SEBM027501
BASE MANUAL
1
D475A-3 (PALM CONTROL SPECIFICATION)
MACHINE MODEL
SERIAL No.
D475A-3
10695 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 mounts the SDA12V140E-1 engine. For details of the engine, see the 12V140-1 Series Engine Shop Manual.
© 2004 1 All Rights Reserved Printed in Japan 01-04(01)
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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
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D475A-5
00-2-5 (1)
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.
FOREWORD
GENERAL
FOREWORD 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
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) 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: Attachments volume: · volume to cover all models
REVISIONS
}
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-todate information before you start any work.
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): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. 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: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
123
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.
Symbol
Item
Remarks
¤
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.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.
s
4 3 2 5 6
FOREWORD
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
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
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°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ ¤
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
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 turn lever (4) to the right (clockwise).
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.
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 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.
Connection
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.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardenin g agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
790-129-9140
50 g
Polyethylene container
2g
Polyethylene container
Adhesives
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl or ide) , rubber, metal and non-metal.
• •
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
•
Used as adhesive or sealant for metal, glass and plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
•
Gasket sealant • LG-6
790-129-9020
200 g
Tube
• •
00-10
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr •
LG-7
790-129-9070
1g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
•
Adhesives
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ 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
27 30 33 36 39
41 46 50 55 60
Thread diameter of bolt
Width across flats
mm
mm
Nm
6 8 10 12
10 13 14 27
7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85
Nm
kgm
0 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35
0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340
1.35 3.2 6.7 11.5 18
13.2 31 66 113 177
kgm
0 0 0 0
0.8 1.9 4.1 8.4
0 0.2 0 0.5 0 0.6 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ 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
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
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
2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5
00-12
Tightening torque
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
65.7 6.8 112 9.8 279 29
0 0 0
6.7 0.7 11.5 1 28.5 3
0
0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14 20 24 33 42
Varies depending on type of connector.
34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3
Norminal No.
02 03, 04 05, 06 10, 12 14
kgm
0 0 0 0 0
0 0.5 01 02 06 0 13.5
3.5 9.5 14.5 43 89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 n 36 n n
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 0 0 0 0 0 0 0 0 0 0 0 0
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
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
0 0 0 0 0 0 0 0 0 0 0 0 0
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6 8 10 12
10 2 24 4 43 6 77 12
kgm
0 0 0 0
1.02 2.45 4.38 7.85
0 0.20 0 0.41 0 0.61 0 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6 8 10 12 14
8 2 10 2 12 2 24 4 36 5
kgm
0 0 0 0 0
0.81 1.02 1.22 2.45 3.67
0 0.20 0 0.20 0 0.20 0 0.41 0 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
00-14
Tightening torque
mm
Nm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3 1 8 2 12 2 15 2 24 4 36 5 60 9
0 0 0 0 0 0 0
kgm 0.31 0.81 1.22 1.53 2.45 3.67 6.12
0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92
FOREWORD
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 Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
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
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm 2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
RY
Black & Red Red & Yellow
n n n n
RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
n n 00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point 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.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40
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
0.197 0.591 0.984 1.378 1.772
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
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
C
FOREWORD
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
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon
l
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
l
1 = 0.21997 U.K. Gal
0
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
00-18
FOREWORD
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
FOREWORD
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
FOREWORD
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 0
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
FOREWORD
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 ............. 01- 2 Specifications ............................................... 01- 4 Weight table ................................................ 01-13 Table of fuel, coolant and lubricants ........ 01-17
D475A-3
01-1
GENERAL
SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS •
SEMI U-TILTDOZER + GIANT RIPPER
•
U-TILTDOZER + GIANT RIPPER
01-2
Unit: mm
D475A-3
GENERAL
•
SUPER DOZER + COUNTERWEIGHT
D475A-3
SPECIFICATION DIMENSION DRAWINGS
Unit: mm
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS •
SEMI U-TILTDOZER, U-TILTDOZER Machine model
D475A-3
Serial No.
10695 and up
Operating weight
Weight
• Bare tractor • With above + semi U-dozer
75,700 kg
• With above + variable giant ripper
99,150
• With above + ROPS cab + air conditioner • + perforated side cover
100,500
Min. turning radius
m
4.6
Gradeability
deg
30
Stability (front, rear, left, fight)
deg
35
Speed ranges
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
Reverse 3rd
0 – 14.3
Bare tractor
119 {1.22}
With semi U-dozer With semi U-dozer + variable giant ripper
145.2 {1.48} kPa {kg/cm2}
159 {1.62}
Overall length
With above + ROPS cab + air conditioner + perforated side cover
156 {1.60}
Bare tractor
With semi U-dozer + variable giant ripper
11,570
With U-dozer + variable giant ripper
11,950
Overall height Overall Width
Ground pressure
Performance
Forward 1st
Dimensions
91,850
Bare tractor
3,610
01-4
6,420
With semi U-dozer
8,710 mm
With semi U-dozer
mm
5,265
With U-dozer
6,205
To top of ROPS
4,570
To tip of exhaust pipe To top of intake duct
mm
4,420 3,760
D475A-3
Dimensions
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 and up
Track gauge Length of track on ground Track shoe width
710
Min. ground clearance
655
Name
SDA12V140E-1
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
4,365 mm
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
2,770
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
Undercarriage
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 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 + 160 + 112)
Scavenging pump (tandem)
Gear type (BAR63 + 320)
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
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
Dimensions of blade dual tilt cylinder Hydraulic cylinders
Dimensions of ripper Dimensions of ripper lift cylinder tilt cylinder
Work equipment hydraulic system
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 and up
Cylinder bore (both left and right)
250
Outside diameter of piston rod (both left and right)
140
Piston stroke (both left and right)
mm
Max. distance between pins (both left and right)
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
2,020
Min. distance between pins
1,480 Control valve assembled type (externally installed) Hydraulic semi U-tiltdozer, Hydraulic U-tiltdozer
Dimensions
Performance
Blade support method
Semi U-dozer
540
Max. distance between pins
Type
Work equipment
645
Max. distance between pins
Hydraulic tank
D475A-3
285
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
01-8
Performance Dimensions Performance Dimensions Performance Performance Performance Dimensions
Semi U-dozer + pitch U-dozer + pitch Giant ripper
Multi-shank ripper
Work equipment
U-dozer
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 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.
10695 and up
Weight
Operating weight • Bare tractor
kg
• Super dozer + ROPS cab + air conditioner • + counterweight Min. turning radius
105,000 m
4.6
Gradeability
deg
30
Stability (front, rear, left, fight)
deg
35
Forward 2nd
0 – 3.5 km/h
0 – 6.3
Forward 3rd
0 – 10.9
Reverse 1st
0 – 4.7 km/h
0 – 8.4
Reverse 3rd
0 – 14.3
Ground pressure
Reverse 2nd
Bare tractor
104.25 {1.07}
Dimensions Overall Overall height Overall Width length
Speed ranges
Forward 1st
Performance
75,700
Bare tractor
D475A-3
Super dozer + ROPS cab + air conditioner + counterweight
mm
146.19 {1.49} 6,420
mm Super dozer + counterweight
10,370
Bare tractor
3,610 mm
With super dozer
6,465
To top of ROPS
4,570
To tip of exhaust pipe To top of intake duct
mm
4,420 3,760
01-9
Dimensions
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 and up
Track gauge Length of track on ground Track shoe width
810
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}
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
Rated horsepower
Engine
4,365 mm
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
2,770
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
01-10
Spur gear 1-stage, planetary gear 1-stage reduction gear, splash type lubrication
D475A-3
Undercarriage
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 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
GENERAL
SPECIFICATIONS
Machine model
D475A-3
Serial No.
10695 and up
Type
Hydraulic super dozer (pitch dozer)
Performance Dimensions
Super dozer
Work equipment
Blade support method
01-12
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
D475A-3
Serial No.
10695 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) Power train unit
858 (2,330) 4,990
• Torque converter, PTO assembly • Transmission assembly • Transmission valve assembly • Steering clutch, brake assembly • Steering valve assembly
750 1,350 40 2,295 13
Final drive assembly (each side)
3,575
Main frame assembly
9,120
Track group assembly (each side)
11,180
• Track frame (each side)
2,996
• Idler assembly (each side)
708
• Track roller assembly (single, each)
222
• Track roller assembly (double, each)
237
• Carrier roller assembly (each)
106
Track shoe assembly (710 mm width)
13,220
Pivot shaft assembly (each side)
370
Equalizer bar
598
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
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
D475A-3
Serial No.
10695 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
600
Cab assembly
415
Operator’s seat assembly
64
fl The figures in (
01-14
) show the dimensions for the U-blade.
D475A-3
GENERAL
•
WEIGHT TABLE
SUPER DOZER
Unit: kg
Machine model
D475A-3
Serial No.
10695 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) Power train unit • Torque converter, PTO assembly • Transmission assembly • Transmission valve assembly • Steering clutch, brake assembly • Steering valve assembly
858 (2,330) 4,980 750 1,350 70 2,290 26
Final drive assembly (each side)
3,575
Main frame assembly
9,120
Track group assembly (each side)
11,180
• Track frame (each side)
2,996
• Idler assembly (each side)
708
• Track roller assembly (single, each)
222
• Track roller assembly (double, each)
237
• Carrier roller assembly (each)
100
Track shoe assembly (810 mm width)
14,060
Pivot shaft assembly (each side)
370
Equalizer bar
598
Hydraulic tank assembly
498
• Main control valve (blade lift)
69
• Main control valve (blade tilt, ripper)
46
D475A-3
01-15
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
D475A-3
Serial No.
10695 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
600
Cab assembly
415
Operator’s seat assembly
64
01-16 (1)
D475A-3
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
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
D475A-3
Diesel fuel Coolant
ASTM D975 No. 2 ASTM D975 No. 1
Add antifreeze
01-17
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.
01-18
D475A-3
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 ................................... 10-32 Transmission ECMV .................................... 10-34 Transmission clutch ECMV ......................... 10-36 Transmission lubrication relief valve ........ 10-40 Priority valve ................................................ 10-41 Steering, brake control ................................ 10-42 Transfer, bevel gear shaft, steering ........... 10-44 Transfer, bevel pinion ................................. 10-45 Steering ECMV ............................................. 10-48 Steering clutch ECMV, Steering brake ECMV ............................ 10-50
D475A-3
Sudden stop prevention valve ................. 10- 57 Final drive ................................................... 10- 58 Track frame ................................................. 10- 62 Hydraulic tank ............................................ 10- 65 PPC valve .................................................... 10- 66 Main control valve ..................................... 10- 78 Pin-puller hydraulic system drawing ....... 10- 86 Pin-puller hydraulic circuit drawing ......... 10- 86 Pin-puller solenoid valve ........................... 10- 87 Air conditioner ........................................... 10- 89 Engine control ............................................ 10- 90 Engine control system ............................... 10- 91 Deceleration potentiometer ...................... 10- 92 Engine control system with electronic engine throttle controller .................... 10- 94 Monitor system .......................................... 10- 96 Monitor panel ............................................. 10- 98 Mode selection system ............................. 10-106 Electrical equipment .................................. 10-112 Steering electronic control ........................ 10-116
10-1
STRUCTURE AND FUNCTION
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
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)
10-2
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.
D475A-3
STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN
Outline • The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3), and 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 (10) installed to the outside of the steering clutch. Steering brake (10) uses the same disc system that is used for the steering clutch. The power output from the steering clutch enters final drive (11), where it is reduced, and rotates sprocket (12). Final drive 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
STRUCTURE AND FUNCTION
POWER TRAIN SKELETON
POWER TRAIN SKELETON
1. 2. 3. 4.
Engine (SDA12V140) Damper Universal joint Power train, hydraulic, lubricating pump (BAL160+160+112) 5. Hydraulic pump (SAL140+100)
10-4
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 PIPING DIAGRAM
POWER TRAIN HYDRAULIC PIPING DIAGRAM
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+160+112) Scavenging pump Power train oil cooler
D475A-3
a. b. c. d. e. f. g. h. i. j. k. l. m. n.
Torque converter inlet pressure pick-up port (IN) Torque converter lock-up pressure pick-up port (LU) Transmission relief pressure pick-up port (TM) Transmission reverse clutch pressure pick-up port (REV) Transmission forward clutch pressure pick-up port (FWD) 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 1st clutch pressure pick-up port (1st) Transmission 2nd clutch pressure pick-up port (2nd) Transmission 3rd clutch pressure pick-up port (3rd) Torque converter stator clutch pressure (SC) Torque converter outlet pressure pick-up port (OUT)
10-5
STRUCTURE AND FUNCTION
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
10-6
D475A-3
STRUCTURE AND FUNCTION
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
A. B. C. D. E.
Oil tank Power train oil strainer Power train pump Torque converter charge pump Power train lubrication pump Power train oil filter Torque converter oil filter Power train lubrication oil filter Main relief valve Priority valve Modulating valve Quick return valve Reducing valve Pilot valve Reverse spool Forward spool 3rd speed spool 2nd speed spool 1st speed spool Transmission speed spool Transmission F-R spool Reverse clutch Forward clutch 3rd clutch 2nd clutch 1st clutch Torque converter relief valve Torque converter Oil cooler Steering clutch and brake lubrication Torque converter case Torque converter lock-up valve Modulating valve Torque converter lock-up clutch Modulating valve Stator clutch Torque converter lock-up solenoid valve Steering check valve R.H. steering valve R.H. brake valve L.H. brake valve L.H. steering valve Steering clutch Steering brake Steering case Transmission lubrication valve Transmission lubrication PTO Lubrication Scavenging pump Solenoid for pin puller
D475A-3
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 O. 2nd speed oil pressure switch P. 1st speed oil pressure switch Q. Modulating oil pressure sensor
10-7
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO
A. B. C. D.
Power train pump installed position Scavenging pump installed position Assist pump installed position Hydraulict pump installed position
D475A-3
10-9 10-9 (1)
STRUCTURE AND FUNCTION
10-10
TORQUE CONVERTER AND PTO
D475A-3
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.
TORQUE CONVERTER AND PTO
Coupling Seal cage Input shaft (59 teeth) Front housing Idler gear (74 teeth) Idler gear shaft Clutch housing Drive case Turbine Rear housing Stator Pump Stator shaft Bearing cage Retainer Shaft Transmission input shaft Stator shaft boss Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lock-up clutch disc Lock-up clutch plate Lock-up clutch piston Scavenging pump gear (65 teeth) Seal seat Spacer Cover Hydraulic pump gear (61 teeth) Power train pump drive gear (61 teeth) Drive shaft Cover
D475A-3
10-11
STRUCTURE AND FUNCTION
Outline • The torque converter is a 3-element, single-stage, 1-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. • 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. fl The condition for the torque converter to enter the lock-up range and torque converter range are as follows. • 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/cm2} • 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/cm2}
10-12
TORQUE CONVERTER AND PTO
Structure • Pump (12) forms one unit with coupling (1), shaft (3), clutch housing (7), 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) (17), and is rotated by oil from the pump. • Stator (11) forms one unit with stator shaft (13) and stator shaft boss (18), and is locked to rear housing (10) by the stator clutch. • The lock-up clutch consists of three parts: clutch plate (26) (meshed with drive case (8)), clutch disc (25) (meshed with turbine boss (24)), and clutch piston (27) (that slides inside housing (7), 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 (13)), clutch plate (21) (supported by a pin to clutch housing (19) and rear housing (10)), and clutch piston (23) (that slides inside the rear housing). • The PTO consists of input shaft (3), 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
TORQUE CONVERTER AND PTO
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 (10) and stator shaft (13) are connected, so stator (11) is locked and the torque converter provides the normal functions of a torque converter. The power generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. The motive force from the pump uses oil to rotate turbine (9), and is transmitted to transmission input shaft (17), which forms one unit with the turbine.
2. Lock-up clutch ON, stator clutch OFF When 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 (10) and stator shaft (13) is cut, so stator (11) follows the rotation of pump (12) and turbine (9). The power generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. In addition, the drive case and turbine (9) are connected by the clutch, so the oil is not used. The motive force is transmitted directly to the turbine and transmission input shaft (17).
D475A-3
10-13
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
Flow of oil • Oil set to within 0.87 MPa {8.7 kg/cm2} by the torque converter relief valve flows from port A, passes through the oil hole inside rear housing (10), and enters pump (12). The pump is always being rotated by the power from the engine, so the oil entering the pump is given centrifugal force, and enters turbine (9). The turbine is rotated by the centrifugal force of the oil. The turbine forms one unit with transmission input shaft (17), so the motive force received by the turbine is transmitted to the transmission. The oil leaving the turbine is sent to stator (11) and enters the pump again, but some of the oil passes from the stator through port B and is sent to the oil cooler.
10-14
D475A-3
STRUCTURE AND FUNCTION
TTORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
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
16. Valve spring (Outer) 17. Valve spring (Inner) 18. Stopper 19. Load piston 20. Cover 21. Cover 22. Valve spring 23. Valve body 24. Lock-up selector valve 25. Piston 26. Cover Lock-up solenoid valve assembly 27. Cover 28. Coil 29. Spring 30. Plunger 31. Valve seat holder
32. 33. 34. 35.
Valve seat Spring Valve seat Cap
P. P3. P8. P10. P11. T.
Stator clutch pressure pickup port Lock-up clutch pressure pickup port Main relief pressure pickup port Lock-up clutch initial pressure pickup port Stator clutch initial pressure pickup port From torque converter pump
D475A-3
STRUCTURE AND FUNCTION
1
2
3
TTORQUE CONVERTER VALVE
4
5
6
21
22
23
24
25
26
7
8 9 6
10
E–E
11 12 13
20
19
18
17
16
15
14
D–D
27 28 29 30 31 32 33 34 35
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/cm2} 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 {8.7 kg/cm2} 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 ↔ OFF. D475A-3
4. 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 ↔ OFF. 5. Stator clutch modulating valve Modulating valve (10) sets the clutch pressure to 2.7 MPa {27 kg/cm2} 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. 6. Lock-up clutch modulating valve Modulating valve (11) acts in the same way as stator clutch modulating valve (10) and sets the clutch pressure to 1.3 MPa {13 kg/ cm2} to protect the stator clutch from abnormally high pressure.
10-17
STRUCTURE AND FUNCTION
TTORQUE CONVERTER VALVE
To torque converter
To oil tank
2 Operation of main relief valve • The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to rise. • When the pressure in the circuit rises, the oil entering port B pushes piston (9). The reaction force compresses spring (4), moves main relief valve (5) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure in the circuit at this point is 2.7 – 3.0 MPa {27.0 – 30.4 kg/cm2}. Operation of torque converter relief valve • 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.
E 3
D
9
A
b 5 C
9 B
4 a From pump To torque converter
SBD00663
To oil tank
2 E 3
D
9
A
b 5 C
9 B
4 a From pump
20 •
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/cm2}.
To torque converter
SBD00664
To oil tank
2 E 3 D 9
A b 5 C
9 B
4 a From pump
10-18
SBD00665
D475A-3
STRUCTURE AND FUNCTION
TTORQUE 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 ↔ 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.
D475A-3
10-19
STRUCTURE AND FUNCTION
TTORQUE CONVERTER VALVE
1. Travel in torque converter drive
When the machine is in the torque converter range, the solenoid valve is DEACTIVATED, so valves (32) is pushed to the left in the direction of the arrow by the tension of spring (29). Ports N and P open.
10-20
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.
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
TTORQUE 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.
2. 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.
10-21
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. fl 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 (10) is returned to the right in the direction of the arrow by the tension of spring (16), 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.
10-22
D475A-3
STRUCTURE AND FUNCTION
TTORQUE CONVERTER VALVE
2. Travel in torque converter drive 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 (10) 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.
As the hydraulic pressure in the circuit rises, the oil passing through orifice d in modulating valve (10) pushes piston (13), and the reaction force moves the modulating valve to the left in the direction of the arrow to throttle ports Q and H. Port Q is connected with port S that applies back pressure to load piston (19), 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 Q and H are closed to complete the rise in hydraulic pressure. The hydraulic pressure at this point is 2.5 ± 0.1 MPa {25 ± 1 kg/cm2}. The hydraulic pressure of the lock-up clutch +1 2 is 1.3 +0.1 +0 MPa {13 +0 kg/cm }.
D475A-3
10-23
STRUCTURE AND FUNCTION
TRANSMISSION
TRANSMISSION
1. 2. 3. 4.
Input shaft Transmission ECMV Front case Rear case
D475A-3
10-25
STRUCTURE AND FUNCTION
10-26
TRANSMISSION
D475A-3
STRUCTURE AND FUNCTION
5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
TRANSMISSION
Front cover Sun gear for REVERSE (32 teeth) 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
10-27
STRUCTURE AND FUNCTION
TRANSMISSION
Outline • The transmission is a forward 3 gear, reverse 3 gear transmission that consists of a combination of a planetary gear system and disc clutches. • The transmission actuates the control valve to use hydraulic pressure to fix two of the clutches in the five sets of planetary gears and disc clutches to select one rotating direction and one gear speed. • The clutches are locked as follows: No. 1 clutch for REVERSE, No. 2 clutch for FORWARD, No. 3 clutch for 3rd, No. 4 clutch for 2nd and No. 5 clutch for 1st. No. of plates and discs used Clutch No. No. 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
Clutch combination (engaged)
FORWARD 1st 2nd 3rd
No. 2 • No. 5 No. 2 • No. 4 No. 2 • No. 3
NEUTRAL
No.5
REVERSE 1st 2nd 3rd
No. 1 • No. 5 No. 1 • No. 4 No. 1 • No. 3
10-28
D475A-3
STRUCTURE AND FUNCTION
TRANSMISSION
Operation of disc clutch • To lock ring gear (7), a disc clutch is used. The clutch consists of piston (36), plates (38), discs (39), pins (42) and piston return springs (37). The internal teeth of the disc engage with the external teeth of the ring gear. The teeth on the outside diameter of the plate engage with pins (42) secured by housing (35). Clutch engaged (locked) • Oil from the control valve flows under pressure through the port in housing (35) to the back of piston (36). The piston presses plates (38) and discs (39) together, and the resulting frictional force stops the rotation of discs (39), so ring gear (7) meshing with the internal teeth of the disc is locked.
Clutch disengaged (free) • When the supply of pressure oil from the control valve is shut off, piston (36) is returned to its original position by the force of piston return spring (37). This relieves the frictional force between plates (38) and discs (39), making 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.
D475A-3
10-29
STRUCTURE AND FUNCTION
TRANSMISSION
OPERATION OF TRANSMISSION FORWARD 1ST
•
•
•
For FORWARD 1st, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 2 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks ring gear (13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and 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 (11) to planet pinion (12).
10-30
•
•
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 (21), planet pinions, ring gears (15) and (18), and No. 4 carrier (30) form one unit. In addition, carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25). Output shaft (25) rotates at the same speed as carrier (32).
D475A-3
STRUCTURE AND FUNCTION
TRANSMISSION
REVERSE 1ST
•
•
•
For REVERSE 1st, No. 1 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 1 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks carrier (34) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and 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 (10). Ring gear (10) rotates in the opposite direction from the input shaft, and it rotates carrier (32). No. 5 clutch is engaged, so No. 5 gear (22), sun gears (17) and (21), planet pinions, ring gears (15) and (18), and No. 4 carrier (30) form one unit. In addition, carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).
10-31
STRUCTURE AND FUNCTION
TRANSMISSION CONTROL
TRANSMISSION CONTROL fl For steering operation concerned to operation of the Palm Command Steering Control lever (PCCS lever), see STEERING AND BRAKE CONTROL.
fl PCCS: Abbreviation for Palm Command Control System
1. Brake pedal 2. Safety lever 3. PCCS lever (Forward-Reverse, gear shift) 3A. FORWARD switch (Machine travels forward when this switch is pressed.) 3B. REVERSE switch (Machine travels reverse when this switch is pressed.) 3C. SHIFT switch (Gear is shifted to 1st → 2nd → 1st each time this switch is pressed.) 4. NEUTRAL switch 5. Transmission neutral safety switch 6. Cable 7. Transmission control valve
Lever or switch positions 1: Neutral 2: OFF 3: Forward 4: Reverse 5: Neutral 6: Shift UP/DOWN 7: Free 8: Lock
10-32
Outline • The transmission is controlled with PCCS lever (3) and NEUTRAL switch (4). The PCCS lever is used to select the travel direction and shift the gear. • Since the safety mechanism is employed, transmission neutral safety switch (5) does not work and the engine does not start unless safety lever (2) is in the LOCK position. D475A-3
STRUCTURE AND FUNCTION
TRANSMISSION ECMV
TRANSMISSION ECMV (Electronic Control Modulation Valve)
10-34
D475A-3
STRUCTURE AND FUNCTION
A: B: C: D: E:
1st clutch pressure detection port 2nd clutch pressure detection port 3rd clutch pressure detection port F clutch pressure detection port R clutch pressure detection port
1. 2. 3. 4. 5. 6. 7. 8. 9.
Filter Priority valve Transmission lubrication relief valve 1st clutch ECMV 2nd clutch ECMV 3rd clutch ECMV F clutch ECMV R clutch ECMV Valve seat
D475A-3
TRANSMISSION ECMV
10-35
STRUCTURE AND FUNCTION
TRANSMISSION CLUTCH ECMV
TRANSMISSION CLUTCH ECMV (Electronic Control Modulation Valve)
A: B: T: Dr: P1: P2:
To clutch From pump Drain Drain Clutch pressure detection port Pilot pressure detection port
10-36
1. 2. 3. 4. 5. 6.
Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve
D475A-3
STRUCTURE AND FUNCTION
OUTLINE OF ECMV The ECMV (Electronic Control Modulation Valve) consists of two components: the pressure control valve and the fill switch. Pressure control valve • The proportional solenoid receives the flow of electricity sent from the transmission controller, and the pressure control valve converts this into hydraulic pressure. Fill switch • This detects when oil has filled the clutch. It has the following functions. 1) When the clutch is filled with oil, it sends a signal (fill signal) to the controller to inform the controller that the filling is completed. 2) While oil pressure is applied to the clutch, it outputs a signal (fill signal) to the controller to inform the controller of the existence of the oil pressure. A range: Before gear shifting (drained) B range: Filling starts (trigger issued) C range: Filling completed D range: Regulation E range: Filling
TRANSMISSION CLUTCH ECMV
ECMV and proportional solenoid • There is one proportional solenoid installed to each ECMV. It generates propulsion as shown in the diagram below according to the command current from the controller. The propulsion generated by the proportional solenoid acts on the pressure control valve spool and generates oil pressure as shown in the diagram below. In this way, the command current is controlled and the propulsion force varies to actuate the pressure control valve and control the oil flow and oil pressure.
ECMV and fill switch • There is one fill switch installed to each ECMV. When the filling of the clutch is completed, the fill switch is turned on by the clutch pressure. With this signal, the oil pressure starts to build up.
D475A-3
10-37
STRUCTURE AND FUNCTION
OPERATION OF ECMV • The ECMV is controlled by the command current from the transmission controller to the proportional solenoid and the fill switch output signal. The relationship between the ECMV proportional solenoid command current and the clutch input pressure and fill switch output signal is as shown in the diagram below. A range: B range: C range: D range: E range:
10-38
TRANSMISSION CLUTCH ECMV
1. When gear shifting (during draining) (Range A in graph) When no current is flowing to proportional solenoid (1), pressure control valve spool (3) drains the oil at clutch port A through drain port Dr. When this happens, there is no hydraulic force acting on pressure detection valve (4), so fill switch (6) is turned OFF.
Before gear shifting (drained) Filling starts (trigger issued) Filling completed Regulation Filling
D475A-3
STRUCTURE AND FUNCTION
2. When filling (when trigger command is input to pressure control valve) (Range B and C in graph) When there is no oil inside the clutch, if electric current is applied to proportional solenoid (1), a hydraulic force balancing the force of the solenoid acts on chamber B, and pressure control valve spool (3) moves to the left. As a result, the circuit between pump port P and clutch port A opens, and oil starts to fill the clutch. When the clutch is filled with oil, fill switch (6) is turned ON.
D475A-3
TTRANSMISSION CLUTCH ECMV
3. Adjusting pressure (Range D in graph) When electric current flows to proportional solenoid (1), the solenoid generates a propulsion force proportional to the current. The pressure is adjusted so that the total of this propulsion force of the solenoid, the propulsion force of the oil pressure at the clutch port, and the reaction force of pressure control valve spring (2) is balanced.
10-39
STRUCTURE AND FUNCTION
TRANSMISSION LUBRICATION RELIEF VALVE
TRANSMISSION LUBRICATION RELIEF VALVE
1. Lubrication oil pressure measurement plug 2. Lubrication relief spool 3. Valve body
Function • The lubrication relief valve is installed to the right side face of the transmission, and acts to prevent any abnormal pressure in the transmission lubricating oil. Cracking pressure: 0.26 MPa {2.7 kg/cm2}
10-40
D475A-3
STRUCTURE AND FUNCTION
PRIORITY VALVE
PRIORITY VALVE Outline • The priority valve is installed on the circuit between the pump and the clutch ECMV. When the transmission circuit hydraulic pressure drops drastically during gear shifting, this valve closes the passages of the transmission and pilot circuits to keep the hydraulic pressure of the pilot circuit operating five clutch ECMVs, enabling it to endure gear shifting operation. Operation 1. During gear shifting The oil enters priority valve port A from the pump, then chamber C via orifice a. As the oil flow rate increases the hydraulic pressure inside the chamber C rises, causing the oil to push piston (1), and its reaction force retracts spring (2) to move valve (3) to the left. Subsequently, ports A and B are opened, allowing the oil to flow from port B to the ECMV. At this time, the hydraulic pressure (cracking pressure) is 1.13 MPa {11.5 kg/cm2}, and the oil flowing from port B to the ECMV raises the clutch set pressure up to 2.65 MPa {27 kg/cm2}. 2. Immediately after gear shifting Operating the gear shift lever causes the ECMV to reduce the hydraulic pressure behind port B drastically to almost zero. This also causes the hydraulic pressure of port A to fall, and when it falls below 1.13 MPa {11.5 kg/cm2}, valve (3) is turned back to the right by the tension of spring (2) to close passages A and B. This prevents the hydraulic pressure of port A (pilot valve port pressure) from falling any more, enabling to keep the pilot pressure 1.13 MPa {11.5 kg/cm2} (the specified pressure) or more.
D475A-3
10-41
STRUCTURE AND FUNCTION
STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL fl Regarding the transmission-related description of the operation of the PCCS lever, refer to the “Transmission Control”. fl PCCS: Palm Command Control System
10-42
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Brake pedal Safety lever PCCS lever (Steering) Steering controller Limit switch Steering ECMV Brake valve Parking brake lever (From safety lever) Cable Rod (From brake pedal) Potentiometer
Outline • PCCS lever (3) sends an electric signal to steering controller (4). After receiving it, steering controller (4) sends a proportional current to steering ECMV (6) to operate the steering clutch and brake. • The brake pedal (1) sends an electric signal to steering controller (4) via potentiometer (11). After receiving it, steering controller (4) sends a proportional current to steering ECMV (6) to operate the brake. In this case, the right and left brakes operate at the same time to activate braking. Rod (10) operates the brake via brake valve (7) for redundant use. (Only at the time of complete braking) • If you slightly tilt PCCS lever (3) leftward, the left steering clutch is partially disengaged, causing the machine to make a slow left swing.
D475A-3
STEERING, BRAKE CONTROL
Positions of lever and pedal 1: Neutral 2: Forward straight-travel 3: Reverse straight-travel 4: Left clutch OFF 5: Left clutch OFF Left brake ON 6: Right clutch OFF 7: Right clutch OFF Right brake ON 8: Brake RELEASE 9: Brake ON 0: Free A: Lock
•
•
If you completely tilt PCCS lever (3) leftward, the left steering clutch is turned “OFF” completely and the left steering brake is turned “ON”, causing the machine to make a sudden left swing. Safety lever (2) is connected to parking brake lever (8) and it also serves as a parking brake.
10-43
STRUCTURE AND FUNCTION
TRANSFER, BEVEL GEAR SHAFT, STEERING
TRANSFER, BEVEL GEAR SHAFT, STEERING
1. 2. 3. 4. 5.
Transmission Steering ECMV Steering unit Breather Torque converter output shaft speed sensor
A. Center of bevel gear shaft B. Center of crankshaft C. Center of bevel gear
10-44
D475A-3
STRUCTURE AND FUNCTION
TRANSFER, BEVEL PINION
TRANSFER, BEVEL PINION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
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
10-45
STRUCTURE AND FUNCTION
TRANSFER, BEVEL PINION
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
10-46
D475A-3
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
TRANSFER, BEVEL PINION
Outline • 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.
10-47
STRUCTURE AND FUNCTION
STEERING ECMV
STEERING ECMV (Electronic Control Modulation Valve)
10-48
D475A-3
STRUCTURE AND FUNCTION
A. B. C. D. E. F. G. H. J. K. L. M. N. P.
Left clutch operating pressure pick-up port Right clutch operating pressure pick-up port Left brake operating pressure pick-up port Right brake operating pressure pick-up port To left clutch To left lubrication To left brake To right clutch To right lubrication To right brake Bevel gear shaft lubrication inlet To pin puller solenoid valve From pin puller solenoid valve From pump
1. 2. 3. 4. 5. 6. 7. 8.
Filter ECMV (For right clutch) ECMV (For left clutch) Sudden braking prevention valve ECMV (For right brake) ECMV (For left brake) Parking braking valve Valve seat
D475A-3
STEERING ECMV
Outline • The machine employs four ECMV (electroniccontrolled modulation valve) on the steering control valve. • The steering control valve is provided on respective valve sheets as the assembly. • The steering control valve is situated in the circuit between the power train pump via the main relief valve and the piston of the steering clutch and the brake. It is configured with two pairs of the steering ECMV (right and left) and the brake ECMV (right and left). • Shifting the PCCS lever (steering and forward/reverse) right or left disconnects the steering clutch. Shifting it further turns “ON” the brake. The controller sends the instruction to respective ECMV to cause the gradual or sudden turn whichever is designated by the operating position of the PCCS lever (steering lever). Depending on depth of the pedal depression, the controller instructs ECMV to apply the right and left brakes to stop the machine. The controller that is electrically connected to the PCCS lever and pedal performs above operations by switching the steering control valves (each ECMV). The steering control valves feed the oil from the power train pump to the steering clutch and brake to operate their disc clutches. • The sudden stop prevention valve disables sudden braking that can result when a failure is detected in the electric systems. • Shifting the parking brake lever to the “Lock” position switches the port of the parking brake valve, thereby draining the oil between the ECMV for left-and-right brakes and the brake. As the result, the machine brake is turned on. The parking brake is also connected to the brake pedal via the linkage.
10-49 10-49 (1)
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
STEERING CLUTCH, STEERING BRAKE ECMV (Electronic Control Modulation Valve)
A: P: T: Dr: P1: P2:
To clutch or brake From pump Drain Drain Clutch or brake pressure pick-up port Pilot pressure pick-up port
10-50
1. 2. 3. 4. 5. 6.
Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve
D475A-3
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
ECMV outline •
•
•
The ECMV (Electronic Control Modulation Valve) consists of a pressure control valve and a fill switch. Pressure control valve Proportional solenoid of this valve receives current from the steering controller, then the valve converts it to hydraulic pressure. Fill switch This switch detects the completion of the clutch oil replenishment. The detailed functions are as follows. 1) Signal (fill signal) of completion of oil replenishment is given from the valve to the controller. 2) This signal is kept while the pressure is applied to the clutch.
ECMV and proportional solenoid •
Each ECMV is equipped with one proportional solenoid. A thrust is generated by its controller command current. The hydraulic pressure is generated by activating the generated thrust on the pressure control valve spool. Therefore, the oil flow and the hydraulic pressure are controlled by controlling the command current volume to change the thrust. ECMV operation • The ECMV is controlled by the command current running from the controller to the proportional solenoid and the fill switch output signal.
Steering clutch and steering brake ECMVs Outline • They are used to set the steering clutch and steering brake hydraulic pressures to the specified settings, as well as to serve as valves to switch the circuits connected to the clutch and brake chambers.
D475A-3
10-51
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
Operation 1. In case of PCCS lever “Neutral”, brake pedal “Released”: Straight travel (Left and right clutch “ON”, left and right brake “Released”, parking brake “OFF”)
•
•
In the position of PCCS lever “Neutral” and brake pedal “Released”, because the solenoid valve (1) of the steering ECMV is deenergized, the sealing portion of the ball (2) is opened. The oil from the power train pump enters the port Pc of the steering ECMV via the main relief valve. The oil that entered the port Pc passes through the orifice a and passes through the sealing portion of the ball (2), then is drained. The valve (3) is moved right by the tension of the spring (4) and closes the Pc and C ports, then opens the C and Dr ports. At this time, the oil from the back pressure port of a clutch piston is drained from the port C and the clutch is set to “ON” by the tension of the clutch spring. The oil pressure of the brake circuit is ensured by the orifice a.
10-52
•
•
Further, the proportional solenoid valve (5) of the brake ECMV is energized and pushes the ball (6) to the left direction, then closes the sealing portion. The oil that entered the pump port Pb enters the E port, pushes the valve (7) left, opens the Pb and B ports, and closes the B and Dr ports. The oil that entered the Pb port passes through the B port and flows into the back pressure port of the brake piston. Subsequently, the piston moves to the left direction waiting for the rise of the circuit oil pressure and compresses the brake spring, then sets the brake “Released”. In the parking brake “OFF”, the parking brake is closed and the oil of the brake circuit is not drained.
D475A-3
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
2. When the PCCS lever is actuated halfway to the left: Slow swing (Left clutch “OFF”, left brake “Semi-released”, right clutch “ON”, right brake “Released”, parking brake “OFF”)
•
•
•
When the PCCS lever is actuated halfway to the left, the solenoid valve (1) of the left steering ECMV is energized and pushes the ball (2) to the left direction, then closes the sealing portion. The oil from the power train pump passes through the orifice a from the port Pc and enters F. Subsequently, the oil pushes the valve (3) to the left and opens the Pc and C ports, then closes the C and Dr ports. The oil of the C port flows into the clutch piston port and becomes the back pressure, then sets the left clutch to “OFF”. Further, the proportional solenoid valve (5) of the left ECMV is energized and pushes the ball (6) to the left direction, then closes the sealing portion. The oil that entered the pump port Pb enters the E port and pushes the valve (7) to the left. Besides, the oil pressure of the port B and
D475A-3
•
•
later outputs a command current from the controller to the proportional solenoid valve (5) in accordance with the stroke of the PCCS lever. When the current flows into the proportional solenoid (5), the solenoid generates a thrust in proportion to the current. The sum of the thrust of this solenoid, the thrust caused by the brake port oil pressure, and the restitution of the pressure control valve spring (8) is balanced and pressure-adjusted. Accordingly, if the stroke of the PCCS lever is small, the oil pressure of the port B and later is also specified high and the brake changes from “Released” to “Semi-released”. If the stroke is large, the oil pressure is specified low and the bake changes from “Semi-released” to “ON” In the parking brake “OFF”, the parking brake valve is closed and the oil of the brake circuit is not drained.
10-53
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
3. When the PCCS lever is actuated fully to the left: Sudden swing (Left clutch “OFF”, left brake “ON”, right clutch “ON”, right brake “Released”, parking brake “OFF”)
•
•
When the PCCS lever is actuated fully to the left from the state of Section 2, the proportional solenoid valve (5) of the left brake ECMV is deenergized and sets the ball (6) free, then opens the sealing portion. Because the oil of the port E passes through the sealing portion and is drained, the valve (7) is moved right by the tension of the spring (8). At this time, the port Pb closes and the port B and drain port Dr open. The oil from the power train pump passes through the orifice b from the port Pb and passes through the sealing portion, then is drained. The oil pressure of the clutch circuit is ensured by the orifice b. On the other hand, the oil that flows into the brake piston port and reached the back pressure is drained from the port B to Dr.
10-54
•
The left brake is set to “ON” by the tension of the brake spring. In the parking brake “OFF”, the parking brake valve is closed and the oil of the brake circuit is not drained.
D475A-3
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
4. In case of brake pedal “Stepped on” (Clutch “ON”, brake “ON”, parking brake “OFF”)
•
•
When the brake pedal is stepped on, the proportional solenoid valve (5) of the left and right brake ECMVs is deenergized from energization by the pedal full actuation. A command current is output from the controller to the proportional solenoid valve (5) in accordance with the actuation stroke of the brake pedal. When the current flows into the proportional solenoid valve (5), the solenoid generates a thrust that is proportional to the current. The sum of the thrust of this solenoid, the thrust caused by the oil pressure of the brake port, and the restitution of the pressure control valve spring (8) is balanced and oil pressure is specified, thereby enabling adjustment of the effect of the brake. Besides, because the PCCS lever is not actuated, the solenoid valve (1) of the left and
D475A-3
•
right steering ECMVs is deenergized and the left and right clutches are set to “ON”. Further, when the brake pedal is stepped on, the parking brake valve linked using a linkage is actuated and drains the oil of the brake circuit.
10-55
STRUCTURE AND FUNCTION
STEERING CLUTCH, STEERING BRAKE ECMV
5. In case of brake pedal “ON” (Clutch “ON”, brake “ON”, PCCS lever “Neutral”, braking pedal “Released”)
•
•
•
When the safety lever for the PCCS lever is set to the position of “Locked”, the parking brake valve (1) moves to the left direction and the ports A, B and C open. Accordingly, the oil that flows into the brake piston port and reached the back pressure passes through the port C from the ports A and B and is drained. The back pressure of the brake piston port continues decreasing and the brake is fully set to “ON”, then is held in the state. Further, because the ports A and B continue being opened together with the drain port C even if the engine is restarted, the state of the brake “ON” is held. In the parking brake “OFF”, the parking brake valve (1) moves right and is closed between
10-56
the port A, port B and drain port C, then the brake is set “Released” by oil pressure.
D475A-3
STRUCTURE AND FUNCTION
SUDDEN STOP PREVENTION VALVE
SUDDEN STOP PREVENTION VALVE
Outline • This sudden stop prevention valve is installed to prevent a vehicle from being braked suddenly when an error occurs in an electrical system. • When the sudden stop prevention valve (1) is installed in the drain circuit of the brake ECMV and the solenoid valve (2) of the brake ECMV is deenergized, the oil of the brake circuit D is drained and sudden braking is prevented from being applied. Accordingly, when the solenoid valve (3) of the sudden stop prevention valve (1) is deenergized, the brake is set to “Semi-released” by throttling the brake drain circuit D that works as the orifice a circuit.
D475A-3
10-57
STRUCTURE AND FUNCTION
FINAL DRIVE
FINAL DRIVE
Outline • The final drive is a single stage spur gear, single stage planetary gear reduction type. The lubrication is of splash type using the rotation of the gears. The final drive can be removed and installed as a single unit.
10-58
•
Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7.
Floating seal Sun gear Carrier Hub Cover Sprocket boss Sprocket teeth
D475A-3
FINAL DRIVE
8. 9. 10. 11. 12. 13. 14.
Floating seal guard Cover Planetary pinion Ring gear Cover No. 1 gear No. 1 gear hub
15. 16. 17. 18. 19. 20.
No. 1 pinion Final drive case Bearing cage Boss Shaft Wear guard
10-59
STRUCTURE AND FUNCTION
FINAL DRIVE
PATH OF POWER TRANSMISSION
10-60
D475A-3
STRUCTURE AND FUNCTION
•
FINAL DRIVE
The power from the bevel gear and steering clutch is transmitted to No. 1 pinion (15). It then passes through No. 1 gear (13), which is meshed with the No. 1 pinion, and is transmitted to sun gear (2) to rotate it. The rotation of sun gear (2) is transmitted to planet pinion (10), but ring gear (11), which is meshed with the planet pinion, is fixed to cover (9), so the planet pinion rotates on its own axis and moves around the sun gear along the ring gear. Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports the planet pinion, and is transmitted to sprocket hub (4). The direction of rotation of carrier (3) is the same as that of sun gear (2). The rotating force transmitted to sprocket hub (4) is transmitted to sprocket teeth (7).
D475A-3
10-61
STRUCTURE AND FUNCTION
TRACK FRAME
TRACK FRAME
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
10-62
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
10-63
STRUCTURE AND FUNCTION
HYDRAULIC TANK
HYDRAULIC TANK
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
P1: From large pump P2: From small pump A: To blade lift cylinder head B: To blade lift cylinder bottom A1: To blade tilt cylinder head
B1: To blade tilt cylinder bottom A2: To ripper lift cylinder head B2: To ripper lift cylinder bottom A3: To ripper tilt cylinder head B3: To ripper tilt cylinder bottom
10-65
STRUCTURE AND FUNCTION
PPC VALVE
PPC VALVE FOR BLADE LIFT, TILT
P. From PPC charge valve port P2 (through PPC lock valve) T. To hydraulic tank P1. To blade lift valve (LOWER) port PA P2. To blade lift valve (RAISE) port PB P3. To blade tilt valve (Left tilt) port PA1 P4. To blade tilt valve (right tilt) port PB1
10-66
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
Spool Metering spring Centering spring Piston Disc
D475A-3
PPC VALVE
6. 7. 8. 9. 10.
Nut (for lever joint) Joint Plate Retainer Body
10-67
STRUCTURE AND FUNCTION
PPC VALVE
Operation 1) At neutral (i) PPC valve for blade lift Ports PA and PB of the blade lift control valve, and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control notch f2 in spool (1).
(ii) PPC valve for blade tilt Ports PA1 and PB1 of the blade tilt control valve, and ports P3 and P4 of the PPC valve are connected to drain chamber D through fine control notch f2 in spool (1).
10-68
D475A-3
STRUCTURE AND FUNCTION
PPC VALVE
2) During fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, 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 f1 for fine control and goes from port P1 to port PA. When the pressure at port P1 becomes higher, spool (1) is pushed back and notch f1 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 P1. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with pressure at port P1. The relationship in the position of the spool (1) and body (10) (notch f1, 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 (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber PA (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced.
D475A-3
10-69
STRUCTURE AND FUNCTION
PPC VALVE
3) During fine control (When control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up to the force of centering spring (3) and the pressure at port P1. When this happens, notch f2 for fine control is connected to drain chamber D, and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and notch f1 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 P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from 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.
4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), 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 f1 for fine control and flows to chamber PA from port P1, 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.
10-70
D475A-3
STRUCTURE AND FUNCTION
PPC VALVE
5) Blade operated to FLOAT When piston (4) at port P1 (LOWER side) is pushed by disc (5) and moves down, protrusion a of the piston contacts ball (11) during the downward stroke. (The detent starts to be actuated.) If piston (4) is pushed further, ball (11) pushes up collar (12), which is being held by detent spring (13), and moves to the outside, so the ball passes over protrusion a of the piston. At this point, piston (4’) at the opposite side is pushed up by the spring (14). As a result, the oil inside chamber F flows through b and c and enters chamber E, and piston (4’) follows disc (5). Passage d is interconnected with port P1, so it is under more or less the same pressure as port P1. Chamber E is normally interconnected with drain chamber D, but when ball (11) passes over protrusion a of the 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’), so even if the lever is released, it is held at the FLOAT position. 6) 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
10-71
STRUCTURE AND FUNCTION
PPC VALVE
FOR RIPPER
A
C
C
A
B
E D
E
D a
B
c
d
f
e
a. P port (from charge pump) b. T port (to hydraulic tank) c. P2 port (blade RIGHT TILT/ripper TILT IN)
10-72
b
SYD00313
d. P4 port (blade LOWER/ripper RAISE) e. P1 port (blade LEFT TILT/ripper TILT BACK) f. P3 port (blade RAISE/ripper LOWER)
D475A-3
STRUCTURE AND FUNCTION
PPC VALVE
6 7
5 4
8
3
9
2
10
1 A-A
B-B
11
D-D
C-C 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
10-73
STRUCTURE AND FUNCTION
PPC VALVE
Operation 1) At neutral Ports A and B of the control valve and ports P1, P2, P3, and P4 of the PPC valve are connected to drain chamber D through fine control hole f of spool (1).
10-74
D475A-3
STRUCTURE AND FUNCTION
PPC VALVE
2) During fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the charging pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of the spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel in the control lever. In this way the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced.
D475A-3
10-75
STRUCTURE AND FUNCTION
PPC VALVE
3) During fine control (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil.
4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber A from port P1, 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.
10-76
D475A-3
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
MAIN CONTROL VALVE BLADE LIFT VALVE
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.
10-78
P1. From large pump P2. From small pump A. To blade lift cylinder head B. To blade lift cylinder bottom T. To hydraulic tank PA. From blade lift PPC valve port P2 PB. From blade lift PPC valve port P1 PL. From ripper Lo valve
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7.
Check valve spring Small pump circuit check valve Check valve Check valve spring Valve body Return spring Blade lift valve
D475A-3
MAIN CONTROL VALVE
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
10-79
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BLADE LIFT VALVE MAIN RELIEF, SHUTTLE VALVE
10-80
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 {210 kg/cm2}. • 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).
10-81
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BLADE TILT, RIPPER LO VALVE
P. From small pump A1. To blade tilt cylinder head B1. To blade tilt cylinder bottom A2. To ripper tilt cylinder head (through ripper Hi valve PA1) B2. To ripper tilt cylinder bottom (through ripper Hi valve PB1) A3. To ripper lift cylinder head (through ripper Hi valve PB2) B3. To ripper lift cylinder bottom (through ripper Hi valve PA2)
10-82
CO. To PL. To PA1. To PA2. To PA3. To PB1. To PB2. To PB3. To
demand valve shuttle valve inside blade lift valve blade tilt PPC valve P3 (left tilt) ripper tilt PPC valve P2 (tilt in) ripper lift PPC valve P3 (lower) blade tilt PPC valve P4 (right tilt) ripper tilt PPC valve P1 (tilt back) ripper lift PPC valve P4 (raise)
D475A-3
STRUCTURE AND FUNCTION
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
MAIN CONTROL VALVE
9. 10. 11. 12. 13. 14. 15. 16. 17.
Sleeve 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
10-83
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
RIPPER HIGH VALVE
P: From large pump PA1: From low valve tilt back PB1: From low valve tilt on PA2: From low valve ripper raise PB2: From low valve ripper lower A1-1: To right tilt cylinder head B1-1: To right tilt cylinder bottom A1-2: To left tilt cylinder head B1-2: To left tilt cylinder bottom A2-1: To right lift cylinder head B2-1: To right lift cylinder bottom A2-2: To left lift cylinder head B2-2: To left lift cylinder bottom T: To hydraulic tank
10-84
D475A-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Check valve Check valve spring Plug Fixed differential pressure valve (for ripper tilt) Valve body Shuttle valve seat Shuttle valve ball Valve body Plug Fixed differential pressure valve spring Fixed differential pressure valve (for ripper lift)
D475A-3
MAIN CONTROL VALVE
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
10-85
STRUCTURE AND FUNCTION
PIN-PULLER HYDRAULIC SYSTEM DRAWING PIN-PULLER HYDRAULIC CIRCUIT DRAWING
PIN-PULLER HYDRAULIC SYSTEM DRAWING
PIN-PULLER HYDRAULIC CIRCUIT DRAWING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
10-86
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
D475A-3
STRUCTURE AND FUNCTION
PIN-PULLER SOLENOID VALVE
PIN-PULLER SOLENOID VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9.
Plug Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly
A. B. C. D.
To pin-puller cylinder head From power train pump To pin-puller cylinder bottom To steering case
D475A-3
10-87
STRUCTURE AND FUNCTION
PIN-PULLER 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 (10). 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 (8), 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 (10). 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).
10-88
D475A-3
STRUCTURE AND FUNCTION
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER PIPING
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. Fresh air B. Recirculated air C. Hot air/cold air
10-89
STRUCTURE AND FUNCTION
ENGINE CONTROL
ENGINE CONTROL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Battery relay (Right) Battery (Right) Decelerator pedal Starting switch Decelerator pedal potentiometer Engine controller Steering controller Transmission controller Fuel control dial Battery (left) Battery relay (left) Starting motor Fuel injection pump (left) (electronic engine controller)
10-90
Outline • Engine control is carried out in the following 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 decelerator pedal signal enter the steering controller, are processed together with other data, and are sent to the electronic engine controller as the throttle command. The electronic engine 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
Outline • The engine controller receives the manual signals of the 1st throttle, 2nd throttle and the 3rd throttle signals which is the control signals from the machine body, then selects the lower engine speed and controls the Electronic engine throttle. The 3rd throttle control signals contain the following. 1 High idling speed control 2 SSC (Shoe Slip Control) control 3 Automatic deceleration (F3, R3, R2) •
•
•
The information of the engine controller is used commonly by the all controllers through the network for the optimum control of the engine and machine body. The automatic deceleration function sets the engine speed to 1,000 rpm temporarily when the travel direction is changed from F3, R3, or R2 (to protect the transmission clutch).
The steering controller selects the lowest engine speed from information 1, 2, and 3 and transmits it as the throttle to the engine controller.
D475A-3
10-91
STRUCTURE AND FUNCTION
DECELERATION POTENTIOMETER
DECELERATION POTENTIOMETER
1. 2. 3. 4. 5. 6. 7.
Connector Lever Body Potentiometer Coupling Shaft Stopper
10-92
Outline • The deceleration potentiometer is installed to the front lower part of the operator’s cab and connected to the decelerator pedal by linkage. •
If the decelerator pedal is pressed, the throttle potentiometer shaft rotates by the linkage and the potentiometer resistance changes. Constant voltage is applied between pins A and C of the potentiometer and an electric signal is sent through pin B to the engine controller according to the position of the decelerator pedal.
D475A-3
STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER SYSTEM DRAWING
Outline • 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).
10-94
D475A-3
STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR STRUCTURAL DIAGRAM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Delivery valve Plunger barrel Plunger Hydraulic piston Hydraulic control valve (quantity adjustment) Hydraulic control valve (injection timing adjustment) Gear pump (as seen from rear, left: oil, right: fuel) Center bearing Cam shaft Roller Tappet Pump housing Tappet guide Spring nut
D475A-3
Function • After the governor 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.
10-95
STRUCTURE AND FUNCTION
MONITOR SYSTEM
MONITOR SYSTEM
•
The monitor system monitors the machine condition with the sensors installed to various parts of the machine and processes and displays the obtained information on the panel quickly to notify the operator of the machine condition. The main display sections and functions of the panel are as follows. 1) Monitor unit which turns on the alarm when the machine has a trouble. 2) Gauge unit which constantly displays the machine condition (coolant temperature, torque converter oil temperature, fuel level, hydraulic oil level, etc.) 3) Function of displaying error codes. 4) Function of monitoring the current and voltage of the sensors and solenoids.
•
In the monitor panel, there are various mode selector switches of the SSC (Shoe Slip Control), which are used to operate the machine control system.
10-96
•
The monitor panel has the functions of displaying data and selecting the SSC mode. The CPU (Central Processing Unit) in it processes, displays, and outputs the information. The display unit is LCD (Liquid Crystal Display) and the switches are seat switches.
D475A-3
STRUCTURE AND FUNCTION
MONITOR SYSTEM
Processing in monitor panel (Common to all specifications) Display of monitor panel 1 Contents and conditions of processing
2 Method
3 Flow of signals
1)
Display of travel direction and gear speed. F1, R3, etc. are notified by CAN according to information of transmission controller.
2)
Display of engine speed in gauge number. The number of pulses the engine rotation is converted into a gauge number and notified to the monitor panel by CAN.
CAN
Engine speed sensor – Steering controller – Monitor panel
3)
Display of troubleshooting When the machine has a trouble, the corresponding failure code is notified to the monitor panel by CAN. Which one should be turned on, the buzzer or the caution lamp, is notified, too. 1 In normal state User code 2 In trouble history display mode The service code (6-digit code) and the following items ate displayed 1. Time after first occurrence 2. Time after latest occurrence 3. Number of past occurrence The monitor panel displays code on the hour meter section.
CAN
Engine sensor/solenoid – Steering controller or transmission controller – Monitor panel
Transmission controller – Steering controller – Monitor panel
Sensors and solenoids – Engine controller – Steering controller – Monitor panel
Display of monitoring conditon 1 Contents and conditions of processing
2 Method
3 Flow of signals
1)
CAN
Each sensor – Steering controller or transmission controller – Monitor panel
2)
The communication conditions of each sensor, each solenoid, and CAN are displayed. The item Nos. and device conditions are notified to the monitor panel by CAN. The monitor panel displays the items and each value on its multi-information section.
Sensors – Engine controller – Steering controller – Monitor panel Monitor panel – Controller – Monitor panel
Each items is selected by using the cursor switches, selector switches, buzzer cancel switch, and shift UP/DOWN switches.
Other items 1 Contents and conditions of processing
2 Method
3 Flow of signals
1)
CAN
Steeging controller – Monitor panel
2) 3) 4)
Function selection mode (Displayed each time cancel switch is turned to left) 1 Replacement periods of oil filter and oil are displayed. 2 Engine speed, oil pressure in work equipment circuit, etc. are displayed. 3 Failure codes related to electronic control are displayed. 4 Brightness of display, etc. are adjusted. Mode to change replacement periods of maintenance mode Mode to display failure codes related to machine body such as overheating, abnormal water temperature, etc. Mode to display service meter and information related to load on machine
D475A-3
10-97
STRUCTURE AND FUNCTION
MONITOR PANEL
MONITOR PANEL Monitor portion
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Engine cooling water temperature gauge Power train oil temperature gauge Hydraulic oil temperature gauge Fuel gauge Radiator coolant level check lamp Hydraulic oil level check lamp Engine oil level check lamp Charge level monitor Engine oil pressure caution lamp Engine cooling water temperature caution lamp Power train oil temperature caution lamp Hydraulic oil temperature caution lamp Air cleaner clogging caution lamp
Outline • The monitor potion consists of a monitor that issues an alarm when an error occurred in a vehicle, a gauge that always displays the state of the vehicle, and the service meter. The monitor portion installs a microcomputer and processes and displays signals from each sensor. Besides, the items displayed on the monitor portion and gauge portion are listed in the table on the next page. Operation 1. When the power turns on (When the starting switch is ON) 1) All items of the gauge and monitor portions come on for three seconds. 2) The alarm lamp comes on for two seconds.
10-98
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Engine preheating pilot lamp Maintenance caution lamp Warming lamp Filter, oil change interval lamp Display panel A (Speed range, Engine speed) Display panel B (Multi-information) Dual/single tilt selector display lamp Lock up mode switch Economy mode selector switch Reverse slow mode selector switch Shoe slip selection mode switch Rock selection mode selector switch
2. Start-up inspection 1) After all lighting of Section 1 is terminated, if there is an error in a start-up inspection item, the item flashes. 2) If the engine is started, the check items before starting go off. (If the engine running is judged by the signal (CAN) from the engine controller.) 3. Cautions Caution items are checked until the engine stops after the engine starts. If an error occurs, the error is displayed by flashing and the alarm lamp synchronously flashes. Further, if an emergency item flashes, the alarm buzzer also sounds synchronously. fl Flashing of the monitor and alarm lamp is repeated. They come on and off for about 0.8 second. fl The flashing period of the monitor slightly changes when atmospheric temperature is low (below about –10°C), but this case is not abnormal. D475A-3
STRUCTURE AND FUNCTION
MONITOR PANEL
Monitor panel display Symbol
Check
Display category
Display item
Display range
Radiator water level
Below low level
Engine oil level
When sensor is abnormal or when wiring harness is disconnected
Display method Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: Flashes
Caution 1
Display when normal: OFF Display when abnormal: ON Hydraulic oil level
Below low level
Battery charge
When charge is defective
Air cleaner clogging
When clogged: Less than –650 mmH2O
Engine oil pressure
Below 49.0 kPa {0.5 kg/cm2}
Radiator water level
Below low level
SAP00522
Caution 2
When at highest level Engine water temperature (108°C or above) on engine water temperature gauge Torque converter oil temperature
When at highest level (130°C or above) on torque converter temperature gauge
Hydraulic oil temperature
105 ± 3°C or above
Hydraulic oil level
Below low level
Maintenance
When replacement time of filter or oil has been passed
Dual tilt
D475A-3
Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Alarm buzzer sounds
When preheating
Lights according to required time determined by engine controller based. It also lights at the time of manual preheat by setting starting switch at preheat position (turning it counterclockwise).
All the time of operation
Displays lights at the time of operation. It goes off at the time non-operation.
Pilot
Preheating
Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes
10-99
STRUCTURE AND FUNCTION
Display category
Symbol
Display item
MONITOR PANEL
Display range
Display method
Engine water temperature
One place lights up to show applicable level
Gauges
Torque converter oil temperature
Hydraulic oil temperature
All lamps light up below applicable level
Multi information
Fuel level
10-100
Service meter (Hours meter)
From 0 to 99999
Actuated when the engine is rotating.
D475A-3
STRUCTURE AND FUNCTION
MONITOR PANEL
Switch portion 1. Switch functions a) ON-OFF switching in lock-up mode b) Economy mode setting – OFF, mode 1, mode 2 c) ON-OFF switching in reverse slow mode d) ON-OFF switching in SSC mode e) SSC mode level setting – Mode 1 to 5 a), b), and c) are mounted for all specifications and d) and e) are mounted for the SSC specifications.
•
•
SSC specifications
Without SSC specifications
2. Initial Setup at key ON The function the operator desires according to the situation of an operating place is selected and all functions shall be set to the OFF state.
D475A-3
Economy Mode Function In a field, such as a rock-bed place where many shoe slips are generated, the following power is output in each mode so that the frequency of decelerator operation can decrease. • Economy mode 1 → Set to about 90% of the full power. • Economy mode 2 → Set to about 70% of the full power. • REVERSE slow mode → Set to about 80% of the full travel speed at reverse time.
10-101
STRUCTURE AND FUNCTION
MONITOR PANEL
SENSORS Type of sensor
Sensor method
When normal
When abnormal
Engine oil pressure
Contact
OFF
ON
Engine water temperature
Resistance
—
—
Torque converter oil temperature
Resistance
—
—
Hydraulic oil temperature
Resistance
—
—
Radiator water level
Contact
ON
OFF
Fuel level
Resistance
—
—
Engine oil level
Contact
ON
OFF
All cleaner clogging
Contact
ON
OFF
Engine oil pressure sensor
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
10-102 (1)
D475A-3
STRUCTURE AND FUNCTION
MONITOR PANEL
Engine cooling water temperature sensor Torque converter oil temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
4. Tube 5. Wire 6. Connector
Radiator water level sensor
1. Float 2. Sensor 3. Tube
D475A-3
4. Wire 5. Connector
10-103
STRUCTURE AND FUNCTION
MONITOR PANEL
Fuel level sensor
1. 2. 3. 4. 5. 6. 7.
Connector Float Arm Body Spring Contact Spacer
10-104
Function • 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
MONITOR PANEL
Engine oil level sensor
1. Float 2. Sensor 3. Tube
4. Wire 5. Connector
Air cleaner clogging sensor
1. Boss 2. Switch 3. Conduit
D475A-3
4. Wire 5. Connector
10-105
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
MODE SELECTION SYSTEM (SSC (Shoe Slip Control) System) System diagram
Outline • The 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, the SSC (shoe slip control) used when ripping, and the reverse slow mode control, which can be used for either operation.
10-106
•
The lock-up control mode is the same as the conventional lock-up function. It cannot be selected in combination with the above modes.
D475A-3
STRUCTURE AND FUNCTION
Function of mode selection system • The system consists of the mode selection panel (containing a microcomputer) to select working condition, steering controller (containing a microcomputer) to control the engine, engine controller to receive the commands from the steering controller and controls the fuel injection pump, transmission controller to turn on and off the lock-up system of the torque converter according to the signals from the transmission output speed sensor, and various sensors. The function of each controller is explained below.
MODE SELECTION SYSTEM
Function of engine controller • The engine controller controls the fuel injection pump according to the lowest engine speed (highest voltage) in the 3 signals of the manual command input from the deceleration potentiometer, manual signal of the throttle dial, and the SSC command signal.
Functions of steering controller and transmission controller 1. The steering controller calculates the travel speed of the ground from the signals of the acceleration sensor and inputs the transmission output speed sensor signal to it to calculate the shoe speed, then obtains the shoe slip rate. 2. If the engine speed sensor signal and transmission output speed sensor signal are input, the steering controller calculates the traction force. 3. The steering controller calculates the optimum engine speed from the results of 1 and 2 above, mode set signal of the monitor panel, and speed information from the transmission controller, then sends it as the SSC command to the engine controller. 4. The transmission controller sends the lockup signal to the lock-up solenoid valve, judging from the input gear speed information of the transmission controller. fl See “OPERATION OF TORQUE CONVERTER LOCK-UP CONTROL SYSTEM”.
D475A-3
10-107
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
Operation of mode selection system • Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in accordance with the contents of work. Single SimultaWork Mode selection neous switch selection
Mode work conditions •
ON/OFF switching is automatically performed in accordance with the load.
T/C output shaft speed
F1, F2, F3 R1, R2, R3
Low ON 1,360 rpm or more speed side OFF 1,330 rpm or more
Reverse slow SSC (Shoe Slip Control) Rock-bed selection
Ripping
1. When the torque converter approaches to the stall area or performs gear shift operation, lockup is set to OFF. When the torque converter reaches a light load, lock-up is set to ON. 2. Can be used in all number of gear ratios. 3. Simultaneous selection disabled with another mode 4. Suitable for dozing work of comparatively a few load fluctuations.
High ON 2,570 rpm or more speed side OFF 2,600 rpm or more
1. When F1 is shifted with the economy mode switch 1 or 2 ON
1. When the economy mode (1 or 2) and SSC are set simultaneously, the F1 shift economy control is performed. When the ripper lever is actuated and the switch is turned on, the slip control is performed. 2. The engine output can be suppressed in two stages without performing the decelerator operation of the engine. Mode 1: 90% (at 1.5 km/h) Mode 2: 65% (at 1.5 km/h) 3. At neutral time, the engine speed can be suppressed partially.
1. When R1, R2, and R3 are shifted
1. The engine speed can be suppressed without performing the decelerator operation of the engine. 2. Target travel speed at reverse time R1 R2 70% at full operation R3
Economy
Dozing
Lock-up
Speed number of gear ratios
Mode operation, characteristic
}
The following conditions are satisfied: 1 When F1 is shifted. 2 After the ripper down, ripper tilt levers are actuated and the switch is set to ON
1. At start, to prevent rashing out, the modulating valve is actuated. At this time, the steering controller performs index characteristic down of about 40% and performs the engine output control if a ripper down signal is input. 2. The steering controller performs the engine output control in accordance with the index force characteristic (refer to the rock-bed selection shown below) selected by the operator among the index force characteristics set in five stages and suppresses the generation of a slip. 3. The steering controller regards the index force immediately before the slip (exceeding the shoe slipping ratio of 30% is generated, as the maximum, and performs the engine output control. At this time, the steering controller performs index characteristic down of about 30 to 80% and performs the engine output control if a ripper tilt or ripper up signal is input. 4. At neutral time, the engine speed is suppressed partially.
Set to ON in connection with SSC
1. When the SSC is set to ON, the selection mode 3 comes on. 2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the state and load of the rock-bed.
fl When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the engine output control is performed in accordance with the command having the smallest value among the control command, throttle command, and decelerator command.
10-108
D475A-3
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
SENSORS Transmission output shaft speed sensor
1. 2. 3. 5. 6.
Magnet Terminal Case Boots Connector
D475A-3
10-109
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
Torque converter speed sensor
1. Connector 2. Flange 3. Sensor
Acceleration sensor
1. Sensor portion 2. Wire 3. Connector
• •
•
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.
10-110
D475A-3
STRUCTURE AND FUNCTION
MODE SELECTION SYSTEM
Pitch angle sensor
1. 2. 3. 4.
Body Tube Wire Connector
D475A-3
10-111
STRUCTURE AND FUNCTION
ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT Relay box
10-112
D475A-3
STRUCTURE AND FUNCTION
ELECTRICAL EQUIPMENT
Operation of lamp system
Lamp system circuit diagram
D475A-3
10-113
STRUCTURE AND FUNCTION
ELECTRICAL EQUIPMENT
Preheating (Electrical intake air heater) control
Preheating circuit
10-114
D475A-3
STRUCTURE AND FUNCTION
STEERING ELECTRONIC CONTROL
STEERING ELECTRONIC CONTROL
1. 2. 3. 4. 5.
Monitor panel (Speed range display) Auto shift down switch Engine controller Transmission controller Steering controller
6. Steering control valve 7. Transmission output shaft speed sensor (ª Torque converter output shaft speed sensor) 8. Transmission control valve 9. Engine speed sensor
ª
10-116
Serial No.: 10695, 10698, 10700 – 10704
D475A-3
STRUCTURE AND FUNCTION
STEERING ELECTRONIC CONTROL
• Shift Mode Function 1. Function If you shift the lever to the forward or reverse, the gear speed selected from the shift mode is turned on. • Shift mode 1 • Shift mode 2 2. Type of Modes 1 F1-R2 2 F2-R2A 3 F1-R1 (Manual mode) 3. Selecting method Shift the steering or forward-reverse lever to “N”. Shift switch ON Manual mode
Shift switch ON Shift mode 1
Neutral switch ON
Shift mode 2 Neutral switch ON
4. Displaying method Monitor panel
• Auto Shift-down Function 1. Operating condition This function automatically shifts the gear speed down if load is increased while the machine is travelling at 2nd or 3rd speed or while the machine is in operation. 2. Selecting method Turn auto shift-down switch (1) “ON”. 3. Operation and features of the mode 1) This function turns on the shift-down automatically by calculating the drawbar pull (load to the machine body) based the engine speed, transmission speed and throttle information from the steering controller. 2) Once the machine is automatically shifted down, shift-up won’t be turned on automatically (shift up from the manual switch is available, though). 1) This function is available for both the forward and reverse travel.
