
PIVOT SHAFT
Unit: mm
No.
Check item
Criteria Tolerance
Remedy
Standard size
Shaft
Hole
270
+0.216 +0.086
–0.234 –0.286
0.320 – 0.502
—
2
Interference between thrust washer and seal
194
+0.096 +0.050
–0.075 –0.147
0.125 – 0.243
—
3
Interference between pivot shaft and seal
263
+0.108 +0.056
–0.122 –0.203
0.178 – 0.311
—
Interference between thrust washer and seal
1
Standard Interference interference limit
Replace
Clearance between pivot shaft and bushing
4
Clearance between pivot shaft and bushing
5
40-40 1 5
Tolerance
Standard size
Shaft
Hole
Standard clearance
Clearance limit
260
–0.190 –0.271
+0.138 +0.026
0.216 – 0.409
1.0
220
–0.170 –0.242
+0.114 +0.038
0.208 – 0.356
1.0
Replace bushing
D475A-3
MAINTENANCE
HYDRAULIC (SAL140
HYDRAULIC PUMP
STANDARD
PUMP
+ 100)
176.5519.6Nm ~16*2bml
SAR-100
SAR-140
SWD03071
Unit: mm
No
1
Check item
Clearance between gear case and side plate gear
Remedy
Criteria
I
Type
Standard clearance
SAL1 40
0.11 - 0.16
SAL100
0.13 - 0.18
SAL140
0.069 - 0.140
Clearance limit
0.22
-
2
Clearance between plain bearing I.D. and gear shaft O.D.
0.20 SAL100
SAR-140 3
Pin insertion depth
4
Rotational torque of spline shaft I
3eplace
0.078 - 0.149 SAR-100
-
Type
-
16.67 - 26.48 Nm Il.7 - 2.7 kgml Revolution (rpm)
Discharge pressure
Standard discharge Wmin)
Discc;ge Wmin)
Discharge EOIO - CD 45 - 55°C
D475A-3
40-41 0
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
MAIN CONTROL VALVE BLADE LIFT VALVE
m
278*31.9Nm (28.3*3.25bml
m ksml
QKi 368*24.5Nm (37.5*2.50kPml
1 A-A
‘3
G= 34.3*4.90Nm (3.50*0.50kPml
278*31.9Nm ~28.3*3.25ksml
D-D SJD03063
0475A-3
40-43 0
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
BLADE LIFT VALVE
f
Main relief, valve
SBD01246
Unit: mm Remedy
1
Spool return spring
2 3
4
Replace
5
Check valve spring
6
Suction valve spring
7
Demand spool spring
8
75.9
38.5
11.38 N II.16 kg)
68.4
9.12 N lo.93 kg)
94.03
60
401.8 N 141 kg1
114.7
321.4 N i32.8 kg}
Main relief valve spring
41.1
32.6
258.9 N I26.4 kg}
39.4
206.9 N I21.1 kg?
9
Shuttle valve spring
42.7
22.0
8.14 N IO.83 kg1
38.6
6.47 N IO.66 kg)
IC
Height of main relief pressure adjustment screw
-
-
40-44 0
8 (I turn of screw adjusts by 2.4 MPa l24.8 kg/cm%
Adjust
D475A-3
MAINTENANCE
MAIN
STANDARD
CONTROL
VALVE
BLADE TILT, RIPPER LOW VALVE
Es=
34.3*4.90Nm i3.50*0.50bml
30.9*3.43Nm 13.15*0.35kml
w
39.2*9.61Nm t4.0*l.Oksml
34.3*4.90Nm
w 66.7*961Nm (7.0*l.OkPml w 93.2-t490Nm (9.50*0.50bml
A-A
34.3*4.90Nm ~3.50~0.50kml
%3*4.90Nm ~3.50*0.50kom1
SJD03064
Unit: mm Criteria
NC
1
Remedy
Spool return spring
Replace 2
3
4 5
Adjust
-
D475A-3
40-45 0
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
RIPPER HIGH VALVE
a=
211*29.4Nm (21.5~3.0kPml
Unit: mm
No
Criteria
Check item
Repair limit
Standard size
1
Spool return spring
2
Check valve spring
3
Suction valve spring
4
Fixed differential pressure valve spring
Free length
Installation length
Remedy
Installation load
Free length
Installation load
-
40-46 0
D475A-3
MAINTENANCE
PPC VALVE
STANDARD
PPC VALVE .