D475A-3
10-117
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
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
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
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
Neutral → FORWARD
30 ± 5
Max. 8.0
Neutral → REVERSE
30 ± 5
30 ± 5
40 ± 5 (Play: Max. 3)
40 ± 5 (Play: Max. 3)
9±5
9±5
45 ± 15
45 ± 15
75 ± 10
75 ± 10
54 ± 10
54 ± 10
72 ± 10
72 ± 10
53 ± 10
53 ± 10
81 ± 10
81 ± 10
81 ± 10
81 ± 10
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 lever knob
Unit
rpm
PCCS lever
Direction
Full stroke (Neutral – Left, right)
Control lever, pedal stroke
Steering
Deceleration pedal
Until clutch is completely disengaged • Engine stopped • Center of pedal • Engine at low idling • Center of pedal
Brake pedal
Blade lever
Ripper lever
D475A-3
mm
mm Full stroke mm Stroke until oil pressure becomes 0
• Engine at low idling HOLD – RAISE, • Hydraulic oil FLOAT temperature: 45 – 55°C • Center of lever knob HOLD – Left, right tilt • Engine at low idling HOLD – RAISE, • Hydraulic oil LOWER temperature: 45 – 55°C • Center of lever knob HOLD – Tilt in, tilt out
mm
mm
20-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Category
Item
D475A-3
• Engine stopped • Center of lever knob
Left
PCCS lever
Direction
Steering
Right
Control lever, pedal operating effort
Standard value
Permissible value
Neutral → FORWARD
53.9 ± 9.8 {5.5 ± 1.0}
53.9 ± 9.8 {5.5 ± 1.0}
Neutral → REVERSE
53.9 ± 9.8 {5.5 ± 1.0}
53.9 ± 9.8 {5.5 ± 1.0}
Until clutch is completely disengaged
14.7 ± 4.9 {1.5 ± 0.5}
14.7 ± 4.9 {1.5 ± 0.5}
26.5 ± 4.9 {2.7 ± 0.5}
26.5 ± 4.9 {2.7 ± 0.5}
Until clutch is completely disengaged
16.7 ± 4.9 {1.7 ± 0.5}
16.7 ± 4.9 {1.7 ± 0.5}
Until brake takes effect and machine turns
29.4 ± 4.9 {3.0 ± 0.5}
29.4 ± 4.9 {3.0 ± 0.5}
Measurement conditions
Until brake takes effect and machine turns
Unit
N {kg}
Deceleration pedal
• Engine stopped • Center of pedal
N {kg}
49.0 ± 9.8 {5.0 ± 1.0}
49.0 ± 9.8 {5.0 ± 1.0}
Brake pedal
• Engine at low idling • Center of pedal
N {kg}
460.6 ± 49.0 {47.0 ± 5.0}
460.6 ± 49.0 {47.0 ± 5.0}
32.7 ± 4.9 {3.3± 0.5}
32.7 ± 4.9 {3.3± 0.5}
Blade lever
• Engine at low idling HOLD → RAISE • Hydraulic oil temperature: 45 – 55°C • Center of lever knob HOLD → FLOAT
80.0 ± 3.9 {8.2 ± 0.4}
80.0 ± 3.9 {8.2 ± 0.4}
27.7 ± 9.8 {2.8 ± 1.0}
27.7 ± 9.8 {2.8 ± 1.0}
18.6 ± 4.9 {1.9 ± 0.5}
18.6 ± 4.9 {1.9 ± 0.5}
18.6 ± 4.9 {1.9 ± 0.5}
18.6 ± 4.9 {1.9 ± 0.5}
Low idling
0.03 – 0.20 {0.3 – 2.0}
0.03 – 0.20 {0.3 – 2.0}
High idling
0.8 – 1.0 {8.0 – 10.0}
0.8 – 1.0 {8.0 – 10.0}
Low idling
0.03 – 0.15 {0.3 – 1.5}
0.03 – 0.15 {0.3 – 1.5}
0.44 – 0.64 {4.5 – 6.5}
0.44 – 0.64 {4.5 – 6.5}
1.12 – 1.42 {11.5 – 14.5}
1.12 – 1.42 {11.5 – 14.5}
High idling
1.12 – 1.42 {11.5 – 14.5}
1.12 – 1.42 {11.5 – 14.5}
Low idling
2.55 – 2.74 {26.0 – 28.0}
Min. 2.45 {Min. 25}
High idling
2.55 – 2.74 {26.0 – 28.0}
Min. 2.55 {Min. 26}
N {kg}
HOLD – Left, right tilt
Ripper lever
Power train oil pressure
Torque converter inlet pressure
Torque converter outlet pressure
Torque converter lock-up clutch pressure
Torque converter stator clutch pressure
20-4
HOLD – • Engine at low idling RAISE, LOWER • Hydraulic oil temperature: 45 – 55°C HOLD – • Center of lever knob Tilt in, tilt out • Torque converter oil temperature: Within operating range
High idling Low idling
N {kg}
MPa {kg/ cm2}
D475A-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Category
Item
Transmission main relief pressure
D475A-3 Standard value
Permissible value
Low idling
2.56 – 2.91 {26.1 – 29.7}
Min. 2.45 {Min. 25}
High idling
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
2.35 – 2.74 {24.0 – 28.0}
Min. 2.25 {Min. 23}
2.50 – 2.74 {25.5 – 28.0}
Min. 2.40 {Min. 24.5}
Low idling
2.35 – 2.74 {24.0 – 28.0}
Min. 2.25 {Min. 23}
High idling
2.50 – 2.74 {25.5 – 28.0}
Min. 2.40 {Min. 24.5}
Low idling
1.96 – 2.35 {20.0 – 24.0}
Min. 1.86 {Min. 1.9}
High idling
2.13 – 2.35 {21.7 – 24.0}
Min. 2.0 {Min. 20.5}
Low idling
2.35 – 2.74 {24.0 – 28.0}
Min. 2.25 {Min. 23}
2.50 – 2.74 {25.5 – 28.0}
Min. 2.40 {Min. 24.5}
Low idling
2.35 – 2.74 {24.0 – 28.0}
Min. 2.25 {Min. 23}
High idling
2.50 – 2.74 {25.5 – 28.0}
Min. 2.40 {Min. 24.5}
High idling
0.1 – 0.2 {1.0 – 2.0}
0.1 – 0.2 {1.0 – 2.0}
Low idling
2.56 – 2.91 {26.1 – 29.7}
Min. 2.45 {Min. 25}
High idling
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
Low idling
2.56 – 2.91 {26.1 – 29.7}
Min. 2.45 {Min. 25}
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
2.56 – 2.91 {26.1 – 29.7}
Min. 2.45 {Min. 25}
High idling
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
Low idling
2.56 – 2.91 {26.1 – 29.7}
Min. 2.45 {Min. 25}
High idling
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
Measurement conditions • Torque converter oil temperature: Within operating range
Low idling Transmission F clutch pressure High idling
Unit
MPa {kg/ cm2}
Transmission R clutch pressure
Power train oil pressure
Transmission 1st clutch pressure
• Torque converter oil temperature: Within operating range
Transmission 2nd clutch pressure High idling
MPa {kg/ cm2}
Transmission 3rd clutch pressure
Transmission lubrication pressure • Torque converter oil temperature: Within Steering left clutch operating range pressure
Steering left brake pressure High idling Low idling
MPa {kg/ cm2}
Steering right clutch pressure
Steering right brake pressure
Pin puller actuation pressure
D475A-3
• Torque converter oil temperature: Within operating range
High idling
MPa {kg/ cm2}
20-5
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
20-6
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
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
Blade lift (Superdozer specification)
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
Permissible value
Unit
sec
• Hydraulic oil temperature: 45 – 55°C • Blade: No load • Blade in contact with ground – Raised to max. height
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
D475A-3
Standard value
Measurement conditions
Low idling High idling
20-7
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
20-8
Standard value
Measurement conditions
D475A-3
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)
D475A-3
20-9
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model Category
Item
Measurement conditions
D475A-3 Unit
Standard value
Permissible value
mm/ min
Max. 50/5
Max. 100/5
mm/ min
Max. 50/5
Max. 100/5
mm/ min
Max. 80/15
Max. 160/15
mm/ min
Max. 30/5
Max. 60/5
Measurement posture
Blade tilt
• Hydraulic oil temperature: 45 – 55°C • Lowest shank hole • Tilt blade fully to raise track on one side, then measure hydraulic drift for 5 minutes at bottom tip shoe (change in height h)
Hydraulic drift
Work equipment
Measurement posture
Hydraulic drift of chassis (blade)
• Hydraulic oil temperature: 45 – 55°C • Engine stopped • Raise front of machine with blade, then measure hydraulic drift for 5 minutes at center of idler (change in height h) Measurement posture
Ripper lift • Hydraulic oil temperature: 45 – 55°C • Engine stopped • Raise ripper fully, then measure hydraulic drift for 15 minutes at bottom tip of shank (change in height h) Measurement posture
Hydraulic drift of chassis (ripper)
20-10
• Hydraulic oil temperature: 45 – 55°C • Engine stopped • Raise rear of machine with ripper, then measure hydraulic drift for 5 minutes at center of final drive (change in height h)
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) .................................................................................................. 20-106 Measuring exhaust temperature ............................................................................................................................. 20-107 Measuring exhaust color ......................................................................................................................................... 20-108 Adjusting valve clearance ........................................................................................................................................ 20-109 Measuring compression pressure ........................................................................................................................... 20-110 Measuring blow-by pressure ................................................................................................................................... 20-111 Measuring engine oil pressure ............................................................................................................................... 20-112 Testing and adjusting fuel injection timing ........................................................................................................... 20-113 Testing and adjusting alternator belt tension ....................................................................................................... 20-114 Testing and adjusting belt tension for air conditioner compressor ................................................................... 20-114 Adjusting engine speed sensor ............................................................................................................................... 20-115 Adjusting fuel control dial and decelerator pedal ................................................................................................ 20-116 Measuring power train oil pressure ....................................................................................................................... 20-118 Simple method of testing brake performance ...................................................................................................... 20-127 Adjusting brake pedal and parking brake lever .................................................................................................... 20-128 Adjusting PCCS lever console position .................................................................................................................. 20-131 Emergency escape method when power train has trouble ................................................................................. 20-132 Adjusting clearance of idler ..................................................................................................................................... 20-135 Testing and adjusting track shoe tension .............................................................................................................. 20-136 Measuring and adjusting work equipment oil pressure ...................................................................................... 20-137 Testing and adjusting work equipment control circuit pressure ........................................................................ 20-142 Measuring PPC valve and pitch • tilt control valve output pressure .................................................................. 20-144 Adjusting PPC valve ................................................................................................................................................. 20-148 Measuring output pressure of demand solenoid valve ....................................................................................... 20-149 Measuring output pressure of ripper pin-puller solenoid valve ......................................................................... 20-150 Checking location of cause of hydraulic drift of blade and ripper ..................................................................... 20-151 Measuring leakage inside hydraulic cylinder ........................................................................................................ 20-152 Releasing remaining pressure in hydraulic circuit ............................................................................................... 20-153 Bleeding air from hydraulic cylinders .................................................................................................................... 20-153 Adjusting work equipment safety lever ................................................................................................................. 20-154 Adjusting ripper lever position ............................................................................................................................... 20-155 Procedure for adjusting blade tilt limit angle (dual tilt dozer specification) ..................................................... 20-156 Special function of monitor panel (EMMS) ........................................................................................................... 20-158 Adjustment method of replaced controller ............................................................................................................ 20-202 Preparation work for troubleshooting for electric system ................................................................................... 20-204 Handling of optional devices ................................................................................................................................... 20-206 Pm clinic service ....................................................................................................................................................... 20-207 Undercarriage troubleshooting report .................................................................................................................... 20-215
D475A-3
20-101
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check or measurement item Symbol
Part No.
Part Name
Remarks
Air supply pressure (boost pressure)
A
799–201–2202
Boost gauge kit
–101 – 199.9 kPa {–760 – 1,500 mmHg} Negative pressure measurement type
Water temperature, oil temperature, exhaust temperature
B
799–101–1512
Digital temperature gauge
–99.9 – 1.299°C
1
799–201–9000
Handy smoke checker
2
Commercially available
Smoke meter
Discoloration: 0 – 70% (with standard color) (discoloration x 1/10 = Bosch index)
795–125–1210
Feeler gauge
Intake: 0.43 mm, exhaust: 0.80 mm
795–502–1205
Compression gauge
0 – 6.9 MPa {0 – 70 kg/cm2}
795–502–1510
• Adapter
795–502–1520
• Plate
799–201–1504
Blow-by checker
799–101–5002
Hydraulic tester
790–261–1203
Digital hydraulic tester
799–101–5220
Nipple
07002–11023
O-ring
Exhaust color
C
D
Valve clearance
E
Compression pressure
For 140 Engine Series
F
Blow-by pressure
1 Oil pressure
G
0 – 4.9 kPa {0 – 500 mmH2O} Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2}
For 10 x 1.25 plug
2 Blade tilt control angle
J
Operating effort
K
Hydraulic gauge
799–402–3800
Angle gauge
79A–264–0021
Push-pull scale
0 – 294 N {0 – 30 kg}
79A–264–0091
Push-pull scale
0 – 490 N {0 – 50 kg}
Stroke, hydraulic drift
L
Commercially available
Scale
Work equipment speed
M
Commercially available
Stopwatch
Voltage, resistance value
N
79A–264–0211
Tester
Troubleshooting of wiring harness, sensor
799–601–8000
T-adapter assembly
P 799–601–7360
Adapter
20-102
Pressure gauge: 0.98 MPa {10 kg/cm2}
799–401–2320
For relay (5 pin)
D475A-3
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED fl Measure the engine speed under the following condition. • Engine water temperature: Within operating range • Torque converter oil temperature: Within operating range • Power train oil temperature: Within operating range
fl The engine speed can be measured in the “Pm Clinic auxiliary mode” of the monitor panel (Measure the high idling speed of the engine in the “Adjustment mode”, however).
1. Preparation work Turn the starting switch ON and set the monitor panel in the “Monitoring mode” to prepare for measurement of the engine speed. fl For the operating method, see “SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)”. • Monitoring code: 01000 (Engine speed)
2. Measuring low idling speed 1) Start the engine and set the fuel control dial in the low idling position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed.
D475A-3
20-103
TESTING AND ADJUSTING
3. Measuring high idling speed 1) Start the engine and set the fuel control dial in the high idling position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. fl The high idling speed measured in the “Monitoring mode” or in the “Pm Clinic auxiliary mode” is the auto-deceleration speed. fl When measuring the high idling speed of the engine, use the “Adjustment mode”. Adjustment code: 0007 (Engine decelerator cut mode)
4. Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idling position. 2) Set the PCCS lever and work equipment control lever in neutral and press the decelerator pedal and measure the engine speed.
20-104
MEASURING ENGINE SPEED
5. Measuring torque converter stall speed 1) Start the engine and set the fuel control dial in the low idling position. 2) Press the brake pedal securely and set the parking brake lever in the FREE position and push the FORWARD switch and 2nd gear speed position. fl Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F2]. fl Keep the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idling position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idling. ¤ Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 5) Just after the power train oil temperature gauge reads the top line of the green range, push the neutral switch to neutral.
6) Repeat above steps 2) – 5) 3 times. 7) Perform steps 2) – 4) again and measure the engine speed about 5 seconds after the power train oil temperature gauge reads the top line of the green range. fl After finishing measurement, push the neutral switch to neutral and lower the power train oil temperature with the engine at high idling.
D475A-3
TESTING AND ADJUSTING
6. Torque converter stall + Work equipment relief speed (Full stall speed) 1) Start the engine and set the fuel control dial in the low idling position and raise the ripper to the stroke end. 2) Keep pressing the brake pedal securely and set the parking brake lever in the FREE position and push the FORWARD switch and 2nd gear speed position. fl Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F2]. fl Set the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idling position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idling. ¤ Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 5) Just after the torque converter oil temperature gauge reads the top line of the green range, push the neutral switch to neutral.
MEASURING ENGINE SPEED
7) Perform steps 2) – 4) again and relieve the ripper in the raising direction and measure the engine speed about 5 seconds after the power train oil temperature gauge reads the top line of the green range. fl After finishing measurement, push the neutral switch to neutral and lower the power train oil temperature with the engine at high idling.
6) Repeat above steps 2) – 5) 3 times.
D475A-3
20-105
TESTING AND ADJUSTING
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) ¤ Be
careful not to touch any hot parts when removing or installing the measuring tools. fl Measure the air supply pressure separately for the left and right banks. fl 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 plugs (1) or (2) (PT1/8). • Plug (1): For right bank • Plug (2): For left bank 2. Fit nipple 1 (PT 1/8) and hose 2 of oil pressure gauge kit H1, then connect boost gauge A.
3. Run the engine at a mid-range speed or above to bleed the oil from the hose. fl 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. fl If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. fl If there is oil inside the hose, the gauge will not work, so always bleed the oil. 4. Run the engine at high idling to stall the torque converter, and read the air supply pressure (boost pressure). fl For details of the procedure for stalling the torque converter, see MEASURING TORQUE CONVERTER STALL SPEED. fl 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.
20-106
D475A-3
TESTING AND ADJUSTING
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE ¤ Wait
for the mainfold temperature to go down before removing or installing the sensor. fl 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 the engine right bank adiabatic cover. 2. Remove exhaust temperature measurement plug (1) or (2) (PT 1/8). • Plug (1): For right bank • Plug (2): For left bank 3. Fit sensor 1 of digital temperature gauge B, then connect digital temperature gauge B. fl 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. fl Use the PEAK mode of the digital temperature gauge. fl The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation using the following formula. • Compensation value [°C] = Measured value + 2 x (20 – ambient temperature)
D475A-3
20-107
TESTING AND ADJUSTING
MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR ¤ Be
careful not to touch any hot parts when removing or installing the measuring tools. • When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker C1; when recording formal data, use Smoke Meter C2. fl Measure the exhaust color under the following conditions. • Engine water temperature: Within operating range
1. Measuring with Handy Smoke Checker C1. 1) Install fillter paper to Handy Smoke Checker C1. 2) Insert the exhaust gas suction port into the exhaust pipe. 3) Accelerate the engine suddenly, and operate the handle of Handy Smoke Checker C1 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 1 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. fl Keep the pressure of the air supply below 1.5 MPa {15 kg/cm2}. 3) Connect the power cord to the AC socket. fl 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. fl 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.
20-108
D475A-3
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE 1. Remove the cylinder head cover. fl For details, see TESTING AND ADJUSTING, REMOVAL OF CYLINDER HEAD ASSEMBLY. 2. Rotate the crankshaft in the normal direction to align the R1.6TOP line on crankshaft pulley (1) with pointer (2) and set the R1 cylinder to compression top dead center. fl 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. fl Use the hexagonal shaft of the alternator drive pulley when cranking. 3. Insert feeler gauge D between crosshead (4) and rocker arm (3) of the R1 cylinder, adjust with adjustment screw (5) until the clearance is a sliding fit, then tighten locknut (6) to hold adjustment screw (5) in position. 3 Locknut: 58.8 ± 5.9 Nm {6 ± 0.6 kgm} fl After tightening the locknut, check the valve clearance again. 4. After adjusting the R1 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. fl Firing order : R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 – L4
D475A-3
20-109
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE ¤ When measuring the compression pressure, be extremely careful not to touch the exhaust manifold or any other hot parts or get caught in the fan belt or any other rotating parts. 1. Adjust the valve clearance. fl For details, see ADJUSTING VALVE CLEARANCE. 2. Warm up the engine so that the engine oil temperature is 40 – 60°C. 3. Remove nozzle holder assembly (1) from the cylinder which is to be measured. fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF NOZZLE HOLDER ASSEMBLY. 4. Fit adapter 1 of compression gauge E, then connect compression gauge E. 5. Disconnect governor solenoid connector E15 (1) of the right fuel injection pump and governor solenoid connector E11 (2) of the left fuel injection pump. 6. Turn the starting switch on and set the monitor panel to monitoring code [99]. fl For details, see MEASURING ENGINE SPEED. 7. Crank the engine with the starting motor and measure the compression pressure. fl Measure the compression pressure at the point where the pressure gauge indicator remains steady. fl When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range.
20-110
D475A-3
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE fl 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 (1) of blow-by checker F to blowby hose 2 of the left bank, then block the hose connection. fl Connect the short hose and throttle the outlet port. 2. Install nozzle 1 and hose (2) of blow-by checker F to blow-by hose (2) of the right bank, then connect blow-by checker F. 3. Run the engine at engine high idling and measure the value on the gauge when the torque converter is stalled. fl For details of the procedure for torque converter stall, see MEASURING TORQUE CONVERTER STALL SPEED. fl 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. fl 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. fl 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.
D475A-3
20-111
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE fl Measure the engine oil pressure under the following conditions. • Coolant temperature: Within operating range 1. Remove engine pressure pickup plug (1) (PT 1/8).
2. Fit nipple 1 and hose 2 of oil pressure gauge G1, then connect to oil pressure gauge G2 (0.98 MPa {10 kg/cm2}).
3. Start the engine, and measure the oil pressure at low idling and high idling.
20-112
D475A-3
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING fl 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 (1) on the crankshaft pulley with pointer (2). fl 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. fl 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 fl 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) and 2 sets of mounting bolts and nuts (5). 3 Lock bolt: 157 – 196 Nm {16 – 20 kgm} Mounting bolt, nut: 98.0 – 122.6 Nm {8.5 – 9.5 kgm}
D475A-3
20-113
TESTING AND ADJUSTING
TESTING AND ADJUSTING ALTERNATOR BELT TENSION TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER 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 {approx. 6 kg} at a point midway between the alternator pulley and the drive pulley. • Deflection a of belt: 20 ± 2 mm Adjusting fl If the belt tension is not correct, adjust as follows. 1. Loosen the mounting bolt and nut, mounting bolt (1), and locknut (2). 2. Turn adjustment nut (3) and move alternator (4) to adjust the tension of the belt. 3. Tighten locknut (2), mounting bolt (1) and the mounting bolt and nut.
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 kg} at a point midway between the compressor pulley and the engine drive pulley. • Deflection a of belt: 20 ± 2 mm Adjusting fl If the belt tension is not correct, adjust as follows. 1. Loosen 3 mounting bolts and nuts (1) and locknut (2). 2. Turn the adjustment nut and move air conditioner compressor (3) together with the bracket to adjust the tension of the belt. 3. Tighten locknut (2) and 3 mounting bolts and nuts (1).
20-114
D475A-3
TESTING AND ADJUSTING
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR fl Adjust both left bank speed sensor (1) and right bank speed sensor (2) in the same way. 1. Screw in sensor body (3) so that the tip contacts ring gear (2). fl Be careful not to damage the sensor tip or let iron particles stick to it. 2 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). 3 Locknut : 49.0 – 68.6 Nm {5.0 – 7.0 kgm} fl When fixing the wiring in position, be careful that no excessive force is brought to bear on the sensor wiring.
D475A-3
20-115
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system • The speed signals from the fuel control dial 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.
20-116
D475A-3
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
2. Preparation work 1) Start the engine and set the monitor panel in the “Adjustment mode” to prepare for measurement of the engine speed. fl For the operating method, see “SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)”. • Adjustment code: 0007 (Engine decelerator cut mode) fl The unit of displayed engine speed is 1 rpm.
3. Adjusting decelerator pedal speed Set the fuel control dial in the high idling position and press decelerator pedal (2) to the stopper and check that the decelerator pedal speed is normal. • Decelerator pedal speed: 800 – 850 rpm fl If the decelerator pedal speed is abnormal, adjust dimension a of rod (1). • Standard dimension a of rod: 122 mm (For reference) 4. High idling speed Set the fuel control dial in the high idling position and check that the high idling speed is normal. • High idling speed: 2,150 ± 50 rpm fl When engine speed is above 1,950 rpm: Lower the engine speed below 1,900 rpm temporarily with stopper bolt (3) to eliminate the play of the decelerator pedal, then heighten it to the high idling speed. fl When engine speed is below 1,950 rpm: Heighten the engine speed to the high idling speed with stopper bolt (3).
2) Set the fuel control dial in the high idling position and check that the engine speed is above 1,000 rpm. fl If the engine speed is below 1,000 rpm, heighten it above 1,000 rpm by increasing dimension a of rod (1).
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE fl Measuring instrument for power train pressure Symbol 1 G 2
Part No. 799-101-5002
Name Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-2320
Hydraulic tester (1.0 MPa {10 kg/cm2})
¤ Stop
the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and safety lock lever in the LOCK position. fl Measure the power train oil pressure under the following condition. • Torque converter oil temperature: Within operating range fl The centralized power train pressure pick-up ports are installed inside the inspection cover on the right outside of the operator’s cab. fl List of oil pressure measuring points and gauges to be used No. Mark
Measured oil pressure
Gauge MPa {kg/cm2}
Torque converter inlet pressure
2.5 {25}
OUT
Torque converter outlet pressure
0.98 {10}
3
LU
Torque converter lockup clutch pressure
5.9 {60}
4
SC
Torque converter stator clutch pressure
5.9 {60}
5
TM
Transmission main relief pressure
5.9 {60}
6
FWD
Transmission forward clutch pressure
5.9 {60}
7
R
Transmission reverse clutch pressure
5.9 {60}
8
1ST
Transmission 1st clutch pressure
5.9 {60}
9
2ND
Transmission 2nd clutch pressure
5.9 {60}
10
3RD
Transmission 3rd clutch pressure
5.9 {60}
11
LC
Steering left clutch pressure
5.9 {60}
12
LB
Steering left brake pressure
5.9 {60}
13
RC
Steering right clutch pressure
5.9 {60}
14
RB
Steering right brake pressure
5.9 {60}
15
—
Transmission lubrication pressure
0.98 {10}
1
IN
2
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
1. Measuring torque converter inlet pressure (IN) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (1). fl Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
2. Measuring torque converter outlet pressure (OUT) 1) Connect hydraulic tester G2 to oil pressure pick-up nipple (2). fl Use an oil pressure gauge of 0.98 MPa {10 kg/cm2}.
2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling.
4) After finishing measurement, remove the measuring instrument and return the removed parts.
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2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling.
4) After finishing measurement, remove the measuring instrument and return the removed parts.
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
3. Measuring torque converter lock-up clutch pressure (LU) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (3). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
6) After finishing measurement, remove the measuring instrument and return the removed parts.
2) Run the engine and lift up the machine body with the blade and ripper so that the track shoes can run idle. ¤ After lifting up the machine body, set the safety lock lever in the LOCK position.
3) Turn on the lock-up mode switch. 4) Press the forward switch of the PCCS lever and 1st speed position and make the shoes run idle. ¤ Take care not to be caught in the track shoes during measurement. 5) Raise the engine speed gradually and measure the oil pressure when the lockup pilot lamp lights up.
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
4. Measuring torque converter stator clutch pressure (SC) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (4). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
5. Measuring transmission main relief pressure (TM) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (5). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
2) Run the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling.
2) Run the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling.
4) After finishing measurement, remove the measuring instrument and return the removed parts.
4) After finishing measurement, remove the measuring instrument and return the removed parts.
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
6. Measuring transmission forward clutch pressure (FWD) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (6). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
7. Measuring transmission reverse clutch pressure (R) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (7). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
2) Run the engine and set the parking brake lever in the FREE position. 3) Press the brake pedal and set the PCCS lever in the FORWARD and 3rd speed position. 4) Measure the oil pressure while the engine is running at high idling. ¤ Since the torque converter will be stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
2) Run the engine and set the parking brake lever in the FREE position. 3) Press the brake pedal and set the PCCS lever in the REVERSE 3rd speed position. 4) Measure the oil pressure while the engine is running at high idling. ¤ Since the torque converter will be stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
5) After finishing measurement, remove the measuring instrument and return the removed parts.
5) After finishing measurement, remove the measuring instrument and return the removed parts.
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
8. Measuring transmission 1st clutch pressure (1ST) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (8). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
9. Measuring transmission 2nd clutch pressure (2ND) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (9). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
2) Run the engine and set the parking brake lever in the FREE position. 3) Press the brake pedal and set the PCCS lever in the FORWARD and 1st speed position. 4) Measure the oil pressure while the engine is running at low idling. ¤ Since the torque converter will be stalled, keep pressing the brake pedal securely. ¤ Do not raise the engine speed to high idling during measurement.
2) Run the engine and set the parking brake lever in the FREE position. 3) Press the brake pedal and set the PCCS lever in the FORWARD and 2nd speed position. 4) Measure the oil pressure while the engine is running at low idling. ¤ Since the torque converter will be stalled, keep pressing the brake pedal securely. ¤ Do not raise the engine speed to high idling during measurement.
5) After finishing measurement, remove the measuring instrument and return the removed parts.
5) After finishing measurement, remove the measuring instrument and return the removed parts.
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TESTING AND ADJUSTING
10. Measuring transmission 3rd clutch pressure (3RD) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure pick-up nipple (10). fl Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
2) Run the engine and set the parking brake lever in the FREE position. 3) Press the brake pedal and depress the forward switch and 2nd speed position. 4) Measure the oil pressure while the engine is running at low idling. ¤ Since the torque converter will be stalled, keep pressing the brake pedal securely. ¤ Do not raise the engine speed to high idling during measurement.
5) After finishing measurement, remove the measuring instrument and return the removed parts.
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MEASURING POWER TRAIN OIL PRESSURE
11. Measuring left steering clutch pressure (LC) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure measurement nipple (11). fl Use a 5.9 MPa {60 kg/cm2} oil pressure gauge.
2) Start the engine and set the parking lever to the FREE position. 3) Operate the PCCS lever fully to the left. fl Set the direction to the neutral position. 4) Measure the oil pressure with the engine at low idling and high idling. fl Check that the oil pressure becomes 0 when the PCCS lever is returned to neutral.
5) After completing the measurement, remove the measuring equipment and set to the original condition.
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TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
12. Measuring left steering brake pressure (LB) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure measurement nipple (12). fl Use a 5.9 MPa {60 kg/cm2} oil pressure gauge.
13. Measuring right steering clutch pressure (RC) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure measurement nipple (13). fl Use a 5.9 MPa {60 kg/cm2} oil pressure gauge.
2) Start the engine and set the parking lever to the FREE position. 3) Measure the oil pressure with the engine at low idling and high idling. fl Check that the oil pressure becomes 0 when the PCCS lever is operated fully to the left. fl Check that the oil pressure becomes 0 when the brake pedal is depressed or the parking lever is operated to the LOCK position.
2) Start the engine and set the parking lever to the FREE position. 3) Operate the PCCS lever fully to the right. fl Set the direction to the neutral position. 4) Measure the oil pressure with the engine at low idling and high idling. fl Check that the oil pressure becomes 0 when the PCCS lever is returned to neutral.
4) After completing the measurement, remove the measuring equipment and set to the original condition.
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5) After completing the measurement, remove the measuring equipment and set to the original condition.
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TESTING AND ADJUSTING
14. Measuring right steering brake pressure (RB) 1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure measurement nipple (14). fl Use a 5.8 MPa {60 kg/cm2} oil pressure gauge.
MEASURING POWER TRAIN OIL PRESSURE
15. Measuring transmission lubrication pressure 1) Remove oil pressure measurement plug (15) (PT1/8). 2) Fit nipple 1 and hose 2 of oil pressure gauge G1, then connect oil pressure gauge G2 (0.98 MPa {10 kg/cm2}) . 3) Start the engine and set all the functions of the full PCCS lever to neutral. fl Any position can be used for the speed range. 4) Measure the oil pressure at engine high idling.
2) Start the engine and set the parking lever to the FREE position. 3) Measure the oil pressure with the engine at low idling and high idling. fl Check that the oil pressure becomes 0 when the PCCS lever is operated fully to the right. fl Check that the oil pressure becomes 0 when the brake pedal is depressed or the parking lever is operated to the LOCK position.
4) After completing the measurement, remove the measuring equipment and set to the original condition.
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TESTING AND ADJUSTING
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE fl Carry out the simple test of brake performance under the following condition. • Torque converter oil temperature: Within operating range 1. Set the blade and ripper in the travel position on a level place.
2. Run the engine and set the parking brake lever in the FREE position. 3. Run the engine at low idling and press the brake pedal and depress the forward switch and 2nd speed position. ¤ If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd speed. fl Set the steering unit in neutral. 4. Press the decelerator pedal and set the fuel control dial in the high idling position. 5. Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idling level. ¤ Since the torque converter will be stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
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TESTING AND ADJUSTING
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER Adjusting brake pedal
1. Adjusting brake pedal stroke Adjust stroke a of brake pedal (1) by adjusting dimension b of stopper bolt (2). fl Adjust the brake pedal stroke with the brake rod separated from the pedal. • Pedal stroke a: 74 mm • Dimension b of stopper bolt: 42 mm 2. Adjusting brake rod length (Temporary installation) 1) Install brake rod (3) and release brake pedal (1) (Do not press the brake pedal). 2) Adjust dimensions c and d of brake rod (3) with turnbuckle (5) so that the spool of brake valve (4) will be at the OFF position. fl The locknut on the brake pedal side of the turnbuckle is a left-handed (reversing) screw. • Dimension c: 32 mm • Dimension d: 14 mm 3 Locknut: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
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3. Checking brake pedal stroke 1) Press brake pedal (1) and check that its stroke is as set in step 1 above. 2) Press brake pedal (1) and check that it is stopped by stopper (6). 3) Press brake pedal (1) and check that spool stroke e of brake valve (4) is in the normal range. • Spool stroke e: 19 – 23 mm
D475A-3
TESTING AND ADJUSTING
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
4. Adjusting brake fl For the method of measuring the brake oil pressure, see MEASURING POWER TRAIN OIL PRESSURE. Since electrical control by the potentiometer being built into the brake pedal and mechanical control (at emergencies and when parking the machine) by the control rod and push-pull cable are being commonly used for the brake, it becomes necessary to make adjustment to synchronize these two control methods. 1) Initial setting for the brake potentiometer Make this adjustment to correct the output voltage error occurring from the mounting deviation of the brake potentiometer. Enter into the Service Adjustment mode and, under the Service Adjustment mode, input the service mode No. 0005 (initial setting mode for the brake potentiometer) to the “0000-SELECT NO.” in the multi-information indication column and turn the brake cancel switch to the select potion (). Then, 0005-BRAKE BASE **mV will be indicted. (Here, ** is the value of the deviation from the specified voltage at the neutral position.) Under the above state, turn the buzzer cancel switch to the select potion () and the buzzer will sound and the setting will be completed. (The value being indicated on the lower line as above will not change even when this adjustment has been finished.) 2) Adjustment of the brake rod Stop the electric control for the brake to make adjustment of the mechanical brake. Connect the Bourdon tube (5.9 MPa {60 kg/cm2} meter) to the LB port (LH brake pressure) in the centralized pressure checking ports.
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After starting the engine, enter into the Service Adjustment mode and, under the Service Adjustment mode, input the service mode No. 9996 (electric brake release mode) to the “0000-SELECT NO.” in the multi-information indication column and turn the brake cancel switch to the select potion (). Then, 9996-MECHA BRAKE BASE 2500 mV will be indicted. (This indication means that the voltage is 2450 – 2550 mV under the state where the brake pedal is not being depressed.) Under the above state, when the parking brake lever is turned to the FREE position, the Bourdon tube for the LB pressure will indicate 2.5 – 2.7 MPa {25 – 27 kg/cm2}. When the brake pedal is depressed, the indicated voltage value will increase but adjust the brake rod so that the indication on the Bourdon tube for the LB pressure may drop below 8 kg/cm2 within the range when the aforementioned increasing voltage value exceeds 3060 mV until the stroke end of the brake pedal. When the brake pedal is depressed gradually, in case the oil pressure will not drop below 8 kg/cm2 even at the stroke end: —— Adjust the turnbuckle to shorten the brake rod. When the brake pedal is depressed gradually, in case the oil pressure starts dropping before the aforementioned increasing voltage value reaches 3060 mV: —— Adjust the turnbuckle to prolong the brake rod. When the above adjustment has been finished, turn the buzzer cancel switch to the cancel position (■) and the electric brake release mode will be cancelled. (Turning OFF the starting key will also cancel the electric brake release mode and, when the starting key is turned on after that, the normal mode will be called.)
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TESTING AND ADJUSTING
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
Adjusting at parking brake lever end
5. Assembling and installing lever assembly 1) Assemble lever assembly (7) and adjust the operation of limit switch (8). fl When assembling the lever assembly, disconnect the parking brake cable from the lever. • When lever is raised: OFF, lowered: ON • Operation stroke of limit switch: 3 mm 2) Install lever assembly (7). 6. Adjusting length of parking brake cable 1) Connect parking brake cable (9) to the lever and valve and adjust dimensions f and g. • Dimension f of cable: 112.8 mm • Dimension g of cable: 114.0 mm 2) Operate parking brake lever (10) between the FREE and LOCK positions and adjust rod end (11) so that spool stroke h of brake valve will be normal. • Spool stroke h: 30.0 mm
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7. Checking brake oil pressure Check that the brake oil pressure is as follows when the parking brake lever is set in the FREE and ROCK positions. fl For the method of measuring the brake oil pressure, see MEASURING POWER TRAIN OIL PRESSURE. • LOCK position: 0 FREE position: Specified pressure 8. Checking limit switch Change the monitor panel to the monitoring display mode and set the parking brake lever in the FREE and ROCK positions. Check that the limit switch signal is normal at this time. fl For the operating method of the monitoring display mode, see “SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)”. • Monitoring code: 40910 (Steering controller switch input 1)
D475A-3
TESTING AND ADJUSTING
ADJUSTING PCCS LEVER CONSOLE POSITION
ADJUSTING PCCS LEVER CONSOLE POSITION
1. Set operator’s seat (1) in the forward (dozing) position. 2. Under this condition, check that console (2) is in parallel with operator’s seat (1). fl If the console is not parallel with the operator’s seat, adjust dimension a of rod (3). • Standard dimension a: 179 mm fl The locknut on the rear side of the turnbuckle is a left-handed (reversing) screw.
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TESTING AND ADJUSTING
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE fl Devices used for emergency escape Symbol 1 H 2
Part No.
Part name
19M-06-32820
Switch assembly
7824-66-6430
Resistor
195-06-71220
Wiring harness
790-190-1600
Pump assembly
1. Escape with switch box (Use H1) fl If the machine cannot be moved because of a trouble in the electric system of the power train control unit (travel direction, gear speed, steering), escape according to the following procedure. fl The engine must be startable for the following procedure. If the engine cannot be started, see EMERGENCY ESCAPE WITH BRAKE RELEASING DEVICE. 1) Connect switch assembly 1 and resistor 2 to wiring harness 3 of emergency escape device H1. ¤ Since resistor 2 controls the drive voltage of the solenoid, connect it to the wiring harness before connecting to the machine. ¤ Set the all gear speed switches of switch assembly 1 in the OFF position and the direction switch in the P position to prevent the machine from starting suddenly.
fl Since the female side of connector PL2 is kept disconnected, mask it with a vinyl sheet, etc. fl Put switch assembly 1 in the cab through the cab window.
3) Disconnect neutral safety relay (NSF) in the fuse room and connect pins 3 and 5 of the connector on the wiring harness side. fl Perform this operation only when the engine does not start electrically because of a trouble in the transmission controller. ¤ If the engine is started by this method, the neutral safety function does not work. Accordingly, before starting the engine, set the parking brake lever in the LOCK position and set the PCCS lever in the full neutral position. ¤ Start the engine by this method only in an emergency. If the engine does not start in another case, be sure to carry out troubleshooting and repair the trouble.
2) Open the left fender inspection cover and connect wiring harness 3 to connectors PL1 (1) and PL2 (2). • Connector PL1 (1): Connect to male side and female side. • Connector PL2 (2): Connect to male side.
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TESTING AND ADJUSTING
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
4) Start the engine and set the parking brake lever in the FREE position. 5) Operate switch assembly 1 and move the machine to a safe place. fl The gear speed switch is so made that the switch on the lower gear speed will be operated first.
2. Escape with brake releasing device (Use H2) fl If the engine cannot be started and the parking brake cannot be released, escape according to the following procedure. fl The engine must be startable for the following procedure. If the engine cannot be started, see EMERGENCY ESCAPE WITH BRAKE RELEASING DEVICE. 1) Assemble pump assembly H2.
2) Install volume pump 1 of pump assembly H2 to the outside of the operator’s cab.
3) Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller solenoid valve.
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EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
4) Connect end hose (3) of pump assembly H2 to the supply hose. fl Block the solenoid valve side with plug.
5) Turn the starting switch ON and set the parking brake lever in the FREE position. 6) Operate the vacuum pump to raise the brake releasing oil pressure to the initial pressure. • Initial pressure: Approx. 2.74 MPa {28 kg/cm2} fl Since an accumulator is installed in the circuit, the handle must be operated 30 – 50 times to raise the oil pressure. fl If the oil pressure does not rise above a certain level, the relief valve may be set to low pressure. In this case, adjust the set pressure of the relief valve. 7) Tow the machine to a safe place. fl The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again about 1 minute after. Accordingly, work quickly. fl If the brake releasing pressure lowers to about 1.5 MPa {16 kg/cm2}, the brake is applied. In this case, operate the volume pump again to raise the brake releasing pressure to the initial pressure.
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TESTING AND ADJUSTING
ADJUSTING CLEARANCE OF IDLER
ADJUSTING CLEARANCE OF IDLER The idler moves forward and backward under external pressure. When this happens, side guide (1) 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 (1). 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. fl There are two types of shim (thickness: 0.5 mm and 1.0 mm).
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a
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TESTING AND ADJUSTING
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Drive the machine forward and stop on a horizontal surface. fl Stop the machine without using the brake. 2. Pull steel rod (1) 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
Adjusting fl If the track shoe tension is not normal, adjust as follows. 1. Remove cover (2). 2. If tension is too high: Loosen plug (3) and release some of the grease. ¤ There is danger that the plug may fly out under the high internal pressure of the grease, so never loosen the plug more than 1 turn. 3. If tension is too low: Pump in grease through grease fitting (4). fl If the track tension is poor, move the machine backwards or forwards slowly. fl After complection of the adjustment, repeat the above procedure to check the tension again.
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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}).
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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 [5A]) 1. Measuring front pump relief pressure 1) Turn the starting switch ON. 2) Change the monitor panel indication to the “monitoring mode” to prepare for measurement of the work equipment oil pressure. • Monitoring Code: 70700 (Work equipment oil pressure high) 3) Start the engine and set the safety lever to the FREE position. 4) 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) Change the monitor panel indication to the “monitoring mode” to prepare for measurement of the work equipment oil pressure. • Monitoring Code: 70700 (Work equipment oil pressure high) 3) Start the engine and set the safety lever to the FREE position.
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TESTING AND ADJUSTING
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
4) 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.
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
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.
Pump Front RAISE LOWER Right Left Right Left DUMP BACK RAISE LOWER IN BACK
Rear
Assist
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
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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}
20-140
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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}
D475A-3
20-141
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.
20-142
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TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE
Adjusting fl If the oil pressure is not correct, adjust PPC relief valve (2) as follows.
1. Loosen locknut (3). 2. Turn adjustment screw (4) to adjust. fl Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE 3 Locknut: 9.8 Nm {1.0 kgm} fl After complection of the adjustment, repeat the above procedure to check the oil pressure again.
D475A-3
20-143
TESTING AND ADJUSTING
MEASURING PPC VALVE AND PITCH • TILT CONTROL VALVE OUTPUT PRESSURE
MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE ¤ 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 PPC valve output pressure under the following conditions. • Hydraulic oil temperature: 45 – 55°C 1. Method of measuring PPC valve portion fl 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. fl See the circuit drawing on the next page 2) Fit adapter 1 and nipple 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (5.9 MPa {60 kg/cm2}) with hose 3. 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. fl Operate the control lever fully when measuring. fl For blade LOWER, operate to the FLOAT position.
2. Method of measuring relay block portion fl 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. fl See the circuit drawing on the next page.
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MEASURING PPC VALVE AND PITCH • TILT CONTROL VALVE OUTPUT PRESSURE
2) Fit adapter 1 and nipple 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (5.9 MPa {60 kg/cm2}) with hose 3. 3) Start the engine and set the safety lever to the FREE position. 4) Operate the control lever or knob switch of the circuit to be measured, and measure the oil pressure at engine high idling. fl Operate the control lever fully when measuring. fl 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. fl 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.
D475A-3
20-145
TESTING AND ADJUSTING
20-146
MEASURING PPC VALVE AND PITCH • TILT CONTROL VALVE OUTPUT PRESSURE
D475A-3
TESTING AND ADJUSTING
D475A-3
MEASURING PPC VALVE AND PITCH • TILT CONTROL VALVE OUTPUT PRESSURE
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TESTING AND ADJUSTING
ADJUSTING PPC VALVE
ADJUSTING PPC VALVE fl 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) fl The diagram shows the ripper PPC valve. 1. Remove boot (1). 2. Loosen locknut (2), then turn disc (3) to adjust the play. fl When doing this, do not move the piston. 3. Secure disc (3) in position and tighten locknut (2). 3 Locknut: 98.07 – 127.49 Nm {10 – 13 kgm} 4. Install boot (1).
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MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID 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. fl Measure the solenoid valve output pressure under the following conditions. . • Hydraulic temperature: 45 – 55°C 1. Disconnect hose (1). 2. Fit adapter 1 and nipple 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (39.2 MPa {400 kg/cm2}) with hose 3. fl The blade Lo circuit is used for the basic pressure of the solenoid valve of the demand valve. 3. Start the engine and set the safety lever to the 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. fl The pressure should be as follows. When lever is at HOLD: Approx. 0 MPa {0 kg/cm2} When lever is operated to lift: Almost same as blade lift circuit pressure
D475A-3
20-149
TESTING AND ADJUSTING
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID 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. fl Measure the output pressure of the ripper pin puller solenoid valve under the following conditions. • Power train oil temperature: 45 – 55°C 1. Disconnect output hoses (1) and (2). 2. Fit adapter 1 and nipple 2 of oil pressure gauge G1, then connect oil pressure gauge G1 (5.9 MPa {60 kg/cm2}) with hose 3. fl The power train circuit is used for the basic pressure of the ripper pin puller solenoid valve. 3. Start the engine and run at low idling. 4. Operate the pin-puller switch and measure the oil pressure when the ripper pin-puller cylinder is operated fully.
20-150
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TESTING AND ADJUSTING
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER fl 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. fl 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. fl 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. Reference: If the cause of the hydraulic drift is in the packing, the speed of downward movement in the above operation will become faster for the following reasons. 1) With the work equipment in the posture 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.
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TESTING AND ADJUSTING
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER fl Measure the oil leakage inside the hydraulic cylinder under the following conditions. • Hydraulic oil temperature: 45 – 55°C fl 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. 1) 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. fl Remove the cover when disconnecting the blade tilt cylinder hose.
¤ Be
careful not to disconnect the piping at the bottom end.
3. Run the engine at high idling and apply the relief pressure to the bottom end of the cylinder. fl Blade tilt cylinder: Tilt blade to right Ripper lift cylinder: Lower ripper Ripper tilt cylinder: Tilt ripper to front 4. Wait for 30 seconds, then measure the amount of leakage over the next 1 minute.
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TESTING AND ADJUSTING
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT BLEEDING AIR FROM HYDRAULIC CYLINDERS
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT fl 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 the pressure inside the hydraulic tank. 2. Operate the work equipment control levers to the front, rear, left, and right. fl 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. fl If the above operation is repeated 2 – 3 times, the remaining pressure will be completely released. fl For the ripper cylinder, the remaining pressure is released through the ripper Hi valve, so repeat the above procedure several times.
D475A-3
BLEEDING AIR FROM HYDRAULIC CYLINDERS fl After replacing or installing hydraulic cylinders or disconnecting and connecting hydraulic piping, bleed the air from the circuit as follows. 1. Start the engine and run at low idling for about 5 minutes. 2. Run the engine at low idling, and extend and retract the hydraulic cylinders 4 – 5 times. fl 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 idling and repeat the 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.
20-153
TESTING AND ADJUSTING
ADJUSTING WORK EQUIPMENT SAFETY LEVER
ADJUSTING WORK EQUIPMENT SAFETY LEVER 1. Adjust dimension a between the pins of rod (1), then connect to safety lever (2) and PPC lock valve (3). • Dimension a between pins: 330 mm
20-154
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TESTING AND ADJUSTING
ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
fl Adjust the ripper lever to the best position according to the following procedure. fl The ripper lever can be adjusted forward and in reverse within the range of ±40 mm from the center of the lever shaft.
5) Loosen nut (3). 6) Reverse knob (4). 7) Tighten nut (3) to secure knob (4).
1. Adjusting within range of backward 40 mm from neutral position 1) Loosen lock bolt (1). 2) Set lever (2) to the best position. 3) Tighten lock bolt (1) to secure lever (2). 2. Adjusting within range of forward 40 mm from neutral position 1) Remove lock bolt (1). 2) Remove lever (2) and reverse it. 3) Install lever (2) to lever (5) and set it to the best position. 4) Tighten lock bolt (1) to secure lever (2).
D475A-3
20-155
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) fl 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. fl 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. fl 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 (1), and connect to potentiometer lever (2) and yoke (3). • Installation dimension a: 376.5 mm
3. The diagram on the right is the mode used to set the tilt limit. The method for setting the tilt limit is as follows. 4. Hold the buzzer cancel switch at the SELECT position () for 3 seconds. (This enters the user adjustment mode) 5. When the information switch is turned to the right or left, the service mode on the multi-information display changes, and 04: TILT LIMIT is displayed. Following this, if the buzzer cancel switch is operated to the SELECT position (), the system enters the control adjustment mode, but before starting, there are operations necessary for adjusting the tilt limit, so follow the procedure below.
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PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION)
6. Use the toggle switch on the work equipment control lever to select DUAL TILT, tilt the work equipment back fully, then lower it to the ground. 7. Operate the buzzer cancel switch to the SELECT position () to enter the tilt limit adjustment mode. When the pitch switch on the work equipment control lever is pressed, the buzzer sounds and the basic position of the work equipment is saved to memory. 8. Raise the work equipment 1000 mm (39.4 in), then tilt it 12° to the left. In this condition, use the toggle switch on the work equipment control lever to switch to SINGLE TILT, then switch back to DUAL TILT. The buzzer sounds and the left limit position is saved to memory. 9. Set the buzzer cancel switch to the CANCEL position (■) to exit the tilt limit adjustment mode. 10. Operate the work equipment to pitch dump to set to the full pitch dump position. (Keep the work equipment horizontal.) 11. Operate the buzzer cancel switch to the SELECT position () to enter the tilt limit adjustment mode again. 12. Raise the work equipment 1000 mm (39.4 in), then tilt it 12° to the right. 13. In this condition, use the toggle switch on the work equipment control lever to switch to SINGLE TILT, then switch back to DUAL TILT. The buzzer sounds and the right limit position is saved to memory. This completes the adjustment operation, so set the buzzer cancel switch to the CANCEL position (■) to exit the tilt limit adjustment mode, then lower the work equipment to the ground 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.
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SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special functions 1. Upper display section (Gear speed display section) 2. Lower display section (Multi-information section)
Operation section 1 of special functions (Basic operation) 3. Service switch 4. Buzzer cancel switch
Operation section 2 of special functions (Changeover operation) 5. Information switch 6. Shift switch 7. Neutral switch
fl EMMS: Equipment Management Monitoring System
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SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Normal function and special functions of monitor panel (EMMS) The monitor panel (EMMS) has the normal function and special functions and displays information of various types at the gear speed display section at its center and the multi-information section. Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed according to the operation of the switches. 1. Normal function: Operator mode With this function, the operator can display and change the items displayed normally. 2. Special function 1: Service mode With this function, a serviceman can display and change the displayed items with special switches for testing, adjusting, and troubleshooting. Flow of modes and functions Operator mode Normal display (Default)
Travel direction/Gear speed + Shift mode/Service meter
(Automatic)
1
Maintenance mode [>] [<]
Maintenance item: 12 items Auxiliary menu: 4 items
2 [ ] (ª)
Pm clinic auxiliary mode [>] [<]
3
Error code display mode
[■]
4
[>] [<] Adjustment mode [>] [<]
1
Maintenance mode
Adjustment menu: 4 items
Action code display function
[ON] & [](ª)
[■]
Service mode 5
Maintenance interval change mode [>] [<]
6
Electric system error code display mode
7
[>] [<] Mechanical system error code display mode
Maintenance item: 12 items
8
[>] [<] Adjustment mode
Adjustment menu: 25 items
9
[>] [<] Load memory mode
Display menu: 3 items
[>] [<] 10 Real-time monitoring mode [>] [<] 11 Dual display monitoring mode
5
[>] [<] Maintenance interval change mode
D475A-3
[ON]: []: [■]: [>]: [<]: (ª):
Service switch Buzzer cancel switch (Left) Buzzer cancel switch (Right) Information switch (Right) Information switch (Left) Min. 2.5 sec
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TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Operation and display in operator mode (Outline) fl In this section, only the outline of the operation mode is described. For the details of the contents and operation method of each function and mode, see Operation Manual. Normal display mode (Default) The monitor panel displays the following information normally. Gear speed display section (1): • Front side: Travel direction (P·N·F·R) • Rear side: Gear speed (1·2·3) • Graphics: Engine speed Multi-information section (2): fl Information is displayed in 2 lines of 16 characters each. • Front side: Gear shift mode (F1-R1·F1-R2·F2-R2) • Rear side: Service meter (Unit: 0.1 h)
1. Maintenance mode (1-OIL, FILTER MAINTENANCE MODE) In this mode, the time up to the next replacement of oils and filters is displayed on the multiinformation section (2) and reset after the replacement. fl Gear speed display section (1) keeps displaying normally. No.
Maintenance item
01
Engine oil
02
Engine oil filter
03
Fuel filter
04
Hydraulic oil filter
05
Corrosion resistor
06
Bypass filter
07
Damper oil
08
Final drive oil
09
Hydraulic oil
10
Power train oil
11
Power train oil filter
12
HSS charge filter (not use)
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SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
2. Pm clinic auxiliary mode (2-PM CLINIC MODE) In this mode, the condition of the machine is displayed on multi-information section (2) as an auxiliary function of the periodic diagnoses such as the Pm clinic, even if any measuring instrument is not connected. fl Gear speed display section (1) keeps displaying normally. No.
Pm clinic auxiliary item
01
Engine speed
02
Hydraulic oil pressure (large)
03
Work equipment pressure (assist)
04
Battery voltage
3. Error code display mode (3-ERROR CODE DISPLAY MODE) In this mode, the contents of each fault in the machine are displayed by a 6-character error code on the multi-information section (2). When the user or the operator needs to be notified of the error code of each fault, this mode is applied. fl Gear speed display section (1) keeps displaying normally. fl When a serviceman needs to check the error codes for troubleshooting, the Electric system error code display mode and the Mechanical system error code display mode should be used for more detailed information. fl Method of checking error code: Turn buzzer cancel switch (4) to the[ ] position on the screen shown at right, and the all error codes detected currently are displayed at the interval of about 2 seconds. (To finish displaying, turn the buzzer cancel switch to the [ ] position.)
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TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Error codes table Error code 1500L0 15SAL1 15SALH 15SBL1 15SBLH 15SEL1 15SELH 15SFL1 15SFLH 15SGL1 15SGLH 1800MW 2201L1 2201LH 2202L1 2202LH 2301L1 2301LH 2302L1 2302LH A70XLK A70YLK AA1ANX AB00MA B@BAZG B@BAZK B@BCNS B@BCZK B@CENS B@HANS B@HAZK D110KA D110KB D130KA D130KB D161KA D161KB D1D0KA D1D0KB D1D1KA D1D1KB D5ZFKA D5ZFKB D5ZFL4 D5ZGKA D5ZGKB D5ZKKX DAFRKR DAQ0KK
20-162 20-162 (1)
Failure phenomenon Transmission double failure 1, 2 Forward clutch oil pressure 1 Forward clutch oil pressure 2 Reverse clutch oil pressure 1 Reverse clutch oil pressure 2 1st speed clutch oil pressure 1 1st speed clutch oil pressure 2 2nd speed clutch oil pressure 1 2nd speed clutch oil pressure 2 3rd speed clutch oil pressure 1 3rd speed clutch oil pressure 2 P/L clutch slip RH clutch oil pressure 1 RH clutch oil pressure 2 LH clutch oil pressure 1 LH clutch oil pressure 2 RH brake oil pressure 1 RH brake oil pressure 2 LH brake oil pressure 1 LH brake oil pressure 2 Failure with the governor servo circuit, RH Failure with the governor servo circuit, LH Air cleaner clogging Battery charge failure Engine oil pressure drop Engine oil quantity decrease Coolant overheated Coolant level drop Power train overheated Hydraulic oil overheated Hydraulic oil level drop BR relay holding 2 BR relay holding 1 N safety relay 2 N safety relay 1 Back alarm relay 2 Back alarm relay 1 Governor cut relay, RH disconnected Governor cut relay, RH shorting Governor cut relay, LH disconnected Governor cut relay, LH shorting N signal 1 - 2 N signal 1 - 1 N signal abnormality N signal 2 - 2 N signal 2 - 1 Chassis throttle signal failure RTCDB failure Supply voltage failure
Controller TM TM TM TM TM TM TM TM TM TM TM TM ST ST ST ST ST ST ST ST ENG ENG Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical ST ST TM TM TM TM ENG ENG ENG ENG TM TM ENG TM TM ENG MON TM
Action code Alarm lamp Alarm buzzer E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E02 E04 E04 E04 E04 E04 E04 E04 E04 E04 E04
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‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
E02 E02 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 CALL E03 CALL E03 CALL E04
‡ ‡
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‡ ‡ ‡
CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL
D475A-3
TESTING AND ADJUSTING
Error code DAQ0KT DAQ5KK DAQ6KK DAQ9KQ DAQRKR DAQSKR DB30KK DB30KT DB35KK DB36KK DB39KQ DB3RKR DB3SKR DB40KK DB41KK DB42KK DB43KK DB44KK DB45KP DB49KM DB49KQ DD14KA DD14KB DDB9KA DDB9KB DDK3KA DDK3KB DDK5KA DDK5KB DDN2LD DDN3LD DDN7KA DDN7KB DDN9KA DDN9KB DDNALD DDNBLD DDNCLD DDNDLD DDNELD DDNFLD DDQ2KA DDQ2KB DDQ2L4 DDT5KA DDT5KB DDT5KQ DGE2KX DGS1KX
D475A-3
Failure phenomenon Memory value failure Potentiometer power failure Sensor power failure Model selection 1, 2, 3 RTCDB failure Network failure Supply voltage failure Memory value failure Potentiometer power failure Sensor power failure Model selection 1, 2, 3 RTCDB failure Network failure Supply voltage failure Switch power failure Solenoid power 1 failure Backup power failure Solenoid power 2 failure Rack sensor power failure Connector connection error Model selection abnormality Travel lock SW 2 Travel lock SW 1 Reverse SW 2 Reverse SW 1 Forward SW 2 Forward SW 1 Shift SW 2 Shift SW 1 PPC tilt, RH oil pressure SW PPC tilt, LH oil pressure SW Pitch SW 2 Pitch SW 1 Dual tilt SW 2 Dual tilt SW 1 PPC lift up full oil pressure SW PPC ripper up oil pressure SW PPC ripper down oil pressure SW PPC ripper tilt oil pressure SW PPC ripper tilt back oil pressure SW PPC lift down full oil pressure SW Travel lock SW 2 Travel lock SW 1 Travel lock discordance 1, 2 Neutral SW 2 Neutral SW 1 Lever spec. selection error Water temperature sensor failure Hydraulic oil temperature sensor
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Controller TM TM TM TM TM TM ST ST ST ST ST ST ST ENG ENG ENG ENG ENG ENG ENG ENG TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM ST ST ST TM TM TM ENG TM
Action code Alarm lamp Alarm buzzer E01 CALL E03 E01 CALL E04 CALL E03 E01 CALL E04 E01 CALL E03 CALL E03 CALL E04 CALL E03 E01 CALL E04 CALL E03 CALL E04 CALL E03 CALL E04 CALL E03 CALL E04 E02 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 E02 E02 E02 E02 E02 E02 E01 E01
CALL CALL CALL CALL CALL CALL
E03 E03 E03 E04 E04 E04 E02
‡
‡
‡ ‡
‡ ‡
‡
‡
‡ ‡ ‡ ‡
‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡
‡ ‡ ‡ ‡ ‡ ‡
20-163 20-163 (1)
TESTING AND ADJUSTING
Error code DH22KA DH22KB DH23KA DH23KB DK01KA DK01KB DK03KA DK03KB DK10KX DK11KA DK11KB DK12KX DK30KA DK30KB DK30KX DK30KZ DK30L8 DK31KA DK31KB DK40KA DK40KB DK60KA DK60KB DKF1KX DKF2KX DKH1KA DKH1KB DLE1KA DLE4LC DLE5LC DLF1KA DV00KB DW55KA DW55KB DW56KA DW56KB DW57KA DW57KB DW58KA DW58KB DW5AKA DW5AKB DW5JKA DW5JKB DW5LKA DW5LKB DW98KA DW98KB DWN3KA
20-164 20-164 (1)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Failure phenomenon Hydraulic oil pressure 1 (L, F) sensor 2 Hydraulic oil pressure 1 (L, F) sensor 1 Hydraulic oil pressure 1 (S, R) sensor 2 Hydraulic oil pressure 1 (S, R) sensor 1 LH yoke corner sensor 2 LH yoke corner sensor 1 RH yoke corner sensor 2 RH yoke corner sensor 1 Fuel dial failure Decelerator potentiometer failure (ST) Decelerator potentiometer failure (ST) Decelerator potentiometer failure Swing potentiometer 1 disconnected Swing potentiometer 1 shorting Swing circuit 2 circuit One is defective and others become defective when the starting key is turned on. Swing potentiometer deviation Swing potentiometer 2 shorting Swing circuit 2 circuit Brake potentiometer 2 Brake potentiometer 1 Acceleration sensor 2 Acceleration sensor 1 Rack sensor, RH failure Rack sensor, LH failure Inclination angle sensor 1 Inclination angle sensor 2 Engine revolution sensor Engine revolution sensor A failure Engine revolution sensor B failure Transmissions revolution sensor Alarm buzzer Pitch back solenoid 2 Pitch back solenoid 1 Pitch dump solenoid 2 Pitch dump solenoid 1 LH tilt limiting solenoid 2 LH tilt limiting solenoid 1 RH tilt limiting solenoid 2 RH tilt limiting solenoid 1 Pitch selection solenoid 2 Pitch selection solenoid 1 Pitch independent solenoid 2 (PIT) Pitch independent solenoid 1 (PIT) Dump support solenoid 2 (PDA) Dump support solenoid 1 (PDA) Unload valve 2 (UNL) Unload valve 1 (UNL) Abrupt stop preventive solenoid 2
Controller TM TM TM TM TM TM TM TM ENG ST ST ENG ST ST ST ST ST ST ST ST ST ST ST ENG ENG ST ST ST ENG ENG TM MON TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM ST
Action code Alarm lamp Alarm buzzer
CALL
CALL CALL CALL CALL CALL CALL CALL CALL CALL CALL
CALL CALL CALL CALL CALL CALL
CALL CALL CALL CALL
CALL CALL CALL CALL CALL CALL CALL
E02 E02 E02 E02 E03 E01 E01 E03 E03 E03 E04 E04 E03 E03 E03 E03 E03 E01 E01 E03 E03 E03 E03 E01 E03 E03 E01 E01 E03 E03 E03 E03 E02 E02 E02 E02 E02 E02 E03 E03 E03 E03 E03 E03 E04
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—
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D475A-3
TESTING AND ADJUSTING
Error code DWN3KB DXH1KA DXH1KB DXH4KA DXH4KB DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXH8KA DXH8KB DXH9KA DXH9KB DXHAKA DXHAKB DXHBKA DXHBKB DXHCKA DXHCKB DXHDKA DXHDKB DXHEKA DXHEKB DXHFKA DXHFKB DXHGKA DXHGKB
D475A-3
Failure phenomenon Abrupt stop preventive solenoid 1 Lock up solenoid 2 Lock up solenoid 1 1st speed clutch ECMV2 1st speed clutch ECMV1 2nd speed clutch ECMV2 2nd speed clutch ECMV1 3rd speed clutch ECMV2 3rd speed clutch ECMV1 Reverse clutch ECMV2 Reverse clutch ECMV1 Forward clutch ECMV2 Forward clutch ECMV1 RH clutch ECMV2 RH clutch ECMV1 LH clutch ECMV2 LH clutch ECMV1 RH brake ECMV2 RH brake ECMV1 LH brake ECMV2 LH brake ECMV1 Governor solenoid, RH disconnected Governor solenoid, RH shorting Governor solenoid, LH disconnected Governor solenoid, LH shorting Pre-stroke solenoid, RH disconnected Pre-stroke solenoid, RH shorting Pre-stroke solenoid, LH disconnected Pre-stroke solenoid, LH shorting
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Controller ST TM TM TM TM TM TM TM TM TM TM TM TM ST ST ST ST ST ST ST ST ENG ENG ENG ENG ENG ENG ENG ENG
Action code Alarm lamp Alarm buzzer CALL E04 E01 E01 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E03 CALL E04 CALL E04 CALL E04 CALL E04 CALL E04 CALL E04 CALL E04 CALL E04 CALL E03 CALL E03 CALL E03 CALL E03
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‡
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20-165 20-165 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Separate table: Detailed faults Error code
Details of fault
Error code
KA
Disconnection
L0
KB
Short circuit
L1
Details of fault Clutch fill signals which are not in combination table are turned on in 2 or more channels. When command current for ECMV is turned OFF, fill signal is turned ON.
KR
Lowering of source voltage/Input Nonconformance of model selection signal Defective communication
KT
Fault in controller
L6
KX
L8 LC
Speed signals of 2 systems are not matched.
MA
Out of input signal range Disconnection or short circuit Malfunction
ON and OFF signals of 2 systems are not matched. Engine speed signal, terminal-C signal, oil pressure switch signal, water temperature sensor signal, etc. are not matched to operating or stopping condition. Analog signals of 2 systems are not matched.
LD
MB
Defective function
LH
Switch is pressed and held for abnormally long time. When command current to ECMV is turned ON, fill signal is turned OFF.
MW NS NX ZG ZK
Slip Overheat Clogging Oil pressure reduction Level reduction
KK KQ
KZ
L2
Fuel pressure is higher than maximum specified value.
L3
Corresponding part cannot be controlled.
L4
4. Adjustment mode (4-USER ADJUST MODE) In this mode, the display condition of the monitor panel can be adjusted and the fan speed (for cleaning the radiator) can be changed on the multi-information section (2). fl Gear speed display section (1) keeps displaying normally. No.
Adjustment item
01
Brightness of LCD
02
Brightness of display
03
Contrast of display
04
Tilt limit mode (dual tilt type)
20-166
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Action code display function If a fault to be notified to the operator occurs during work, an action code and a phone No. are displayed on the multi-information section (2). fl Gear speed display section (1) keeps displaying normally. fl The phone No. is displayed for only important action codes. The display shown at right is an example. (The form of the displayed phone No. depends on the form of the input No.) fl If an important action code is displayed, the caution lamp flashes and the caution buzzer sounds. An action code is displayed only when a serious fault occurs. Even if an action code is not displayed, a fault may have occurred. If you feel any abnormality, be sure to check for a error code in the “Electric system error code display mode” and “Mechanical system error code display mode” of the service mode.
Action codes table Action code
Indication method of fault
Contents of fault
Remedy
• Only action code is displayed.
• Torque converter is not locked up. • Blade dual tilt mechanism does not work.
• Automatic function stops or normal function stops partially but machine can work. • Call your Komatsu distributor for repair.
• Action code is displayed. • Caution lamp flashes. • Caution buzzer sounds.
• Gear is not shifted up or down. • Blade tilt is not limited. • Blade pitch mechanism does not work.
• Stop engine and start it again, and you can operate machine without limiting function. You must take care, however. • Call your Komatsu distributor for repair.
CALL E03
• Action code is displayed. • Caution lamp flashes. • Caution buzzer sounds.
• Engine water temperature is defective. • Usable gear speeds are limited. • Engine speed does not rise fully. • Gear shifting shocks become large. • Steering performance lowers. • Brake shocks become large. • Blade is pitched by tilt operation. • Blade pitch operation stops.
• Move machine to safe place. • Call your Komatsu distributor for repair.
CALL E04
• Action code is displayed. • Caution lamp flashes. • Caution buzzer sounds.
• Engine cannot be controlled. • Machine cannot travel. • Machine stops
• Stop machine immediately. • Call your Komatsu distributor for repair.
E01
E02
D475A-3
20-167
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Operation and display in service mode Method of changing to service mode fl When using the service mode, change the screen by the following special operation. 1) Special operation of switches Set the monitor panel in the service mode by operating service switch (3) and buzzer cancel switch (4). • Keeping the service switch in the ON position, hold the buzzer cancel switch in the [ ] position for 2.5 seconds. fl If the monitor panel is set in the service mode, [1C] is displayed on the gear speed display section. fl Each time the monitor panel is set in the service mode, the “Maintenance interval change mode” is displayed first. 2) Selecting and executing mode to be used Select the mode to be used with information switch (5) and execute it with buzzer cancel switch (4). • [ > ]: Next mode No. • [ < ]: Previous mode No. • [ ]: Execute mode. fl For the details of operation in each mode, see the following pages. 3) Finishing mode and function The current mode and function can be finished by either of the following method, regardless of the current mode and hierarchy. 1 When continuing the operation in another mode or function or in the operator mode: Return to the mode screen or function screen to be used next by operating buzzer cancel switch (4). • [ ■ ]: Screen returns. 2 When finishing the all operation: Turn off the starting switch.
20-168
Gear speed No. display section 5
1C
6
EE
7
bE
8 9 10 11
Cb Ld 5R dR
Service mode item Maintenance interval change mode Electric system error code display mode Mechanical system error code display mode Adjustment mode Load memory display mode Real-time monitoring mode Dual display monitoring mode
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
5. Maintenance interval change mode (5-EXCHG. INTVAL. SET MODE) In this mode, you can check and set the maintenance interval times of various filters and oils which are the bases of the maintenance display function in the operator mode. 1) Selecting and executing mode i) Select “Maintenance interval change mode” on the mode selection screen. fl If the mode is selected, code (1C) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the maintenance item selection screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Selecting and displaying maintenance item i) Operate information switch (5) on the maintenance item selection screen to select a maintenance item. • [ > ]: Next code • [ < ]: Previous code ii) Display the maintenance item selection screen by operating buzzer cancel switch (4). • [ ]: Execute item.
3) Contents of information section The following items are displayed on the information section. 1: Code 2: Maintenance item 3: Replacement interval time (Set time) fl The items shown at right are examples. fl If the replacement interval does not need to be changed, finish the operation on this screen. fl If the replacement interval needs to be changed, go to step 4).
D475A-3
20-169
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
4) Changing replacement interval time i) Change the set time by operating information switch (5), shift switch (6), and neutral switch (7). • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. • Shift switch: Increase number. • Neutral switch: Decrease number.
fl If you do not use the maintenance function, set the all times to 0.
ii) If the input time is correct, enter the change of setting by operating buzzer cancel switch (4). • [ ]: Enter change. fl If the change is finished normally, the information display screen appears after the screen shown at right.
fl If the change is not finished normally, the information display screen before the change appears after the screen shown at right. In this case, execute the above operation again.
20-170
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Maintenance items table Replacement interval time Code
Maintenance item
1st time (Cannot be changed)
2nd time and after (Can be changed)
01
ENG OIL
Engine oil
0250 h
0500 h
02
ENG FILT
Engine oil filter
0250 h
0500 h
03
FUEL FILT
Fuel filter
0250 h
0500 h
04
HYD FILT
Hydraulic oil filter
0250 h
2000 h
05
CORR RES
Corrosion resistor
1000 h
1000 h
06
BYPS FILT
Bypass filter
0250 h
0500 h
07
DAMP OIL
Damper oil
2000 h
2000 h
08
FNL OIL
Final drive oil
0250 h
2000 h
09
HYD OIL
Hydraulic oil
0250 h
2000 h
10
POWL OIL
Power train oil
0250 h
1000 h
11
POWL FILT
Power train oil filter
0250 h
0500 h
12
HSS FILT
HSS charge filter (HSS specification)
—
—
fl The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd and after interval times.
D475A-3
20-171
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
6. Electric system error code display mode (6-ELEC. ERROR CODE MODE) In this mode, you can check the past electric system error codes. 1) Selecting and executing mode i) Select “Electric system error code display mode” on the mode selection screen. fl If the mode is selected, code (EE) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the error code display screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Display in the case where no codes are recorded If no error codes have been output up to now, the information section displays as shown at right.
3) Display in the case where 1 or more codes are recorded If any error code has been output up to now, the information section displays as shown at right. 1: Record No. (Up to 20) 2: Error code (Code being output currently is flashing) 3: Number of past occurrences 4: Time measured by service meter after first occurrence 5: Time measured by service meter after last occurrence fl The items shown at right are examples. fl For the details of displayed error codes, see the “ERROR CODES TABLE” in the operator mode.
20-172
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
fl Flashing and lighting of error code Flashing: Code is being output currently. Lighting: Code is not being output currently. fl Condition for detecting and keeping error code If a error code of any item other than communication is output, it keeps flashing until the starting switch is turned off. After the starting switch is turned on or the engine is started again, the error code keeps lighting until the same fault is detected. A error code of communication starts lighting when the fault is solved, even if the starting switch is turned off. 4) Operation to take when multiple codes are recorded. When multiple codes are recorded, they can be displayed one by one by operating information switch (5). • [ > ]: Next code • [ < ]: Previous code fl The error codes are displayed from the oldest one in order of length of time after they were output. 5) Method of deleting error code While a error code to be deleted, operate shift switch (6) or neutral switch (7). • Shift or neutral switch: Delete error code. fl A error code which is being output currently (which is flashing) cannot be deleted.
D475A-3
20-173
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
7. Mechanical system error code display mode (7-MACHINE ERROR CODE MODE) In this mode, you can check the past mechanical system error codes. 1) Selecting and executing mode i) Select “Mechanical system error code display mode” on the mode selection screen. fl If the mode is selected, code (bE) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the error code display screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Display in the case where no codes are recorded If no error codes have been output up to now, the information section displays as shown at right.
3) Display in the case where 1 or more codes are recorded If any error code has been output up to now, the information section displays as shown at right. 1: Record No. (Up to 20) 2: Error code (Code being output currently is flashing) 3: Number of past occurrences 4: Time measured by service meter after first occurrence 5: Time measured by service meter after last occurrence fl The items shown at right are examples. fl For the details of displayed error codes, see the “ERROR CODES TABLE” in the operator mode.
20-174
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
fl Flashing and lighting of error code Flashing: Code is being output currently. Lighting: Code is not being output currently. fl Condition for detecting and keeping error code If an error code of any item other than communication is output, it keeps flashing until the starting switch is turned off. After the starting switch is turned on or the engine is started again, the error code keeps lighting until the same fault is detected. An error code of communication starts lighting when the fault is solved, even if the starting switch is turned off. 4) Operation to take when multiple codes are recorded. When multiple codes are recorded, they can be displayed one by one by operating information switch (5). • [ > ]: Next code • [ < ]: Previous code fl The error codes are displayed from the oldest one in order of length of time after they were output. 5) Method of deleting error code The mechanical system error codes cannot be deleted.
D475A-3
20-175
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
8. Adjustment mode (8-SERVICE ADJUST MODE) In this mode, you can adjust the control system and various devices of the machine. 1) Selecting and executing mode i) Select “Adjustment mode” on the mode selection screen. fl If the mode is selected, code (Cb) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the adjustment code input screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Selecting adjustment items On the adjustment code input screen, input the 4-digit code of the item to be adjusted by operating information switch (5), shift switch (6), and neutral switch (7). • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. • Shift switch: Increase number. • Neutral switch: Decrease number. fl If the 4-digit code is input, the information of that code is displayed automatically.
3) Contents of display on adjustment screen 1: Code 2: Adjustment item 3: Related information fl For the detailed information and adjustment procedure, see “ADJUSTMENT MODE TABLE AND ADJUSTMENT PROCEDURE”.
20-176
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
fl If an incorrect code is input, the adjustment code input screen appears again after the screen shown at right. In this case, execute the above operation again.
4) When operating machine in adjustment mode If the parking brake lever is set in the FREE position, gear speed display section (2) displays normally and the machine can be operated normally. fl To select another screen, return the parking brake lever to the LOCK position and perform the necessary procedure.
5) Changing adjustment item (Limited function) Once the adjustment items are selected, they can be selected with the information switch without inputting the codes again. • [ > ]: Next code • [ < ]: Previous code fl This function is limited to Nos. 1 – 6 in the “Adjustment mode table and adjustment procedure”. fl This operation is not accepted while the parking brake lever is in the FREE position. Take care. fl An adjustment item can be selected by returning to the input screen and inputting the code for that item.
D475A-3
20-177
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Adjustment mode table and adjustment procedure No. Code
Adjustment item
Related information
Indication
1
0002 S/T S. CODE
Steering controller specification set
CODE
D475-3 AAA, D475m/c 666
2
0003 T/M S. CODE
Transmission controller spedification set
CODE
D475-3 999, D475m/c 555
3
0004 BODY TYPE
Machine specification set
CODE
ABB 3 digit indication A Section 0: PCCS, 1: SW type lever 4: Retro-machine PCCS, 5 Retro-machine SW type lever
4
0005 BRAKE BASE
Brake potentiometer initial set
mv
Offset value
5
0007 ENG. FULL CH
Engine deceleration-cut mode
rpm
Engine revolution
6
0009 PITCH SENS.
Pitch angle sensor initial set
mV
Inclination angle sensor offsetting voltage
7
0001 INP TEL NO.
Phone number input mode
8
1012 S/T N-SET
Steering lever neutral set
mV
S/T potentiometer 2 voltage mV
9
1013 S/T M. L-SET
Steering lever left set
mV
S/T potentiometer 2 voltage mV
0
1014 S/T M. R-SET
Steering lever right set
mV
S/T potentiometer 2 voltage mV
A
1031 BR AUTO-SET
Brake automatic adjustment
MPa
Brake pressure setting MPa
B
1015 BRK LH. OFST
Left brake oil pressure offset
MPa
Offsetting oil pressure
C
1016 BRK RH. OFST Right brake oil pressure offset
MPa
Offsetting oil pressure
D
2223 R SLOW CUT
E
5535 CLUTCH OPEN Both steering clutches released
F
5536 CL AUTO-SET
G
Telephone number
DEACTIVE or ACTIVE
Reverse slow stop set rpm
Transmission revolution rpm
Steering clutch automatic adjustment
MPa
Brake pressure setting MPa
5537 CLT LH. OFST
Left steering clutch oil pressure offset
MPa
Offsetting oil pressure
H
5538 CLT RH. OFST
Right steering clutch oil pressure offset
MPa
Offsetting oil pressure
I
9993 HYD. LEVEL
Hydraulic oil level setting mode
J
9994 BRAKE DECEL Decelerator interlocking setting mode
K
9995 LOCK BRAKE
L
9996 MECHA BRAKE Electric brake release mode
M
9997 HI IDLE SET
High Idling limit mode
rpm
N
9998 SFT INHIBIT
Gear speed limit mode
Bit
O
0523 SMR SET
Service meter adjustment
20-178
Electric brake normally ON mode
DEACTIVE or ACTIVE DEACTIVE or ACTIVE mV
Brake potentiometer voltage mV
mV
Brake potentiometer voltage mV
SMR
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
1 0002: Steering controller specification set • This code is used to initialize the specification codes recognized by the steering controller and the set values of the memory in the controller. • The specification code is displayed on the lower line. • Adjustment method (HSS specification): 1) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. 2) Check that the displayed specification code has changed from [A*A] to [AAA]. fl If specification code [AAA] is not displayed, the controller wiring harness or the controller unit may be defective. fl Even if this code is turned off, the setting is effective. 2 0003: Transmission controller specification set • This code is used to initialize the specification codes recognized by the transmission controller and the set values of the memory in the controller. • The specification code is displayed on the lower line. • Adjustment method: 1) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. 2) Check that the displayed specification code has changed from [9*9] to [999]. fl If specification code [999] is not displayed, the controller wiring harness or the controller unit may be defective. fl Even if this code is turned off, the setting is effective.
D475A-3
20-179
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
3 0004: Machine specification set • This code is used to have the machine specification recognized by the controllers which compose the system. • The machine specification code is displayed on the lower line. • Adjustment method: fl Since this code is reset when “Transmission controller specification set” is executed, adjust it after that. 1) Select the code of the machine specification by setting information switch (5) in the [ > ] position. fl Be sure to select “SSC power setting 1” as the SSC type. 2) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. ¤ If the machine specification is different from the setting in the controller, the machine may move abnormally or an error may be made. Accordingly, be sure to match the setting to the machine specification. fl Even if this code is turned off, the setting is effective.
Section A No.
Travel control lever spec.
Factory shipment or local modification
0
PCCS
Factory shipment
1
PCCS R type
Factory shipment
4
PCCS
Local modification
5
PCCS R type
Local modification
Section B No. Work equipment type
SSC type
00
Single tilt
SSC function OFF
01
Single tilt
SSC power setting 1
02
Single tilt
SSC power setting 2
10
Dual tilt
SSC function OFF
11
Dual tilt
SSC power setting 1
12
Dual tilt
SSC power setting 2
4 0005: Brake potentiometer initial set • This code is used to adjust the neutral position of the brake pedal. • The deviation from the standard neutral position is displayed by voltage on the lower line (Display range: 0 – 5000). • Adjustment method: Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl Even if the neutral position of the brake pedal is adjusted, the display of the lower line does not change. fl Even if this code is turned off, the setting is effective.
20-180
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
5 0007: Engine deceleration-cut mode • This code is used to stop the auto-deceleration function of the engine and check the high idling speed of the engine singly. • The engine speed is displayed on the lower line (Display range: 0 – 3000). • Using method: While this code is displayed, its function is turned on and the auto-deceleration function is turned off. fl If this code is turned off, its function is turned off.
6 0009: Pitch angle sensor initial set • This code is used to adjust the zero point and installation error of the pitch angle sensor. • The deviation from the standard neutral position is displayed by voltage on the lower line (Display range: 0 – 5000). • Adjustment method: Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl Even if this code is turned off, the setting is effective. 7 0001: Phone number input mode • This code inputs or changes a phone number to be displayed simultaneously with when the user code is displayed. • The lower part displays a phone number and symbols. • Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ? • Instructions for use: By operating the information switch (5), shift switch (6), and neutral switch (7), input a phone number and symbols. • [ > ]: Moves the cursor rightward. • [ < ]: Moves the cursor leftward. • Shift switch: Advance the numeric character or character (in the order of available characters). • Neutral switch:Reverse the numeric character or character (in the reverse order of available characters). fl Sixteen digits of numeric characters are provided. To avoid confusion, input symbols other than numeric characters at digits you will not use. fl 0 (zero) is input at all places of the lower part before shipment from our factory. (No phone number is displayed under this condition.) fl The setting is enabled even after ending this code. D475A-3
20-181
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
8 1012: Steering lever neutral set • This code is used to adjust the steering neutral position of the PCCS lever. • The deviation of the steering potentiometer from the standard neutral position is displayed by voltage on the lower line (Display range: 0 – 5000). • Adjustment method: Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl Even if this code is turned off, the setting is effective.
9 1013: Steering lever left set • This code is used to adjust the maximum left steering position of the PCCS lever. • The deviation of the steering potentiometer from the standard maximum left position is displayed by voltage on the lower line (Display range: 0 – 5000). • Adjustment method: 1) Set the PCCS lever to the left steering stroke end. 2) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl Even if this code is turned off, the setting is effective. 0 1014: Steering lever right set • This code is used to adjust the maximum right steering position of the PCCS lever. • The deviation of the steering potentiometer from the standard maximum right position is displayed by voltage on the lower line (Display range: 0 – 5000). • Adjustment method: 1) Set the PCCS lever to the right steering stroke end. 2) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl Even if this code is turned off, the setting is effective.
20-182
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
A 1031: Brake automatic adjustment • This code is the function to maintain the performance of the brake control by automatically adjusting any changes in the performance caused by variation or wear in the brake parts. • The bottom display shows the brake command oil pressure (unit: 0.01 kg/cm2). ¤ With this adjustment, the machine moves approx. 1 – 2 m forward, so carry out the adjustment on flat ground where it is possible to ensure safety in the surrounding area. • Method of adjustment 1 (preparatory work) fl Check that the torque converter oil temperature is in the operating range when carrying out this adjustment. 1) Start the engine and select this code. 2) Set the parking lever to the FREE position. 3) Set the auto shift down switch to OFF 4) Run the engine at low idling. 5) Depress the brake pedal and decelerator pedal to hold the machine. 6) Operate the PCCS lever direction to F and the speed to 2. fl Keep the steering at the neutral position. 7) Gradually release the decelerator pedal and brake pedal and check that the machine does not move. ¤ If the machine moves, there is an abnormality, so stop the adjustment immediately. fl If it is confirmed that the machine does not move, go on to the following Method of adjustment 2. • Method of adjustment 2 (adjusting left clutch) 1) Operate the PCCS lever steering fully to the left. 2) Check that the display for the command oil pressure changes automatically. 3) Drive the machine forward 1 – 2 m, then stop the machine and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. fl After completing the adjustment of the left clutch, go on to the following Method of adjustment 3. fl It is possible to check the compensation value for the left brake oil pressure with adjustment code 1015. • Method of adjustment 3 (adjusting right brake) 1) Operate the PCCS lever steering fully to the right. 2) Check that the display for the command oil pressure changes automatically.
D475A-3
20-183
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
3) Drive the machine forward 1 – 2 m, then stop the machine and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. fl It is possible to check the compensation value for the right brake oil pressure with adjustment code 1016. fl Even when this code is finished, the setting remains effective. B 1015: Left brake oil pressure offset • This code is the function to adjust the left brake oil pressure manually. • The bottom display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.). • Method of adjustment fl The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift switch and set the offset oil pressure. • Shift switch (6): Oil pressure increases • Neutral switch (7): Oil pressure increases fl The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Turn the buzzer cancel switch (4) toward the [ ] side and check that the alarm buzzer sounds. fl Even when this code is finished, the setting remains effective. C 1016: Right brake oil pressure offset • This code is the function to adjust the right brake oil pressure manually. • The bottom display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.). • Method of adjustment fl The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift switch or neutral switch and set the offset oil pressure. • Shift switch (6): Oil pressure increases • Neutral switch (7): Oil pressure increases fl The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Turn the buzzer cancel switch (4) toward the [ ] side and check that the alarm buzzer sounds. fl Even when this code is finished, the setting remains effective.
20-184
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
D 2233: Reverse slow stop set • This code is used to stop the reverse slow function forcibly, regardless of operation of the switches on the monitor panel. • Whether the reverse slow function is turned on is displayed by letters on the lower line. • Adjustment method: Change the setting by operating information switch (5). • [ < ], [ > ]: Change setting. • [DEACTIVE]: Turn off reverse slow function. • [ACTIVE]: Turn on reverse slow function. fl If the reverse slow function is turned off, the reverse travel speed is not lowered even if the reverse slow mode switch on the monitor panel is turned on. fl Even if this code is turned off, the setting is effective.
E 5535: Both steering clutches released • This code is the function to engage the transmission clutch without allowing the machine to move when carrying out inspection, maintenance, troubleshooting, or Pm clinic. • The bottom display shows the transmission speed (unit: rpm). • Method of use The function is effective when this code is being displayed. Both steering clutches are disengaged, so the machine does not travel even if the PCCS lever is operated. fl When this code is finished, the function becomes ineffective.
D475A-3
20-185
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
F 5536: Steering clutch automatic adjustment • This code is the function to maintain the performance of the steering control by automatically adjusting any changes in the performance caused by variation or wear in the steering clutch parts. • The bottom display shows the clutch command oil pressure (unit: 0.01kg/cm2). • Method of adjustment 1 (preparatory work) fl Check that the torque converter oil temperature is in the operating range when carrying out this adjustment. 1) Start the engine and select this code. 2) Set the parking lever to the FREE position. 3) Set the auto shift down switch to OFF. 4) Run the engine at low idling. 5) Depress the brake pedal and decelerator pedal to hold the machine. 6) Operate the PCCS lever direction to F and the speed to 2. fl Keep the steering at the neutral position. 7) Gradually release the decelerator pedal and brake pedal and check that the machine does not move. ¤ If the machine moves, there is an abnormality, so stop the adjustment immediately. fl If it is confirmed that the machine does not move, go on to the following Method of adjustment 2. • Method of adjustment 2 (adjusting left clutch) 1) Operate the PCCS lever steering fully to the left. 2) Check that the display for the command oil pressure changes automatically. 3) Raise the engine speed and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. fl After completing the adjustment of the left clutch, go on to the following Method of adjustment 3. fl It is possible to check the compensation value for the left clutch oil pressure with adjustment code 5537.
20-186
D475A-3
TESTING AND ADJUSTING
•
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Method of adjustment 3 (adjusting right clutch) 1) Operate the PCCS lever steering fully to the right. 2) Check that the display for the command oil pressure changes automatically. 3) Raise the engine speed and check that the alarm buzzer sounds. 4) Return the PCCS lever steering to the neutral position. fl It is possible to check the compensation value for the right clutch oil pressure with adjustment code 5538. fl Even when this code is finished, the setting remains effective.
G 5537: Left steering clutch oil pressure offset • This code is the function to adjust the left steering clutch oil pressure manually. • The bottom display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.) • Method of adjustment fl The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift switch or neutral switch and set the offset oil pressure. • Shift switch (6): Oil pressure increases • Neutral switch (7): Oil pressure increases fl The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Turn the buzzer cancel switch (4) toward the [ ] side and check that the alarm buzzer sounds. fl Even when this code is finished, the setting remains effective.
D475A-3
20-187
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
H 5538: Right steering clutch oil pressure offset • This code is the function to adjust the right steering clutch oil pressure manually. • The bottom display shows the offset oil pressure (unit: 0.01 kg/cm2). (If it has already been adjusted, the value is displayed, but if it is within the permitted range, it is possible to adjust further.) • Method of adjustment fl The maximum permitted range for adjustment is ± 3 kg/cm2 (display: 300). 1) Operate the shift switch or neutral switch and set the offset oil pressure. • Shift switch (6): Oil pressure increases • Neutral switch (7): Oil pressure increases fl The offset oil pressure changes 0.5 kg/ cm2 (display: 50) at a time. 2) Turn the buzzer cancel switch (4) toward the [ ] and check that the alarm buzzer sounds. fl Even when this code is finished, the setting remains effective.
I 9993: Hydraulic oil level setting mode • This code is for the function to make settings for activation of the hydraulic oil level caution. • On the lower line, activation or cancellation of the hydraulic oil level caution will be indicated by characters. • Adjustment method Change the setting by use of the information switch (5). • [ < ] [ > ]: The indication will change. • [DEACTIVE]: Cancels the hydraulic oil level cautioning function. • [ACTIVE]: Activates the hydraulic oil level cautioning function. fl To use this function, it is necessary to install the hydraulic oil level switch (option). If the above [ACTIVE] setting is made without installation of the hydraulic oil level switch, the caution will keep sounding and be careful about this point. fl The setting will be valid even after ending this code.
20-188
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
J 9994: Decelerator interlocking brake setting mode • This code is for the function to make settings for activation of the decelerator interlocking brake. • On the lower line, activation or cancellation of the decelerator interlocking brake will be indicated by characters. • Adjustment method Change the setting by use of the information switch (5). • [ < ] [ > ]: The indication will change. • [DEACTIVE]: Cancels the decelerator interlocking brake function. • [ACTIVE]: Activates the decelerator interlocking brake function. fl The setting will be valid even after ending this code.
K 9995: Electric brake normally ON mode • This code is used to check that the sudden stop prevention valve works normally. • The voltage of the brake potentiometer is displayed on the lower line. • Using method: While this code is displayed, its function is turned on and the electric brake is normally turned on. fl If this code is turned off, its function is turned off.
L 9996: Electric brake release mode • This code is used to check the operation of the mechanical brake. • The voltage of the brake potentiometer is displayed on the lower line. • Using method: While this code is displayed, its function is turned on and the electric brake is normally released. fl If this code is turned off, its function is turned off.
D475A-3
20-189
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
M 9997: High idling limit mode • This code is used to limit the use of the high idling speed. • The engine speed (set value) is displayed on the lower line. • Limit range: High idling speed – High idling speed – 400 rpm • Using method: 1) Select a limit speed by setting information switch (5) in the [ > ] position or [ < ] position. 2) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl If the high idling speed is limited, the engine speed is not raised to the normal high idling level even if the fuel control dial is controlled so. fl Even if this code is turned off, the setting is effective.
N 9998: Gear speed limit mode • This code is used to limit the use of the 3 gear speeds. • The usable gear speeds are displayed by bits on the lower line (in the order of the 3rd, 2nd, and 1st from the left). • Using method: Limit or allow the use of the maximum gear speed by operating information switch (5) and buzzer cancel switch (4). • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. • [ ]: Change setting. • Display on lower line [o]: Gear speed is effective. • Display on lower line [ ]: Gear speed is not effective. fl If the use of a gear speed is limited, the transmission is not shifted to that gear speed even if the gear shift-up switch is operated. fl Even if this code is turned off, the setting is effective.
20-190
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
O 0523: Service meter adjustment • This code is used to match the value of a new service meter to the value of the machine. ¤ Since this code can only put the service meter forward and cannot put it back, operate carefully. • The service meter reading is displayed on the lower line (Display range: 00000 – 99999). • Using method: fl If you input a wrong value, do not enter the setting but cancel this code, then execute the setting again. 1) Set the service meter reading by operating information switch (5) and shift switch (6). • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. • Shift switch: Increase number. fl The actual service meter displays by the unit of 0.1h, but this code displays by the unit of 1h. 2) Set buzzer cancel switch (4) in the [ ] position and check that the caution buzzer sounds. fl Even if the adjustment mode is turned off, the setting is effective.
D475A-3
20-191
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
9. Load memory display mode (9-LOAD MEMORY DISPLAY MODE) In this mode, you can check the load on the machine, odometer, and reverse odometer. 1) Selecting and executing mode i) Select “Load memory display mode” on the mode selection screen. fl If the mode is selected, code (Ld) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the adjustment code input screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Changing information screen Change the information screen by operating information switch (5). • [ > ]: Next screen. • [ < ]: Previous screen.
No.
Displayed information
01
1,000 rpm service meter
02
Forward odometer
03
Reverse odometer
3) Display of 1,000 rpm service meter (01) This code is used to display the service meter which integrates the operation hours only while the engine speed is higher than 1,000 rpm. fl The data cannot be reset.
20-192
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
4) Display of forward odometer (02) On this screen, the integrated forward travel distance is displayed. fl The data cannot be reset.
5) Display of reverse odometer (02) On this screen, the integrated reverse travel distance is displayed. fl The data cannot be reset.
6) When operating machine in load memory display mode If the parking brake lever is set in the FREE position, gear speed display section displays normally and the machine can be operated normally. fl To select another screen, return the parking brake lever to the LOCK position and perform the necessary procedure.
D475A-3
20-193
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
10. Real-time monitoring mode (10-REAL TIME MONITORING MODE) In this mode, the speeds, oil pressures, oil temperatures, currents, voltages, etc. can be monitored by using the signals from sensors, switches, and solenoids installed various parts of the machine. fl This mode is used to monitor 1 item. When monitoring 2 items simultaneously, use the “Dual display monitoring mode”. 1) Selecting and executing mode i) Select “Real-time monitoring mode” on the mode selection screen. fl If the mode is selected, code (5R) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the monitoring code input screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Selecting and entering monitored items i) On the code input screen, input the 5digit code of the item to be monitored by operating information switch (5), shift switch (6), and neutral switch (7). • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. • Shift switch: Increase number. • Neutral switch: Decrease number.
ii) After inputting the code, display the monitoring screen by operating buzzer cancel switch (4). • [ ]: Enter input code. fl If the input code is normal, the monitoring screen shown at right appears.
20-194
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TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
fl If the input code is abnormal, the code input screen appears again after the screen shown at right.
3) Contents of display on monitoring screen (Right figure shows examples) 1: Code 2: Monitoring item 3: Information 4: Unit (Not displayed for some items) fl For the details, see the “MONITORING MODE TABLE”.
4) Function of holding monitoring information If an information item such as the engine speed is not stabilized and cannot be read easily in the monitoring mode, it can be held and released by operating buzzer cancel switch (4). • [ ]: Hold and release. fl While the monitored item is held, the letter “H” is displayed at the left end of the lower line.
5) When operating machine in monitoring mode If the parking brake lever is set in the FREE position, gear speed display section displays normally and the machine can be operated normally. fl To select another screen, return the parking brake lever to the FREE position and perform the necessary procedure.
D475A-3
20-195
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
6) Changing monitored items (Limited function) Once the monitoring screen is selected in step 2), the monitored item can be changed by operating only information switch (5) without inputting the code again. • [ > ]: Next code • [ < ]: Previous code fl This function is applicable to only Nos. 1 – 29 in the “Monitoring mode table”. fl This operation is not accepted while the parking brake lever is in the FREE position. Take care.
20-196
D475A-3
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Monitoring mode table No. Code
Unit
Display range
Engine revolution A Fuel control command Decelerator command Track shoe control command T/M controller FR potentiometer 1 voltage T/M controller FR potentiometer 2 voltage S/T potentiometer 1 voltage S/T potentiometer 2 voltage Brake potentiometer voltage LH brake ECMV output current (F/B) RH brake ECMV output current (F/B) LH clutch ECMV output current (F/B) RH clutch ECMV output current (F/B) Forward ECMV output current (F/B) Reverse ECMV output current (F/B) 1st ECMV output current (F/B) 2nd ECMV output current (F/B) 3rd ECMV output current (F/B) Water temperature sensor Torque converter oil temperature sensor Fuel level sensor T/M controller T/M revolution S/T controller abrupt stop preventive solenoid voltage value T/M controller lockup solenoid voltage value T/M controller neutral safety relay voltage value Logical travel speed Logical traction force S/T controller pitch angle sensor Battery voltage S/T controller pitch angle sensor voltage S/T controller acceleration sensor voltage Hydraulic oil temperature S/T controller SW input 1
rpm rpm rpm rpm mV mV mV mV mV mA mA mA mA mA mA mA mA mA °C °C mV rpm mA mA mV km/h W ° mV mV mV °C bit
34 40911 S/T-SW2
S/T controller SW input 2
bit
35 40913 S/T-SW5
S/T controller SW input 5
bit
36 60400 S/T-SW6
S/T controller SW input 6
bit
0 – 3000 0 – 3000 0 – 3000 0 – 3000 0 – 5000 0 – 5000 0 – 5000 0 – 5000 0 – 5000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 150 0 – 150 0 – 5000 0 – 5000 0 – 1000 0 – 1000 0 – 30000 0 – 100 0–5 –30 – 30 0 – 30000 0 – 5000 SSC spec only 0 – 5000 0 – 150 5Parking lever SW: Free 6Parking lever SW: Lock 1Buzzer cancel SW: Cancel 2Buzzer cancel SW: Select 3Information SW: LH 4Information SW: RH 5Service SW 1ACC signal: When turned ON 2Turbo timer signal: When turned ON 3Engine Li signal: When turned ON 4Monitoring signal: When turned ON 5N signal 1: When turned ON 6N signal 2: When turned ON 1Electrical intake air heater signal: When turned ON 2C signal: When turned ON 4Night time lighting signal: When turned ON 5Hydraulic oil level SW signal: When turned ON
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
01002 51100 50002 60300 50200 50201 50300 50301 50400 31619 31618 90600 90601 31622 31606 31602 31603 31604 04102 30100 04200 31400 31628 31627 50900 40001 60000 32900 03200 60100 60200 04401 40910
D475A-3
Monitored item ENG. SPEED1 FUEL DIAL DECEL PEDL SSC ORDER T/M LEVR 1 T/M LEVR 2 S/T LEVR 1 S/T LEVR 2 BRAKE PEDL BRAKE L.H. BRAKE R.H. S/T CLT LH S/T CLT RH F CLUTCH F R CLUTCH F 1 CLUTCH F 2 CLUTCH F 3 CLUTCH F WATER HIGH T/C TEMP. FUEL SENS T/M OUT E. BRAKE SL L/U SOL N-SAFTY VEHICLE SP TRACTION BODY ANGLE BATTERY BODY ANGLE ACCELERATN HYD. TEMP. S/T-SW1
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TESTING AND ADJUSTING
No. Code
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Monitored item
Unit
Display range 1LH brake fill SW: When turned ON 2LH clutch fill SW: When turned ON 5RH clutch fill SW: When turned ON 6RH brake fill SW: When turned ON 0 – 1000 0 – 1000 0 – 1000 0 – 1000 4Engine controller drive: When turned ON 5Battery relay drive: When turned ON 6Abrupt stop preventive solenoid: When turned ON 0 – 30000 0 – 30000 1Track shoe slippage ratio: 30% or more
37 31521 S/T FILL
S/T controller fill SW input
bit
38 39 40 41 42
31621 31620 90602 90603 40914
BRAKE L.H. BRAKE R.H. S/T CLT LH S/T CLT RH S/T SOL. 1
LH brake ECMV current command RH brake ECMV current command LH clutch ECMV current command RH clutch ECMV current command S/T comptroller on/off output
mA mA mA mA bit
43 44 45 46 47 48 49 50 51 52 53 54
60500 60600 70100 20200 20201 20202 60700 60800 60909 70000 70200 40905
ENG. CON. PW BR HOLD SLIP FLAG MON. PROGRM T/M. PROGRM S/T. PROGRM S/T MODE FILL MODE MOD. MODE CHG. P. MODE T/M OUT T/M-SW1
S/T controller engine control drive command S/T controller battery relay drive voltage value Slip flag Tachometer module program No. T/M controller program No. S/T controller program No. Steering state code Fill condition setting parameter Modulation condition setting parameter Speed changing point condition setting parameter T/M controller T/M revolution sensor voltage T/M controller SW input 1
mV mV bit Letter Letter Letter Letter Letter Letter Letter mV bit 1Forward SW: When turned OFF 2Forward SW: When turned ON 3Reverse SW: When turned OFF 4Reverse SW: When turned ON 5Parking lever SW: Free 6Parking lever SW: Lock bit 1Auto shift down SW: When turned ON 2Neutral SW: When turned OFF 3Neutral SW: When turned ON 4Shift SW: When turned OFF 5Shift SW: When turned ON 1Forward clutch fill SW: When turned ON 2Reverse clutch fill SW: When turned ON 31st speed clutch fill SW: When turned ON 42nd speed clutch fill SW: When turned ON 53rd speed clutch fill SW: When turned ON mA 0 – 1000 mA 0 – 1000 mA 0 – 1000 mA 0 – 1000 mA 0 – 1000 bit 1N signal 1: When turned ON 2N signal 2: When turned ON 4Backup alarm relay: When turned ON 5Neutral safety relay: When turned ON 6Lockup: When turned ON mV 0 – 30000
55 40906 T/M-SW2
T/M controller SW input 2
56 31520 T/M-FILL
T/M controller fill SW input
57 58 59 60 61 62
Forward clutch ECMV current command Reverse clutch ECMV current command 1st clutch ECMV current command 2nd clutch ECMV current command 3rd clutch ECMV current command T/M controller on/off output
31608 31606 31602 31603 31604 40909
Frd CLUTCH Rev CLUTCH 1st CLUTCH 2nd CLUTCH 3rd CLUTCH T/M SOL. 2
63 70400 BACK ALARM T/M controller back alarm relay voltage value
20-198
D475A-3
TESTING AND ADJUSTING
No. Code
Monitored item
64 40908 T/M SW2
65 70300 B. KONB SW
66 67 68 69 70
70700 70701 70702 70703 70305
HYD. PUMP 1 HYD. PUMP 1 HYD. PUMP 2 HYD. PUMP 2 T/M RIPER2
71 90000 T/M SOL. 3
72 90001 T/M SOL. 4 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87
90002 90003 01004 31703 50001 51200 51300 51400 51500 51600 51700 60301 51800 51000 04102
D475A-3
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
BL YOKE L BL YOKE R ENG. SPEED2 FUEL DIAL DECEL PEDL RACK S. RH RACK S. LH GOV. SOL RH GOV. SOL LH PRE. SOL RH PRE. SOL LH CNTR. THRTL NEUTRAL S. FINL. THRTL ENG. W. TEMP
Unit
Display range
1Blade lift up oil pressure SW: When turned ON 2Blade lift down oil pressure SW: When turned ON 5Blade lift LH tilt oil pressure SW: When turned ON 6Blade lift RH tilt oil pressure SW: When turned ON T/M controller toggle SW input bit 1Blade lever tilt SW: When using DUAL 2Blade lever tilt SW: When using SINGLE 3Blade lever pitch SW: When turned OFF 4Blade lever pitch SW: When turned ON T/M controller work equipment oil pressure 1 MPa 0 – 50 T/M controller work equipment oil pressure 1 sensor voltage mV 0 – 5000 T/M controller work equipment oil pressure 2 MPa 0 – 50 T/M controller work equipment oil pressure 2 sensor voltage mV 0 – 5000 T/M controller ripper oil pressure SW input bit 2Ripper lift up oil pressure SW: When turned ON 3Ripper lift down oil pressure SW: When turned ON 4Ripper tilt in oil pressure SW: When turned ON 5Ripper tilt back oil pressure SW: When turned ON T/M controller on/off output 3 bit 1Unload solenoid: When turned ON 2Dump support solenoid: When turned ON 3LH tilt limiting solenoid: When turned ON 4RH tilt limiting solenoid: When turned ON 5Pitch selecting solenoid: When turned ON 6Pitch independent solenoid: When turned ON T/M controller on/off output 3 bit 1Pitch dumping solenoid: When turned ON 2Pitch back solenoid: When turned ON LH yoke angle sensor mV 0 – 5000 RH yoke angle sensor mV 0 – 5000 Engine revolution B rpm 0 – 3000 Accelerator voltage mV 0 – 5000 Decelerator voltage mV 0 – 5000 RH rack sensor voltage mV 0 – 5000 LH rack sensor voltage mV 0 – 5000 RH governor solenoid current value mA 0 – 1000 LH governor solenoid current value mA 0 – 1000 RH pre-stroke solenoid current value mA 0 – 1000 LH pre-stroke solenoid current value mA 0 – 1000 Track shoe controller voltage mV 0 – 5000 T/M N signal bit data bit Regulation command rpm 0 – 3000 Water temperature sensor mV 0 – 5000 T/M controller blade oil pressure SW input
bit
20-199
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
11. Dual display monitoring mode (11-DUAL DISPLAY MONITORING MODE) In this mode, 2 monitored items can be displayed simultaneously. fl Note that only codes and monitoring information are displayed in this mode since the usable display columns are limited. (Item names and units cannot be displayed.) 1) Selecting and executing mode i) Select “Dual display monitoring mode” on the mode selection screen. fl If the mode is selected, code (dR) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the monitoring code input screen by operating buzzer cancel switch (4). • [ ]: Execute mode.
2) Selecting and entering monitored items i) On the code input screen, input the 5digit codes of the items to be monitored to the upper and lower lines by operating information switch (5), shift switch (6), and neutral switch (7). • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. • Shift switch: Increase number. • Neutral switch: Decrease number. ii) After inputting the codes, display the monitoring screen by operating buzzer cancel switch (4). • [ ]: Enter input code. fl If the input codes are normal, the monitoring screen shown at right appears.
20-200
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TESTING AND ADJUSTING
fl
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
If the input codes are abnormal, the code input screen appears again after the screen shown at right.
3) Contents of display on monitoring screen (Right figure shows examples) 1: Code 1 2: Information 1 3: Code 2 4: Information 2 fl For the details, see the “MONITORING MODE TABLE”.
4) When operating machine in monitoring mode If the parking brake lever is set in the FREE position, gear speed display section (1) displays normally and the machine can be operated normally. fl To select another screen, return the parking brake lever to the FREE position and perform the necessary procedure.
D475A-3
20-201
TESTING AND ADJUSTING
ADJUSTMENT METHOD OF REPLACED CONTROLLER
ADJUSTMENT METHOD OF REPLACED CONTROLLER fl After the machine is assembled or transmission controller or steering controller is replaced, adjust the system according to the following procedure. ¤ If the system is not adjusted, the machine may not operate normally and may move suddenly. Accordingly, be sure to adjust it. fl Precautions for replacing a controller: If a controller is replaced, the memory of the oil and filter maintenance mode is reset. Accordingly, take a record of the next replacement periods of the oils and filters. fl Precautions for replacing a controller: When replacing a controller, stop the machine in a safe place and turn the starting switch off. 1. Setting system in service mode Turn the starting switch on and set the monitor panel in the “Adjustment mode” of the service mode. 2. Adjusting steering controller Select Steering controller specification set (0002) and adjust the steering controller. fl Execute this code when only the transmission controller is replaced, too.
20-202
3. Adjusting transmission controller Select Transmission controller specification set (0003) and adjust the transmission controller. fl Execute this code when only the steering controller is replaced, too.
4. Turning power on again Turn the starting switch off and on, then set the monitor panel in the “Adjustment mode” of the service mode again. 5. Adjusting machine specification Select Machine specification set (0004) and adjust the machine specification.
D475A-3
TESTING AND ADJUSTING
ADJUSTMENT METHOD OF REPLACED CONTROLLER
6. Adjusting brake potentiometer Select Brake potentiometer initial set (0005) and adjust the brake potentiometer.
7. Turning power on again Turn the starting switch off and on. 8. Checking error codes 1) Set the monitor panel in the “Electric system error code display mode” of the service mode. 2) See if any error code is being output currently. If any error code is not being output, delete the all error codes. fl If any error code is being output, remove its cause by troubleshooting and execute steps 7 and 8 again. fl Precautions after replacing controller: If any controller is replaced, the service meter in the oil and filter maintenance mode is reset to 0. As a result, the replacement period displayed on the monitor panel may be different from the actual operating hours. To solve this problem, determine the first replacement periods of the oils and filters after the replacement of the controller according to the replacement periods recorded before the replacement of the controller.
D475A-3
20-203
TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM fl When carrying out troubleshooting for an electric circuit related to the monitor panel, engine controller, transmission controller, or steering controller, expose the related connectors according to the following procedure.
2. Engine controller 1) Remove cover (3).
1. Monitor panel 1) Remove cover (1). 2) Remove the 2 mounting bolts and pull out monitor panel (2) toward the operator’s seat.
2) Insert or connect T-adapters in or to connectors ECN1, ECN2, ECN3, ECN4 connectors and ECN5 connectors of engine controller (4). fl If the connectors cannot be disconnected and connected easily, remove the controller from the floor frame.
3) Insert or connect T-adapters in or to connectors S01, S02, S03, and S04 of monitor panel (2).
20-204
D475A-3
TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC ELECTRIC SYSTEM
3. Transmission controller 1) Remove cover (5).
2) Insert or connect T-adapters in or to connectors TMCN1, TMCN2, and TMCN3 of transmission controller (6). fl If the connectors cannot be disconnected and connected easily, remove the controller from the floor frame. fl Since the connectors are secured with screws, loosen those screws before disconnecting. fl When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
D475A-3
4. Steering controller 1) Remove cover (5).
2) Insert or connect T-adapters in or to connectors STCN1, STCN2, and STCN3 of transmission controller (7). fl If the connectors cannot be disconnected and connected easily, remove the controller from the floor frame. fl Since the connectors are secured with screws, loosen those screws before disconnecting. fl When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
20-205
TESTING AND ADJUSTING
HANDLING OF OPTIONAL DEVICES
HANDLING OF OPTIONAL DEVICES fl D475A-3 has connectors to install optional devices in its fuse box. When installing any optional device, receive the necessary signals and power through those connectors without modifying the wiring harness. 1. Taking out ACC signal of starting switch If the ACC signal (ON signal) of the starting switch is necessary to an optional device such as the turbocharger timer, take it out through the following connector pin. • Pin B of CN-ESD (3-pole heavy duty wire connector) fl A 20A fuse is installed on the upstream side of this connector pin. 2. Inputting engine controller holding signal If it is required to keep the engine running with the starting switch turned off for an optional device such as the turbocharger timer, connect the following connector pin to the chassis ground. • Pin A of CN-ESD (3-pole heavy duty wire connector) fl While this connector pin is connected to the chassis ground, the starting switch works as it is at the ON position even if it is at the OFF position. 3. Inputting engine low-idling command If it is required to keep the engine speed at low idling for an optional device such as the engine protector, connect the following connector pin to the chassis ground. • Pin C of CN-ESD (3-pole heavy duty wire connector) fl While this connector pin is connected to the chassis ground, the engine speed is kept at low idling, regardless of the position of the fuel control dial.
20-206
4. Taking out C signal of starting switch If the C signal (starting signal) of the starting switch is necessary to an optional device such as the pre-lubricator, take it out through the following connector pin. • CN-PRS (2-pole heavy duty wire connector) fl Remove the connector installed when the machine is shipped and connect pin 1 to the starting signal to be output finally by the pre-lubricator and connect pin 2 to the input signal from the starting switch. 5. Taking out external power source If an external power source is necessary, take it through the following connectors. • AUX1 (Plug connector) • AUX2 (Plug connector) fl A 20A fuse is installed on the upstream side of each of these connectors. 6. Inputting the engine shut down command If it is necessary to stop the engine for an optional device, modify the following connector pin circuit to connect to the grounding circuit. • No. 1 pin of the SDC (2-pole heavy duty wire connector) fl While this connector pin is being connected to the GND circuit, the engine will not start.
D475A-3
Pm CLINIC SERVICE Model
Serial No.
Service meter
D475A-3
h
User name
Date of clinic
Serviceman
Blade
Specifications Rear attachment
Shoe width
Semi-U blade U-blade Dual tilt blade
Multi-shank ripper Variable giant ripper Counterweight (
kg)
710 mm 810 mm 910 mm
Operating conditions Quarry, mine Coal Gold Limestone
Construction Construction Civil engineering Roads Tunnels
Type of soil (specific gravity) Rock Gravel Sand Clay
Type of work Dozing Side cutting Ripping Travel
% % % %
Existence of abnormalities Oil, water level check Engine coolant level Engine oil level Hydraulic oil level Engine coolant temperature Max. range
When necessary Damper case (
Power train Final drive Power train oil temperature Max. range
)
Ambient temperature Max. Min.
Height above sea level m Operator's opinion
Visual check results
Service code history E
h
Content: E Content:
D475A-3
E
h
Content: h
E
h
Content:
20-207
Pm-clinic measuring points for D475A-3 (1/2)
“Reference Page for Measurement Procedure” designated ª1. Engine speed: 20-103 page ª2. Blow-by pressure: 20-111 page ª3. Lubricating oil pressure: 20-112 page ª4. Boost pressure: 20-106 page ª5. Exhaust gas temperature: 20-107 page
20-208
D475A-3
Pm-clinic measuring points for D475A-3 (2/2)
“Reference Page for Measurement Procedure” designated ª6. Centralized pressure pickup points: 20-124 – 126 page ª7. Centralized pressure pickup points: 20-121 – 124 page ª8. Lubricating oil filter portion of transmission: 20-126 page ª9. Centralized pressure pickup points: 20-119 – 120 page ª10. Hydraulic pressure: 20-142 page
D475A-3
20-209
MEASURING POWER TRAIN OIL PRESSURE AND OTHERS ‡ Connect the measuring equipment to the engine and machine body.
¤ Always carry out removal or installation of equipment for measuring the hydraulic pressure with the engine stopped.
¤ Always carry out removal or installation of measuring equipment with the engine stopped, and be careful not to touch any high temperature part.
20-210
D475A-3
Pm CLINIC CHECK SHEET Work order No.
D475A-3
Date
Serial No.
Serviceman
Service meter h
1
ITEM 1-1 Eng. Speed • Super & Dual tilt dozer Blade pitch back relief • Single tilt dozer Unnecessary
ENGINE
1-2 Blow-by Press. 1-3
Condition Eng. Low idling Deceleration slow Eng. Full (Display A must show 0007) T/C Stall T/C Stall & Relief
SAE10W-30
Eng. Full Lub. Oil Press.
Eng. Low idling Eng. Full
1-4 Boost Press.
MPa {kg/cm2} SAE15W-40, SAE30
R.H. Bank T/C Stall L.H. Bank
1-5 Exhaust Gas Temp. (at 20°C)
rpm
kPa {mmH2O}
T/C Stall Eng. Low idling
Unit
R.H. Bank T/C Stall L.H. Bank Ambient Temp.
kPa {mmHg}
°C
STD. 600 – 700 850 – 950 2100 – 2200 1630 – 1730 (1480 – 1600) Max. 1.47 {Max. 150} Min. 0.10 {Min. 1.0} 0.29 – 0.44 {3.0 – 4.5} Min. 0.12 {Min. 1.2} 0.39 – 0.54 {4.0 – 5.5} Min. 120 {Min. 900} Min. 120 {Min. 900} Max. 650 Max. 650 —
PMS. 600 – 700 850 – 950 2100 – 2200 Min. 1590 Min. 1420 Max. 2.94 {Max. 300} Min. 0.08 {Min. 0.8} Min. 0.20 {Min. 2.0} Min. 0.10 {Min. 1/0} Min. 0.25 {Min. 2.5} Min. 107 {Min. 800} Min. 107 {Min. 800} Max. 750 Max. 750 —
Result
Sat Us
ª When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to “Both steering clutches release mode (Co mode)”. (Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
TORQUE CONVERTER
2
3
2-1 Inlet Oil Press. 2-2 Outlet Oil Press. 2-3 Lock-up Clutch Press. 2-4 Stator Clutch Press. 2-5 Inlet Oil Press. 2-6 Outlet Oil Press. 2-7 Lock-up Clutch Press. 2-8 Stator Clutch Press. 2-9 Lock-up Clutch Press. 2-10 Stator Clutch Press.
Transmission: Neutral Oil temperature: 70 – 90 °C
Transmission: F1
TRANSMISSION
Min. 2.45 {Min. 25} Min. 2.55 {Min. 26} — — 0.1 – 0.2 {1 – 2} Min. 2.25 {Min. 23} Min. 2.25 {Min. 23} Min. 1.86 {Min. 19} Min. 2.25 {Min. 23} Min. 2.25 {Min. 23}
Raise engine speed, when lock-up lamp lights up Eng. Low idling
Transmission: Neutral
Lub. Oil Press.
D475A-3
MPa {kg/cm2}
2.56 – 2.91 {26.1 – 29.7} 2.65 – 3.03 {27 – 30.9} — — 0.1 – 0.2 {1 – 2} 2.35 – 2.74 {24 – 28} 2.35 – 2.74 {24 – 28} 1.96 – 2.35 {20 – 24} 2.35 – 2.74 {24 – 28} 2.35 – 2.74 {24 – 28}
Eng. High idling
Main Relief Press.
3-3 F Clutch Press. 3-4 R Clutch Press. 3-5 1st Clutch Press. 3-6 2nd Clutch Press. 3-7 3rd Clutch Press.
0.03 – 0.20 {0.3 – 2.0} 0.03 – 0.15 {0.3 – 1.5} 0–0 {0 – 0} 2.45 {Min. 25} 0.8 – 1.0 {8.0 – 10.0} 0.44 – 0.64 {4.5 – 6.5} 0–0 {0 – 0} Min. 2.55 {Min. 26} 1.12 – 1.42 {11.5 – 14.5} 0–0 {0 – 0}
Eng. Low idling
3-1
3-2
MPa {kg/cm2}
0.03 – 0.20 {0.3 – 2.0} 0.03 – 0.15 {0.3 – 1.5} 0–0 {0 – 0} 2.55 – 2.74 {26 – 28} 0.8 – 1.0 {8.0 – 10.0} 0.44 – 0.64 {45 – 6.5} 0–0 {0 – 0} 2.55 – 2.74 {26 – 28} 1.12 – 1.42 {11.5 – 14.5} 0–0 {0 – 0}
Eng. High idling Eng. Low idling Eng. High idling
Transmission: F3 Transmission: R3 Transmission: F1 Transmission: F2 Transmission: F3
Eng. Low idling Eng. Low idling Eng. Low idling Eng. Low idling Eng. Low idling
20-211
Pm-CLINIC SERVICE
STEERING
4
ITEM 4-1 L.H. Clutch Press. 4-2 L.H. Brake Press. 4-1 L.H. Clutch Press. 4-2 L.H. Brake Press. 4-3 R.H. Clutch Press. 4-4 R.H. Brake Press. 4-3 R.H. Clutch Press. 4-4 R.H. Brake Press. Brake Performance
Condition
Unit
STD. 2.56 – 2.91 {26.1 – 29.7} 2.56 – 2.91 {26.1 – 29.7} 2.65– 3.03 {27 – 30.9} 2.65– 3.03 {27 – 30.9} 2.56 – 2.91 {26.1 – 29.7} 2.56 – 2.91 {26.1 – 29.7} 2.65– 3.03 {27.0 – 30.9} 2.65– 3.03 {27 – 30.9}
PMS. Min. 2.45 {Min. 25} Min. 2.45 {Min. 25} Min. 2.55 {Min. 26} Min. 2.55 {Min. 26} Min. 2.45 {Min. 25} Min. 2.45 {Min. 25} Min. 2.55 {Min. 26} Min. 2.55 {Min. 26}
No movement
No movement
3.73 – 4.41 {38.0 – 45.0} 4.02 – 4.71 {41.0 – 48.0}
Min. 3.53 {Min. 36.0} Min. 3.92 {Min. 40.0}
18.6 – 20.6 {190 – 210}
Min. 18.1 {Min. 185}
20.1 – 21.6 {205 – 220}
Min. 19.6 {Min. 200}
18.6 – 20.6 {190 – 210}
Min. 18.1 {Min. 185}
20.1 – 21.6 {205 – 220}
Min. 19.6 {Min. 200}
18,6 – 20.6 {190 – 210} 20.1 – 21.6 {205 – 220}
Min. 18.1 {Min. 185} Min. 19.6 {Min. 200}
Eng. Low idling
13 – 18
Max. 20
Eng. Full
3.6 – 4.6
Max. 5.0
8 – 12
Max. 14
2.7 – 3.7
Max. 4.5
10 – 13
Max. 15
3.8 – 4.8
Max. 5.5
Eng. Low idling
10 – 15
Max. 18
Eng. Full
3.5 – 4.5
Max. 5.0
Eng. Low idling T/M : N
Eng. Full T/M : N MPa {kg/cm2} Eng. Low idling T/M : N
Eng. Full T/M : N Eng. Full T/M : F2
Result
Sat
Us
Single or Dual Tilt Dozer Spec. 5
5-1
Eng. Low idling T/M : N Eng. Full T/M : N 5-2 Eng. Low idling (Single spec.) Single tilt relief (Dual spec.) Pitch back relief Rear Pump Press. Eng. Full (Single spec.) Single tilt relief (Dual spec.) Pitch back relief 5-3 Eng. Low idling (Single spec.) Unnecessary (Dual spec.) Pitch back relief Assist Pump Press. Eng. Full (Single spec.) Unnecessary (Dual spec.) Pitch back relief 5-4 Eng. Low idling Ripper relief Front Pump Press. Eng. Full Ripper relief
HYDRAULIC PRESSURE
PPC Press.
WORK EQUIPMENT SPEED
6
6-1 Blade Lift Speed (G.L ➝ END)
6-2 (#10601 – 10672) Eng. Low idling Blade pitch Speed (Pitch dump ➝ Pitch back) Eng. Full 6-2 (#10673 and up) Eng. Low idling Blade pitch Speed (Pitch dump ➝ Pitch back) Eng. Full 6-3 Ripper Tilt Speed (Tilt in ➝ Tilt out)
20-212
MPa {kg/cm2}
sec
D475A-3
Pm-CLINIC SERVICE
D475A-3 SDA12V140
—HOUR INSPECTION WORK ORDER No.
CARRIED OUT DATE
SERVICE METER
Machine Serial No. # Engine Serial No. # INSPECTED BY
Month Day ’Year hrs.
OPERATOR’S OPINION Any abnormality ?
Coolant Temp. max. range ? White
Green
Red
Sat Us
T/C, T/M oil . max. range ? Green
Red
1 2 3 4 5 6 7
1 2 3 4 5 6 7
(during operation)
(during operation)
Ambient Temp. Max. Min. Altitude
°C (°F) °C (°F) m (Ft)
‡ HOT BUSHING CHECKING RIGHT AFTER WORKING ! H: HOT Can not keep to be touched. (Min. 50°C) W: WARM Hotter than link temp. (Approx. 35°C) C: COOL Similar to link temp. (Approx. 25°C)
H: HOT Can not keep to be touched. (Min. 50°C) W: WARM Hotter than link temp. (Approx. 35°C) C: COOL Similar to link temp. (Approx. 25°C)
Track link loosening A: Protrusion of pin B: Clearance between links L.H. SIDE R.H. SIDE Pin No. Bush Temp. A (Inner) A (Outer) B (Inner) B (Outer) Pin No. Bush Temp. A (Inner) A (Outer) B (Inner) B (Outer) Standard value — 4.4 mm 4.4 mm 1.6 mm 1.6 mm Standard value — 4.4 mm 4.4 mm 1.6 mm 1.6 mm
D475A-3
20-213
Pm-CLINIC SERVICE SET BLADE, PITCH & RIPPER, THEN STOP THE ENGINE ! DRIFT
7
F/D
8
Hyd. Oil Temp. Condition Blade Lift cylinder Eng. Stopped Pitch cylinder (Super) Hyd. Oil Temp.: 45 – 55°C Ripper Lift cylinder Final Drive Lub. Filter Visual Check
NOTE:
Eng. Stopped
°C(°F) mm/ 5 min.
—
Max. 60 Max. 10 Max. 30
Max. 100 Max. 20 Max. 50
No excessive metallic powder
Write-down any phenomena or information you found by your five sences during today’s inspection.
Hydraulic pump usage No.
Blade & Ripper Lever position
Single Tilt Dozer
Dual Tilt Dozer Front Pump
Rear Pump
Assist Pump
Front Pump
Rear Pump
Assist Pump
1
Blade lift (Raise & Lower)
2
Blade single tilt
—
—
—
—
3
Blade dual tilt
—
—
—
—
4
Blade pitch dump
—
—
—
—
5
Blade pitch back
—
—
—
—
6
Ripper lift & tilt
fl
fl
:
It’s worked when lever is applied. (Relief pressure can be measured) : It’s worked when lever is applied. (Relief pressure can’t be measured)
20-214
: It’s worked at lever stroke end only. fl: It’s drained at cylinder stroke end.
D475A-3
D475A-3
20-215
20-216
D475A-3
TROUBLESHOOTING
20
TROUBLESHOOTING Points to remember when troubleshooting .............................................................................................. Sequence of events in troubleshooting ................................................................................................... Points to remember when carrying out maintenance .............................................................................. Checks before troubleshooting................................................................................................................. Classification and procedures of troubleshooting .................................................................................... Table of connectors .................................................................................................................................. Connector arrangement drawing .............................................................................................................. Connection table for connector pin numbers ........................................................................................... Troubleshooting when error code is displayed (error code) ..................................................................... Troubleshooting of electrical system (E-mode) ........................................................................................ Troubleshooting of hydraulic and mechanical system (H mode) ..............................................................
D475A-3
20-302 20-303 20-304 20-312 20-313 20-314 20-318 20-326 20-401 20-601 20-701
20-301
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING ¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. ¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine. 2) Check the CHECKS BEFORE STARTING items.
20-302
3) 4)
4.
5.
6.
Other inspection items. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. fl When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. fl The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
D475A-3
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop
Jobsite TEW00180
TEW00181
Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. • Name of customer • Type, serial number of machine • Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history, details of maintenance, etc.
Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes.
Step Repair at jobsite Hurray ! It's repalred
Step 3 Preparation of troubleshooting tools TEW00185
1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. • T-adapter • Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.
Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take
TEW00186
1) Before starting troubleshooting, locate and repair simple failures. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual, select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.
TEW00187
Step 6 Re-enacting failure •
Step 4 Go to jobsite
Drive and operate the machine to confirm the condition and judge if there is really a failure.
Step 5 Ask operator questions to failure.
TEW00189
confirm details of
Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure? TEW00190
D475A-3
20-303
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
1
2
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
20-304
D475A-3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3 Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
TEW00194
4 High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. fl When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. fl If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
D475A-3
TEW00195
TEW00196
20-305
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors and wiring harnesses ·
Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. ★ Never pull with one hand.
1
2
When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. ★ If the connector is twisted up and down or to the left or right, the housing may break.
TBW00484
3
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
TEW00198
20-306
D475A-3
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. ★ If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ★ If there is any damage or breakage, replace the connector. Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. ★ If the connector cannot be corrected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
•
TEW00200
TBW00487
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c
D475A-3
20-307
TROUBLESHOOTING
•
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. 1) Disconnect the connector and wipe off the water with a dry cloth. + If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. + Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. + After completely drying the connector, blow it with contact restorer and reassemble.
20-308
D475A-3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
1. Handling control box 1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2) Do not open the cover of the control box unless necessary.
3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) During rainy weather, do not leave the control box in a place where it is exposed to rain.
6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2. 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. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. + If there is any change, there is probably defective contact in that circuit.
D475A-3
20-309
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and 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.
4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
20-310
D475A-3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
D475A-3
20-311
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
Electrics, electrical equipment
Hydraulic, Electrical mechanical equipment equipment
Lubricating oil, coolant
Item
Judgement value
Action
— — — — — — — — —
Add fuel Clean, drain Add oil Clean, drain Add oil Add water Clean or replace Replace Add oil
1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring
— — —
Tighten or replace Tighten or replace Tighten or replace
1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding
— — —
Repair Repair Bleed air
1. 2. 3. 4. 5. 6. 7. 8. 9.
Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check engine oil level (oil pan oil level) Check coolant level Check dust indicator for clogging Check hydraulic filter Check final drive oil level
20 – 30V Check battery voltage (engine stopped) — Check battery electrolyte level — Check for discolored, burnt, exposed wiring — Check for missing wiring clamps, hanging wiring — Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) — 6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above) After running for several minutes : 27.5 – 29.5V — 8. Check operating sound of battery relay (when switch is turned ON/OFF) 1. 2. 3. 4. 5.
20-312
Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
Replace
D475A-3
TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING Classification of Troubleshooting Mode Error code
Explanation Troubleshooting when a service code is displayed
E Mode
Troubleshooting of the electrical system
H Mode
Troubleshooting of the hydraulic and mechanical systems
(Engine)
Troubleshooting of the engine body (Refer to the Shop Manual for 12V140-1 Series Engine.)
Troubleshooting Procedures When any phenomenon supposed to be a failure appeared on the machine, select a Troubleshooting No. according to the procedures below and proceed to the text of the relevant troubleshooting: 1. Troubleshooting Procedures when any action code is displayed on the monitor panel: When an action code is displayed on the monitor panel, display an error code in the error code display mode (electrical system, mechanical system) on the monitor display (EMMS). Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code. + Since an error code flashes when a problem was detected, the failure has not always been corrected even if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when the starting switch is set to ON.) + When an error code has been recorded, be sure to reproduce the code and check if the problem of the code has still remained or has already been corrected. (For the reproducing method, refer to the troubleshooting of the error code.) 2. Troubleshooting Procedures when error codes have been recorded: When no action code is displayed on the monitor panel, check an error code in the error code display mode (electrical system, mechanical system) on the monitor panel (EMMS). When error codes have been recorded, execute a troubleshooting of the relevant [Error Code] in accordance with the error code. + Since a error code flashes when a problem was detected, the failure has not always been corrected even if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when the starting switch is set to ON.) + When an error code has been recorded, be sure to reproduce the code and check if the problem of the code has still remained or has already been corrected. (For the reproducing method, refer to the troubleshooting of the error code.) 3. Troubleshooting Procedures when no action code is displayed and error codes have not been recorded: When error codes have not been recorded in the monitor panel (EMMS), a failure that the machine cannot diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system. In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out of the table of “Phenomena supposed to be Failures and Troubleshooting No.” Then, execute the troubleshooting in the [E Mode] or [H Mode] related to the phenomenon.
D475A-3
20-313
TROUBLESHOOTING
TABLE OF CONNECTORS
TABLE OF CONNECTORS + Addresses show approximate posititions of these devices in arrangement drawings. Connector No.
Type
Number of Pins
101
X
16
Intermediate connector
J2, Q2
103
X
2
Intermediate connector
H1
104
X
2
Intermediate connector
H1
422
X X
Description
Address
Connector No. 414
Type Terminal
Number of Pins
Description
Address
Electrical intake air heater relay (left bank)
A3
2
Fuel level sensor
V2
2
Intermediate connector
I9
1
111
X
4
Intermediate connector
J2, Q2
431
112
X
4
Intermediate connector
J2, Q1
452
X
1
Hydraulic oil sensor
R1
122
DT
12
Intermediate connector
U1
453
X
2
K3
1
Electrical intake air heater (right bank)
Torque converter oil temperature sensor
C7
578
—
23
Intermediate connector
V2
653
DT
2
L/U solenoid
H9
800
One pin connector
1
Intermediate connector
—
801
One pin connector
1
Intermediate connector
—
995
SWP
14
Intermediate connector
I1, Q2, AP7
135 136
Terminal Terminal
1
Electrical intake air heater (left bank)
B7 C8
137
Terminal
1
Electrical intake air heater (right bank)
201
SWP
12
Intermediate connector
B2
202
X
3
Intermediate connector
C2
203
M
1
Right headlamp
A7
204
M
1
Left headlamp
A5
205
Terminal
1
Horn
A3
AF1
Terminal
1
Air cleaner clogging sensor
206
M
1
Right headlamp
A7
AFL
X
4
Intermediate connector
C8, I1
206
Terminal
1
Horn
A5
ANB
Terminal
1
Alternator (Terminal B)
A3
207
M
1
Left headlamp
A6
ANE
Terminal
1
Alternator (Terminal E)
A4
209
X
4
Intermediate connector
A6
ANR
Terminal
1
Alternator (Terminal R)
A4
C8, AM6
213
—
4
Preheater switch
—
B14
L
2
Intermediate connector
—
214
DT
12
Intermediate connector
—
BLD
X
2
P6
215
DT
12
Intermediate connector
—
Blade LOWER oil pressure switch
216
DT
12
Intermediate connector
—
BLU
X
2
Q7
218
—
4
Rear lamp switch
—
Blade LIFT oil pressure switch
220
—
2
Diode
—
BSW
—
14
Intermediate connector
AI6
221
M
1
Left working lamp
CA1
DT
3
CAN terminating resistance
AI6
223
M
1
Left rear lamp
L6
CA2
DT
3
CAN terminating resistance
—
241
SWP
4
Intermediate connector
E9
CN-1
1
Lamp connector
—
241
One pin connector
One pin connector
1
Back alarm lamp
R4
CN-2
Terminal
1
Right rear speaker
U8
242
SWP
6
Intermediate connector
P2
CN-3
Terminal
1
Right rear speaker
V8
243
M
1
Right rear lamp
H9
CN-4
—
4
Rear wiper motor
U8
CN-5
Terminal
1
Left rear speaker
S9
2
Ripper pin puller solenoid valve
I9
CN-6
Terminal
1
Left rear speaker
T9
CN-9
—
6
Front wiper motor
Q7 R8
244
X
J2, S1
250
Terminal
1
Starting switch (Terminal B)
P9
255
Terminal
1
Starting switch (Terminal R1)
P9
260
Terminal
1
Starting switch (Terminal BR)
P8
262
—
2
Horn switch
W6
263
—
2
Ripper pin puller switch
W5
264
SWP
6
Intermediate connector
W5
270
Terminal
1
Starting switch (Terminal ACC)
280
Terminal
1
301
X
4
351
X
371 372
CN-10
—
9
Radio
CN-11
—
6
Left wiper switch
X8
CN-12
—
6
Front wiper switch
X8
CN-13
—
6
Right wiper switch
X8
CN-14
—
6
Rear wiper switch
X8
CN-15
—
2
Lamp switch
—
Q8
CN-17
—
4
Right door wiper motor
—
Starting switch (Terminal C)
P9
CN-18
—
4
Left door wiper motor
P5
Intermediate connector
I1
CN-19
—
4
Intermediate connector
—
1
Air conditioner compressor
—
CN-22
Terminal
1
Cigarette lighter
—
M
2
Window washer motor
—
CN-23
Terminal
1
Converter
U9
M
2
Window washer motor
—
373
M
2
Window washer motor
—
CN-23
1
Converter
T9
374
M
2
Window washer motor
—
One pin connector
375
M
4
Caution lamp
—
CN-24
1
Converter
T9
A3
One pin connector
CN-25
One pin connector
1
Revolving warning lamp connector
—
CN-26
—
2
Revolving warning lamp switch
—
CN-81
—
2
Room lamp
S9
402
X
2
Engine water temperature sensor
403
Terminal
1
Engine oil pressure sensor
B7
404
X
2
Engine oil level sensor
C2
405
X
2
Engine water level sensor (main)
B7
20-314
D475A-3
TROUBLESHOOTING
Connector No.
TABLE OF CONNECTORS
Type
Number of Pins
CN-C
—
2
Accessory socket
—
CN-C1
One pin connector
1
Converter
U8
CN-C2
One pin connector
1
Converter
U8
CSL
X
3
Right cylinder stroke sensor
—
CSR
X
3
Left cylinder stroke sensor
A4
CUR
—
3
Cursor switch
—
DRT
X
2
Radiator coolant level sensor (dual)
B7
DST
X
2
Dual selection solenoid valve
E9
E9
—
4
Left fuel injection pump rack sensor
AP4
3
Left fuel injection pump prestroke solenoid
AP4 AP3
E10
—
Description
Address
E11
—
2
Left fuel injection pump governor solenoid
E11
MIC
17
Engine controller
AE4
E12
—
2
Engine speed sensor (left)
AP5
E13
—
4
Right fuel injection pump rack sensor
AN7 AN7
E14
—
3
Right fuel injection pump prestroke solenoid
E15
—
2
Right fuel injection pump governor solenoid
AO7
E16
—
2
Engine speed sensor (right)
AM7
E21
MIC
21
Engine controller
AI4
E31
AMP040
20
Engine controller
AI4
E32
AMP040
16
Engine controller
AI4
E41
AMP040
12
Engine controller
AI4
E51
AMP040
20
Engine controller
AI4
E52
AMP040
16
Engine controller
AI4
F1T8
DT
2
Transmission 1st speed ECMV
H9
F2T6
DT
2
Transmission 2nd speed ECMV
I9
F3T4
DT
2
Transmission 3rd speed ECMV
I9
Connector No.
Type
Number of Pins
H0L
X
1
Hydraulic oil level sensor [machine with sensor]
HP1
X
3
Work equipment oil pressure sensor (Pump 140)
G9 G9
Description
Address D8, O4
HP2
X
3
Work equipment oil pressure sensor (Pump 100)
KEY
M
6
Starting switch
—
2
Left bottom drain solenoid valve
J2
LBD
X
LUG
—
2
Diode
—
M11
MIC
13
Machine controller
—
M21
MIC
21
Machine controller
—
M26
—
6
Air conditioner controller
—
M31
AMP040
20
Machine controller
—
M32
AMP040
16
Machine controller
—
M41
AMP
12
Machine controller
—
M51
MIC
17
Machine controller
—
NSW
DT
3
Travel lock switch
—
P01
One pin connector
1
Blade control lever front button switch
—
P02
One pin connector
1
Blade control lever upper button switch
—
P03
One pin connector
1
Blade control lever front button switch
—
PBA
X
2
Pitch back support solenoid valve
D8
PCV
X
2
Demand solenoid valve
O5
PDA
X
2
Pitch dump support solenoid valve
D8
PIT
X
2
Pitch independent solenoid valve
K3
PL1
—
23
Intermediate connector
W3
PL2
—
31
Intermediate connector
W3
PPB
X
2
Pitch back solenoid valve
P6
PPD
X
2
Pitch dump solenoid valve
P6
PRE
DT
2
Pre-lubrication
—
PST
X
2
Pitch selection solenoid valve
D9
FCD
X
3
Decelerator potentiometer
—
PT1
DT
3
Each inclination sensor
Q2
FD5
DT
12
Intermediate connector
U1
PWR1
DT
1
Intermediate connector
U2
FFT2
DT
2
Transmission F clutch ECMV
J9
PWR2
DT
1
Intermediate connector
U2
FL82
DT
2
Left brake ECMV
L7
FLC6
DT
2
Left clutch ECMV
K8
RHT
DT
3
Electrical intake air heater timer
—
RTB
X
2
Ripper tilt back oil pressure switch
—
RT1
X
2
Ripper tilt-in oil pressure switch
Q6
RPD
X
2
Ripper LOWER oil pressure switch
Q6
Ripper LIFT oil pressure switch
Q7
FR84
DT
2
Right brake ECMV
K8
FRC8
DT
2
Right clutch ECMV
K8
FRT1
DT
2
Transmission R clutch ECMV
FSB
—
31
Intermediate connector
G3
—
2
Diode
—
G4
—
2
Diode
—
G5
—
2
Diode
—
G6
—
2
Diode
GCL
R
5
Left governor cut relay
— AE1
RPU
X
2
—
S01
—
12
Monitor panel
—
AI5
S02
—
2
Monitor panel
—
GCR
R
5
Right governor cut relay
AI5
S03
—
20
Monitor panel
—
GND1
Terminal
—
Grounding to machine body
AE1
S04
—
12
Monitor panel
—
—
H9
GND2
Terminal
—
Grounding to machine body (transmission)
GND3
Terminal
—
Grounding to machine body (left fender)
—
GND5
Terminal
—
Grounding to machine body (floor frame)
—
GNDE
Terminal
—
Grounding to machine body (damper governor)
—
GNDR
Terminal
—
Grounding to machine body
—
D475A-3
S1T7
DT
2
Transmission 1st speed ECMV
S12
DT
12
Intermediate connector
—
3
SSC initialization jumper connector
— — —
S21
—
S22
—
3
SSC initialization jumper connector
S24
Terminal
6
Service switch
20-315
TROUBLESHOOTING
TABLE OF CONNECTORS
Connector No.
Type
Number of Pins
S25
X
4
Machine controller writing connector
S26
X
4
Engine controller writing connector
S28
X
4
LE controller memory writing
S2T5
DT
2
Transmission 2nd speed ECMV
I9
S3T3
DT
2
Transmission 3rd speed ECMV
J9
Description
S40
M
3
Connector
SDC
DT
2
Engine shut-down connector
SDS
DT
2
Hydraulic oil temperature sensor
Address — — AG2
— AG1 G9
SFT1
DT
2
Transmission F clutch ECMV
J9
SLC5
DT
2
Left clutch ECMV
K8
SR1
Terminal
1
Upper starting motor (Terminal C)
C1
SR2
Terminal
1
Upper starting motor (Terminal R)
C1
SR3
Terminal
1
Upper starting motor (Terminal B)
B2
SR4
Terminal
1
Upper starting motor (Terminal C)
D1 D1 D1
SR5
Terminal
1
Upper starting motor (Terminal R)
SR6
Terminal
1
Upper starting motor (Terminal B)
SR83
DT
2
Right brake ECMV
L7
SRC7
DT
2
Right clutch ECMV
K8
SRT1
DT
2
transmission R clutch ECMV
K3
SS3
X
4
Acceleration sensor
—
SSA
DT
4
Acceleration sensor
R1
ST8
DT
2
Sudden stop prevention solenoid
—
STCN1
—
24
Steering controller
AI6
STCN2
—
40
Steering controller
AH7
STCN3
—
40
Steering controller
AG8
SW1
—
3
Blade lever front button switch
— —
SW2
—
3
Blade lever upper button switch
SX8
Terminal
1
Grounding to machine body
— L3
TC1
X
2
Torque converter speed sensor
TLL
X
2
Left tilt restriction solenoid valve
P5 P5
TLR
X
2
Right tilt restriction solenoid valve
TRS
X
2
Blade tilt left oil pressure switch
—
TM1
X
2
Transmission 1st speed oil pressure switch
L7
TMCN1
—
24
Transmission controller
AG9
TMCN2
—
40
Transmission controller
AF9
TMCN3
—
40
Transmission controller
AF9
2
Blade tilt right oil pressure switch
—
TRS
X
UNL
X
2
Unload solenoid valve
K2
USB
DT
1
Intermediate connector
—
VHMS
DT
2
Constant power supply
—
WRL
X
2
Intermediate connector
E9, O4
20-316
D475A-3
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
CONNECTOR ARRANGEMENT DRAWING
20-318
D475A-3
TROUBLESHOOTING
D475A-3
CONNECTOR ARRANGEMENT DRAWING
20-319
TROUBLESHOOTING
20-320
CONNECTOR ARRANGEMENT DRAWING
D475A-3
TROUBLESHOOTING
D475A-3
CONNECTOR ARRANGEMENT DRAWING
20-321
TROUBLESHOOTING
20-322
CONNECTOR ARRANGEMENT DRAWING
D475A-3
TROUBLESHOOTING
20-324
CONNECTOR ARRANGEMENT DRAWING
D475A-3
TROUBLESHOOTING
D475A-3
CONNECTOR ARRANGEMENT DRAWING
20-325
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS + The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. X Type Connector
Number of Pins
Male (Female housing)
Female (Male housing)
T-adapter Part Number
1
Part number: 08055-00181
Part number: 08055-00191
799-601-7010
2
799-601-7020
Part number: 08055-00282
Part number: 08055-00292
3
799-601-7030
Part number: 08055-00381
Part number: 08055-00391
4
—
—
799-601-7040
Part number: 08055-00481
Part number: 08055-00491
Terminal part number: 79A-222-3370 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black Terminal part number: 79A-222-3380 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red
Terminal part number: 79A-222-3390 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black Terminal part number: 79A-222-3410 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red
20-326
—
—
D475A-3
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP Type Connector Male (Female housing)
Female (Male housing)
6
799-601-7050
Part number: 08055-10681
Part number: 08055-10691
8
799-601-7060
Part number: 08055-10881
Part number: 08055-10891
12
799-601-7310
Part number: 08055-11281
Part number: 08055-11291
14
799-601-7070
Part number: 08055-11481
D475A-3
T-adapter Part Number
Part number: 08055-11491
20-327
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP Type Connector
Number of Pins
Male (Female housing)
Female (Male housing)
16
—
—
T-adapter Part Number
799-601-7320
Part number: 08055-11681 Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black
Part number: 08055-11691 Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black
Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red
Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red
20-328
—
—
D475A-3
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M Type Connector
Number of Pins
Male (Female housing)
Female (Male housing)
T-adapter Part Number
1
Part number: 08056-00171
Part number: 08056-00181
799-601-7080
2
799-601-7090
Part number: 08056-00271
Part number: 08056-00281
3
799-601-7110
Part number: 080565-00371
Part number: 08056-00381
4
799-601-7120
Part number: 08056-00471
Part number: 08056-00481
6
799-601-7130
Part number: 08056-00671
Part number: 08056-00681
8
799-601-7390
Part number: 08056-00871
D475A-3
Part number: 08056-00881
20-329
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector Male (Female housing)
Female (Male housing)
8
799-601-7140
Part number: 08056-10871
Part number: 08056-10881
10 (white)
799-601-7150
Part number: 08056-11071
Part number: 08056-11081
12 (white)
799-601-7350
Part number: 08056-11271
Part number: 08056-11281
16 (white)
799-601-7330
Part number: 08056-11671
20-330
T-adapter Part Number
Part number: 08056-11681
D475A-3
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector Male (Female housing)
Female (Male housing)
10 (blue)
—
—
—
12 (blue)
799-601-7160
Part number: 08056-11272
Part number: 08056-11282
16 (blue)
799-601-7170
Part number: 08056-11672
D475A-3
T-adapter Part Number
Part number: 08056-11682
20-331
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC Type Connector Male (Female housing)
Female (Male housing)
T-adapter Part Number
7
Body part number: 79A-222-2640 (Quantity: 5 pieces)
Body part number: 79A-222-2630 (Quantity: 5 pieces)
—
11
Body part number: 79A-222-2680 (Quantity: 5 pieces)
Body part number: 79A-222-2670 (Quantity: 5 pieces)
—
5
799-601-2710
Body part number: 79A-222-2620 (Quantity: 5 pieces)
Body part number: 79A-222-2610 (Quantity: 5 pieces)
9
799-601-2950
Body part number: 79A-222-2660 (Quantity: 5 pieces)
Body part number: 79A-222-2650 (Quantity: 5 pieces)
13
799-601-2720
Body part number: 79A-222-2710 (Quantity: 2 pieces)
20-332
Body part number: 79A-222-2690 (Quantity: 2 pieces)
D475A-3
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC Type Connector Male (Female housing)
Female (Male housing)
17
799-601-2730
Body part number: 79A-222-2730 (Quantity: 2 pieces)
Body part number: 79A-222-2720 (Quantity: 2 pieces)
21
D475A-3
T-adapter Part Number
799-601-2740
Body part number: 79A-222-2750 (Quantity: 2 pieces)
Body part number: 79A-222-2740 (Quantity: 2 pieces)
Terminal part number: 79A-222-2770 (Quantity: 50 pieces)
Terminal part number: 79A-222-2760 (Quantity: 50 pieces)
—
20-333
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP040 Type Connector Male (Female housing)
Female (Male housing)
8
T-adapter Part Number
799-601-7180
—
Housing part number: 79A-222-3430 (Quantity: 5 pieces)
12
799-601-7190
—
Housing part number: 79A-222-3440 (Quantity: 5 pieces)
16
799-601-7210
—
Housing part number: 79A-222-3450 (Quantity: 5 pieces)
20
799-601-7220
—
Housing part number: 79A-222-3460 (Quantity: 5 pieces)
+ Terminal part number: 79A-222-3470 (for all numbers of pins).
20-334
D475A-3
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070 Type Connector Male (Female housing)
Female (Male housing)
10
799-601-7510
—
Part number: 08195-10210
12
799-601-7520
—
Part number: 08195-12210
14
799-601-7530
—
Part number: 08195-14210
18
799-601-7540
—
Part number: 08195-18210
20
799-601-7550
—
D475A-3
T-adapter Part Number
Part number: 08195-20210
20-335
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L Type Connector Male (Female housing)
Female (Male housing)
2
—
—
Number of Pins
—
PA Type Connector Male (Female housing)
Female (Male housing)
9
—
BENDIX (MS) Type Connector Male (Female housing)
Female (Male housing)
10
T-adapter Part Number
799-601-3460
—
20-336
T-adapter Part Number
—
—
Number of Pins
T-adapter Part Number
—
D475A-3
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES1 Automobile Type Connector Male (Female housing)
Female (Male housing)
2
—
Part number: 08027-10210 (Natural color) 08027-10220 (Black)
Part number: 08027-10260 (Natural color) 08027-10270 (Black)
3
—
Part number: 08027-10310
Part number: 08027-10360
4
—
Part number: 08027-10410 (Natural color) 08027-10420 (Black)
Part number: 08027-10460 (Natural color) 08027-10470 (Black)
6
—
Part number: 08027-10610 (Natural color) 08027-10620 (Black)
D475A-3
T-adapter Part Number
Part number: 08027-10660 (Natural color) 08027-10670 (Black)
20-337
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES1 Automobile Type Connector Male (Female housing)
Female (Male housing)
8
—
Part number: 08027-10810 (Natural color) 08027-10820 (Black)
20-338
T-adapter Part Number
Part number: 08027-10860 (Natural color) 08027-10870 (Black)
D475A-3
TROUBLESHOOTING
Number of Pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F Type Connector Male (Female housing)
Female (Male housing)
4
—
—
D475A-3
T-adapter Part Number
—
20-339
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part Number
799-601-9210
18-8 (1)
Part number: 08191-11201, 08191-11202 08191-11205, 08191-11206
Part number: 08191-14101, 08191-14102 08191-14105, 08191-14106
Pin (female terminal)
Pin (male terminal)
799-601-9210
Part number: 08191-11201, 08191-12202 08191-11205, 08191-12206
Part number: 08191-13101, 08191-13102 08191-13105, 08191-13106
Pin (male terminal)
Pin (female terminal)
799-601-9220
18-14 (2)
Part number: 08191-21201, 08191-12202 08191-21205, 08191-12206
Part number: 08191-24101, 08191-24102 08191-24105, 08191-24106
Pin (female terminal)
Pin (male terminal)
799-601-9220
Part number: 08191-22201, 08191-22202 08191-22205, 08191-22206
20-340
Part number: 08191-23101, 08191-23102 08191-23105, 08191-23106
D475A-3
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part Number
799-601-9230
18-20 (3)
Part number: 08191-31201, 08191-31202 Pin (female terminal)
Part number: 08191-34101, 08191-34102 Pin (male terminal)
799-601-9230
Part number: 08191-32201, 08191-32202
Part number: 08191-33101, 08191-33102
Pin (male terminal)
Pin (female terminal)
799-601-9240
18-21 (4)
Part number: 08191-41201, 08191-42202 Pin (female terminal)
Part number: 08191-44101, 08191-44102 Pin (male terminal)
799-601-9240
Part number: 08191-42201, 08191-42202
D475A-3
Part number: 08191-43101, 08191-43102
20-341
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part Number
799-601-9250
24-9 (5)
Part number: 08191-51201, 08191-51202 Pin (female terminal)
Part number: 08191-54101, 08191-54102 Pin (male terminal)
799-601-9250
Part number: 08191-52201, 08191-52202
Part number: 08191-53101, 08191-53102
Pin (male terminal)
Pin (female terminal)
799-601-9260
24-16 (6)
Part number: 08191-61201, 08191-62202 08191-61205, 08191-62206
Part number: 08191-64101, 08191-64102 08191-64105, 08191-64106
Pin (female terminal)
Pin (male terminal)
799-601-9260
Part number: 08191-62201, 08191-62202 08191-62205, 08191-62206
20-342
Part number: 08191-63101, 08191-63102 08191-63105, 08191-63106
D475A-3
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part Number
799-601-9270
24-21 (7)
Part number: 08191-71201, 08191-71202 08191-71205, 08191-71206
Part number: 08191-74101, 08191-74102 08191-74105, 08191-74106
Pin (female terminal)
Pin (male terminal)
799-601-9270
Part number: 08191-72201, 08191-72202 08191-72205, 08191-72206 Pin (male terminal)
Part number: 08191-73102, 08191-73102 08191-73105, 08191-73106 Pin (female terminal)
799-601-9280
24-22 (8)
Part number: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-80206
Part number: 08191-84101, 08191-84102, 08191-84103, 18191-84104, 08191-84105, 08191-84106
Pin (female terminal)
Pin (male terminal)
799-601-9280
Part number: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206
D475A-3
Part number: 08191-83101, 08191-83102, 08191-83103, 18191-83104, 08191-83105, 08191-83106
20-343
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part Number
799-601-9290
24-31 (9)
Part number: 08191-91203, 08191-91204 08191-91205, 08191-91206
Part number: 08191-94103, 08191-94104 08191-94105, 08191-94106
Pin (female terminal)
Pin (male terminal)
799-601-9290
Part number: 08191-92203, 08191-92204 08191-92205, 08191-92206
20-344
Part number: 08191-93103, 08191-93104 08191-93105, 08191-93106
D475A-3
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] Number of Pins
DT Series connector Body (plug)
Body (receptacle)
2
799-601-9020
Part number: 08192-12200 (normal type) 08192-22200 (fine wire type)
Part number: 08192-12100 (normal type) 08192-22100 (fine wire type)
3
799-601-9030
Part number: 08192-13200 (normal type) 08192-23200 (fine wire type)
Part number: 08192-13100 (normal type) 08192-23100 (fine wire type)
4
799-601-9040
Part number: 08192-14200 (normal type) 08192-24200 (fine wire type)
Part number: 08192-14100 (normal type) 08192-24100 (fine wire type)
6
799-601-9050
Part number: 08192-16200 (normal type) 08192-26200 (fine wire type)
D475A-3
T-adapter Part Number
Part number: 08192-16100 (normal type) 08192-26100 (fine wire type)
20-345
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] Number of Pins
DT Series connector Body (plug)
Body (receptacle)
T-adapter Part Number
8GR: 799-601-9060
8
8B:
799-601-9070
8G:
799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 (normal type) 08192-2820 (fine wire type)
Part number: 08192-1810 (normal type) 08192-2810 (fine wire type)
12GR: 799-601-9110 12B: 799-601-9120
10
12G: 799-601-9130 12BR: 799-601-9140
Part number: 08192-1920 (normal type) 08192-2920 (fine wire type)
20-346
Part number: 08192-1910 (normal type) 08192-2910 (fine wire type)
D475A-3
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] Number of Pins
DTM Series connector Body (plug)
Body (receptacle)
2
799-601-9010
Part number: 08192-02200
Number of Pins
T-adapter Part Number
Part number: 08192-02100
DTHD Series connector Body (plug)
Body (receptacle)
1
T-adapter Part Number
—
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12) 08192-41200 (Contact size #8) 08192-41100 (Contact size #8) 08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D475A-3
20-347
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) Information described in troubleshooting list ........................................................................................... 20-405 Trouble code table ................................................................................................................................... 20-406 Error code 1500LO (Transmission clutch: see the list. (L0)) .................................................................. 20-407 Error code 15SAL1 (Forward clutch: see the list. (L1)) .......................................................................... 20-408 Error code 15SALH (Forward clutch: see the list. (LH)) ......................................................................... 20-409 Error code 15SBL1 (Reverse clutch: see the list. (L1)) .......................................................................... 20-410 Error code 15SBLH (Reverse clutch: see the list. (LH)) ........................................................................ 20- 411 Error code 15SEL1 (1st clutch: See the list. (L1)) .................................................................................. 20-412 Error code 15SELH (1st clutch: See the list. (LH)) ................................................................................ 20-413 Error code 15SFL1 (2nd clutch: See the list. (L1)) ................................................................................. 20-414 Error code 15SFLH (2nd clutch: See the list. (LH)) ............................................................................... 20-415 Error code 15SGL1 (3rd clutch: See the list. (L1)) ................................................................................. 20-416 Error code 15SGLH (3rd clutch: See the list. (LH)) ................................................................................ 20-417 Error code 1800MW (Power train clutch: Slip (MW)) ............................................................................. 20-418 Error code 2201L1 (Right clutch: See the list. (L1)) ............................................................................... 20-419 Error code 2201LH (Right clutch: See the list. (LH)) .............................................................................. 20-420 Error code 2202L1 (Left clutch: See the list. (L1)) ................................................................................. 20-421 Error code 2202LH (Left clutch: See the list. (LH)) ................................................................................ 20-422 Error code 2301L1 (Right brake: See the list. (L1)) ............................................................................... 20-423 Error code 2301LH (Right brake: See the list. (LH)) .............................................................................. 20-424 Error code 2302L1 (Left brake: See the list. (L1)) .................................................................................. 20-425 Error code 2302LH (Left brake: See the list. (LH)) ................................................................................ 20-426 Error code A70XLK (Governor servo system right: Refer to table (LK))............................................... 20-426-1 Error code A70YLK (Governor servo system left: Refer to table (LK)) ................................................. 20-426-2 Error code AA1ANX (Air cleaner: CLOGGING (NX)) ............................................................................ 20-427 Error code AB00MA (Alternator: Malfunction (MA)) ............................................................................... 20-428 Error code B@BAZG (Engine oil: Oil pressure reduction (ZG)) ............................................................ 20-429 Error code B@BAZK (Engine oil: Level reduction (ZK)) ........................................................................ 20-429 Error code B@BCNS (Radiator coolant: Overheat (NS)) ....................................................................... 20-430 Error code B@BCZK (Radiator coolant: Level reduction (ZK)) .............................................................. 20-431 Error code B@CENS (Power train oil: Overheat (NS)) .......................................................................... 20-431 Error code B@HANS (Hydraulic oil: Overheat (NS)) ............................................................................. 20-432 Error code B@HAZK (Hydraulic oil: Level reduction (ZK)) .................................................................... 20-432 Error code D110KA (Battery relay: DISCONNECTION (KA)) ................................................................. 20-433 Error code D110KB (Battery relay: Short circuit (KB)) ............................................................................ 20-434 Error code D130KA (Neutral relay: Disconnection (KA)) ........................................................................ 20-435 Error code D130KB (Neutral relay: Short circuit (KB)) ........................................................................... 20-437 Error code D161KA (Back-up alarm relay: Disconnection (KA)) ............................................................ 20-438 Error code D161KB (Back-up alarm relay: Short circuit (KB)) ............................................................... 20-440 Error code D1D0KA (Governor cutout relay right: Disconnection (KA)) ............................................... 20-441-1 Error code D1D0KB (Governor cutout relay right: short circuit (KB)) ................................................... 20-441-2 Error code D1D1KA (Governor cutout relay left: Disconnection (KA)) ................................................. 20-441-4 Error code D1D1KB (Governor cutout relay left: Short circuit (KB))..................................................... 20-441-6 Error code D5ZFKA (Neutral signal 1: Disconnection (KA)) .................................................................. 20-442 Error code D5ZFKB (Neutral signal 1: SHORT CIRCUIT (KB)) ............................................................ 20-443 Error code D5ZFL4 (Engine controller neutral signal: ON and OFF signals do not agree (L4))........... 20-443-1 Error code D5ZGKA (Neutral signal 2: DISCONNECTION (KA)) .......................................................... 20-444 Error code D5ZGKB (Neutral signal 2: SHORT CIRCUIT (KB)) ............................................................ 20-445 D475A-3
20-401 (1)
TROUBLESHOOTING
Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code
20-402 (1)
D5ZKKX DAFRKR DAQ0KK DAQ0KT DAQ5KK
(Chassis throttle signal: Out of input signal range (KX)) ..................................... 20-445-1 (Monitor panel “can” communication: Defective communication (KR)) ................. 20-446 (Transmission controller: Source voltage reduction/input (KK)) ............................ 20-448 (Transmission controller: Abnormality in controller (KT)) ...................................... 20-449 (Transmission controller potentiometer power supply: Source voltage reduction/input (KK)) ................................................................... 20-450 DAQ6KK (Transmission controller sensor power supply: Source voltage reduction/input (KK)) ................................................................... 20-452 DAQ9KQ (Transmission controller type collation: Type select signal inconsistency (KQ)) .. 20-453 DAQRKR (Transmission controller can communication: Defective communication (KR)) ... 20-454 DAQSKR (Transmission controller S-NET communication: Defective communication (KR)) 20-456 DB30KK (Steering controller: Source voltage reduction/input (KK)) ..................................... 20-458 DB30KT (Steering controller: Abnormality in controller (KT)) ............................................... 20-459 DB35KK (Steering controller potentiometer power supply: Source voltage reduction/input (KK)) .................................................................... 20-460 DB36KK (Steering controller sensor power supply: Source voltage reduction input (KK)) .................................................................... 20-462 DB39KQ (Steering controller type collation: Type select signal inconsistency (KQ)) ........... 20-463 DB3RKR (Steering controller can communication: Defective communication (KR)) ............ 20-464 DB3SKR (Steering controller S-NET communication: Defective communication (KR)) ....... 20-466 DB40KK (Engine controller: Lowering of source voltage (KK)) .......................................... 20-466-1 DB41KK (Switch power supply: Lowering of source voltage (KK)) .................................... 20-466-2 DB42KK (Solenoid power supply 1: Lowering of source voltage (KK)).............................. 20-466-4 DB43KK (Backup power supply: Lowering of source voltage (KK))................................... 20-466-6 DB44KK (Solenoid power supply 2: Lowering of source voltage (KK)).............................. 20-466-8 DB45KP (Rack sensor power supply: Lowering of output voltage (KP)).......................... 20-466-10 DB49KM (Wrong connection of connector: Mistake in operation or setting (KM)) ........... 20-466-12 DB49KQ (Engine controller specification: Disagreement of model selection signals (KQ))............................................... 20-466-13 DD14KA (Parking lever switch: Disconnection (KA)) ............................................................ 20-468 DD14KB (Parking lever switch: Short circuit (KB)) ............................................................... 20-470 DDB9KA (Reverse switch: Disconnection (KA)) ................................................................... 20-472 DDB9KB (Reverse switch: Short circuit (KB)) ...................................................................... 20-474 DDK3KA (Forward switch: Disconnection (KA)) ................................................................... 20-476 DDK3KB (Forward switch: Short circuit (KB)) ...................................................................... 20-478 DDK5KA (Shift switch: Disconnection (KA)) ......................................................................... 20-480 DDK5KB (Shift switch: Short circuit (KB)) ............................................................................ 20-482 DDN2LD (See table (LD) Blade tilt right oil pressure switch system) ................................... 20-483 DDN3LD (See table (LD) Blade tilt left oil pressure switch system) ..................................... 20-484 DDN7KA (Blade pitch switch: DIsconnection (KA)) .............................................................. 20-486 DDN7KB (Blade pitch switch: Short circuit (KB)) ................................................................. 20-488 DDN9KA (Blade tilt switch: Disconnection (KA)) .................................................................. 20-490 DDN9KB (Blade tilt switch: Short circuit (KB)) ...................................................................... 20-492 DDNALD (Blade lift up full pressure switch: Refer to table (LD)) ......................................... 20-494 DDNBLD (Ripper lift up pressure switch: Refer to table (LD)) .............................................. 20-495 DDNCLD (Ripper lower pressure switch: Refer to table (LD)) ............................................. 20-496 DDNDLD (Ripper tilt in pressure switch: Refer to table (LD)) ............................................... 20-497 DDNELD (Ripper tilt back pressure switch: Refer to table (LD)) .......................................... 20-498 DDNFLD (Blade lower full pressure switch: Refer to table (LD)) .......................................... 20-499 DDQ2KA (Parking brade lever switch: Disconnection (KA)) ................................................. 20-500 DDQ2KB (Parking brake lever switch: Short circuit (KB)) .................................................... 20-502 DDQ2L4 (Parking brake lever switch: See table (L4)) ......................................................... 20-504 DDT5KA (Neutral switch: Disconnection (KA)) ..................................................................... 20-506 DDT5KB (Neutral switch: Short circuit (KB)) ........................................................................ 20-508 D475A-3
TROUBLESHOOTING
Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code D475A-3
DDT5KQ (PCCS lever specification signal inconsistency (KQ)) .......................................... 20-510 DGE2KX (Engine coolant temperature: Out of input signal range (KX)) ............................ 20-510-1 DGS1KX (Hydraulic oil temperature sensor: Input signal is out of normal range (KX)) ....... 20- 511 DH22KA (Work equipment large pump oil pressure sensor: Disconnection (KA)) ............... 20-512 DH22KB (Work equipment large pump oil pressure sensor: Short circuit (KB)) .................. 20-513 DH23KA (Work equipment assistance pump oil pressure sensor: Disconnection (KA)) ...... 20-514 DH23KB (Work equipment assistance pump oil pressure sensor: Short circuit (KB)) ......... 20-515 DK01KA (Left yoke angle sensor: Disconnection (KA)) ....................................................... 20-516 DK01KB (Left yoke angle sensor: Short circuit (KB)) .......................................................... 20-517 DK03KA (Right yoke angle sensor: Disconnection (KA)) ..................................................... 20-518 DK03KB (Right yoke angle sensor: Short circuit (KB)) ........................................................ 20-519 DK10KX (Fuel dial: Out of input signal range (KX))............................................................ 20-519-1 DK11KA (Deceleration potentiometer: Disconnection (KA)) ................................................ 20-520 DK11KB (Deceleration potentiometer: Short circuit (KB)) .................................................... 20-522 DK12KX (Decelerator potentiometer: Out of input signal range (KX))................................ 20-523-1 DK30KA (Steering potentiometer 1: Disconnection (KA)) .................................................... 20-524 DK30KB (Steering potentiometer 1: Short circuit (KB)) ....................................................... 20-526 DK30KX (Steering potentiometer 1: Input signal is out of normal range (KX)) .................... 20-527 DK30KZ (Steering potentiometer 1: Disconnection or short circuit (KZ)) ............................ 20-527 DK30L8 (Steering potentiometer 1: See table (L8)) ............................................................ 20-528 DK31KA (Steering potentiometer 2: Disconnection (KA)) .................................................... 20-530 DK31KB (Steering potentiometer 2: Short circuit (KB)) ....................................................... 20-532 DK40KA (Brake potentiometer: Disconnection (KA)) ........................................................... 20-533 DK40KB (Brake potentiometer: Short circuit (KB)) .............................................................. 20-534 DK55KX (Forward-reverse potentiometer: Input signal is out of normal range (KX)) .......... 20-535 DK55KZ (Forward-reverse potentiometer: Disconnection or short circuit (KZ)) .................. 20-535 DK55L8 (Forward-reverse potentiometer: See table (L8)) .................................................. 20-536 DK56KA (Forward-reverse potentiometer 1: Disconnection (KA)) ....................................... 20-537 DK56KB (Forward-reverse potentiometer 1: Short circuit (KB)) .......................................... 20-538 DK57KA (Forward-reverse potentiometer 2: Disconnection (KA)) ....................................... 20-540 DK57KB (Forward-reverse potentiometer 2: Short circuit (KB)) .......................................... 20-542 DK60KA (Acceleration sensor: Disconnection (KA)) ............................................................ 20-543 DK60KB (Acceleration sensor: Short circuit (KB)) ............................................................... 20-544 DKF1KX (Rack sensor right: Out of input signal range (KX)) ............................................. 20-544-1 DKF2KX (Rack sensor left: Out of input signal range (KX)) ............................................... 20-544-3 DKH1KA (Pitch angle sensor: Disconnection (KA)) ............................................................. 20-545 DKH1KB (Pitch angle sensor: Short circuit (KB)) ................................................................ 20-546 DLE1KA (Engine NE speed sensor: Disconnection (KA)) ................................................... 20-548 DLE4LC (Engine speed sensor A: Refer to table (LC)) ...................................................... 20-549-1 DLE5LC (Engine speed sensor B: Refer to table (LC)) ...................................................... 20-549-3 DLF1KA (Torque converter output speed sensor: Disconnection (KA)) ............................... 20-550 DV00KB (Caution buzzer: Short circuit (KB)) ...................................................................... 20-551 DW55KA (Blade pitch back solenoid: Disconnection (KA)) ................................................. 20-552 DW55KB (Blade pitch back solenoid: Short circuit (KB)) ..................................................... 20-553 DW56KA (Blade pitch dump solenoid: Disconnection (KA)) ................................................ 20-554 DW56KB (Blade pitch dump solenoid: Short circuit (KB)) ................................................... 20-555 DW57KA (Blade pitch selector solenoid: Disconnection (KA)) ............................................ 20-556 DW57KB (Blade pitch selector solenoid: Short circuit (KB)) ................................................ 20-557 DW58KA (RIGHT tilt solenoid: Disconnection (KA)) ............................................................ 20-558 DW58KB (RIGHt tilt solenoid: Short circuit (KB)) ................................................................. 20-559 DW5AKA (Blade pitch selector solenoid: Disconnection (KA)) ............................................ 20-560 DW5AKB (Blade pitch selector solenoid: Short circuit (KB)) ............................................... 20-561 DW5JKA (Blade pitch selector solenoid: Disconnection (KA)) ............................................. 20-562 DW5JKB (Blade pitch selector solenoid: Short circuit (KB)) ................................................ 20-563
20-403 (1)
TROUBLESHOOTING
Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code Error code
20-404 (1)
DW5LKA (Blade pitch dump assist solenoid: Disconnection (KA)) ...................................... 20-564 DW5LKB (Blade pitch dump assist solenoid: Short circuit (KB)) .......................................... 20-565 DW98KA (Unload solenoid: Disconnection (KA)) ................................................................. 20-566 DW98KB (Unload solenoid: Short circuit (KB)) .................................................................... 20-567 DWN3KA (Sudden stop prevention solenoid: Disconnection (KA)) ...................................... 20-568 DWN3KB (Sudden stop prevention solenoid: Short circuit (KB)) ......................................... 20-569 DXH1KA (Lock-up solenoid: Disconnection (KA)) ................................................................ 20-570 DXH1KB (Lock-up solenoid: Short circuit (KB)) ................................................................... 20-571 DXH4KA (1st clutch ECMV: Disconnection (KA)) ................................................................. 20-572 DXH4KB (1st clutch ECMV: Short circuit (KB)) .................................................................... 20-573 DXH5KA (2nd clutch ECMV: Disconnection (KA)) ............................................................... 20-574 DXH5KB (2nd clutch ECMV: Short circuit (KB)) ................................................................... 20-575 DXH6KA (3rd clutch ECMV: Disconnection (KA)) ................................................................ 20-576 DXH6KB (3rd clutch ECMV: Short circuit (KB)) ................................................................... 20-577 DXH7KA (Reverse clutch ECMV: Disconnection (KA)) ........................................................ 20-578 DXH7KB (Reverse clutch ECMV: Short circuit (KB)) ........................................................... 20-579 DXH8KA (Forward clutch ECMV: Disconnection (KA)) ........................................................ 20-580 DXH8KB (Forward clutch ECMV: Short circuit (KB)) ........................................................... 20-581 DXH9KA (Right steering clutch ECMV system: Disconnection (KA)) ................................... 20-582 DXH9KB (Right steering clutch ECMV: Short circuit (KB)) .................................................. 20-583 DXHAKA (Left steering clutch ECMV: Disconnection (KA)) ................................................. 20-584 DXHAKB (Left steering clutch ECMV: Short circuit (KA)) .................................................... 20-585 DXHBKA (Right brake ECMV: Disconnection (KA)) ............................................................. 20-586 DXHBKB (Right brake ECMV: Short circuit (KB)) ................................................................ 20-587 DXHCKA (Left brake ECMV: Disconnection (KA)) ............................................................... 20-588 DXHCKB (Left brake ECMV: Short circuit (KB)) .................................................................. 20-589 DXHDKA (Governor solenoid right: Disconnection (KA))................................................... 20-589-1 DXHDKB (Governor solenoid right: Short circuit (KB)) ...................................................... 20-589-2 DXHEKA (Governor solenoid left: Disconnection (KB)) ..................................................... 20-589-3 DXHEKB (Governor solenoid left: Short circuit (KB))......................................................... 20-589-4 DXHFKA (Pre-stroke solenoid right: Disconnection (KA)).................................................. 20-589-5 DXHFKB (Pre-stroke solenoid right: Short circuit (KB)) ..................................................... 20-589-6 DXHGKA (Pre-stroke solenoid left: Disconnection (KA)) ................................................... 20-589-7 DXHGKB (Pre-stroke solenoid left: Short circuit (KB))....................................................... 20-589-8
D475A-3
TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST + The troubleshooting list and related circuit diagram summarize the following information. Understand their contents well to advance troubleshooting. Action code Panel display Contents of trouble Action of monitor panel or controller Problem that appears on machine Related information
Error code Panel display
Trouble
State where the monitor panel or controller detects the trouble Action to be taken to protect the system and equipment when the monitor panel or controller detects a trouble Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or controller (above) Information related to a detected trouble or troubleshooting Cause
1
2
Possible causes and standard value in normal state
Cause by which a trouble is assumed to be detected 3 (The order number indicates a serial number, not a priority sequence.)
4
5
D475A-3
Trouble that appeared on machine
Standard value in normal state/Remarks on troubleshooting • Standard value in normal state required to judge the assumed cause (good or not) • Remarks required to judge whether the cause is good • Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Grounding fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. • Defective hot short A harness not connected to the power (24V) circuit comes into contact with the power (24V) circuit. • Defective short A harness of an independent circuit abnormally comes into contact with one of another circuit. 1Method of indicating connector numbers and handling T-junction For troubleshooting, insert or connect the T-junction adapter as shown below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the T-junction adapter in both the male and female. • When “male” or “female” is indicated for a connector number, disconnect the connector, and insert the T-junction adapter in only either the male or female. 2Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.
20-405
TROUBLESHOOTING
TROUBLE CODE TABLE
Related circuit diagram
This is the excerpted circuit diagram related to trouble • Connector No.: Indicates (Model-No. of pins) (Color). • Arrow (⇔): Roughly indicates mounting place on machine.
TROUBLE CODE TABLE + Regarding trouble code provided with instruction “Refer to table”, check it against table below. Trouble code KA
Disconnection in wiring
L0
KB
L1 L2
Fuel pressure is above maxim specified value.
L3
Object part is uncontrollable.
KR
Short circuit Source voltage reduction/ input Type select signal inconsistency Defective communication
Contents of trouble Fill signals at two or more channels which are not set as combination are turned ON at the same time. Fill signal is ON when command current to ECMV is OFF.
L4
KT
Abnormality in controller
L6
KX
Outside input signal range Disconnection or short circuit Malfunction Performance reduction Sliding Overheat Clogging Oil pressure reduction Level reduction
L8
ON and OFF signals at two systems are inconsistent. Engine rotation signal, terminal C signal, oil pressure switch signal, water temperature sensor signal, etc. are inconsistent with operation state or stop state. Analog signals in two systems are inconsistent.
LC
rpm signals in two systems are inconsistent.
LD LH
Switch is pressed for usually unthinkable long time. Fill signal is OFF when command current to ECMV is ON.
KK KQ
KZ MA MB MW NS NX ZG ZK
20-406
Contents of trouble
Trouble code
D475A-3
TROUBLESHOOTING
ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (L0)) Action code CALL E03 •
• Contents of trouble
Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
D475A-3
• • • • •
Error code Transmission clutch: See the list. (LO) Trouble (Transmission controller system) 1500L0 Of the error codes related to the transmission clutch, the following codes were displayed at the same time. (Connection error) 1Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB] Of the error codes related to the transmission clutch, the following codes were displayed at the same time. (Disconnection error) 2Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB] 3[DXH6KA] and [DXH6KB] 4[15SFL1] and [15SGL1] 5[15SFLH] and [15SGLH] 6[15SAL1], [15SBL1], and [15SEL1] 7[15SALH] and [15SBLH] 8[15SALH] and [15SELH] 9[15SBLH] and [15SELH] Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. The auto shift down function does not start. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F3 and R3.
• Method of reproducing error code: Engine start + Run Cause Standard value in normal state/Remarks on troubleshooting Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes. [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH] [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA], [DXH8KB]
20-407
TROUBLESHOOTING
ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SAL1
Trouble
Forward clutch: See the list. (L1) (Transmission controller system)
• The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Decides that engine speed is neutral (N) at reverse operation. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to F1. • The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Neutral running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective forward clutch fill FFT2 (male) PCCS lever Resistance switch (Internal short) N Min. 1MΩ Between 1 – chassis ground F (Forward) Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between TMCN1 (female) 5 – cuit) Resistance Max. 1MΩ FFT2 (female) 1 with chassis ground + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller N 20 – 30V Between 5 – chassis ground F (Forward) Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
20-408
D475A-3
TROUBLESHOOTING
ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SALH
Trouble
• The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Decides that engine speed is neutral (N) at forward operation. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to R1. • The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Cause
Possible causes and standard value in normal state
Forward clutch: See the list. (LH) (Transmission controller system)
1
Defective forward clutch fill switch (Internal short)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Defective transmission controller
4
Defective hydraulic pressure system
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. FFT2 (male) PCCS lever Resistance N Min. 1MΩ Between b – chassis ground F (Forward) Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN1 (female) f – Resistance Max. 1Ω FFT2 (female) b + Prepare with starting switch OFF, then start the engine for troubleshooting. TMCN1 PCCS lever Voltage N 20 – 30V Between f – chassis ground F (Forward) Max. 1V When no fault is detected in the electric system, the hydraulic pressure system is assumed to be abnormal. Carry out the related troubleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
D475A-3
20-409
TROUBLESHOOTING
ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SBL1
Trouble
Reverse clutch: See the list. (L1) (Transmission controller system)
• The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Decides that engine speed is neutral (N) at forward operation. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to R1. • The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective reverse clutch fill FRT2 (male) PCCS lever Resistance switch (Internal short) N Min. 1MΩ Between 1 – chassis ground R (Reverse) Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between TMCN1 (female) N – cuit) Resistance Max. 1MΩ FRT2 (female) 1 with chassis ground + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller N 20 – 30V Between N – chassis ground R (Reverse) Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission reverse clutch ECMV
20-410
D475A-3
TROUBLESHOOTING
ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SBLH
Trouble
• The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Decides that engine speed is neutral (N) at reverse operation. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to F1. • The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Cause
Possible causes and standard value in normal state
Reverse clutch: See the list. (LH) (Transmission controller system)
1
Defective reverse clutch fill switch (Internal short)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Defective transmission controller
4
Defective hydraulic pressure system
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. FRT2 (male) PCCS lever Resistance N Min. 1MΩ Between 1 – chassis ground R (Reverse) Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN1 (female) N – Resistance Max. 1MΩ FRT2 (female) 1 + Prepare with starting switch OFF, then start the engine for troubleshooting. TMCN1 PCCS lever Voltage N 20 – 30V Between N – chassis ground R (Reverse) Max. 1V When no fault is detected in the electric system, the hydraulic pressure system is assumed to be abnormal. Carry out the related troubleshooting (H mode).
Circuit diagram related to transmission reverse clutch ECMV
D475A-3
20-411
TROUBLESHOOTING
ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SEL1
Trouble
1st clutch: See the list. (L1) (Transmission controller system)
• The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to F1 and R1. • The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 1st clutch fill F1T8 (male) PCCS lever Resistance switch (Internal short) Other than F1/R1 Min. 1MΩ Between 1 – chassis ground F1·R1 Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between TMCN1 (female) M – cuit) Resistance Max. 1MΩ F1T8 (female) 1 with chassis ground + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller Other than F2/R2 20 – 30V Between M – chassis ground F2·R2 Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission level 1 clutch ECMV
20-412
D475A-3
TROUBLESHOOTING
ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SELH
Trouble
Level 1 clutch: See the list. (LH) (Transmission controller system)
• The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. The auto shift down function does not start. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F2 and R2. The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + F1 or R1 running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 1st clutch fill F1T8 (male) PCCS lever Resistance switch (Internal short) Other than F1/R1 Min. 1MΩ Between 1 – chassis ground F1·R1 Max. 1Ω Disconnection in wiring har- + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between TMCN1 (female) M – Resistance Max. 1MΩ connector) F1T8 (female) 1 + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller Other than F1/R1 20 – 30V Between N – chassis ground F1·R1 Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 1st clutch ECMV
D475A-3
20-413
TROUBLESHOOTING
ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SFL1
Trouble
2nd clutch: See the list. (L1) (Transmission controller system)
• The fill switch signal is not set off at stop of output to the transmission 2nd clutch solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. The auto shift down function does not operate. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F2 and R2. The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Neutral running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance switch (Internal short) Other than F2/R2 Min. 1MΩ Between 1 – chassis ground F2·R2 Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between TMCN1 (female) G – cuit) Resistance Max. 1MΩ F2T6 (female) 1 with chassis ground + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller Other than F2/R2 20 – 30V Between G – chassis ground F2·R2 Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
20-414
D475A-3
TROUBLESHOOTING
ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SFLH
Trouble
2nd clutch: See the list. (LH) (Transmission controller system)
• The fill switch signal is not set off at output to the transmission level 2 clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to F1 and R1. • The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + F2 or R2 running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance switch (Internal short) Other than F2/R2 Min. 1MΩ Between 1 – chassis ground F2·R2 Max. 1Ω Disconnection in wiring har- + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between TMCN1 (female) G – Resistance Max. 1MΩ connector) F2T6 (female) 1 + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller Other than F2/R2 20 – 30V Between G – chassis ground F2·R2 Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
D475A-3
20-415
TROUBLESHOOTING
ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SGL1
Trouble
3rd clutch: See the list. (L1) (Transmission controller system)
• The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. The auto shift down function does not operate. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F3 and R3. The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Neutral running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance switch (Internal short) Other than F3/R3 Min. 1MΩ Between 1 – chassis ground F3·R3 Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between TMCN1 (female) A – cuit) Resistance Max. 1MΩ F3T4 (female) 1 with chassis ground + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller Other than F3/R3 20 – 30V Between A – chassis ground F3·R3 Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
20-416
D475A-3
TROUBLESHOOTING
ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 15SGLH
Trouble
3rd clutch: See the list. (LH) (Transmission controller system)
• The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, running is limited to F1 and R1. • The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + F3 or R3 running Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance switch (Internal short) Other than F3/R3 Min. 1MΩ Between 1 – chassis ground F3·R3 Max. 1Ω Disconnection in wiring har- + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between TMCN1 (female) A – Resistance Max. 1Ω connector) F3T4 (female) 1 + Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission conTMCN1 PCCS lever Voltage troller Other than F3/R3 20 – 30V Between A – chassis ground F3·R3 Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
D475A-3
20-417
TROUBLESHOOTING
ERROR CODE 1800MW (POWER TRAIN CLUTCH: SLIP (MW))
ERROR CODE 1800MW (POWER TRAIN CLUTCH: SLIP (MW)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code Power train clutch slip Trouble (Transmission controller system) 1800MW • At lock-up of the torque converter, the number of transmission rotations obtained from the number of engine rotations is different from the actual number of rotations by 200rpm or more. • Flashes caution lamp and turns on caution buzzer. • The auto shift down function does not operate. • The number of engine rotations and the number of transmission rotations can be checked in monitoring mode. (Code 01000: Number of engine rotations, code 31400: Number of transmission rotations) • Method of reproducing error code: Engine start + Lock-up switch ON + Actual running
1 Possible causes and standard value in normal state
2 3 4
20-418
Cause Power train clutch slip (When the system is normal) Defective engine rotation sensor Defective transmission rotation sensor system
Standard value in normal state/Remarks on troubleshooting + Clutch slip was detected; check the cause and machine damage state, then repair the machine.
Check whether error codes [DLE3LE], [DLH1LC], and [DLH1LF] are displayed. If they are displayed, carry out the troubleshooting. Check whether error code [DLF1KA] is displayed. If it is displayed, carry out the troubleshooting. Internally trouble; troubleshooting is impossible. Defective transmission con(If no visible abnormality is detected on the machine, the controller troller may be used continuously.)
D475A-3
TROUBLESHOOTING
ERROR CODE 2201L1 (RIGHT CLUTCH: SEE THE LIST. (L1))
ERROR CODE 2201L1 (RIGHT CLUTCH: SEE THE LIST. (L1)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2201L1
Trouble
Right clutch: See the list. (L1) (Steering controller system)
• The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start. Defective left steering clutch FRC8 (male) PCCS lever Resistance fill switch N (Neutral) Min. 1MΩ Between 1 – (Internal short) chassis ground Right steering Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between STCN3 (female) ] – cuit) Resistance Max. 1MΩ FRC8 (female) 1 with chassis ground + Prepare with starting switch OFF. Engine start. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 20 – 30V Between ] – chassis ground Right steering Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to right steering clutch ECMV
D475A-3
20-419
TROUBLESHOOTING
ERROR CODE 2201LH (RIGHT CLUTCH: SEE THE LIST. (LH))
ERROR CODE 2201LH (RIGHT CLUTCH: SEE THE LIST. (LH)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2201LH
Trouble
Right clutch: See the list. (LH) (Steering controller system)
• The fill switch signal is not set off at output to the right steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start+ Parking lever release + PCCS lever operation (right streering) Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start. Defective right steering FRC8 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1MΩ Between 1 – (Internal short) chassis ground Right steering Max. 1Ω Disconnection in wiring har- + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between STCN3 (female) ] – Resistance Max. 1MΩ connector) FRC8 (female) 1 + Prepare with starting switch OFF. Engine start. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 20 – 30V Between ] – chassis ground Right steering Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to right steering clutch ECMV
20-420
D475A-3
TROUBLESHOOTING
ERROR CODE 2202L1 (LEFT CLUTCH: SEE THE LIST. (L1))
ERROR CODE 2202L1 (LEFT CLUTCH: SEE THE LIST. (L1)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2202L1
Trouble
Left Clutch: See the list. (L1) (Steering controller system)
• The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start. Defective left steering clutch FLC6 (male) PCCS lever Resistance fill switch N (Neutral) Min. 1MΩ Between 1 – (Internal short) chassis ground Right steering Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between STCN3 (female) S – cuit) Resistance Max. 1MΩ FLC6 (female) 1 with chassis ground + Prepare with starting switch OFF. Engine start. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 20 – 30V Between S – chassis ground Right steering Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to left steering clutch ECMV
D475A-3
20-421
TROUBLESHOOTING
ERROR CODE 2202LH (LEFT CLUTCH: SEE THE LIST. (LH))
ERROR CODE 2202LH (LEFT CLUTCH: SEE THE LIST. (LH)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2202LH
Trouble
Left clutch: See the list. (LH) (Steering controller system)
• The fill switch signal is not set off at output to the left steering clutch solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it never runs. • The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start + Parking lever release + PCCS lever operation (left streering) Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start. Defective left steering clutch FLC6 (male) PCCS lever Resistance fill switch N (Neutral) Min. 1MΩ Between 1 – (Internal short) chassis ground Left steering Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between STCN3 (female) S – cuit) Resistance Max. 1MΩ FLC6 (female) 1 with chassis ground + Prepare with starting switch OFF. Engine start. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 20 – 30V Between S – chassis ground Left steering Max. 1V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to left steering clutch ECMV
20-422
D475A-3
TROUBLESHOOTING
ERROR CODE 2301L1 (RIGHT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2301L1 (RIGHT BRAKE: SEE THE LIST. (L1)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2301L1
Trouble
Right brake: See the list. (L1) (Steering controller system)
• The fill switch signal is not set off at output stop of the right steering brake solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. The loose brake functions during running. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start + Parking lever release Defective right steering FRB4 (male) PCCS lever Resistance clutch fill switch (Internal short) N (Neutral) Max. 1Ω Between 1 – chassis ground Right steering Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between STCN2 (female) O – cuit) Resistance Max. 1MΩ FRB4 (female) 1 with chassis ground + Prepare with starting switch OFF. Engine start + Parking lever release STCN2 PCCS lever Voltage Defective steering controller N (Neutral) Max. 1V Between O – chassis ground Right steering 20 – 30V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to right steering brake ECMV
D475A-3
20-423
TROUBLESHOOTING
ERROR CODE 2301LH (RIGHT BRAKE: SEE THE LIST. (LH))
ERROR CODE 2301LH (RIGHT BRAKE: SEE THE LIST. (LH)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2301LH
Trouble
Right brake: See the list. (LH) (Steering controller system)
• The fill switch signal is not set off at output to the right steering brake solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. The loose brake functions during running. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start + Parking lever release Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start + Parking lever release Defective right steering FRB4 (male) PCCS lever Resistance clutch fill switch (Internal short) N (Neutral) Max. 1Ω Between 1 – chassis ground Right steering Min. 1MΩ Disconnection in wiring har- + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between STCN2 (female) O – Resistance Max. 1MΩ connector) FRB4 (female) 1 + Prepare with starting switch OFF. Engine start + Parking lever release STCN2 PCCS lever Voltage Defective steering controller N (Neutral) Max. 1V Between O – chassis ground Right steering 20 – 30V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to right steering brake ECMV
20-424
D475A-3
TROUBLESHOOTING
ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2302L1
Trouble
Left brake: See the list. (L1) (Steering controller system)
• The fill switch signal is not set off at output stop of the left steering brake solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. The loose brake functions during running. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start + Parking lever release Defective left steering brake FLB2 (male) PCCS lever Resistance fill switch (Internal short) N (Neutral) Max. 1Ω Between 1 – chassis ground Right steering Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground cirWiring harness between STCN2 (female) Y – cuit) Resistance Max. 1MΩ FLB2 (female) 1 with chassis ground + Prepare with starting switch OFF. Engine start + Parking lever release. STCN2 PCCS lever Voltage Defective steering controller N (Neutral) Max. 1V Between Y – chassis ground Left steering 20 – 30V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to left steering brake ECMV
D475A-3
20-425
TROUBLESHOOTING
ERROR CODE 2302LH (LEFT BRAKE: SEE THE LIST. (LH))
ERROR CODE 2302LH (LEFT BRAKE: SEE THE LIST. (LH)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code 2302LH
Trouble
• The fill switch signal is not set off at output stop of the left steering brake solenoid circuit. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. The loose brake functions during running. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) • Method of reproducing error code: Engine start Cause
Possible causes and standard value in normal state
Left brake: See the list. (LH) (Steering controller system)
1
Defective left steering brake fill switch (Internal short)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Defective steering controller
4
Defective hydraulic pressure system
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF. Engine start + Parking lever release. FLB2 (male) PCCS lever Resistance N (Neutral) Max. 1Ω Between 1 – chassis ground Left steering Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN2 (female) Y – Resistance Max. 1MΩ FLB2 (female) 1 + Prepare with starting switch OFF. Engine start + Parking lever release. STCN2 PCCS lever Voltage N (Neutral) Max. 1V Between Y – chassis ground Left steering 20 – 30V When no fault is detected in the electric system, the hydraulic pressure system is assumed to be abnormal. Carry out the related troubleshooting (H mode).
Circuit diagram related to left steering brake ECMV
20-426
D475A-3
TROUBLESHOOTING
A70XLK
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE (LK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
D475A-3
Error code Governor servo system right: Refer to table (LK) Trouble (Engine controller system) A70XLK • Abnormality was detected in the governor solenoid system or rack sensor system of the right bank (The governor command value does not agree with the rack sensor signal). • Flashes the caution lamp and turns on the caution buzzer. • Stops the right bank fuel injection pump injecting. • Only the left bank of the engine operates. • Method of reproducing error code: Start the engine. Cause Defective solenoid power 1 supply R system Defective right bank fuel 2 injection pump
Standard value in normal state/Remarks on troubleshooting The solenoid power supply R system may be defective. Carry out troubleshooting for error code [DB42KK]. The right bank fuel injection pump may have a defect in it. Check it directly. If neither of causes 1 and 2 is the cause of the trouble, the engine con3 Defective engine controller troller may be defective (Troubleshooting cannot be carried out since the defect is in the engine controller).
20-426-1 (1)
TROUBLESHOOTING
A70YLK
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE (LK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-426-2 (1)
Error code Governor servo system left: Refer to table (LK) Trouble (Engine controller system) A70YLK • Abnormality was detected in the governor solenoid system or rack sensor system of the left bank (The governor command value does not agree with the rack sensor signal). • Flashes the caution lamp and turns on the caution buzzer. • Stops the left bank fuel injection pump injecting. • Only the right bank of the engine operates. • Method of reproducing error code: Start the engine. Cause Defective solenoid power 1 supply L system Defective left bank fuel 2 injection pump
Standard value in normal state/Remarks on troubleshooting The solenoid power supply L system may be defective. Carry out troubleshooting for error code [DB43KK]. The left bank fuel injection pump may have a defect in it. Check it directly. If neither of causes 1 and 2 is the cause of the trouble, the engine con3 Defective engine controller troller may be defective (Troubleshooting cannot be carried out since the defect is in the engine controller).
D475A-3
TROUBLESHOOTING
A70YLK
Circuit diagram related to right governor cutout relay
D475A-3
20-426-3 (1)
TROUBLESHOOTING
ERROR CODE AA1ANX (AIR CLEANER:CLOGGING (NX))
ERROR CODE AA1ANX (AIR CLEANER:CLOGGING (NX)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
D475A-3
Error code AA1ANX
Trouble
Air Cleaner:Clogging (NX)
• During rotation of engine, air cleaner clogging caution lamp flashes. • Sounds caution buzzer (monitor panel function.) • If machine is operated as it is, engine may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Standard value in normal state/Remarks on troubleshooting Air cleaner clogging It is suspected that problem causing air cleaner clogging is occurring (When system is in normal at present or occurred in past. Investigate cause and damage condistate) tion, and correct it. Carry out troubleshooting of air cleaner clogging caution lamp system Defective air cleaner clogin accordance with “While the engine is operating, the emergency ging caution lampsystem warning item flashes” in E mode.
20-427
TROUBLESHOOTING
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-428
Error code AB00MA
Trouble
Alternator: Malfunction (MA) (Mechanical system)
• During rotation of engine, charge level caution lamp flashes.
• If machine is operated as it is, battery may be discharged. • Method of reproducing error code: Start engine.
1
2
Cause Standard value in normal state/Remarks on troubleshooting Defective battery charge It is suspected that problem causing defective battery charge is oc(When system is in normal curring at present or occurred in past. Investigate cause and damage state) condition, and correct it. Carry out troubleshooting of charge level caution lamp system in acDefective charge level caucordance with “While the engine is operating, the emergency warning tion lamp system item flashes” in E mode.
D475A-3
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) ERROR CODE ERROR B@BAZG CODE B@BAZK (ENGINE (ENGINE OIL: OIL PRESSURE OIL: LEVEL REDUCTION (ZG)) (ZK))
TROUBLESHOOTING
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
Error code B@BAZG
Trouble
Engine oil: Oil pressure reduction (ZG) (Mechanical system)
• During rotation of engine, engine oil pressure caution lamp flashes. • Turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, engine may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Standard value in normal state/Remarks on troubleshooting Engine oil pressure reduc- It is suspected that problem causing engine oil pressure reduction is tion (When system is in nor- occurring at present or occurred in past. Investigate cause and dammal state) age condition, and correct it. Carry out troubleshooting of engine oil pressure caution lamp system Defective engine oil presin accordance with “While the engine is operating, the emergency sure caution lamp system warning item flashes” in E mode.
ERROR CODE B@BAZK (ENGINE OIL: LEVEL REDUCTION (ZK)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
D475A-3
Error code B@BAZK
Trouble
Engine oil: Level reduction (ZK) (Mechanical system)
• During rotation of engine, engine oil level caution lamp flashes. • Turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, engine may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Standard value in normal state/Remarks on troubleshooting Engine oil level reduction It is suspected that problem causing engine oil level reduction is oc(When system is in normal curring at present or occurred in past. Investigate cause and damage state) condition, and correct it. Carry out troubleshooting of engine oil level caution lamp system in Defective engine oil level accordance with “While the engine is operating, the emergency warncaution lamp system ing item flashes” in E mode.
20-429
TROUBLESHOOTING
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS))
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-430
Error code B@BCNS
Trouble
Radiator coolant: Overheat (NS) (Mechanical system)
• During rotation of engine, engine water temperature caution lamp flashes. • Turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, engine may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Engine water temperature overheat (When system is in normal state) Defective engine water temperature caution lamp system
Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing engine water temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of engine water temperature caution lamp system in accordance with “While the engine is operating, the emergency warning item flashes” in E mode.
D475A-3
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) ERROR CODE ERROR B@BCZK CODE (RADIATOR B@CENS (POWER COOLANT: TRAIN LEVEL OIL:REDUCTION OVERHEAT (NS)) (ZK))
TROUBLESHOOTING
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
Error code B@BCZK
Trouble
Radiator coolant: Level reduction (ZK) (Mechanical system)
• When turning starting switch ON, radiator coolant caution lamp flashes.
• If machine is operated as it is, engine may be damaged. • Method of reproducing error code: Turn starting switch ON.
1
2
Cause Standard value in normal state/Remarks on troubleshooting Radiator coolant level reIt is suspected that problem causing radiator coolant level reduction duction (When system is in is occurring at present or occurred in past. Investigate cause and normal state) damage condition, and correct it. Carry out troubleshooting of radiator coolant level caution lamp sysDefective radiator coolant tem in accordance with “When the starting switch is turned on, the balevel caution lamp system sic check items flash” in E mode.
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT (NS)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
D475A-3
Error code B@CENS
Trouble
Power train oil: Overheat (NS) (Mechanical system)
• During rotation of engine, power train oil temperature caution lamp flashes. • Turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, power train may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Power train oil temperature overheat (When system is in normal state) Defective power train oil temperature overheat caution lamp system
Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing power train oil temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of power train oil temperature caution lamp system in accordance with “While the engine is operating, the emergency warning item flashes” in E mode.
20-431
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS)) ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (ZK)) (NS)) ERROR CODE B@HAZK (HYDRAULIC OIL: LEVEL REDUCTION
TROUBLESHOOTING
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
Error code B@HANS
Trouble
Hydraulic oil: Overheat (NS) (Mechanical system)
• During rotation of engine, hydraulic oil temperature caution lamp flashes. • Turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, work equipment circuit units may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Hydraulic oil temperature overheat (When system is in normal state) Defective hydraulic oil temperature caution lamp system
Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing hydraulic oil temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of hydraulic oil temperature caution lamp system in accordance with “During running of engine, emergency caution item flashes” in E mode.
ERROR CODE B@HAZK (HYDRAULIC OIL: LEVEL REDUCTION (ZK)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-432
Error code B@HAZK
Trouble
Hydraulic oil level reduction (ZK) (Mechanical system)
• During rotation of engine, hydraulic oil caution lamp flashes. • Turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, work equipment circuit units may be damaged. • Method of reproducing error code: Start engine.
1
2
Cause Hydraulic oil level reduction (When system is in normal state) Defective hydraulic oil level reduction caution lamp system
Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing hydraulic oil level reduction is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of hydraulic oil level caution lamp system in accordance with “During running of engine, emergency caution item flashes” in E mode.
D475A-3
TROUBLESHOOTING
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA))
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code D110KA
Trouble
Battery relay: Disconnection (KA) (Steering controller system)
• Current does not flow when outputting it to battery relay circuit. • Stops output to battery relay circuit. • Problem may occur in data writing to ROM (nonvolatile storage) of each controller. • Output state (voltage) to battery relay can be checked in monitoring mode. (Code 60600: Battery relay drive voltage) • Method of reproducing error code: Switch starting switch from ON to OFF. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective battery relay (Internal disconnection) Battery relay Continuity Between terminals SW – E Continue + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN3 (female) 4 – Resistance Max. 1Ω ing or defective contact in battery relay SW terminal connector) Wiring harness between battery relay terminal Resistance Max. 1Ω E – chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring harness (Contact with 24V Short circuit of wiring harness between STCN3 circuit) (female) 4 – battery relay terminal BR – KEY Voltage Max. 1V (female) 4 with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering controller STCN3 (female) Continuity Between 4 – chassis ground Continue
Circuit diagram related to battery relay
D475A-3
20-433
TROUBLESHOOTING
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB))
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code D110KB
Trouble
Battery relay: Short circuit (KB) (Steering controller system)
• Abnormal current flowed to battery relay circuit when outputting it. • Stops output to battery relay circuit. • Problem may occur in data writing to ROM (nonvolatile storage) of each controller. • Output state (voltage) to battery relay can be checked in monitoring mode. (Code 60600: Battery relay drive voltage) • Method of reproducing error code: Switch starting switch from ON to OFF. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery relay Continuity/resistance Defective battery relay (Internal short circuit) Between terminals SW – E Continue Between terminal SW – Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN3 (Contact with ground circuit) (female) 4 – battery relay terminal BR – KEY Resistance Min. 1MΩ (female) 4 with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN3 Starting switch Voltage Defective steering controller Between 4 – ON 20 – 30V chassis ground
Circuit diagram related to battery relay
20-434
D475A-3
TROUBLESHOOTING
ERROR CODE D130KA (NEUTRAL RELAY: DISCONNECTION (KA))
ERROR CODE D130KA (NEUTRAL RELAY: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D130KA
Neutral safety relay: Disconnection (KA) (Transmission controller system)
• 24V is not generated when ground of neutral safety relay circuit is interrupted. • Flashes caution lamp and turns on caution buzzer. • Stops ground output to neutral safety relay circuit. • Engine does not start. • Output state (voltage) to neutral safety relay can be checked in monitoring mode. (Code 50900: Neutral safety relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position). + This error code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side)
1
Cause Defective circuit breaker (CB3)
2
Defective neutral safety relay (Internal disconnection)
3
Defective disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
4
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
5
Defective transmission controller
Possible causes and standard value in normal state
D475A-3
Trouble
Standard value in normal state/Remarks on troubleshooting If circuit breaker is tripped, circuit probably has short circuit with ground. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NSF (male) Resistance Between 1 – 2 200 – 400Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) 8 – Resistance Max. 1Ω NSF (female) 2 Wiring harness between NSF (female) 1 – Resistance Max. 1Ω CB3 (1) + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) 8 – NSF (female) 2 with chassis ground Short circuit of wiring harness between NSF Resistance Min. 1MΩ (female) 1 – CB3 (1) with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 Parking lever Voltage Lock position 20 – 30V Between 8 – chassis ground Free position Max. 1V
20-435
TROUBLESHOOTING
ERROR CODE D130KA (NEUTRAL RELAY: DISCONNECTION (KA))
Circuit diagram related to neutral safety relay
20-436
D475A-3
TROUBLESHOOTING
ERROR CODE D130KB (NEUTRAL RELAY: SHORT CIRCUIT (KB))
ERROR CODE D130KB (NEUTRAL RELAY: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D130KB
Trouble
Neutral safety relay: Short circuit (KB) (Transmission controller system)
• Abnormal current flowed in neutral safety relay circuit at the time of ground output. • Flashes caution lamp and turns on caution buzzer. • Stops ground output to neutral safety relay circuit. • Engine does not start. • Output state (voltage) to neutral safety relay can be checked in monitoring mode. (Code 50900: Neutral safety relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position). + This error code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side) Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective neutral safety reNSF (male) Resistance lay (Internal short circuit) Between 1 – 2 200 – 400Ω + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN2 (female) 8 – NSF (female) 2 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN2 Parking lever Voltage troller Lock position 20 – 30V Between 8 – chassis ground Free position Max. 1V
Circuit diagram related to neutral safety relay
D475A-3
20-437
TROUBLESHOOTING
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine
Related information
Error code D161KA
Trouble
• 24V is not generated when ground output of back-up alarm relay circuit is interrupted. • Stops output to back-up alarm relay circuit. • Back-up alarm is not turned on. • Output state (voltage) to back-up alarm relay can be checked in monitoring mode. (Code 70900: Back-up alarm relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral position). + This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side) Cause 1
Defective fuse FS4-1
2
Defective back-up alarm relay (Internal disconnection)
3
Defective disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
4
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
5
Defective transmission controller
Possible causes and standard value in normal state
20-438
Back-up alarm relay: Disconnection (Transmission controller system)
Standard value in normal state/Remarks on troubleshooting If fuse is burnout, circuit probably has short circuit with chassis ground. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. BKA (male) Resistance Between 1 – 2 200 – 400Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) H – Resistance Max. 1Ω BKA (female) 2 Wiring harness between BKA (female) 1 – Resistance Max. 1Ω FS4-1 outlet port + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) H – BKA (female) 2 with chassis ground Short circuit of wiring harness between BKA Resistance Min. 1MΩ (female) 1 – FS4-1 outlet port with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 PCCS lever Voltage Neutral position 20 – 30V Between H – Max. 1V ⇔ 20 – 30V chassis ground Reverse position (Alternately)
D475A-3
TROUBLESHOOTING
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Circuit diagram related to back-up alarm relay
D475A-3
20-439
TROUBLESHOOTING
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine
Related information
Error code D161KB
Trouble
Back-up alarm relay: Short circuit (KB) (Transmission controller system)
• Abnormal current flowed in back-up alarm relay circuit at the time of ground output. • Stops output to back-up alarm relay circuit. • Back-up alarm is not turned on. • Output state (voltage) to back-up alarm relay can be checked in monitoring mode. (Code 70400: Back-up alarm relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse position). + This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side) Cause
1
Possible causes and standard value in normal state
2
3
20-440
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting Defective back-up alarm re- without turning starting switch ON. lay (Internal short circuit) BKA (male) Resistance Between 1 – 2 200 – 400Ω + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring harness (Contact with 24V Short circuit of wiring harness between circuit) Voltage Max. 1V TMCN2 (female) H – BKA (female) 2 with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 Parking lever Voltage Defective transmission controller Neutral position 20 – 30V Between H – Max. 1V ⇔ 20 – 30V chassis ground Reverse position (Alternately)
D475A-3
TROUBLESHOOTING
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Circuit diagram related to back-up alarm relay
D475A-3
20-441
TROUBLESHOOTING
D1D0KA
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D1D0KA
Trouble
• The output voltage to the right governor cutout relay is below 2 V. • None in particular.
• If cause 4 occurs, circuit breaker CB6 is turned OFF and other systems will also have abnormalities. • Method of reproducing error code: Turn the starting switch ON. Cause Defective right governor 1 cutout relay (Internal disconnection)
Defective engine shut down 2 relay (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection in wiring harness or defective contact in connector)
Short circuit with chassis 4 ground in wiring harness (Contact with ground circuit)
5 Defective engine controller
20-441-1 (1)
Governor cutout relay right: Disconnection (KA) (Engine controller system)
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. GCR (male) Resistance Between (1) and (2) 200 – 900 z You may replace the right governor cutout relay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDR (male) Resistance Between (3) and (6) Max. 1 z You may replace the engine shut down replay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch termiResistance Max. 1 z nal ACC and SDR (female) (3) Wiring harness between SDR (female) (6) and Resistance Max. 1 z GCR (female) (1) Wiring harness between GCR (female) (2) and Resistance Max. 1 z LE1 (female) (4) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch terminal ACC and SDR (female) (3), and other Resistance Min. 1 Mz related circuits and chassis ground Wiring harness between SDR (female) (6) and GCR (female) (1), and other related circuits and Resistance Min. 1 Mz chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE1 Voltage Between (4) and (13) 20 – 30 V
D475A-3
TROUBLESHOOTING
D1D0KB
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D1D0KB
Trouble
Governor cutout relay right: short circuit (KB) (Engine controller system)
• The output voltage to the right governor cutout relay is 5 – 15 V. • None in particular.
• Method of reproducing error code: Turn the starting switch OFF, then ON. Cause
Possible causes and standard value in normal state
D475A-3
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right governor GCR (male) Resistance 1 cutout relay Between (1) and (2) 200 – 900 z (Internal short circuit) You may replace the right governor cutout relay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with power 2 source in wiring harness Between wiring harness between GCR (Contact with 24-V circuit) (female) (2) and LE1 (female) (4) and chassis Voltage Max. 1 V ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller LE1 Voltage Between (4) and (13) Max. 1 V
20-441-2 (1)
TROUBLESHOOTING
D1D0KB
Circuit diagram related to right governor cutout relay
20-441-3 (1)
D475A-3
TROUBLESHOOTING
D1D1KA
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D1D1KA
Trouble
• The output voltage to the left governor cutout relay is below 2 V. • None in particular.
• If cause 4 occurs, circuit breaker CB6 is turned OFF and other systems will also have abnormalities. • Method of reproducing error code: Turn the starting switch ON. Cause Defective left governor 1 cutout relay (Internal disconnection)
Defective engine shut down 2 relay (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection in wiring harness or defective contact in connector)
Short circuit with chassis 4 ground in wiring harness (Contact with ground circuit)
5 Defective engine controller
D475A-3
Governor cutout relay left: Disconnection (KA) (Engine controller system)
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. GCL (male) Resistance Between (1) and (2) 200 – 900 z You may replace the left governor cutout relay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDR (male) Resistance Between (3) and (6) Max. 1 z You may replace the engine shut down replay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch termiResistance Max. 1 z nal ACC and SDR (female) (3) Wiring harness between SDR (female) (6) and Resistance Max. 1 z GCL (female) (1) Wiring harness between GCL (female) (2) and Resistance Max. 1 z LE1 (female) (5) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch terminal ACC and SDR (female) (3), and other Resistance Min. 1 Mz related circuits and chassis ground Wiring harness between SDR (female) (6) and GCL (female) (1), and other related circuits and Resistance Min. 1 Mz chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE1 Voltage Between (5) and (14) 20 – 30 V
20-441-4 (1)
TROUBLESHOOTING
D1D1KA
Circuit diagram related to left governor cutout relay
20-441-5 (1)
D475A-3
TROUBLESHOOTING
D1D1KB
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D1D1KB
Trouble
Governor cutout relay left: Short circuit (KB) (Engine controller system)
• The output voltage to the left governor cutout relay is 5 – 15 V. • None in particular.
• Method of reproducing error code: Turn the starting switch OFF, then ON. Cause
Possible causes and standard value in normal state
D475A-3
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left governor GCL (male) Resistance 1 cutout relay Between (1) and (2) 200 – 900 z (Internal short circuit) You may replace the left governor cutout relay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with power out turning starting switch ON. 2 source in wiring harness Between wiring harness between GCL (female) (Contact with 24-V circuit) Voltage Max. 1 V (2) and LE1 (female) (5) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller LE1 Voltage Between (5) and (14) Max. 1 V
20-441-6 (1)
TROUBLESHOOTING
D1D1KB
Circuit diagram related to left governor cutout relay
20-441-7 (1)
D475A-3
TROUBLESHOOTING
ERROR CODE D5ZFKA (NEUTRAL SIGNAL 1: DISCONNECTION (KA))
ERROR CODE D5ZFKA (NEUTRAL SIGNAL 1: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D5ZFKA
Trouble
Neutral signal 1: Disconnection (Transmission controller system)
• 24V is not generated when ground output of neutral safety relay circuit is interrupted. • Stops output to neutral signal 1 circuit.
• Output state (ON – OFF) to Neutral signal 1 can be checked in monitoring mode. (Code 40909: transmission controller ON/OFF output) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral position). Cause 1
Defective disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Defective transmission controller
4
Defective engine controller
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) I – Resistance Max. 1Ω CN5 (female) 5 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) I – CN5 (female) 5 with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 (male) PCCS lever Voltage Neutral position Max.1V Between I – Forward-reverse chassis ground 20 – 30V position ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECN5 (male) Voltage Between 5 – chassis 20 – 30V ground
Circuit diagram related to Neutral signal 1
20-442 (1)
D475A-3
TROUBLESHOOTING
ERROR CODE D5ZFKB (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB))
ERROR CODE D5ZFKB (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D5ZFKB
Trouble
Neutral signal 1: Short circuit (KB) (Transmission controller system)
• Abnormal current flowed in Neutral signal 1 circuit at the time of ground output. • Stops output to Neutral signal 1 relay circuit.
• Output state (ON – OFF) to Neutral signal 1 can be checked in monitoring mode. (Code 40909: transmission controller ON/OFF output) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse position). Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring harness (Contact with 24V Short circuit of wiring harness between circuit) TMCN2 (female) I – CN5 (female) 5 with Voltage Max. 1V chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 Parking lever Voltage Defective transmission controller Neutral position Max.1V Between I – Forward Reverse chassis ground 20 – 30V position ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller CN5 (male) Voltage Between 5 – chassis 20 – 30V ground
Circuit diagram related to Neutral signal 1
D475A-3
20-443 (1)
TROUBLESHOOTING
D5ZFL4
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNALS DO NOT AGREE (L4)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code Engine controller neutral signal: ON and OFF signals do not agree (L4) Trouble (Engine controller system) D5ZFL4 • The neutral signal circuit from the transmission controller to the engine controller is disconnected or has a grounding fault. • None in particular.
Cause
Possible causes and standard value in normal state
20-443-1 (1)
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Wiring harness between TMCN2 (female) (9) Resistance Max. 1 z harness and LE51 (female) (6) 1 (Disconnection in wiring harness or defective contact aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. in connector) Wiring harness between TMCN2 (female) (19) Resistance Max. 1 z and LE51 (female) (5) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMCN2 (female) (9) and LE51 (female) (6) and chassis Resistance Min. 1 Mz Short circuit with chassis ground ground in wiring harness (Contact with ground circuit) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMCN2 (female) (19) and LE51 (female) (5) and chas- Resistance Min. 1 Mz sis ground 2 aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between TMCN2 Voltage Max. 1 V (female) (9) and LE51 (female) (6) Short circuit with power source in wiring harness aPrepare with starting switch OFF, then turn starting switch ON and (Contact with 24 V circuit) carry out troubleshooting. Between wiring harness between TMCN2 (female) (19) and LE51 (female) (5) and chasVoltage Max. 1 V sis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 PCCS lever Voltage 3 Defective engine controller Neutral Max. 1V Between (9), (19) and chassis ground Forward or reverse 20 – 30 V
D475A-3
TROUBLESHOOTING
D5ZFL4
Circuit diagram related to engine controller neutral signal
D475A-3
20-443-2 (1)
TROUBLESHOOTING
ERROR CODE D5ZGKA (NEUTRAL SIGNAL 2: DISCONNECTION (KA))
ERROR CODE D5ZGKA (NEUTRAL SIGNAL 2: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D5ZGKA
Trouble
Neutral signal 2: Disconnection (Transmission controller system)
• 24V is not generated when ground output of neutral safety relay circuit is interrupted. • Stops output to Neutral signal 2 circuit.
• Output state (ON – OFF) to Neutral signal 2 can be checked in monitoring mode. (Code 40909: transmission controller ON/OFF output) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral position). Cause 1
Defective disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Defective transmission controller
4
Defective engine controller
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) 9 – Resistance Max. 1Ω BKA (female) 6 ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) 9 – CN5 (female) 6 with chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 PCCS lever Voltage Neutral position Max.1V Between 9 – Forward – Reverse chassis ground 20 – 30V position ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CN5 (male) Voltage Between 6 – chassis 20 – 30V ground
Circuit diagram related to Newtral signal 2
20-444 (1)
D475A-3
TROUBLESHOOTING
ERROR CODE D5ZGKB (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB))
ERROR CODE D5ZGKB (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D5ZGKB
Trouble
Neutral signal 2: Short circuit (KB) (Transmission controller system)
• Abnormal current flowed in Neutral signal 2 circuit at the time of ground output. • Stops output to Neutral signal 2 circuit.
• Output state (ON – OFF) to Neutral signal 2 can be checked in monitoring mode. (Code 40909: transmission controller ON/OFF output) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse position). Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring harness (Contact with 24V Short circuit of wiring harness between circuit) TMCN2 (female) 9 – CN5 (female) 6 with Voltage Max. 1V chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 Parking lever Voltage Defective transmission controller Neutral position Max.1V Between 9 – Forward – Reverse chassis ground 20 – 30V position ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller CN5 (male) Voltage Between 6-chassis 20 – 30V ground
Circuit diagram related to Newtral signal 2
D475A-3
20-445 (1)
TROUBLESHOOTING
D5ZKKX
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code D5ZKKX
Trouble
• The input voltage of the shoe slip control signal is below 0.3 V or above 4.75 V. • Flashes the caution lamp and turns on the caution buzzer. • Keeps the last value in the normal range. • Stops the shoe slip function after the machine stops. • The shoe slip control does not operate normally. • Method of reproducing error code: Turn the starting switch ON or start the engine in the SSC mode. Cause Disconnection in wiring harness (Disconnection in 1 wiring harness or defective contact in connector) Short circuit with chassis 2 ground in wiring harness (Contact with ground circuit)
Possible causes and standard value in normal state
Chassis throttle signal: Out of input signal range (KX) (Engine controller system)
Short circuit with power 3 source in wiring harness (Contact with 24-V circuit)
4 Defective engine controller
5 Defective steering controller
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LE31 (female) (9) and Resistance Max. 1 z STCN2 (female) (11) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE31 (female) (9) and STCN 2 (female) (11) and Resistance Min. 1M z chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE31 (female) (9) and STCN 2 (female) (11) and Voltage Max. 1 V chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE31 Voltage Between (9) and chassis ground 0.3 – 4.75 V aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Voltage Between (11) and chassis ground 0.3 – 4.75 V
Circuit diagram related to shoe slip control signal
20-445-1 (1)
D475A-3
ERROR CODE DAFRKR (MONITOR PANEL “CAN” COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
TROUBLESHOOTING
ERROR CODE DAFRKR (MONITOR PANEL “CAN” COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DAFRKR
Trouble
• Monitor panel cannot recognize steering controller with CAN communication circuit. • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1.
• Method of reproducing error code: Turn starting switch ON. Cause
1
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Hot short circuit in wiring harness (Contact with 24V circuit)
4
Defective CAN terminal resistance
5
Defective monitor panel or defective steering controller
Possible causes and standard value in normal state
20-446
Monitor panel CAN communication: Defective communication (KR) (Monitor panel system)
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) 1, 2 – Resistance Max. 1Ω STCN2 (female) V – TMCN2 (female) V – CA1 (female) A – CA2 (female) A Wiring harness between S04 (female) 3 4 – Resistance Max. 1Ω STCN2 (female) L – TMCN2 (female) L – CA1 (female) B – CA2 (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 Resistance Min. 1MΩ (female) V – CA1 (female) A – CA2 (female) A with chassis ground Short circuit of wiring harness between S04 (female) 3, 4 – STCN2 (female) L – TMCN2 Resistance Min. 1MΩ (female) L – CA1 (female) B – CA2 (female) B with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 Voltage Max. 1V (female) V – CA1 (female) A – CA2 (female) A with chassis ground hort circuit of wiring harness between S04 (female) 3, 4 – STCN2 (female) L – TMCN2 Voltage Max. 1V (female) L – CA1 (female) B – CA2 (female) B with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CA1 (male), CA2 (male) Resistance Between A – B 40 – 80Ω If no problem is found in causes 1 to 4, it is suspected that monitor panel or steering controller is defective. (Troubleshooting cannot be carried out since it is internal defect.)
D475A-3
TROUBLESHOOTING
ERROR CODE DAFRKR (MONITOR PANEL “CAN” COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to CAN communication
D475A-3
20-447
TROUBLESHOOTING
ERROR CODE DAQ0KK SOURCE VOLTAGE ERROR (TRANSMISSION CODE DAQ0KK CONTROLLER: (TRANSMISSION CONTROLLER: REDUCTION/INPUT (KK)) (KK)) SOURCE VOLTAGE REDUCTION/INPUT
ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DAQ0KK
Transmission controller power supply: Source voltage reduction/input (KK) (Transmission controller system)
• Source voltage of transmission controller is below 17V. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Monitor panel may not display normally. Relays and solenoids cannot operate, not allowing system operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Charge level (voltage) of battery can be checked in monitoring mode. (Code 03200: Battery voltage) • Method of reproducing error code: Turn starting switch ON.
1
Cause Defective circuit breaker (CB3)
2
Defective fusible link (96A)
3
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
4
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
5
Defective transmission controller
Possible causes and standard value in normal state
20-448
Trouble
Standard value in normal state/Remarks on troubleshooting If circuit breaker is tripped, circuit probably has short circuit with chassis ground. If fusible link is burnout, circuit probably has short circuit with chassis ground. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) 1, Resistance Max. 1Ω A – CB3 (1) Wiring harness between CB3 (2) – fusible link Resistance Max. 1Ω – battery relay terminal C Wiring harness between TMCN3 (female) K Resistance Max. 1Ω U V W – chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) 1, A – CB3 (1) with chassis Resistance Min. 1MΩ ground Short circuit of wiring harness between CB3 (2) Resistance Min. 1MΩ – fusible link – battery relay terminal C with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 Voltage Between 1, A – K, U, V, W 20 – 30V
D475A-3
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: CONTROLLER (KK)) (KT)) SOURCE VOLTAGE REDUCTION/INPUT
TROUBLESHOOTING
Circuit diagram related to transmission controller power supply
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
D475A-3
Error code DAQ0KT
Trouble
Transmission controller: abnormality in controller (KT) (Transmission controller system)
• Information of ROM (nonvolatile storage) of transmission controller is not normal. • Flashes caution lamp and turns on caution buzzer. • Sets default internal adjustment value. • Gear shift feeling of transmission may become worse. • Method of reproducing error code: Turn starting switch ON. Cause
1
Standard value in normal state/Remarks on troubleshooting Troubleshooting cannot be carried out since it is internal defect. Defective transmission con(It is no problem even if you use controller unless no visible problem troller appears on machine.)
20-449
TROUBLESHOOTING
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code CALL 03 Contents of trouble Action of controller Problem that appears on machine Related information
• • • • • • • •
Error code Transmission controller potentiometer power supply: Source voltage Trouble reduction/input (KK) (Transmission controller system) DAQ5KK Voltage of 5V power supply circuit of transmission controller sensor is below 4.5V or above 5.5V. Abnormal current flowed in 5V power supply circuit of transmission controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output to 5V power supply circuit if abnormal voltage flows Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 an R1.
• Method of reproducing error code: Turn starting switch ON. Cause
1
2 Possible causes and standard value in normal state
3
4
5
20-450
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then and hold it in the OFF position during troubleshooting. TL1 (male) Resistance L J Between – 2kΩ ± 20% Defective forward-reverse Sensor 1 (FR3) potentiometer (Internal Between L – Min. 1MΩ short circuit) chassis ground Between O – Q 2kΩ ± 20% Sensor 2 (FR4) Between O – Min. 1MΩ chassis ground + Prepare with starting switch OFF, then hold it in the OFF position during troubleshooting. CSL (male) Resistance Between A – C 4.6 – 6.0kΩ Left yoke angle sensor Defective yoke angle senBetween C – chassis Min. 1MΩ sor ground CSR (male) Resistance Between A – C 4.6 – 6.0kΩ Right yoke angle sensor Between C – chassis Min. 1MΩ ground + Prepare with starting switch OFF, then hold it in the OFF position during troubleshooting. Short circuit with chassis Short circuit of wiring harness between ground in wiring harness (Contact with ground circuit) TMCN1 (female) L – TL1 (female) L – TL1 Resistance Min. 1MΩ (female) O – CSL (female) A, – CSR (female) A with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring Short circuit of wiring harness between harness (Contact with 24V TMCN1 (female) L – TL1 (female) L – TL1 circuit) Voltage Max. 1V (female) O – CSL (female) A, – CSR (female) A with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN1 Voltage troller Between L – K 4.5 – 5.5V
D475A-3
TROUBLESHOOTING
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
Circuit diagram related to transmission controller 5V power supply
D475A-3
20-451
TROUBLESHOOTING
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code Transmission controller sensor power supply: Source voltage reducTrouble tion/input (KK) (Transmission controller system) DAQ6KK • Voltage of 24V power supply circuit of transmission controller sensor is below 17V or above 30V. • Abnormal current flowed in 24V power supply circuit of transmission controller sensor. • Stops output to 24V power supply circuit if abnormal voltage flows • Oil pressure of work equipment cannot be monitored in service mode. • Method of reproducing error code: Turn starting switch ON. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting It is internal defect if error code lights on (reset disDefective work equipment play) when disconnecting right connector. large pump oil pressure HP 1 + Disconnect connector with starting switch OFF, then sensor (Internal short circonnector turn starting switch ON and carry out troubleshootcuit) ing. It is internal defect if error code lights on (reset disDefective work equipment play) when disconnecting right connector. large pump oil pressure HP 2 + Disconnect connector with starting switch OFF, then sensor (Internal short circonnector turn starting switch ON and carry out troubleshootcuit) ing. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) F – HHP (female) B with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN1 Voltage troller F–K 20 – 30V
Circuit diagram related to transmission controller 24V power supply
20-452
D475A-3
ERROR CODE DAQ9KQ (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
TROUBLESHOOTING
ERROR CODE DAQ9KQ (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DAQ9KQ
Trouble
• Internal spec. setting of transmission controller is inconsistent with spec. set signal. • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops all outputs to transmission controller. Limits operation of engine, transmission, and brake. Machine does not operate at all. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
• Method of reproducing error code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Transmission controller type collation/type select signal inconsistency (KQ) (Transmission controller system)
1
Defective transmission controller adjustment
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting It is normal if error code lights on (reset display) after carrying out adjustment mode. • Adjustment code: 0003: Transmission controller spec. + Prepare with starting switch OFF, carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Max. 1Ω TMCN3 (female) @ with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 Voltage Between @ – chassis ground Max. 1V
Circuit diagram related to transmission controller type select
D475A-3
20-453
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
TROUBLESHOOTING
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
• • • • • •
Error code Transmission controller CAN communication: Defective communicaTrouble tion (KR) (Transmission controller and realer system) DAQRKR Transmission controller cannot recognize monitor panel or steering controller, with CAN communication circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1.
• Method of reproducing error code: Turn starting switch ON. Cause
1
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Hot short circuit in wiring harness (Contact with 24V circuit)
4
Defective CAN terminal resistance
5
Defective monitor panel, de- If no problem is found in causes 1 to 4, it is suspected that monitor fective transmission controlpanel, transmission controller, or steering controller is defective. ler or defective steering (Troubleshooting cannot be carried out since it is internal defect.) controller
Possible causes and standard value in normal state
20-454
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) 1, 2 – Resistance Max. 1Ω STCN2 (female) V – TMCN2 (female) V – CA1 (female) A – CA2 (female) A Wiring harness between S04 (female) 3 4 – Resistance Max. 1Ω STCN2 (female) L – TMCN2 (female) L – CA1 (female) B – CA2 (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 Resistance Min. 1MΩ (female) V – CA1 (female) A – CA2 (female) A with chassis ground Short circuit of wiring harness between S04 (female) 3, 4 – STCN2 (female) L – TMCN2 Resistance Min. 1MΩ (female) L – CA1 (female) B – CA2 (female) B with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 Voltage Max. 1V (female) V – CA1 (female) A – CA2 (female) A with chassis ground Short circuit of wiring harness between S04 (female) 3, 4 – STCN2 (female) L – TMCN2 Voltage Max. 1V (female) L – CA1 (female) B – CA2 (female) B with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CA1 (male), CA2 (male) Resistance Between A – B 40 – 80Ω
D475A-3
TROUBLESHOOTING
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to CAN communication
D475A-3
20-455
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
TROUBLESHOOTING
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DAQSKR
Trouble
• Transmission controller cannot recognize S-NET. • Takes no particular action. • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system. • Method of reproducing error code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
20-456
Transmission controller S-NET communication: Defective communication (KR) (Transmission controller system)
1
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Hot short circuit in wiring harness (Contact with 24V circuit)
4
Defective monitor panel (Switch module)
5
Defective transmission controller
6
Defective steering controller
7
Defective engine controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) K – Resistance Max. 1Ω S01 (female) 8 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) K – S01 (female) 8 with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN2 (female) K – S01 (female) 8 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S01 Voltage Between 8 – chassis ground 6 – 9V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN2 Voltage Between K – U 6 – 9V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Voltage Between K – U 6 – 9V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECN4 Voltage Between 0 – 6, B 6 – 9V
D475A-3
TROUBLESHOOTING
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to S-NET communication
D475A-3
20-457
ERROR CODE DB30KK CONTROLLER: SOURCE VOLTAGE ERROR(STEERING CODE DB30KK (STEERING CONTROLLER: REDUCTION/INPUT (KK)) SOURCE VOLTAGE REDUCTION/INPUT (KK))
TROUBLESHOOTING
ERROR CODE DB30KK (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/ INPUT (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DB30KK
Steering controller power supply: Source voltage reduction/input (KK) (Steering controller system)
• Source voltage of steering controller is below 17V. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Monitor panel may not display normally. Relays and solenoids cannot operate, not allowing system operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Charge level (voltage) of battery can be checked in monitoring mode. (Code 03200: Battery voltage) • Method of reproducing error code: Turn starting switch ON.
1
Cause Defective circuit breaker (CB1)
2
Defective fusible link (96A)
3
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
4
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
5
Defective steering controller
Possible causes and standard value in normal state
20-458
Trouble
Standard value in normal state/Remarks on troubleshooting If circuit breaker is tripped, circuit probably has short circuit with chassis ground. If fusible link is burnout, circuit probably has short circuit with chassis ground. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) 1 A Resistance Max. 1Ω – CB1 1 Wiring harness between CB1 (2) – fusible link Resistance Max. 1Ω – battery relay terminal M Wiring harness between STCN3 (female) K, Resistance Max. 1Ω U, V, W – chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN3 Resistance Min. 1MΩ (female) 1, A – CB1 (1) with chassis ground Short circuit of wiring harness between CB1 (2)– fusible link – battery relay terminal M with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. STCN3 Voltage Between 1, A – K, U, V, W 20 – 30V
D475A-3
ERROR CODE DB30KT (STEERING CONTROLLER: ABNORMALITY IN ERROR CODE DB30KK (STEERING CONTROLLER: CONTROLLER (KK)) (KT)) SOURCE VOLTAGE REDUCTION/INPUT
TROUBLESHOOTING
Circuit diagram related to steering controller power supply
ERROR CODE DB30KT (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
D475A-3
Error code DB30KT
Trouble
Steering controller power supply: Abnormality in controller (KT) (Steering controller system)
• Information of ROM (nonvolatile storage) of steering controller is not normal. • Sets default internal adjustment value. • Steering performance may be reduced. • Brake performance may be reduced. • Method of reproducing error code: Turn starting switch ON. Cause
1
Standard value in normal state/Remarks on troubleshooting Troubleshooting cannot be carried out since it is internal defect. (It is Defective steering controller no problem even if you use controller unless no visible problem appears on machine.)
20-459
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
TROUBLESHOOTING
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
• • • • • • • •
Error code Steering controller potentiometer power supply: Source voltage reTrouble duction (KK) (Steering controller system) DB35KK Voltage of 5V power supply circuit of steering controller sensor is below 4.5V or above 5.5V. Abnormal current flowed in 5V power supply circuit of steering controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output to 5V power supply circuit if abnormal voltage flows. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 an R1.
• Method of reproducing error code: Turn starting switch ON. Cause 1
Defective brake potentiometer (Internal short circuit)
2
Defective acceleration sensor (Internal short circuit)
3
Defective steering potentiometer (Internal short circuit)
4
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
5
Hot short circuit in wiring harness (Contact with 24V circuit)
6
Defective steering controller
Possible causes and standard value in normal state
20-460
Standard value in normal state/Remarks on troubleshooting It is internal defect if error code lights on (reset display) when disconnecting right connector. BRK + Disconnect connector with starting switch OFF, then connector turn starting switch ON and carry out troubleshooting. It is internal defect if error code lights on (reset display) when disconnecting right connector. SSA + Disconnect connector with starting switch OFF, then connector turn starting switch ON and carry out troubleshooting. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL1 (male) Resistance Between A – G 2kΩ ± 20% Sensor 1 (ST1) Between A – Min. 1MΩ chassis ground Between M – F 2kΩ ± 20% Sensor 2 (ST2) Between M – Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN1 (female) L – TL1 (female) A – TL1 (female) M Resistance Min. 1MΩ – BRK (female) C – SSA (female) 1 with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN1 (female) L – TL1 (female) A – TL1 (female) M Voltage Max. 1V – BRK (female) C – SSA (female) 1 with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. STCN1 Voltage Between L – K 4.5 – 5.5V
D475A-3
TROUBLESHOOTING
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
Circuit diagram related to steering controller 5V power supply
D475A-3
20-461
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK))
TROUBLESHOOTING
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
• • • • • • • •
Error code Steering controller sensor power supply: Source voltage reduction/inTrouble put (KK) (Steering controller system) DB36KK Voltage of 24V power supply circuit of steering controller sensor is below 17V or above 30V. Abnormal current flowed in 24V power supply circuit of steering controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output of 24V power supply circuit if abnormal voltage flows. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 an R1.
• Method of reproducing error code: Turn starting switch ON. Cause
1 Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting It is internal defect if error code lights on (reset display) Defective blade pitch angle when disconnecting right connector. PAS sensor (Internal short cir+ Disconnect connector with starting switch OFF, then connector cuit) turn starting switch ON and carry out troubleshooting. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN1 (Contact with ground circuit) (female) F – PT1 (female) C with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between F – K 20 – 30V
Circuit diagram related to steering controller 24V power supply
20-462
D475A-3
ERROR CODE DB39KQ (STEERING CONTROLLER TYPETYPE COLLATION: TYPE ERROR CODE DB39KQ (STEERING CONTROLLER COLLATION: SELECTSIGNAL SIGNALINCONSISTENCY INCONSISTENCY (KQ)) (KQ)) TYPE SELECT
TROUBLESHOOTING
ERROR CODE DB39KQ (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DB39KQ
Trouble
• Internal spec. setting of steering controller is inconsistent with spec. set signal. • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops all outputs of steering controller. Limits operation of engine, transmission, and brake. Machine does not operate at all. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
• Method of reproducing error code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Steering controller type collation: Type select signal inconsistency (KQ) (Steering controller system)
1
Defective steering controller adjustment
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Defective steering controller
Standard value in normal state/Remarks on troubleshooting It is normal if error code indicates P (reset display) after carrying out adjustment mode. • Adjustment code: 0002 (Steering controller spec. set) + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) J – Resistance Max. 1Ω chassis ground Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. STCN3 Voltage Between J – chassis ground Max. 1V
Circuit diagram related to steering controller type select
D475A-3
20-463
TROUBLESHOOTING
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
• • • • • •
Error code Steering controller CAN communication: Defective communication Trouble (KR) (Transmission controller and realer system) DB3RKR Steering controller cannot recognize monitor panel or transmission controller with CAN communication circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1.
• Method of reproducing error code: Turn starting switch ON. Cause
1
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Hot short circuit in wiring harness (Contact with 24V circuit)
4
Defective CAN terminal resistance
5
Defective monitor panel, deIf no problem is found in causes 1 to 4, it is suspected that monitor fective transmission controlpanel, transmission controller, or steering controller is defecler or defective steering tive.(Troubleshooting cannot be carried out since it is internal defect.) controller
Possible causes and standard value in normal state
20-464
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 (female) Resistance Max. 1Ω V – CA1 (female) A – CA2 (female) A Wiring harness between S04 (female) 3 4 – Resistance Max. 1Ω STCN2 (female) L – TMCN2 (female) L – CA1 (female) B – CA2 (female) + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 Resistance Min. 1MΩ (female) V – CA1 (female) A – CA2 (female) A with chassis ground Short circuit of wiring harness between S04 (female) 3, 4 – STCN2 (female) L – TMCN2 Resistance Min. 1MΩ (female) L – CA1 (female) B – CA2 (female) B with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between S04 (female) 1, 2 – STCN2 (female) V – TMCN2 Voltage Max. 1V (female) V – CA1 (female) A – CA2 (female) A with chassis ground Short circuit of wiring harness between S04 (female) 3, 4 – STCN2 (female) L – TMCN2 Voltage Max. 1V (female) L – CA1 (female) B – CA2 (female) B with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CA1 (male), CA2 (male) Resistance Between A – B 40 – 80Ω
D475A-3
TROUBLESHOOTING
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to CAN communication
D475A-3
20-465
TROUBLESHOOTING
ERROR CODE DB3SKR (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE DB3SKR (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DA3SKR
Trouble
• Transmission controller cannot recognize S-NET. • Takes no particular action. • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system. • Method of reproducing error code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
20-466
Steering controller S-NET communication: Defective communication (KR) (Transmission controller system)
1
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Hot short circuit in wiring harness (Contact with 24V circuit)
4
Defective monitor panel (Switch module)
5
Defective steering controller
6
Defective transmission controller
7
Defective engine controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN2 (female) K – Resistance Max. 1Ω S01 (female) 8 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN2 Resistance Min. 1MΩ (female) K – S01 (female) 8 with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN2 (female) K – S01 (female) 8 with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. S01 Voltage Between 8 – chassis ground 6 – 9V + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. STCN2 Voltage Between K – U 6 – 9V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Voltage Between K – U 6 – 9V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECN4 Voltage Between 0 – 6, B 6 – 9V
D475A-3
TROUBLESHOOTING
DB40KK
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
D475A-3
Error code DB40KK
Trouble
Engine controller: Lowering of source voltage (KK) (Engine controller system)
• The source voltage of the engine controller is below 17 V. • Flashes the caution lamp and turns on the caution buzzer.
• Method of reproducing error code: Turn the starting switch ON. Cause Defective switch power 1 supply system of controller Defective backup power 2 supply system of controller
Standard value in normal state/Remarks on troubleshooting The switch power supply system of the controller may be defective. Carry out troubleshooting for error code [DB41KK]. The backup power supply system of the controller may be defective. Carry out troubleshooting for error code [DB43KK]. If neither of causes 1 and 2 is the cause of the trouble, the engine con3 Defective engine controller troller may be defective (Troubleshooting cannot be carried out since the defect is in the engine controller).
20-466-1 (1)
TROUBLESHOOTING
DB41KK
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DB41KK
Trouble
• The switch source voltage of the controller is 5 V or more below the backup source voltage. • Flashes the caution lamp and turns on the caution buzzer. • Controls with the backup power supply.
• If cause 3 occurs, circuit breaker CB6 is turned OFF and other systems will also have abnormalities. • Method of reproducing error code: Turn the starting switch ON. Cause Defective engine shut down 1 relay (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)
Short circuit with chassis 3 ground in wiring harness (Contact with ground circuit)
4 Defective engine controller
20-466-2 (1)
Switch power supply: Lowering of source voltage (KK) (Engine controller system)
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDR (male) Resistance Between (3) and (6) Max. 1 z You may replace the engine shut down replay with another one and check by reproducing the error code. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch termiResistance Max. 1 z nal ACC and SDR (female) (3) Wiring harness between SDR (female) (6) and Resistance Max. 1 z LE1 (female) (9), (17) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between starting switch terminal ACC and SDR (female) (3), and other Resistance Min. 1 Mz related circuits and chassis ground Wiring harness between SDR (female) (6) and LE1 (female) (9), (17), and other related circuits Resistance Min. 1 Mz and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE1 Voltage Between (9), (17) and (8), (16) 20 – 30 V
D475A-3
TROUBLESHOOTING
DB41KK
Circuit diagram related to controller power source (constant and switch)
D475A-3
20-466-3 (1)
TROUBLESHOOTING
DB42KK
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-466-4 (1)
Error code Solenoid power supply 1: Lowering of source voltage (KK) Trouble (Engine controller system) DB42KK • While the switch source voltage of the controller is above 24 V, the voltage of solenoid power supply R is below 5 V. • Flashes the caution lamp and turns on the caution buzzer. • Only the left bank of the engine operates. • Method of reproducing error code: Turn the starting switch OFF. Cause Standard value in normal state/Remarks on troubleshooting Defective right governor Replace the right governor cutout relay with another relay. 1 GCR cutout relay (Internal defect) If the condition becomes normal, the relay is defective. aPrepare with starting switch OFF, then carry out troubleshooting withDisconnection in wiring out turning starting switch ON. harness (Disconnection in 2 wiring harness or defective Wiring harness between LE2 (female) (1) and Resistance Max. 1 z contact in connector) GCR (female) (6) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. 3 ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (1) and GCR (female) (6) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller LE2 Voltage Between (1) and (21) 20 – 30 V
D475A-3
TROUBLESHOOTING
DB42KK
Circuit diagram related to right governor cutout relay
D475A-3
20-466-5 (1)
TROUBLESHOOTING
DB43KK
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-466-6 (1)
Error code DB43KK
Trouble
Backup power supply: Lowering of source voltage (KK) (Engine controller system)
• The backup source voltage of the controller is 5 V or more below the switch source voltage. • Flashes the caution lamp and turns on the caution buzzer. • Controls with the switch power supply.
• If cause 2 occurs, circuit breaker CB6 is turned OFF and other systems will also have abnormalities. • Method of reproducing error code: Turn the starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting withDisconnection in wiring out turning starting switch ON. harness (Disconnection in 1 wiring harness or defective Wiring harness between FSB (male) (3) and Resistance Max. 1 z contact in connector) LE1 (female) (7) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. 2 ground in wiring harness Between wiring harness between FSB (male) (Contact with ground circuit) Resistance Min. 1 Mz (3) and LE1 (female) (7) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller LE1 Voltage Between (7) and (8), (16) 20 – 30 V
D475A-3
TROUBLESHOOTING
DB43KK
Circuit diagram related to controller power supply (constant/switch)
D475A-3
20-466-7 (1)
TROUBLESHOOTING
DB44KK
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Possible causes and standard value in normal state
20-466-8 (1)
Error code Solenoid power supply 2: Lowering of source voltage (KK) Trouble (Engine controller system) DB44KK • While the switch source voltage of the controller is above 24 V, the voltage of solenoid power supply L is below 5 V. • Flashes the caution lamp and turns on the caution buzzer. • Only the right bank of the engine operates. • Method of reproducing error code: Turn the starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Defective left governor cut- Replace the left governor cutout relay with another relay. If 1 GCL out relay (Internal defect) the condition becomes normal, the relay is defective. aPrepare with starting switch OFF, then carry out troubleshooting withDisconnection in wiring out turning starting switch ON. harness (Disconnection in 2 wiring harness or defective Wiring harness between LE2 (female) (12) and Resistance Max. 1 z contact in connector) GCL (female) (6) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. 3 ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (12) and GCL (female) (6) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller LE2 Voltage Between (12) and (21) 20 – 30 V
D475A-3
TROUBLESHOOTING
DB44KK
Circuit diagram related to left governor cutout relay
D475A-3
20-466-9 (1)
TROUBLESHOOTING
DB45KP
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DB45KP
Trouble
• The source voltage of the rack sensor is below 3.4 V. • Flashes the caution lamp and turns on the caution buzzer. • Lowers the engine output by 20%. • The output is lowered. • Method of reproducing error code: Turn the starting switch OFF. Cause Defective rack sensor of right or left bank 1 (Internal disconnection or short circuit)
Possible causes and standard value in normal state
20-466-10 (1)
Rack sensor power supply: Lowering of output voltage (KP) (Engine controller system)
Standard value in normal state/Remarks on troubleshooting Disconnect the devices at right in order. If the error code disappears when a device is disconnected, that device has a defect in it.
Rack sensor of right bank
Connector E13
Rack sensor of left bank
Connector E9
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LE2 (female) (16) and E13 (female) (1) [Rack sensor system of right Resistance Max. 1 z bank] Disconnection in wiring Wiring harness between LE2 (female) (16) and harness (Disconnection in E9 (female) (1) [Rack sensor system of left Resistance Max. 1 z 2 wiring harness or defective bank] contact in connector) Wiring harness between LE31 (female) (16) and E13 (female) (2) [Rack sensor system of Resistance Max. 1 z right bank] Wiring harness between LE31 (female) (16) and E9 (female) (2) [Rack sensor system of left Resistance Max. 1 z bank] aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE2 (female) Short circuit with chassis (16) and E13 (female) (1) and chassis ground Resistance Min. 1 Mz 3 ground in wiring harness [Rack sensor system of right bank] (Contact with ground circuit) Between wiring harness between LE2 (female) (16) and E9 (female) (1) and chassis ground Resistance Min. 1 Mz [Rack sensor system of left bank] aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller LE2, LE31 Voltage Between LE2 (16) and LE31 (16) 4.6 – 5.4 V
D475A-3
TROUBLESHOOTING
DB45KP
Circuit diagram related to right bank rack sensor and left bank rack sensor
D475A-3
20-466-11 (1)
TROUBLESHOOTING
DB49KM
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DB49KM
Trouble
Wrong connection of connector: Mistake in operation or setting (KM) (Engine controller system)
• Wrong connection of connectors LE31 and LE51 of the controller is detected. • Flashes the caution lamp and turns on the caution buzzer. • The engine cannot be started. • Method of reproducing error code: Turn the starting switch ON. Cause Wrong connection of 1 controller connectors
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting Connectors LE31 and LE51 may be connected wrongly (inversely). Check them directly. aPrepare with starting switch OFF, then carry out troubleshooting withDisconnection in wiring out turning starting switch ON. harness (Disconnection in 2 wiring harness or defective Wiring harness between LE51 (female) (1) and Resistance Max. 1 z contact in connector) chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective engine controller LE51 Voltage Between (1) and chassis ground Max. 1 V
Circuit diagram related to connection of connector check harness
20-466-12 (1)
D475A-3
TROUBLESHOOTING
DB49KQ
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes
D475A-3
Error code DB49KQ
Trouble
Engine controller specification: Disagreement of model selection signals (KQ) (Engine controller system)
• Model selection circuit of engine controller is defective. • Flashes the caution lamp and turns on the caution buzzer.
Cause 1 Defective engine controller
20-466-13 (1)
TROUBLESHOOTING
ERROR CODE DB3SKR (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to S-NET communication
D475A-3
20-467
TROUBLESHOOTING
ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine
Related information
Error code DD14KA
Parking lever switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes parking lever is in Free position. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. + Signals of parking brake switch are commonly used by transmission controller and steering controller. Depending on where problem occurs, related codes may be displayed at the same time. (Related code: DDQ2KA, DDQ2L4). • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate parking lever.
1 Possible causes and standard value in normal state 2
1 Possible causes and standard value in normal state 2
20-468
Trouble
When error code [DD14KA] occurred alone Cause Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between CN1 (female) H – Resistance Max. 1Ω ing or defective contact in branched point of circuit connector) Wiring harness between CN1 (female) B – Resistance Max. 1Ω branched point of circuit + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking lever CN1 Defective transmission conFree position Lock position troller Between H – Max. 1V 20 – 30V chassis ground Between B – 20 – 30V Max. 1V chassis ground When error codes [DD14KA] and [DDQ2KA] occurred at the same time Cause Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking lever Parking lever switch NSW Free position Lock position (Internal disconnection) Between A – B Max. 1Ω Min. 1MΩ Between A – B Min. 1MΩ Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NSW (female) B – Disconnection in wiring harResistance Max. 1Ω ness (Disconnection in wir- merged point of circuit ing or defective contact in Wiring harness between NSW (female) C – Resistance Max. 1Ω connector) merged point of circuit Wiring harness between NSW (female) A – Resistance Max. 1Ω chassis ground
D475A-3
TROUBLESHOOTING
ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Cause Possible causes and standard value in normal state
3
Hot short circuit in wiring harness (Contact with 24V circuit)
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW (female) B – TMCN1 (female) H – STCN2 (fe- Voltage Max. 1V male) 5 with chassis ground Short circuit of wiring harness between NSW (female) C – TMCN1 (female) B – STCN2 (fe- Voltage Max. 1V male) E with chassis ground
Circuit diagram related to parking brake switch
D475A-3
20-469
TROUBLESHOOTING
ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine
Related information
Error code DD14KB
Trouble
Parking lever switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of parking lever switch circuit were turned ON (CLOSE) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes parking lever is in Free position. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. + Signals of parking brake switch are commonly used by transmission controller and steering controller. Depending on where problem occurs, related codes may be displayed at the same time. (Related code: DDQ2KB, DDQ2L4). • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate parking lever. Cause
1
Possible causes and standard value in normal state
2
3
20-470
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking lever Parking lever switch NSW Free position Lock position (Internal disconnection) Between A – B Max. 1Ω Min. 1MΩ Between A – B Min. 1MΩ Max. 1Ω + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Wiring harness between NSW (female) B – Short circuit with chassis CN1 (female) H – CN2 (female) 5 with chas- Resistance Min. 1MΩ ground in wiring harness sis ground (Contact with ground circuit) Wiring harness between NSW (female) C – CN1 (female) B – CN2 (female) E with chas- Resistance Min. 1MΩ sis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking lever CN1 Free position Lock position Defective transmission controller Between H – Max. 1V 20 – 30V chassis ground Between B – 20 – 30V Max. 1V chassis ground
D475A-3
TROUBLESHOOTING
ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to parking lever switch
D475A-3
20-471
TROUBLESHOOTING
ERROR CODE DDB9KA (REVERSE SWITCH: DISCONNECTION (KA))
ERROR CODE DDB9KA (REVERSE SWITCH: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDB9KA
Trouble
Reverse switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of reverse switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Reverse is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from reverse switch can be checked in monitoring mode. (Code 40905:Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate reverse switch. Cause
1
2
Possible causes and standard value in normal state 3
4
20-472
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Reverse switch TL1 (male) Defective reverse switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ D–V Resistance between Min. 1MΩ Max. 1Ω D–C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between TMCN3 (female) I – Resistance Max. 1Ω ness (Disconnection in wir- TL1 (female) V ing or defective contact in Wiring harness between TMCN3 (female) S – Resistance Max. 1Ω connector) TL1 (female) C Wiring harness between TMCN1 (female) 4, Resistance Max. 1Ω @ – TL1 (female) D + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short circuit in wiring TMCN3 (female) I – TL1 (female) V with Voltage Max. 1V harness (Contact with 24V chassis ground circuit) Short circuit of wiring harness between TMCN3 (female) S – TL1 (female) C with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Reverse switch TMCN1, TMCN3 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN3 S – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN3 S – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDB9KA (REVERSE SWITCH: DISCONNECTION (KA))
Circuit diagram related to forwrd switch and reverse switch
D475A-3
20-473
TROUBLESHOOTING
ERROR CODE DDB9KB (REVERSE SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDB9KB (REVERSE SWITCH: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDB9KB
Trouble
Reverse switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of reverse switch circuit were turned ON (CLOSE) or OFF at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Reverse is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from reverse switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate reverse switch. Cause
1
Possible causes and standard value in normal state
2
3
20-474
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Reverse switch TL1 (male) Defective reverse switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ D–V Resistance between Min. 1MΩ Max. 1Ω D–C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Short circuit with chassis Resistance Min. 1MΩ TMCN3 (female) I – TL1 (female) V with ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between Resistance Min. 1MΩ TMCN3 (female) S – TL1 (female) C with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Reverse switch TMCN1, TMCN3 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN3 I – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN3 S – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDB9KB (REVERSE SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to forwrd switch and reverse switch
D475A-3
20-475
TROUBLESHOOTING
ERROR CODE DDK3KA (FORWARD SWITCH: DISCONNECTION (KA))
ERROR CODE DDK3KA (FORWARD SWITCH: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDK3KA
Trouble
Forward switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of forward switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Forward is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from shift up switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate forward switch. Cause
1
2
Possible causes and standard value in normal state 3
4
20-476
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Forward switch TL1 (male) Defective forward switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ N–U Resistance between Min. 1MΩ Max. 1Ω N–B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between TMCN1 (female) 6 – Resistance Max. 1Ω ness (Disconnection in wir- TL1 (female) U ing or defective contact in Wiring harness between TMCN2 (female) [ – Resistance Max. 1Ω connector) TL1 (female) B Wiring harness between TMCN1 (female) 4, Resistance Max. 1Ω @ – TL1 (female) N + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short circuit in wiring TMCN1 (female) 6 – TL1 (female) U with Voltage Max. 1V harness (Contact with 24V chassis ground circuit) Short circuit of wiring harness between TMCN2 (female) [ – TL1 (female) B with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Forward switch TMCN1,TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN1 6 – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 [ – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDK3KA (FORWARD SWITCH: DISCONNECTION (KA))
Circuit diagram related to forward switch and reverse switch
D475A-3
20-477
TROUBLESHOOTING
ERROR CODE DDK3KB (FORWARD SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDK3KB (FORWARD SWITCH: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDK3KB
Trouble
Forward switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of forward switch circuit were turned ON (CLOSE) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Forward is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from forward switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate forward switch. Cause
1
Possible causes and standard value in normal state
2
3
20-478
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Forward switch TL1 (male) Defective forward switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ N–U Resistance between Min. 1MΩ Max. 1Ω N–B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Short circuit with chassis Resistance Min. 1MΩ TMCN1 (female) 6 – TL1 (female) U with ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) [ – TL1 (female) B with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Forward switch TMCN1,TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN1 6 – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 [ – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDK3KB (FORWARD SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to forward switch and reverse switch
D475A-3
20-479
TROUBLESHOOTING
ERROR CODE DDK5KA (SHIFT SWITCH: DISCONNECTION (KA))
ERROR CODE DDK5KA (SHIFT SWITCH: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDK5KA
Trouble
Shift switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of shift switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Shift down or shift up is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from shift down switch can be checked in monitoring mode. (Code 40906:Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate shift switch. Cause
1
2
Possible causes and standard value in normal state 3
4
20-480
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift switch BSW (male) Defective shift switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Min. 1MΩ Max. 1Ω A–B Resistance between Max. 1Ω Min. 1MΩ A–C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between TMCN2 (female) 7 – Resistance Max. 1Ω ness (Disconnection in wir- BSW (female) B ing or defective contact in Wiring harness between TMCN2 (female) 0 – Resistance Max. 1Ω connector) BSW (female) C Wiring harness between TMCN1 (female) 4, Resistance Max. 1Ω @ – BSW (female) A + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short circuit in wiring TMCN2 (female) 7 – BSW (female) B with Voltage Max. 1V harness (Contact with 24V chassis ground circuit) Short circuit of wiring harness between TMCN2 (female) 0 – BSW (female) C with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift switch TMCN1, TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller 20 – 30V Max. 1V TMCN2 7 – TMCN1 4, @ Voltage between Max. 1V 20 – 30V TMCN2 @ – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDK5KA (SHIFT SWITCH: DISCONNECTION (KA))
Circuit diagram related to shift switch
D475A-3
20-481
TROUBLESHOOTING
ERROR CODE DDK5KB (SHIFT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDK5KB (SHIFT SWITCH: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDK5KB
Trouble
Shift switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of shift switch circuit were turned ON (CLOSE) or OFF at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Shift down or shift up is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from shift switch can be checked in monitoring mode. (Code 40906: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate shift switch. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift switch BSW (male) Defective shift switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Min. 1MΩ Max. 1Ω A–B Resistance between Max. 1Ω Min. 1MΩ A–C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Short circuit with chassis Resistance Min. 1MΩ TMCN2 (female) 7 – BSW (female) B with ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) 0 – BSW (female) C with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift switch TMCN1, TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller 20 – 30V Max. 1V TMCN2 7 – TMCN1 4, @ Voltage between Max. 1V 20 – 30V TMCN2 0 – TMCN1 4, @
Circuit diagram related to shift switch
20-482
D475A-3
ERROR CODE DDN2LD (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM)
TROUBLESHOOTING
ERROR CODE DDN2LD (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM) Action code
Error code
E02
DDN2LD
Trouble
See table (LD) blade tilt right oil pressure switch system (Transmission controller system)
Contents of trouble • Signal of blade tilt right oil pressure switch circuit was kept turned ON for 180 seconds.
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Judges that oil pressure switch is turned OFF.
• When pitch and dump operation or right dual tilt operation is performed, right single tilt mechanism Problem that appears on machine operates. • Inputting from blade tilt right oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code 40908: Blade lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Error code is reproduced after 180 seconds). Cause
Standard value in normal state/Remarks on troubleshooting
After return operation, if Error code P is still displayed (to indicate that Defective operation of lever trouble is repaired), lever may have been so operated that error would 1 (Electric system is normal) be detected. Defective blade tilt right oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state
+ Prepare with starting switch OFF, then start engine and carry out troubleshooting. TRS (male) Between 1 – 2
Blade lever
Resistance
Neutral
Min. 1 MΩ
Right tilt
Max. 1 Ω
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) TMCN2 (female) 6 – TRS (female) 1 with Resistance 1 MΩ chassis ground + Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4
Defective transmission controller
TMCN2, TMCN1
Blade lever
Voltage
Between TMCN2 6 – TMCN1 4, @
Neutral
20 – 30 V
Right tilt
Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
D475A-3
20-483
ERROR CODE DDN3LD (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)
TROUBLESHOOTING
ERROR CODE DDN3LD (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM) Action code
Error code
E02
DDN3LD
Trouble
See table (LD) blade tilt left oil pressure switch system (Transmission controller system)
Contents of trouble • Signal of blade tilt left oil pressure switch circuit was kept turned ON for 180 seconds.
Action of controller
• Flashes caution lamp and turns on caution buzzer. • Judges that oil pressure switch is turned OFF.
• When pitch and dump operation or right dual tilt operation is performed, left single tilt mechanism opProblem that appears on machine erates. • Inputting from blade tilt left oil pressure switch (ON·OFF) can be checked in monitoring mode. (Code 40908: Blade lever oil pressure switch input) Related information • Method of reproducing service code: Turn starting switch ON (Error code is reproduced after 180 seconds). Cause
Standard value in normal state/Remarks on troubleshooting
After return operation, if error code P is still displayed (to indicate that Defective operation of lever trouble is repaired), lever may have been so operated that error would 1 (Electric system is normal) be detected. Defective blade tilt left oil 2 pressure switch (Internal short circuit) Possible causes and standard value in normal state
+ Prepare with starting switch OFF, then start engine and carry out troubleshooting. TLS (male) Between 1 – 2
Blade lever
Resistance
Neutral
Min. 1 MΩ
Left tilt
Max. 1 Ω
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 3 ground in wiring harness Short circuit of wiring harness between Max. (Contact with ground circuit) TMCN2 (female) F – TLS (female) 1 with Resistance 1 MΩ chassis ground + Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4
Defective transmission controller
TMCN2, TMCN1
Blade lever
Voltage
Between TMCN2 F – TMCN1 4, @
Neutral
20 – 30 V
Left tilt
Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
20-484
D475A-3
TROUBLESHOOTING
ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDN7KA
Trouble
• Signals of two systems of blade pitch switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Blade pitch does not function. (Operating blade pitch causes tilt operation.) • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input signal 1) • Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch). Cause
1
Defective blade pitch switch (Internal disconnection)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Hot short circuit in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Possible causes and standard value in normal state
20-486
Blade pitch switch: Disconnection (KA) (Transmission controller system)
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) OFF (Release) ON (Press) Resistance between Max. 1Ω Min. 1MΩ 1–5 Resistance between Min. 1MΩ Max. 1Ω 1–2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) E – Resistance Max. 1Ω P03 (female) 5 Wiring harness between TMCN2 (female) 5 – Resistance Max. 1Ω P03 (female) 2 Wiring harness between TMCN1 (female) 4, Resistance Max. 1Ω @ – P03 (female) 1 + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1V chassis ground Short circuit of wiring harness between TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade pitch switch TMCN1, TMCN2 OFF (Release) ON (Press) Voltage between Max. 1V 20 – 30V TMCN2 E – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 5 – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
Circuit diagram related to blade pitch switch & blade tilt switch
D475A-3
20-487
TROUBLESHOOTING
ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDN7KB
Trouble
Blade pitch switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Blade pitch does not function (Operating blade pitch causes tilt operation.) • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input) • Method of reproducing error code: Turn starting switch ON and operate blade tilt switch. Cause
1
Possible causes and standard value in normal state
2
3
20-488
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade pitch switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ 1–5 Resistance between Min. 1MΩ Max. 1Ω 1–2 + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Short circuit with chassis TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1V ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade pitch switch TMCN1, TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN2 E – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 5 – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to blade pitch switch & blade tilt switch
D475A-3
20-489
TROUBLESHOOTING
ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDN9KA
Trouble
Blade tilt switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time. • Recognizes switch is set at SINGLE side. • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.) • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input signal) • Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch). Cause
1
2
Possible causes and standard value in normal state 3
4
20-490
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade tilt switch SINGLE DUAL (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ 3–6 Resistance between Min. 1MΩ Max. 1Ω 3–4 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between TMCN2 (female) Y – Resistance Max. 1Ω ness (Disconnection in wir- P03 (female) 6 ing or defective contact in Wiring harness between TMCN2 (female) O – Resistance Max. 1Ω connector) P03 (female) 4 Wiring harness between TMCN1 (female) 4, Resistance Max. 1Ω @ – P03 (female) 3 + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short circuit in wiring TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1V harness (Contact with 24V chassis ground circuit) Short circuit of wiring harness between TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade pitch switch TMCN1, TMCN2 SINGLE DUAL Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN2 Y – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 O – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
Circuit diagram related to blade pitch switch & blade tilt switch
D475A-3
20-491
TROUBLESHOOTING
ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DD9NKB
Trouble
Blade tilt switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time. • Recognizes switch is set at SINGLE side. • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.) • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input state) • Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch). Cause
1
Possible causes and standard value in normal state
2
3
20-492
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade pitch switch SINGLE DUAL (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ 3–6 Resistance between Min. 1MΩ Max. 1Ω 3–4 + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Short circuit with chassis TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1V ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade pitch switch TMCN1, TMCN2 SINGLE DUAL Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN2 Y – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 O – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to blade pitch switch & blade tilt switch
D475A-3
20-493
ERROR CODE DDNALD (BLADE LIFT UP FULL SWITCH: REFER ERROR CODE DDNALD (BLADE LIFT UP PRESSURE FULL PRESSURE SWITCH: TOTABLE TABLE (LD) REFER TO
TROUBLESHOOTING
ERROR CODE DDNALD (BLADE LIFT UP FULL PRESSURE SWITCH: REFER TO TABLE (LD) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDNALD
Trouble
Blade lift up full pressure switch: Refer to table (LD). (Steering control system)
• Signals of Blade lift up full pressure switch was continuously ON for 180 seconds. • Recognizes ripper tilt IN pressure switch is OFF. • Blade lift up speed is slow. • Input state (ON/OFF) from blade lift up full pressure switch can be checked in monitoring mode. (Code 40908: Blade lever pressure switch input) • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least 180 seconds.) Cause
1
2 Possible causes and standard value in normal state
3
4
Standard value in normal state/Remarks on troubleshooting If error code lights on (reset display) even after carrying out reset, it Defective lever operation is suspected that lever operation causing error was performed in (Electric system is normal.) past. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective blade lift up full BLU (male) Blade lever Resistance pressure switch (Internal short circuit) Neutral Min. 1MΩ Between 1 – 2 UP Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN2 (female) Z – BLU (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN1, TMCN2 Blade lever Voltage troller Neutral 20 – 30V Between TMCN2 Z – TMCN1 4, @ UP Max. 1V
Circuit diagram related to blade lift UP full pressure switch
20-494
D475A-3
ERROR ERROR CODE DDNBLD (RIPPER (RIPPER LIFT UP PRESSURE SWITCH: REFER TO CODE DDNBLD LIFT UP PRESSURE SWITCH: TABLE (LD) (LD) REFER TO TABLE
TROUBLESHOOTING
ERROR CODE DDNBLD (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDNBLD
Trouble
• Signals from ripper lift UP pressure switch was continuously ON for 60 seconds. • Recognizes ripper lift UP pressure switch is turned OFF. • Shoe slip control (SSC) does not operate normally. • Ripper raise speed is slow. • Input state (ON/OFF) from ripper lift UP pressure switch can be checked in monitoring mode. (Code 70305: Steering controller input signal 3) • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least 60 seconds.) Cause
Possible causes and standard value in normal state
Ripper lift UP pressure switch: Refer to table (LD). (Transmission control system)
1
Defective lever operation (Electric system is normal.)
2
Defective ripper lift UP pressure switch (Internal short circuit)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting If error code lights on (reset display) even after carrying out reset, it is suspected that lever operation causing error was performed in past. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPU (male) Ripper lever Resistance Neutral Min. 1MΩ Between 1 – 2 UP Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) C – RPU (female) 1 with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN1, TMCN2 Ripper lever Voltage Neutral 20 – 30V Between TMCN2 C – TMCN1 4, @ UP Max. 1V
Circuit diagram related to ripper lift UP pressure switch
D475A-3
20-495
ERROR ERROR CODE DDNCLD (RIPPER (RIPPER LOWER PRESSURE SWITCH: REFER TO CODE DDNCLD LOWER PRESSURE SWITCH: TABLE (LD) REFER TO TABLE
TROUBLESHOOTING
ERROR CODE DDNCLD (RIPPER LOWER PRESSURE SWITCH: REFER TO TABLE (LD) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDNCLD
Trouble
• Signals from ripper lower pressure switch was continuously ON for 60 seconds. • Recognizes ripper lower pressure switch is OFF. • Shoe slip control (SSC) does not operate normally. • Ripper lower speed is slow. • Input state (ON/OFF) from ripper lower pressure switch can be checked in monitoring mode. (Code 70305: Steering controller input signal 3) • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least 60 seconds.) Cause
Possible causes and standard value in normal state
Ripper lower pressure switch: Refer to table (LD). (Transmission control system)
1
Defective lever operation (Electric system is normal.)
2
Defective ripper lower pressure switch (Internal short circuit)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting If error code lights on (reset display) even after carrying out reset, it is suspected that lever operation causing error was performed in past. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPD (male) Ripper lever Resistance Neutral Min. 1MΩ Between 1 – 2 Lower Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) 3 – RPD (female) 1 with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN1, TMCN2 Ripper lever Voltage Neutral 20 – 30V Between TMCN2 3 – TMCN1 4, @ UP Max. 1V
Circuit diagram related to ripper lower pressure switch
20-496
D475A-3
ERROR ERROR CODE DDNDLD (RIPPER TILT IN PRESSURE SWITCH: REFER TO CODE DDNDLD (RIPPER TILT IN PRESSURE SWITCH: TABLE (LD)) (LD)) REFER TO TABLE
TROUBLESHOOTING
ERROR CODE DDNDLD (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDNDLD
Trouble
• Signals of ripper tilt IN pressure switch was continuously ON for 60 seconds. • Recognizes ripper tilt IN pressure switch is OFF. • Shoe slip control (SSC) does not operate normally. • Ripper tilt IN speed is slow. • Input state (ON/OFF) from ripper tilt IN pressure switch can be checked in monitoring mode. (Code 70305: Ripper lever pressure switch input) • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least 60 seconds.) Cause
Possible causes and standard value in normal state
Ripper tilt IN pressure switch: Refer to table (LD). (Transmission control system)
1
Defective lever operation (Electric system is normal.)
2
Defective ripper tilt IN pressure switch (Internal short circuit)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting If error code lights on (reset display) even after carrying out reset, it is suspected that lever operation causing error was performed in past. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RTI (male) Ripper lever Resistance Neutral Min. 1MΩ Between 1 – 2 Tilt IN Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN2 Resistance Min. 1MΩ (female) 2 – RTI (female) 1 with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN1, TMCN2 Ripper lever Voltage Neutral 20 – 30V Between TMCN2 2 – TMCN1 4, @ Tilt IN Max. 1V
Circuit diagram related to ripper tilt IN pressure switch
D475A-3
20-497
TROUBLESHOOTING
ERRORERROR CODE DDNELD (RIPPER (RIPPER TILT BACK PRESSURE SWITCH: REFER TO CODE DDNELD TILT BACK PRESSURE SWITCH: TABLE (LD)) (LD)) REFER TO TABLE
ERROR CODE DDNELD (RIPPER TILT BACK PRESSURE SWITCH: REFER TO TABLE (LD)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDNELD
Trouble
Ripper tilt BACK pressure switch: Refer to table (LD). (Transmission control system)
• Signals of ripper tilt BACK pressure switch was continuously ON for 60 seconds. • Recognizes ripper tilt BACK pressure switch is OFF. • Shoe slip control (SSC) does not operate normally. • Ripper tilt back speed is slow. • Input state (ON/OFF) from ripper tilt BACK pressure switch can be checked in monitoring mode. (Code 70305: Ripper lever pressure switch input) • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least 60 seconds.) Cause
1
2 Possible causes and standard value in normal state
3
4
Standard value in normal state/Remarks on troubleshooting If error code lights on (reset display) even after carrying out reset, it Defective lever operation is suspected that lever operation causing error was performed in (Electric system is normal.) past. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective ripper tilt BACK RT8 (male) Ripper lever Resistance pressure switch (Internal short circuit) Neutral Min. 1MΩ Between 1 – 2 Tilt IN Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN2 (female) \ – RT8 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN1, TMCN2 Ripper lever Voltage troller Neutral 20 – 30V Between TMCN2 \ – TMCN1 4, @ Tilt IN Max. 1V
Circuit diagram related to ripper tilt Back pressure switch
20-498
D475A-3
20 ERROR CODE DDNFLD (BLADE LOWER FULL PRESSURE SWITCH: REFER ERROR CODE DDNFLD (BLADE LOWER FULL PRESSURE SWITCH: TOTABLE TABLE (LD)) (LD)) REFER TO
TROUBLESHOOTING
ERROR CODE DDNFLD (BLADE LOWER FULL PRESSURE SWITCH: REFER TO TABLE (LD)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDNFLD
Trouble
Blade lower full pressure switch: Refer to table (LD). (Transmission control system)
• Signals of blade lower full pressure switch was continuously ON for 180 seconds. • Recognizes blade lower full pressure switch is OFF. • Blade lower speed is slow. • Input state (ON/OFF) from blade lower full pressure switch can be checked in monitoring mode. (Code 40908: blade lever pressure switch input) • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least 180 seconds.) Cause
1
2 Possible causes and standard value in normal state
3
4
Standard value in normal state/Remarks on troubleshooting If error code lights on (reset display) even after carrying out reset, it Defective lever operation is suspected that lever operation causing error was performed in (Electric system is normal.) past. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective Blade lower full BLD (male) Blade lever Resistance pressure switch (Internal short circuit) Neutral Min. 1MΩ Between 1 – 2 Lower full Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN2 (Contact with ground circuit) (female) P – BLD (female) 1 with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN1, TMCN2 Blade lever Voltage troller Neutral 20 – 30V Between TMCN2 P – TMCN1 4, @ Down full Max. 1V
Circuit diagram related to blade lower full pressure switch
D475A-3
20-499
ERROR CODE DDQ2KA (PARKING BRAKE LEVER SWITCH: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DDQ2KA (PARKING BRAKE LEVER SWITCH: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine
Related information
Error code DDQ2KA
Parking lever switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes parking lever is in Free position. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. + Signals of parking brake switch are commonly used by transmission controller and steering controller. Depending on where problem occurs, related codes may be displayed at the same time. (Related code: DD14KA, DDQ2L4). • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. (Code 40907: Blade lever knob switch input signal) • Method of reproducing error code: Turn starting switch ON and operate parking lever.
1 Possible causes and standard value in normal state 2
1 Possible causes and standard value in normal state 2
20-500
Trouble
When error code [DDQ2KA] occurred alone Cause Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN2 (female) 5 – Resistance Max. 1Ω ing or defective contact in branched point of circuit connector) Wiring harness between STCN2 (female) E – Resistance Max. 1Ω branched point of circuit + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking lever STCN2 Free position Lock position Defective steering controller Between 5 – Max. 1V 20 – 30V chassis ground Between E – 20 – 30V Max. 1V chassis ground When error codes [DDQ2KA] and [DD14KA] occurred at the same time Cause Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking lever Parking lever switch NSW Free position Lock position (Internal disconnection) Between A – B Max. 1Ω Min. 1MΩ Between A – B Min. 1MΩ Max. 1Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NSW (female) B – Disconnection in wiring harResistance Max. 1Ω ness (Disconnection in wir- merged point of circuit ing or defective contact in Wiring harness between NSW (female) C – Resistance Max. 1Ω connector) merged point of circuit Wiring harness between NSW (female) A – Resistance Max. 1Ω chassis ground
D475A-3
ERROR CODE DDQ2KA (PARKING BRAKE LEVER SWITCH: DISCONNECTION (KA))
TROUBLESHOOTING
Cause Possible causes and standard value in normal state
3
Hot short circuit in wiring harness (Contact with 24V circuit)
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW (female) B – TMCN1 (female) H – STCN2 Voltage Max. 1V (female) 5 with chassis ground Short circuit of wiring harness between NSW (female) C – TMCN1 (female) B – STCN2 (fe- Voltage Max. 1V male) E with chassis ground
Circuit diagram related to parking brake switch
D475A-3
20-501
TROUBLESHOOTING
ERROR CODEERROR DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORTSWITCH: CIRCUIT CODE DDQ2KB (PARKING BRAKE LEVER (KB)) SHORT CIRCUIT (KB))
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine
Related information
Possible causes and standard value in normal state
20-502
Error code DDQ2KB
Trouble
Parking brake lever switch: Short circuit (KB) (Steering controller system)
• Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously. • Flashes caution lamp and turns on caution buzzer. • Recognizes that parking brake lever is at FREE position. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. + Since parking brake switch signal is used by both transmission controller and steering controller, related codes may be displayed simultaneously, depending on troubled part. (Related codes: DD14KB, DDQ2L4) • NO and NC signals of both switch systems are for detecting operation and error respectively. • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code 40907: Blade control lever knob switch input signal) • Method of reproducing error code: Turn starting switch ON and operate parking brake lever. When error codes [DDQ2KA] and [DD14KA] are displayed simultaneously Cause Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective parking brake leParking brake lever NSW 1 ver switch (Internal short cirAt FREE At LOCK cuit) Between A – B Max. 1Ω Min. 1MΩ Between A – B Min. 1MΩ Max. 1Ω + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Short circuit with chassis (female) B – TMCN1 (female) H – STCN2 (fe- Resistance Min. 1MΩ 2 ground in wiring harness male) 5 with chassis ground (Contact with ground circuit) Short circuit of wiring harness between NSW (female) C – TMCN1 (female) B – STCN2 (fe- Resistance Min. 1MΩ male) E with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever STCN2 At FREE At LOCK 3 Defective steering controller Between 5 – Max. 1V 20 – 30V chassis ground Between E – 20 – 30V Max. 1V chassis ground
D475A-3
TROUBLESHOOTING
ERROR CODEERROR DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORTSWITCH: CIRCUIT CODE DDQ2KB (PARKING BRAKE LEVER (KB)) SHORT CIRCUIT (KB))
Circuit diagram related to parking brake switch
D475A-3
20-503
TROUBLESHOOTING
ERROR CODE DDQ2L4 (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
ERROR CODE DDQ2L4 (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine
Related information
Error code Parking brake lever switch: See table (L4) Trouble (Steering controller system) DDQ2L4 • Switch input signal of steering controller disagrees with communication signal from transmission controller. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. + Since parking brake switch signal is used by both transmission controller and steering controller and information is exchanged by CAN communication, related codes may be displayed simultaneously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR, DD14KA, DD14KB, DDQ2KA, DDN4LD, DDN5LD) • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code 40905, 40910: Parking brake lever switch input signal) • Method of reproducing error code: Turn starting switch ON and operate parking brake lever. Cause
Possible causes and standard value in normal state
1
2 3
20-504
Standard value in normal state/Remarks on troubleshooting See if error codes [DAFRKR], [DB2RKR], [DB3RKR], and [DAQRKR] Defective CAN communicaare displayed. If they are displayed, carry out troubleshooting for tion signal system them first. See if error codes [DD14KA], [DD14KB], [DDQ2KA], and [DDQ2KB] Defective parking brake leare displayed. If they are displayed, carry out troubleshooting for ver switch signal system them first. Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
D475A-3
TROUBLESHOOTING
ERROR CODE DDT5KA (NEUTRAL SWITCH: DISCONNECTION (KA))
ERROR CODE DDT5KA (NEUTRAL SWITCH: DISCONNECTION (KA)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDT5KA
Trouble
Neutral switch: Disconnection (KA) (Transmission controller system)
• Signals of two systems of Neutral switch circuit were turned OFF (OPEN) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Travel is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from neutral switch can be checked in monitoring mode. (Code 40906:Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate neutral switch. Cause
1
2
Possible causes and standard value in normal state 3
4
20-506
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Neutral switch NTL (male) Defective neutral switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ 1–3 Resistance between Min. 1MΩ Max. 1Ω 2–3 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between TMCN2 (female) Q – Resistance Max. 1Ω ness (Disconnection in wir- NTL (female) 1 ing or defective contact in Wiring harness between TMCN2 (female) G – Resistance Max. 1Ω connector) NTL (female) 2 Wiring harness between TMCN1 (female) 4, Resistance Max. 1Ω @ – NTL (female) 3 + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short circuit in wiring TMCN2 (female) Q – NTL (female) 1 with Voltage Max. 1V harness (Contact with 24V chassis ground circuit) Short circuit of wiring harness between TMCN2 (female) G – NTL (female) 2 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Neutral switch TMCN1, TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN2 Q – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 G – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDT5KA (NEUTRAL SWITCH: DISCONNECTION (KA))
Circuit diagram related to neutral switch disconnection
D475A-3
20-507
TROUBLESHOOTING
ERROR CODE DDT5KB (NEUTRAL SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDT5KB (NEUTRAL SWITCH: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDT5KB
Trouble
Neutral switch: Short circuit (KB) (Transmission controller system)
• Signals of two systems of neutral switch circuit were turned ON (CLOSE) or OFF at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Travel is not possible. • Auto shift down does not function. • Of signals of two systems of switch, NO is for operation detection and NC is for error detection. • Input state (ON/OFF) from neutral switch can be checked in monitoring mode. (Code 40906: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate neutral switch. Cause
1
Possible causes and standard value in normal state
2
3
20-508
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Neutral switch NTL (male) Defective neutral switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1Ω Min. 1MΩ D–V Resistance between Min. 1MΩ Max. 1Ω D–C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Short circuit with chassis Resistance Min. 1MΩ TMCN2 (female) Q – NTL (female) 1 with ground in wiring harness chassis ground (Contact with ground circuit) Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) G – NTL (female) 2 with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Neutral switch TMCN1, TMCN2 OFF (Release) ON (Press) Defective transmission con- Voltage between troller Max. 1V 20 – 30V TMCN2 Q – TMCN1 4, @ Voltage between 20 – 30V Max. 1V TMCN2 G – TMCN1 4, @
D475A-3
TROUBLESHOOTING
ERROR CODE DDT5KB (NEUTRAL SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to neutral switch short circuit
D475A-3
20-509
ERROR CODE DDT5KQ (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ))
TROUBLESHOOTING
ERROR CODE DDT5KQ (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DDT5KQ
Trouble
PCCS lever specification signal inconsistency (KQ) (Transmission controller system)
• . • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Travel is not possible. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
• Method of reproducing error code: Turn starting switch ON. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting When PCCSR type is installed, it is normal if error code lights on (reDefective setting for PCCS set display) after carrying out adjustment mode. lever specification • Adjustment code: 0004: Transmission controller spec. + Prepare with starting switch OFF, carry out troubleshooting without turning starting switch ON. Short circuit in wiring har- Short circuit of wiring harness between Resistance Min. 1Ω ness TMCN2 (female) Q with chassis ground Short circuit of wiring harness between Resistance Min. 1Ω TMCN2 (female) G with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. troller TMCN2 Voltage Between Q – chassis ground 20 – 30V
Circuit diagram related to PCCS lever specification
20-510
D475A-3
TROUBLESHOOTING
DGE2KX
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DGE2KX
Trouble
Engine coolant temperature: Out of input signal range (KX) (Engine controller system)
• The input voltage from the engine coolant temperature sensor is below 0.3 V or above 4.7 V. • Assumes the engine coolant temperature to be 90°C for control.
• The signals of the engine coolant temperature sensor are used by the monitor panel, too. Depending on the cause of the trouble, the engine coolant temperature gauge may not indicate normally. • Method of reproducing error code: Turn the starting switch ON or start the engine. Cause
1
2
Possible causes and standard value in normal state
3
4
5
6
D475A-3
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine coolant 402 (male) Resistance temperature sensor (Internal disconnection or Between (1) and (2) 3.8 k – 80 kz short circuit) Between (1), (2) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE32 (female) (5) and Resistance Max. 1 z wiring harness or defective 402 (female) (1) contact in connector) Wiring harness between LE31 (female) (16) Resistance Max. 1 z and 402 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Between wiring harness between LE32 (Contact with ground circuit) (female) (5), 402 (female) (1), or S04 (female) Resistance Min. 1 Mz (11) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Between wiring harness between LE32 (Contact with 24-V circuit) (female) (5), 402 (female) (1), or S04 (female) Voltage Max. 1 V (11) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine controller LE31 (female), LE32 (female) Resistance Between LE32 (5) and LE31 (16) 3.8 k – 80 kz If none of causes 1 – 5 is the cause of the trouble, the monitor panel may Defective monitor panel be defective (Troubleshooting cannot be carried out since the defect is in the monitor panel).
20-510-1 (1)
TROUBLESHOOTING
DGE2KX
Circuit diagram related to engine coolant temperature sensor
20-510-2 (1)
D475A-3
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: SIGNAL OUTOF OFNORMAL NORMALRANGE RANGE (KX)) (KX)) INPUT SIGNAL ISISOUT
TROUBLESHOOTING
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DGS1KX
Trouble
• Hydraulic oil temperature sensor signal is out of normal range. • Does not take any particular action. • Hydraulic oil temperature gauge of monitor panel may not display normally. • Hydraulic oil temperature (temperature) can be checked in monitoring mode. (Code 04401: Hydraulic oil temperature) • Method of reproducing error code: Turn starting switch ON or start engine. Cause
Possible causes and standard value in normal state
Hydraulic oil temperature sensor: Input signal is out of normal range (KX) (Transmission controller system)
1
Defective hydraulic oil temperature sensor (Internal disconnection or short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Short circuit with power source in wiring harness (Contact with 24V circuit)
5
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDS (male) Resistance Between 1 – 2 3.5k – 90kΩ Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN1 (female) D – Resistance Max. 1Ω SDS (female) 1 Wiring harness between TMCN1 (female) K – Resistance Max. 1Ω SDS (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN1 (female) D – SDS (female) 1 with chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN1 (female) D – SDS (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN1 (female) Resistance Between D – K 3.5k – 90kΩ Between D – chassis ground Min. 1MΩ
Circuit diagram related to hydraulic oil temperature sensor
D475A-3
20-511
ERROR CODE DH22KA (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DH22KA (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DH22KA
Work equipment large pump oil pressure sensor: Disconnection (KA) (Transmission controller system)
• Signal voltage of work equipment large pump oil pressure sensor circuit is below 0.5V. • Does not take any particular action. • Work equipment large pump oil pressure cannot be monitored. • Input (Voltage) from work equipment large pump oil pressure sensor can be checked in monitoring mode. (Code 70701: Voltage of work equipment large pump oil sensor) • Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipment out troubleshooting. large pump oil pressure HP1 Voltage sensor (Internal trouble) Between C – A 0.5 – 6.0V + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN1 (female) F – Resistance Max. 1Ω ing or defective contact in HP1 (female) B connector) Wiring harness between TMCN1 (female) 9 – Resistance Max. 1Ω HP1 (female) C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) 9 – HP1 (female) C with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry Defective transmission con- out troubleshooting. TMCN1 (female) Voltage troller Between 9 – K 0.5 – 6.0V
Circuit diagram related to work equipment large pump oil pressure sensor
20-512
D475A-3
ERROR CODE DH22KB (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DH22KB (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DH22KB
Work equipment large pump oil pressure sensor: Short circuit (KB) (Transmission controller system)
• Signal voltage of work equipment large pump oil pressure sensor circuit is above 6.0V • Does not take any particular action. • Work equipment large pump oil pressure cannot be monitored. • Input (Voltage) from work equipment large pump oil pressure sensor can be checked in monitoring mode. (Code 70701: Voltage of work equipment large pump oil pressure sensor) • Method of reproducing error code: Turn starting switch ON.
1
2 Possible causes and standard value in normal state
Trouble
3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipment out troubleshooting. large pump oil pressure HP1 Voltage sensor (Internal trouble) Between C – A 0.5 – 6.0V + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN1 (female) 9 – HP1 (female) C with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry Defective transmission con- out troubleshooting. troller TMCN1 (female) Voltage Between 9 – K 0.5 – 6.0V
Circuit diagram related to work equipment large pump oil pressure sensor
D475A-3
20-513
ERROR CODE DH23KA (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DH23KA (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) Action code
Error code
E01 Contents of trouble Action of controller Problem that appears on machine Related information
DH23KA
Work equipment assistance pump oil pressure sensor: Disconnection (KA) (Transmission controller system)
• Signal voltage of work equipment assistance pump oil pressure sensor circuit is below 0.5V. • Does not take any particular action. • Work equipment assistance pump oil pressure cannot be monitored. • Input (Voltage) from work equipment assistance pump oil pressure sensor can be checked in monitoring mode. (Code 70701: Voltage of work equipment assistance pump oil sensor) • Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out system troubleshooting for it first. Defective work equipment + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. assistance pump oil presHP2 Voltage sure sensor (Internal trouble) Between C – A 0.5 – 6.0V + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN1 (female) F – Resistance Max. 1Ω ing or defective contact in HP2 (female) B connector) Wiring harness between TMCN1 (female) 3 – Resistance Max. 1Ω HP2 (female) C + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) 3 – HP2 (female) C with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry Defective transmission con- out troubleshooting. TMCN1 (female) Voltage troller Between 3 – K 0.5 – 6.0V
Circuit diagram related to work equipment assistance pump oil pressure sensor
20-514
D475A-3
ERROR CODE DH23KB (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DH23KB (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information
Error code DH23KB
Work equipment assistance pump oil pressure sensor: Short circuit (KB)(Transmission controller system)
• Signal voltage of work equipment assistance pump oil pressure sensor circuit is above 6.0V • Does not take any particular action. • Work equipment assistance pump oil pressure cannot be monitored. • Input (Voltage) from work equipment assistance pump oil pressure sensor can be checked in monitoring mode. (Code 70703: Voltage of work equipment assist pump oil pressure sensor) • Method of reproducing error code: Turn starting switch ON.
1
2 Possible causes and standard value in normal state
Trouble
3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipment out troubleshooting. assist pump oil pressure HP2 Voltage sensor (Internal trouble) Between C – A 0.5 – 6.0V + Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN1 (female) 3 – HP2 (female) C with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, turn starting switch ON and carry Defective transmission con- out troubleshooting. troller TMCN1 (female) Voltage Between 3 – K 0.5 – 6.0V
Circuit diagram related to work equipment assistance pump oil pressure sensor
D475A-3
20-515
ERROR CODE ERROR DK01KA CODE (LEFT YOKE ANGLE SENSOR: DISCONNECTION DK01KA (LEFT YOKE ANGLE SENSOR: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK01KA (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK01KA
Left yoke angle sensor: Disconnection (KA) (Transmission controller system)
• Signal voltage of left yoke angle sensor circuit is below 0.5V. • Flashes caution lamp and turns on caution buzzer. • Tilt limit function does not work. • Input (Voltage) from left yoke angle sensor can be checked in monitoring mode. (Code 90002: Voltage of left yoke angle sensor) • Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left yoke angle CSL (male) Resistance sensor (Internal disconnecBetween A – C 4.0 – 6.0kΩ tion or short circuit) Between A – B 0.25 – 7.0kΩ Between B – C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN1 (female) L – Resistance Max. 1Ω ing or defective contact in CSL (female) A connector) Wiring harness between TMCN1 (female) 7 – Resistance Max. 1Ω CSL (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) 7 – CSL (female) B with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. troller TMCN1 Voltage Between 7 – K 0.5 – 4.5V
Circuit diagram related to left yoke angle sensor
20-516
D475A-3
TROUBLESHOOTING
ERROR CODE DK01KB (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DK01KB (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK01KB
Trouble
Left yoke angle sensor: Short circuit (KB) (Transmission controller system)
• Signal voltage of left yoke angle sensor circuit is below 0.5V or above 4.5V. • Flashes caution lamp and turns on caution buzzer. • Tilt limit function does not work. • Input (Voltage) from left yoke angle sensor can be checked in monitoring mode. (Code 90002: Voltage of left yoke angle sensor) • Method of reproducing error code: Turn starting switch ON.
1
2 Possible causes and standard value in normal state 3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left yoke angle CSL (male) Resistance sensor (Internal disconnecA–C 4.0 – 6.0kΩ tion or short circuit) A–B 0.25 – 7.0kΩ B–C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN1 (female) 7 – CSL (female) B with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMCN1 Voltage Between 7 – K 0.5 – 4.5V
Circuit diagram related to left yoke angle sensor
D475A-3
20-517
ERROR CODE DK03KA ANGLE SENSOR: DISCONNECTION ERROR (RIGHT CODE YOKE DK01KA (LEFT YOKE ANGLE SENSOR: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK03KA (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA)) Action code CALL E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK03KA
Right yoke angle sensor: Disconnection (KA) (Transmission controller system)
• Signal voltage of right yoke angle sensor circuit is below 0.5V. • Flashes caution lamp and turns on caution buzzer. • Tilt limit function does not work. • Input (Voltage) from right yoke angle sensor can be checked in monitoring mode. (Code 90003: Voltage of right yoke angle sensor) • Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right yoke angle CSR (male) Resistance sensor (Internal disconnecBetween A – C 4.0 – 6.0kΩ tion or short circuit) Between A – B 0.25 – 7.0kΩ Between B – C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN1 (female) L – Resistance Max. 1Ω ing or defective contact in CSR (female) A connector) Wiring harness between TMCN1 (female) C – Resistance Max. 1Ω CSR (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) C – CSR (female) B with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller TMCN1 Voltage Between C – K 0.5 – 4.5V
Circuit diagram related to right yoke angle sensor
20-518
D475A-3
ERROR CODEERROR DK03KB (RIGHT YOKE ANGLE SHORTSENSOR: CIRCUIT CODE DK03KB (RIGHTSENSOR: YOKE ANGLE (KB)) SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DK03KB (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB)) Action code CALL E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK03KB
Trouble
Right yoke angle sensor: Short circuit (KB) (Transmission controller system)
• Signal voltage of right yoke angle sensor circuit is below 0.5V or above 4.5V. • Flashes caution lamp and turns on caution buzzer. • Tilt limit function does not work. • Input (Voltage) from right yoke angle sensor can be checked in monitoring mode. (Code 90003: Voltage of right yoke angle sensor) • Method of reproducing error code: Turn starting switch ON.
1
2 Possible causes and standard value in normal state 3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right yoke angle CSR (male) Resistance sensor (Internal disconnecA–C 4.0 – 6.0kΩ tion or short circuit) A–B 0.25 – 7.0kΩ B–C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN1 (female) C – CSR (female) B with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission controller TMCN1 Voltage Between C – K 0.5 – 4.5V
Circuit diagram related to right yoke angle sensor
D475A-3
20-519
TROUBLESHOOTING
DK10KX
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF INPUT SIGNAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK10KX
Trouble
Fuel dial: Out of input signal range (KX) (Engine controller system)
• The input voltage from the fuel dial is below 0.3 V or above 4.75 V. • Flashes the caution lamp and turns on the caution buzzer. • Keeps the last value in the normal range. • Fixes the engine speed at 1,300 rpm after the machine is stopped (and set in neutral). • The engine speed cannot be controlled. • Method of reproducing error code: Turn the starting switch ON. Cause
1
2
Possible causes and standard value in normal state
3
4
5
20-519-1 (1)
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fuel dial DIAL (male) Resistance (Internal disconnection or Between (1) and (3) 4.0 – 6.0 kz short circuit) Between (1) and (2) 0.25 – 7.0 kz Between (3) and (2) 0.25 – 7.0 kz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LE31 (female) (6) and Disconnection in wiring Resistance Min. 1 Mz harness (Disconnection in DIAL (female) (1) wiring harness or defective Wiring harness between LE31 (female) (16) Resistance Min. 1 Mz contact in connector) and DIAL (female) (3) Wiring harness between LE32 (female) (1) and Resistance Min. 1 Mz DIAL (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE31 Short circuit with chassis (female) (6) and DIAL (female) (1) and chassis Resistance Min. 1 Mz ground in wiring harness ground (Contact with ground circuit) Between wiring harness between LE32 (female) (1) and DIAL (female) (2) and chassis Resistance Min. 1 Mz ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE31 Short circuit with power (female) (6) and DIAL (female) (1) and chassis Voltage Max. 1 V source in wiring harness ground (Contact with 24-V circuit) Between wiring harness between LE32 (female) (1) and DIAL (female) (2) and chassis Voltage Max. 1 V ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE31, LE32 Voltage Defective engine controller Between LE31 (6) Power supply 4.6 – 5.4 V and (16) Between LE32 (1) Signal 0.3 – 4.75 V and LE31 (16)
D475A-3
TROUBLESHOOTING
DK10KX
Circuit diagram related to fuel dial
D475A-3
20-519-2 (1)
ERROR CODE DK11KA (DECELERATION POTENTIOMETER: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK11KA (DECELERATION POTENTIOMETER: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK11KA
Trouble
• Signal voltage of deceleration potentiometer circuit is below 0.5V. • Recognizes full deceleration. • Transmission shift shock becomes heavy. • Auto-shift down function does not work properly. • Method of reproducing error code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
20-520
Deceleration potentiometer Disconnection (KA) (Steering controller system)
1
Defective deceleration potentiometer (Internal disconnection or short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Defective steering controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FCD (male) Resistance Between A – C 4.0 – 6.0kΩ Between A – B 0.25 – 7.0kΩ Between B – C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CN3 (female) 6 – Resistance Max. 1Ω FCD (female) A Wiring harness between STCN1 (female) 9 – Resistance Max. 1Ω FCD (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN1 Resistance Min. 1MΩ (female) 9 – FCD (female) B with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN1 Voltage Between 9 – ground 0.5 – 4.5V
D475A-3
TROUBLESHOOTING
ERROR CODE DK11KA (DECELERATION POTENTIOMETER: DISCONNECTION (KA))
Circuit diagram related to decel potentiometer
D475A-3
20-521
TROUBLESHOOTING
ERROR CODEERROR DK11KB (DECELERATION POTENTIOMETER: SHORT CIRCUIT CODE DK11KB (DECELERATION POTENTIOMETER: (KB)) SHORT CIRCUIT (KB))
ERROR CODE DK11KB (DECELERATION POTENTIOMETER: SHORT CIRCUIT (KB)) Action code CALL E01 Contents of trouble Action of controller
• Signal voltage of deceleration potentiometer circuit is above 4.5V.
Problem that appears on machine
• • • •
Related information
Error code DK11KB
Trouble
Deceleration potentiometer: short circuit (KB) (Engine controller system)
• Confirms that the speed went down to the deceleration speed. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Transmission shift shock becomes heavy. Auto-shift down function does not work properly.
• Method of reproducing error code: Turn starting switch ON. Cause
1 Possible causes and standard value in normal state
2
3
20-522
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective deceleration poDCL (male) Resistance tentiometer (Internal disconBetween A – C 4.0 – 6.0kΩ nection or short circuit) Between A – B 0.25 – 7.0kΩ Between B – C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between STCN1 (Contact with 24V circuit) (female) 9 – DCL (female) B with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 9 – ground 0.5 – 4.5V
D475A-3
TROUBLESHOOTING
CODE DK11KB (DECELERATION POTENTIOMETER: ERROR CODEERROR DK11KB (DECELERATION POTENTIOMETER: SHORT CIRCUIT SHORT CIRCUIT (KB)) (KB))
Circuit diagram related to decel potentiometer
D475A-3
20-523
TROUBLESHOOTING
DK12KX
ERROR CODE [DK12KX] (DECELERATOR POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK12KX
Trouble
Decelerator potentiometer: Out of input signal range (KX) (Engine controller system)
• The input voltage from the decelerator potentiometer is below 0.3 V or above 4.75 V. • Flashes the caution lamp and turns on the caution buzzer. • Keeps the last value in the normal range. • Fixes the engine speed at 1,300 rpm after the machine is stopped (and set in neutral). • The engine speed cannot be controlled. • Method of reproducing error code: Turn the starting switch ON. Cause
1
2
Possible causes and standard value in normal state
3
4
5
20-523-1 (1)
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective decelerator FCD (male) Resistance potentiometer (Internal disconnection or Between (A) and (C) 4.0 – 6.0 kz short circuit) Between (A) and (B) 0.25 – 7.0 kz Between (C) and (B) 0.25 – 7.0 kz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LE31 (female) (6) and Disconnection in wiring Resistance Min. 1 Mz harness (Disconnection in FCD (female) (A) wiring harness or defective Wiring harness between LE31 (female) (16) Resistance Min. 1 Mz contact in connector) and FCD (female) (C) Wiring harness between LE32 (female) (11) Resistance Min. 1 Mz and FCD (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE31 Short circuit with chassis (female) (6) and FCD (female) (A) and chassis Resistance Min. 1 Mz ground in wiring harness ground (Contact with ground circuit) Between wiring harness between LE32 (female) (11) and FCD (female) (B) and chassis Resistance Min. 1 Mz ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE31 Short circuit with power (female) (6) and FCD (female) (A) and chassis Voltage Max. 1 V source in wiring harness ground (Contact with 24-V circuit) Between wiring harness between LE32 (female) (11) and FCD (female) (B) and chassis Voltage Max. 1 V ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE31, LE32 Voltage Defective engine controller Between LE31 (6) Power supply 4.6 – 5.4 V and (16) Between LE32 (6) Signal 0.3 – 4.75 V and LE31 (16)
D475A-3
TROUBLESHOOTING
DK12KX
Circuit diagram related to decelerator potentiometer
D475A-3
20-523-2 (1)
ERROR CODE ERROR DK30KACODE (STEERING POTENTIOMETER 1: DISCONNECTION DK30KA (STEERING POTENTIOMETER 1: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK30KA
• Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of steering potentiometer 2 system (ST2). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from steering potentiometer 1 (ST1) can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
2
3
4
5
20-524
Steering potentiometer 1: Disconnection (KA) (Steering controller system)
• Signal voltage of steering potentiometer 1 system (ST1) is below 0.5V.
1
Possible causes and standard value in normal state
Trouble
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering potentiTL1 (male) Resistance ometer 1 (Internal disconBetween A – G 2kΩ ± 20% nection or short circuit) Between H – A Between H – G + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN1 (female) L – Resistance Max. 1Ω ing or defective contact in TL1 (female) A connector) Wiring harness between STCN1 (female) 2 – Resistance Max. 1Ω TL1 (female) H + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN1 (Contact with ground circuit) (female) 2 – TL1 (female) H with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 2 – K 0.5 – 4.5V
D475A-3
TROUBLESHOOTING
ERROR CODE ERROR DK30KACODE (STEERING POTENTIOMETER 1: DISCONNECTION DK30KA (STEERING POTENTIOMETER 1: (KA)) DISCONNECTION (KA))
Circuit diagram related to steering potentiometer
D475A-3
20-525
ERROR CODEERROR DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT CODE DK30KB (STEERING POTENTIOMETER 1: (KB)) SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK30KB
Trouble
Steering potentiometer 1: Short circuit (KB) (Steering controller system)
• Signal voltage of steering potentiometer 1 system (ST1) is above 4.5V. • Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of steering potentiometer 2 system (ST2). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from steering potentiometer 1 (ST1) can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
1
2 Possible causes and standard value in normal state 3
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering potentiTL1 (male) Resistance ometer 1 (Internal disconBetween A – G 2kΩ ± 20% nection or short circuit) Between H – A Between H – G + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between STCN1 (Contact with 24V circuit) (female) 2 – TL1 (female) H with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 2 – K 0.5 – 4.5V
Circuit diagram related to steering potentiometer
20-526
D475A-3
TROUBLESHOOTING
ERROR CODE DK30KX POTENTIOMETER 1:OFINPUT SIGNAL IS ERROR CODE DK30KX (STEERING(STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT NORMAL RANGE (KX)) OF NORMAL RANGE (KX)) ERROR CODE DK30KZ (STEERING POTENTIOMETER 1:OUT DISCONNECTION OR SHORT CIRCUIT (KZ))
ERROR CODE DK30KX (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
Error code Steering potentiometer 1: Input signal is out of normal range (KX) Trouble (Steering controller system) DK30KX • Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and error codes [DK31KA] and [DK31KB] are displayed simultaneously. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Input (Voltage) from steering potentiometers can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer 1) (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
ERROR CODE DK30KZ (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
D475A-3
Error code Steering potentiometer 1: Disconnection or short circuit (KZ)) Trouble (Steering controller system) DK30KZ • When starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal, then either of error codes [DK30KA] and [DK30KB] and error codes [DK31KA] and [DK31KB] are displayed simultaneously. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Input (Voltage) from steering potentiometers can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer 1) (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
20-527
TROUBLESHOOTING
ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8))
ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
20-528
• • • •
Error code Steering potentiometer 1: See table (L8) Trouble (Steering controller system) DK30L8 Total signal voltage of each of steering potentiometer 1 system (ST1) and 2 system (ST2) is below 4.41V or above 5.59V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of normal one of steering potentiometer 1 system (ST1) and 2 (ST2). Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from steering potentiometers can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer 1) (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D475A-3
ERROR CODE ERROR DK31KACODE (STEERING POTENTIOMETER 2: DISCONNECTION DK31KA (STEERING POTENTIOMETER 2: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK31KA (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK31KA
20-530
Steering potentiometer 2: Disconnection (KA) (Steering controller system)
• Signal voltage of steering potentiometer 2 system (ST2) is below 0.5V. • Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of steering potentiometer 1 system (ST1). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from steering potentiometer 2 (ST2) can be checked in monitoring mode. (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
1
Possible causes and standard value in normal state
Trouble
Cause Defective sensor power source system
2
Defective steering potentiometer 2 (Internal disconnection or short circuit)
3
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
4
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
5
Defective steering controller
Standard value in normal state/Remarks on troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL1 (male) Resistance Between M – F 2kΩ ± 20% Between E – M Between E – F + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) L – Resistance Max. 1Ω TL1 (female) M Wiring harness between STCN1 (female) I – Resistance Max. 1Ω TL1 (female) E + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN1 Resistance Min. 1MΩ (female) I – TL1 (female) E with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN1 Voltage Between I – K 0.5 – 4.5V
D475A-3
TROUBLESHOOTING
ERROR CODE ERROR DK31KACODE (STEERING POTENTIOMETER 2: DISCONNECTION DK31KA (STEERING POTENTIOMETER 2: (KA)) DISCONNECTION (KA))
Circuit diagram related to steering potentiometer
D475A-3
20-531
ERROR CODEERROR DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT CODE DK31KB (STEERING POTENTIOMETER 2: (KB)) SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK31KB
Trouble
Steering potentiometer 2: Short circuit (KB) (Steering controller system)
• Signal voltage of steering potentiometer 2 system (ST2) is above 4.5V. • Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of steering potentiometer 1 system (ST1). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from steering potentiometer 2 (ST2) can be checked in monitoring mode. (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
1
2 Possible causes and standard value in normal state 3
5
Cause Defective sensor power source system
Standard value in normal state/Remarks on troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering potentiTL1 (male) Voltage ometer 2 (Internal disconBetween M – F 2kΩ ± 20% nection or short circuit) Between E – M Between E – F + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between STCN1 (Contact with 24V circuit) Resistance Max. 1V (female) I – TL1 (female) E with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between I – K 0.5 – 4.5V
Circuit diagram related to steering potentiometer
20-532
D475A-3
TROUBLESHOOTING
ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK40KA
Brake potentiometer: Disconnection (KA) (Steering controller system)
• Signal voltage of brake potentiometer circuit is below 0.5V. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Does not control with signal of brake potentiometer (Brake can be operated with pedal). Limits operation of engine and transmission. Brake control performance of brake pedal lowers. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from brake potentiometer can be checked in monitoring mode. (Code 50400: Voltage of brake potentiometer) • Method of reproducing error code: Turn starting switch ON and operate brake pedal.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake potentiomBRK (male) Resistance eter (Internal disconnection Between A – C 4.0 – 6.0kΩ or short circuit) Between A – B 0.25 – 7.0kΩ Between B – C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN1 (female) L – Resistance Max. 1Ω ing or defective contact in BRK (female) C connector) Wiring harness between STCN1 (female) 3 – Resistance Max. 1Ω BRK (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN1 (Contact with ground circuit) (female) 3 – BRK (female) B with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 3 – K 0.5 – 4.5V
Circuit diagram related to brake potentiometer
D475A-3
20-533
TROUBLESHOOTING
ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK40KB
Trouble
Brake potentiometer: Short circuit (KB) (Steering controller system)
• Signal voltage of brake potentiometer circuit is below 0.5V or above 4.5V. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Does not control with signal of brake potentiometer (Brake can be operated with pedal). Limits operation of engine and transmission. Brake control performance of brake pedal lowers. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from brake potentiometer can be checked in monitoring mode. (Code 50400: Voltage of brake potentiometer) • Method of reproducing error code: Turn starting switch ON and operate brake pedal.
1
2 Possible causes and standard value in normal state 3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake potentiomBRK (male) Resistance eter (Internal disconnection A–C 4.0 – 6.0kΩ or short circuit) A–B 0.25 – 7.0kΩ B–C 0.25 – 7.0kΩ + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between STCN1 (Contact with 24V circuit) (female) 3 – BRK (female) B with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 3 – K 0.5 – 4.5V
Circuit diagram related to brake potentiometer
20-534
D475A-3
ERROR DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT ERROR CODE DK55KXCODE (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) TROUBLESHOOTING
SIGNAL IS OUT OF NORMAL RANGE (KX)) ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ))
ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code Forward-reverse potentiometer: Input signal is out of normal range Trouble (KX) (Transmission controller system) DK55KX • Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and either of error codes [DK57KA] and [DK57KB] are displayed simultaneously. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine, transmission, and brake. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state
D475A-3
•
• • • •
•
Error code Forward-reverse potentiometer: Disconnection or short circuit (KZ)) Trouble (Transmission controller system) DK55KZ When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnormal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and [DK57KB] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
20-535
TROUBLESHOOTING
ERROR CODE DK55L8 POTENTIOMETER: SEE TABLE ERROR CODE (FORWARD-REVERSE DK55L8 (FORWARD-REVERSE POTENTIOMETER: (L8)) SEE TABLE (L8))
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) Action code CALL E03 Contents of trouble Action of controller
• • • •
Problem that appears on machine Related information
Possible causes and standard value in normal state
20-536
Error code Forward-reverse potentiometer: See table (L8) Trouble (Transmission controller system) DK55L8 Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is below 4.41V or above 5.59V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3) and 2 (FR4). Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
D475A-3
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK56KA
Forward-reverse potentiometer 1: Disconnection (KA) (Transmission controller system)
• Signal voltage of forward-reverse potentiometer 1 system (FR3) is below 0.5V. • Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of forward-reverse potentiometer 2 system (FR4). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from forward-reverse potentiometer 1 (FR3) can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward-reverse TL1 (male) Resistance potentiometer 1 (Internal disconnection or short cirBetween L – J 2kΩ ± 20% cuit) Between K – L Between K – J + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN1 (female) L – Resistance Max. 1Ω ing or defective contact in TL1 (female) L connector) Wiring harness between STCN1 (female) 2 – Resistance Max. 1Ω TL1 (female) K + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN1 (Contact with ground circuit) (female) 2 – TL1 (female) K with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. STCN1 Voltage troller Between 2 – K 0.5 – 4.5V
Circuit diagram related to forward-reverse potentiometer
D475A-3
20-537
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: CIRCUIT (KB)) (KB)) SHORT CIRCUIT
TROUBLESHOOTING
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK56KB
Trouble
Forward-reverse potentiometer 1: Short circuit (KB) (Transmission controller system)
• Signal voltage of forward-reverse potentiometer 1 system (FR3) is above 4.5V. • Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of forward-reverse potentiometer 2 system (FR4). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from forward-reverse potentiometer 1 (FR3) can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
1
2 Possible causes and standard value in normal state 3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward-reverse TL1 (male) Resistance potentiometer 1 (Internal disconnection or short cirBetween L – J 2kΩ ± 20% cuit) Between K – L Between K – J + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) Resistance Max. 1V TMCN1 (female) 2 – TL1 (female) K with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN1 Voltage troller Between 2 – K 0.5 – 4.5V
Circuit diagram related to forward-reverse potentiometer
20-538
D475A-3
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK57KA
• Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of forward-reverse potentiometer 1 system (FR3). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from forward-reverse potentiometer 2 (FR4) can be checked in monitoring mode. (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
2
3
4
5
20-540
Forward-reverse potentiometer 2: Disconnection (KA) (Transmission controller system)
• Signal voltage of forward-reverse potentiometer 2 system (FR4) is below 0.5V.
1
Possible causes and standard value in normal state
Trouble
Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power + See if error code [DAQ5KK] is displayed. If it is displayed, carry out source system troubleshooting for it first. + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward-reverse TL1 (male) Resistance potentiometer 2 (Internal disconnection or short cirBetween O – Q 2kΩ ± 20% cuit) Between P – O Between P – Q + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN1 (female) L – Resistance Max. 1Ω ing or defective contact in TL1 (female) O connector) Wiring harness between TMCN1 (female) I – Resistance Max. 1Ω TL1 (female) P + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN1 (female) I – TL1 (female) P with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN1 Voltage troller Between I – K 0.5 – 4.5V
D475A-3
TROUBLESHOOTING
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))
Circuit diagram related to forward-reverse potentiometer
D475A-3
20-541
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: CIRCUIT (KB)) (KB)) SHORT CIRCUIT
TROUBLESHOOTING
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK57KB
Forward-reverse potentiometer 2: Short circuit (KB) (Transmission controller system)
• Signal voltage of forward-reverse potentiometer 2 system (FR4) is above 4.5V. • Flashes caution lamp and turns on caution buzzer. • Continues controlling with signal of forward-reverse potentiometer 1 system (FR3). • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input (Voltage) from forward-reverse potentiometer 2 (FR4) can be checked in monitoring mode. (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
1
Possible causes and standard value in normal state
Trouble
2
3
4
Cause Standard value in normal state/Remarks on troubleshooting Disconnection in wiring harness (Disconnection in wir- See if error code [DAQ5KK] is displayed. If it is displayed, carry out ing or defective contact in troubleshooting for it first. connector) + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward-reverse TL1 (male) Resistance potentiometer 2 (Internal Between O – Q 2kΩ ± 20% disconnection or short circuit) Between P – O Between P – Q + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN1 (female) I - TL1 (female) P with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. troller TMCN1 Voltage Between I - K 0.5 – 4.5V
Circuit diagram related to forward-reverse potentiometer
20-542
D475A-3
TROUBLESHOOTING
ERROR CODE DK60KA (ACCELERATION SENSOR: DISCONNECTION (KA))
ERROR CODE DK60KA (ACCELERATION SENSOR: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK60KA
Acceleration sensor: Disconnection (KA) (Steering controller system)
• Signal voltage of acceleration sensor is below 0.5V. • Turns shoe slip control (SSC) function OFF. • Even if shoe slips, engine speed does not change. • Input (Voltage) from acceleration sensor can be checked in monitoring mode. (Code 60200: Voltage of acceleration sensor) • Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DB36KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective acceleration sensor (Internal trouble) SSA Voltage Between 2 – 3 0.75 – 4.25V + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN1 (female) L – Resistance Max. 1Ω ing or defective contact in SSA (female) 1 connector) Wiring harness between STCN1 (female) 1 – Resistance Max. 1Ω SSA (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN1 (Contact with ground circuit) (female) 1 – SSA (female) 2 with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 1 – K 0.75 – 4.25V
Circuit diagram related to acceleration sensor
D475A-3
20-543
TROUBLESHOOTING
ERROR CODE DK60KB (ACCELERATION SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DK60KB (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DK60KB
Acceleration sensor: Short circuit (KB) (Steering controller system)
• Signal voltage of acceleration sensor is above 4.7V. • Turns shoe slip control (SSC) function OFF. • Even if shoe slips, engine speed does not change. • Input (Voltage) from acceleration sensor can be checked in monitoring mode. (Code 60200: Voltage of acceleration sensor) • Method of reproducing error code: Turn starting switch ON.
1
2 Possible causes and standard value in normal state
Trouble
3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DB36KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective acceleration sensor (Internal trouble) SSA Voltage Between 2 – 3 0.75 – 4.25V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) STCN1 (female) 1 – SSA (female) 2 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between 1 – K 0.75 – 4.25V
Circuit diagram related to acceleration sensor
20-544
D475A-3
TROUBLESHOOTING
DKF1KX
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DKF1KX
Trouble
• The input voltage from the right bank rack sensor is below 0.1 V or above 4.4 V. • Flashes the caution lamp and turns on the caution buzzer. • Stops injection from the right bank fuel pump. • Only the left bank of the engine operates. • Method of reproducing error code: Turn the starting switch ON or start the engine. Cause Defective sensor power 1 supply system
2
3 Possible causes and standard value in normal state
4
5
D475A-3
Rack sensor right: Out of input signal range (KX) (Engine controller system)
Standard value in normal state/Remarks on troubleshooting If error code [DB45KP] is displayed, carry out troubleshooting for it first.
aPrepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. E13 Voltage Between (1) and (2) Power supply 4.6 – 5.4 V Defective right bank rack Between (3) and (2) Signal (+) 0.1 – 4.4 V sensor (Internal defect) Between (4) and (2) Signal (–) 0.1 – 4.4 V The voltage of the rack sensor is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE31 (female) (7) and Resistance Max. 1 z wiring harness or defective E13 (female) (3) contact in connector) Wiring harness between LE31 (female) (17) Resistance Max. 1 z and E13 (female) (4) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE31 Short circuit with chassis (female) (7) and E13 (female) (3) and chassis Resistance Min. 1 Mz ground in wiring harness ground (Contact with ground circuit) Between wiring harness between LE31 (female) (17) and E13 (female) (4) and chassis Resistance Min. 1 Mz ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE2 (female) (16), JE2, and E13 (female) (1) and chassis Voltage Max. 1 V ground Short circuit with power source in wiring harness Between wiring harness between LE31 (Contact with 24-V circuit) (female) (7) and E13 (female) (3) and chassis Voltage Max. 1 V ground Between wiring harness between LE31 (female) (17) and E13 (female) (4) and chassis Voltage Max. 1 V ground
20-544-1 (1)
TROUBLESHOOTING
DKF1KX
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE2, LE31 Voltage Between LE2 (16) Power supply 4.6 – 5.4 V 6 Defective engine controller and LE31 (16) Between LE31 (7) Signal (+) 0.1 – 4.4 V and LE31 (16) Between LE31 (17) Signal (–) 0.1 – 4.4 V and LE31 (16)
Circuit diagram related to right bank rack sensor
20-544-2 (1)
D475A-3
TROUBLESHOOTING
DKF2KX
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DKF2KX
Trouble
• The input voltage from the left bank rack sensor is below 0.1 V or above 4.4 V. • Flashes the caution lamp and turns on the caution buzzer. • Stops injection from the left bank fuel pump. • Only the right bank of the engine operates. • Method of reproducing error code: Turn the starting switch ON or start the engine. Cause Defective sensor power 1 supply system
2
Possible causes and standard value in normal state
3
4
5
D475A-3
Rack sensor left: Out of input signal range (KX) (Engine controller system)
Standard value in normal state/Remarks on troubleshooting If error code [DB45KP] is displayed, carry out troubleshooting for it first.
aPrepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. E9 Voltage Between (1) and (2) Power supply 4.6 – 5.4 V Defective left bank rack Between (3) and (2) Signal (+) 0.1 – 4.4 V sensor (Internal defect) Between (4) and (2) Signal (–) 0.1 – 4.4 V The voltage of the rack sensor is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE31 (female) (8) and Resistance Max. 1 z wiring harness or defective E9 (female) (3) contact in connector) Wiring harness between LE31 (female) (18) Resistance Max. 1 z and E9 (female) (4) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE31 Short circuit with chassis (female) (8) and E9 (female) (3) and chassis Resistance Min. 1 Mz ground in wiring harness ground (Contact with ground circuit) Between wiring harness between LE31 (female) (18) and E9 (female) (4) and chassis Resistance Min. 1 Mz ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE2 (female) Voltage Max. 1 V (16) and E9 (female) (1) and chassis ground Short circuit with power Between wiring harness between LE31 source in wiring harness Voltage Max. 1 V (Contact with 24-V circuit) (female) (8) and E9 (female) (3) and chassis ground Between wiring harness between LE31 (female) (18) and E9 (female) (4) and chassis Voltage Max. 1 V ground
20-544-3 (1)
TROUBLESHOOTING
DKF2KX
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LE2, LE31 Voltage Between LE2 (16) Power supply 4.6 – 5.4 V 6 Defective engine controller and LE31 (16) Between LE31 (8) Signal (+) 0.1 – 4.4 V and LE31 (16) Between LE31 (18) Signal (–) 0.1 – 4.4 V and LE31 (16)
Circuit diagram related to left bank rack sensor
20-544-4 (1)
D475A-3
TROUBLESHOOTING
ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA))
ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DKH1KA
Pitch angle sensor: Disconnection (KA) (Steering controller system)
• Signal voltage of pitch angle sensor is below 0.15V. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Cannot recognize pitch angle. Limits operation of engine and transmission. Shocks are made when gear is shifted on slope and when machine is steered on level place. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from pitch angle sensor can be checked in monitoring mode. (Code 60100: Voltage of pitch angle sensor) • Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes and standard value in normal state
Trouble
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DB36KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective pitch angle sensor (Internal trouble) PT1 Voltage Between B – A 0.15 – 4.85V + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN1 (female) F – Resistance Max. 1Ω ing or defective contact in PT1 (female) C connector) Wiring harness between STCN1 (female) C – Resistance Max. 1Ω PT1 (female) B + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN1 (Contact with ground circuit) (female) C – PT1 (female) B with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between C – K 0.15 – 4.85V
Circuit diagram related to pitch angle sensor
D475A-3
20-545
TROUBLESHOOTING
ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DKH1KB
Pitch angle sensor: Short circuit (KB) (Steering controller system)
• Signal voltage of pitch angle sensor is above 4.85V. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Cannot recognize pitch angle. Limits operation of engine and transmission. Shocks are made when gear is shifted on slope and when machine is steered on level place. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from pitch angle sensor can be checked in monitoring mode. (Code 60100: Voltage of pitch angle sensor) • Method of reproducing error code: Turn starting switch ON.
1
2 Possible causes and standard value in normal state
Trouble
3
4
Cause Standard value in normal state/Remarks on troubleshooting Defective 24V power source See if error code [DB36KK] is displayed. If it is displayed, carry out system troubleshooting for it first. + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective pitch angle sensor (Internal trouble) PT1 Voltage Between B – A 0.15 – 4.85V + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between STCN1 (Contact with 24V circuit) Voltage Max. 1V (female) C – PT1 (female) B with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between C – K 0.15 – 4.85V
Circuit diagram related to pitch angle sensor
20-546
D475A-3
ERROR CODE ERROR DLE1KACODE (ENGINE NE SPEED SENSOR: DISCONNECTION DLE1KA (ENGINE NE SPEED SENSOR: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DLE1KA (ENGINE NE SPEED SENSOR: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DLE1KA
Trouble
• Engine Ne speed sensor signal cannot be input to the controller. • After stopping the machine, the controller recognizes that the engine speed is 0. • Excessive shift shock of transmission. • Method of reproducing error code: Start engine. Cause
Possible causes and standard value in normal state
20-548
Engine Ne speed sensor: Disconnection (KA) (Steering controller system)
1
Defective engine Ne speed sensor (Internal disconnection or short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Defective steering controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. E12 (male) Resistance Between 1 – 2 500 – 1000Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN2 (female) ^ – Resistance Max. 1Ω E12 (female) 1 Wiring harness between ECN2 (female) S – Resistance Max. 1Ω E12 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN2 Resistance Min. 1MΩ (female) ^ – E12 (female) 1 with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN2 (female) Resistance Between S – ^ 500 – 1000Ω Between ^ – chassis ground Min. 1MΩ
D475A-3
TROUBLESHOOTING
ERROR CODE ERROR DLE1KACODE (ENGINE NE SPEED SENSOR: DISCONNECTION DLE1KA (ENGINE NE SPEED SENSOR: (KA)) DISCONNECTION (KA))
Circuit diagram related to engine speed sensor
D475A-3
20-549
TROUBLESHOOTING
DLE4LC
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DLE4LC
Trouble
• After the engine is started, the input value from engine speed sensor A is below 300 rpm. • Flashes the caution lamp and turns on the caution buzzer. • Controls with the signals from engine speed sensor B.
• Method of reproducing error code: Start the engine. Cause Defective engine speed 1 sensor A (Internal disconnection or short circuit) 2
Possible causes and standard value in normal state
20-549-1 (1)
Engine speed sensor A: Refer to table (LC) (Engine controller system)
Defective adjustment of engine speed sensor A
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. E16 (male) Resistance Between (1) and (2) 500 – 1,000 z Between (1) and chassis ground Min. 1 Mz Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE31 (female) (2) and 3 Resistance Max. 1 z wiring harness or defective E16 (female) (1) contact in connector) Wiring harness between LE31 (female) (14) Resistance Max. 1 z and E16 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 4 ground in wiring harness Between wiring harness between LE31 (Contact with ground circuit) (female) (2) and E16 (female) (1) and chassis Resistance Min. 1 Mz ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE31 (female) Resistance 5 Defective engine controller Between (2) and (14) 500 – 1,000 z Between (2) and chassis ground Min. 1 Mz
D475A-3
TROUBLESHOOTING
DLE4LC
Circuit diagram related to engine speed sensor A
D475A-3
20-549-2 (1)
TROUBLESHOOTING
DLE5LC
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DLE5LC
Trouble
• After the engine is started, the input value from engine speed sensor B is below 300 rpm. • Flashes the caution lamp and turns on the caution buzzer. • Controls with the signals from engine speed sensor A.
• The signals of engine speed sensor B are used by the steering controller, too. Depending on the cause of the trouble, error code [DLE1KA] may be displayed at the same time. • Method of reproducing error code: Start the engine. Cause Defective engine speed sensor B 1 (Internal disconnection or short circuit) 2
Possible causes and standard value in normal state
20-549-3 (1)
Engine speed sensor B: Refer to table (LC) (Engine controller system)
Defective adjustment of engine speed sensor B
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. E12 (male) Resistance Between (1) and (2) 500 – 1,000 z Between (1) and chassis ground Min. 1 Mz Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE31 (female) (3) and 3 Resistance Max. 1 z wiring harness or defective E12 (female) (1) contact in connector) Wiring harness between LE31 (female) (14) Resistance Max. 1 z and E12 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. 4 ground in wiring harness Between wiring harness between LE31 (Contact with ground circuit) Resistance Min. 1 Mz (female) (3) and E12 (female) (1) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE31 (female) Resistance 5 Defective engine controller Between (3) and (14) 500 – 1,000 z Between (3) and chassis ground Min. 1 Mz
D475A-3
TROUBLESHOOTING
DLE5LC
Circuit diagram related to engine speed sensor B
D475A-3
20-549-4 (1)
ERROR CODE DLF1KA (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DLF1KA (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DLF1KA
Trouble
• Signal is not input from torque converter output speed sensor. • Flashes caution lamp and turns on caution buzzer. • Assumes that transmission output speed is 0rpm. • Transmission speed cannot be monitored. • Traction force cannot be calculated. • Input (rpm) from torque converter output speed sensor can be checked in monitoring mode. (Code 31400: Transmission speed • Method of reproducing error code: Start engine and travel machine actually. Cause
Possible causes and standard value in normal state
Torque converter output speed sensor: Disconnection (KA) (Transmission controller system)
1
Defective torque converter output speed sensor (Internal disconnection or short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TC1 (male) Resistance Between 1 – 2 500 – 1,000Ω Between 1, 2 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN2 (female) J – Resistance Max. 1Ω TC1 (female) 1 Wiring harness between TMCN2 (female) ] – Resistance Max. 1Ω TC1 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN2 (female) J – TC1 (female) 1 with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN2 (female) Resistance Between J – ] 500 – 1,000Ω Between J – chassis ground Min. 1MΩ
Circuit diagram related to torque converter output speed sensor
20-550
D475A-3
TROUBLESHOOTING
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB))
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DV00KB
Trouble
• Abnormal current flowed when caution buzzer circuit output ground signal. • Flashes caution lamp. • Stops caution buzzer circuit from outputting ground signal. • Caution buzzer does not sound. • Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1 second). Cause
Possible causes and standard value in normal state
Caution buzzer: Short circuit (KB) (Monitor panel system)
1
Defective caution buzzer (Internal short circuit)
2
Short circuit with power source in wiring harness (Contact with 24V circuit)
3
Defective monitor panel
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 217 (male) Resistance Between 1 – 2 200Ω + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between 217 (feVoltage Max. 1V male) 2 – S03 (female) H with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S03 Caution buzzer Voltage When turned OFF 20 – 30V Between H – When turned ON chassis ground Max. 3V (sounding)
Circuit diagram related to caution buzzer
D475A-3
20-551
ERROR CODE ERROR DW55KACODE (BLADE PITCH BACK SOLENOID: DISCONNECTION DW55KA (BLADE PITCH BACK SOLENOID: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DW55KA (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW55KA
Trouble
• When signal is output to blade pitch back solenoid circuit, any current does not flow. • Stops outputting to blade pitch back solenoid circuit. • Blade pitch back mechanism does not work. • Output (ON – OFF) to blade pitch back solenoid can be checked in monitoring mode.] (Code 90001: transmission controller ON – OFF output 3.4) • Method of reproducing error code: Turn starting switch ON and perform blade pitch back operation. Cause
Possible causes and standard value in normal state
Blade pitch back solenoid: Disconnection (KA) (Transmission controller system)
1
Defective blade pitch back solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PPB (male) Resistance Between 1 – 2 20 – 60Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) P – Resistance Max. 1Ω PPB (female) 1 Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω PPB (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) P – PPB (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female) Resistance Between P – M 20 – 60Ω
Circuit diagram related to blade pitch back solenoid
20-552
D475A-3
ERROR CODEERROR DW55KB (BLADE PITCH (BLADE BACK SOLENOID: SHORT CIRCUIT CODE DW55KB PITCH BACK SOLENOID: (KB)) DISCONNECTION (KB))
TROUBLESHOOTING
ERROR CODE DW55KB (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW55KB
Trouble
Blade pitch back solenoid: Short circuit (KB) (Transmission controller system)
• When signal is output to blade pitch back solenoid circuit, abnormal current flowed. • Stops outputting to blade pitch back solenoid circuit. • Blade pitch back mechanism does not work. • Output to blade pitch back solenoid can be checked in monitoring mode. (Code 90001: Transmission controller ON-OFF output 4) • Method of reproducing error code: Turn starting switch ON and perform blade pitch back operation. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch back PPB (male) Resistance solenoid (Internal short circuit) Between 1 – 2 20 – 60Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) P – PPB (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between P – M 20 – 60Ω Between P – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch back solenoid
D475A-3
20-553
TROUBLESHOOTING
ERROR CODE ERROR DW56KACODE (BLADE PITCH DUMP SOLENOID: DISCONNECTION DW56KA (BLADE PITCH DUMP SOLENOID: (KA)) DISCONNECTION (KA))
ERROR CODE DW56KA (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA)) Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW56KA
Trouble
• When signal is output to blade pitch dump solenoid circuit, any current does not flow. • Stops outputting to blade pitch dump solenoid circuit. • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works). • Output (ON – OFF) to blade pitch dump solenoid can be checked in monitoring mode. (Code 90001: Transmission controller ON – OFF output 4) • Method of reproducing service code: Turn starting switch ON and perform blade pitch dump operation. Cause
Possible causes and standard value in normal state
Blade pitch dump solenoid: Disconnection (KA) (Transmission controller system)
1
Defective blade pitch dump solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PPD (male) Resistance Between 1 – 2 20 – 60Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) F – Resistance Max. 1Ω PPD (female) 1 Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω PPD (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) F – PPD (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female) Resistance Between F – M 10 – 40Ω
Circuit diagram related to blade pitch dump solenoid
20-554
D475A-3
CODE DW56KB PITCH DUMP SOLENOID: ERROR CODEERROR DW56KB (BLADE PITCH (BLADE DUMP SOLENOID: SHORT CIRCUIT SHORT CIRCUIT (KB)) (KB))
TROUBLESHOOTING
ERROR CODE DW56KB (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW56KB
Trouble
• When signal is output to blade pitch dump solenoid circuit, abnormal current flowed. • Stops outputting to blade pitch dump solenoid circuit. • Blade pitch dump mechanism does not work (When it is operated, single tilt mechanism works). • Output (ON – OFF) to blade pitch dump selector solenoid can be checked in monitoring mode. (Code 90001: Transmission controller ON-OFF output 4) • Method of reproducing error code: Turn starting switch ON and perform blade pitch dump operation. Cause
Possible causes and standard value in normal state
Blade pitch dump solenoid: Short circuit (KB) (Transmission controller system)
1
Defective blade pitch dump solenoid (Internal short circuit)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PPD (male) Resistance Between 1 – 2 10 – 40Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between Resistance Min. 1MΩ TMCN3 (female) F – PPD (female) 1 with chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female) Resistance Between F – M 20 – 60Ω Between F – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch dump solenoid
D475A-3
20-555
TROUBLESHOOTING
ERROR CODE DW57KA (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA))
ERROR CODE DW57KA (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW57KA
Trouble
Left tilt limit solenoid: Disconnection (KA) (Transmission controller system)
• When signal is output to left tilt limit solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to left tilt limit solenoid circuit. • Blade pitch back mechanism does not work. • Left tilt limit function does not operate. • Output (Current) to left tilt limit solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform dual tilt mode. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left tilt limit solenoid (Internal short circuit) TLL (male) Resistance Between 1 – 2 20 – 60Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) Q – Resistance Max. 1Ω ing or defective contact in TLL (female) 1 connector) Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω TLL (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) Q – TLL (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN3 (female) Resistance troller Between Q – M 20 – 60Ω
Circuit diagram related to left tilt limit solenoid
20-556
D475A-3
TROUBLESHOOTING
ERROR CODE DW57KB (LEFT TILT LIMIT SOLENOID: ERROR CODE DW57KB (LEFT TILT LIMIT SOLENOID:SHORT SHORTCIRCUIT CIRCUIT (KB)) (KB))
ERROR CODE DW57KB (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW57KB
Trouble
Left tilt limit solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to left tilt limit solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to left tilt limit solenoid circuit. • Blade pitch back mechanism does not work. • Left tilt limit function does not operate. • Output (ON – OFF) to left tilt limit solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output.) • Method of reproducing service code: Turn starting switch ON and perform dual tilt mode. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left tilt limit soleTLL (male) Resistance noid (Internal short circuit) Between 1 – 2 20 – 60Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) Q – TLL (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between Q – M 20 – 60Ω Between Q – chassis ground Min. 1MΩ
Circuit diagram related to left tilt limit solenoid
D475A-3
20-557
ERROR CODE ERROR DW58KACODE (RIGHT TILT LIMIT SOLENOID: DISCONNECTION DW58KA (RIGHT TILT LIMIT SOLENOID: (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DW58KA (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW58KA
Trouble
• When signal is output to right tilt limit solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to right tilt limit solenoid circuit. • Blade pitch back mechanism does not work. • Right tilt limit function does not operate. • Output (ON – OFF) to right tilt limit solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON – OFF output 3.) • Method of reproducing service code: Turn starting switch ON and perform dual tilt mode. Cause
Possible causes and standard value in normal state
Right tilt limit solenoid: Disconnection (KA) (Transmission controller system)
1
Defective right tilt limit solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TLR (male) Resistance Between 1 – 2 20 – 60Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) [ – Resistance Max. 1Ω TLR (female) 1 Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω TLR (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) [ – TLR (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female) Resistance Between [ – M 20 – 60Ω
Circuit diagram related to right tilt limit solenoid
20-558
D475A-3
TROUBLESHOOTING
ERROR CODE DW58KB (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DW58KB (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW58KB
Trouble
Right tilt limit solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to right tilt limit solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to right tilt limit solenoid circuit. • Blade pitch dump mechanism does not work. • Right tilt limit function does not operate. • Output (ON – OFF) to right tilt limit solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON – OFF output.) • Method of reproducing service code: Turn starting switch ON and perform dual tilt mode. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective Right tilt limit soleTLR (male) Resistance noid (Internal short circuit) Between 1 – 2 20 – 60Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female)[ – TLR (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between [ – M 20 – 60Ω Between [ – chassis ground Min. 1MΩ
Circuit diagram related to right tilt limit solenoid
D475A-3
20-559
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW5AKA
Trouble
• When signal is output to blade pitch selector solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to blade pitch selector solenoid circuit. • Blade pitch back mechanism does not work (When it is operated, pitch back mechanism works). • Left dual tilt does not work (Single tilt works when dual tilt is operated) • Output (ON – OFF) to blade pitch selector solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade pitch back operation. Cause
Possible causes and standard value in normal state
Blade pitch selector solenoid: Disconnection (KA) (Transmission controller system)
1
Defective blade pitch selector solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PST (male) Resistance Between 1 – 2 10 – 40Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) R – Resistance Max. 1Ω PST (female) 1 Wiring harness between TMCN3 (female) 3 – Resistance Max. 1Ω PST (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) R – PST (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female) Resistance Between R – 3 10 – 40Ω
Circuit diagram related to blade pitch selector solenoid
20-560
D475A-3
ERROR CODECODE DW5AKB (BLADE PITCHPITCH SELECTOR SOLENOID: SHORT ERROR DW5AKB (BLADE SELECTOR SOLENOID: CIRCUIT (KB)) (KB)) SHORT CIRCUIT
TROUBLESHOOTING
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW5AKB
Trouble
Blade pitch selector solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to blade pitch selector solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to blade pitch selector solenoid circuit. • Blade pitch back mechanism does not work (When it is operated, pitch back mechanism works). • Left dual tilt does not work. • Output (ON – OFF) to blade pitch selector solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON – OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade pitch back operation. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch selec- without turning starting switch ON. PST (male) Resistance tor solenoid (Internal short circuit) Between 1 – 2 10 – 40Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) R – PST (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between R – 3 10 – 40Ω Between R – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch selector solenoid
D475A-3
20-561
TROUBLESHOOTING
ERROR CODE DW5JKA (BLADE PITCH SOLENOID: DISCONNECTION (KA))
ERROR CODE DW5JKA (BLADE PITCH SOLENOID: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW5JKA
Trouble
Blade pitch solenoid: Disconnection (KA) (Transmission controller system)
• When signal is output to blade pitch solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to blade pitch solenoid circuit. • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works). • Dual tilt does not work (Single tilt works when dual tilt is operated). • Output (Current) to blade pitch solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade pitch operation. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch solenoid (Internal short circuit) PIT (male) Resistance Between 1 – 2 10 – 40Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) 6 – Resistance Max. 1Ω ing or defective contact in PIT (female) 1 connector) Wiring harness between TMCN3 (female) C – Resistance Max. 1Ω PIT (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) 6 – PIT (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN3 (female) Resistance troller Between 6 – C 10 – 40Ω
Circuit diagram related to blade pitch solenoid
20-562
D475A-3
TROUBLESHOOTING
ERROR CODE DW5JKB (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DW5JKB (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW5JKB
Trouble
Blade pitch solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to blade pitch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to blade pitch solenoid circuit. • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works). • Dual tilt does not work (Single tilt works when dual tilt is operated). • Output (ON – OFF) to blade pitch solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade pitch operation. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch solePIT (male) Resistance noid (Internal short circuit) Between 1 – 2 10 – 40Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) 6 – PIT (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between 6 – C 10 – 40Ω Between 6 – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch solenoid
D475A-3
20-563
ERROR CODE DW5LKA (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DW5LKA (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW5LKA
Trouble
• When signal is output to blade pitch dump assist solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to blade pitch dump assist solenoid circuit. • Blade pitch dump mechanism does not work (When it is operated, blade tilt mechanism works). • Right dual tilt does not work • Output (ON – OFF) to blade pitch dump assist solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade pitch operation. Cause
Possible causes and standard value in normal state
Blade pitch dump assist solenoid: Disconnection (KA) (Transmission controller system)
1
Defective blade pitch dump assist solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PDA (male) Resistance Between 1 – 2 10 – 40Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) G – Resistance Max. 1Ω PDA (female) 1 Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω PDA (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) G – PDA (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMCN3 (female) Resistance Between G – M 10 – 40Ω
Circuit diagram related to blade pitch dump assist solenoid
20-564
D475A-3
ERROR CODE DW5LKB (BLADE PITCHPITCH DUMPDUMP ASSISTASSIST SOLENOID: SHORT ERROR CODE DW5LKB (BLADE SOLENOID: CIRCUIT (KB)) (KB)) SHORT CIRCUIT
TROUBLESHOOTING TROUBLESHOOTING
ERROR CODE DW5LKB (BLADE PITCH DUMP ASSIST SOLENOID: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW5LKB
Trouble
Blade pitch dump assist solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to blade pitch dump assist solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to blade pitch dump assist solenoid circuit. • Blade pitch dump mechanism does not work (When it is operated, blade tilt mechanism works). • Right dual tilt does not work • Output (ON – OFF) to blade pitch dump assist solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade pitch operation. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch dump PDA (male) Resistance assist solenoid (Internal short circuit) Between 1 – 2 10 – 40Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) G – PDA (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between G – M 10 – 40Ω Between G – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch dump assist solenoid
D475A-3
20-565
TROUBLESHOOTING
ERROR CODE DW98KA (UNLOAD SOLENOID: DISCONNECTION (KA))
ERROR CODE DW98KA (UNLOAD SOLENOID: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW98KA
Trouble
Unload solenoid: Disconnection (KA) (Transmission controller system)
• When signal is output to unload solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to unload solenoid circuit. • Blade lift speed is slow • Ripper speed is slow • Output (Current) to unload solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON-OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade lift full operation. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective unload solenoid (Internal short circuit) UNL (male) Resistance Between 1 – 2 40– 80Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) 7 – Resistance Max. 1Ω ing or defective contact in UNL (female) 1 connector) Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω UNL (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) 7 – UNL (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN3 (female) Resistance troller Between 7 – M 40 – 80Ω
Circuit diagram related to unload solenoid
20-566
D475A-3
TROUBLESHOOTING
ERROR CODE DW98KB (UNLOAD SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DW98KB (UNLOAD SOLENOID: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DW98KB
Trouble
Unload solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to unload solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to unload solenoid circuit. • Blade lift speed is slow • Ripper speed is slow • Output (ON – OFF) to unload solenoid can be checked in monitoring mode. (Code 90000: Transmission controller ON – OFF output 3) • Method of reproducing service code: Turn starting switch ON and perform blade lift full operation. Cause
1
Possible causes and standard value in normal state
2
3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective unload solenoid UNL (male) Resistance (Internal short circuit) Between 1 – 2 40 – 80Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) 7 – UNL (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 (female) Resistance troller Between 7 – M 40 – 80Ω Between 7 – chassis ground Min. 1MΩ
Circuit diagram related to unload solenoid
D475A-3
20-567
ERROR CODE DWN3KA (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DWN3KA (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DWN3KA
Trouble
• When signal is output to sudden stop prevention solenoid circuit, any current does not flow. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Brake is applied lightly during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode. (Code 31628: Sudden stop prevention solenoid drive current) • Method of reproducing error code: Turn starting switch ON. Cause
Possible causes and standard value in normal state
Sudden stop prevention solenoid: Disconnection (KA) (Steering controller system)
1
Defective sudden stop prevention solenoid (Internal disconnection)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective steering controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STB (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) 7 – Resistance Max. 1Ω STB (female) 1 Wiring harness between STCN3 (female) C – Resistance Max. 1Ω STB (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN3 (female) 7 – STB (female) 1 with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN3 Resistance Between 7 – C 5 – 25Ω
Circuit diagram related to sudden stop prevention solenoid
20-568
D475A-3
ERROR CODE DWN3KB (SUDDEN STOP STOP PREVENTION SOLENOID: SHORT ERROR CODE DWN3KB (SUDDEN PREVENTION SOLENOID: CIRCUIT (KB)) (KB)) SHORT CIRCUIT
TROUBLESHOOTING
ERROR CODE DWN3KB (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DWN3KB
Trouble
Sudden stop prevention solenoid: Short circuit (KB) (Steering controller system)
• When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed. • • • • • •
Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Brake is applied lightly during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode. (Code 31628: Sudden stop prevention solenoid drive current) • Method of reproducing error code: Turn starting switch ON. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective sudden stop preSTB (male) Resistance vention solenoid (Internal short circuit) Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN3 (Contact with ground circuit) (female) 7 – STB (female) 1 with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between STCN3 ness (with another wiring (female) 7 – STB (female) 1 with wiring harharness) Resistance Min. 1MΩ ness between CN3 (female) C – STB (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN3 Resistance Defective steering controller Between 7 – C 5 – 25Ω Between 7 – chassis ground Min. 1MΩ
Circuit diagram related to sudden stop prevention solenoid
D475A-3
20-569
TROUBLESHOOTING
ERROR CODE DXH1KA (LOCK-UP SOLENOID: DISCONNECTION (KA))
ERROR CODE DXH1KA (LOCK-UP SOLENOID: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH1KA
Trouble
Lock-up solenoid: Disconnection (KA) (Transmission controller system)
• When signal is output to torque converter lock-up solenoid circuit, any current does not flow. • Stops outputting to torque converter lock-up solenoid circuit. • Torque converter is not locked-up. • Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode. (Code 31627: Torque converter lock-up solenoid drive current) • Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting Defective torque converter without turning starting switch ON. lock-up solenoid (Internal 653 (male) Resistance short circuit) Between 1 – 2 40 – 80Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) \ – Resistance Max. 1Ω ing or defective contact in 653 (female) 1 connector) Wiring harness between TMCN3 (female) M – Resistance Max. 1Ω 653 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) \ – 653 (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then turn starting switch ON and Defective transmission con- carry out troubleshooting. TMCN3 (female) Resistance troller Between \ – M 40 – 80Ω
Circuit diagram related to torque converter lock-up solenoid
20-570
D475A-3
TROUBLESHOOTING
ERROR CODE DXH1KB (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DXH1KB (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH1KB
Trouble
Torque converter lock-up solenoid: Short circuit (KB) (Transmission controller system)
• When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed. • Stops outputting to torque converter lock-up solenoid circuit. • Torque converter is not locked-up. • Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode. (Code 31627: Torque converter lock-up solenoid drive current) • Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective torque converter 653 (male) Resistance lock-up solenoid (Internal short circuit) Between 1 – 2 40 – 80Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) \ – 653 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMCN3 ness (with another wiring (female) \ – 653 (female) 1 with wiring harharness) Resistance Min. 1MΩ ness between TMCN3 (female) M – 653 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission conTMCN3 Resistance troller Between \ – M 40 – 80Ω Between \ – chassis ground Min. 1MΩ
Circuit diagram related to torque converter lock-up solenoid
D475A-3
20-571
TROUBLESHOOTING
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH4KA
Trouble
1st clutch ECMV: Disconnection (KA) (Transmission controller system)
• When signal is output to 1st clutch solenoid circuit, any current does not flow. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 1st clutch solenoid circuit. Limits operation of engine and transmission. Automatic shift-down function does not work. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F2 and R2. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. (Code 31602, 31612: Output current of 1st clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F1 or R1. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch solenoid (Internal short circuit) S1T7 (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) E – Resistance Max. 1Ω ing or defective contact in S1T7 (female) 1 connector) Wiring harness between TMCN3 (female) 3 – Resistance Max. 1Ω S1T7 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) E – S1T7 (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then carry out troubleshooting Defective transmission con- without turning starting switch ON. troller TMCN3 (female) Resistance Between E – 3 5 – 25Ω
Circuit diagram related to transmission 1st clutch ECMV
20-572
D475A-3
TROUBLESHOOTING
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH4KB
Trouble
1st clutch ECMV: Short circuit (KB) (Transmission controller system)
• When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 1st clutch solenoid circuit. Limits operation of engine and transmission. Automatic shift-down function does not work. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F2 and R2. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. (Code 31602, 31612: Output current of 1st clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F1 or R1. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch soleS1T7 (male) Resistance noid (Internal short circuit) Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) E – S1T7 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMCN3 ness (with another wiring (female) E – S1T7 (female) 1 with wiring harharness) Resistance Min. 1MΩ ness between TMCN3 (female) 3 – S1T7 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission conTMCN3 Resistance troller Between E – 3 5 – 25Ω Between E – chassis ground Min. 1MΩ
Circuit diagram related to transmission 1st clutch ECMV
D475A-3
20-573
TROUBLESHOOTING
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH5KA
Trouble
2nd clutch ECMV: Disconnection (KA) (Transmission controller system)
• When signal is output to 2nd clutch solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission 2nd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. (Code 31603, 31613: Output current of 2nd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F2 or R2. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 2nd clutch solenoid (Internal short circuit) S2T5 (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) Z – Resistance Max. 1Ω ing or defective contact in S2T5 (female) 1 connector) Wiring harness between TMCN3 (female) C – Resistance Max. 1Ω S2T5 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) Z – S2T5 (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then carry out troubleshooting Defective transmission con- without turning starting switch ON. troller TMCN3 (female) Resistance Between Z – C 5 – 25Ω
Circuit diagram related to transmission 2nd clutch ECMV
20-574
D475A-3
TROUBLESHOOTING
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH5KB
Trouble
2nd clutch ECMV: Short circuit (KB) (Transmission controller system)
• When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission 2nd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. (Code 31603, 31613: Output current of 2nd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F2 or R2. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 2nd clutch soleS2T5 (male) Resistance noid (Internal short circuit) Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) Z – S2T5 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMCN3 ness (with another wiring (female) Z – S2T5 (female) 1 with wiring harharness) Resistance Min. 1MΩ ness between TMCN3 (female) C – S2T5 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission conTMCN3 Resistance troller Between Z – C 5 – 25Ω Between Z – chassis ground Min. 1MΩ
Circuit diagram related to transmission 2nd clutch ECMV
D475A-3
20-575
TROUBLESHOOTING
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH6KA
Trouble
3rd clutch ECMV: Disconnection (KA) (Transmission controller system)
• When signal is output to 3rd clutch solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission 3rd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. (Code 31604, 31614: Output current of 3rd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F3 or R3. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch solenoid (Internal short circuit) S3T3 (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between TMCN3 (female) 5 – Resistance Max. 1Ω ing or defective contact in S3T3 (female) 1 connector) Wiring harness between TMCN3 (female) 3 – Resistance Max. 1Ω S3T3 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between (Contact with 24V circuit) TMCN3 (female) 5 – S3T3 (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then carry out troubleshooting Defective transmission con- without turning starting switch ON. troller TMCN3 (female) Resistance Between 5 – 3 5 – 25Ω
Circuit diagram related to transmission 3rd clutch ECMV
20-576
D475A-3
TROUBLESHOOTING
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH6KB
Trouble
3rd clutch ECMV: Short circuit (KB) (Transmission controller system)
• When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission 3rd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. (Code 31604, 31614: Output current of 3rd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F3 or R3. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch soleS3T3 (male) Resistance noid (Internal short circuit) Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) TMCN3 (female) 5 – S3T3 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMCN3 ness (with another wiring (female) 5 – S3T3 (female) 1 with wiring harharness) Resistance Min. 1MΩ ness between TMCN3 (female) 3 – S3T3 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission conTMCN3 Resistance troller Between 5 – 3 5 – 25Ω Between 5 – chassis ground Min. 1MΩ
Circuit diagram related to transmission 3rd clutch ECMV
D475A-3
20-577
TROUBLESHOOTING
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH7KA
Trouble
• When signal is output to reverse clutch solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission reverse clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606, 31616: Output current of reverse clutch ECMV) • Method of reproducing service code: Start engine and drive machine in reverse. Cause
Possible causes and standard value in normal state
Reverse clutch ECMV: Disconnection (KA) (Transmission controller system)
1
Defective reverse clutch solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRT1 (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) O – Resistance Max. 1Ω SRT1 (female) 1 Wiring harness between TMCN3 (female) C – Resistance Max. 1Ω SRT1 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) O – SRT1 (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN3 (female) Resistance Between O – C 5 – 25Ω
Circuit diagram related to transmission reverse clutch ECMV
20-578
D475A-3
TROUBLESHOOTING
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH7KB
Trouble
Reverse clutch ECMV: Short circuit (KB) (Transmission controller system)
• When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission reverse clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1. • Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606, 31616: Output current of reverse clutch ECMV) • Method of reproducing service code: Start engine and drive machine in reverse. Cause
1
Defective reverse clutch solenoid (Internal short circuit)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Short circuit in wiring harness (with another wiring harness)
4
Defective transmission controller
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRT1 (male) Resistance Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) O – SRT1 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness between TMCN3 (female) O – SRT1 (female) 1 with wiring harResistance Min. 1MΩ ness between TMCN3 (female) C – SRT1 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN3 Resistance Between O – C 5 – 25Ω Between O – chassis ground Min. 1MΩ
Circuit diagram related to transmission reverse clutch ECMV
D475A-3
20-579
TROUBLESHOOTING
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH8KA
Trouble
• When signal is output to forward clutch solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission forward clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output current of forward clutch ECMV) • Method of reproducing service code: Start engine and drive machine forward. Cause
Possible causes and standard value in normal state
Forward clutch ECMV: Disconnection (KA) (Transmission controller system)
1
Defective forward clutch solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective transmission controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SFT1 (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMCN3 (female) Y – Resistance Max. 1Ω SFT1 (female) 1 Wiring harness between TMCN3 (female) C – Resistance Max. 1Ω SFT1 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMCN3 (female) Y – SFT1 (female) 1 with Voltage Max. 1V chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN3 (female) Resistance Between Y – C 5 – 25Ω
Circuit diagram related to transmission forward clutch ECMV
20-580
D475A-3
TROUBLESHOOTING
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXH8KB
Trouble
Forward clutch ECMV: Short circuit (KB) (Transmission controller system)
• When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission forward clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output current of forward clutch ECMV) • Method of reproducing service code: Start engine and drive machine forward. Cause
1
Defective forward clutch solenoid (Internal short circuit)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Short circuit in wiring harness (with another wiring harness)
4
Defective transmission controller
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SFT1 (male) Resistance Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMCN3 (female) Y – SFT1 (female) 1 with Resistance Min. 1MΩ chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness between TMCN3 (female) Y – SFT1 (female) 1 with wiring harResistance Min. 1MΩ ness between TMCN3 (female) C – SFT1 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMCN3 Resistance Between Y – C 5 – 25Ω Between Y – chassis ground Min. 1MΩ
Circuit diagram related to transmission forward clutch ECMV
D475A-3
20-581
ERROR CODE DXH9KA (RIGHT STEERING CLUTCH ECMV : DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DXH9KA (RIGHT STEERING CLUTCH ECMV : DISCONNECTION (KA)) Action code
Error code
CALL E03
DXH9KA
Trouble
Disconnection in right steering clutch ECMV (KA) (Steering controller system)
Contents of trouble • When signal is output to right steering clutch solenoid circuit, current does not flow.
• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right.
Problem that • Once machine is stopped, engine speed is limited to medium (half). appears on machine
• Once machine is stopped, travel is limited to F1 and R1.
• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90603, 90601: Right steering clutch ECMV output current) Related information • Method of reproducing error code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right). Cause Defective right steering 1 clutch solenoid (Internal short circuit)
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRC7 (male)
Resistance
Between 1 – 2
5 – 25 Ω
+ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between STCN3 (female) Y – Resistance Max. 1 Ω SRC7 (female) 1 defective contact in connecPossible causes Wiring harness between STCN3 (female) M – tor) and standard valResistance Max. 1 Ω SRC7 (female) 2 ue in normal state + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 3 source in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) Y – SRC7 (female) 1 with Voltage Max. 1 V chassis ground
4 Defective steering controller
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN3 (female)
Resistance
Between Y – M
5 – 25 Ω
Circuit diagram related to right steering clutch ECMV
20-582
D475A-3
ERROR CODEERROR DXH9KB (RIGHT STEERING CLUTCH ECMV: CLUTCH SHORT CIRCUIT CODE DXH9KB (RIGHT STEERING ECMV: (KB)) SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DXH9KB (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code
Error code
CALL03
DXH9KB
Trouble
Short circuit in right steering clutch ECMV (KB) (Steering controller system)
Contents of trouble • When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to right steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to right.
Problem that • Once machine is stopped, engine speed is limited to medium (half). appears on machine
• Once machine is stopped, travel is limited to F1 and R1.
• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90603, 90601: Right steering clutch ECMV output current) Related information • Method of reproducing error code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right). Cause Defective right steering 1 clutch solenoid (Internal short circuit)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SRC7 (male)
Resistance
Between 1 – 2
5 – 25 Ω
Between 1 – chassis ground
Min. 1 MΩ
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) STCN3 (female) Y – SRC7 (female) 1 with Resistance Min. 1 MΩ chassis ground Short circuit in wiring harness 3 (with another wiring harness)
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN3 (female) Y – SRC7 (female) 1 with Resistance Min. 1 MΩ wiring harness between STCN3 (female) M – SRC7 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective steering controller
STCN3 (female)
Resistance
Between Y – M
5 – 25 Ω
Between Y – chassis ground
Min. 1 MΩ
Circuit diagram related to right steering clutch ECMV
D475A-3
20-583
ERROR CODE ERROR DXHAKACODE (LEFTDXHAKA STEERING(LEFT CLUTCH ECMV : DISCONNECTION STEERING CLUTCH ECMV : (KA)) DISCONNECTION (KA))
TROUBLESHOOTING
ERROR CODE DXHAKA (LEFT STEERING CLUTCH ECMV : DISCONNECTION (KA)) Action code
Service code
CALL E03
DXHAKA
Trouble
Disconnection in left steering clutch ECMV (KA) (Steering controller system)
Contents of trouble • When signal is output to left steering clutch solenoid circuit, current does not flow.
• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left.
Problem that • Once machine is stopped, engine speed is limited to medium (half). appears on machine
• Once machine is stopped, travel is limited to F1 and R1.
• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90602, 90600: Left steering clutch ECMV output current) Related information • Method of reproducing error code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left). Cause Defective left steering clutch 1 solenoid (Internal short circuit)
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLC5 (male)
Resistance
Between 1 – 2
5 – 25 Ω
+ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between STCN3 (female) O – Resistance Max. 1 Ω SLC5 (female) 1 defective contact in connecPossible causes Wiring harness between STCN3 (female) M – tor) and standard valResistance Max. 1 Ω SLC5 (female) 2 ue in normal state + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 3 source in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) O – SLC5 (female) 1 with Voltage Max. 1 V chassis ground
4 Defective steering controller
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN3 (female)
Resistance
Between O – M
5 – 25 Ω
Circuit diagram related to left steering clutch ECMV
20-584
D475A-3
ERROR CODEERROR DXHAKB (LEFT STEERING CLUTCH ECMV :CLUTCH SHORT CIRCUIT CODE DXHAKB (LEFT STEERING ECMV : (KB)) SHORT CIRCUIT (KB))
TROUBLESHOOTING
ERROR CODE DXHAKB (LEFT STEERING CLUTCH ECMV : SHORT CIRCUIT (KB)) User code
Service code
CALL E03
DXHAKB
Trouble
Short circuit in left steering clutch ECMV (KB) (Steering controller system)
Contents of trouble • When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer. Action of controller • Stops outputting to left steering clutch solenoid circuit. • Limits operation of engine and transmission. • Machine cannot be steered to left.
Problem that • Once machine is stopped, engine speed is limited to medium (half). appears on machine
• Once machine is stopped, travel is limited to F1 and R1.
• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90602, 90600: Left steering clutch ECMV output current) Related information • Method of reproducing error code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left). Cause Defective left steering clutch 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLC5 (male)
Resistance
Between 1 – 2
5 – 25 Ω
Between 1 – chassis ground
Min. 1 MΩ
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness Short circuit of wiring harness between (Contact with ground circuit) STCN3 (female) O – SLC5 (female) 1 with Resistance Min. 1 MΩ chassis ground Short circuit in wiring harness 3 (with another wiring harness)
+ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN3 (female) O – SLC5 (female) 1 with Resistance Min. 1 MΩ wiring harness between STCN3 (female) M – SLC5 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN3 (female)
4 Defective steering controller
Resistance
Between O – M
5 – 25 Ω
Between O – chassis ground
Min. 1 MΩ
Circuit diagram related to left steering clutch ECMV
D475A-3
20-585
TROUBLESHOOTING
ERROR CODE DXHBKA (RIGHT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE DXHBKA (RIGHT BRAKE ECMV: DISCONNECTION (KA)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHBKA
Trouble
Right brake ECMV: Disconnection (KA) (Steering controller system)
• When signal is output to right steering brake solenoid circuit, any current does not flow. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering brake solenoid circuit. Limits operation of engine, transmission and brake. Brake is applied lightly during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Output current of right steering brake ECMV) • Method of reproducing service code: Turn starting switch ON and release parking brake lever. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. brake solenoid (Internal SRB3 (male) Resistance short circuit) Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring har- without turning starting switch ON. ness (Disconnection in wir- Wiring harness between STCN3 (female) E – Resistance Max. 1Ω ing or defective contact in SRB3 (female) 1 connector) Wiring harness between STCN3 (female) C – Resistance Max. 1Ω SRB3 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power source in wiring harness Short circuit of wiring harness between STCN3 (Contact with 24V circuit) (female) E – SRB3 (female) 1 with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering controller STCN3 (female) Resistance Between E – C 5 – 25Ω
Circuit diagram related to right steering brake ECMV
20-586
D475A-3
TROUBLESHOOTING
ERROR CODE DXHBKB (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHBKB (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHBKB
Trouble
Right brake ECMV: Short circuit (KB) (Steering controller system)
• When signal was output to right steering brake solenoid circuit, abnormal current flowed. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering brake solenoid circuit. Limits operation of engine, transmission, and brake. Brake is applied lightly during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Output current of right steering brake ECMV) • Method of reproducing service code: Start engine and release parking brake lever. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right steering SRB3 (male) Resistance brake solenoid (Internal short circuit) Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness Short circuit of wiring harness between STCN3 (Contact with ground circuit) (female) E – SRB3 (female) 1 with chassis Resistance Min. 1MΩ ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between STCN3 ness (with another wiring (female) E – SRB3 (female) 1 with wiring harharness) Resistance Min. 1MΩ ness between STCN3 (female) C – SRB3 (female) 2 + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN3 Resistance Defective steering controller Between E – C 5 – 25Ω Between E – chassis ground Min. 1MΩ
Circuit diagram related to right steering brake ECMV
D475A-3
20-587
TROUBLESHOOTING
ERROR CODE DXHCKA (LEFT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE DXHCKA (LEFT BRAKE ECMV: DISCONNECTION (KA)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHCKA
Trouble
• When signal is output to left steering brake solenoid circuit, any current does not flow. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering brake solenoid circuit. Limits operation of engine, transmission and brake. Brake is applied lightly during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Output current of left steering brake ECMV) • Method of reproducing service code: Turn starting switch ON and release parking brake lever. Cause
Possible causes and standard value in normal state
Left brake ECMV: Disconnection (KA) (Steering controller system)
1
Defective left steering brake solenoid (Internal short circuit)
2
Disconnection in wiring harness (Disconnection in wiring or defective contact in connector)
3
Short circuit with power source in wiring harness (Contact with 24V circuit)
4
Defective steering controller
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLB1 (male) Resistance Between 1 – 2 5 – 25Ω + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) 5 – Resistance Max. 1Ω SLB1 (female) 1 Wiring harness between STCN3 (female) C – Resistance Max. 1Ω SLB1 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN3 (female) 5 – SLB1 (female) 1 with chassis Voltage Max. 1V ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. STCN3 (female) Resistance Between 5 – C 5 – 25Ω
Circuit diagram related to left steering brake ECMV
20-588
D475A-3
TROUBLESHOOTING
ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHCKB
Trouble
Left brake ECMV: Short circuit (KB) (Steering controller system)
• When signal was output to left steering brake solenoid circuit, abnormal current flowed. • • • • • • •
Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering brake solenoid circuit. Limits operation of engine, transmission, and brake. Brake is applied lightly during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Output current of left steering brake ECMV) • Method of reproducing error code: Start engine and release parking brake lever. Cause
1
Defective left steering brake solenoid (Internal short circuit)
2
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
3
Short circuit in wiring harness (with another wiring harness)
4
Defective steering controller
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SLB1 (male) Resistance Between 1 – 2 5 – 25Ω Between 1 – chassis ground Min. 1MΩ + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between STCN3 Resistance Min. 1MΩ (female) 5 – SLB1 (female) 1 with chassis ground + Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness between STCN3 (female) 5 – SLB1 (female) 1 with wiring harResistance Min. 1MΩ ness between STCN3 (female) C – SLB1 (female) 2 + Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN3 Resistance Between 5 – C 5 – 25Ω Between 5 – chassis ground Min. 1MΩ
Circuit diagram related to left steering brake ECMV
D475A-3
20-589
TROUBLESHOOTING
DXHDKA
ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHDKA
Trouble
Governor solenoid right: Disconnection (KA) (Engine controller system)
• The output current to the right bank governor solenoid is below 0.1 A. • Flashes the caution lamp and turns on the caution buzzer. • Only the left bank of the engine operates. • Method of reproducing error code: Start the engine. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right bank E15 (male) Resistance governor solenoid Between (1) and (2) 10 – 21 z (Internal disconnection) Between (1), (2) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE2 (female) (7) and Resistance Max. 1 z wiring harness or defective E15 (female) (1) contact in connector) Wiring harness between LE2 (female) (17) and Resistance Max. 1 z E15 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (17) and E15 (female) (2) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (7) and (17) 10 – 21 z Between (7), (17) and Min. 1 Mz chassis ground
Circuit diagram related to right bank governor solenoid
20-589-1 (1)
D475A-3
TROUBLESHOOTING
DXHDKB
ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHDKB
Trouble
Governor solenoid right: Short circuit (KB) (Engine controller system)
• The output current to the right bank governor solenoid is above 2.1 A. • Flashes the caution lamp and turns on the caution buzzer. • Only the left bank of the engine operates. • Method of reproducing error code: Start the engine. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right bank E15 (male) Resistance governor solenoid Between (1) and (2) 10 – 21 z (Internal disconnection) Between (1), (2) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (7) and E15 (female) (1) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power Between wiring harness between LE2 (female) source in wiring harness Voltage Max. 1 V (7) and E15 (female) (1) and chassis ground (Contact with 24-V circuit) Between wiring harness between LE2 (female) Voltage Max. 1 V (17) and E15 (female) (2) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (7) and (17) 10 – 21 z Between (7), (17) and Min. 1 Mz chassis ground
Circuit diagram related to right bank governor solenoid
D475A-3
20-589-2 (1)
TROUBLESHOOTING
DXHEKA
ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHEKA
Trouble
• The output current to the left bank governor solenoid is below 0.1 A. • Flashes the caution lamp and turns on the caution buzzer. • Only the right bank of the engine operates. • Method of reproducing error code: Start the engine. Cause Defective left bank governor 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Governor solenoid left: Disconnection (KA) (Engine controller system)
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector) Short circuit with chassis 3 ground in wiring harness (Contact with ground circuit)
4 Defective engine controller
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. E11 (male) Resistance Between (1) and (2) 10 – 21 z Between (1), (2) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LE2 (female) (8) and Resistance Max. 1 z E11 (female) (1) Wiring harness between LE2 (female) (18) and Resistance Max. 1 z E11 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between LE2 (female) Resistance Min. 1 Mz (18) and E11 (female) (2) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Between (8) and (18) 10 – 21 z Between (8), (18) and Min. 1 Mz chassis ground
Circuit diagram related to left bank governor solenoid
20-589-3 (1)
D475A-3
TROUBLESHOOTING
DXHEKB
ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHEKB
Trouble
Governor solenoid left: Short circuit (KB) (Engine controller system)
• The output current to the left bank governor solenoid is above 2.1 A. • Flashes the caution lamp and turns on the caution buzzer. • Only the right bank of the engine operates. • Method of reproducing error code: Start the engine. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left bank governor E11 (male) Resistance solenoid Between (1) and (2) 10 – 21 z (Internal disconnection) Between (1), (2) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (8) and E11 (female) (1) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE2 (female) Short circuit with power (8) and E11 (female) (1) and short circuit or source in wiring harness Voltage Max. 1 V short circuit with chassis ground in wiring (Contact with 24-V circuit) between Between wiring harness between LE2 (female) Voltage Max. 1 V (18) and E11 (female) (2) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (8) and (18) 10 – 21 z Between (8), (18) and Min. 1 Mz chassis ground
Circuit diagram related to left bank governor solenoid
D475A-3
20-589-4 (1)
TROUBLESHOOTING
DXHFKA
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHFKA
Trouble
Pre-stroke solenoid right: Disconnection (KA) (Engine controller system)
• The output current deviation to the right bank pre-stroke solenoid is above 0.2 A. • Flashes the caution lamp and turns on the caution buzzer. • Reduces the engine output by 20%. • The output is reduced. • Method of reproducing error code: Start the engine. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right bank E14 (male) Resistance pre-stroke solenoid Between (A) and (B) 10 – 21 z (Internal disconnection) Between (A), (B) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE2 (female) (9) and Resistance Max. 1 z wiring harness or defective E14 (female) (A) contact in connector) Wiring harness between LE2 (female) (19) and Resistance Max. 1 z E14 (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (9) and E14 (female) (B) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (9) and (19) 10 – 21 z Between (9), (19) and Min. 1 Mz chassis ground
Circuit diagram related to right bank pre-stroke solenoid
20-589-5 (1)
D475A-3
TROUBLESHOOTING
DXHFKB
ERROR CODE [DXHFKB] (PRE-STROKE SOLENOID RIGHT: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHFKB
Trouble
Pre-stroke solenoid right: Short circuit (KB) (Engine controller system)
• The output current to the right bank pre-stroke solenoid is above 4 A. • Flashes the caution lamp and turns on the caution buzzer. • Reduces the engine output by 20%. • The output is reduced. • Method of reproducing error code: Start the engine. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right bank E14 (male) Resistance pre-stroke solenoid Between (A) and (B) 10 – 21 z (Internal disconnection) Between (A), (B) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (9) and E14 (female) (A) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power Between wiring harness between LE2 (female) source in wiring harness Voltage Max. 1 V (9) and E14 (female) (A) and chassis ground (Contact with 24-V circuit) Between wiring harness between LE2 (female) Voltage Max. 1 V (19) and E14 (female) (B) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (9) and (19) 10 – 21 z Between (9), (19) and Min. 1 Mz chassis ground
Circuit diagram related to right bank pre-stroke solenoid
D475A-3
20-589-6 (1)
TROUBLESHOOTING
DXHGKA
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHGKA
Trouble
Pre-stroke solenoid left: Disconnection (KA) (Engine controller system)
• The output current deviation to the left bank pre-stroke solenoid is above 0.2 A. • Flashes the caution lamp and turns on the caution buzzer. • Reduces the engine output by 20%. • The output is reduced. • Method of reproducing error code: Start the engine. Cause
1
Possible causes and standard value in normal state
2
3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left bank E10 (male) Resistance pre-stroke solenoid Between (A) and (B) 10 – 21 z (Internal disconnection) Between (A), (B) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between LE2 (female) (10) and Resistance Max. 1 z wiring harness or defective E10 (female) (A) contact in connector) Wiring harness between LE2 (female) (20) and Resistance Max. 1 z E10 (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (10) and E10 (female) (B) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (10) and (20) 10 – 21 z Between (10), (20) and Min. 1 Mz chassis ground
Circuit diagram related to left bank pre-stroke solenoid
20-589-7 (1)
D475A-3
TROUBLESHOOTING
DXHGKB
ERROR CODE [DXHGKB] (PRE-STROKE SOLENOID LEFT: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information
Error code DXHGKB
Trouble
Pre-stroke solenoid left: Short circuit (KB) (Engine controller system)
• The output current to the left bank pre-stroke solenoid is above 4 A. • Flashes the caution lamp and turns on the caution buzzer. • Reduces the engine output by 20%. • The output is reduced. • Method of reproducing error code: Start the engine. Cause
1
2 Possible causes and standard value in normal state 3
4
Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left bank E10 (male) Resistance pre-stroke solenoid Between (A) and (B) 10 – 21 z (Internal disconnection) Between (A), (B) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch ON. ground in wiring harness Between wiring harness between LE2 (female) (Contact with ground circuit) Resistance Min. 1 Mz (10) and E10 (female) (A) and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between LE2 (female) Short circuit with power (10) and E10 (female) (A) and short circuit or source in wiring harness Voltage Max. 1 V short circuit with chassis ground in wiring (Contact with 24-V circuit) between Between wiring harness between LE2 (female) Voltage Max. 1 V (20) and E10 (female) (B) and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LE2 (female) Resistance Defective engine controller Between (10) and (20) 10 – 21 z Between (10), (20) and Min. 1 Mz chassis ground
Circuit diagram related to left bank pre-stroke solenoid
D475A-3
20-589-8 (1)
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
Information described in troubleshooting list ........................................................................................... E-1 The engine does not start. ................................................................................................................ E-2 The preheater does not operate. (Manual preheating function) ........................................................ E-3 The ripper pin puller cylinder does not operate.................................................................................. E-4 The monitor panel does not come on at all when the starting switch is turned ON. .......................... E-5 When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out................................................................................................................................. E-6 When the starting switch is turned on, the basic check items flash (The radiator water level caution lamp flashes)................................................................................ E-7 When the starting switch is turned on, the basic check items flash (The hydraulic oil temperature caution lamp flashes)....................................................................... E-8 When the starting switch is turned on, the basic check items flash (The engine oil level caution lamp flashes). ..................................................................................... E-9 While the engine is operating, any caution item flashes. ................................................................... E-10 While the engine is operating, the emergency warning item flashes. .............................................. E-11 While the preheater is operating, the preheating pilot lamp does not come on. .............................. E-12 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-mounted machine) ............................................................................................................ E-13 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on. ......................................................... E-14 The engine water temperature gauge does not indicate normally. .................................................. E-15 Indication of the power train temperature gauge is abnormal.......................................................... E-16 The hydraulic oil temperature gauge does not indicate normally. .................................................... E-17 Indication of the fuel gauge is abnormal. ......................................................................................... E-18 Indications of gear speed and engine speed are abnormal. ............................................................ E-19 Indication of the shift mode service meter is abnormal.................................................................... E-20 The switch module cannot be operated. .......................................................................................... E-21 The warning lamp does not flash or does not go out. ...................................................................... E-22 The alarm buzzer does not sound or does not stop......................................................................... E-23 Auto shift down is not possible or is not released. ........................................................................... E-24 The alarm buzzer cannot be cancelled. ........................................................................................... E-25 The operator mode cannot be operated. ......................................................................................... E-26 The service mode cannot be operated. ........................................................................................... E-27 The back-up alarm does not sound. ................................................................................................ E-28 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on.. E-29 The air conditioner does not operate. ..............................................................................................
D475A-3
20-602 20-604 20-606 20-608 20-609 20-610 20- 611 20-612 20-613 20-614 20-616 20-620 20-622 20-622 20-623 20-624 20-625 20-626 20-627 20-627 20-628 20-629 20-630 20-631 20-632 20-633 20-634 20-636 20-637 20-642
20-601
TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST + Troubleshooting lists and related circuit diagrams contain the following information all together. Understand the contents carefully and troubleshoot the machine. Trouble Related information
Problem that appears on the machine. Information related to problems occurred or troubleshooting Cause
Standard value in normal state/Remarks on troubleshooting • Standard value in normal state required to judge the assumed cause (good or not) • Remarks required to judge whether the cause is good
1
2
Possible causes and standard value in normal state
Cause by which a trouble is assumed to be detected (The order number indicates a serial number, not a priority sequence.) 3
4
• Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Grounding fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. • Defective hot short A harness not connected to the power (24V) circuit comes into contact with the power (24V) circuit. • Defective short A harness of an independent circuit abnormally comes into contact with one of another circuit. 1Method of indicating connector numbers and handling T-junction For troubleshooting, insert or connect the T-junction adapter as shown below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the T-junction adapter in both the male and female. • When “male” or “female” is indicated for a connector number, disconnect the connector, and insert the T-junction adapter in only either the male or female. 2Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble • Connector No.: Indicates (Model-No. of pins) (Color). • Arrow (⇔): Roughly indicates mounting place on machine.
20-602
D475A-3
TROUBLESHOOTING
E-1
E-1 THE ENGINE DOES NOT START. Trouble Related information
• The engine does not start. • The engine start circuit has the neutral safety function, and the engine does not start if the parking lever is set to the lock position. • If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when the starting switch is set to ON, the main electric power supply system is supposed to be out of order. So, inspect the main electric power supply system. Cause
Possible causes and standard value in normal state
20-604
1
Insufficient battery capacity
2
Defective starting switch (internal disconnection)
3
Defective neutral safety relay (internal disconnection)
4
Defective alternator (internal short-circuit)
5
Detective starting motor (internal defect)
6
Disconnection in wiring harness (disconnection in wiring or defective contact in connector)
7
Hot short circuit of wiring harness (Contact with 24V circuit)
Standard value in normal state/Remarks on troubleshooting Battery voltage Battery specific gravity Min. 24V Min. 1.26 + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. KEY (male) Switch position Resistance OFF Min. 1MΩ Between 5 and 3 START Max. 1Ω + Prepare with the starting switch OFF, then turn the starting switch to START and carry out troubleshooting. If the engine starts in accordance with the engine starting arrangement after the neutral safety relay (NSF) is replaced with another one while the starting switch is set to OFF, the relay is defective. + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Alternator Voltage Between Terminal R and ground Max. 1V + Prepare with the starting switch OFF, then turn the starting switch to START and carry out troubleshooting. Starting motor Voltage Electric power supply : between 20 – 30V Terminal ST/B and ground Charge : between 103 or 104 2 Max. 1V and ground Starting : between 103 or 104 1 20 – 30V and ground When the voltages of electric power supply, for charging and starting are normal but the starting motor does not rotate, the starting motor is defective. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between KEY (female) 3 and Resistance Max. 1Ω NFS (female) 3 Wiring harness between NSF (female) 5 and Resistance Max. 1Ω 103 or 104 (female) 2 + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Hot short circuit of wiring harness between alternator R terminal and 103 or 104(female) 2 or TMCN1 (female) E or S04 (female) 9 with Voltage Max. 1V ground (Note : While a hot short circuit occurs, the battery charge level lamp comes on when the starting switch is turned ON.)
D475A-3
TROUBLESHOOTING
E-1
Engine start/charge-related circuit diagram
D475A-3
20-605
TROUBLESHOOTING
E-2
E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION) Trouble
Related information
• The preheater does not operate. (Manual preheating function) + This troubleshooting describes the procedures to be followed when the manual preheating function cannot heat the electrical intake air heater. (When the preheating lamp only does not come on, carry out the troubleshooting of “The preheating lamp does not come on.”) • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are available. When either function is performed, the preheating lamp comes on. • If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when the starting switch is turned ON, the main electric power supply system supposed to be out of order. So, inspect the main electric power supply system. Cause
1
2
Possible causes and standard value in normal state 3
4
20-606
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective starting switch KEY (male) Switch position Resistance (Internal disconnection) OFF Min. 1MΩ Between 5 and 2 HEAT Max. 1Ω + Prepare with the starting switch OFF, then set the starting switch to HEAT and carry out troubleshooting. Heater relay Voltage Electric power supply : between Defective heater relay (in20 – 30V Terminal HT/A (A) and ground ternal defect) Signal : between Terminal HT (C) 20 – 30V and ground When the both voltages of electric power supply and signal are normal and no operating sound is caused, the heater relay is defective. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective electrical intake air heater (internal defect) Electrical intake air heater Continuity Between terminals Continue + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between KEY (female) 2 and Resistance Max. 1Ω heater relay 137 terminal or 136 terminal Disconnection in wiring harness (Disconnection in wir- Wiring harness between RHR (female) 3 and KEY (female) 2, or between RHR (female) 3 Resistance Max. 1Ω ing or defective contact in and 136, or between RHR (female) 3 and 137 connector) Wiring harness between battery relay M and starting motor, or between starting motors, or Resistance Max. 1Ω between starting motor and electrical intake air heater.
D475A-3
TROUBLESHOOTING
E-2
Engine preheat-related circuit diagram
D475A-3
20-607
TROUBLESHOOTING
E-3
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE. Trouble Related information
• The ripper pin puller cylinder does not operate.
Cause
1
2
3
Possible causes and standard value in normal state
4
5
6
Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have possibly occurred Defective fuse (FS4-1) to the circuit. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective pin puller switch 263 (male) Switch Resistance (Internal disconnection or short circuit) Pull Max. 1Ω Between 1 and 2 Press Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective pin puller solenoid 224 (male) Resistance (Internal disconnection or short circuit) Between 1 and 2 40 – 80Ω Between 1 and ground Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring har- Wiring harness between FS4-1 outlet and 263 Resistance Max. 1Ω ness (Disconnection in wir- (female) 1 ing or defective contact in Wiring harness between 263 (female) 2 and Resistance Max. 1Ω connector) 224 (female) 1 Wiring harness between 224 (female) 2 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring harBetween wiring harness related to FS4-1 (outResistance Min. 1MΩ ness (Contact with ground let side) and ground circuit) Between wiring harness (between 263 (feResistance Min. 1MΩ male) 2 and 224 (female) 1) and ground + Prepare with the starting switch OFF, then turn the starting switch Hot short circuit of wiring ON and carry out troubleshooting. harness (Contact with 24V Between wiring harness (between 263 (fecircuit) Voltage Max. 1V male) 2 and 224 (female) 1) and ground
Circuit diagram related to ripper pin puller solenoid
20-608
D475A-3
TROUBLESHOOTING
E-4
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON. Trouble Related information
• The monitor panel does not come on at all when the starting switch is turned ON. • When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for 2 sec.
1
2 Possible causes and standard value in normal state 3
4
Cause Defective circuit breaker (CB2)
Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off, the circuit may have possibly been short-circuited with ground. + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between S03 (female) 1 2 Resistance Max. 1Ω ing or defective contact in and CB2 outlet connector) Wiring harness between S03 (female) 3 4 Resistance Max. 1Ω and ground + Prepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring harwithout turning the starting switch ON. ness (Contact with ground Between wiring harness related to CB2 (outlet circuit) Resistance Min. 1MΩ side) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel (Gauge/lamp module) S03 Voltage Between 1 2 and 3 4 20 – 30V
Circuit diagram related to monitor panel electric power supply
D475A-3
20-609
TROUBLESHOOTING
E-5
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT. Trouble Related information Possible causes and standard value in normal state
20-610
• When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out. • When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for 2 sec. and go out. Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This internal defect cannot be diagnosed.
D475A-3
TROUBLESHOOTING
E-6
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH. Trouble Related information
• The radiator water level caution lamp flashes. • When any basic check items are detected to be abnormal before the engine starts, they will flash. Cause
Possible causes and standard value in normal state
1
Drop of radiator water level (when the system is normal)
2
The main radiator water level sensor is defective. (Internal disconnection)
3
The sub radiator water level sensor is defective. (Internal disconnection)
4
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
5
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting A drop of radiator water level (main radiator or sub radiator) was detected, inspect the radiator water levels. (The lamp flashes when the level is below the specified level.) + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 405 (male) Radiator water level Resistance Normal level Max. 1Ω Between 1 and 2 Lower level Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. DRT (male) Radiator water level Resistance Normal level Max. 1Ω Between 1 and 2 Lower level Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between S03 (female) A and Resistance Max. 1Ω 405 (female) 1 Wiring harness between 405 (female) 2 and Resistance Max. 1Ω DRT (female) 1 Wiring harness between DRT (female) 2 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Radiator water level Voltage Normal level Max. 1V Between A and ground Lower level 20 – 20V
Circuit diagram related to radiator water level sensor power supply
D475A-3
20-611
TROUBLESHOOTING
E-7
E-7 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH. Trouble Related information
• The hydraulic oil temperature caution lamp flashes. • When any basic check items are detected to be abnormal before the engine starts, they will flash.
1
2
Possible causes and standard value in normal state
3
4
5
Cause Standard value in normal state/Remarks on troubleshooting Drop of hydraulic oil temper- A drop of hydraulic oil temperature (hydraulic oil tank) was detected, ature (when the system is inspect the hydraulic oil temperatures. (The lamp flashes when the normal) level is below the specified level.) + Prepare with the starting switch OFF, then carry out troubleshooting The main hydraulic oil temwithout turning the starting switch ON. perature sensor is defecHLS (male) Radiator water level Resistance tive. Normal level Max. 1Ω (Internal disconnection) Between 1 and 2 Lower level Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring har- Wiring harness between STCN3 (female) A Resistance Max. 1Ω ness (Disconnection in wir- and HLS(female) 1 ing or defective contact in Wiring harness between HLS (female) 2 and Resistance Max. 1Ω connector) LLS (female) 2 Wiring harness between LLS (female) 2 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel STCN3 Radiator water level Voltage (Gauge/lamp module) Normal level Max. 1V Between A and ground Lower level 20 – 20V When the hydraulic oil level sensor is not installed, and when perform Defective setting for hydrau- the adjusting mode, if the failure code(resetting display) is flashing, it lic oil level sensor is normal. Adjusting code: 9993 (hydraulic oil level display mode)
Circuit diagram related to hydraulic oil temperature electric power supply
20-612
D475A-3
TROUBLESHOOTING
E-8
E-8 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH. Trouble Related information
• The engine oil level caution lamp flashes. • When any basic check items are detected to be abnormal before the engine starts, they will flash. Cause
1
2 Possible causes and standard value in normal state
3
4
Standard value in normal state/Remarks on troubleshooting A drop of engine oil level (engine oil pan) was detected, inspect the Drop of engine oil level engine oil levels. (The lamp flashes when the level is below the spec(when the system is normal) ified level.) + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. The main engine oil level 404 (male) Engine oil level Resistance sensor is defective. (Internal disconnection) Normal level Max. 1Ω Between 1 and 2 Lower level Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between S03 (female) 0 and Resistance Max. 1Ω ing or defective contact in 404 (female) 1 connector) Wiring harness between 404 (female) 2 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S03 Engine oil Voltage (Gauge/lamp module) Normal level Max. 1V Between 0 and ground Lower level 20 – 20V
Circuit diagram related to engine oil level electric power supply
D475A-3
20-613
TROUBLESHOOTING
E-9
E-9 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES. Trouble Related information
• The battery charge level caution lamp flashes. • When any abnormality is detected during engine operation, the relevant caution item will flash. Cause
1
2 Possible causes and standard value in normal state 3
4
20-614
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then start the engine and carry out troubleshooting. Defective alternator (insuffiAlternator Engine speed Voltage cient power generation) Between Terminal R Min. medium speed 20 – 30V and ground (half) Disconnection of wiring har- + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between S04 (female) 9 and Resistance Max. 1Ω connector) alternator R terminal + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring harBetween wiring harness (between S04 (feness (Contact with ground male) 9 and alternator R terminal, 103 (fecircuit) Resistance Min. 1MΩ male) 1, 104(female) 1or TMCN2 (female) 0) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S04 Voltage (Gauge/lamp module) Between 9 and Min. medium speed 20 – 30V ground (half)
D475A-3
TROUBLESHOOTING
E-9
Engine start/charge-related circuit diagram
D475A-3
20-615
TROUBLESHOOTING
E-10
E-10 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES. Trouble (1) Related information
• The engine oil pressure caution lamp flashes. • When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. • The engine oil pressure switch signal is received from the monitor panel through communication.
Possible causes and standard value in normal state
Cause
1
2
3
4
Standard value in normal state/Remarks on troubleshooting
Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de(when the system is normal) tected. + Prepare with the starting switch OFF, then carry out troubleshooting The engine oil switch is de- without turning the switch ON or after starting the engine. 403 Engine Resistance fective. (Internal short circuit) Stop Max. 1Ω Between terminal and ground Min. 600rpm Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring harwithout turning the starting switch ON. ness (Contact with ground Between wiring harness (between S03 (fecircuit) Resistance Min. 1MΩ male) B and 301 3) Defective monitor panel This is an internal defect, which cannot be troubleshot. (Gauge/lamp module)
Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch
20-616
D475A-3
TROUBLESHOOTING
Trouble (2) Related information
• The engine water temperature caution lamp flashes. • When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. • The engine water temperature caution lamp flashes or goes out as it links with indication on the engine water temperature gauge.
1
Possible causes and standard value in normal state
E-10
2
Cause Standard value in normal state/Remarks on troubleshooting Overheated engine water As overheated engine water was detected, check the engine water temperature (when the sys- temperature. (When the water temperature is over 108°C, the lamp tem is normal) flashes.) Check the indication on the engine water temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the engine water temperature gauge is abnormal.” + Water temperatures are guides for selecting indications. The engine water temperature sensor system is defective. (Engine controller system)
Water temperature gauge
White range/ Red range Green range Goes out. Flashes. When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.) Water temperature lamp
3
Trouble (3) Related information
• The power train oil temperature caution lamp flashes. • When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. • The power train oil temperature caution lamp flashes or goes out as it links with indication on the power train oil temperature gauge.
1
Possible causes and standard value in normal state
Defective monitor panel (Gauge/lamp module)
2
Cause Standard value in normal state/Remarks on troubleshooting Overheated oil temperature As an overheated power train oil temperature was detected, check of power train (when the the power train oil temperature. (When the oil temperature is over system is normal) 130°C, the lamp flashes.) Check the indication on the power train oil temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the power train oil temperature gauge is abnormal.” + Oil temperatures are guides for selecting indications. The power train oil temperature sensor system is defec- Oil temperature gauge tive. (Monitor panel system)
White range/ Red range Green range Goes out. Flashes. When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.) Oil temperature lamp
3
D475A-3
Defective monitor panel (Gauge/lamp module)
20-617
TROUBLESHOOTING
Trouble (4) Related information
• The hydraulic oil temperature caution lamp flashes. • When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. • The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic oil temperature gauge.
1
Possible causes and standard value in normal state
E-10
2
Cause Standard value in normal state/Remarks on troubleshooting Overheated hydraulic oil As an overheated hydraulic oil temperature was detected, check the temperature (when the sys- hydraulic oil temperature. (When the oil temperature is over 130°C, tem is normal) the lamp flashes.) Check the indication on the engine water temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the hydraulic oil temperature gauge is abnormal.” + Oil temperatures are guides for selecting indications. The hydraulic oil temperature sensor system is defec- Oil temperature gauge tive. (Monitor panel system)
White range/ Red range Green range Goes out. Flashes. When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.) Oil temperature lamp
3
20-618
Defective monitor panel (Gauge/lamp module)
D475A-3
TROUBLESHOOTING
Trouble (5) Related information
• Air cleaner clogging caution lamp flashes. • When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer.
1
2 Possible causes and standard value in normal state
E-10
3
4
Cause Standard value in normal state/Remarks on troubleshooting Air cleaner clogging (when Check the air cleaner clogging as the drop of air cleaner clogging is the system is normal) detected. + Prepare with the starting switch OFF, then carry out troubleshooting The HSS charge oil preswithout turning the switch ON or after starting the engine. sure switch is defective. AF1 (male) Resistance (Internal disconnection) Between 1 and 2 Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between S03 (female) C and Resistance Min. 1MΩ ing or defective contact in AFI (female) 1 connector) Wiring harness between AFI (female) 2 and Resistance Min. 1MΩ ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. Defective monitor panel (Gauge/lamp module) S03 Voltage Between C and ground Max. 1V
Circuit diagram related to air cleaner clogging switch
D475A-3
20-619
TROUBLESHOOTING
E-11
E-11 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON. Trouble Related information
• While the preheater is operating, the preheating pilot lamp does not come on. + This troubleshooting describes the procedures to be followed when the preheating lamp doe not come on. (When the preheater mounting section is not heated, carry out the troubleshooting of “The preheater does not work.”) • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are available. Even when either function is performed, the preheating lamp comes on. Cause
1 Possible causes and standard value in normal state
2
3
20-620
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring harwithout turning the starting switch ON. ness (Disconnection in wirWiring harness between S03 (female) 9 and ing ) Resistance Max. 1Ω heater relay + Prepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring harwithout turning the starting switch ON. ness (Contact with ground Between wiring harness between S03 (female) circuit) Resistance Min. 1MΩ 9 and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S03 Starting switch Voltage (Gauge/lamp module) ON Max. 1V Between 9 and ground HEAT 20 – 30V
D475A-3
TROUBLESHOOTING
E-11
Engine preheat-related circuit diagram
D475A-3
20-621
TROUBLESHOOTING
E-11 E-12, E-13
E-12 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE) Trouble Related information Possible causes and standard value in normal state
• At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-mounted machine) • Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does not operate normally, the electrical system on the machine side or the hydraulic/mechanical system is supposed to be out of order. So, troubleshoot the relevant system.) Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
E-13 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON. Trouble Related information Possible causes and standard value in normal state
20-622
• At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on. • Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lockup does not operate normally, the electrical system on the machine side or the hydraulic/mechanical system is supposed to be out of order. So, troubleshoot the relevant system.) Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
D475A-3
TROUBLESHOOTING
E-14
E-14 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY. Trouble (1) Related information
• The engine water temperature gauge does not indicate normally. • Signals of the engine water high temperature sensor are received from the monitor panel through communication. • When any abnormality occurred in the engine hot water temperature sensor system, the failure code [DGE2KX] is displayed sometimes. Cause
Possible causes and standard value in normal state
1
The engine water high temperature sensor is defective. (Internal disconnection or short circuit)
2
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
3
Ground fault of wiring harness (Contact with ground circuit)
4
Hot short circuit of wiring harness (Contact with 24V circuit)
5
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 402 Resistance Between 1 and 2 3.5k – 90kΩ Between 1 2 and ground Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between S04 (female) A and Resistance Max. 1Ω 402 (female) 1 Resistance Max. 1Ω Wiring harness between ground and 402 2 Resistance Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between S04 A and Resistance Min. 1MΩ 402 (female) 1) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Between wiring harness (between S04 (feVoltage Max. 1V male) A and 402 (female) 1) and ground This is an internal defect, which cannot be troubleshot.
Circuit diagram related to engine water high temperature sensor
D475A-3
20-623
TROUBLESHOOTING
E-15
E-15 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL. Trouble Related information
• Indication of the power train temperature gauge is abnormal.
Cause
1
Possible causes and standard value in normal state
2
3
4
5
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Torque converter oil The power train oil tempera453 (male) Resistance temperature ture sensor is defective. (Internal disconnection or About 3.8k – Between 1 and 2 short circuit) about 80kΩ 10 – 100°C Between 1 and Min. 1MΩ ground + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between S04 (female) B and Resistance Max. 1Ω ing or defective contact in 453 (female) 1 connector) Wiring harness between 453 (female) 1 and Resistance Max. 1Ω ground Resistance Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring harwithout turning the starting switch ON. ness (Contact with ground Between wiring harness (between S04 (fecircuit) Resistance Min. 1MΩ male) B and 453 (female) 1) and ground + Prepare with the starting switch OFF, then turn the starting switch Hot short circuit of wiring ON and carry out troubleshooting. harness (Contact with 24V Between wiring harness (between S04 (fecircuit) Voltage Max. 1V male) B and 453 (female) 1) and ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective wiring harness 453 (female) Resistance Between 2 and ground Max. 1Ω
Circuit diagram related to power train oil temperature sensor
20-624
D475A-3
TROUBLESHOOTING
E-16
E-16 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY. Trouble Related information
• The hydraulic oil temperature gauge does not indicate normally. • Signals of the hydraulic oil temperature sensor are received from the transmission controller through communication. • When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code [DGS1KX] is displayed sometimes. Cause
Possible causes and standard value in normal state
1
The hydraulic oil temperature sensor is defective. (Internal disconnection or short circuit)
2
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
3
Ground fault of wiring harness (Contact with ground circuit)
4
Hot short circuit of wiring harness (Contact with 24V circuit)
5
Defective transmission controller
6
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. SDS (male) Resistance Between 1 and 2 3.5k – 90kΩ Between 1 and ground Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between TMCN1 (female) D Resistance Max. 1Ω and SDS (female) 1 Wiring harness between TMCN1 (female) K Resistance Max. 1Ω and SDS (female) 2 + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between TMCN1 (feResistance Min. 1MΩ male) D and SDS (female) 1) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Between wiring harness (between TMCN1 (feVoltage Max. 1V male) D and SDS (female) 1) and ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. TMCN1 (female) Resistance Between D and K 3.5k – 90kΩ Between D and ground Min. 1MΩ This is an internal defect, which cannot be troubleshot.
Circuit diagram related to hydraulic oil temperature sensor
D475A-3
20-625
TROUBLESHOOTING
E-17
E-17 INDICATION OF THE FUEL GAUGE IS ABNORMAL. Trouble Related information
• Indication of the fuel gauge is abnormal.
Cause
1
2 Possible causes and standard value in normal state
3
4
5
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective fuel level sensor. 422 (male) Remained fuel level Resistance (Internal disconnection or short circuit) Full About 4Ω Between 1 and 2 (ground) Empty About 85Ω + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between S04 (female) @ and Resistance Max. 1Ω ing or defective contact in 422 (female) 1 connector) Wiring harness between 422 (female) 2 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring harwithout turning the starting switch ON. ness (Contact with ground Between wiring harness (between S04 (fecircuit) Resistance Min. 1MΩ male) @ and 422 (female) 1) and ground + Prepare with the starting switch OFF, then turn the starting switch Hot short circuit of wiring ON and carry out troubleshooting. harness (Contact with 24V Between wiring harness (between S04 (fecircuit) Voltage Max. 1V male) @ and 422 (female) 1) and ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective monitor panel S04 (female) Remained fuel level Resistance (Gauge/lamp module) Full About 4Ω Between @ and ground Empty About 85Ω
Circuit diagram related to fuel level sensor
20-626
D475A-3
TROUBLESHOOTING
E-17 E-18, E-19
E-18 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL. Trouble Related information Possible causes and standard value in normal state
• Indications of gear speed and engine speed are abnormal. • Signals of gear speed and engine speed are received from the transmission controller and the steering controller through communication. Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
E-19 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL. Trouble (1) Related information
• During engine operation, the service meter does not advance. • The service meter measures time according to engine drive signals (alternator voltage and engine oil pressure). Cause
Possible causes and standard value in normal state
1
2 3
Trouble (2) Related information Possible causes and standard value in normal state
D475A-3
Standard value in normal state/Remarks on troubleshooting When the battery charge level caution lamp flashes during engine opDefective alternator system eration, carry out the troubleshooting of “While the engine is operating, caution items flash.” The engine oil pressure When the engine oil pressure caution lamp flashes during engine opsensor system is defective. eration, carry out the troubleshooting of “While the engine is operat(Engine controller system) ing, emergency warning items flash.” Defective monitor panel This is an internal defect, which cannot be troubleshot. (Gauge/lamp module)
• Shift mode and service meter are not displayed at all.
Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
20-627
TROUBLESHOOTING
E-20
E-20 THE SWITCH MODULE CANNOT BE OPERATED. Trouble (1) Related information Possible causes and standard value in normal state
Trouble (2) Related information
• Though the switch is used, lamps do not change.
Cause 1
Defective monitor panel (Switch module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
• Though the switch is used, the system setting does not change. • Switch module signals are transmitted to each controller through communication. Cause
Possible causes and standard value in normal state
1
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring harwithout turning the starting switch ON. ness (Disconnection in wirWiring harness between S01 (female) 8 and ing or defective contact in Resistance Max. 1Ω STCN2 (female) K, or TMCN2 (female) K, connector) ECN4 6 and B + Prepare with the starting switch OFF, then start the engine and carry out the troubleshooting. Defective monitor panel S01 Voltage (Switch module) Between 8 and ground 6 – 9V
Circuit diagram related to S-NET Communication
20-628
D475A-3
TROUBLESHOOTING
E-21
E-21 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT. Trouble Related information Possible causes and standard value in normal state
D475A-3
• The warning lamp does not flash or does not go out.
Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
20-629
TROUBLESHOOTING
E-22
E-22 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP. Trouble Related information
• The alarm buzzer does not sound or does not stop. • When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other failure codes are displayed.
1
2
Possible causes and standard value in normal state
3
4
5
Cause Defective circuit breaker (CB2)
Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective alarm buzzer (In217 (male) Resistance ternal disconnection or short circuit) Between 1 and 2 200Ω Between 2 and ground Min. 1MΩ + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between S03 (female) H and Resistance Max. 1Ω ing or defective contact in 217 (female) 1 connector) Wiring harness between 217 (female) 2 and Resistance Max. 1Ω CB2 outlet + Prepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring harwithout turning the starting switch ON. ness (Contact with ground Between wiring harness related to CB2 (outlet circuit) Resistance Min. 1MΩ side) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Alarm buzzer Voltage Defective monitor panel (Gauge/lamp module) At stop 20 – 30V Between H and At operation ground Max. 3V (sounding)
Circuit diagram related to alarm buzzer
20-630
D475A-3
TROUBLESHOOTING
E-23
E-23 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED. Trouble Related information
• Auto shift down is not possible or is not released. Defective auto shift down switch (Internal disconnection or short circuit) Cause
Possible causes and standard value in normal state
1
Defective auto shift down switch (Internal disconnection or short circuit)
2
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
3
Ground fault of wiring harness (Contact with ground circuit)
4
Defective transmission controller
5
Defective transmission control system
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ASD (male) Auto shift down switch Resistance OFF (0) Min. 1MΩ Between 2 and 3 ON (1) Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between TMCN3 (female) ] Resistance Max. 1Ω and ASD (female) 2 Wiring harness between ADS (female) 2 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between CN3 (feResistance Min. 1MΩ male) ] and ASD (female) 2) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN3 Auto shift down switch Voltage OFF (0) 20 – 30V Between ] and ground ON (1) Max. 3V When Causes 1 to 4 are not applicable, the transmission control system is supposed to be out of order. (Since the system is defective, the control system cannot be troubleshot.)
Circuit diagram related to auto shift down switch
D475A-3
20-631
TROUBLESHOOTING
E-24
E-24 THE ALARM BUZZER CANNOT BE CANCELLED. Trouble Related information
• The alarm buzzer cannot be cancelled.
Cause
1
2 Possible causes and standard value in normal state
3
4
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. BUZ (male) Buzzer cancel switch Resistance Defective buzzer cancel OFF (0) Min. 1MΩ switch (Internal disconnecBetween 1 and 2 tion or short circuit) Max. 1Ω OFF (0) Min. 1MΩ Between 1 and 3 Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CN2 Z and BUZ (feDisconnection of wiring harResistance Max. 1Ω male) 2 ness (Disconnection in wiring or defective contact Wiring harness between CN2 P and BUZ (feResistance Max. 1Ω in connector) male) 3 Wiring harness between BUZ (female) 1 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring harBetween wiring harness (between CN2 Z and Resistance Min. 1MΩ ness (Contact with ground BUZ (female) 2) and ground circuit) Between wiring harness (between CN2 P and Resistance Min. 1MΩ BUZ (female) 3) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out the troubleshooting. CN2 Buzzer cancel switch Voltage OFF (0) 20 – 30V Defective steering controller Between Z and ground Max. 1V OFF (0) 20 – 30V Between P and ground Max. 1V
Circuit diagram related to buzzer cancel switch
20-632
D475A-3
TROUBLESHOOTING
E-25
E-25 THE OPERATOR MODE CANNOT BE OPERATED. Trouble Related information
• The operator mode cannot be operated.
Cause
Possible causes and standard value in normal state
1
Defective buzzer cancel switch system
2
Defective information switch (Internal short circuit or disconnection)
3
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
4
Ground fault of wiring harness (Contact with ground circuit)
5
Defective steering controller
Standard value in normal state/Remarks on troubleshooting Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of “The alarm buzzer cannot be cancelled.” + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. CUR (male) Information switch Resistance OFF (0) Min. 1MΩ Between 1 and 2 Max. 1Ω OFF (0) Min. 1MΩ Between 1 and 3 Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CN2 F and CUR (feResistance Max. 1Ω male) Wiring harness between CN2 6 and CUR (female) 3 Wiring harness between CUR (female) 1 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between CN2 F and Resistance Min. 1MΩ CUR (female) 2) and ground Between wiring harness (between CN2 6 and Resistance Min. 1MΩ CUR (female) 3) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN2 Buzzer cancel switch Voltage OFF (0) 20 – 30V Between F and ground Max. 1V OFF (0) 20 – 30V Between 6 and ground Max. 1V
Circuit diagram related to information switch
D475A-3
20-633
TROUBLESHOOTING
E-26
E-26 THE SERVICE MODE CANNOT BE OPERATED. Trouble Related information
• The service mode cannot be operated.
Cause
Possible causes and standard value in normal state
20-634
1
Defective buzzer cancel switch system
2
Defective information switch system
3
Defective circuit breaker (CB6)
4
Defective service switch (Internal short circuit or disconnection)
5
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
6
Ground fault of wiring harness (Contact with ground circuit)
7
Defective monitor panel (Gauge/lamp module)
8
Defective steering controller
Standard value in normal state/Remarks on troubleshooting Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of “The alarm buzzer cannot be cancelled.” Since the information switch system is supposed to be out of order, carry out the troubleshooting of “The operator mode cannot be cancelled.” When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. S24 Service switch Resistance OFF Min. 1MΩ Between 2 and 3, Between 5 and 6 ON Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CB6 outlet and S24 3 Resistance Max. 1Ω Resistance Max. 1Ω Wiring harness between S24 6 and ground Wiring harness between S03 (female) F and Resistance Max. 1Ω S24 2 Wiring harness between CN1 (female) 6 and Resistance Max. 1Ω S24 5 + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness related to CB6 (outlet Resistance Min. 1MΩ side) and ground + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Service switch Voltage OFF Max. 1V Between F and ground ON 20 – 30V + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN1 Service switch Voltage OFF 20 – 30V Between 6 and ground ON Max. 1V
D475A-3
TROUBLESHOOTING
E-26
Circuit diagram related to service switch
D475A-3
20-635
TROUBLESHOOTING
E-27
E-27 THE BACK-UP ALARM DOES NOT SOUND. Trouble Related information
• The back-up alarm does not sound. • When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure code is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed. Cause
Possible causes and standard value in normal state
1
Defective fuse (FS4-1)
2
Defective back-up relay (internal disconnection)
3
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
4
Ground fault of wiring harness (Contact with ground circuit)
5
Defective back-up alarm (internal defect)
Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have probably occurred in the circuit. + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. When the relay is replaced with another relay while the starting switch is set to OFF and the alarm sounds after the starting switch is turned on and the machine is operated in reverse, the back-up alarm relay (BKA) is defective. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between FS4-1 outlet and BKA Resistance Max. 1Ω (female) 3 Wiring harness between BKA (female) 5 and Resistance Max. 1Ω 244 (female) 2 Wiring harness between 244 (female) 1 and Resistance Max. 1Ω ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness related to FS4-1 (outResistance Min. 1MΩ let side) and ground Between wiring harness (between BKA (feResistance Min. 1MΩ male) 5 and 244 (female) 2) and ground When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.
Circuit diagram related to back-up alarm
20-636
D475A-3
TROUBLESHOOTING
E-28
E-28 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON. Trouble(1) Related information
• None of the night light, the headlamp, the working lamp and the rear lamp on the panel comes on.
Cause
1
2 Possible causes and standard value in normal state 3
Trouble(2) Related information
Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have probably occurred Defective fuse (FS2-5) in the circuit. Disconnection of wiring har- + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ness (Disconnection in wiring or defective contact in Wiring harness between FS2-5 outlet and cirResistance Max. 1Ω connector) cuit branching point + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness related to FS2-5 (outResistance Min. 1MΩ let side) and ground Ground fault of wiring har- Between wiring harness (between 219 (feness (Contact with ground male) 2 and S01 (female) @, S02 (female) 1, Resistance Min. 1MΩ circuit) S03 (female) 8, BB1 (female) 1 or BB3 (female) 3) and ground Between wiring harness (between 218 (female) 3 and 233 (female) 1 or 431 (female) Resistance Min. 1MΩ 1) and ground
• None of the night light, the headlamp and the working lamp on the panel comes on.
Cause
1
Headlamp and working lamp switch (international disconnection)
2
Ground fault of wiring harness (Contact with ground circuit)
Possible causes and standard value in normal state
D475A-3
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 219 (male) Switch Resistance OFF Min. 1MΩ Between 2 and 3 ON Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between 219 (female) 3 and Resistance Max. 1Ω circuit branching point Wiring harness between 219 (female) 2 and Resistance Max. 1Ω BB1 (female) 1 or BB3 (female) 1 Wiring harness between BB1 (female) 2 or Resistance Max. 1Ω BB3 (female) 1 and ground
20-637
TROUBLESHOOTING
Trouble(3) Related information
• Only the night light on the panel does not comes on. (whole or part)
1
2 Possible causes and standard value in normal state 3
4
Trouble(4) Related information
2
3
4
5
20-638
Cause Defective night lamp (blown)
Standard value in normal state/Remarks on troubleshooting The night lamp is supposed to be defective. Check if the bulb is blown. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring har- Wiring harness between S01 (female) @ and Resistance Max. 1Ω ness (Disconnection in wir- circuit branching point ing or defective contact in Wiring harness between S02 (female) 1 and Resistance Max. 1Ω connector) circuit branching point Wiring harness between S03 (female) 8 and Resistance Max. 1Ω circuit branching point + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Between S01 @ Defective monitor panel and 2 (Switch module) Light switch ON 20 – 30V Between S02 1 and 2 + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel (Gauge/lamp module) Between S03 Light switch ON 20 – 30V 8 and 3 4
• Only the headlamp does not comes on. (Both right and left, or one side only)
1
Possible causes and standard value in normal state
E-28
Cause Standard value in normal state/Remarks on troubleshooting Defective headlamp (blown) The headlamp is supposed to be defective. Check if the bulb is blown. Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possibly (CB5) occurred in the circuit. + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective headlamp relay When the relay is replace with another relay while the starting switch (Internal disconnection) is set to OFF and the headlamp comes on after the starting switch is turned ON and the light switch is turned ON, the headlamp relay (BB1) is defective. + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between CB5 outlet and BB1 Resistance Max. 1Ω ing or defective contact in (female) 3 connector) Wiring harness between BB1 (female) 5 and Resistance Max. 1Ω 203 (female) 1 or 204 (female) 1 + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har- Between wiring harness related to CB5 (outlet Resistance Min. 1MΩ ness (Contact with ground side) and ground circuit) Between wiring harness (between BB1(female) 5 and 203 (female) 1 or 204 (female) Resistance Min. 1MΩ 1) and ground
D475A-3
TROUBLESHOOTING
Trouble(5) Related information
• Only the working lamp does not comes on. (Both right and left, or one side only)
1
Possible causes and standard value in normal state
Trouble(6) Related information
E-28
Cause Defective working lamp (blown)
2
Defective fuse (FS2-4)
3
Defective working lamp relay (Internal disconnection)
4
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
5
Ground fault of wiring harness (Contact with ground circuit)
Standard value in normal state/Remarks on troubleshooting The working lamp is supposed to be defective. Check if the bulb is blown. When the fuse is blown, a ground fault may have probably occurred in the circuit. + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. When the relay is replace with another relay while the starting switch is set to OFF and the headlamp comes on after the starting switch is turned ON and the light switch is turned ON, the working lamp relay (BB3) is defective. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between FS2-4 outlet and BB3 Resistance Max. 1Ω (female) 3 Wiring harness between BB3 (female) 5 and Resistance Max. 1Ω 221 (female) 1 or 242 (female) 1 + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness related to FS2-4 (outResistance Min. 1MΩ let side) and ground Between wiring harness (between BB3 (female) 5 and 221 (female) 1 or WRL (female) Resistance Min. 1MΩ 1) and ground
• Only the rear lamp does not comes on. (Both right and left, or one side only)
Cause
1
Possible causes and standard value in normal state
2
4
D475A-3
Standard value in normal state/Remarks on troubleshooting The working lamp is supposed to be defective. Check if the bulb is Defective rear lamp (blown) blown. + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective rear lamp switch 218 (male) Switch Resistance (international disconnection) OFF Min. 1MΩ Between 2 and 3 ON Max. 1Ω + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between 218 (female) 2 and Resistance Max. 1Ω ing or defective contact in circuit branching point connector) Wiring harness between 218 (female) 3 and Resistance Max. 1Ω 233 (female) 1 or 243 (female) 1
20-639
TROUBLESHOOTING
E-28
Circuit diagram related to night light, headlamp, working lamp and rear lamp on panel
20-640
D475A-3
TROUBLESHOOTING
E-29
E-29 THE AIR CONDITIONER DOES NOT OPERATE. Trouble (1) Related information
• No air flow
1
Possible causes and standard value in normal state
20-642
Cause Defective circuit breaker (CB4)
2
Defective blower main relay (coil side)
3
Defective blower main relay (contact side)
4
Defective blower Hi relay (coil side)
5
Defective blower Hi relay (contact side)
6
Defective blower Mi relay (coil side)
7
Defective blower Mi relay (contact side)
8
Defective blower motor
9
Disconnection of wiring harness (Disconnection in wiring or defective contact in connector)
Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. CN-R1 (male) Resistance Between (1) and (2) 240 ± 40Ω + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN-R1 Voltage Between (6C) and ground 20 – 30V + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. CN-R2 (male) Resistance Between (1) and (2) 240 ± 40Ω + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. The relay is in order when the motor rotates after the starting switch is turned ON and the blower Hi switch is turned on. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. CN-R3 (male) Resistance Between (1) and (2) 240 ± 40Ω + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. The relay is in order when the motor rotates after the starting switch is turned ON and the blower Mi switch is turned on. + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. The motor is in order when it rotates after the starting switch is turned ON and the blower Lo switch is turned on. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CN-R3 (female) (0B), CN-AC1 (female) (0C), CN-R (female) (0D) or Resistance Max. 1Ω CN-R2 (female) (0E) and ground Wiring harness between CN-B(female) (10A) Resistance Max. 1Ω and CN-R1 (female) (10B) Wiring harness between CN-B (female) (11A) and CN-R2 (female) (11B) or CN-R (female) Resistance Max. 1Ω (11C) Wiring harness between CB4 outlet and CNAC1 (female) (13C), CN-R1 (female) (13D), Resistance Max. 1Ω CN-R2 (female) (13E) or CN-R3 (female) (13H) Wiring harness between CN-R1 (female) (14A) Resistance Max. 1Ω and CN-AC1 (female) (14B)
D475A-3
TROUBLESHOOTING
E-29
Cause
Possible causes and standard value in normal state
D475A-3
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring har- without turning the starting switch ON. ness (Disconnection in wir- Wiring harness between CN-R3 (female) (17A) Resistance Max. 1Ω 9 ing or defective contact in and CN-AC1 (female) (17B) connector) Wiring harness between CN-R2 (female) (18A) Resistance Max. 1Ω and CN-AC1 (female) (18B) When Causes 1 to 9 are not applicable, the control panel is supposed 10 Defective control panel to be defective. When any cause cannot be specified, failure phenomenon may have Different failure phenome11 been mistaken. Carry out the troubleshooting of “Cooling is not posnon sible.”
20-643
TROUBLESHOOTING
Trouble (2) Related information
E-29
• Cooling is not possible.
Cause
Possible causes and standard value in normal state
1
Defective pressure switch
2
Defective compressor clutch relay (coil side)
3
Defective compressor clutch relay (contact side)
4
Defective condenser relay (contact side)
5
Defective thermistor
6
Defective condenser blower resistor
7
Defective condenser motor
8
Defective compressor magnet clutch
9
Defective compressor
Disconnection of wiring harness (Disconnection in wir10 ing or defective contact in connector)
20-644
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN-P Blower switch Voltage Between (26A) and ON 20 – 30V ground + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. CN-R4 (male) Resistance Between (1) and (2) 240 ± 40Ω + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN-R4 Voltage Between (9B) and ground 20 – 30V + Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. CN-R5 Voltage Between (7B) and ground 20 – 30V + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. CN-AC1 (male) Resistance Between (15B) and (16C) Max. 3,500Ω + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Condenser blower resistor Resistance Between terminals 2.8Ω ± 5% + Turn the starting switch on and carry out the troubleshooting. The motor is in order if it is rotating when the air conditioner is switched ON. + Start the engine and carry out the troubleshooting. The compressor magnet clutch is supposed to be out of order, so inspect it directly. + Start the engine and carry out the troubleshooting. The compressor is supposed to be out of order, so inspect it directly. + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CB4 outlet and CNResistance Max. 1Ω R5 (female) (6B) or CN-R4 (female) (6D) Wiring harness between CN-R5 (female) (7B) Resistance Max. 1Ω and ARC (female) 2 Wiring harness between CN-R4 (female) (9B) Resistance Max. 1Ω and 351 (female) 1 Wiring harness between CB4 outlet and CN-R Resistance Max. 1Ω (female) (131) Wiring harness between CN-T (female) (15A) Resistance Max. 1Ω and CN-AC1 (female) (15B)
D475A-3
TROUBLESHOOTING
E-29
Cause
Possible causes and standard value in normal state
D475A-3
Standard value in normal state/Remarks on troubleshooting + Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CN-P (female) (19A) Disconnection of wiring harResistance Max. 1Ω ness (Disconnection in wir- and CN-R4 (female) (19C) 10 ing or defective contact in Wiring harness between CN-P (female) (26A) Resistance Max. 1Ω connector) and CN-AC1 (female) (26B) Wiring harness between ARC (female) 1 and Resistance Max. 1Ω ground When Causes 1 to 10 are not applicable, the control panel is sup11 Defective control panel posed to be defective.
20-645
TROUBLESHOOTING
E-29
Circuit diagram related to air conditioner
20-646
D475A-3
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
Information described in troubleshooting list ........................................................................................... H-1 No travel power (No drawbar pull) ................................................................................................... H-2 Machine does not move (At 2nd or 3rd speed) ................................................................................ H-3 Machine does not move in any speed range ................................................................................... H-4 Machine travels only in one direction in forward or in reverse ......................................................... H-5 When gear is shifted or travel direction is changed, large time lag is made .................................... H-6 Steering is not possible ..................................................................................................................... H-7 Steering is possible only on one side .............................................................................................. H-8 Steering overrun occurs ................................................................................................................... H-9 Brake does not work ........................................................................................................................ H-10 Torque converter does not lock-up ................................................................................................ H-11 Overheat of power train oil temperature ........................................................................................ H-12 All work equipment speeds are slow ............................................................................................. H-13 All work equipment does not operate ............................................................................................ H-14 Blade lift raising speed is slow or the blade lift has no power ........................................................ H-15 Blade tilt raising speed is slow or the blade tilt has no power ........................................................ H-16 Ripper lift raising speed is slow or the ripper lift has no power ...................................................... H-17 Ripper tilting speed is slow or the blade tilt has no power ............................................................. H-18 Excessive hydraulic drift of blade lift .............................................................................................. H-19 Excessive hydraulic drift of blade tilt .............................................................................................. H-20 Excessive hydraulic drift of ripper lift ............................................................................................. H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ................................ H-22 Blade pitch does not work (Dual tilt attachment machine) ............................................................. H-23 Abnormal sound comes out from around work equipment pump ..................................................
D475A-3
20-702 20-703 20-704 20-705 20-706 20-707 20-708 20-708 20-709 20-709 20-710 20- 711 20-712 20-713 20-714 20-714 20-715 20-715 20-716 20-717 20-717 20-718 20-718 20-720
20-701
TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST + Troubleshooting lists contain the following information all together. Understand the contents carefully and troubleshoot the machine. Trouble Related information
Problem that appears on the machine. Information related to problems occurred or troubleshooting Cause
Standard value in normal state/Remarks on troubleshooting
1 Possible causes and standard value in normal state
Cause supposed to have caused failure (The sequence shows reference • Standard values in normal state for judging possible causes numbers and does not mean pri- • Remarks for making judgment 3 ority.) 2
4
20-702
D475A-3
TROUBLESHOOTING
H-1
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) Trouble Related information
• There is no travel power. (No drawbar pull). • Confirm that the oil quantity on the power train is normal before troubleshooting. Cause
1 2
3
4 Possible causes and standard value in normal state
5
6
7 8
D475A-3
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Defective engine Measurement conditions Number of engine rotations F3 stall 1,590rpm Defective power train pump The power train pump is assumed to be defective; directly check it. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Original pressure of Torque converter Internally defective torque PCCS lever torque converter delivery pressure converter 0.8 – 1.0MPa 0.3 – 0.6MPa Full neutral {8 – 10kg/cm2} {3 – 6kg/cm2} + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Transmission main relief PCCS lever pressure Defective set pressure of Full neutral Min. 2.4MPa{Min. 24.0kg/cm2} transmission main relief + Prepare with the starting switch OFF, then carry out troubleshooting valve and internal defect without turning the starting switch ON. Directly check that the spring length are normal and also that the spool rotates smoothly. • Free length of spring: 120.3mm + Prepare with starting switch OFF, then drive the engine in low idling mode for troubleshooting. Transmission clutch Clutch pressure FWD Min. 2.35MPa {Min. 24kg/cm2} Defective transmission valve (ECMV) function REV Min. 2.35MPa {Min. 24kg/cm2} 1ST Min. 1.96MPa {Min. 20kg/cm2} 2ND Min. 2.35MPa {Min. 24kg/cm2} 3RD Min. 2.35MPa {Min. 24kg/cm2} + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Parking lever Left brake pressure Right brake pressure Defective brake valve Min. 2.26MPa Min. 2.26MPa Free {Min. 23kg/cm2} {Min. 23kg/cm2} If the result of the troubleshooting in cause 5 is abnormal, the parking Defective parking lever or lever or brake pedal linkage is not assumed to be adjusted normally. brake pedal linkage Directly check it. Internally defective transThe transmission is assumed to be defective internally; directly check mission it.
20-703
TROUBLESHOOTING
H-2
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) Trouble Related information
• Machine does not move. (At 2nd or 3rd speed) • Confirm that the oil quantity on the power train is normal before troubleshooting. • Confirm that the transmission main relief pressure is normal before troubleshooting. (See H-1.) Cause
Possible causes and standard value in normal state
1
Internally defective torque converter
2
Defective transmission valve (ECMV) function
3 4
20-704
Internally defective transmission clutch Defective parking brake function (Drag)
5
Defective brake function (Drag)
6
Internally defective transmission
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Original pressure of Torque converter PCCS lever torque converter delivery pressure 0.78 – 1.0MPa 0.29 – 0.59MPa Full neutral {8 – 10kg/cm2} {3 – 6kg/cm2} + Prepare with starting switch OFF, then drive the engine in low idling mode for troubleshooting. Transmission clutch Clutch pressure 2ND Min. 2.35MPa {Min. 24kg/cm2} 3RD Min. 2.35MPa {Min. 24kg/cm2} The transmission clutch (2nd or 3rd speed) is assumed to be defective internally; directly check it. The parking brake function is assumed to be defective (dragged); check the linkage valves. + Move to a flat place, and start the engine for troubleshooting. If the machine does not run by low idling + F2 operation, brake drag occurs. (Carry out troubleshooting “Brake does not work.”) The transmission is assumed to be defective internally; directly check it.
D475A-3
TROUBLESHOOTING
H-3
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE Trouble Related information
• Machine does not move in any speed range. • Confirm that the oil quantity on the power train is normal before troubleshooting.
1
2
Possible causes and standard value in normal state
3
4
5
D475A-3
Cause Standard value in normal state/Remarks on troubleshooting Defective power train pump The power train pump is assumed to be defective; directly check it. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Transmission main relief PCCS lever pressure Defective and Internally defective set pressure of Full neutral Min. 2.35MPa {Min. 24kg/cm2} transmission main relief + Prepare with the starting switch OFF, then carry out troubleshooting valve without turning the starting switch ON. Directly check that the spring length are normal and also that the spool rotates smoothly. • Free length of spring:120.3mm + Prepare with starting switch OFF, then drive the engine in low idling mode for troubleshooting. (Before this, confirm that the transmission main relief pressure is normal.) Transmission clutch Clutch pressure Defective transmission FWD Min. 2.35MPa {Min. 24kg/cm2} valve (ECMV) function REV Min. 2.35MPa {Min. 24kg/cm2} 1ST Min. 1.96MPa {Min. 20kg/cm2} 2ND Min. 2.35MPa {Min. 24kg/cm2} 3RD Min. 2.35MPa {Min. 24kg/cm2} Internally defective transThe transmission clutch (2nd or 3rd speed) is assumed to be defecmission clutch tive internally; directly check it. + Move to a flat place, and drive the engine in high idling mode for troubleshooting. (Before this, confirm that the transmission main relief pressure is normal.) Brake hydraulic pressure Brake pedal (left/right) Defective brake function Release Min. 2.26MPa {Min. 23kg/cm2} Pedal 0 {0} When the hydraulic pressure is abnormal, carry out troubleshooting “Brake does not work.”
20-705
TROUBLESHOOTING
H-4
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE Trouble Related information
• Machine travels only in one direction Forward or in reverse. • Confirm that the oil quantity on the power train is normal before troubleshooting.
1
2 Possible causes and standard value in normal state 3
4 5
20-706
Cause Standard value in normal state/Remarks on troubleshooting Defective power train pump The power train pump is assumed to be defective; directly check it. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Transmission main relief PCCS lever pressure Defective set pressure of Full neutral Min. 2.35MPa {Min. 24kg/cm2} transmission main relief + Prepare with the starting switch OFF, then carry out troubleshooting valve or internal defect without turning the starting switch ON. Directly check that the spring length are normal and also that the spool rotates smoothly. • Free length of spring: 120.3mm + Prepare with starting switch OFF, then drive the engine in low idling mode for troubleshooting. (Before this, confirm that the transmission main relief pressures is normal.) Defective transmission Transmission clutch Clutch pressure valve (ECMV) function FWD Min. 2.35MPa {Min. 24kg/cm2} REV Min. 2.35MPa {Min. 24kg/cm2} Defective transmission When the troubleshooting in cause 4 is abnormal, the clutch seal is clutch seal assume to be defective; directly check it. Internally defective transThe transmission clutch (forward or backward) is assumed to be demission clutch fective internally; directly check it.
D475A-3
TROUBLESHOOTING
H-5
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE Trouble Related information
• Time lag is excessive when shifting gear or changing direction. • Confirm that the oil quantity on the power train is normal before troubleshooting.
1
2
Possible causes and standard value in normal state 3
4 5 6
D475A-3
Cause Standard value in normal state/Remarks on troubleshooting Defective power train pump The power train pump is assumed to be defective; directly check it. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Transmission main relief PCCS lever pressure Full neutral Min. 2.35MPa{Min. 24kg/cm2} Defective set pressure of + Prepare with the starting switch OFF, then carry out troubleshooting transmission main relief without turning the starting switch ON. valve or internal defect Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly. • Free length of large spring: 122mm • Free length of small spring: 108mm • Number of shims: 6 + Prepare with starting switch OFF, then drive the engine in low idling mode for troubleshooting. (Before this, confirm that the transmission main relief pressure is normal.) Transmission clutch Clutch pressure Defective transmission FWD Min. 2.35MPa {Min. 24kg/cm2} valve (ECMV) function REV Min. 2.35MPa {Min. 24kg/cm2} 1ST Min. 2.35MPa {Min. 24kg/cm2} 2ND Min. 2.35MPa {Min. 24kg/cm2} 3RD Min. 2.35MPa {Min. 24kg/cm2} Defective transmission When the troubleshooting in cause 4 is abnormal, the clutch seal is clutch seal assume to be defective; directly check it. Internally defective transThe transmission clutch is assumed to be defective internally; directly mission clutch check it. + Move to a flat place, then start the engine for troubleshooting. Defective brake function If the machine does not run by low idling + F2 operation, brake drag (Drag) occurs. (Carry out troubleshooting “Brake does not work.”)
20-707
STEERING IS NOT POSSIBLE STEERING IS POSSIBLE ONLY ON ONE SIDE H-5
TROUBLESHOOTING
H-6 STEERING IS NOT POSSIBLE Trouble
• Steering is not possible. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
1
Possible causes and standard value in normal state 2
3 4
Standard value in normal state/Remarks on troubleshooting + Start the engine for preparation and idle it at a low speed for troubleshooting. Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for F3 travel (or R3 travel). If the track shoe stops, the brake is defective. (Execute the troubleshooting of “Brake does not work.”) + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} Defective operation of steerMin. 2.26 MPa 0 ing clutch valve (ECMV) Right clutch pressure {Min. 24 kg/cm2} {0} 0 Min. 2.26 MPa Left brake pressure {0} {Min. 23 kg/cm2} Min. 2.26 MPa 0 Right brake pressure {Min. 23 kg/cm2} {0} Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to be clutch defective. Check it directly. Internal defect of steering The inside of the steering clutch is supposed to be defective, check it clutch directly.
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE Trouble
• Steering is possible only on one side. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
Standard value in normal state/Remarks on troubleshooting + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} Defective operation of steer1 0 Min. 2.4 MPa ing clutch valve (ECMV) Possible causes Right clutch pressure {0} {Min. 24 kg/cm2} and standard val0 Min. 2.26 MPa ue in normal state Left brake pressure {0} {Min. 23 kg/cm2} 0 Min. 2.26 MPa Right brake pressure {0} {Min. 23 kg/cm2} Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to be 2 clutch defective. Check it directly. Internal defect of steering The inside of the steering clutch is supposed to be defective, check it 3 clutch directly.
20-708
D475A-3
STEERING OVERRUN OCCURS BRAKE DOES NOT WORK H-5
TROUBLESHOOTING
H-8 STEERING OVERRUN OCCURS Trouble
• Steering overrun occurs. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
Standard value in normal state/Remarks on troubleshooting + Start the engine for preparation and idle it at a low speed for troubleshooting. Possible causes 1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for and standard valF3 travel (or R3 travel). If the track shoe stops, the brake is defective. ue in normal state (Execute the troubleshooting of “Brake does not work.”) When the track shoe does not stop in the troubleshooting of the cause Defective operation of steer2 1, the steering clutch is defective. (Execute the troubleshooting of ing clutch “Steering is not possible.”)
H-9 BRAKE DOES NOT WORK Trouble
• Brake does not work. • Before troubleshooting, check that the power train oil level is normal. Related information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Cause
1
2
Possible causes and standard value in normal state 3
4 5
D475A-3
Standard value in normal state/Remarks on troubleshooting + Start the engine for troubleshooting. Step on the brake pedal, shift the gear to F2 and idle the engine at a Degradation of brake high speed. When the machine moves, the brake performance is degraded. Defective operation of brake The brake pedal and the brake valve are supposed not to work norpedal mally. Check them directly. + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. PCCS lever Left stroke end Right stroke end 0 Min. 2.4 MPa Left clutch pressure {0} {Min. 24 kg/cm2} Defective operation of steer0 Min. 2.4 MPa ing brake valve (ECMV) Right clutch pressure {0} {Min. 24 kg/cm2} 0 Min. 2.26 MPa Left brake pressure {0} {Min. 23 kg/cm2} 0 Min. 2.26 MPa Right brake pressure {0} {Min. 23 kg/cm2} When the brake seal is not normal in the troubleshooting of the cause Defective brake seal 3, the brake seal is supposed to be defective. Check it directly. Internal defect of brake The inside of the brake is supposed to be defective. Check it directly.
20-709
TROUBLESHOOTING
H-10 H-5
H-10 TORQUE CONVERTER DOES NOT LOCK-UP Trouble Related information
• Torque converter does not lock-up. • Confirm that the oil quantity on the power train is normal before troubleshooting. • Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.) 1
2 Possible causes and standard value in normal state
3 4
5
20-710
Cause Standard value in normal state/Remarks on troubleshooting Defective power train pump The power train pump is assumed to be defective; directly check it. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Defective torque converter Torque converter Lock-up clutch pressure lock-up valve function Min.1.08 MPa At lock-up {Min. 18kg/cm2} Defective lock-up clutch If the troubleshooting in cause 2 is abnormal, the lock-up clutch seal seal is assumed to be defective; directly check it. Internally defective lock-up The lock-up clutch is assumed to be defective internally; directly clutch check it. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Internally defective torque converter Measurement conditions Number of engine rotations F3 stall 1,590rpm
D475A-3
TROUBLESHOOTING
H-11
H-11 OVERHEAT OF POWER TRAIN OIL TEMPERATURE Trouble Related information
• The oil temperature of the power train overheats. • Confirm that the oil quantity on the power train is normal before troubleshooting. • Confirm that the value of the oil temperature of the power train matches the actual oil temperature before troubleshooting. (If they do not match, carry out troubleshooting “Abnormal Power Train Oil temperature.”) Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.) Cause
1 2
3 Possible causes and standard value in normal state
4
5
6
D475A-3
Standard value in normal state/Remarks on troubleshooting The engine cooling system is assumed to be defective or the engine Defective engine system output is assumed to be increased; see the Shop Manual: Engine. Defective power train pump + The power train pump is assumed to be defective or aired from the suction circuit; directly check it. or air from suction circuit + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Original pressure of Torque converter Internally defective torque PCCS lever torque converter delivery pressure converter 0.78 – 1.0MPa 0.29 – 0.59MPa Full neutral {8 – 10kg/cm2} {3 – 6kg/cm2} Defective transmission The transmission clutch is assumed to be defective internally clutch function (Slip) (slipped); directly check it. + Prepare with starting the engine for troubleshooting. 1. Use the blades and ripper to float the machine from the ground. Defective brake function 2. Convert the drive position while low-idling. (Drag) 3. If the track shoe does not rotate, brake drag occurs. (Carry out troubleshooting "Brake does not work.") + Prepare with starting the engine for troubleshooting. Defective brake function Carry out F3 stall. If the machine does not stop completely, brake slip (Slip) occurs.
20-711
TROUBLESHOOTING
H-12
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY Trouble • All work equipment operates slowly. Related information • Before troubleshooting, check that the hydraulic tank oil level is normal.
1 2 3 4 5
6 Possible causes and standard value in normal state 7
8
9
10 11
20-712
Cause Defective PTO (work equipment pump drive) Defective work equipment large pump Defective work equipment small pump Defective PPC charge pump
Standard value in normal state/Remarks on troubleshooting The work equipment pump drive of the PTO is supposed to be defective. Check it directly. The work equipment large pump is supposed to be defective. Check it directly. The work equipment small pump is supposed to be defective. Check it directly. The PPC charge pump is supposed to be defective. Check it directly. + Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade lift Blade lever Main relief pressure valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be valve for blade lift valve defective. Check it directly. + Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade tilt Blade lever Main relief pressure ripper Lo valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo posed to be defective. Check it directly. valve + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Improper pressure set to charge relief valve Work equipment lever Control relief pressure Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2} Internal defect of charge re- The inside of the charge relief valve is supposed to be defective. lief valve Check it directly. Internal leak of PPC valve Internal leak of PPC valve is supposed. Check it directly.
D475A-3
TROUBLESHOOTING
H-13
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE Trouble • All work equipment does not operate. Related information • Before troubleshooting, check that the hydraulic tank oil level is normal.
1 2 3 4 5
Possible causes and standard value in normal state
6
7
8
9
10 11
D475A-3
Cause Defective PTO (work equipment pump drive) Defective work equipment large pump Defective work equipment small pump Defective PPC charge pump
Standard value in normal state/Remarks on troubleshooting The work equipment pump drive of the PTO is supposed to be defective. Check it directly. The work equipment large pump is supposed to be defective. Check it directly. The work equipment small pump is supposed to be defective. Check it directly. The PPC charge pump is supposed to be defective. Check it directly. + Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade lift Blade lever Main relief pressure valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be valve for blade lift valve defective. Check it directly. + Set the starting switch to OFF for preparation and idle the engine at Improper pressure set to a high speed for troubleshooting. main relief valve for blade tilt Blade lever Main relief pressure ripper Lo valve Raise Min. 19.6 MPa {Min. 200 kg/cm2} Internal defect of main relief The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo posed to be defective. Check it directly. valve + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Improper pressure set to charge relief valve Work equipment lever Control relief pressure Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2} Internal defect of charge re- The inside of the charge relief valve is supposed to be defective. lief valve Check it directly. Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the lelock valve ver linkage or the lock valve directly.
20-713
H-14, H-15 H-14
TROUBLESHOOTING
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER Trouble
• • • Related information •
Blade lift raising speed is slow or the blade lift has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Check if the blade has been modified. In case of large hydraulic drift of the blade lift, execute the troubleshooting of “Hydraulic drift of blade lift is large.” Cause
1
Defective operation of PPC valve
Defective operation of blade Possible causes 2 lift control valve (spool) and standard value in normal state Defective operation of blade 3 lift control valve (suction valve) 4 Air entry in blade lift cylinder
Standard value in normal state/Remarks on troubleshooting + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Blade lever PPC valve output pressure Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2} The spool of the blade lift control valve is suppose to operate abnormally. Check it directly. The suction valve of the blade lift control valve is suppose to operate abnormally. Check it directly. + It is also acceptable to replace the suction valve on the head side with the one on the bottom side to check change of the phenomenon as another method. Air is supposed to enter the blade lift cylinder. Bleed air and check the change of phenomenon.
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER Trouble
• • • Related information •
Blade tilt raising speed is slow or the blade tilt has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Check if the blade has been modified. In case of large hydraulic drift of the blade lift, execute the troubleshooting of “Hydraulic drift of blade lift is large.” Cause
Standard value in normal state/Remarks on troubleshooting + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Defective operation of PPC 1 valve Blade lever PPC valve output pressure Possible causes and standard valTilt stroke end Min. 3.9 MPa {Min. 40 kg/cm2} ue in normal state Defective operation of blade The spool of the blade tilt control valve is suppose to operate abnor2 tilt control valve (spool) mally. Check it directly. Air is supposed to enter the blade tilt cylinder. Bleed air and check the 3 Air entry in blade tilt cylinder change of phenomenon.
20-714
D475A-3
TROUBLESHOOTING
H-16, H-16 H-17
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER Trouble
• • • Related information •
Ripper lift raising speed is slow or the ripper lift has no power. Before troubleshooting, check that the hydraulic tank oil level is normal. Check if the ripper has been modified. In case of large hydraulic drift of the blade lift, execute the troubleshooting of “Hydraulic drift of blade lift is large.” Cause
1
Defective operation of PPC valve
Defective operation of ripper Possible causes 2 lift control valve (spool) and standard value in normal state Defective operation of ripper lift control valve 3 (constant differential pressure valve) 4 Air entry in ripper lift cylinder
Standard value in normal state/Remarks on troubleshooting + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Ripper lever PPC valve output pressure Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2} The spool of the ripper lift control valve (Lo, Hi) is suppose to operate abnormally. Check it directly. The constant differential pressure valve of the ripper lift control valve (Hi) is suppose to operate abnormally. Check it directly. + It is also acceptable to replace the constant differential pressure valve on the head side with the one on the bottom side to check change of the phenomenon as another method. Air is supposed to enter the ripper lift cylinder. Bleed air and check the change of phenomenon.
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER Trouble
• Ripper tilting speed is slow or the ripper has no power. • Before troubleshooting, check that the hydraulic tank oil level is normal. Related information • Check if the ripper has been modified. Cause 1
Defective operation of PPC valve
Defective operation of ripper Possible causes 2 tilt control valve (spool) and standard value in normal state Defective operation of ripper tilt control valve 3 (constant differential pressure valve) 4 Air entry in ripper tilt cylinder
D475A-3
Standard value in normal state/Remarks on troubleshooting + Set the starting switch to OFF for preparation and idle the engine at a high speed for troubleshooting. Ripper lever PPC valve output pressure Tilt end Min. 3.9 MPa {Min. 40 kg/cm2} The spool of the ripper tilt control valve (Lo, Hi) is suppose to operate abnormally. Check it directly. The constant differential pressure valve of the ripper tilt control valve (Hi) is suppose to operate abnormally. Check it directly. + It is also acceptable to replace the constant differential pressure valve on the head side with the one on the bottom side to check change of the phenomenon as another method. Air is supposed to enter the ripper tilt cylinder. Bleed air and check the change of phenomenon.
20-715
TROUBLESHOOTING
H-18
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT Trouble Related information
• Excessive hydraulic drift of blade lift. • Confirm whether the blade is remodeled. • Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Cause
Possible causes and standard value in normal state
20-716
1
Defective seal of blade lift operation valve (Spool)
2
Defective seal of blade lift cylinder
Standard value in normal state/Remarks on troubleshooting Prepare with starting the engine, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes high, the spool seal of the blade lift operation valve is assumed to be defective. 1. Prop up the machine using the blade lift, and lift the front of the machine. 2. Stop the engine, and release the safety lock lever. 3. Set the blade lever to the lift lowering side, and confirm how the phenomenon changes. The seal of the blade lift cylinder is assumed to be defective; directly check it.
D475A-3
TROUBLESHOOTING
H-19, H-18 H-20
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT Trouble Related information
• Excessive hydraulic drift of blade tilt. • Confirm whether the blade is remodeled. • Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Cause
Possible causes and standard value in normal state
1
Defective seal of blade tilt operation valve (Spool)
2
Defective seal of blade tilt cylinder
Standard value in normal state/Remarks on troubleshooting + Prepare with starting the engine, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes high, the spool seal of the blade tilt operation valve is assumed to be defective. 1. Prop up the machine using the blade tilt, and lift the right of the machine. 2. Stop the engine, and release the safety lock lever. 3. Set the blade lever to the right tilt side, and confirm how the phenomenon changes. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Blade tilt cylinder Cylinder leak quantity Right tilt stroke end 12cc/min
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT Trouble Related information
• Excessive hydraulic drift of ripper lift. • Confirm whether the ripper is remodeled. • Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Cause
Possible causes and standard value in normal state
D475A-3
1
Defective seal of ripper lift operation valve (Spool)
2
Defective seal of ripper lift cylinder
Standard value in normal state/Remarks on troubleshooting + Prepare with starting the engine, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes high, the spool seal of the ripper lift operation valve (Hi) is assumed to be defective. 1. Prop up the machine using the blade tilt, and lift the rear of the machine. 2. Stop the engine, and release the safety lock lever. 3. Set the blade lever to the lift lowering side, and confirm how the phenomenon changes. + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Ripper lift cylinder Cylinder leak quantity Lowering stroke end 16cc/min
20-717
TROUBLESHOOTING
H-21, H-22
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) Trouble Related information
• The ripper pin puller cylinder does not work. • Confirm that the main relief pressure for transmission is normal before troubleshooting. Cause
Possible causes and standard value in normal state
1
2
Standard value in normal state/Remarks on troubleshooting + Prepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Pin puller working Defective function of pin Pin puller switch Measurement position pressure puller solenoid Push-in Cylinder bottom side 2.3 – 2.9MPa {23.5 – 30.0kg/cm2} Pull-in Cylinder head side Internally defective pin pull- The pin puller cylinder is assumed to be defective internally; directly er cylinder check it.
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE) Trouble Related information
• The blade pitch does not work.
1 Possible causes and standard value in normal state
2
3
20-718
Cause Defective function of work equipment solenoid valve
Standard value in normal state/Remarks on troubleshooting The spool of the work equipment valve is assumed to be defective; directly check it. The function of the blade pitch cylinder is assumed to be defective; Defective function of blade directly check it. pitch operation valve Operations of solenoids during pitch and tilt operation are indicated in (Spool) the following chart. Defective function of blade The function of the blade pitch selection solenoid valve is assumed to pitch cylinder be defective; directly check it.
D475A-3
D475A-3
TILT BACK Relief at ripper stroke end
{ { { { { { { {
z
{ { { { { { { { { {
ON
z z z
{
z
{ { {
z
z
{ { { { { { { { { { { {
z z
z
{ {
{
z z
z
TILT BACK Relief at ripper stroke end
z { { { { z
TILT
z z
TILT IN
ON
OFF
ON
z
Ripper
OFF
PST
{
Each ripper PPC pressure sensor+Large pump pressure sensor
Ripper TILT BACK PPC pressure sensor
Ripper TILT IN PPC pressure sensor
Ripper LOWER PPC pressure sensor
Ripper PAISE PPC pressure sensor
Pirct switch ON+Left tilt PPC pressure sensor
Pitch switch ON+Right tilt PPC pressure sensor
Left and right yoke angle sensor
Dual switch ON+Right tilt PPC pressure sensor
Left and right yoke angle sensor
Dual switch ON+Left tilt PPC pressure sensor
Left and right yoke angle sensor
Left and right yoke angle sensor
Blade LOWER PPC pressure sensor
Blade RAISE PPC pressure sensor
Applicable sensor or switch
Each PPC pressure sensor+Large pump pressure sensor
Ripper TILT BACK PPC pressure sensor
Ripper TILT IN PPC pressure sensor
Pump Large Small Assist 140 100 100
z z z z
RAISE, RAISE LOWER LOWER
z {
PITCH BACK
ON
{ { { { { { { { { {
PITCH
OFF
{ { { { { { {
RIGHT DUAL TILT R I G H T D U A L T I LT LIMIT PITCH DUMP
ON
z
LEFT DUAL TILT LIMIT
OFF
PDA
Ripper RAISE PPC pressure sensor
z
DUAL TILT
ON
{
RIGHT SINGLE TILT LIMIT LEFT DUAL TILT
OFF
PIT
PITH DUMP ASSIST PITCH SELECTION
Blade LOWER PPC pressure sensor
z
Blade
LOWER (Short stroke) LOWER (long stroke), FLOAT LEFT SINGLE TILT LEFT SINGLE TILT SINGLE LIMIT TILT RIGHT SINGLE TILT
ON
{
RAISE (Long stroke)
OFF
{
RAISE (Short stroke)
Dual tilt mode
ON
UNL
{ { {
LIFT
NEUTRAL
Single tilt mode
z z z z UNLOAD
{
Operation
{ {
TLR
z z z z z
TLL
z
PPB
z z z
PPD
PITCH DUMP PITCH BACK LEFT TILT LIMIT RIGHT TILT LIMIT
z z z z z z z
Solenoid name
z
Ripper LOWER PPC pressure sensor
z z z
z z z z
Connector
Pump Large Small Assist 140 100 100
z
Blade RAISE PPC pressure sensor
Applicable sensor or switch
z
DUAL TILT DOZER
TILT
z
TILT IN
z
RAISE, RAISE LOWER LOWER
LOWER (long stroke), FLOAT SINGLE LEFT SINGLE TILT TILT RIGHT SINGLE TILT
OFF
{
Ripper
Blade
LOWER (Short stroke)
RAISE (Long stroke)
ON
UNL
UNLOAD
{ {
LIFT
RAISE (Short stroke)
All in neutral
Operation
Connector
Solenoid name
SINGLE TILT DOZER
TROUBLESHOOTING H-22
WORK EQUIPMENT SOLENOID OPERATION CHART z z z z z z z z z z z
z z z z z z z z z z z z z z z z z z z z z z z z
z
{
{
z z z z
{
z z
{ { { z
{
20-719
TROUBLESHOOTING
H-23
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP Trouble Related information
• Abnormal noise from around work equipment pump. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
1 Possible causes and standard value in normal state
2 3 4
20-720
Cause Inappropriate oil Clogged hydraulic oil tank strainer
Standard value in normal state/Remarks on troubleshooting The oil used is assumed to be inappropriate; directly check it. The strainer of the hydraulic oil tank is assumed to be clogged; directly check it. Air is assumed to be inhaled in the suction circuit of the work machine Air inhaled in suction circuit pump; directly check the pipes. Internally defective work The work equipment pump is assumed to be defective internally; diequipment pump rectly check it.
D475A-3
30 DISASSEMBLY AND ASSEMBLY ❉ marks show the items which are common to D475A-3 SHOP MANUAL. As to the common items, see D475A-3 SHOP MANUAL (Form No. SEBM017207). ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉
❉ ❉
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
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30-23
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30-24 ❉ 30-25 30-27
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30-28
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30-30
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30-33 ❉ 30-37 30-38 30-40 30-41 30-43 ❉ 30-47 30-49 ❉ 30-52 ❉ 30-56 30-59
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30-61
❉
30-72
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 ....... 30-116 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 STEERING CONTROL VALVE ASSEMBLY Removal and Installation ............. 30-135 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 TRACK ROLLER ASSEMBLY Removal and Installation ............. 30-173 Disassembly and Assembly ......... 30-175
30-1
❉ ❉ ❉ ❉
❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉
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
❉ ❉ ❉ ❉ ❉ ❉ ❉ ❉
❉ ❉
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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
POWER TRAIN UNIT
REMOVAL OF POWER TRAIN UNIT ASSEMBLY 1. Drain oil from hydraulic tank and power train case. 6 Hydraulic tank : Approx. 140 ¬ 6 Power train case : Approx. 210 ¬ 2. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 3. Remove fuel tank assembly. For details, see REMOVAL OF FUEL TANK ASSEMBLY. 4. Disconnect lubrication hoses (1) and (3). 5. Disconnect pin-puller hoses (2).
6. Disconnect connectors. (241, 242, BR)
7. Disconnect connectors. (PL1, PL2, 578)
30-52
D475A-3
DISASSEMBLY AND ASSEMBLY
POWER TRAIN UNIT
8. Remove hydraulic pump inlet tube coupling (8) and tube (9).
9. Disconnect hoses (10).
10. Disconnect ripper hose (11), then disconnect clamp (1 place) on top of steering case.
11. Remove universal joint (12).
1
4 Universal joint : 65 kg
D475A-3
30-53
DISASSEMBLY AND ASSEMBLY
12. Remove front mount bolt (13).
POWER TRAIN UNIT
2
13. Remove rear mount bolt (14), then remove mount cap (15). 3 4 Mount cap : 30 kg
14. Remove housing clip (16), and move flange (17) towards final drive end. 4 15. Using forcing screws 1, remove cover (18).
16. Remove shaft (19). fl Pull out the shaft with forcing screws 2. fl If the shaft will not come out, set jack 3 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 (20).
5
4 Power train unit assembly : 5,500 kg
30-54
D475A-3
DISASSEMBLY AND ASSEMBLY
POWER TRAIN UNIT
INSTALLATION OF POWER TRAIN UNIT ASSEMBLY •
Carry out installation in the reverse order to removal.
1 3 Universal joint mounting bolt : 156.8 – 196 Nm {16 – 20 kgm} 2 3 Front mount bolt : 1,519 – 1,911 Nm {155 – 195 kgm} 3 3 Rear mount bolt : 823.2 – 1,029 Nm {84 – 105 kgm} 4 fl Check that the housing clip is fitted securely in the flange. 3 Housing clip : 4.9 – 8.8 Nm {0.5 – 0.9 kgm} 5 fl 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. 5
Power train case : Approx. 210 ¬
5
Hydraulic tank : Approx. 140 ¬
D475A-3
30-55
DISASSEMBLY AND ASSEMBLY
PTO, TORQUE CONVERTER
REMOVAL OF PTO, TORQUE CONVERTER ASSEMBLY 1. Remove power train unit assembly. For details, see REMOVAL OF POWER TRAIN UNIT ASSEMBLY. 2. Raise power train unit assembly (1) and set on block 1. fl Set blocks under the front of the oil pan, transmission rear case, and steering case.
3. Remove brake rod (2) and parking brake cable (20). 1
4. Disconnect central pressure detection hose (3), then remove together with central pressure detection bracket (4). fl Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing. 5. Remove oil filler tube (5). 6. Sling filter assembly (6), then remove. 4 Filter assembly : 40 kg 7. Remove power train pump (7) and strainer assembly (8). ¤ Sling the power train pump, then remove together with the strainer. 4 Power train pump, strainer assembly : 100 kg 8. Lift off mount bracket (9). 2 4 Mount bracket : 70 kg 9. Remove tube (10) and scavenging pump (11). ¤ Sling the scavenging pump, then remove the mounting bolts. 4 Scavenging pump : 24 kg
30-56
D475A-3
DISASSEMBLY AND ASSEMBLY
PTO, TORQUE CONVERTER
10. Remove hose (12). 11. Remove gauge guide (13).
12. Removal of hydraulic pump 1) Remove tube (14). 2) Remove tube (15). 3) Lift off right pump assembly (16). 4 Pump assembly : 40 kg 4) Lift off left pump assembly (17). 4 Pump assembly : 25 kg
13. Remove oil pan (18). fl Remove the block under the oil pan, sling the oil pan, then remove the mounting bolts and disconnect the oil pan. 4 Oil pan : 120 kg
14. Remove PTO and torque converter assembly (19). 3 ¤ Sling the PTO and torque converter assembly, then remove the mounting bolts. fl Using a lever block, lift off the PTO and torque converter assembly horizontally. 4 PTO, torque converter assembly : 850 kg
D475A-3
30-57
DISASSEMBLY AND ASSEMBLY
PTO, TORQUE CONVERTER
INSTALLATION OF PTO, TORQUE CONVERTER ASSEMBLY •
Carry out installation in the reverse order to removal.
1
¤ Bend the cotter pin securely. 2 2 PTO boss rotating portion : Grease (G2-LI) 3 fl 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.
30-58
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
DISASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY •
Put transmission assembly on the block.
1. Transmission control valve assembly Remove transmission control valve assembly (1). fl Remove four bolts marked by and each bolt marked by ▲, ª, and ■.
2. Valve sheet, sleeve 1) Remove valve sheet (2). fl Remove seven bolts marked by .
2) Pull out sleeves (3).
3. Transmission case 1) Turn over transmission assembly, and remove plate (10). 2) Using eyebolts, remove transmission case (11).
30-80
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
4. Housing 1) Remove 17 tie bolts (12). 2) Using eyebolts, remove housing (13). 3) Remove seal ring (14) from housing.
5. Spring Remove spring (15). 6. Discs, plates, springs Remove discs (16), plates (17), and springs (18) in turn. fl Keep the discs and plates in a flat place to prevent them from becoming deformed. 7. No. 1 ring gear Remove ring gear (19).
8. No. 1 housing, piston 1) Using eyebolts, remove No. 1 housing and piston assembly (20). 2) Remove piston (22) from housing (21).
9. Spring Remove spring (23). 10. Discs, plates, springs Remove discs (24), plates (25), and springs (26) in turn. fl 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
30-81
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
12. Shaft, No. 1, 2, 3 carrier assembly Using eyebolts, remove No. 1, 2, and 3 carrier assembly (29). 4 Shaft, No. 1, 2, 3 carrier assembly : 200 kg 1) Disassemble the shaft and carrier assembly as follows. i) Remove snap ring (130), then remove sun gear (30).
ii) Using eyebolts, remove shaft and No. 1 carrier assembly (31) from No. 2 and 3 carrier assembly (32). 2) Disassemble the shaft and No. 1 carrier assembly as follows. i) Raise the assembly, then using forcing screw 2, remove shaft and cage assembly (33).
ii) Using plastic hammer, remove cage assembly (34), spacer (35), and bearing (36). iii) Remove seal ring (37) from cage assembly. iv) Remove seal ring (38) from cage. v) Remove seal ring (40) from shaft (39).
vi) Remove shaft (42), ball (43), thrust washer (44), gear (45), and bearing (46) from No. 1 carrier assembly (41). vii) Remove seal rings (47) and (131).
30-82
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
3) Disassemble the No. 2, No.3 carrier assembly as follows. i) Remove sun gear (48). ii) Using eyebolts, remove plate and gear assembly (49).
iii) Remove ring (50), and disassemble plate (51) and gear (52). iv) Remove plate (54) from No. 2, 3 carrier assembly (53). v) Remove seal ring (55) from plate.
vi) Remove shaft (56), ball (57), thrust washer (58), gear (59), and bearing (60).
vii) Using push tool, remove collar and bearing assembly (61) from carrier. viii)Using push tool, remove bearing (62).
D475A-3
30-83
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
ix) Using puller and push tool, remove bearing (63) and spacer (64) from collar (65). x) Remove seal ring (66).
13. No. 2 ring gear Remove ring gear (67). 14. No. 2 housing, piston 1) Using eyebolts, remove No. 2 housing and piston assembly (68). 4 No. 2 housing, piston : 80 kg 2) Remove piston (70) from housing (69).
15. No. 3 piston Remove No. 3 piston (71). 16. Spring Remove spring (72). 17. Discs, plates, springs Remove discs (73), plates (74), and springs (75) in turn. fl 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, remove No. 3 housing (77). 4 No. 3 housing : 55 kg 20. No. 4 piston Remove No. 4 piston (78).
30-84
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
21. Spring Remove spring (79). 22. Discs, plates, springs Remove discs (80), plates (81), and springs (82) in turn. fl Keep the discs and plates in a flat place to prevent them from becoming deformed. 23. Guide pin Remove guide pin (83).
24. Sun gear Remove snap ring (132), then remove sun gear (84). 25. Plate, bearing 1) Using eyebolts, remove plate and bearing assembly (85). 2) Using push tool 3, remove bearing (87) from plate (86).
3) Using puller 4 and push tool 3, remove bearing (88). 4) Using push tool, remove bearing (90) from collar (89).
26. No. 3 ring gear 1) Remove ring gear (91). 2) Remove ring (92) from ring gear.
D475A-3
30-85
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).
1) Disassemble the No. 4 carrier and No. 5 clutch assembly as follows. i) Remove 2 mounting bolts, then install guide bolts. ii) Remove remaining mounting bolts, then loosen guide bolts 5 slowly, and remove No. 4 carrier assembly (96) from No. 5 clutch assembly (97). 4 No. 4 carrier assembly, No. 5 clutch assembly : 160 kg
iii) Remove shaft (98), ball (99), thrust washer (100), gear (101), and bearing (102).
iv) Remove spring (103) and pin (104). v) Remove discs (105), plates (106), and springs (107). fl 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.
30-86
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
ix) Remove piston (112) from No. 5 housing (111). x) Remove spacer (113) and seal ring (114) 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). 4 Shaft assembly: 80 kg 1) Disassemble the shaft assembly as follows. i) Remove snap ring, then using eyebolts, sling shaft assembly, knock out bearing portion, and remove shaft assembly (118).
ii) Remove cage (119). iii) Using stand 6, remove bearing (120).
iv) Remove snap ring (134), then remove bearing (121) from cage (133). v) Remove seal ring (122). vi) Remove cover (123).
D475A-3
30-87
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
vii) Remove bearing (124). viii)Remove seal ring (126).
ix) Remove snap ring (135), then remove boss and bearing (127). x) Remove snap ring (136), then using push tool, remove bearing (129) from boss (128).
30-88
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY fl 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. fl 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. fl Align the notches of the oil groove when installing the discs.
1. Shaft assembly 1) Assemble the shaft assembly as follows. i) Install seal ring (126). ii) Using push tool, install baring (124).
iii) Install cover (123). iv) Install seal ring (122). v) Install bearing (121) to cage (133) and secure with snap ring (134).
vi) Using push tool, press fit bearing (120). vii) Fit seal ring and install cage (119).
D475A-3
30-89
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
viii)Using eyebolts, sling shaft assembly (118), 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 (116).
2. 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 (113) to No. 5 housing (111). ii) Install seal ring (114). iii) Install piston assembly (112) to No. 5 housing (111).
iv) v) vi) vii)
Install seal ring (110) to inner gear. Install inner gear (109). Install guide pin (108). Install springs (107), plates (106), and discs (105) in turn. viii)Install pin (104) and spring (103). fl Free length of spring : 103.5 mm
ix) Assemble bearing (102) in gear (101), and fit thrust washers (100) to both sides, then set in position in carrier. x) Assemble ball (99) to shaft (98), and push shaft into carrier.
30-90
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
xi) Set No. 4 carrier assembly (96) to No. 5 clutch assembly (97), and using 2 guide bolts 5, compress spring, then tighten mounting bolts. fl Check that the spring is fitted securely in the hole of the housing, then tighten the mounting bolts. 2 Mounting bolt : Thread tightener (LT-2) 3 Mounting bolt : 157 – 196 Nm {16 – 20 kgm}
2) Using eyebolts, install No. 4 carrier and No. 5 clutch assembly (95). 3. Plate, ring gear 1) Using eyebolts, align with dowel pin, then install plate (93). fl 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) in collar (89). 2) Using push tool, press fit bearing (88).
D475A-3
30-91
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
3) Using push tool, press fit bearing (87) in plate (86). fl Set the large protrusion of the bearing assembly on top as shown in the diagram right, and install to the plate. 4) Using eyebolts, install plate and bearing assembly (85).
6. Sun gear Install sun gear (84), and secure with snap ring (132). 7. Guide pin Install guide pin (83). 8. Discs, plates, springs Install springs (82), plates (81), and discs (80) in turn. 9. Spring Install spring (79). fl Free length of spring : 81.7 mm 10. No. 4 piston Fit seal ring and install No. 4 piston (78). 11. No. 3 housing Using eyebolts, fit seal ring and install No. 3 housing (77). 12. Seat Install seat (76).
30-92
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
13. Discs, plates, springs Install springs (75), plates (74), and discs (73) in turn. 14. Spring Install spring (72). fl Free length of spring : 84 mm 15. No. 3 piston Fit seal ring and install No. 3 piston (71).
16. No. 2 housing, piston 1) Fit seal ring, and install piston (70) to housing (69). 2) Using eyebolts, install No. 2 housing and piston (68). fl Check that the spring is fitted securely in the hole of the housing. 17. No. 2 ring gear Install ring gear (67).
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).
iii) Using push tool, press fit bearing (62). iv) Using push tool, press fit collar and bearing (61) in carrier.
D475A-3
30-93
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
v) Assemble bearing (60) in gear (59), then fit thrust washers (58) to both sides, and set in carrier. vi) Assemble ball (57) to shaft (56), and push shaft into carrier.
vii) Install seal ring (55) to plate. viii)Install plate (54) to No. 2, 3 carrier assembly (53). ix) Set plate (51) to gear (52), and install ring (50).
x) Using eyebolts, install plate and gear assembly (49). xi) Install sun gear (48), and secure with snap ring.
2) Assemble the shaft and No. 1 carrier assembly as follows. i) Install seal ring (47), (131) to carrier. ii) Assemble bearing (46) in gear (45), then fit thrust washers (44) to both sides, and set in carrier. iii) Assemble ball (43) to shaft (42), and push shaft into carrier case (41).
30-94
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
iv) Install seal ring (40) to shaft (39). v) Install seal ring (38) to cage.
vi) Using push tool, press fit bearing (37) in cage. vii) Press fit bearing (36) in shaft.
viii)Set spacer (35) to bearing and cage assembly (34), and press fit shaft (39).
ix) Using eyebolts, install shaft and cage assembly (33). 3) Assemble the shaft and carrier assembly as follows. i) Using eyebolts, install shaft and No. 1 carrier assembly (31) to No. 2, 3 carrier assembly (32). fl Align the sun gear with the tooth face of the planetary gear, and tap with a plastic hammer to install.
D475A-3
30-95
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
ii) Set carrier assembly on its side, then install sun gear (30), and secure with snap ring (130). 4) Using eyebolts, install shaft and No. 1, 2, 3 carrier assembly (29) to housing.
19. Sleeve, guide pin 1) Install guide pin (28). 2) Install sleeve (27). 20. Discs, plates, springs Install springs (26), plates (25), and discs (24) in turn. 21. Spring Install spring (23). fl Free length of spring : 112 mm
22. No. 1 housing, piston 1) Fit seal ring and install piston (22) to housing (21). 2) Using eyebolts, install No. 1 housing and piston (20). fl Check that the spring is fitted securely in the hole of the housing.
23. No. 1 ring gear Install ring gear (19). 24. Discs, plates, springs. Install springs (18), plates (17), and discs (16) in turn. 25. Spring Install spring (15). fl Free length of spring : 112 mm
30-96
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW 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. 3 Tie bolts: 353 – 392 Nm { 36 – 40 kgm}
27. Checking piston stroke Using tool D, check each piston stroke. fl Air pressure : 0.5 – 0.6 MPa {5 – 6 kg/cm2} Unit : mm Piston
Standard stroke
No. 1 (R)
7.4
No. 2 (F)
8.4
No. 3 (3)
4.8
No. 4 (2)
5.0
No. 5 (1)
7.1
28. Transmission case 1) Using eyebolts, install transmission case (11). 2) Install plate (10).
D475A-3
30-97
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. fl Check that the tip of the shaft is mated with the lock portion of its mating boss.
2) Using push tool, install bearing (129) to boss (128), and secure with snap ring (136). 3) Install boss and bearing assembly (127) to output shaft, and secure with snap ring (135). fl Install the bearing slowly and be careful that shaft (115) is mated with the lock portion of boss (128).
30. Sleeve, valve sheet 1) Mount sleeves (3). 2 Sleeve (4 pieces): Grease (G2-LI)
2) Mount valve sheet (2). 3 Mounting bolt: 59 – 74Nm {6 – 7 kgm} 2 Mounting bolt (7 pieces): Liquid gasket (LG-5)
30-98
D475A-3
DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
31. Transmission control valve assembly 1) Mount transmission control valve assembly (1). 3 Mounting bolt marked by (4 pieces): 59 – 74 Nm {6 – 7 kgm} Mounting bolt marked by ª (1 piece): 59 – 74 Nm {6 – 7 kgm} Mounting bolt marked by ■ (1 piece): 59 – 74 Nm {6 – 7 kgm} Mounting bolt marked by ▲ (1 piece): 27 – 34 Nm {2.8 – 3.5 kgm} 2 Mounting bolt marked by (4 pieces): Liquid gasket (LG-5)
D475A-3
30-99
DISASSEMBLY AND ASSEMBLY
STEERING CASE
DISASSEMBLY OF STEERING CASE ASSEMBLY 1. Clutch, brake assembly Using tool E1, sling clutch and brake assembly, then remove mounting bolts, and remove clutch and brake assembly. fl 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.
2. Shafts Remove left and right shafts (4). 3. Lubrication tube Remove lubrication tube (5).
4. Pipes 1) Remove left and right pipes (6). 2) Remove pipe (7). 5. Steering valve assembly 1) Remove protection cover (2A). 2) Remove bracket (2B). 3) Remove steering valve assembly (1).
6. Input shaft 1) Remove cage assembly (8). 2) Remove snap ring, and pull out input shaft (9) from case.
30-100
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CASE
7. Transfer, gear housing assembly Fit guide bolt and screw in forcing screws 1, then remove housing assembly (10). 8. Cage 1) Turn over so that right cage is at top, then remove bearing cage (11). fl Check the number and thickness of the shims, and keep in a safe place.
2) Using eyebolts 2, remove cage (12). 9. Bevel gear, shaft assembly Using eyebolts, remove bevel gear and shaft assembly (13).
1) Disassemble the bevel gear and shaft assembly as follows. i) Pull out reamer bolt, and remove bevel gear (14) from shaft (15). ii) Using puller 3, remove bearings (16) and (17) from shaft.
10. Cage 1) Turn over steering case, and remove bearing cage (18). fl Check the number and thickness of the shims, and keep in a safe place. 2) Remove outer race (19) from bearing cage.
D475A-3
30-101
DISASSEMBLY AND ASSEMBLY
STEERING CASE
ASSEMBLY OF STEERING CASE ASSEMBLY fl 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 1) Using push tool, press fit outer race (19) 2) Assemble shim, and install bearing cage (18). fl Standard shim thickness : 2 mm 3 Mounting bolt : 245 – 308.7 Nm {25 – 31.5 kgm}
2. Bevel gear, shaft assembly 1) Assemble bevel gear and shaft as follows. i) Using tool E2, press fit bearings (17) and (16). ii) Set bevel gear (14) to shaft (15), and tighten reamer bolt. 3 Reamer bolt : 490 – 607.6 Nm {50 – 62 kgm}
iii) Using eyebolts, install bevel gear and shaft assembly (13). 3. Cage 1) Using eyebolts 2, install cage (12). 3 Mounting bolt : 245 – 308.7 Nm {25 – 31.5 kgm}
2) Assemble shim, and install bearing cage (11). fl Standard shim thickness : 2 mm 3 Mounting bolt : 245 – 308.7 Nm {25 – 31.5 kgm} 4. Adjusting preload Rotate bevel gear 2 – 3 turns, and fit push-pull scale 4 to tip of teeth, then measure rotating torque of bevel gear shaft. fl Standard value of rotating torque: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
30-102
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CASE
5. Transfer, gear housing assembly Fit guide bolt 5 to steering case, and install housing assembly (10). 3 Mounting bolt : 245 – 308.7 Nm {25 – 31.5 kgm}
6. Adjusting tooth contact, backlash 1) Adjusting backlash Put the probe of dial gauge 6 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. fl Standard value for backlash : 0.3 – 0.4 mm fl 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. i) 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
DBD02993
ii) 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). fl 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. D475A-3
When backlash is large
DBD02994
30-103
DISASSEMBLY AND ASSEMBLY
2) Adjusting tooth contact Testing i) Coat the tooth face of the bevel pinion lightly with red lead (minium). 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% fl 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. fl 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.
30-104
STEERING CASE
Dedendum (root of tooth) Addendum (tip of tooth) Big end
Small end DBD02995
D475A-3
DISASSEMBLY AND ASSEMBLY
Adjustment If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. i) If bevel pinion is too far from center line of bevel gear. Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. [Correct the tooth contact as follows.] 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) 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.] 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. fl 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.
D475A-3
STEERING CASE
B
A DBD00161
B
A DBD00162
30-105
DISASSEMBLY AND ASSEMBLY
STEERING CASE
7. Input shaft 1) Assemble input shaft (9) in case, and secure with snap ring. 2) Install cage assembly (8).
8. Steering valve assembly 1) Mount steering valve assembly (1). 3 Mounting bolt marked by ✩ (2 pieces): 245 – 309 Nm {25 – 31.5 kgm} 2) Tighten bracket (2B) together with steering case. 3 Mounting bolt marked by ▲ (1 piece): 245 – 309 Nm {25 – 31.5 kgm} 3) Tighten protection cover (2A) together with steering case. 3 Mounting bolt marked by fl (4 pieces): 245 – 309 Nm {25 – 31.5 kgm} Mounting bolt marked by ª (1 piece): 245 – 309 Nm {25 – 31.5 kgm} 9. Pipes 1) Install pipe (7). 2) Install left and right pipes (6). fl Coat the O-rings thinly with grease (G2LI), and be careful not to damage them when installing.
10. Lubrication tube Install lubrication tube (5). 11. Clutch, brake assembly Using tool E1, install clutch and brake assembly (3). 3 Mounting bolt : 279 ± 30 Nm {28.5 ± 3 kgm}
30-106
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CASE
12. Shafts Install left and right shafts (4). fl If it is difficult to insert the shafts with the bevel locked, release the steering brake before inserting. 1) Remove plugs (20), then remove bolts (21), and tighten them in plug holes to compress clutch spring and release brake.
D475A-3
30-107
DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY 1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR CAB’S ASSEMBLY. 2. Remove operator’s seat and floor frame cover. fl Use turnbuckle (1) when disconnecting the brake rod. Check the mounting dimensions of the rod before disconnecting. 1
3. Disconnect wires, cables, and rods. 4. Remove transmission control valve assembly (2). fl Remove four bolts marked by and each bolt marked by ▲, ª, and ■. 2
D475A-3
30-127
DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE
INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY •
Carry out installation in the reverse order to removal.
1 fl Adjust the brake pedal and parking lever. For details, see TESTING AND ADJUSTING, adjusting brake pedal and parking brake lever. 3 Turnbuckle locknut : 34.3 – 58.8 Nm {3.5 – 6 kgm} 2 2 Mounting bolt (4 pieces): Liquid gasket (LG-5) 3 Mounting bolt marked by (4 pieces): 59 – 74 Nm {6 – 7 kgm} Mounting bolt marked by ª (1 piece): 59 – 74 Nm {6 – 7 kgm} Mounting bolt marked by ■ (1 piece): 59 – 74 Nm {6 – 7 kgm} Mounting bolt marked by ▲ (1 piece): 27 – 34 Nm {2.8 – 3.5 kgm}
30-128
D475A-3
DISASSEMBLY AND ASSEMBLY
STEERING CONTROL VALVE
REMOVAL OF STEERING CONTROL VALVE ASSEMBLY 1. Remove fuel tank assembly. For details, see REMOVAL OF FUEL TANK ASSEMBLY. 2. Disconnect wires, cables, and rods. 3. Steering control valve assembly 1) Remove protection cover (2A). 2) Remove bracket (2B). 1 3) Remove steering control valve assembly (1).
INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY 1 3 Steering control valve assembly Mounting bolt marked by ✩ (2 pieces): 245 – 309 Nm {25 – 31.5 kgm} Mounting bolt marked by ▲ (1 piece): 245 – 309 Nm {25 – 31.5 kgm} Mounting bolt marked by fl (4 pieces): 245 – 309 Nm {25 – 31.5 kgm} Mounting bolt marked by ª (1 piece): 245 – 309 Nm {25 – 31.5 kgm} D475A-3
30-135
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
REMOVAL OF FLOOR FRAME ASSEMBLY 1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY. 2. Remove covers (1), (2) and (3).
3. Remove step cover (5). 4. Lift off operator’s seat (6). fl Remove the seat together with the undercover. 4 Operator’s seat : 108 kg
5. Disconnect 2 air conditioner hoses (7). 1 fl Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. fl Disconnect at the air conditioner end, then move the hoses towards the engine. fl Fit blind plugs to prevent dirt or moisture from entering the hoses. fl Be careful not to damage or drop the Orings. 6. Disconnect 2 heater hoses (8). fl Close the heater valve at the engine end. 7. Disconnect blade PPC hose (10) and hose clamp (11). 8. Disconnect blade PPC hoses (12), (13), and (14). • Single tilt specification machine only. 2
D475A-3
30-235
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
9. Disconnect ripper PPC hoses (15), (16), (17), and (18). 3
10. Disconnect accumulator hose (19). 11. Disconnect tank return hoses (20) and (21).
12. Disconnect clamps (22) (2 places) for wiring harness and washer tank hose. 13. Disconnect ground wiring (23) (SX-8). 14. Disconnect wiring connectors CN-PL1, CN-PL2, CN-578, CN-PWR1, CN-PWR2, CN-USB, CN-FD5, CN-122, and CN-599.
15. Disconnect parking brake cable (34) on lever side, then remove it from bracket. fl Before disconnection, check cable mounting length. 4 16. Disconnect brake pedal linkage (35) on turn buckle unit. 5 fl Before disconnection, check brake rod mounting length. fl Be careful that turn buckle unit is mounted with reverse helical screws.
30-236
D475A-3
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
17. Remove arm rest (36). 18. Remove right console (37). fl Disconnect cable connectors (CN-262 and CN263) in console. fl Remove lever boots from console, then remove console. 19. Remove left console cover (38).
20. Remove eight bolts (four on each side) on the left and right of rear mounting bolts (39). 6
21. Remove earth cable (40). 22. Remove one left front mounting bolt (41). 7 23. Remove one right front mounting bolt (42). 7
24. Lift off floor frame assembly (45) to remove. 4 Floor frame assembly: 600 kg fl Use chain block to lift floor frame assembly by degrees while balancing front, rear, left, and right.
D475A-3
30-237
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
INSTALLATION OF FLOOR FRAME ASSEMBLY •
Carry out installation in the reverse order to removal. 1 fl Install the hoses without twisting or interference. fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. fl 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). 3 Tighten the air conditioner gas piping to the following tightening torques. Thread size
Tightening torque (Nm {kgm})
16 × 1.5
13.23±1.47 {1.35±0.15}
22 × 1.5
22.05±2.45 {2.25±0.25}
24 × 1.5
31.85±2.45 {3.25±0.25}
M6 bolt (receiver portion) M6 bolt (compressor portion)
O-ring DBD02985
5.39±1.47 {0.55±0.15} 9.8±1.96 {1.0±0.2}
23 fl Adjust the directional, speed control, and parking brake linkage. 4 fl Adjust parking brake lever linkage, referring to “Adjustment of Brake Pedal and Parking Lever” in TESTING and ADJUSTING. 5 fl Adjust brake pedal linkage, referring to “Adjustment of Brake Pedal and Parking Lever” in TESTING AND ADJUSTING. 3 Brake pedal linkage turn buckle: 45.56 ± 12.25 Nm {4.76 ± 1.25 kgm} 67 3 Rear mounting bolt: 279 ± 30 Nm {28.5 ± 3 kgm} 3 Front mounting bolt: 1,320 ± 140 Nm {135 ± 15 kgm}
D475A-3
30-239
DISASSEMBLY AND ASSEMBLY
DASHBOARD
REMOVAL OF DASHBOARD ASSEMBLY 1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY. 2. Disconnect 2 air conditioner hoses (1). 1 fl Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. fl Disconnect at the air conditioner end, then move the hoses towards the engine. fl Fit blind plugs to prevent dirt or moisture from entering the hoses. fl Be careful not to damage or drop the Orings. 3. Disconnect 2 heater hoses (2). fl Close the heater valve at the engine end. 4. Disconnect cable connectors ((CN-S13), (CN-214), (CN-215), (CN-216), and (CN-DL1)), and earth cable.
5. Lift off dashboard assembly (7). 4 Dashboard assembly : 120 kg
30-240
D475A-3
DISASSEMBLY AND ASSEMBLY
DASHBOARD
INSTALLATION OF DASHBOARD ASSEMBLY •
Carry out installation in the reverse order to removal.
1 fl Install the hoses without twisting or interference. fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. fl 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). 3 Tighten the air conditioner gas piping to the following tightening torques. Thread size
Tightening torque (Nm {kgm})
16 × 1.5
13.23±1.47 {1.35±0.15}
22 × 1.5
22.05±2.45 {2.25±0.25}
24 × 1.5
31.85±2.45 {3.25±0.25}
M6 bolt (receiver portion) M6 bolt (compressor portion)
DBD02985
5.39±1.47 {0.55±0.15} 9.8±1.96 {1.0±0.2}
•
Charging with air conditioner gas Using tool X, charge the air conditioner circuit with air conditioner gas (R134a).
•
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
O-ring
30-241
DISASSEMBLY AND ASSEMBLY
CONTROLLER
REMOVAL OF CONTROLLER ASSEMBLY ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Remove cover (1). 2. Disconnect wiring connectors of main controller (2). (CN- S40, M11, M21, M31, M41, M51) 3. Disconnect wiring connectors of engine controller (3). (CN-E11, E21, E31, E32, E41, E51, E52) 4. Remove main controller (2) and engine controller (3).
INSTALLATION OF CONTROLLER ASSEMBLY •
Carry out installation in the reverse order to removal.
30-242
D475A-3
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY 1. Remove left and right covers (1) and cover (2).
2. Disconnect 2 air conditioner hoses (3). 1 fl Loosen the sleeve nut slightly and release the air conditioner gas (R134a) completely before disconnecting the hoses. fl Disconnect at the air conditioner end, then move the hoses towards the engine. fl Fit blind plugs to prevent dirt or moisture from entering the hoses. fl Be careful not to damage or drop the Orings. 3. Disconnect 2 heater hoses (4). fl Close the heater valve at the engine end. 4. Disconnect cable connectors ((5) (CN-S13), (6) (CN-214), (7) (CN-215), (8) (CN-216), and (9) (CNDL1)), and earth cable (CN-GND1).
5. Remove covers (12) and (13).
30-246
D475A-3
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
6. Remove panel (16), then remove cover (17).
7. Remove ducts (18) and (19).
8. Remove monitor (20) and cover (21).
9. Remove RECIRC air filter (22) and FRESH air filter (23). fl There is 1 mounting bolt for the air conditioner unit beyond the FRESH air filter bracket.
D475A-3
30-247
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
10. Disconnect bracket (24) and clamp (25).
11. Disconnect relays (26) (CN-R1), (27) (CN-R2), (28) (CN- R3) and connector (29) (CN-M26) inside right side of dashboard.
12. Remove air conditioner unit (30). 13. Remove blower motor (31).
30-248
D475A-3
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
INSTALLATION OF AIR CONDITIONER UNIT •
Carry out installation in the reverse order to removal.
1 fl Install the hoses without twisting or interference. fl Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. fl 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). 3 Tighten the air conditioner gas piping to the following tightening torques. Thread size
Tightening torque (Nm {kgm})
16 × 1.5
13.23±1.47 {1.35±0.15}
22 × 1.5
22.05±2.45 {2.25±0.25}
24 × 1.5
31.85±2.45 {3.25±0.25}
M6 bolt (receiver portion) M6 bolt (compressor portion)
DBD02985
5.39±1.47 {0.55±0.15} 9.8±1.96 {1.0±0.2}
•
Charging with air conditioner gas Using tool X, charge the air conditioner circuit with air conditioner gas (R134a).
•
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
O-ring
30-249
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 Power train, hydraulic, lubrication pump ................................... 40-10 Transfer, bevel pinion ................................. 40-11 Bevel gear shaft, steering clutch, brake ...................................................... 40-12 Parking brake valve .................................... 40-14 Final drive ..................................................... 40-16 Main frame ................................................... 40-18 Track frame ................................................... 40-20 Recoil spring ................................................. 40-21 Idler ................................................................ 40-22 Track roller .................................................... 40-24 Carrier roller ................................................ 40-26 Track shoe ................................................... 40-28 Equalizer bar ................................................ 40-32 Pivot shaft ..................................................... 40-34 Hydraulic pump ........................................... 40-35 Work equipment control pump ................. 40-36 Main control valve ...................................... 40-37 PPC valve ..................................................... 40-41 Work equipment cylinder ........................... 40-44 Cylinder stay ................................................ 40-46 Blade ............................................................. 40-48 Ripper equipment ....................................... 40-54
D475A-3
40-1
MAINTENANCE STANDARD
ENGINE MOUNT
ENGINE MOUNT
Unit: mm
No.
1
Check item
Clearance between bracket and cushion
2
Clearance between bracket and bushing
3
Free height of rubber mount
40-2
Criteria Standard size
Tolerance
Remedy
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
Standard size
Repair limit
118
116
Replace
D475A-3
MAINTENANCE STANDARD
DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
Unit: mm
No.
1
Check item
Clearance between flywheel housing and cover
Criteria Standard size
Tolerance
Remedy
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
0.2
2
Clearance between flywheel and damper
Standard size
Repair limit
3
Outer diameter of oil seal contact face on coupling
120
119.9
Outer diameter of bearing contact face on output shaft
55
54.9
4
D475A-3
Replace
40-3
MAINTENANCE STANDARD
TORQUE CONVERTER
TORQUE CONVERTER
40-4
D475A-3
MAINTENANCE STANDARD
TORQUE CONVERTER
Unit: mm
No.
Check item
1
Outside diameter of oil seal contact surface of coupling
Criteria
Remedy
Standard size
Tolerance
Repair limit
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
7
Wear of stator shaft seal ring
8
9
0.250 – 0.420 0.204 – 0.516 Standard size
Repair limit
Width: 5.95 Height: 6.50
Width: 5.35 Height: 5.85
Lock-up clutch
Backlash of input shaft gear and driven gear
Clearance limit
Thickness of disc
5.4
5.0
Thickness of plate
5.0
4.5
Thickness of total assembly
26.2
24.0
Stator clutch
6
Standard clearance
Thickness of disc
5.4
5.1
Thickness of plate
5.0
4.5
Thickness of total assembly
15.8
14.7
Replace
Standard size
10
Stator clutch spring
Free length 54.1
D475A-3
Repair limit
Installation Installation length load 37.0
25.5N {12.8 kg}
Free length
Installation load
50.9
106.9N {10.9 kg}
40-5
MAINTENANCE STANDARD
TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
40-6
D475A-3
MAINTENANCE STANDARD
TORQUE CONVERTER VALVE
Unit: mm
No.
1
2 3 4 5
Check item
Clearance between main relief valve and valve body Clearance between torque converter relief valve and valve body Clearance between stator clutch modulating valve and valve body Clearance between lock-up clutch modulating valve and valve body Clearance between lock-up valve and valve body
Criteria Standard size
Tolerance Shaft
Hole
Standard clearance
40
–0.035 –0.045
+0.016 0
0.035 – 0.061
0.08
40
–0.035 –0.045
+0.016 0
0.035 – 0.061
0.08
25
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.08
25
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.08
40
–0.035 –0.045
+0.016 0
0.035 – 0.061
0.08
Standard size 6
Main relief valve spring
Remedy
Free length
Clearance limit
Repair limit
Installation Installation length load
Free length
Installation load
120.3
101.5
1495.5 N {152.5 kg}
116.7
1346.4 N {137.3 kg}
7
Torque converter relief valve spring
116.92
90.8
550.4 N {56.16 kg}
113.41
495.2 N {50.5 kg}
8
Stator clutch modulating valve spring
103.5
92.7
197.1 N {20.1 kg}
100.4
117.5 N {18.1 kg}
9
Lock-up clutch modulating valve spring (outer)
141.4
88.7
158.6 N {16.18 kg}
137.16
150.7 N {15.37 kg}
10
Lock-up clutch modulating valve spring (inner)
80.5
41.8 N 72.5 {4.26 kg} (Normal height) (Normal load)
78.09
675.7 N {68.9 kg}
11
Lock-up valve spring
97
27.9 N {2.85 kg}
D475A-3
110.07
100.0
29.4 N {3.0 kg}
Replace
40-7
MAINTENANCE STANDARD
TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
Unit: mm
No.
Check item
Criteria Repair limit
Standard size 1
No. 1 clutch spring (12 pcs)
Free length
Remedy
Installation Installation length load
Free length
Installation load
100.0
90.0
40.2 N {14.3 kg}
94.0
119.6 N {12.2 kg}
2
No. 2 clutch spring (12 pcs)
100.0
94.0
83.4 N {8.5 kg}
94.0
70.6 N {7.2 kg}
3
No. 3 clutch spring (12 pcs)
84.0
72.0
150 N {15.3 kg}
79.0
127.4 N {13 kg}
4
No. 4 clutch spring (12 pcs)
81.7
63.0
119.6 N {12.2 kg}
76.5
102.0 N {10.4 kg}
5
No. 5 clutch spring (12 pcs)
103.5
76.0
238.3 N {24.3 kg}
97.0
203 N {20.7 kg}
40-8
Replace
D475A-3
MAINTENANCE STANDARD
TORQFLOW TRANSMISSION
Unit: mm
No.
Check item
6
Thickness of total assembly for No. 1 clutch
Criteria
Remedy
Standard size
Tolerance
Repair limit
72.6
0.36
68.9
7
Thickness of total assembly for No. 2 clutch
72.6
0.36
68.9
8
Thickness of total assembly for No. 3 clutch
50.2
0.30
47.5
9
Thickness of total assembly for No. 4 clutch
39.0
0.26
36.9
10
Thickness of total assembly for No. 5 clutch
61.4
0.33
58.2
11
Thickness of a clutch disc
5.4
±0.1
4.9
12
Thickness of a clutch plate
5.8
±0.1
5.2
Width
3.0
–0.01 –0.03
2.6
13
Wear of seal ring on transmission input shaft
Thickness
4.0
±0.12
3.85
Wear of seal ring on transmission output shaft
Width
4.0
–0.01 –0.03
3.5
Thickness
5.0
±0.15
4.85
Width
6.0
–0.01 –0.03
5.65
Thickness
6.8
±0.15
6.65
14
15
16 17
Wear of seal ring for No. 5 clutch
Backlash between each sun gear and planetary pinion Backlash between each planetary pinion and inner gear on ring gear
D475A-3
Replace
0.16 – 0.35 0.18 – 0.38
40-9
MAINTENANCE STANDARD
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP (BAL160 + 160 + 112)
Unit: mm
No.
1
2
Check item
Clearance between gear case and side plate, gear
Criteria Type
Standard clearance
Clearance limit
BAL160
0.04 – 0.10
0.13
BAL112
0.04 – 0.10
0.13
0.060 – 0.145
0.20
Clearance between plain bearing inner BAL160 diameter and gear shaft outer diamBAL112 eter Type
3
Pin insertion depth
Remedy
Replace
Standard size
Tolerance
Repair limit
14
0 –0.5
—
BAL160 BAL112
4
—
Rotating torque of spline shaft
Delivery EO10 – CD 45 – 55°C
40-10
5.88 Nm {0.6 kgm}
Type
Speed (rpm)
Delivery pressure MPa {kg/cm2}
Standard delivery (¬/min.)
Delivery limit (¬/min.)
BAL160
2,000
2.94 {30}
288
266
BAL112
2,000
2.94 {30}
205
188
—
D475A-3
MAINTENANCE STANDARD
TRANSFER, BEVEL PINION
TRANSFER, BEVEL PINION
Unit: mm
No.
1
Check item
Backlash of transfer gear
2
Thickness of collar between transfer gear and bearing
3
Thickness of shims for bearing cage
D475A-3
Criteria
Remedy
Standard clearance
Clearance limit
0.26 – 0.67
0.75
Standard size
Repair limit
19.3
18.9
Adjust or replace
Replace
2.0
Adjust
40-11
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
40-12
D475A-3
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
Unit: mm
No.
Check item
Criteria
Thickness of brake, clutch plate
Standard size
Repair limit
4.2
3.9
Tolerance
Repair limit
less than 0.3
0.4
Standard size
Repair limit
5.4
5.1
Tolerance
Repair limit
less than 0.3
0.4
Standard size
Repair limit
82.2
78.5
1 Warping of brake, clutch plate Thickness of brake, clutch disc
Remedy
2 Warping of brake, clutch disc
Replace
Replace
3
Thickness of total brake plate and disc assembly
4
Thickness of total brake plate and disc assembly
76.8
74.1
Backlash of brake, clutch disc, and brake hub
Standard clearance
Repair limit
5
0.4 – 07
1.0
6
Backlash between bevel gear and pinion
0.3 – 0.4
0.75
7
Clearance between seal ring and piston seal ring groove
0.5 – 0.8
0.8
8
Clearance between seal ring and cage seal ring groove
0.5 – 0.8
0.8
9
Inside diameter of seal ring contact surface of cage
10
Inside diameter of seal ring contact surface of piston
Standard size
Tolerance Shaft
Hole
Standard clearance
350
–0.5 –0.7
+0.089 0
0.5 – 0.789
300
–0.110 –0.191
+0.052 0
0.110 – 0.243
12
13
Brake belleville spring
Clutch belleville spring
Interference between bevel gear and reamer bolt
14
Runout of rear face of bevel gear
15
Preload of bevel gear shaft taper roller bearing
16
Standard shim thickness of bearing cage
D475A-3
Free length
Correct or replace
Replace
Adjust or replace
Clearance limit
Replace
Repair limit
Standard size 11
Correct or replace
Installation Installation length load
Free length
Installation load
19.7
12.9
46.97 kN {4,790 kg}
19.1
44.62 kN {4,550 kg}
20.4
12.9
55.7 kN {5,680 kg}
20.0
53.35 kN {5,440 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)
Correct or replace
Standard rotating torque: 9.8 – 11.8 Nm {1.0 – 1.2 kgm} (When bevel pinion and gear are not meshed, at tip of bevel gear: 51.0 – 61.8 N {5.2 – 6.3 kg}
Adjust
2.0
Adjust shim
40-13
MAINTENANCE STANDARD
PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm
No.
1
2
Check item
Clearance between parking brake valve spool and valve body Outer diameter of sliding section (spool) between dust seal and V-packing
Criteria Standard size 14
Tolerance Shaft
Hole
Standard clearance
–0.020 –0.030
+0.011 0
0.020 – 0.041
3
40-14
Clearance limit Replace 0.05
Tolerance
Repair limit
–0.020 –0.030
13.9
14
Standard size Parking brake valve spool spring
Remedy
Modify or replace the hard chrome plating.
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
65
47.7
38.2 N {3.9 kg}
63.1
36.3 N {3.71 kg}
Replace
D475A-3
MAINTENANCE STANDARD
FINAL DRIVE
FINAL DRIVE
40-16
D475A-3
MAINTENANCE STANDARD
FINAL DRIVE
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
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
Standard size
Repair limit
4
Outside diameter of No. 1 pinion oil seal contact surface
120.0
119.9
1
5 6 7
8
9 10
Clearance between pinion shaft and carrier
24.8
24.6
14.0
13.5
72.0
70.5 Tolerance
Standard size
Shaft
Hole
Standard clearance
Clearance limit
110
–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
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 button
Wear of sprocket teeth tip
D475A-3
2 7.3 – 8.3
Adjust
3.1 – 4.7 Standard size
Repair limit
30
24
486
470
Rebuild or replace
40-17
MAINTENANCE STANDARD
MAIN FRAME
MAIN FRAME
40-18
D475A-3
MAINTENANCE STANDARD
MAIN FRAME
Unit: mm
No.
Check item
Criteria Standard size
1
Interference between steering case and bushing
Remedy Repair limit
Tolerance
Standard size
Shaft
Hole
Standard clearance
315
+0.108 +0.056
+0.052 0
(Std. interference) 0.004 – 0.108
Clearance limit
Above 0
2
Clearance between steering frame and final drive cage
390
–0.018 –0.075
+0.057 0
0.018 – 0.132
0.2
3
Clearance between bracket and cushion
78
–0.030 –0.060
+0.006 –0.048
–0.018 – 0.066
0.1
140
–0.043 –0.106
+0.210 +0.050
0.093 – 0.316
1.5
110
–0.036 –0.090
+0.301 +0.118
0.154 – 0.371
1.5
Hole 100.2 Shaft 100
–0.036 –0.090
+0.164 +0.062
0.298 – 0.454
1.5
Hole 115.2 Shaft 115
–0.043 –0.106
+0.140 +0.031
0.274 – 0.446
1.5
140
–0.043 –0.083
+0.208 +0.131
0.174 – 0.291
1.5
4 5 6 7 8
9
Clearance between ripper arm mounting pin and bushing Clearance between ripper cylinder mounting pin and bushing Clearance between radiator guard mounting pin and bushing Clearance between radiator guard mounting pin and bushing Clearance between equalizer bar shaft and bushing Protrusion of rubber at end face of seal
Standard size
Repair limit
1
0.5
10
Free height of front mount rubber
118
116
11
Free height of rear mount rubber
58
56
12 13 14 15 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 bushing Press-fitting force for equalizer bar shaft mounting bushing
D475A-3
Replace
126.5 – 253 kN {12.9 – 25.8 ton} 111.8 – 267.7 kN {11.4 – 27.3 ton} 62.8 – 142.2 kN {6.4 – 14.5 ton}
Adjust
53.9 – 106.9 kN {5.5 – 10.9 ton} 65.7 – 153 kN {6.7 – 15.6 ton}
40-19
MAINTENANCE STANDARD
TRACK FRAME
TRACK FRAME
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
40-20
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 —
D475A-3
MAINTENANCE STANDARD
RECOIL SPRING
RECOIL SPRING
Unit: mm
No.
Check item
Criteria Repair limit
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
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
40-21
MAINTENANCE STANDARD
IDLER
IDLER
40-22
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
Hole
Standard clearance
Clearance limit
180
–0.350 –0.413
+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
—
40-23
MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER
40-24
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
40-25
MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER
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
40-26
Rebuild or replace
0 – 0.22
Replace
Clearance limit 0.3
D475A-3
MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE
fl Portion P shows the link on the side where the bushing is pressed fitted.
40-28
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
40-29
MAINTENANCE STANDARD
TRACK SHOE
SHINGLE SHOE
Unit: mm
No.
Check item
Criteria Standard size
Repair limit
105
35
1
Height
2
Thickness
28
3
Length of base
52
4
Length at tip
36
40-30
Remedy
Repair by build-up welding or replace
D475A-3
MAINTENANCE STANDARD
EQUALIZER BAR
EQUALIZER BAR
40-32
D475A-3
MAINTENANCE STANDARD
EQUALIZER BAR
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
—
—
40-33
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
—
1
Interference between thrust washer and seal
Standard Interference interference limit
Replace
4
5
Clearance between pivot shaft and bushing
Clearance between pivot shaft and bushing
40-34
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 STANDARD
HYDRAULIC PUMP
HYDRAULIC PUMP (SAL140 + 100)
Unit: mm
No.
1
2
Check item
Clearance between gear case and side plate gear
Criteria Type
Standard clearance
SAL140
0.11 – 0.16
Remedy Clearance limit
0.22
Clearance between plain bearing I.D. and gear shaft O.D.
SAL100
0.13 – 0.18
SAL140
0.069 – 0.140 0.20
SAL100
SAR-100
SAR-140 3
Pin insertion depth 0
0
14 –0.5
21 –0.5 4
Rotational torque of spline shaft Type
—
Replace
0.078 – 0.149
Discharge EO10 – CD 45 – 55°C
Revolution (rpm)
Discharge pressure
2,000
20.6 MPa {210 kg/cm2}
SAL140 SAL100
D475A-3
16.67 – 26.48 Nm {1.7 – 2.7 kgm} Standard discharge (¬/min)
Discharge limit (¬/min)
260
236
180
163
—
40-35
MAINTENANCE STANDARD
WORK EQUIPMENT CONTROL PUMP
WORK EQUIPMENT CONTROL PUMP (SAR100 + 32)
Unit: mm
No.
1
Check item
Clearance between gear case and side plate, gear
Criteria Type
Standard clearance
SAR100
0.13 – 0.18
3
4
Clearance between inside SAR100 diameter of plain bearing and outside diameter SAR32 of gear shaft
Pin insertion depth
0.10 – 0.15 0.078 – 0.149 0.20
14
0 –0.5
SAR32
10
0 –0.5
Rotatinal torque of spline shaft
Delivery EO10 – CD 45 – 55°C
40-36
8.83 – 16.67 Nm {0.9 – 1.7 kgm} Speed (rpm)
SAR100 2,500 SAR32
Replace
0.060 – 0.149
SAR100
Type —
Clearance limit
0.22 SAR32
2
Remedy
Delivery pressure
Standard delivery (¬/min.)
Delivery limit (¬/min.)
231
214
75
67
—
20.6 MPa {210 kg/cm2}
D475A-3
MAINTENANCE STANDARD
MAIN CONTROL VALVE
MAIN CONTROL VALVE BLADE LIFT VALVE
D475A-3
40-37
MAINTENANCE STANDARD
MAIN CONTROL VALVE
BLADE LIFT VALVE Main relief, shuttle valve
Unit: mm
No.
Check item
Criteria Standard size
1
Spool return spring
Free length
Remedy Repair limit
Installation Installation length load
Free length
Installation load
104.35
103
116.6 N {11.9 kg}
—
93.3 N {9.5 kg}
2
Spool return spring
130.62
124
764.6 N {78 kg}
—
611.5 N {62.4 kg}
3
Spool return spring (For FLOAT)
56.29
45
744.4 N {76 kg}
—
595.8 N {60.8 kg}
4
Check valve spring
95
77
7.3 N {0.74 kg}
69.3
5.8 N {0.59 kg}
5
Check valve spring
32.7
24.5
44.1 N {4.5 kg}
31.0
35.3 N {3.6 kg}
6
Suction valve spring
75.9
38.5
11.38 N {1.16 kg}
68.4
9.12 N {0.93 kg}
7
Demand spool spring
94.03
60
401.8 N {41 kg}
114.7
321.4 N {32.8 kg}
8
Main relief valve spring
41.1
32.6
258.9 N {26.4 kg}
39.4
206.9 N {21.1 kg}
9
Shuttle valve spring
42.7
22.0
8.14 N {0.83 kg}
38.6
6.47 N {0.66 kg}
10
Height of main relief pressure adjustment screw
40-38
8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2})
Replace
Adjust
D475A-3
MAINTENANCE STANDARD
MAIN CONTROL VALVE
BLADE TILT, RIPPER LOW VALVE
Unit: mm
No.
Check item
Criteria Standard size
1
Spool return spring
Free length
Remedy Repair limit
Installation Installation length load
Free length
Installation load
48.14
46
156.8 N {16.0 kg}
—
125.4 N {12.8 kg}
2
Check valve spring
32.8
24.5
3.82 N {0.39 kg}
26.2
3.0 N {0.31 kg}
3
Main relief valve spring
24.2
18.3
31.4 N {3.2 kg}
23.0
25.1 N {2.56 kg}
4
Main relief valve poppet spring
41.1
32.6
258.9 N {26.4 kg}
39.4
206.9 N {21.1 kg}
5
Height of main relief pressure adjustment screw
D475A-3
8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2})
Replace
Adjust
40-39
MAINTENANCE STANDARD
MAIN CONTROL VALVE
RIPPER HIGH VALVE
Unit: mm
No.
Check item
Criteria Standard size
1
Spool return spring
Free length
Remedy Repair limit
Installation Installation length load
Free length
Installation load
92.6
52.0
229.5 N {23.4 kg}
74.1
183.4 N {18.7 kg}
2
Check valve spring
49.0
29.0
8.8 N {0.9 kg}
39.2
7.1 N {0.72 kg}
3
Suction valve spring
75.8
57.5
5.59 N {0.57 kg}
60.7
4.4 N {0.45 kg}
4
Fixed differential pressure valve spring
61.9
37.0
224.6 N {22.9 kg}
49.5
179.5 N {18.3 kg}
40-40
Replace
D475A-3
MAINTENANCE STANDARD
PPC VALVE
PPC VALVE •
FOR RIPPER
112.8±14.7Nm (11.5±1.5kgm) 13.2±1.5Nm (1.35±0.15kgm)
1 44.1±4.9Nm (4.5±0.5kgm)
3
39.2±4.9Nm (4±0.5kgm)
8.5±2.5Nm (0.85±0.25kgm)
2
6.5±2.5Nm (0.65±0.25kgm)
3
SYD00454
Unit: mm
No.
Check item
Criteria Standard size
1
Centering spring (for P3, P4)
Remedy Repair limit
Free length Installation Installation x OD length load
Free length
Installation load
50.05 x 15.5
34
71.39 N {7.28 kg}
—
56.9 N {5.8 kg}
2
Centering spring (for P1, P2)
50.35 x 15.5
34
55.9N {5.7 kg}
—
45.1 N {4.6 kg}
3
Metering spring
26.53 x 8.15
24.9
16.7 N {1.7 kg}
—
17.7 N {1.4 kg}
D475A-3
Replace spring if damaged or deformed
40-41
MAINTENANCE STANDARD
•
PPC VALVE
FOR BLADE LIFT, BLADE TILT
40-42
D475A-3
MAINTENANCE STANDARD
PPC VALVE
Unit: mm
No.
Check item
Criteria Repair limit
Standard size 1
Centering spring (for P1)
Remedy
Free length Installation Installation x O.D. length load
Free length
Installation load
37.9 x 15.6
32.5
156 N {15.9 kg}
—
124.5 N {12.7 kg}
2
Metering spring
26.53 x 8.15
24.9
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
3
Centering spring (for P2)
48.6 x 15.5
32.5
108 N {11.0 kg}
—
86.2 N {8.8 kg}
4
Centering spring (for P3, P4)
48.6 x 15.5
32.5
108 N {11.0 kg}
—
86.2 N {8.8 kg}
5
Detent spring (for P1)
20.39 x 19.5
12.7
168 N {17.1 kg}
—
134 N {13.7 kg}
6
Detent spring (for P2)
45.36 x 7.5
26
38.44 N {3.92 kg}
—
30.79 N {3.14 kg}
D475A-3
Replace spring if damaged or deformed
40-43
MAINTENANCE STANDARD
WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER •
BLADE LIFT CYLINDER
•
BLADE TILT CYLINDER, SUPER DOZER PITCH CYLINDER
•
RIPPER CYLINDER
•
PIN PULLER CYLINDER
40-44
D475A-3
MAINTENANCE STANDARD
WORK EQUIPMENT CYLINDER
Unit: mm
No.
1
2
3
4
13
Check item
Clearance between piston rod and bushing
Clearance between piston rod support shaft and bushing
Clearance between cylinder support shaft bushing and yoke
Clearance between cylinder bottom support shaft and bushing
Criteria
Hole
Standard clearance
Clearance limit
Shaft
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
Ripper tilt
140
–0.043 –0.143
+0.277 +0.061
0.104 – 0.420
0.72
Pin puller
30
–0.065 –0.117
+0.133 +0.007
0.072 – 0.250
0.55
Blade lift
Ball 125
–0.300 –0.200
+0.300 0
0.300 – 0.500
0.8
Blade tilt
90
–0.200 –0.300
+0.100 0
0.200 – 0.400
1.0
Ripper lift
110
+0.207 +0.120
1.0
Ripper tilt
110
+0.207 +0.120
1.0
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
±0.1
Clearance between cylinder bottom support shaft and boss
D475A-3
Tolerance
Standard size
Remedy
+0.457 +0.390
0.570 – 0.757
Replace
1.0
40-45
MAINTENANCE STANDARD
CYLINDER STAY
CYLINDER STAY
Unit: mm
No.
Check item
Criteria Tolerance Shaft
Hole
Standard clearance
Clearance limit
210
–0.050 –0.122
+0.167 +0.005
0.145 – 0.289
0.5
2
Clearance between cylinder yoke and bushing
160
–0.043 –0.106
+0.192 +0.129
0.172 – 0.298
0.5
3
Clearance between lift cylinder supporting shaft and bushing
145
–0.145 –0.245
+0.040 0
0.145 – 0.285
0.5
1
Clearance between cylinder yoke and bushing
Standard size
Remedy
Replace
40-46
D475A-3
MAINTENANCE STANDARD
BLADE
BLADE •
SEMI U-BLADE
40-48
D475A-3
MAINTENANCE STANDARD
BLADE
Unit: mm
No.
1
Check item
Clearance between brace pin and brace
Criteria Standard size
Tolerance
Remedy Standard clearance
Clearance limit
+0.5 +0.3
0.5 – 0.8
2
–0.2 –0.3
+0.3 +0.1
0.3 – 0.6
2
+0.1 0
0.2 – 0.4
1
Shaft
Hole
90
–0.2 –0.3
90
2
Clearance between brace pin and bracket
3
Clearance between brace pin and bracket
90
–0.2 –0.3
4
Clearance between brace pin and joint bushing
90
–0.2 –0.3
+0.1 0
0.2 – 0.4
1
5
Spherical clearance between arm and cap
200
–0.2 –0.3
+0.3 0
0.2 – 0.6
1
6
Clearance between joint and bracket
240
–0.2 –0.4
+0.3 +0.1
0.3 – 0.7
3
7
Clearance between frame pin and joint
120
–0.3 –0.5
+0.3 0
0.3 – 0.8
3
8
Clearance between frame pin and bracket
120
–0.3 –0.5
+0.5 +0.2
0.5 – 1.0
2
9
Spherical clearance between joint bushings of straight frames
165
0.3 – 0.4
1
10
Spherical clearance between trunnion and cap
250
–0.5 –1.0
+0.5 0
0.5 – 1.5
8
11
Clearance between joint and bracket
240
–0.2 –0.4
+0.3 +0.1
0.3 – 0.7
3
12
Clearance between blade pin and joint
120
–0.3 –0.5
+0.3 0
0.3 – 0.8
3
13
Clearance between blade pin and bracket
120
–0.3 –0.5
+0.5 +0.2
0.5 – 1.0
2
14
Spherical clearance between arm and cap
200
–0.2 –0.3
+0.3 0
0.2 – 0.6
1
15
Clearance between arm pin and arm
90
–0.3 –0.5
+0.5 +0.3
0.6 – 1.0
2
16
Clearance between arm pin and bracket
90
–0.3 –0.5
+0.3 +0.1
0.4 – 0.8
D475A-3
Replace
Adjust shim or replace
Replace
Adjust shim or replace
Replace 2
40-49
MAINTENANCE STANDARD
•
BLADE
U-DOZER, SUPER DOZER
40-50
D475A-3
MAINTENANCE STANDARD
BLADE
Unit: mm
No.
1
Check item
Clearance between brace pin and brace
Criteria Standard size
Tolerance Shaft
Hole
Remedy Standard clearance
Clearance limit
90
–0.2 –0.3
+0.3 +0.1
0.3 – 0.6
2
2
Clearance between brace pin and bracket
90
–0.2 –0.3
+0.3 +0.1
0.3 – 0.6
2
3
Clearance between brace pin and bracket
90
–0.3 –0.4
+0.1 0
0.3 – 0.5
1
4
Clearance between brace pin and bushing
90
–0.3 –0.4
+0.1 0
0.3 – 0.5
1
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
+1.5 +1.0
1.2 – 1.9
3
7
Clearance between frame pin and joint
120
–0.3 –0.5
+0.3 0
0.3 – 0.8
3
8
Clearance between frame pin and bracket
120
–0.3 –0.5
+0.207 +0.120
0.420 – 0.707
2
185
+0.206 +0.166
–0.014 –0.060
–0.152 – –0.266
—
250
–0.5 –1.0
+1.0 0
0.5 – 2.0
8
9 10
Clearance between straight frame joint bushings Clearance between trunnion and cap spherical surface
11
Clearance between joint and bracket
240
–0.2 –0.4
+0.3 +0.1
0.3 – 0.7
3
12
Clearance between blade pin and joint
120
–0.3 –0.5
+0.3 0
0.3 – 0.8
3
13
Clearance between blade pin and bracket
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
+0.225 +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
17
Clearance between center brace spherical surface and cap
200
–0.2 –0.3
+0.3 0.
0.2 – 0.6
1
D475A-3
Replace
Adjust shim or replace
Replace
Adjust shim or replace
40-51
MAINTENANCE STANDARD
•
BLADE
CUTTING EDGE, END BIT
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
510
383
1
Height of end bit outside
2
Width of end bit
720
635
3
Height of end bit inside
393
330
4
Height of cutting edge
405
351 (240 after turned)
40-52
Replace
Replace or turn
D475A-3
MAINTENANCE STANDARD
RIPPER EQUIPMENT
RIPPER EQUIPMENT •
VARIABLE GIANT RIPPER
40-54
D475A-3
MAINTENANCE STANDARD
RIPPER EQUIPMENT
Unit: mm
No.
Check item
1
Clearance between bushing and bracket and arm mount pin
2 3
4
Clearance between bushing and beam and arm mount pin Clearance between cylinder mount pin and bushing Clearance between shank and mount pin
5
Wear of point
6
Wear of protector
D475A-3
Criteria Tolerance
Remedy
Standard size
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.193 +0.050
0.093 – 0.299
1.5
140
–0.043 –0.106
+0.500 +0.300
0.343 – 0.606
1.5
110
–0.036 –0.090
+0.289 +0.123
0.159 – 0.379
1.5
Standard size
Tolerance
100
±0.3
Repair limit
Standard size
Repair limit
460
300
224
184
Replace
40-55
90
OTHERS
Work equimpmet hydraulic circuit diagram Single tilt specification ......................................................................... 90- 3 Dual tilt specfication ............................................................................. 90- 5 Super dozer specfication ...................................................................... 90- 7 Electrical circuit diagram Single tilt and dual tilt specifications Chassis electrical circuit diagram (1/4) ......................................... 90- 9 Chassis electrical circuit diagram (2/4) .........................................90-11 Chassis electrical circuit diagram (3/4) .........................................90-13 Chassis electrical circuit diagram (4/4) .........................................90-15 Super dozer specfication Chassis electrical circuit diagram (1/3) .........................................90-17 Chassis electrical circuit diagram (2/3) .........................................90-19 Chassis electrical circuit diagram (3/3) .........................................90-21 Electrical circuit diagram for inside cab ............................................. 90-23
D475A-3
90-1
OTHERS
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM SINGLE TILT SPECIFICATION
D475A-3
90-3
OTHERS
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM DUAL TILT SPECIFICATION
D475A-3
90-5
OTHERS
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM SUPER DOZER SPECIFICATION
D475A-3
90-7
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SINGLE TILT AND DUAL TILT SPECIFICATIONS) (1/4)
D475A-3
90-9
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SINGLE TILT AND DUAL TILT SPECIFICATIONS) (2/4)
D475A-3
90-11
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SINGLE TILT AND DUAL TILT SPECIFICATIONS) (3/4)
D475A-3
90-13
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SINGLE TILT AND DUAL TILT SPECIFICATIONS) (4/4)
D475A-3
90-15
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SUPER DOZER SPECIFICATION) (1/3)
D475A-3
90-17
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SUPER DOZER SPECIFICATION) (2/3)
D475A-3
90-19
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (SUPER DOZER SPECIFICATION) (3/3)
D475A-3
90-21
OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB
D475A-3
90-23