FOR RIPPER
112.8&14.7Nm (11.5~1.5kgm) 13.2t1.5Nm (1.35+0.15kgm)
44.124.9Nm (4.5+0.5kgm)
39.2*4.9Nm (4?0.5kgm)
8.5+2.5Nm (0.85+0.25kgm)
SYDoO454
Unit: mm
No.
1
I
Standard size
I
Centering spring (for P3, P4)
Centering
spring
(for PI, P2) 3
I
Metering spring
D475A-3
Criteria
Check item
Remedy Repair limit
I
I
Free length x OD
Installation length
Installation load
Free length
50.05 x 15.5
34
71.39 N 17.28 kg)
-
50.35 x 15.5
34
55.9N
26.53x8.15
24.9
15.7 kg1 16.7 N (1.7 kg}
56.9 N 15.8 kg} 45.1 N
-
-
I
Installation load I
14.6 kg)
Replace spring if damaged or deformed
17.7 N Il.4 kg}
40-47 a
MAINTENANCE
.
PPC VALVE
STANDARD
FOR BLADE LIFT, BLADE TILT
m
P3
113* 14.7Nm (tl.5* 1.5kml
P4 A-A
P2
Pl c-c
SJD03066
40-48 0
D475A-3
MAINTENANCE STANDARD
PPC VALVE
Unit: mm
Check item
No -
Criteria Standard size
1
-
2
Centering spring (for PI)
Metering spring
3
Centering spring (for P2)
4
Centering spring (for P3, P4)
5
Detent spring (for PI)
6
Ietent spring (for P2)
D475A-3
Remedy
Free length Installation Installation x O.D. 1 length 1 load 1
lLL:h
37.9 x 15.6
32.5
156 N l15.9 kg}
-
26.53x8.15
24.9
16.7 N il.7 kg}
-
48.6x 15.5 /
32.5
j {;190”Fgl 1
1
Repair limit
I
-
Installation load 124.5 N (12.7 kg} 13.7 N il.4 kg)
86.2 N i8.8 kg)
Replace spring if damaged or deformed
86.2 N 18.8 kg}
134 N 113.7 kg1
45.36 x 7.5
26
38.44 N (3.92 kg}
-
30.79 N 13.14 kg}
40-49
MAINTENANCE
WORK EQUIPMENT
STANDARD
CYLINDER
WORK EQUIPMENT CYLINDER .
BLADE ~STD
LIFT CYLINDER :343*34.5Nm {35.0*3.5kPml Super dozer:490f49.ONm ~50.0*5.Okom~
m
112.8*14.7Nm
A
4mm
SXD03129
.
BLADE TILT CYLINDER, SUPER DOZER PITCH CYLINDER 1
2
SJD03075
.
RIPPER CYLINDER
1323.9*147.1Nm
.
PIN PULLER CYLINDER ~,::\~;$l~rn
2
1
SWD03077
40-50 0
D475A-3
MAINTENANCE
WORK EQUIPMENT CYLINDER
STANDARD
Unit: mm
NC -
1
Criteria
Check item
Clearance between piston rod and bushing
Tolerance
Remedy
Standard size
Shaft
Hole
Standard clearance
Clearance limit
Blade lift
110
-0.036 -0.123
+0.274 +0.060
0.096 0.397
0.72
Blade tilt
140
-0.043 -0.143
+0.277 +0.061
0.104 0.480
0.82
Ripper lift
120
-0.036 -0.123
+0.277 +0.062
0.098 0.400
0.70
Ball 125
-0.300 -0.200
+0.300 0
0.300 0.500
0.8
Ripper tilt Pin puller
-
Blade lift
2
Clearance between piston rod support shaft and bushing
3 -
4
1: -
Clearance between cylinder support shaft bushing and yoke
Clearance between cylinder bottom surx~ort shaft and bushing
Blade tilt Ripper lift Ripper tilt I
110
Pin puller
Ball 29
-0.100 -0.200
Blade lift
145
-0.145 -0.245
Blade tilt
90
-0.200 -0.300
Ripper lift
110
+0.207 +0.120
1.0
Ripper tilt
110
+0.195 +0.122
1.0
26
zo. 1
Clearance between cylinder bottom support shaft and boss
D475A-3
Replace +0.207 +0.120
I
+0.457 +0.390
0.570 0.757
1.0
40-5 1 a
MAINTENANCE
CYLINDER STAY
STANDARD
CYLINDER STAY
SJD03067
Unit: mm Criteria
Clearance between cylinder yoke and bushing
40-52 0
DA75A-3
MAINTENANCE
STANDARD
BLADE
BLADE l
SEMI U-BLADE
13 /‘I E
E-E
’
I-e
D
F-F
H-H
G-G
K-K
J-J
A-A
M-M SWD03068
40-54 0
D475A-3
MAINTENANCE
BLADE
STANDARD
Unit: mm
NC -
Check
Remedy
item
Clearance between pin and brace
Tolerance
Standard clearance
Clearance limit
+0.5 +0.3
0.5 - 0.8
2
-0.2 -0.3
+0.3 +O.l
0.3 - 0.6
2
90
-0.2 -0.3
+O.l 0
0.2 - 0.4
1
Standard size
brace
Shaft
Hole
90
-0.2 -0.3
90
2
Clearance between pin and bracket
brace
3
Clearance between pin and bracket
brace
4
Clearance between brace pin and joint bushing
90
-0.2 -0.3
+O.l 0
0.2 - 0.4
1
5
Spherical clearance between arm and
200
-0.2 -0.3
+0.3 0
0.2 - 0.6
1
6
Clearance between and bracket
joint
7
Clearance between pin and joint
frame
8
Clearance between pin and bracket
frame
9
Spherical clearance f.e$e;;fl;;fe;ushings
IO
Spherical clearance between trunnion and cap 1
250
/
::z
/
+zm5
1 o-5- 1.5 /
11
Clearance between and bracket
joint
1
240
/
2:;
1
1;:;
1 0.3 - 0.7
1
3
12
Clearance between pin and joint
blade
1
120
/
2:;
/
+;‘3
1 0.3 - 0.8
1
3
13
Clearance between pin and bracket
blade
1
120
/
-g
/
1;:;
I 0.5-
1
2
14
Spherical clearance between arm and cap
1
200
1
21%
1
+is3
1 0.2 - 0.6 1
1
15
Clearance between pin and arm
arm
0.6 - 1.0
2
16
Clearance between pin and bracket
arm
-
Replace
-
-
-
cap
1
240
/
2:;
1
1;:;
/ 0.3 - 0.7
1
3
1
120
1
;I;
/
+;‘3
1 0.3 - 0.8
1
3
120
1
2:;
/
1;:;
10.5-1.0
1
2
165
1
/ 0.3 - 0.4
/
I
Adjust shim or replace
-
-
of 1
/
-
Replace
8
-
1.0
Adjust shim or replace
-
90
-0.3 -0.5
+0.5 +0.3
90
-0.3 -0.5
io.3 +O.l
Replace 0.4 - 0.8
2
-
D475A-3
40-55 0
MAINTENANCE
l
STANDARD
BLADE
U-DOZER, SUPER DOZER
A,
A-A
D-D
G-G
i
‘7 E-E
F-F
H-H
J-J SED01257
40-56 0
D475A-3
MAINTENANCE
BLADE
STANDARD
Unit: mm
No -
Criteria
Check item
Remedy
1
Clearance between pin and brace
brace
2
Clearance between pin and bracket
brace
3
Clearance between pin and bracket
brace
4
Clearance between pin and bushing
brace
5
Clearance between center brace and cap spherical surface
200
-0.2 -0.3
+0.3 0
0.2 - 0.6
1
6
Clearance between joint and bracket
240
-0.2 -0.4
+I.5 +I.0
1.2 - 1.9
3
7
Clearance between pin and joint
frame 120
-0.3 -0.5
+0.3 0
0.3 - 0.8
3
Clearance between pin and bracket
frame
8
120
-0.3 -0.5
+0.207 +0.120
0.420 0.707
2
-0.152 -0.266
-
(
90
-0.2 -0.3
+0.3 +O.l
0.3 - 0.6
2
90
-0.3 -0.4
+O.l 0
0.3 - 0.5
1
90
1
2:;
1
+y
1 0.3 - 0.5
1
1
Replace
1
-
-
-
-
Clearance between 9
straight bushings frame joint
185
+0.206 +0.166
-0.014 -0.060
10
Clearance between trunnion and cap spherical surface
250
-0.5 -1 .o
+I.0 0
0.5 - 2.0
8
11
Clearance and bracketbetween
joint
240
-0.2 -0.4
+0.3 +O.l
0.3 - 0.7
3
12
Clearance between pin and joint
blade
120
-0.3 -0.5
+0.3 0
0.3 - 0.8
3
Clearance between pin and bracket
blade
13
120
-0.3 -0.5
+0.208 +0.118
0.418 0.708
2
14
Clearance between center link pin and blade bracket
145
-0.043 -0.108
iO.225 +0.106
0.149 0.333
2
15
Clearance between center link pin and center link
145
-0.043 -0.108
+0.225 +0.106
0.149 0.333
2
16
Clearance between center link and blade bracket
550
-0.2 -0.8
+0.3 0.
0.2 - 1.1
2
Clearance between center brace spherical surface
200
-0.2 -0.3
+0.3 0.
0.2 - 0.6
1
-
Adjust shim or replace
-
Replace
-
-
-
17 -
and cap
D475A-3
Adjust shim or replace
40-57 0
MAINTENANCE
.
CUlTING
BLADE
STANDARD
EDGE, END BIT
w
3344* 373Nm (341*38kPml /
s=
3344* 373Nm (341*38kPmI I
.-__---------------------------------------------
4
SWD03069
Unit: mm
Criteria
Check item
No.
Standard of end bit outside
1
Height
2
Width
3
Height
of end bit inside
4
Height
of cutting
40-58 0
of end bit
edge
size
Remedy Repair
limit
510
383
720
635
393
330
405
351 (240 after turned)
Replace
Replace or turn
D475A-3
MAINTENANCE
RIPPER EQUIPMENT
STANDARD
RIPPER EQUIPMENT .
VARIABLE
GIANT
_-________\
RIPPER
,_._
____.___* ___---_-,--L______-_ --------_____
__-______
__-J
D-D
c-c
E-E
40-60 0
SWD03070
D475A-3
MAINTENANCE
STANDARD
RIPPER EQUIPMENT
Unit: mm
1
Clearance between bushing and bracket and arm mount pin
2 3
4
Clearance between shank and mount pin
5
6
D475A-3
40-61 0
90
OTHERS
Work equimpmet hydraulic circuit diagram Single tilt specification ......................................................................... 90- 3 Dual tilt specification (Serial No.: 10601 – 10674) ............................. 90- 5 Dual tilt specification (Tandem circuit specification) (Serial No.: 10675 and up) ...... 90- 5-2 Dual tilt specification (Parallel circuit specification) (Serial No.: 10675 and up) ....... 90- 5-4 Super dozer specification ..................................................................... 90- 7 Electrical circuit diagram Single tilt and dual tilt specifications Chassis electrical circuit diagram (1/3) ......................................... 90- 9 Chassis electrical circuit diagram (2/3) ......................................... 90-11 Chassis electrical circuit diagram (3/3) ......................................... 90-13 Super dozer specification Chassis electrical circuit diagram (1/3) ......................................... 90-15 Chassis electrical circuit diagram (2/3) ......................................... 90-17 Chassis electrical circuit diagram (3/3) ......................................... 90-19 Heavy-duty specification Chassis electrical circuit diagram (1/3) ...................................... 90-19-2 Chassis electrical circuit diagram (2/3) ...................................... 90-19-4 Chassis electrical circuit diagram (3/3) ...................................... 90-19-6 Electrical circuit diagram for inside cab ............................................. 90-21
D475A-3
90-1 8
OTHERS
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM DUAL TILT SPECIFICATION (Serial No.: 10601 – 10674)
D475A-3
90-5 8
OTHERS
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM DUAL TILT SPECIFICATION (TANDEM CIRCUIT SPECIFICATION) (Serial No.: 10675 and up)
D475A-3
90-5-2 8
OTHERS
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM DUAL TILT SPECIFICATION (PARALLEL CIRCUIT SPECIFICATION) (Serial No.: 10675 and up)
D475A-3
90-5-4 8
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SINGLE TILT SPECIFICATION AND DUAL TILT SPECIFICATION) (1/3)
D475A-3
90-9 8
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SINGLE TILT SPECIFICATION AND DUAL TILT SPECIFICATION) (2/3)
D475A-3
90-11 8
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (HEAVY-DUTY SPECIFICATION) (1/3)
D475A-3
90-19-2 8
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (HEAVY-DUTY SPECIFICATION) (2/3)
D475A-3
90-19-4 8
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (HEAVY-DUTY SPECIFICATION) (3/3)
D475A-3
90-19-6 8
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM INSIDE CAB
90-21 0
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:
