SEN00203-18
BULLDOZER
-5E0 D475A D475ASD -5E0 SERIAL NUMBERS
D475A30001 and up D475ASD- 30001
SEN00205-18
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
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1
SEN00205-18
00 Index and foreword
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00203-18 00 Index and foreword ......................................................................................................... SEN00204-18 Index ............................................................................................................................... SEN00205-18 q Foreword and general information .................................................................................. SEN00206-05 01 Specification.................................................................................................................... SEN00207-01 Specification and technical data...................................................................................... SEN00208-01 10 Structure, function and maintenance standard ............................................................... SEN00209-04 Engine and cooling system ............................................................................................. SEN00210-00 Power train, Part 1 ...........................................................................................................SEN00211-01 Power train, Part 2 .......................................................................................................... SEN00212-02 Undercarriage and frame ................................................................................................ SEN00213-02 q Hydraulic system, Part 1 ................................................................................................. SEN00214-00 Hydraulic system, Part 2 ................................................................................................. SEN00215-01 q Hydraulic system, Part 3 ................................................................................................. SEN00216-01 Work equipment.............................................................................................................. SEN00217-00 Cab and its attachments ................................................................................................. SEN00218-00 Electrical system ............................................................................................................. SEN00219-02 20 Standard value table ....................................................................................................... SEN00220-01 Standard service value table........................................................................................... SEN01816-01 30 Testing and adjusting ...................................................................................................... SEN00221-06 Testing and adjusting, Part 1........................................................................................... SEN01817-03 Testing and adjusting, Part 2........................................................................................... SEN01818-03 Testing and adjusting, Part 3........................................................................................... SEN01819-04 Testing and adjusting, Part 4........................................................................................... SEN01820-03 40 Troubleshooting .............................................................................................................. SEN00222-06 Failure code table and fuse locations ............................................................................. SEN01821-04 General information on troubleshooting.......................................................................... SEN01822-03 Troubleshooting by failure code, Part 1 .......................................................................... SEN01823-03 Troubleshooting by failure code, Part 2 .......................................................................... SEN01824-01 Troubleshooting by failure code, Part 3 .......................................................................... SEN01825-03
2
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00 Index and foreword
SEN00205-18
Troubleshooting by failure code, Part 4 .......................................................................... SEN01826-01 Troubleshooting by failure code, Part 5 .......................................................................... SEN01827-03 Troubleshooting by failure code, Part 6 .......................................................................... SEN01828-03 Troubleshooting by failure code (Display of code), Part 7 .............................................. SEN01829-02 Troubleshooting by failure code (Display of code), Part 8 .............................................. SEN01830-01 Troubleshooting of electrical system (E-mode)............................................................... SEN01831-02 Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN01832-02 Troubleshooting of engine (S-mode) .............................................................................. SEN01833-01 50 Disassembly and assembly ............................................................................................ SEN00223-10 General information on disassembly and assembly ....................................................... SEN02013-06 Engine and cooling system (SAA12V140E-3) ................................................................ SEN02014-01 Engine (SAA12V140E-3) ................................................................................................ SEN02338-03 Power train, Part 1 .......................................................................................................... SEN02015-01 Power train, Part 2 .......................................................................................................... SEN02016-03 Undercarriage and frame, Part 1 .................................................................................... SEN02017-04 q Undercarriage and frame, Part 2 .................................................................................... SEN02018-02 Hydraulic system ............................................................................................................ SEN02019-01 Work equipment.............................................................................................................. SEN02020-00 Cab and its attachments ................................................................................................. SEN02021-01 Electrical system............................................................................................................. SEN02339-02 90 Diagrams and drawings .................................................................................................. SEN00224-03 Hydraulic diagrams and drawings................................................................................... SEN00225-00 Electrical diagrams and drawings ................................................................................... SEN00226-03
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00 Index and foreword
Table of contents
1
00 Index and foreword Index ............................................................................................................................... SEN00205-18 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information .................................................................................. SEN00206-05 Safety notice ............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data...................................................................................... SEN00208-01 Specification drawings ............................................................................................................. 2 Specifications........................................................................................................................... 3 Weight table ............................................................................................................................. 12 Fuel, coolant and lubricants..................................................................................................... 16 10 Structure, function and maintenance standard Engine and cooling system ............................................................................................. SEN00210-00 Radiator and oil cooler............................................................................................................. 2 Engine mount........................................................................................................................... 3 Cooling fan pump..................................................................................................................... 4 Cooling fan motor .................................................................................................................... 26 Power train, Part 1 ...........................................................................................................SEN00211-01 Power train............................................................................................................................... 2 Power train hydraulic equipment arrangement diagram .......................................................... 4 Damper and universal joint ...................................................................................................... 6 Power train system .................................................................................................................. 8 General view of power train unit .............................................................................................. 8 Torque converter, PTO............................................................................................................. 10 Torque converter valve ............................................................................................................ 18 Torque converter lockup control system .................................................................................. 28 Scavenging pump .................................................................................................................... 29 Transmission control................................................................................................................ 31 Transmission............................................................................................................................ 32 Power train, Part 2 .......................................................................................................... SEN00212-02 Transmission control valve ...................................................................................................... 2 Transmission clutch ECMV...................................................................................................... 4 Priority valve ............................................................................................................................ 8 Lubricating oil relief valve ........................................................................................................ 10 Torque converter, power train, lubricating oil pump ................................................................. 11 Steering, brake control............................................................................................................. 12 Final drive ................................................................................................................................ 14 Sprocket................................................................................................................................... 18 Steering unit............................................................................................................................. 21 Steering control valve .............................................................................................................. 32 Steering clutch ECMV, Steering brake ECMV ......................................................................... 34 Parking brake valve ................................................................................................................. 40 Sudden stop prevention valve ................................................................................................. 42
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Undercarriage and frame................................................................................................ SEN00213-02 Track frame.............................................................................................................................. 2 Recoil spring............................................................................................................................ 4 Idler.......................................................................................................................................... 6 Track roller............................................................................................................................... 8 Carrier roller............................................................................................................................. 12 Track roller bogie ..................................................................................................................... 13 Track shoe ............................................................................................................................... 14 Main frame............................................................................................................................... 18 Suspension.............................................................................................................................. 20 Hydraulic system, Part 1................................................................................................. SEN00214-00 Work equipment hydraulic equipment arrangement diagram .................................................. 2 PPC control piping diagram..................................................................................................... 6 Work equipment control........................................................................................................... 8 Work equipment pump ............................................................................................................ 10 PPC valve................................................................................................................................ 27 PCCS lever.............................................................................................................................. 38 Hydraulic system, Part 2................................................................................................. SEN00215-01 Control valve............................................................................................................................ 2 CLSS ....................................................................................................................................... 17 Unload valve............................................................................................................................ 20 Introduction of LS pressure ..................................................................................................... 21 LS bypass plug ........................................................................................................................ 22 Pressure compensation valve ................................................................................................. 23 Blade lift valve ......................................................................................................................... 26 Merge-divider valve ................................................................................................................. 34 Self pressure reducing valve ................................................................................................... 36 Pilot solenoid valve.................................................................................................................. 40 Hydraulic system, Part 3................................................................................................. SEN00216-01 Hydraulic tank, hydraulic filter.................................................................................................. 2 Accumulator............................................................................................................................. 4 Work equipment cylinder ......................................................................................................... 6 Piston valve ............................................................................................................................. 8 Quick drop valve...................................................................................................................... 10 Blade control knob (Dual tilt specification)............................................................................... 12 Blade control knob (Superdozer specification) ........................................................................ 13 Pitch and dual solenoid valve .................................................................................................. 14 Pin puller hydraulic circuit diagram.......................................................................................... 15 Pin puller solenoid valve.......................................................................................................... 16 Work equipment.............................................................................................................. SEN00217-00 Cylinder stay ............................................................................................................................ 2 Blade ....................................................................................................................................... 4 Ripper equipment .................................................................................................................... 8 Cab and its attachments ................................................................................................. SEN00218-00 Cab mount ............................................................................................................................... 2 Cab .......................................................................................................................................... 3 Air conditioner.......................................................................................................................... 6 Electrical system............................................................................................................. SEN00219-02 Engine control system ............................................................................................................. 2 CRI engine control system ...................................................................................................... 6 Monitor system ........................................................................................................................ 10 Machine monitor ...................................................................................................................... 12 Mode selection system ............................................................................................................ 30 Electrical equipment ................................................................................................................ 34 Palm command control system (PCCS) .................................................................................. 36 Sensors ................................................................................................................................... 38 Vehicle health monitoring system (VHMS) .............................................................................. 45
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00 Index and foreword
ORBCOMM terminal................................................................................................................ 51 20 Standard value table Standard service value table........................................................................................... SEN01816-01 Standard value table for engine ............................................................................................... 2 Standard value table for chassis.............................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1........................................................................................... SEN01817-03 Tools for testing, adjusting, and troubleshooting...................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring intake air pressure (boost pressure) ...................................................................... 10 Measuring exhaust temperature .............................................................................................. 12 Measuring exhaust gas color................................................................................................... 14 Adjusting valve clearance ........................................................................................................ 16 Testing compression pressure ................................................................................................. 18 Measuring blow-by pressure.................................................................................................... 20 Measuring engine oil pressure................................................................................................. 22 Handling of fuel system devices .............................................................................................. 23 Releasing residual pressure from fuel system......................................................................... 23 Testing fuel pressure................................................................................................................ 24 Handling of reduced cylinder mode operation ......................................................................... 25 Handling of no injection cranking operation............................................................................. 25 Testing fuel return and leak amount......................................................................................... 26 Bleeding air from fuel circuit .................................................................................................... 29 Bleeding air from fuel circuit (Low-grade fuel specification) .................................................... 31 Testing fuel circuit for leakage ................................................................................................. 33 Testing and adjusting alternator belt tension ........................................................................... 34 Testing and adjusting belt tension for air conditioner compressor ........................................... 35 Adjusting fuel control dial and decelerator pedal ..................................................................... 36 Testing and adjusting, Part 2........................................................................................... SEN01818-03 Measuring power train oil pressure.......................................................................................... 3 Adjusting transmission speed sensor ...................................................................................... 12 Simple method to test brake performance............................................................................... 13 Adjusting brake pedal and parking brake lever........................................................................ 14 Adjusting PCCS lever console position ................................................................................... 17 Emergency escape method when power train has trouble...................................................... 18 Inspecting wear of sprocket ..................................................................................................... 20 Testing and adjusting track shoe tension................................................................................. 21 Testing and adjusting work equipment oil pressure ................................................................. 22 Testing and adjusting control circuit basic pressure ................................................................ 33 Measuring PPC valve output pressure and solenoid valve output pressure ........................... 34 Adjusting play of PPC valve..................................................................................................... 40 Measuring outlet pressure of ripper pin puller solenoid valve.................................................. 41 Checking parts which caused hydraulic drift of blade and ripper............................................. 42 Measuring internal leakage of work equipment cylinder.......................................................... 43 Releasing residual pressure from work equipment cylinder .................................................... 44 Bleeding air from work equipment cylinder.............................................................................. 44 Adjusting ripper lever position.................................................................................................. 45 Adjusting work equipment lock lever ....................................................................................... 46 Measuring fan motor speed ..................................................................................................... 47 Measuring fan circuit oil pressure ............................................................................................ 48 Bleeding air from fan pump...................................................................................................... 49 Measurement procedure for blade tilt control angle (Dual tiltdozer specification) ................... 50 Measurement procedure for blade tilt control angle (Superdozer specification)...................... 53 Testing and adjusting operator's cab ....................................................................................... 55 Adjusting blade ........................................................................................................................ 59
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Testing and adjusting operator's seat isolator.......................................................................... 61 Testing and adjusting, Part 3 .......................................................................................... SEN01819-04 Special functions of monitor panel (EMMS)............................................................................. 2 Testing and adjusting, Part 4 .......................................................................................... SEN01820-03 Adjustment method when controller has been replaced.......................................................... 2 Preparation work for troubleshooting for electrical equipment system .................................... 4 Inspection procedure of diode ................................................................................................. 8 Handling of optional devices.................................................................................................... 9 Initialization procedures for VHMS controller .......................................................................... 10 Precautions for replacing VHMS controller.............................................................................. 31 Pm Clinic service ..................................................................................................................... 36 40 Troubleshooting Failure code table and fuse locations ............................................................................. SEN01821-04 Failure code table .................................................................................................................... 2 Fuse locations ......................................................................................................................... 12 General information on troubleshooting.......................................................................... SEN01822-03 Points to remember when troubleshooting .............................................................................. 2 Sequence of events in troubleshooting ................................................................................... 3 Checks before troubleshooting................................................................................................ 4 Classification and procedures of troubleshooting.................................................................... 5 Contents of troubleshooting table ............................................................................................ 8 Connection table for connector pin numbers ........................................................................... 10 T- branch box and T- branch adapter table ............................................................................. 46 Troubleshooting by failure code, Part 1 .......................................................................... SEN01823-03 Failure code [1380MW] Lockup clutch: Clutch slip.................................................................. 3 Failure code [1500L0] Transmission clutch: Dual engagement............................................... 4 Failure code [15E0MW] Transmission clutch: Clutch slip........................................................ 5 Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON............................................................................ 6 Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF............................................................................ 7 Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ................. 8 Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF............................................................................ 9 Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON ...... 10 Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF ..... 11 Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON ..... 12 Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF .... 13 Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON ..... 14 Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF..... 15 Failure code [1800MW] Power train clutch: Slip...................................................................... 16 Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON ... 17 Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF... 18 Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON...... 19 Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF ..... 20 Failure code [2300NR] Brake thermal load: Abnormal heating ............................................... 21 Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON.... 22 Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF ... 23 Failure code [2301NR] Right steering brake thermal load: Abnormal heating ........................ 24 Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON ...... 25 Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF...... 26 Failure code [2302NR] Left steering brake thermal load: Abnormal heating ........................... 27 Failure code [6001ZK] Failure code for design........................................................................ 28 Failure code [A000NS] Engine: Overheat ............................................................................... 29 Failure code [AA10NX] Air cleaner: Clogging.......................................................................... 30 Failure code [AB00MA] Battery charge abnormality: Malfunction ........................................... 31
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00 Index and foreword
Failure code [B@BAZG] Engine oil: Oil pressure too low........................................................ 32 Failure code [B@BAZK] Engine oil: Oil level reduction ........................................................... 33 Failure code [B@BCNS] Engine coolant: Overheat ................................................................ 34 Failure code [B@BCZK] Engine coolant: Level too low........................................................... 35 Failure code [B@BEBF] Fuel: Water in fuel ............................................................................ 36 Failure code [B@BFZK] Fuel level: Reduction ........................................................................ 37 Failure code [B@CENS] Power train oil: Overheat ................................................................. 38 Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure...................................... 39 Failure code [B@CHZK] Power train oil: Oil level reduction.................................................... 39 Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction ......................... 40 Failure code [B@HANS] Hydraulic oil: Overheat..................................................................... 40 Failure code [B@HAZK] Hydraulic oil: Level reduction ........................................................... 41 Troubleshooting by failure code, Part 2 .......................................................................... SEN01824-01 Failure code [CA111] Engine controller (Left bank): Internal abnormality................................ 4 Failure code [CB111] Engine controller (Right bank): Internal abnormality ............................. 6 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal............................................................................................. 8 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal............................................................................................. 9 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 10 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 12 Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection.......................................................................................................... 13 Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 15 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 16 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 18 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ....................................................................................... 20 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 22 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 24 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 26 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection .......................................................................................................... 28 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection .......................................................................................................... 29 Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection.......................................................................................................... 30 Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection .......................................................................................................... 31 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 32 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 34 Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected ....................................................................................... 36 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection.......................................................................................................... 38 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed............ 40 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected......................................................................................... 42
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Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected ........................................................................................ 44 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected ....................................................................................... 46 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected ....................................................................................... 48 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection .......................................................................................................... 49 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection .......................................................................................................... 49 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit .......................................... 50 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ....................................... 51 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection................................... 52 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ................................ 53 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit .......................................... 54 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ....................................... 55 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection................................... 56 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ................................ 57 Troubleshooting by failure code, Part 3 .......................................................................... SEN01825-03 Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 4 Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 6 Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 8 Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 10 Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 12 Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 14 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ....................... 16 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch..................... 17 Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit.............. 18 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ....... 20 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection .......................................................................................................... 22 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection .......................................................................................................... 23 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection ......................................................................................................... 24 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection ......................................................................................................... 26 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection .......................................................................................................... 28 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection .......................................................................................................... 28 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection ......................................................................................................... 29 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection ......................................................................................................... 29 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence ................................................................................. 30 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence ................................................................................. 30 Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected ....................................................................................... 32
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Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection.......................................................................................................... 34 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection......................................................................................... 36 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection......................................................................................... 36 Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected..................................................................................... 37 Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected..................................................................................... 38 Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error ....................................................................................................................... 39 Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error ....................................................................................................................... 39 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected............................................................................................ 40 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification)............................................ 44 Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected............................................................................................ 48 Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ..... 52 Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ... 54 Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection ............................................................................... 56 Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection ................................................................................ 58 Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase ................................................................................................................... 59 Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase ................................................................................................................... 59 Troubleshooting by failure code, Part 4 .......................................................................... SEN01826-01 Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data........... 3 Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data......... 3 Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal .......................................................................................................... 4 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error .................................................................................................................. 6 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error............................................................................................................ 8 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error............................................................................................................ 10 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error .................................................................................................................... 11 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error .................................................................................................................... 12 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 14 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 16 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 18 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 20 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 22 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 24 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error ................... 26
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SEN00205-18
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection ............................................................................... 28 Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected........................................................... 30 Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected............................................................................................ 31 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected............................................................................................ 31 Failure code [D110KA] Battery relay: Disconnection ............................................................... 32 Failure code [D110KB] Battery relay: Short circuit .................................................................. 34 Failure code [D130KA] Neutral safety relay: Disconnection.................................................... 36 Failure code [D130KB] Neutral safety relay: Short circuit ....................................................... 38 Failure code [D161KA] Back-up alarm relay: Disconnection................................................... 40 Failure code [D161KB] Back-up alarm relay: Short circuit ...................................................... 42 Failure code [D182KZ] Preheater relay: Disconnection or short circuit................................... 44 Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ................. 46 Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit..................... 48 Failure code [D5ZRKA] Snap shot switch: Disconnection....................................................... 50 Failure code [D5ZRKB] Snap shot switch: Short circuit .......................................................... 51 Failure code [DAFRKR] Monitor panel CAN communication: Communication error ............... 52 Failure code [dAFRKR] Monitor panel CAN communication: Communication error................ 54 Failure code [daFRKR] Monitor panel CAN communication: Communication error ................ 56 Failure code [DAQ0KT] Transmission controller: Abnormality in controller............................. 58 Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input)................................................................................ 60 Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input)................................................................................ 62 Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) .......................................................................................... 64 Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) .......................................................................................... 65 Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input)................................................................................ 66 Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency.......................................................................................... 67 Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality) ...................................... 68 Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system) ............................ 70 Troubleshooting by failure code, Part 5 .......................................................................... SEN01827-03 Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error ........................................................................................................... 4 Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error ........................................................................................................... 6 Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error ........................................................................................................... 8 Failure code [DB30KT] Steering controller: Abnormality in controller...................................... 10 Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input)................................................................................ 12 Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input)................................................................................ 14 Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input)................................................................................ 16 Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) .......................................................................................... 18 Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) .......................................................................................... 19
D475A, D475ASD-5E0
11
SEN00205-18
00 Index and foreword
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency .......................................................................................... 20 Failure code [dB3RKR] Steering controller CAN communication: Communication error......... 22 Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) ............................ 24 Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage ...................................................................... 26 Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection................................... 27 Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage ............................................................ 28 Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage............................................ 29 Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" o "02") VHMS sensor power supply (24 V): Lowering of output voltage.......................................... 30 Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" o "03") VHMS sensor power supply (12 V): Lowering of output voltage.......................................... 32 Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error .............................................................................. 34 Failure code [dbBRKR] VHMS controller CAN communication: Communication error ........... 36 Failure code [DD12KA] Shift up switch: Disconnection ........................................................... 38 Failure code [DD12KB] Shift up switch: Short circuit............................................................... 40 Failure code [DD13KA] Shift down switch: Disconnection....................................................... 42 Failure code [DD13KB] Shift down switch: Short circuit .......................................................... 44 Failure code [DD14KA] Parking brake lever switch: Disconnection ........................................ 46 Failure code [DD14KB] Parking brake lever switch: Short circuit ............................................ 48 Failure code [DDB9L4] Reverse switch: Signal disagreement ................................................ 50 Failure code [DDK3L4] Forward switch: Signal disagreement ................................................ 52 Failure code [DDK5KA] Gearshift switch: Disconnection ........................................................ 54 Failure code [DDK5KB] Gearshift switch: Short circuit ............................................................ 56 Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time.................................................................................................... 58 Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time .. 59 Failure code [DDN7KA] Blade pitch switch: Disconnection ..................................................... 60 Failure code [DDN7KB] Blade pitch switch: Short circuit......................................................... 62 Failure code [DDN9KA] Blade tilt switch: Disconnection ......................................................... 64 Failure code [DDN9KB] Blade tilt switch: Short circuit............................................................. 66 Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ... 68 Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time ........ 69 Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time ....... 70 Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time ............. 71 Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time ....... 72 Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time ... 73 Troubleshooting by failure code, Part 6 .......................................................................... SEN01828-03 Failure code [DDQ2KA] Parking brake lever switch: Disconnection........................................ 4 Failure code [DDQ2KB] Parking brake lever switch: Short circuit ........................................... 6 Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals ........................ 8 Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals ......................... 9 Failure code [DDT5KA] Neutral switch: Disconnection............................................................ 10 Failure code [DDT5KB] Neutral switch: Short circuit ............................................................... 12 Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement ................................................................................... 14 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ....................................................................................... 15 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection ........................... 16 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ....................................................................................... 17
12
D475A, D475ASD-5E0
00 Index and foreword
SEN00205-18
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates "n3" o "12") ...................................... 18 Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates "n3" o "22") ...................................... 20 Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates "n3" o "11") .......................................... 22 Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21") Left bank exhaust temperature sensor system (Rear): Short circuit .................................... 24 Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24") Right bank exhaust temperature sensor system (Front): Disconnection ............................. 26 Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26") Right bank exhaust temperature sensor system (Rear): Disconnection .............................. 28 Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23") Right bank exhaust temperature sensor system (Front): Short circuit................................. 30 Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") Right bank exhaust temperature sensor system (Rear): Short circuit ................................. 32 Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection ......... 34 Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit............. 35 Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection......... 36 Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit ............ 37 Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32") Blow-by pressure sensor system: Disconnection ................................................................ 38 Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31") Blow-by pressure sensor system: Hot short ........................................................................ 39 Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14") Transmission oil pressure sensor: Out of input signal range ............................................... 40 Failure code [DK01KA] Left yoke angle sensor: Disconnection .............................................. 41 Failure code [DK01KB] Left yoke angle sensor: Short circuit.................................................. 42 Failure code [DK03KA] Right yoke angle sensor: Disconnection............................................ 43 Failure code [DK03KB] Right yoke angle sensor: Short circuit ............................................... 44 Failure code [DK10KA] Fuel dial: Disconnection..................................................................... 45 Failure code [DK10KB] Fuel dial: Short circuit ........................................................................ 46 Failure code [DK30KA] Steering potentiometer (1): Disconnection......................................... 48 Failure code [DK30KB] Steering potentiometer (1): Short circuit ............................................ 50 Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range ......... 52 Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit ................. 52 Failure code [DK30L8] Steering potentiometer (1): See table ................................................. 53 Failure code [DK31KA] Steering potentiometer (2): Disconnection......................................... 54 Failure code [DK31KB] Steering potentiometer (2): Short circuit ............................................ 56 Troubleshooting by failure code (Display of code), Part 7 .............................................. SEN01829-02 Failure code [DK40KA] Brake potentiometer: Disconnection .................................................. 3 Failure code [DK40KB] Brake potentiometer: Short circuit...................................................... 4 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range... 5 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit.......... 6 Failure code [DK55L8] Forward-reverse potentiometer: See table ......................................... 7 Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection............................ 8 Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit .............................. 10 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................ 12 Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit .............................. 14 Failure code [DK60KA] Acceleration sensor: Disconnection................................................... 16 Failure code [DK60KB] Acceleration sensor: Short circuit ...................................................... 18 Failure code [DKH1KA] Pitch angle sensor: disconnection..................................................... 19 Failure code [DKH1KB] Pitch angle sensor: Short circuit........................................................ 20 Failure code [DKH1KX] Pitch angle sensor: Out of input signal range.................................... 21 Failure code [DLF1KA] Torque converter output speed sensor: Disconnection ...................... 22 Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 23 Failure code [dLT3KA] Transmission output speed sensor: Disconnection............................. 24 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 26 D475A, D475ASD-5E0
13
SEN00205-18
00 Index and foreword
Failure code [DV00KB] Caution buzzer: Short circuit .............................................................. 27 Failure code [DW55KA] Blade pitch back solenoid: Disconnection......................................... 28 Failure code [DW55KB] Blade pitch back solenoid: Short circuit ............................................ 29 Failure code [DW56KA] Blade pitch dump solenoid: Disconnection ....................................... 30 Failure code [DW56KB] Blade pitch dump solenoid: Short circuit ........................................... 31 Failure code [DW56KY] Blade pitch dump solenoid: Hot short ............................................... 32 Failure code [DW57KA] Left tilt limit solenoid: Disconnection ................................................. 33 Failure code [DW57KB] Left tilt limit solenoid: Short circuit..................................................... 34 Failure code [DW57KY] Left tilt limit solenoid: Hot short ......................................................... 35 Failure code [DW58KA] Right tilt limit solenoid: Disconnection............................................... 36 Failure code [DW58KB] Right tilt limit solenoid: Short circuit .................................................. 37 Failure code [DW58KY] Right tilt limit solenoid: Hot short....................................................... 38 Failure code [DW59KA] Dual tilt selector solenoid: Disconnection.......................................... 39 Failure code [DW59KB] Dual tilt selector solenoid: Short circuit ............................................. 40 Failure code [DW59KY] Dual tilt selector solenoid: Hot short.................................................. 41 Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection ................................... 42 Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit ....................................... 43 Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ........................................... 44 Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection....................................................................................................................... 45 Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit .......................................................................................................................... 46 Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short............................................................................................................................... 47 Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 48 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 49 Failure code [DW7BKY] Fan reverse solenoid: Hot short........................................................ 50 Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection ................................... 51 Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit....................................... 52 Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short ........................................... 53 Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection............................. 54 Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit ................................ 55 Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short..................................... 56 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ............................................... 57 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ................................................... 58 Failure code [DWN5KY] Fan pump solenoid 1: Hot short ....................................................... 59 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection............................................... 60 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .................................................. 61 Failure code [DWNCKY] Fan pump solenoid 2: Hot short....................................................... 62 Troubleshooting by failure code (Display of code), Part 8 .............................................. SEN01830-01 Failure code [DXE0KA] LS set solenoid: Disconnection.......................................................... 3 Failure code [DXE0KB] LS set solenoid: Short circuit ............................................................. 4 Failure code [DXE0KY] LS set solenoid: Hot short.................................................................. 5 Failure code [DXH1KA] Lock-up solenoid: Disconnection....................................................... 6 Failure code [DXH1KB] Lock-up solenoid: Short circuit .......................................................... 7 Failure code [DXH1KY] Lockup solenoid: Hot short ................................................................ 8 Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................ 9 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 10 Failure code [DXH4KY] 1st clutch ECMV: Hot short................................................................ 11 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 12 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .......................................................... 13 Failure code [DXH5KY] 2nd clutch ECMV: Hot short .............................................................. 14 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 15 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 16 Failure code [DXH6KY] 3rd clutch ECMV: Hot short ............................................................... 17 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection ............................................... 18 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................... 19 Failure code [DXH7KY] Reverse clutch ECMV: Hot short ....................................................... 20
14
D475A, D475ASD-5E0
00 Index and foreword
SEN00205-18
Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 21 Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................... 22 Failure code [DXH8KY] Forward clutch ECMV: Hot short ....................................................... 23 Failure code [DXH9KA] Right steering clutch ECMV: Disconnection ...................................... 24 Failure code [DXH9KB] Right steering clutch ECMV: Short circuit.......................................... 25 Failure code [DXH9KY] Right steering clutch ECMV: Hot short .............................................. 26 Failure code [DXHAKA] Left steering clutch ECMV: Disconnection ........................................ 27 Failure code [DXHAKB] Left steering clutch ECMV: Short circuit............................................ 28 Failure code [DXHAKY] Left steering clutch ECMV: Hot short ................................................ 29 Failure code [DXHBKA] Right brake ECMV: Disconnection.................................................... 30 Failure code [DXHBKB] Right brake ECMV: Short circuit ....................................................... 31 Failure code [DXHBKY] Right brake ECMV: Hot short............................................................ 32 Failure code [DXHCKA] Left brake ECMV: Disconnection ...................................................... 33 Failure code [DXHCKB] Left brake ECMV: Short circuit.......................................................... 34 Failure code [DXHCKY] Left brake ECMV: Hot short .............................................................. 35 Failure code [F@BBZL] (or VHMS_LED display "n3" o "38") Engine blow-by pressure sensor: Abnormally high pressure occurrence ............................ 36 Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise ................. 38 Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise .................. 40 Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise ............... 42 Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ................ 44 Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise ................. 46 Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise .................. 48 Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise ............... 50 Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ................ 52 Troubleshooting of electrical system (E-mode)............................................................... SEN01831-02 Contents of troubleshooting table ............................................................................................ 3 E-1 The engine does not start ................................................................................................. 4 E-2 The preheater does not operate ....................................................................................... 8 E-3 The ripper pin puller cylinder does not operate................................................................. 12 E-4 The monitor panel does not come on at all when the starting switch is turned on............ 14 E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.......................................................................................................... 16 E-6 When the starting switch is turned on, the basic check items flash .................................. 17 E-7 While the engine is operating, any caution item flashes ................................................... 18 E-8 An emergency caution item flashes while the engine is running ...................................... 21 E-9 While the preheater is operating, the preheating pilot lamp does not come on ................ 24 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)............................................................................................ 26 E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on ........................................................................................................... 26 E-12 The engine coolant temperature gauge does not indicate normally ............................... 27 E-13 Indication of the power train (torque converter) temperature gauge is abnormal ........... 28 E-14 The hydraulic oil temperature gauge does not indicate normally.................................... 30 E-15 Indication of the fuel gauge is abnormal ......................................................................... 31 E-16 Indications of gear speed and engine speed are abnormal ............................................ 32 E-17 Indication of the shift mode service meter is abnormal ................................................... 32 E-18 The switch module cannot be operated .......................................................................... 33 E-19 The warning lamp does not flash or does not go out ...................................................... 34 E-20 The alarm buzzer does not sound or does not stop........................................................ 35 D475A, D475ASD-5E0
15
SEN00205-18
00 Index and foreword
E-21 Auto shift down is not possible or is not released ........................................................... 36 E-22 The automatic pitch back system does not operate (only superdozer specification) ...... 37 E-23 The alarm buzzer cannot be cancelled ........................................................................... 38 E-24 The operator mode cannot be operated.......................................................................... 39 E-25 The service mode cannot be operated............................................................................ 40 E-26 The back-up alarm does not sound................................................................................. 42 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ............................................................................................................... 44 E-28 Troubleshooting for air conditioner system ..................................................................... 50 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ...................... 65 E-30 Fan does not reverse ...................................................................................................... 67 E-31 Gear cannot be shifted.................................................................................................... 69 E-32 Electric priming pump does not operate or does not stop automatically......................... 70 Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN01832-02 Information in troubleshooting table......................................................................................... 3 H-1 No force (no drawbar pull) ................................................................................................ 4 H-2 No travel (at 2nd or 3rd speed) ......................................................................................... 6 H-3 No travel at all gear speeds .............................................................................................. 7 H-4 Machine travels only in one direction forward or in reverse.............................................. 8 H-5 Large time lag at gear speed shifting or forward-reverse shifting ..................................... 9 H-6 Steering is not possible ..................................................................................................... 10 H-7 Steering is possible only on one side................................................................................ 11 H-8 Steering overrun occurs .................................................................................................... 12 H-9 Brake does not work ......................................................................................................... 13 H-10 Torque converter is not lock-up....................................................................................... 14 H-11 Power train oil is overheated........................................................................................... 15 H-12 All work equipment speeds are slow............................................................................... 16 H-13 Work equipment does not move ..................................................................................... 17 H-14 Blade lift speed is slow or lacks power ........................................................................... 18 H-15 Blade tilt speed is slow or lacks power ........................................................................... 19 H-16 Ripper lift speed is slow or lacks power .......................................................................... 20 H-17 Ripper tilt speed is slow or lacks power .......................................................................... 21 H-18 Excessive hydraulic drift of blade lift ............................................................................... 22 H-19 Excessive hydraulic drift of blade tilt ............................................................................... 23 H-20 Excessive hydraulic drift of ripper lift............................................................................... 24 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) .................. 24 H-22 Blade pitch does not work (dual tilt attachment machine)............................................... 25 H-23 Abnormal sound comes out from around work equipment pump ................................... 25 H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats) ........................................................................................................... 26 H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator)................................................................................................... 27 Troubleshooting of engine (S-mode)............................................................................... SEN01833-01 Method of using troubleshooting chart..................................................................................... 3 S-1 Starting performance is poor ............................................................................................. 6 S-2 Engine does not start ........................................................................................................ 7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations......................................................................................... 11 S-5 Engine does not rotate smoothly....................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16 S-9 Oil becomes contaminated quickly.................................................................................... 17 S-10 Fuel consumption is excessive ....................................................................................... 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 19 S-12 Oil pressure drops........................................................................................................... 20 S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21 S-14 Coolant temperature becomes too high (overheating).................................................... 22
16
D475A, D475ASD-5E0
00 Index and foreword
SEN00205-18
S-15 Abnormal noise is made ................................................................................................. 23 S-16 Vibration is excessive ..................................................................................................... 24 50 Disassembly and assembly General information on disassembly and assembly ....................................................... SEN02013-06 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tools list ....................................................................................................................... 7 Sketches of special tools ......................................................................................................... 14 Engine and cooling system (SAA12V140E-3) ................................................................ SEN02014-01 Removal and installation of engine assembly ......................................................................... 2 Removal and installation of radiator assembly ........................................................................ 6 Removal and installation of aftercooler assembly ................................................................... 8 Removal and installation of radiator guard assembly .............................................................. 10 Removal and installation of fuel tank assembly....................................................................... 12 Removal and installation of engine hood assembly ................................................................ 13 Removal and installation of fan drive assembly ...................................................................... 15 Removal and installation of fan motor assembly ..................................................................... 16 Engine (SAA12V140E-3) ................................................................................................ SEN02338-03 Removal and installation of fuel supply pump assembly ......................................................... 2 Removal and installation of cylinder head assembly ............................................................... 8 Removal and installation of fuel injector assembly .................................................................. 19 Removal and installation of engine front seal .......................................................................... 25 Removal and installation of engine rear seal........................................................................... 27 Power train, Part 1 .......................................................................................................... SEN02015-01 Removal and installation of damper assembly ........................................................................ 2 Disassembly and assembly of damper assembly.................................................................... 4 Removal and installation of power train unit assembly............................................................ 7 Removal and installation of PTO, torque converter assembly................................................. 10 Disconnection and connection of PTO, torque converter assembly ........................................ 12 Disassembly and assembly of torque converter assembly...................................................... 14 Disassembly and assembly of PTO assembly......................................................................... 24 Removal and installation of TORQFLOW transmission assembly .......................................... 31 Disassembly and assembly of TORQFLOW transmission assembly ...................................... 32 Power train, Part 2 .......................................................................................................... SEN02016-03 Disassembly and assembly of steering case assembly .......................................................... 2 Disassembly and assembly of steering clutch, brake assembly.............................................. 15 Disassembly and assembly of transfer gear housing assembly.............................................. 23 Removal and installation of power train pump assembly ........................................................ 27 Removal and installation of scavenging pump assembly ........................................................ 27 Removal and installation of torque converter oil cooler ........................................................... 28 Removal and installation of torque converter valve assembly................................................. 29 Disassembly and assembly of torque converter valve assembly ............................................ 30 Removal and installation of transmission control valve assembly ........................................... 34 Disassembly and assembly of transmission control valve assembly (ECMV assembly) ........ 35 Removal and installation of steering control valve assembly .................................................. 38 Disassembly and assembly of steering control valve assembly.............................................. 39 Removal and installation of final drive assembly ..................................................................... 41 Disassembly and assembly of final drive assembly ................................................................ 43 Undercarriage and frame, Part 1 .................................................................................... SEN02017-04 Removal and installation of track frame assembly .................................................................. 2 Disassembly and assembly of idler assembly ......................................................................... 4 Removal and installation of recoil spring assembly ................................................................. 7 Disassembly and assembly of recoil spring assembly ............................................................ 11 Removal and installation of track roller assembly ................................................................... 13 Disassembly and assembly of track roller assembly ............................................................... 15 Removal and installation of carrier roller assembly ................................................................. 17 Disassembly and assembly of carrier roller assembly............................................................. 18 D475A, D475ASD-5E0
17
SEN00205-18
00 Index and foreword
Removal and installation of bogie assembly............................................................................ 21 Disassembly and assembly of bogie assembly ....................................................................... 25 Removal and installation of No.1 bogie assembly ................................................................... 27 Removal and installation of operator's seat isolator ................................................................ 32 Disassembly and assembly of operator's seat isolator ............................................................ 33 Undercarriage and frame, Part 2 .................................................................................... SEN02018-02 Expansion and installation of track shoe assembly ................................................................. 2 Overall disassembly and overall assembly of track shoe ........................................................ 5 Press-fitting jig dimension table for link press.......................................................................... 21 Field disassembly and assembly of one link............................................................................ 22 Disassembly and assembly of master link............................................................................... 27 Removal and installation of pivot shaft assembly .................................................................... 31 Removal and installation of equalizer bar ................................................................................ 32 Disassembly and assembly of equalizer bar bushing.............................................................. 35 Hydraulic system............................................................................................................. SEN02019-01 Removal and installation of hydraulic pump assembly ............................................................ 2 Removal and installation of hydraulic valve assembly............................................................. 4 Disassembly and assembly of control valve ............................................................................ 5 Disassembly and assembly of merge divider valve and self pressure reducing valve assembly 9 Removal and installation of PPC relief valve assembly ........................................................... 11 Disassembly and assembly of hydraulic cylinder assembly .................................................... 12 Disassembly and assembly of ripper pin puller cylinder assembly.......................................... 17 Work equipment.............................................................................................................. SEN02020-00 Removal and installation of blade assembly............................................................................ 2 Disassembly and assembly of giant ripper assembly .............................................................. 4 Cab and its attachments ................................................................................................. SEN02021-01 Removal and installation of ROPS guard ................................................................................ 2 Removal and installation of operator’s cab assembly.............................................................. 3 Removal and installation of floor frame assembly ................................................................... 4 Electrical system ............................................................................................................. SEN02339-02 Removal and installation of controller assembly...................................................................... 2 Removal and installation of engine controller assembly (left).................................................. 3 Removal and installation of air conditioner condenser assembly ............................................ 4 Removal and installation of air conditioner compressor assembly .......................................... 5 Removal and installation of air conditioner unit ....................................................................... 7 90 Diagrams and drawings Hydraulic diagrams and drawings................................................................................... SEN00225-00 Power train hydraulic circuit diagram....................................................................................... 3 Hydraulic circuit diagram (1/3) ................................................................................................. 5 Hydraulic circuit diagram (2/3) ................................................................................................. 7 Hydraulic circuit diagram (3/3) ................................................................................................. 9 Electrical diagrams and drawings ................................................................................... SEN00226-03 Electrical circuit diagram (1/13) ............................................................................................... 3 Electrical circuit diagram (2/13) ............................................................................................... 5 Electrical circuit diagram (3/13) ............................................................................................... 7 Electrical circuit diagram (4/13) ............................................................................................... 9 Electrical circuit diagram (5/13) ............................................................................................... 11 Electrical circuit diagram (6/13) ............................................................................................... 13 Electrical circuit diagram (7/13) ............................................................................................... 15 Electrical circuit diagram (8/13) ............................................................................................... 17 Electrical circuit diagram (9/13) ............................................................................................... 19 Electrical circuit diagram (10/13) ............................................................................................. 21 Electrical circuit diagram (11/13).............................................................................................. 23 Electrical circuit diagram (12/13) ............................................................................................. 25 Electrical circuit diagram (13/13) ............................................................................................. 27 Electrical circuit diagram of inside cab..................................................................................... 29 Connector arrangement diagram............................................................................................. 31
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D475A, D475ASD-5E0 Bulldozer Form No. SEN00205-18
© 2016 KOMATSU All Rights Reserved Printed in Japan 02-16 (01)
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BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
00 Index and foreword
1
Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
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Safety notice
1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
2
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w elding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
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2.
3.
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) For the machine equipped with a battery disconnct switch, turn the battery disconnect switch to the OFF (O) position and pull the switch key out, before starting the work. For machines without a battery disconnct switch, remove the cable from the battery , before starting the work. Always remove the cable from the negative (-) terminal first.
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5)
When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed.
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12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul ar l y c a r e f u l t o c h e c k t h a t t h e y a r e installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well. 4.
4
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
00 Index and foreword
7)
Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
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11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. q If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. 5.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
D475A, D475ASD-5E0
Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
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7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
8.
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2)
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person.
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How to read the shop manual q q q
1.
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1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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3.
4.
00 Index and foreword
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
2
Coat
5
Oil, coolant
6
Drain
Remarks Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size 120
Tolerance –0.022 –0.126
a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0
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2.
Standard clearance and standard value q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
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5.
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
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Handling of electric equipment and hydraulic component
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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).
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. 2.
Main failures occurring in wiring harness 1) 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. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
Defective crimping or soldering of connectors The pins of the male and female connectors are 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.
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3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5)
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface 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. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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2)
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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
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q
Disconnection
q
Connection (Example of incomplete setting of (a))
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4)
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Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
D475A, D475ASD-5E0
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4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality 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. a If there is any change, there is probably defective contact in that circuit.
D475A, D475ASD-5E0
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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 check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3.
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
18
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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 ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
D475A, D475ASD-5E0
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Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
20
D475A, D475ASD-5E0
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3.
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Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
D475A, D475ASD-5E0
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q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
00 Index and foreword
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
22
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How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile
Symbol AV
AVS
Heat-resistant low-voltAEX age wire for automobile
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
D475A, D475ASD-5E0
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
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2.
00 Index and foreword
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
24
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3.
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Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit
Others
D475A, D475ASD-5E0
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
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Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
26
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30
27
07049-02734
27
22.5
34
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2. q q q q q q q q q q q q q
a
a 3.
SEN00206-05
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
D475A, D475ASD-5E0
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4)
5)
28
00 Index and foreword
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
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Method of disassembling and connecting push-pull type coupler k k
1
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
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Type 2 1.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
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Type 3 1.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
D475A, D475ASD-5E0
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Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Width across flats mm 10 12 14 17
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
32
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2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
SEN00206-05
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
D475A, D475ASD-5E0
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
33
SEN00206-05
5.
00 Index and foreword
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
6.
22 24 27 32 36 41 46 55
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
34
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
D475A, D475ASD-5E0
00 Index and foreword
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
SEN00206-05
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
D475A, D475ASD-5E0
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
35
SEN00206-05
00 Index and foreword
Conversion table
1
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 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
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
D475A, D475ASD-5E0
00 Index and foreword
SEN00206-05
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 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
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
13.473 16.115 18.756 21.398 24.040
D475A, D475ASD-5E0
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
37
SEN00206-05
00 Index and foreword
Liters to U.K. Gallons
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
38
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
D475A, D475ASD-5E0
00 Index and foreword
SEN00206-05
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
D475A, D475ASD-5E0
39
SEN00206-05
00 Index and foreword
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °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
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
40
D475A, D475ASD-5E0
00 Index and foreword
D475A, D475ASD-5E0
SEN00206-05
41
SEN00206-05
D475A, D475ASD-5E0 Bulldozer Form No. SEN00206-05
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
42
SEN00208-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
01 Specification
1
Specification and technical data Specification drawings .................................................................................................................................... 2 Specifications .................................................................................................................................................. 3 Weight table .................................................................................................................................................. 12 Fuel, coolant and lubricants .......................................................................................................................... 16
D475A, D475ASD-5E0
1
SEN00208-01
01 Specification
Specification drawings
1
Dimensions
Symbol
2
Item
Unit
Semi-U tiltdozer + giant ripper
Full-U tiltdozer + giant ripper
Superdozer + counterweight
A
Overall length
mm
11,565
12,065
10,525
B
Overall height (including ROPS)
mm
4,646
4,646
4,646
C
Overall width
mm
5,265
6,205
6,465
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Specifications
1
Semi-U tiltdozer and full-U tiltdozer specifications Machine model
D475A-5E0
Serial Number
30001 and up
Weight
Machine weight • Tractor
83,510
• Above + Semi-U tiltdozer
100,010
• Above + Variable giant ripper
107,370
• Above + ROPS cab + Air conditioner
108,310 m
4.6
Gradeability
deg.
30
Stability (Front, Rear, Left, Right)
deg.
35
Forward
1st
3rd
0 – 10.9
Reverse
Gear speeds
Min. turning radius
Performance
kg
1st
0 – 4.7
2nd
2nd
0 – 3.5 km/h
0 – 6.3
km/h
0 – 8.4
3rd
0 – 14.3 127.5 {1.30}
Ground pressure
Tractor
152.7 {1.56}
Semi-U dozer Semi-U dozer + Variable giant ripper
2
kPa {kg/cm }
163.9 {1.67} 165.3 {1.69}
Above + ROPS cab + Air conditioner + Perforated side cover
6,680
Overall width Overall height
Dimensions
Overall length
Tractor Semi-U dozer Semi-U dozer + Variable giant ripper
mm
8,705 11,565
Full-U dozer + Variable giant ripper
12,065
Tractor
3,620
Semi-U dozer
mm
5,265
Full-U dozer
6,205
Up to ROPS top
4,646
Up to exhaust pipe end
mm
Up to exhaust duct top
3,861 2,770
Track gauge Length of track on ground Track shoe width Minimum ground clearance
D475A, D475ASD-5E0
4,546
mm
4,524 710 711
3
SEN00208-01
01 Specification
Machine model
D475A-5E0
Serial Number
30001 and up
mm l {cc}
Komatsu SAA12V140E-3 4-cycle, water-cooled, V-type, direct-injection engine with turbocharger and aftercooler 12–140 x 165 30.48 {30,480}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
664/2,000 {890/2,000} 3,825/1,400 {390/1,400} 2,150 600 215 {160}
Model name Type
Performance
Engine
Number of cylinder–Bore x Stroke Total displacement Rated output Max. torque High idle Low idle Min. fuel consumption ratio (at rated output)
Starting motor Alternator Battery Type of radiator core Torque converter
Power train
Transmission
3-element, 1-stage, 1-phase type (With lockup clutch) Planetary gear, multiple disc clutch, hydraulic, pump-forced lubrication, 3 forward/reverse gear speeds type Spiral bevel gear, splash lubrication type
Steering clutch
Wet, multiple disc clutch, spring-actuated, hydraulic (hand-operated) type interlocked with brake
Steering brake
Wet, multiple disc clutch, spring-actuated, hydraulic (foot/hand-operated) type interlocked with brake
Type of suspension Undercarriage
D-type
Bevel gear shaft
Final drive
1-stage spur gear and 1-stage planetary gear, splash lubrication type Hard, equalizing beam type
Carrier roller
2 pieces on each side
Track roller
8 pieces on each side
Track shoe
Assembly type single grouser shoe, 41 pieces on each side, Pitch: 317.5 mm, Width: 710 mm
Power train + Lubricating oil pump (Tandem) Scavenging pump (Tandem)
4
24 V, 7.5 kW x 2 24 V, 100 A 12V, 220 Ah x 4
Gear type (BAL 160 + 160 + 112) Gear (BAR 63 + 320)
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model
D475A-5E0
Serial Number
30001 and up
Work equipment pump
Max. pressure
MPa {kg/cm2}
Type
27.5 {280} Variable swash plate type: 2 pcs. (HPV 125 + 125)
Capacity (at engine speed of 2,000 rpm)
l/min
542
Variable swash plate type: 2 pcs. (LPV 90 + 30) Cooling fan pump
2
MPa {kg/cm }
Max. discharge pressure: 17.5 {178}
l/min/rpm
Theoretical discharge pressure: 178/1,934
2
Work equipment valve
MPa {kg/cm }
Max. using pressure: 17.5 {178}
Type • For blade lift 6-spool type: 1 pc. • For blade tilt Hydraulic • For ripper lift • For ripper tilt
Dimensions of blade tilt cylinder
Dimensions of blade lift cylinder
Type
Hydraulic cylinders
Work equipment hydraulic system
Fixed swash plate type (LMF 180) Cooling fan motor
Double acting piston Bore of cylinder
180
Outside diameter of piston rod
110
Stroke of piston
mm
1,925
Max. distance between pins
3,155
Min. distance between pins
1,230
Bore of cylinder
250
Outside diameter of piston rod
140
Stroke of piston
mm
293
Max. distance between pins
1,988
Min. distance between pins
1,695
D475A, D475ASD-5E0
5
Machine model
D475A-5E0
Serial Number
30001 and up
Bore of cylinder (Both of right and left) Outside diameter of piston rod (Both of right and left) Stroke of piston (Both of right and left) Max. distance between pins (Both of right and left) Min. distance between pins (Both of right and left)
250
mm
293 1,988 1,695 225
Outside diameter of piston rod
120
Bore of cylinder
Bore of cylinder
225
Outside diameter of piston rod
140
Stroke of piston
mm
645
Max. distance between pins
2,175
Min. distance between pins
1,530
Stroke of piston
mm
540
Max. distance between pins
2,020
Min. distance between pins
1,480
Hydraulic tank
6
140
Dimensions of ripper lift cylinder
Dimensions of blade dual tilt cylinder
01 Specification
Dimensions of ripper tilt cylinder
Hydraulic cylinders
Work equipment hydraulic system
SEN00208-01
Box type (External control valve type)
D475A, D475ASD-5E0
01 Specification
Machine model
D475A-5E0
Serial Number
30001 and up
Performance Dimensions Performance Dimensions
Width of blade Height of blade Angle of blade cutting edge
Performance
Max. tilting distance Max. pitch angle Max. pitch back angle
Max. tilting distance Max. pitch angle Max. pitch back angle
Max. digging depth Max. lift Digging angle (Standard)
Performance Dimensions
Full-U dozer Giant ripper
Dimensions
Max. lift above ground Max. drop below ground Max. tilting distance Changing range of blade cutting edge angle Capacity of blade
Semi-U dozer
Width of blade Height of blade Angle of blade cutting edge
Performance
Brace type (Right tilt cylinder)
Performance
Blade supporting method
Semi-U dozer + Pitch
Hydraulic semi-U tiltdozer Hydraulic full-U tiltdozer
Full-U dozer + Pitch
Type
Max. lift above ground Max. drop below ground Max. tilting distance Changing range of blade cutting edge angle Capacity of blade
Multi-ripper
Work equipment
SEN00208-01
mm mm mm deg.
1,676 954 770 ±6
m3
38.1
mm mm deg.
5,265 2,690 52
mm mm mm deg.
1,676 954 905 ±6
m3
42.3
mm mm deg.
3,640 1,580 52
mm deg. deg.
1,145 6 6
mm deg. deg.
1,350 6 6
mm mm deg.
1,124 1,196 45 (Adjustable steplessly to 32.5 – 54)
Length of beam
mm
3,085
Number of shanks
pcs.
3
Max. digging depth Max. lift Digging angle (Standard)
mm mm deg.
1,744 1,196 45 (Adjustable steplessly to 34 – 56)
Length of beam
mm
1,477
Number of shanks
pcs.
1
D475A, D475ASD-5E0
7
SEN00208-01
01 Specification
Superdozer specification Machine model
D475ASD-5E0
Serial Number
30001 and up
Weight
Machine weight • Tractor • Superdozer + ROPS cab + Air conditioner
84,430
kg
113,120
+ Counterweight m
4.6
Gradeability
deg.
30
Stability (Front, Rear, Left, Right)
deg.
35
Forward Reverse
Gear speeds
1st
0 – 4.7
Ground pressure
0 – 10.9
Overall length
3rd
Tractor
Overall width
1st
Tractor
Tractor
Overall height
Dimensions
Performance
Min. turning radius
2nd
2nd
0 – 3.5 km/h
km/h
0 – 8.4
3rd
Superdozer + ROPS cab +
0 – 14.3 113.0 {1.15} 2
kPa {kg/cm }
151.4 {1.54}
Air conditioner + Counterweight
Superdozer + Counterweight
Superdozer
mm
mm
Up to ROPS top Up to exhaust pipe end
mm
Up to exhaust duct top
Length of track on ground Track shoe width Minimum ground clearance
6,680 10,525 3,620 6,465 4,646 4,546 3,861 2,770
Track gauge
8
0 – 6.3
mm
4,524 810 711
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model
D475ASD-5E0
Serial Number
30001 and up Komatsu SAA12V140E-3
Model name
4-stroke, water-cooled, V-type, direct-injection
Type
engine with turbocharger and aftercooler mm
12–140 x 165
l {cc}
30.48 {30,480}
Rated output
kW/rpm {HP/rpm}
677/2,000 {908/2,000}
Max. torque
Nm/rpm {kgm/rpm}
3,825/1,400 {390/1,400}
High idle
rpm
2,150
Low idle
rpm
600
g/kWh {g/HPh}
215 {160}
Number of cylinder–Bore x Stroke
Performance
Engine
Total displacement
Min. fuel consumption ratio (at rated output)
Starting motor Alternator Battery Type of radiator core Torque converter
24 V, 7.5 kW x 2 24 V, 100 A 12 V, 220 Ah x 4 D-type 3-element, 1-stage, 1-phase type (With lockup clutch) Planetary gear, multiple disc clutch,
Transmission
hydraulic, pump-forced lubrication,
Power train
3 forward/reverse gear speeds type Bevel gear shaft
Spiral bevel gear, splash lubrication type Wet, multiple disc clutch, spring-actuated,
Steering clutch
hydraulic (hand-operated) type interlocked with brake Wet, multiple disc clutch, spring-actuated,
Steering brake
hydraulic (foot/hand-operated) type interlocked with brake
Final drive
Undercarriage
Type of suspension
1-stage spur gear and 1-stage planetary gear, splash lubrication type Hard, equalizing beam type
Carrier roller
2 pieces on each side
Track roller
8 pieces on each side Assembly type single grouser shoe,
Track shoe
41 pieces on each side, Pitch: 317.5 mm, Width: 810 mm
Power train + Lubrication pump (Tandem) Scavenging pump (Tandem)
D475A, D475ASD-5E0
Gear type (BAL 160 + 160 + 112) Gear (BAR 63 + 320)
9
SEN00208-01
01 Specification
Machine model
D475ASD-5E0
Serial Number
30001 and up
Work equipment pump
Max. pressure
MPa {kg/cm2}
Type
27.5 {280} Variable swash plate type: 2 pcs. (HPV 125 + 125)
Capacity
l/min
542
(at engine speed of 2,000 rpm) Variable swash plate type: 2 pcs. (LPV 90 + 30)
Work equipment valve
Cooling fan motor
Max. discharge pressure: 17.5 {178}
l/min/rpm
Theoretical discharge pressure: 178/1,934 Fixed swash plate type (LMF 180)
MPa {kg/cm2}
Max. using pressure: 17.5 {178}
Type • For blade lift
6-spool type: 1 pc.
• For blade tilt
Hydraulic
• For ripper lift • For ripper tilt
Dimensions of blade lift cylinder Dimensions of blade pitch cylinder
Double acting piston Bore of cylinder
180
Outside diameter of piston rod
110
Stroke of piston
mm
1,925
Max. distance between pins
3,155
Min. distance between pins
1,230
Bore of cylinder
250
Outside diameter of piston rod
140
Stroke of piston
mm
660
Max. distance between pins
2,154
Min. distance between pins
1,494
Hydraulic tank
10
MPa {kg/cm }
Type
Hydraulic cylinders
Work equipment hydraulic system
Cooling fan pump
2
Box type (External control valve type)
D475A, D475ASD-5E0
Performance Dimensions
Superdozer
Work equipment
01 Specification
SEN00208-01
Machine model
D475ASD-5E0
Serial Number
30001 and up
Type
Hydraulic superdozer (Pitchdozer)
Blade supporting method
Cylinder type
Max. lift above ground Max. drop below ground Max. tilting distance Max. pitch dump angle Max. pitch back angle Capacity of blade
mm mm mm deg. deg. m3
2,016 804 900 (at cutting edge angle of 52°) 15 15 45.0
Width of blade
mm
6,465
Height of blade
mm
2,690
Angle of blade cutting edge
deg.
42 – 67
D475A, D475ASD-5E0
11
SEN00208-01
01 Specification
Weight table k
1
This weight table is a reference for handling and transportation of components.
Semi-U tiltdozer and full-U tiltdozer specifications Unit: kg Machine model
D475A-5E0
Serial Number
30001 and up
Engine and damper assembly • Engine assembly • Damper assembly
4,115 3,900 215
Main radiator assembly Aftercooler assembly Oil cooler assembly Fuel tank assembly [When full]
485 30 129 863 [2,335]
Power train unit (Including work equipment pump and fan pump) • Torque converter and PTO assembly • Transmission assembly • Transmission valve assembly • Steering clutch and brake assembly • Steering valve assembly • Work equipment pump • Cooling fan pump • Power train and lubricating oil pump • Scavenging pump • Power train filter assembly (3 pcs.)
5,350 830 1,335 40 2,290 75 180 72 64 25 100
Final drive assembly (Each side) Main frame assembly
3,575 9,120
Track group assembly (Each side) • Track frame • Idler assembly (Each side) • Track roller assembly (1 single flange) • Track roller assembly (1 double flange) • Carrier roller assembly (1 pc.)
13,190 2,976 708 248 237 106
Track shoe assembly (710 mm) Pivot shaft assembly (each side) Equalizer bar
13,530 370 733
Hydraulic tank assembly Control valve
290 195
Blade lift cylinder assembly (Each side) Blade tilt cylinder assembly
509 504
Tiltdozer assembly • Blade • Straight frame (Left) • Straight frame (Right) • Tilt cylinder assembly Variable giant ripper assembly • Shank assembly • Ripper lift cylinder assembly • Ripper tilt cylinder assembly
a
12
16,500 (18,500) 8,550 (9,760) 1,770 (1,770) 1,770 (1,770) 504 (504) 7,300 1,040 389 394
Values in ( ) are for full-U blade.
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: kg Machine model
D475A-5E0
Serial Number
30001 and up
Radiator guard assembly • Radiator guard • Blade lift cylinder assembly (Each side) • Cooling fan motor Radiator mask (Including grille) (Each side) Engine underguard (Front) Engine underguard (Rear) Power train underguard (Front) Power train underguard (Rear) Hood Fender (Left) Fender (Right) ROPS mount assembly (Left) ROPS mount assembly (Right) ROPS assembly Floor frame assembly Cab assembly Operator's seat assembly
D475A, D475ASD-5E0
4,550 2,530 509 65 100 267 324 340 448 197 474 570 527 520 934 600 455 64
13
SEN00208-01
01 Specification
Superdozer specification Unit: kg Machine model
D475ASD-5E0
Serial Number
30001 and up
Engine and damper assembly • Engine assembly • Damper assembly
4,115 3,900 215
Main radiator assembly Aftercooler assembly Oil cooler assembly Fuel tank assembly [When full]
485 30 129 863 [2,335]
Power train unit (Including work equipment pump and fan pump) • Torque converter and PTO assembly • Transmission assembly • Transmission valve assembly • Steering clutch and brake assembly • Steering valve assembly • Work equipment pump • Cooling fan pump • Power train and lubricating oil pump • Scavenging pump • Power train filter assembly (3 pcs.)
5,350 830 1,335 40 2,290 75 180 72 64 25 100
Final drive assembly (Each side) Main frame assembly
3,575 9,120
Track group assembly (Each side) • Track frame • Idler assembly (Each side) • Track roller assembly (1 single flange) • Track roller assembly (1 double flange) • Carrier roller assembly (1 pc.)
13,190 2,976 708 248 237 106
Track shoe assembly (810 mm) Pivot shaft assembly (each side) Equalizer bar
14,450 370 733
Hydraulic tank assembly Control valve
290 195
Blade lift cylinder assembly (Each side) Blade pitch cylinder assembly (Each side)
509 508
Superdozer assembly • Blade • Straight frame (Left) • Straight frame (Right) • Pitch cylinder assembly (Each side)
21,200 11,950 1,770 1,770 508
Counterweight
6,400
Radiator guard assembly • Radiator guard • Blade lift cylinder assembly (Each side) • Cooling fan motor
4,640 2,530 509 65
14
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: kg Machine model
D475ASD-5E0
Serial Number
30001 and up
Radiator mask (Including grille) (Each side) Engine underguard (Front) Engine underguard (Rear) Power train underguard (Front) Power train underguard (Rear) Hood Fender (Left) Fender (Right) ROPS mount assembly (Left) ROPS mount assembly (Right) ROPS assembly Floor frame assembly Cab assembly Operator's seat assembly
D475A, D475ASD-5E0
100 267 324 340 448 197 474 570 527 520 934 600 455 64
15
SEN00208-01
01 Specification
Fuel, coolant and lubricants a
16
1
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: l Refilling points
D475A, D475ASD-5E0 Specified capacity
Refill capacity
Engine oil pan
126
121
Damper case
2.2
2.2
Power train case
410
210
Final drive case (each)
75
75
Hydraulic system (with blade, without ripper)
420
170
Cooling system (including reservoir tank)
210
—
Fuel tank
1670
—
D475A, D475ASD-5E0
17
SEN00208-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN00208-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 08-07 (01)
18
SEN00210-00
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Engine and cooling system Engine and cooling system ............................................................................................................................. 2 Radiator and oil cooler ......................................................................................................................... 2 Engine mount ....................................................................................................................................... 3 Cooling fan pump ................................................................................................................................. 4 Cooling fan motor............................................................................................................................... 26
D475A, D475ASD-5E0
1
SEN00210-00
10 Structure, function and maintenance standard
Engine and cooling system
1
Radiator and oil cooler
1
1. Main radiator 2. Sub radiator 3. Turbocharger 4. Engine 5. Power train oil cooler 6. Water pump
2
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00210-00
Engine mount
1
Unit: mm No.
1
Check item
Clearance between bracket and cushion
Criteria 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 +0.072
0.043 – 0.155
Standard size
Replace 2
Clearance between bracket and bushing
3
Free height of rubber mount
D475A, D475ASD-5E0
Standard size
Repair limit
118
116
0.1
3
SEN00210-00
Cooling fan pump
10 Structure, function and maintenance standard
1
Type: LPV90 + 30
DC: Discharge port SC: Suction port 1. 2.
4
LPV90 Hydraulic pump LPV30 Hydraulic pump
D475A, D475ASD-5E0
SEN00210-00
1.
10 Structure, function and maintenance standard
LPV90 Hydraulic pump
DC: Discharge port SC: Suction port
6
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
IM: PA: PD1: PD2: PDA: PEN: PEPC: PS:
Control current input connector Pump discharge port Drain port Drain port (Plug) Breather Control pressure pick-up port (Plug) EPC basic pressure input port Pump suction port
D475A, D475ASD-5E0
SEN00210-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Shaft Cradle Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston
7
SEN00210-00
Function q The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump converts the rotation and torque into hydraulic energy and discharges hydraulic oil according to the load. q The discharge of this pump can be changed by changing the swash plate angle in it.
8
10 Structure, function and maintenance standard
Structure q Cylinder block (7) is supported on shaft (1) through spline (C). Shaft (1) is supported on the front and rear bearings. q The end of piston (6) has a spherical hollow which is combined with shoe (5). Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) is kept pressed against plane (A) of rocker cam (4) and slid circularly. Rocker cam (4) receives high-pressure oil and forms a static pressure bearing and slides on cylindrical surface B of cradle (2). q Piston (6) in each cylinder of cylinder block (7) moves relatively in the axial direction. q Cylinder block (7) rotates relatively against valve plate (8), sealing the hydraulic oil. The hydraulic balance on the valve plate is maintained properly. q The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Operation 1) Operation of pump q Cylinder block (7) rotates together with shaft (1). Shoe (5) slides on plane (A). At this time, rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. Angle (a) is called the swash plate angle.
q
q
q
SEN00210-00
q
If center line (X) of rocker cam (4) is equal to the axial of cylinder block (7) (the swash plate angle is 0), there is not a difference between volumes (E) and (F) in cylinder block (7) and the oil is not sucked or discharged. (The swash plate angle is not set to 0 actually, however.)
q
In short, swash plate angle (a) is in proportion to the pump discharge.
If angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A) works as a cam for shoe (5). Accordingly, piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder block (7). As a result, each piston (6) sucks and discharges oil by (F) – (E). In other words, if cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from chamber (E). On the other hand, the volume of chamber (F) is increased and the oil is sucked in chamber (F). [In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge stroke.]
D475A, D475ASD-5E0
9
SEN00210-00
2) q
q
q
q
q
10
10 Structure, function and maintenance standard
Control of discharge If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or discharge (Q) is increased. Swash plate angle (a) is changed with servo piston (1). Servo piston (1) reciprocates straight according to the signal pressure of the PC valve. This straight motion is transmitted to rocker cam (4). Then, rocker cam (4) supported on the cylindrical surface of cradle (2) slides in the rotating direction. The pressure receiving area of the top of servo piston (1) is different from that of the bottom. Main pump discharge pressure (self-pressure) (PA) is kept led in the pressure chamber on the small-diameter piston side (upper side). PC valve output pressure (PEN) is led in the pressure chamber on the large-diameter piston side (lower side). The movement of servo piston (1) is controlled according to the difference between pressure (PA) on the small-diameter piston side and pressure (PEN) on the large-diameter piston side and the ratio of the pressure receiving area of the small-diameter piston to that of the large-diameter piston.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
3)
SEN00210-00
PC valve, EPC valve, and servo piston
IM: PA: PEPC:
Control current input connector Pump discharge port EPC basic pressure input port
Servo piston 1. Servo piston 2. Lever 3. Spring
D475A, D475ASD-5E0
PC valve 4. Piston 5. Seat 6. Spring 7. Spool 8. Sleeve 9. Plug
EPC valve 10. EPC valve
11
SEN00210-00
10 Structure, function and maintenance standard
Function q The PC valve works so the relationship between the current input to the EPC valve and pump swash plate angle (a) will be as shown in the figure below.
12
D475A, D475ASD-5E0
SEN00210-00
10 Structure, function and maintenance standard
(1) When EPC output pressure is high [When EPC current (i) is large]
14
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00210-00
Operation q The relationship between the EPC valve input current (i) and EPC valve output pressure (F) is as shown in the figure below.
q
q
q
q
q
q
q
If the EPC discharge pressure rises, spool (7) is pushed to the left because of the difference in sectional areas between parts (S1) and (S2) of the spool (S1 > S2). Port (f) is connected to port (g) and pump discharge pressure (PA) flows through port (g) to port (f). Port (f) is disconnected from the drain circuit. Pump discharge pressure (PA) from port (f) of the PC valve enters chamber (X) on the large diameter side of servo piston (1). Pump pressure (PA) is also constantly applied to chamber (Y) on the small diameter side of servo piston (1). Since a larger force is applied to the large diameter side because of the difference in area between both ends of servo piston (1), however, servo piston (1) moves toward the minimum swash plate angle side (upper side). If servo piston (1) moves up, piston (4) is moved to the right through lever (2). Accordingly, spring (6) is compressed and spool (7) moves to the right. If spool (7) moves to the right and port (f) is disconnected from port (g), servo piston (1) stops moving up. At this time, servo piston (1) stops at a place higher (nearer to the minimum swash plate angle) than when the EPC discharge pressure is low.
D475A, D475ASD-5E0
15
SEN00210-00
10 Structure, function and maintenance standard
(2) When EPC output pressure is low [When EPC current (i) is small]
16
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00210-00
Operation q If EPC current (i) reduces and the EPC output pressure lowers, spool (7) is pushed to the right by the force of spring (6). q Accordingly, port (g) is disconnected from port (f) and port (f) is connected to the drain circuit. q At this time, the oil in chamber (X) on the large diameter side of servo piston (1) flows through port (f) of the PC valve to the drain circuit. q As a result, servo piston (1) is moved toward the maximum swash plate angle side (lower side) by the pressure of chamber (Y) on the small diameter side.
D475A, D475ASD-5E0
17
SEN00210-00
2.
LPV30 Hydraulic pump
P1: PAEPC: PDA2: PEPC: PS: TO:
18
10 Structure, function and maintenance standard
Pump discharge port EPC output pressure pickup port Breather EPC valve basic pressure input port Pump suction port Drain port
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
SEN00210-00
Shaft Oil seal Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston Ball
D475A, D475ASD-5E0
19
SEN00210-00
10 Structure, function and maintenance standard
Function q The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump converts the rotation and torque into hydraulic energy and discharges hydraulic oil according to the load. q The discharge of this pump can be changed by changing the swash plate angle in it. Structure Cylinder block (7) is supported on shaft (1) through spline (B). Shaft (1) is supported on the front and rear bearings. q The end of piston (6) has a spherical hollow which is combined with shoe (5). Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) is kept pressed against plane (A) of rocket cam (4) and slid circularly. Rocker cam (4) slides around ball (11). q Piston (6) in each cylinder of cylinder block (7) moves relatively in the axial direction. q Cylinder block (7) rotates relatively against valve plate (8), sealing the hydraulic oil. The hydraulic balance on the valve plate is maintained properly. q The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8). q
20
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Operation 1) Operation of pump q Cylinder block (7) rotates together with shaft (1). Shoe (5) slides on plane (A). At this time, rocker cam (4) tilts around ball (11). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. Angle (a) is called the swash plate angle. q If angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A) works as a cam for shoe (5). q Accordingly, piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder block (7). As a result, each piston (6) sucks and discharges oil by (F) – (E). q In other words, if cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from chamber (E). On the other hand, the volume of chamber (F) is increased and the oil is sucked in chamber (F). [In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge stroke.]
D475A, D475ASD-5E0
SEN00210-00
q
q
If center line (X) of rocker cam (4) is equal to the axial of cylinder block (7) (the swash plate angle is 0), there is not a difference between volumes (E) and (F) in cylinder block (7) and the oil is not sucked or discharged. (The swash plate angle is not set to 0 actually, however.) In short, swash plate angle (a) is in proportion to the pump discharge.
21
SEN00210-00
2) q
q
22
10 Structure, function and maintenance standard
Control of discharge If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or discharge (Q) is increased. Swash plate angle (a) is changed with servo piston (10). Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. This straight motion is transmitted to rocker cam (4). Then, rocker cam (4) supported on ball (11) rocks around ball (11).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
3)
Servo valve
P: PE: PH: T:
EPC valve basic pressure input port Control piston pressure output port Pump discharge pressure input port Drain port
1. 2. 3. 4. 5. 6. 7.
Plug Lever Retainer Seat Spool Piston Sleeve
D475A, D475ASD-5E0
SEN00210-00
23
SEN00210-00
A: Drain side B: Pump discharge pressure input side C: EPC output pressure receiving pressure
10 Structure, function and maintenance standard
D: EPC output pressure side P: EPC basic pressure input side
Function q The servo valve works so the relationship between the current input to the EPC valve and pump swash plate angle (a) will be as shown in the figure below.
24
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
q
SEN00210-00
The relationship between the EPC valve input current (i) and EPC valve output pressure (F) is as shown in the figure below.
Operation The output oil of the EPC valve flows in the piston chamber (C) to push piston (6). Piston (6) pushes spool (5) until it is balanced with the spring. q Then, land (PE) of the servo piston pressure passage is connected to the pump discharge passage by the cut of spool (5) and the discharge pressure is led to the servo piston. q The servo piston is raised by the rocker cam. The position feedback is applied and the lever moves to compress the spring. q If spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are shut off. The pressure in the servo piston chamber lowers and the rocker cam returns toward the maximum swash plate angle. q These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with the spring force. q Accordingly, as the EPC output pressure is heightened, the swash plate angle is decreased. As the EPC output pressure is lowered, the swash plate angle is increased. q
D475A, D475ASD-5E0
25
SEN00210-00
Cooling fan motor
10 Structure, function and maintenance standard
1
Type: LMF180
P: From fan pump T: From cooler to tank TC: To tank Specifications Type : LMF180 Capacity : 180 cc/rev Rated speed : 982 rpm Rated flow : 178 l/min Check valve cracking pressure: 0.07 MPa {0.7 kg/cm2}
26
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SEN00210-00
Output shaft Case Thrust plate Shoe Piston Cylinder block Valve plate End cover Center spring Safety-suction valve
D475A, D475ASD-5E0
27
SEN00210-00
1.
10 Structure, function and maintenance standard
Hydraulic motor
Function q This hydraulic motor is a swash plate type axial piston motor, which converts the pressure of the hydraulic oil sent from the hydraulic pump into revolution. Principle of operation q The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). This oil can flow on only one side of the (Y – Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). q The oil sent to one side of cylinder block (5) presses pistons (4) (4 or 5 pieces) and generates force (F1) (F1 kg = P kg/cm2 x x/4D2 cm2). q This force is applied to thrust plate (2). Since thrust plate (2) is fixed to the angle of (a) degrees to the output shaft (1), the force is divided into components (F2) and (F3). q Radial component (F3) generates torque against the (Y – Y) line connecting the top dead center and bottom dead center (T = F3 x ri). q The resultant of this torque [T = s (F3 x ri)] rotates cylinder block (5) through the piston. q Since cylinder block (5) is coupled with the output shaft by means of spline, the output shaft revolves to transmit the torque.
28
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
2.
Safety-suction valve
1. 2. 3. 4. 5. 6. 7. 8. 9.
Piston Main valve Piston spring Valve seat Poppet Poppet spring Suction valve Suction valve spring Adjustment screw
SEN00210-00
Function q When the pressure in port (P) of the motor rises at the starting time of the engine, this valve protects the fan system circuit. (Safety valve) q When the fan pump stops, the hydraulic oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the oil stops flowing in from inlet port (P), the safety-suction valve sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation. (Suction valve)
D475A, D475ASD-5E0
29
SEN00210-00
Operation 1) Operation as safety valve q Port (A) is connected to port (P) of the motor and port (B) is connected through port (MB) to port (T). q The hydraulic oil in port (A) flows through the hole of piston (1) to port (C). Since (d2) < (d3), main valve (2) is seated on the left side. q The order of the diameters (areas) of the sections is (d5) > (d4) > (d1) > (d3) > (d2).
q
30
If abnormal pressure generated in port (A) reaches the set pressure of spring (6), poppet (5) opens and the hydraulic oil in port (C) is drained through port (D) and periphery (a) of suction valve (7).
10 Structure, function and maintenance standard
q
If poppet (5) opens, the pressure in port (C) lowers and piston (1) moves to the right. Piston (1) comes in contact with the tip of poppet (5) and the hydraulic oil is drained through throttle (b) and port (D).
q
Since the pressure in port (C) is lower than that in port (A), main valve (2) moves to the right and the hydraulic oil flows through port (A) to port (B), thus generation of abnormal pressure is prevented. Even if abnormal pressure is generated, suction valve (7) having a large section diameter does not operate since (d1) < (d4).
q
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
2) q
q
SEN00210-00
Operation as suction valve If negative pressure is generated in port (P) of the motor, the pressure in ports (A) and (C) becomes negative since those ports are connected. A right force caused by the hydraulic pressure equivalent to the area difference between (d4) and (d1) is applied to suction valve (7). If the differential pressure between ports (B) and (A) increases above the set pressure, it moves suction valve (7) to the right. Accordingly, hydraulic oil flows from port (B) to port (A) to prevent generation of negative pressure in port (A).
D475A, D475ASD-5E0
31
SEN00210-00
10 Structure, function and maintenance standard
3. 1)
Operation for forward and reverse revolution Forward revolution (Counterclockwise revolution)
q
If ON-OFF solenoid (1) for selector valve is deenergized, the hydraulic oil in port (MA) is sent to chamber (E) and spool (5) moves to the left. The hydraulic oil in port (MB) is returned to the tank through passage (a) on the periphery of spool (5). If ON-OFF solenoid (1) for selector valve is deenergized, the hydraulic oil from the pump is blocked by ON-OFF selector valve (2) and port (C) is connected to the tank circuit. Accordingly, selector spool (3) is pushed by spring (4) to the right to open motor port (MA) and then the hydraulic oil flows in the motor to revolve the motor forward (counterclockwise).
q
q
q
32
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
2)
Reverse revolution (Clockwise revolution)
q
If ON-OFF solenoid (1) for selector valve is energized, the hydraulic oil in port (MB) is sent to chamber (F) and spool (5) moves to the right. The hydraulic oil in port (MA) is returned from chamber (E) to the tank through passage (a) on the periphery of spool (5). If ON-OFF solenoid (1) for selector valve is energized, ON-OFF selector valve (2) changes to let the hydraulic oil from the pump flow through port (C) into spool chamber (D). The hydraulic oil in chamber (D) pushes selector spool (3) to the left against spring (4). As a result, motor port (MB) opens and the hydraulic oil flows in the motor to revolve the motor in reverse (clockwise).
q
q
q
D475A, D475ASD-5E0
SEN00210-00
33
SEN00211-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Power train, Part 1 Power train...................................................................................................................................................... 2 Power train hydraulic equipment arrangement diagram ................................................................................. 4 Damper and universal joint ............................................................................................................................. 6 General view of power train unit ..................................................................................................................... 8 Torque converter, PTO .................................................................................................................................. 10 Torque converter valve.................................................................................................................................. 18 Torque converter lockup control system ....................................................................................................... 28 Scavenging pump ......................................................................................................................................... 29 Transmission control ..................................................................................................................................... 31 Transmission................................................................................................................................................. 32
D475A, D475ASD-5E0
1
SEN00211-01
Power train
Outline q 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 lockup clutch assembled to the torque converter, and when the rotating speed beyond the torque converter becomes higher, the lockup 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 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 respec-
2
10 Structure, function and maintenance standard
1
tive 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 moves the machine.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5.
Engine (SAA12V140E-3) Damper Universal joint Power train, lubrication pump (BAL160+160+112) Work equipment pump (HPV125+125)
D475A, D475ASD-5E0
6. 7. 8. 9. 10. 11. 12.
Fan pump (LPV90+30) Torque converter Transmission Steering clutch Steering brake Final drive Sproket
SEN00211-01
13. 14. 15. 16. 17. 18. 19.
Track shoe Transfer Transfer drive gear Bevel pinion Bevel gear PTO Scavenging pump
3
SEN00211-01
10 Structure, function and maintenance standard
Power train hydraulic equipment arrangement diagram
1. 2. 3. 4. 5. 6. 7. 8. 9.
Torque converter oil filter Transmission lubricating oil filter Transmission oil filter Torque converter valve Transmission control valve Steering control valve Power train oil strainer Oil tank Power train, lubrication pump (BAL160+160+112) 10. Scavenging pump 11. Power train oil cooler
4
A. B. C. D. E. F. G. H. J. K. L. M. N. P.
1
Transmission main relief pressure pickup port (TM) Transmission R clutch pressure pickup port (REV) Transmission F clutch pressure pickup port (FWD) Torque converter inlet pressure pickup port (IN) Lockup clutch pressure pickup port (LU) Left clutch pressure pickup port (LC) Left brake pressure pickup port (LB) Right brake pressure pickup port (RB) Right clutch pressure pickup port (RC) Stator clutch pressure pickup port (SC) Torque converter outlet pressure pickup port (OUT) Transmission 1st clutch pressure pickup port (1ST) Transmission 2nd clutch pressure pickup port (2ND) Transmission 3rd clutch pressure pickup port (3RD)
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00211-01
5
SEN00211-01
Damper and universal joint
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Output shaft Flywheel Outer body Flange Oil level gauge Breather Cover Coupling Universal joint Rubber coupling Drain plug
10 Structure, function and maintenance standard
1
Outline q The damper damps the tensional vibration caused by fluctuation of the engine torque and the impact torque caused by sudden acceleration and heavy digging work to protect the torque converter, transmission, and other power train components. q Since this damper employs rubber coupling (10), vibrations are damped by the compressive damping effect of the rubber and less component parts are used. Operation q The power from the engine is transmitted through flywheel (2) to outer body (3). The tensional vibration of the engine is absorbed in rubber coupling (10) and the power is transmitted to output shaft (1), and then transmitted through universal joint (9) to the torque converter and transmission.
6
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Unit: mm No.
12
Check item
Clearance between flywheel housing and cover
13
Clearance between flywheel housing and damper
14
Outer diameter of oil seal contact face on coupling
15
Outer diameter of bearing contact face on output shaft
D475A, D475ASD-5E0
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
647.7
–0.024 –0.104
+0.080 +0.080
0.024 – –0.184
0.2
571.5
–0.022 –0.092
+0.070 +0.070
0.022 – 0.162
0.2
Standard size
Repair limit
120
119.9
55
54.9
Replace
7
SEN00211-01
Power train system 1 General view of power train unit
8
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
A: B: C: D:
Main relief pressure pickup port (TM) R clutch pressure pickup port (REV) F clutch pressure pickup port (FWD) Torque converter inlet pressure pickup port (IN) E: Lockup clutch pressure pickup port (LU) F: Left steering clutch pressure pickup port (LC) G: Left steering brake pressure pickup port (LB) H: Right steering brake pressure pickup port (RB) J: Right steering clutch pressure pickup port (RC) K: Stator clutch pressure pickup port (SC) L: Torque converter outlet pressure pickup port (OUT) M: 1st clutch pressure pickup port (1ST) N: 2nd clutch pressure pickup port (2ND) P: 3rd clutch pressure pickup port (3RD) R: Transmission lubricating pressure pickup port
SEN00211-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Oil filler port Centralized pressure pickup port Oil level gauge Torque converter and PTO Torque converter valve Transmission control valve Transmission Steering control valve Steering unit Torque converter oil filter Transmission lubricating oil filter Power train oil filter Torque converter, power train, and lubricating oil pump 14. Power train oil strainer 15. Scavenging pump
Outline q The power train unit broadly consists of torque converter and PTO (4), transmission (7), and steering unit (9). Therefore, after the power train unit is removed, it can be divided into torque converter and PTO (4), transmission (7), and steering unit (9). q Steering unit (9) consists of the transfer, bevel gear shaft, steering clutch, and the steering brake.
D475A, D475ASD-5E0
9
SEN00211-01
Torque converter, PTO a
10
10 Structure, function and maintenance standard
1
PTO: Abbreviation for Power Take Off
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00211-01
11
SEN00211-01
A: B: C: D: E: F: G: H: J: K: L: M: N: P: R: S:
To transmission control valve To transmission lubrication circuit To transmission oil pan From steering case From power train pump From lubricating oil pump To transmission oil pan To scavenging pump To scavenging pump To power train oil filter To transmission lubricating oil filter From power train oil filter From transmission lubricating oil filter Torque converter outlet oil temperature pickup port Torque converter outlet oil pressure pickup port (OUT) To power train oil cooler
10 Structure, function and maintenance standard
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.
12
Cooling fan pump mounting port Hydraulic pump mounting port Power train, torque converter, and lubricating oil pump mounting port Scavenging pump mounting port Torque converter valve Coupling Retainer Input shaft (number of teeth: 59) Front housing PTO idler gear (number of teeth: 74) PTO idler gear shaft Lockup clutch housing Drive case Turbine Rear housing Stator Pump Stator shaft Guide Retainer Pump shaft Transmission input shaft Stator clutch hub gear Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lockup clutch plate Lockup clutch disc Lockup clutch piston Scavenging pump drive gear (number of teeth: 65) Sleeve Bearing race Power train, torque converter, lubricating oil pump, and cooling fan pump drive gear (number of teeth: 61) Drive gear boss Cover Cover Hydraulic pump drive gear (number of teeth: 61) Cover Strainer
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Outline q The torque converter is a 3-element, 1-stage, and 1-phase type, which is integral with the transmission. q The torque converter is equipped with a wet multiple disc clutch type torque converter lockup device and a wet double disc clutch type stator clutch in order to reduce fuel consumption, to increase the operability, and to reduce the horsepower consumption by the engine. q For higher efficiency of continuous light dozing and leveling operation, the torque converter is locked up and the engine power is transferred directly to the transmissions input shaft. q When the torque converter is locked up (the pump and turbine is integrated into 1 unit), the oil is still supplied to the torque converter. Accordingly, the oil flowing from the pump through the turbine to the stator is obstructed by the stator blades and cannot flow in any direction. As a result, this oil resists the rotation of the pump and turbine (it is agitated). q To reduce the rotating resistance of the pump and turbine, the stator clutch is disengaged simultaneously with lockup of the torque converter so that the stator can rotate freely. As the stator is dragged and turned by the pump and turbine, the oil returns from the turbine to the pump smoothly against less resistance.
SEN00211-01
Structure q Pump (17) is integral with coupling (6), input shaft (8), lockup clutch housing (12), and drive case (13), and rotated by the engine power. q Turbine (14) is integral with turbine boss (29) and transmission input shaft (22), and rotated by the oil from pump (17). q Stator (16) is integral with stator shaft (18) and stator clutch hub gear (23), and fixed to rear housing (15) through the stator clutch unit. q The lockup clutch unit consists of clutch plate (30) meshed with drive case (13), clutch disc (31) meshed with turbine boss (29), and clutch piston (32) which slides inside clutch housing (12) integral with drive case (13). q The stator clutch unit consists of clutch hub gear (23) attached to stator shaft (18) with spline, clutch disc (27) meshed with clutch hub gear (23), clutch plate (26) supported by the pins on clutch housing (24) and rear housing (15), and clutch piston (28) which slides inside rear housing (15). q The PTO unit consists of input shaft (8), PTO idler gear (10), and pump drive gears (33), (36) and (40).
Conditions for the direct (lockup) range Torque converter output shaft speed: Min. 1,360 rpm Set transmission pressure: Min. 1.91 MPa {19.5 kg/cm2} Both conditions must be satisfied. Conditions for the torque converter (unlock) range Torque converter output shaft speed: Max. 1,330 rpm Set transmission pressure: Max. 1.47 MPa {15.0 kg/cm2} Either condition must be satisfied.
D475A, D475ASD-5E0
13
SEN00211-01
14
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Unit: mm No.
Check item
Criteria
1
Outside diameter of oil seal contact surface of input coupling
2
Remedy
Standard size
Tolerance
Repair limit
125
0 –0.063
124.8
Inside diameter of seal ring contact surface of sleeve
115
+0.035 0
115.1
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 pump shaft
120
+0.035 0
120.5
5
Backlash between input shaft and PTO idler gear
0.198 – 0.484
6
Backlash between PTO idler gear and power train, torque converter, lubricating oil pump, and cooling fan pump drive gear
0.198 – 0.484
7
Backlash between PTO idler gear and hydraulic pump drive gear
0.198 – 0.484
8
Backlash between input shaft and scavenging pump drive gear
0.198 – 0.484
9
Wear of input shaft seal ring
10
11
Width
4
–0.01 –0.03
3.6
Thickness
4.05
4.5
±0.12
Thickness of lockup clutch disc
5.4
±0.1
4.9
Thickness of lockup clutch plate
5.0
±0.1
4.5
Overall thickness of lockup clutch assembly
26.2
±0.22
24.6
Thickness of stator clutch disc
5.4
±0.1
4.9
Thickness of stator clutch plate
5.0
±0.05
4.5
Overall thickness of stator clutch assembly
15.8
±0.15
14.7 Tolerance
Standard size 12
13
14
15
Fitting tolerance of PTO idler gear bearing
Fitting tolerance of power train, torque converter, lubricating oil pump, and cooling fan pump drive gear bearing
Fitting tolerance of hydraulic pump drive gear bearing
Fitting tolerance of scavenging pump drive gear bearing
Shaft
Hole
140
0 –0.018
–0.008 –0.033
Inside diameter
80
0 –0.019
0 –0.015
Outside diameter (cover side)
140
0 –0.018
+0.012 –0.028
Outside diameter (case side)
140
0 –0.018
+0.015 –0.010
Inside diameter
65
+0.030 +0.011
0 –0.015
Outside diameter (cover side)
160
0 –0.025
+0.012 –0.028
Outside diameter (case side)
140
0 –0.018
+0.015 –0.010
Inside diameter (cover side)
75
+0.030 +0.011
0 –0.015
Inside diameter (case side)
65
+0.030 +0.011
0 –0.015
Outside diameter
72
0 –0.013
+0.009 –0.021
Inside diameter
35
+0.025 +0.009
0 –0.010
Outside diameter
Standard size 16
Stator clutch return spring
D475A, D475ASD-5E0
37.0
Replace
Repair limit
Free length Installed length Installed load 54.1
Repair by hard chrome plating or replace
125.4 N {12.8 kg}
Free length
Installed load
50.9
106.9 N {10.9 kg}
15
SEN00211-01
10 Structure, function and maintenance standard
Power transmitting route When lockup clutch is “disengaged” and stator clutch is “engaged”
q
q
q
q
16
If lockup clutch (3) is “disengaged”, drive case (5) and turbine (7) are disconnected from each other. If stator clutch (9) is “engaged” at this time, rear housing (10) and stator shaft (11) are connected to each other to fix stator (8). Therefore, the torque converter works as an ordinary torque converter. The power from the engine is transmitted to coupling (1) through the damper and the universal joint. The power transmitted to coupling (1) rotates input shaft (2), clutch housing (4), drive case (5) and pump (6) integrally. The power transmitted to pump (6) rotates turbine (7) through the medium of oil and is transferred to transmission input shaft (12) attached to turbine (7) with spline.
When lockup clutch is “engaged” and stator clutch is “disengaged”
q
q
q
q
If lockup clutch (3) is “engaged”, drive case (5) and turbine (7) are connected to each other. If stator clutch (9) is “disengaged” at this time, rear housing (10) and stator shaft (11) are disconnected from each other, and stator (8) is dragged and turned by pump (6) and turbine (7). Therefore, the torque converter works as a lockup torque converter. The power from the engine is transmitted to coupling (1) through the damper and the universal joint. The power transmitted to coupling (1) rotates input shaft (2), clutch housing (4), drive case (5) and pump (6) integrally. The power transmitted to drive case (5) rotates turbine (7) directly since lockup clutch (3) is fixed, and is transferred to transmission input shaft (12) attached to turbine (7) with spline.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Oil flow
q
q
q
The oil flows through the main relief valve and its pressure is reduced to below the set pressure by the torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of rear housing (1), pump shaft (2) and guide (3), and flows into pump (4). The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5). The oil from turbine (5) is sent to stator (6) and flows in pump (4) again. A part of the oil, however, is sent through outlet port (B) to the power train oil cooler.
D475A, D475ASD-5E0
17
SEN00211-01
Torque converter valve
PTF: TCF: TC : SC : LC : drT: dr: P3 : P8 : PSC: PPL:
18
10 Structure, function and maintenance standard
1
From power train oil filter From torque converter oil filter To torque converter To stator clutch To lockup clutch Drain (Torque converter relief) Drain Lockup clutch oil pressure pickup port (LU) Main relief oil pressure pickup port (TM) Stator clutch oil pressure pickup port (SC) Pilot oil pressure pickup port
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Valve body Torque converter relief valve Cover Main relief valve Piston Piston Stator clutch modulating valve Piston Piston Cover Piston Piston Lockup clutch modulating valve Shaft Stopper Load piston Cover
D475A, D475ASD-5E0
SEN00211-01
18. 19. 20. 21. 22.
Plug Valve body Lockup selector valve Piston Cover
Lockup solenoid valve 23. Cap 24. Coil 25. Valve 26. Ball 27. Valve 28. Base 29. Shaft 30. Case 31. Plunger
19
SEN00211-01
20
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Unit: mm No.
1
Check item
Clearance between main relief valve and valve body
Criteria Standard size
Tolerance Shaft
Hole
Remedy Standard clearance
Clearance limit
40
–0.035 –0.045
+0.016 0
0.035 – 0.061
0.081
2
Clearance between torque converter relief valve and valve body
40
–0.035 –0.045
+0.016 0
0.035 – 0.061
0.081
3
Clearance between stator clutch modulating valve and valve body
25
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.078
4
Clearance between lockup clutch modulating valve and valve body
25
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.078
5
Clearance between lockup selector valve and valve body
25
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.078
Standard size
6
Main relief valve spring
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
120.3
101.5
1,455 N {148.5 kg}
116.7
1,383 N {141.1 kg}
7
Torque converter relief valve spring
116.92
86.3
645.6 N {65.83 kg}
113.4
613 N {62.5 kg}
8
Stator clutch modulating valve spring
103.5
95.2
151.9 N {15.5 kg}
100.4
144 N {14.7 kg}
9
Lockup clutch modulating valve spring (outside)
141.4
88.7
158.6 N {16.18 kg}
137.2
151 N {15.4 kg}
10
Lockup clutch modulating valve spring (inside)
80.5
80.5
—
78.1
—
66
54
55.9 N {5.7 kg}
64.0
53.0 N {5.4 kg}
11 Lockup selector valve spring
D475A, D475ASD-5E0
Replace
21
SEN00211-01
10 Structure, function and maintenance standard
Outline q The torque converter valve is installed at the top of the rear housing of the toque converter, and consists of the following 6 types of valves. Main relief valve The main relief valve maintains each hydraulic circuit of the lockup clutches and stator clutches of the transmission, steering clutch, steering brake and torque converter constantly at the set pressure. Set pressure: 2.6 – 3.0 MPa {27.0 – 30.4 kg/cm2}
q
Torque converter relief valve q The torque converter relief valve maintains the oil pressure in the torque converter inlet circuit always below the set pressure in order to protect the torque converter from abnormally high pressure. Set pressure: 1.00 MPa {10.2 kg/cm2} Lockup solenoid valve q The lockup solenoid valve controls the lockup selector valve by changing the pilot pressure for it in response to electrical signals received from the controller. Lockup selector valve q The lockup selector valve turns the lockup clutch and stator clutch “engaged” and “disengaged”. Stator clutch modulating valve The stator clutch modulating valve maintains the clutch pressure below the set pressure to protect the stator clutch circuit from abnormally high pressure, as well as raising the clutch pressure gradually to the set pressure. Set pressure: 2.7 MPa {27 kg/cm2}
q
Lockup clutch modulating valve q The lockup clutch modulating valve maintains the clutch pressure below the set pressure to protect the lockup clutch circuit from abnormally high pressure, as well as raising the clutch pressure gradually to the set pressure. Set pressure: 1.3 MPa {13 kg/cm2}
22
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Operation of main relief valve
q
The oil from the hydraulic pump flows through the filter, port (A) of the torque converter valve, and orifice (a) of torque converter relief valve (1) to chamber (B).
SEN00211-01
Operation of torque converter relief valve
q
q
q
The oil from the main relief valve flows through port (C) to the torque converter, and at the same time, also flows through orifice (b) of torque converter relief valve (3) to chamber (D). When the oil pressure on the torque converter exceeds the set pressure, the oil in chamber (D) pushes piston (4), the reaction force of which moves torque converter relief valve (3) to the right to open port (C) and port (E). Then the oil in port (C) is drained from port (E) to the oil tank.
When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (B) pushes piston (2), the reaction force of which moves spool (1) to the left to open port (A) and port (C). Then the oil from the pump flows through port (C) into the torque converter.
D475A, D475ASD-5E0
23
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10 Structure, function and maintenance standard
Operation of lockup solenoid valve and lockup selector valve When traveling in torque converter range
q
q
q
24
While the machine is in the “torque converter range”, the lockup solenoid valve is “de-energized” and therefore plunger (1) is pushed back upward by the oil pressure from the pump. As the seats of valve (2) and ball (3) are opened, the drain circuit of port (B) is opened and the oil in port (A) and port (C) is drained. Lockup selector valve (5) is pushed back to the right by the tension of spring (6). As a result, the passages between port (D) and port (F) and between port (E) and port (G) are closed, while the passages between port (D) and port (E) and between port (F) and port (H) are opened.
q
q
The oil from the pump flows through port (D) into port (E) and applies back pressure to stator clutch piston (7). It turns “engaged” the stator clutch as the oil pressure in the circuit is raised. At the same time, the oil which applied back pressure to lockup clutch piston (8) is drained through port (F) into port (H) to turn the lockup clutch “disengaged”. The oil from the pump flows into port (A) and port (D). The oil in port (A) is drained as the lockup solenoid valve is “de-energized”, while the oil pressure in port (D) is secured by orifice (a) and adjusted by modulating valve (9).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
When traveling in direct range
q
q
q
While the machine is in the “direct range”, the lockup solenoid valve is “energized” and therefore plunger (1) moves downward. As the seats of valve (2) and ball (3) are closed, the drain circuit of port (B) is closed and the oil in port (A) flows to port (C) The oil from port (C) pushes piston (4) to move lockup selector valve (5) to the left. As a result, the passages between port (D) and port (E) and between port (F) and port (H) are closed, while the passages between port (D) and port (F) and between port (E) and port (G) are opened.
D475A, D475ASD-5E0
q
q
The oil from the pump flows through port (D) into port (F) and applies back pressure to stator clutch piston (8). It turns the lockup clutch “engaged” as the oil pressure in the circuit is raised. At the same time, the oil which had applied back pressure to stator clutch piston (7) is drained through port (E) into port (G) to turn the stator clutch “disengaged”. The pressure of the oil which flows from the pump into port (D) is adjusted by modulating valve (10).
25
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10 Structure, function and maintenance standard
Modulating valve Outline q The modulating valve is located between the lockup selector valve and the inlet of each clutch. q When each clutch is turned “engaged”, it raises the oil pressure applied to the piston gradually to the set pressure to engage the clutch smoothly and to reduce the shock given to the torque converter and transmission. a Though the following explanation on operation takes the modulating valve for the stator clutch as an example, the modulating valve for the lockup clutch also operates in a similar way. However, please note that the oil flow into the clutches in the torque converter range and in the direct range is opposite in direction. Operation When traveling in torque converter range q While the machine is in the “torque converter range”, lockup solenoid valve (1) is “de-energized” and the oil from the pump and the oil in port (B) are drained. q Lockup selector valve (2) is pushed back to the right by the tension of spring (3). Then the passages between port (A) and port (E) and between port (D) and port (G) are closed, while the passage between port (A) and port (D) is opened. As a result, the circuit is connected through modulating valve (5) to stator clutch (9). q The oil from the pump flows through port (A) into stator clutch (9), and the oil pressure in the circuit starts rising. q If the oil pressure in the circuit rises, the oil flowing through orifice (a) of modulating valve (5) pushes piston (6), the reaction force of which moves modulating valve (5) to the left to throttle part (C). q Port (D) is connected to port (F) which applies back pressure to load piston (7). Load piston (7) is pushed to the right to retract spring (8), the tension of which opens part (C). q By repeating the above operation intermittently, load on spring (8) increases and the oil pressure rises gradually. Ultimately, modulating valve (5) stops at the position where it closed part (C). Rise in the oil pressure is completed and stator clutch (9) is completely turned “engaged”.
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D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
When traveling in direct range q While the machine is in the “direct range”, the lockup solenoid valve is “energized” to let the oil from the pump flow into port (B). q The oil pressure in port (B) becomes higher than the tension of spring (3) and pushes piston (4) to move lockup selector valve (2) to the left. As a result, the passage between port (A) and port (D) is closed and the passage between port (D) and port (G) is opened. q By reducing the oil pressure in port (D), modulating valve (5) is pushed back to the right by the tension of spring (8), and fully opens part (C). At this time, the operating pressure of stator clutch (9) is drained from port (D) to port (G), and the stator clutch is turned “disengaged”. q The oil from the pump flows through port (A) to port (E), and lockup clutch (10) is turned “engaged”.
D475A, D475ASD-5E0
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10 Structure, function and maintenance standard
Torque converter lockup control system
1
System diagram
Operation q The torque converter lockup control system controls the lockup operation of the torque converter automatically with a sensor signal and the controller in it according to the load on the machine. When the torque converter is locked up, the pilot lamp on the machine monitor lights up. q The signal of the transmission outlet speed sensor is input to the transmission controller. q The lockup mode is set with the mode selection panel. q The machine controller receives the gear speed information from the transmission controller and the transmission outlet speed sensor signal from the shoe slip controller and turns ON and OFF the lockup system by connecting and disconnecting the lockup solenoid and pilot lamp to and from the chassis ground. a As for the details of the valve, refer to section “Torque converter valve”.
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D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Scavenging pump
SEN00211-01
1
Type: BAR(3)63+320
A: B: C:
Suction port from torque converter Suction port from steering unit Discharge port
1. 2.
Front pump Rear pump
Outline q The scavenging pump is installed to the PTO case and driven by the power from the engine. q Front pump (1) sucks the oil collected in the torque converter case through the filter and returns it to the power train oil pan. q Rear pump (2) sucks the oil collected in the steering case and returns it to the power train oil pan. Specifications Type Nominal delivery amount (cc/rev)
D475A, D475ASD-5E0
Tandem gear pump Front
63.3
Rear
319.4
Maximum discharge pressure (MPa {kg/cm2})
0.98 {10}
Maximum speed (rpm)
1,997
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10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Transmission control
SEN00211-01
1
a a
PCCS: Abbreviation for Palm Command Control System For steering operation concerned to operation of the Palm Command Control System lever (PCCS lever), see “Steering and brake control”.
1. 2. 3.
Brake pedal Lock lever PCCS lever (Forward-Reverse, Gear shift) Transmission neutral switch Cable Transmission control valve UP switch (Gear is shifted up each time this switch is pressed.) DOWN switch (Gear is shifted down each time this switch is pressed.)
4. 5. 6. 7.
8.
D475A, D475ASD-5E0
Lever positions A: Neutral B: Forward C: Reverse D: Free E: Lock Outline q The transmission is controlled with PCCS lever (3). The PCCS lever is used to select the travel direction and shift the gear. q Since the safety mechanism is employed, transmission neutral switch (4) does not work and the engine does not start unless lock lever (2) is in the FREE position (D).
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Transmission
32
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
A: B: C: D: E: F: G: H: J: K: L: M: N: P: dr:
To transmission lubrication circuit To priority valve To scavenging pump (from steering case) From scavenging pump (to transmission oil pan) From power train oil filter To lubricating oil relief valve From 1st clutch ECMV From 2nd clutch ECMV From F clutch ECMV From 3rd clutch ECMV From R clutch ECMV Air vent (from steering case) To steering control valve From steering case (to scavenging pump) Drain
1. 2. 3. 4.
Transmission input shaft Transmission control valve Front case Rear case
D475A, D475ASD-5E0
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10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
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.
Front cover R sun gear (number of teeth: 32) R ring gear (hub) (number of internal teeth: 89) Pinion shaft R planetary pinion (number of teeth: 25) R ring gear (number of teeth: 82) Pinion shaft F ring gear (number of internal teeth: 89) F planetary pinion (number of teeth: 25) F sun gear (number of teeth: 39) 3rd ring gear (number of internal teeth: 89) 3rd planetary pinion (number of teeth: 25) 3rd sun gear (number of teeth: 39) 2nd ring gear (number of internal teeth: 89) 2nd planetary pinion (number of teeth: 21) 2nd sun gear (number of teeth: 47) Pinion shaft 1st clutch inner drum Output shaft Collar Drive shaft (for sensor) 1st clutch piston housing 1st clutch piston 2nd carrier 2nd clutch piston 2nd clutch piston housing F and 3rd carrier 3rd clutch piston F and 3rd clutch piston housing F clutch piston R carrier R clutch piston housing R clutch piston Tie rod pin Washer spring Clutch spring Clutch plate Clutch disc
SEN00211-01
Outline q The transmission adopted is a “forward 3-gear speed and reverse 3-gear speed” transmission which consists of the planetary gear mechanisms and the disc clutches. q Out of the 5 sets of planetary gear mechanisms and disc clutches, 2 clutches are fixed hydraulically by the operation of ECMV to select 1 rotation direction and 1 speed. q The transmission transmits the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-3rd or reverse 1st-3rd) by any combination of the F, R clutches and 3 speed clutches.
Number of plates and discs used Clutch No.
Number of plates
Number of discs
R clutch
6
7
F clutch
6
7
3rd clutch
4
5
2nd clutch
3
4
1st clutch
5
6
Combinations of clutches at respective gear speeds and reduction ratio Gear speed
Clutch used
Reduction ratio
Forward 1st speed
F × 1st
3.282
Forward 2nd speed
F × 2nd
1.789
Forward 3rd speed
F × 3rd
1.000
Neutral
1st (*)
—
Reverse 1st speed
R × 1st
2.563
Reverse 2nd speed
R × 2nd
1.397
Reverse 3rd speed
R × 3rd
0.781
*: Filled with oil at low pressure. (Except for low temperature and abnormal conditions.)
D475A, D475ASD-5E0
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10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Unit: mm No.
Check item
Criteria Standard size
1
R clutch spring (12 pcs.)
Remedy Repair limit
Free length
Installed length
Installed load
Free length
Installed load
100.0
90.0
140.5 N {14.3 kg}
94.0
119.6 N {12.2 kg}
2
F clutch spring (12 pcs.)
100.0
94.0
84.3 N {8.5 kg}
94.0
70.6 N {7.2 kg}
3
3rd clutch spring (12 pcs.)
84.0
72.0
150.5 N {15.4 kg}
79.0
128.5 N {13.1 kg}
4
2nd clutch spring (12 pcs.)
81.7
63.0
119.1 N {12.2 kg}
76.8
102.0 N {10.4 kg}
5
1st clutch spring (12 pcs.)
103.5
76.0
238.7 N {24.4 kg}
97.3
203.0 N {20.7 kg}
6
Total assembled thickness of 7 discs and 6 plates of R clutch
Standard size
Tolerance
Repair limit
72.6
±0.36
68.9
7
Total assembled thickness of 7 discs and 6 plates of F clutch
72.6
±0.36
68.9
8
Total assembled thickness of 5 discs and 4 plates of 3rd clutch
50.2
±0.30
47.5
9
Total assembled thickness of 4 discs and 3 plates of 2nd clutch
39.0
±0.26
36.9
10
Total assembled thickness of 6 discs and 5 plates of 1st clutch
61.4
±0.43
58.2
5.4
±0.1
4.9
5.4
±0.15
4.9
5.8
±0.1
5.2
Width
3.0
–0.01 –0.03
2.70
Thickness
4.0
±0.12
3.85
Width
4.0
–0.01 –0.03
3.60
Thickness
5.0
±0.15
4.85
Width
4.0
–0.01 –0.03
3.60
Thickness
5.0
±0.15
4.85
Width
6.0
–0.01 –0.03
5.50
Thickness
6.8
±0.15
6.65
Width
4.0
–0.01 –0.04
3.60
Thickness
5.0
±0.15
4.85
Width
4.0
–0.01 –0.04
3.60
Thickness
4.0
±0.15
3.85
F, R,
11 Thickness of clutch disc 2nd, 3rd 1st
12 Thickness of clutch plate 13
14
15
16
17
18
Wear of seal ring (1 place)
Wear of seal ring (4 places)
Wear of seal ring (2 places)
Wear of seal ring (2 places)
Wear of seal ring (1 place)
Wear of seal ring (3 places)
Replace
Backlash between 19 sun gear and planetary pinion
0.16 – 0.35
Backlash between planetary pinion and ring gear
0.18 – 0.38
20
D475A, D475ASD-5E0
37
SEN00211-01
10 Structure, function and maintenance standard
Disc clutch Structure
q
q q
The disc clutch consists of piston (2), plates (3), discs (4), pin (5), return spring (6) etc. to fix ring gear (1). Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). Plate (3) is assembled to clutch housing (7) with pin (5).
Operation When clutch is “engaged” (fixed)
q
q
q
The oil from ECMV is sent with pressure to the rear side of piston (2) through the oil passage of housing (7) and pushes piston (2) leftward. Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them. Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), move of ring gear (1) is stopped.
When clutch is “disengaged” (released)
q q
38
As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6). Plate (3) and disc (4) are released from the frictional force and ring gear (1), as the result, is also released.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Power transmitting route Forward 1st speed
q
q
q
q
When the transmission is set to the forward 1st speed, the F clutch and 1st clutch are engaged. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The F clutch is actuated by the oil pressure applied to the F clutch piston, and fixes F ring gear (4). The 1st clutch is actuated by the oil pressure applied to the 1st clutch piston, and fixes 1st clutch inner drum (16). The power from the torque converter is transmitted to F planetary pinion (3) through input shaft (1) and F sun gear (2). As F ring gear (4) is fixed by the F clutch, the power transmitted to F planetary pinion (3) rotates F and 3rd carrier (10) located inside of F ring gear (4).
D475A, D475ASD-5E0
q
q
q
The rotation of F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) to 3rd ring gear (12). 3rd ring gear (12) and 2nd carrier (13) are meshed with each other and rotate integrally. Accordingly, the rotation of 3rd ring gear (12) is transmitted through 2nd carrier (13) to 1st clutch piston housing (14). As 1st clutch inner drum (16) is fixed by the 1st clutch, the power transmitted to 1st clutch piston housing (14) is transmitted through 1st clutch inner drum (16) to output shaft (20).
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10 Structure, function and maintenance standard
Forward 2nd speed
q
q
q
q
40
When the transmission is set to the forward 2nd speed, the F clutch and 2nd clutch are engaged.The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The F clutch is actuated by the oil pressure applied to the F clutch piston, and fixes F ring gear (4). The 2nd clutch is actuated by the oil pressure applied to the 2nd clutch piston, and fixes 2nd ring gear (17). The power from the torque converter is transmitted to F planetary pinion (3) through input shaft (1) and F sun gear (2). As F ring gear (4) is fixed by the F clutch, the power transmitted to F planetary pinion (3) rotates F and 3rd carrier (10) located inside of F ring gear (4).
q
q
q
The rotation of F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) to 3rd ring gear (12). 3rd ring gear (12) and 2nd carrier (13) are meshed with each other and rotate integrally. Accordingly, the rotation of 2nd carrier (13) is transmitted to 2nd planetary pinion (15). As 2nd ring gear (17) is fixed by the 2nd clutch, the power transmitted to 2nd planetary pinion (15) is transmitted through 2nd sun gear (18) to output shaft (20).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00211-01
Forward 3rd speed
q
q
q
q
When the transmission is set to the forward 3rd s p e ed , t h e F c l u t c h a n d 3 r d c lu t c h ar e engaged. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The F clutch is actuated by the oil pressure applied to the F clutch piston, and fixes F ring gear (4). The 3rd clutch is actuated by the oil pressure applied to the 3rd clutch piston, and fixes 3rd ring gear (12). The power from the torque converter is transmitted to F planetary pinion (3) through input shaft (1) and F sun gear (2). As F ring gear (4) is fixed by the F clutch, the power transmitted to F planetary pinion (3) rotates F and 3rd carrier (10) located inside of F ring gear (4).
D475A, D475ASD-5E0
q
As 3rd ring gear (12) is fixed by the 3rd clutch, the power transmitted to F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) and 3rd sun gear (19) to output shaft (20).
41
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10 Structure, function and maintenance standard
Reverse 1st speed
q
q
q
q
42
When the transmission is set to the reverse 1st s p e e d , t h e R c l u t c h a n d 1 s t c lu t c h a r e engaged. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The R clutch is actuated by the oil pressure applied to the R clutch piston, and fixes ring gear (7). The 1st clutch is actuated by the oil pressure applied to the 1st clutch piston, and fixes 1st clutch inner drum (16). The power from the torque converter is transmitted to R planetary pinion (6) through input shaft (1) and R sun gear (5). Ring gear (7) and R carrier (8) are meshed with each other and fixed by the R clutch. Accordingly, the rotation of R planetary pinion (6) rotates R ring gear (9). The rotation of R ring gear (9), the direction of which is opposite to that of input shaft (1), rotates F and 3rd carrier (10).
q
q
q
The rotation of F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) to 3rd ring gear (12). 3rd ring gear (12) and 2nd carrier (13) are meshed with each other and rotate integrally. Accordingly, the rotation of 3rd ring gear (12) is transmitted through 2nd carrier (13) to 1st clutch piston housing (14). As 1st clutch inner drum (16) is fixed by the 1st clutch, the power transmitted to 1st clutch piston housing (14) is transmitted through 1st clutch inner drum (16) to output shaft (20).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00211-01
43
SEN00211-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN00211-01
© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (01)
44
SEN00212-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Power train, Part 2 Transmission control valve.............................................................................................................................. 2 Transmission clutch ECMV ............................................................................................................................. 4 Priority valve ................................................................................................................................................... 8 Lubricating oil relief valve.............................................................................................................................. 10 Torque converter, power train, lubricating oil pump .......................................................................................11 Steering, brake control .................................................................................................................................. 12 Final drive ..................................................................................................................................................... 14 Sprocket ........................................................................................................................................................ 18 Steering unit .................................................................................................................................................. 21 Steering control valve.................................................................................................................................... 32 Steering clutch ECMV, Steering brake ECMV............................................................................................... 34 Parking brake valve ...................................................................................................................................... 40 Sudden stop prevention valve....................................................................................................................... 42
D475A, D475ASD-5E0
1
SEN00212-02
Transmission control valve
2
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
PF: F clutch oil pressure pickup port (FWD) PR: R clutch oil pressure pickup port (REV) P1: 1st clutch pressure pickup port (1ST) P2: 2nd clutch pressure pickup port (2ND) P3: 3rd clutch pressure pickup port (3RD) PV: To priority valve LV: To lubricating oil relief valve LD: Drain (from lubricating oil relief valve) CF: To F clutch CR: To R clutch C1: To 1st clutch C2: To 2nd clutch C3: To 3rd clutch dr: Drain
1. 2. 3. 4. 5. 6. 7. 8. 9.
SEN00212-02
Operation table of ECMV ECMV Gear speed
F
Forward 1st
Q
Forward 2nd
Q
Forward 3rd
Q
R
2nd
3rd
Q Q Q
Reverse 1st
Q
Reverse 2nd
Q
Reverse 3rd
Q
* Neutral
1st
Q Q Q Q
*: Filled with oil at low pressure. (Except for low temperature and abnormal conditions.)
Filter Priority valve Lubricating oil relief valve 1st clutch ECMV 2nd clutch ECMV 3rd clutch ECMV F clutch ECMV R clutch ECMV Valve seat
D475A, D475ASD-5E0
3
SEN00212-02
Transmission clutch ECMV
10 Structure, function and maintenance standard
1
a a
ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: P: T: Dr: P1:
To clutch From pump Drain Drain Clutch oil pressure pickup port
1. 2. 3. 4. 5. 6. 7.
Fill switch connector Proportional solenoid connector Flow rate pickup valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1)
4
*1: Clutch used
Stamp of the nameplate
F, R, 1st, 2nd, 3rd
A*******
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.
SEN00212-02
ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current – propulsion force characteristics of proportional solenoid
Propulsion force – Hydraulic pressure characteristics of proportional solenoid
Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a
ECMV and fill switch q For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned “ON” by the pressure of the clutch. The oil pressure is built up according to this signal.
The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “ON” during triggering (Range D).
D475A, D475ASD-5E0
5
SEN00212-02
Operation of ECMV q ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.
10 Structure, function and maintenance standard
Before shifting gear (when draining) (Range A in chart)
q
Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a
6
Under the condition where any current is not sent to proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). Also at this time, fill switch (5) is turned “OFF” because oil pressure is not applied to pressure detection valve (4).
The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned “ON” during triggering (Range D).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
During filling (Range B in chart)
q
If current is applied to proportional solenoid (1) with no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. This opens pump port (P) and clutch port (A) to feed oil in the clutch. When the clutch is filled with oil, pressure detection valve (4) actuates to turn “ON” fill switch (5).
D475A, D475ASD-5E0
SEN00212-02
Pressure regulation (Range C in chart)
q
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the tension of pressure control valve spring (2), and then the pressure is settled.
7
SEN00212-02
10 Structure, function and maintenance standard
Priority valve
1
Unit: mm No.
1
Check item
Clearance between spool and valve body
Criteria Standard size 22
Tolerance Shaft
Hole
Standard clearance
Clearance limit
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.078
Standard size
2
3. 4. 5.
8
Return spring
Valve body Spool Piston
Remedy
Replace
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
38.8
28.5
84.7 kN {8.6 kg}
37.6
80.4 kN {8.2 kg}
Outline q The priority valve is installed in the circuit between the pump and the clutch ECMV. When shifting the gear, even if the oil pressure in the transmission circuit decreases sharply, the priority valve disconnects the transmission circuit and pilot circuit and keeps the oil pressure to the set pressure so that the decrease of the brake oil pressure and stator clutch oil pressure can be prevented during the gear shifting operation. Set pressure: 1.56 MPa {16 kg/cm2}
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Operation from start to finish of gear shifting
q q
q
q
The oil from the pump flows through port (A) and orifice (a) to chamber (C). If the oil flow from the pump increases and the oil pressure rises, the oil in chamber (C) pushes piston (1). Then, the reaction force of piston (1) compresses spring (2) and moves valve (3) to the left. If valve (3) moves, port (A) and port (B) are connected and the oil from the pump flows through port (B) to the ECMV. The oil pressure at this time is the set pressure of the priority valve. Then, the oil pressure transmitted from port (B) to the ECMV rises to the set pressure of the clutch.
D475A, D475ASD-5E0
SEN00212-02
Operation right after finishing of gear shifting
q
q
q
If the gear shift lever is operated, the oil pressure in port (B) decreases sharply nearing 0 MPa {0 kg/cm2} as a result of the ECMV operation. Then, the oil pressure in port (A) also decreases, but valve (3) is pushed back to the right by the tension of spring (2). As a result, the oil pressure in port (A) (pilot pressure) is kept to the set pressure.
9
SEN00212-02
10 Structure, function and maintenance standard
Lubricating oil relief valve
1
Unit: mm No.
1
Check item
Clearance between spool and valve body
Criteria Standard size 22
Tolerance Shaft
Hole
Standard clearance
Clearance limit
–0.035 –0.045
+0.013 0
0.035 – 0.058
0.078
Standard size
2
3. 4. 5.
10
Return spring
Remedy
Replace
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
68.5
37
91.9 N {9.37 kg}
66.5
87.3 N {8.9 kg}
Lubricating oil pressure pickup port Spool Valve body
Outline q The lubricating oil relief valve is installed to the transmission control valve. It keeps the lubricating oil circuit below the set pressure. Set pressure: 0.26 MPa {2.7 kg/cm2}
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
Torque converter, power train, lubricating oil pump
1
Type: BAL(4)160+(4)160+(4)112
Unit: mm No.
Check item
Criteria Type
1
Side clearance
BAL(4)160 BAL(4)112
2
Clearance between plain bearing inner diameter and gear shaft
BAL(4)160
3
Depth to knock in pin
BAL(4)160
BAL(4)112 Type
BAL(4)112
4
Clearance limit
0.04 – 0.10
0.13
0.060 – 0.145
0.20 Tolerance
Repair limit
14
0 –0.5
—
5.9 Nm {0.6 kgm}
Type
Speed (rpm)
Discharge pressure (MPa{kg/ cm2})
Standard delivery amount (l/min)
Delivery amount limit (l/min)
BAL(4)160
2,000
2.94 {30}
288
266
BAL(4)112
2,000
2.94 {30}
205
188
5. 6. 7.
Lubricating oil pump Power train pump Torque converter pump
A: B: C: D:
Suction port Lubricating oil pump discharge port Power train pump discharge port Torque converter pump discharge port
D475A, D475ASD-5E0
Replace
Standard size
Rotating torque of spline shaft
Delivery amount — Oil: SAE10WCD Oil temperature: 45 – 55 °C
Remedy
Standard clearance
—
Outline q The torque converter pump, power train pump and lubricating oil pump are installed to the PTO case. They are driven by the power from the engine to supply the oil pressure to the torque converter, transmission and steering unit.
11
SEN00212-02
Steering, brake control a a
12
10 Structure, function and maintenance standard
1
PCCS: Abbreviation for Palm Command Control System Regarding the transmission related description of operation of the PCCS lever, refer to “Transmission control”.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Brake pedal Lock lever PCCS lever (Steering) Limit switch Steering ECMV Brake valve Parking brake lever (From lock lever) Cable Rod (From brake pedal) Potentiometer Steering controller Transmission controller Engine controller
Positions of lever and pedal A: Neutral B: Forward straight-travel C: Reverse straight-travel D: Left clutch OFF E: Left clutch OFF Left brake ON F: Right clutch OFF G: Right clutch OFF Right brake ON H: Brake RELEASE J: Brake ON K: Free L: Lock
D475A, D475ASD-5E0
SEN00212-02
Outline q PCCS lever (3) sends an electric signal to steering controller (11). After receiving it, steering controller (11) sends a proportional current to steering ECMV (5) to operate the steering clutch and brake. q The brake pedal (1) sends a proportional current to steering controller (11) through potentiometer (10) to operate the brake. In this case, the right and left brakes operate at the same time to activate braking. Rod (9) operates the brake through brake valve (6) for emergency brake activation. (Only at the time of complete braking) q If you slightly tilt PCCS lever (3) towards the left, the left steering clutch is partially disengaged, causing the machine to make a slow left turn. q If you completely tilt PCCS lever (3) towards the left, the left steering clutch is turned “disengaged” and the left steering brake is turned “engaged”, causing the machine to make a sudden left turn. q Lock lever (2) is connected to parking brake lever (7) and it also serves as a parking brake.
13
SEN00212-02
Final drive
10 Structure, function and maintenance standard
1
Outline q 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. q 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.
14
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Floating seal Sun gear Carrier Hub Cover Sprocket hub Sprocket teeth Floating seal guard Cover Planetary pinion
D475A, D475ASD-5E0
SEN00212-02
11. 12. 13. 14. 15. 16. 17. 18. 19.
Ring gear Cover No. 1 gear No. 1 gear hub No. 1 pinion Final drive case Bearing cage Shaft Wear guard
15
SEN00212-02
10 Structure, function and maintenance standard
Unit: mm No.
20
Check item Backlash between No.1 pinion and No.1 gear
Criteria
Remedy
Standard clearance
Clearance limit
0.26 – 0.96
0.96
21
Backlash between sun gear and planet pinion
0.25 – 0.70
0.70
22
Backlash between planetary pinion and ring gear
0.26 – 0.83
0.83
Outside diameter of No.1 pinion oil seal contact surface
Standard size
Repair limit
23
120.0
119.9
24
Thickness of thrust collar of inner body roller bearing
24.8
24.75
25
Thickness of thrust coller of No.1 gear boss roller bearing
14.0
13.95
26
Dimensions from cover mounting face to button head
72
70.5
27
Clearance between planetary pinion shaft and carrier (small end)
Replace
Tolerance Shaft
Hole
Standard clearance
Clearance limit
110
–0.035 –0.054
–0.024 –0.059
–0.024 – 0.030
0.030
135
–0.035 –0.054
–0.067 –0.107
–0.072 – –0.013
–0.013
Standard size
28
Clearance between planetary pinion shaft and carrier (large end)
29
Standard shim thickness for No.1 pinion bearing cage
2
30
Dimension of end face of final drive cover and end face of bearing
7.3 – 8.3
31
Clearance of floating seal guard
3.1 – 4.7
32
Wear of wear guard
16
Adjust
Standard size
Repair limit
47.5
17
Rebuild or replace
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
Path of power transmission
q
The power from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (15). It then passes through No. 1 gear (13), which is meshed with the No. 1 pinion, and is transmitted to sun gear (2) to rotate it. The rotation of sun gear (2) is transmitted to planetary pinion (10), but ring gear (11), which is meshed with the planetary pinion, is fixed to cover (9), so the planetary pinion rotates on its own axis and moves around the sun gear along the ring gear.
D475A, D475ASD-5E0
Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports the planetary pinion, and is transmitted to sprocket hub (6). The rotation direction of carrier (3) is the same as sun gear (2). The rotating force transmitted to sprocket hub (6) is transmitted to sprocket teeth (7).
17
SEN00212-02
10 Structure, function and maintenance standard
Sprocket
1
Unit: mm No.
1 2
18
Check item
Criteria
Remedy
Standard size
Repair limit
486
470
32.5
26.5
Wear of tooth tip Thickness of tooth root
Replace or overlaying welding
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
Full-scale drawing of sprocket tooth profile
D475A, D475ASD-5E0
19
SEN00212-02
20
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Steering unit
A: B: C: D: E: F: G:
1
To steering control valve Air vent (To transmission case) To scavenging pump To pin puller solenoid valve From pin puller solenoid valve From power train oil cooler Torque converter output speed sensor mounting port PLC: L.H. steering clutch oil pressure pickup port (LC) PLB: L.H. steering brake oil pressure pickup port (LB) PRC: R.H. steering clutch oil pressure pickup port (RC) PRB: R.H. steering brake oil pressure pickup port (RB) D475A, D475ASD-5E0
SEN00212-02
1. 2. 3. 4. 5.
Transmission Steering control valve Steering unit Breather Drain plug
21
SEN00212-02
22
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Output shaft Sleeve Pin Clutch piston Pin Clutch plate Clutch disc Stopper Clutch hub Clutch cage Flange Bevel gear (number of teeth: 37) Cage Steering shaft Clutch spring Housing Stopper Brake plate Brake disc
D475A, D475ASD-5E0
SEN00212-02
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Brake hub Brake cage Brake piston Brake spring Case Input shaft Drive shaft Drive gear (number of teeth: 27) Transmission output speed sensor Case Cage Torque converter output speed sensor Cage Drum Cover Cage Driven gear (number of teeth: 30) Bevel pinion (number of teeth: 22)
23
SEN00212-02
10 Structure, function and maintenance standard
Outline Transfer q The transfer transmits the output power from the transmission to the bevel pinion with reduced speed. q The transfer consists of input shaft (30) meshed with the transmission output shaft, drive gear (32), driven gear (41) and bevel pinion (42). Bevel gear shaft q The bevel gear shaft changes the direction of the power transmitted to the bevel pinion by a right angle to the left-and-right direction by using a bevel pinion and a bevel gear, and also decelerates the output speed. q The bevel gear shaft has spiral gears for a bevel pinion and a bevel gear, and adopts the forced lubrication by the pressurized oil for the lubrication. q The bevel gear shaft consists of bevel gear (17) meshed with the bevel pinion, steering shaft (19) and the bearing to support the steering shaft. Steering clutch The steering clutch is connected to the bevel gear shaft through the spline. It transmits and cuts out the power from the bevel gear shaft to the final drive to change the turning direction of the machine. q The steering clutch has a wet-type multipledisc hydraulic clutch and is driven hydraulically, together with the brake by the steering control valve operated with the PCCS lever. q As for the lubrication, the steering clutch adopts the forced lubrication system where the oil from the power train lubricating pump is sent through the hydraulic circuit in the steering case to the cage and hub, and eventually to the discs and plates. q The steering clutch consists of hub (14) connected to the bevel gear shaft by the spline, discs (12) engaged with the hub, plates (11) whose periphery is fixed to housing (21) by pin (10), housing (21), piston (9) to press the discs and the plates against each other and cage (15), and the bearing to support these parts. And as housing (21) is connected to hub (25), the power from the bevel gear shaft is transmitted to output shaft (6) through hub (25). q
24
Steering brake q The steering brakes are connected to the L.H. and R.H. steering clutch respectively. They control the power transmitted from the steering clutches to the final drive to change the turning direction of the machine and to brake the machine. q The steering brakes have wet-type multipledisc hydraulic clutches and are driven hydraulically together with the clutches by the brake pedal and steering control valve operated with the PCCS lever. q As for the lubrication, the steering brakes adopt the forced lubrication system where the oil from the power train lubricating pump is sent through the hydraulic circuit in the steering case to the cage, and eventually to the discs and plates. q While the engine is stopped, even if the brake pedal is not depressed, the back pressure of the brake piston decreases and the steering brakes become “applied”. When restarting the engine, if the parking brake lever is not in “locked” position, the engine does not start. q The steering brakes consist of hub (25) connected to housing (21), discs (24) engaged with the hub, plates (23) fixed to piston (27) by pin (8), piston (27) to press the discs and plates against each other, cage (26) to support these parts, case (29), the bearing and output shaft (6) connected to the hub by the spline. And piston (27) and case (29) are fixed to the steering case.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00212-02
25
SEN00212-02
26
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
Unit: mm No.
1
Check item
Brake plate
Criteria Standard size
Tolerance
Repair limit
Thickness
4.2
±0.1
3.8
Strain
—
Max. 0.3
0.4
Thickness
5.4
±0.1
4.3
Replace
Strain
—
Max. 0.3
0.4
Repair or replace
82.2
±0.41
72.6
4.2
±0.1
3.8
2
Brake disc
3
Total assembled thickness of 8 brake plates and 9 discs
4
Remedy
Thickness Clutch plate
Repair or replace
Strain
—
Max. 0.3
0.4
Repair or replace
5.4
±0.1
4.5
Replace
Strain
Repair or replace
Clutch disc
—
Max. 0.4
0.5
6
Total assembled thickness of 8 clutch plates and 8 discs
76.8
±0.40
69.3
7
Inside diameter of seal ring contact surface of sleeve
190
+0.046 0
190.5
Large diameter parts
350
+0.089 0
350.1
Small diameter parts
300
+0.052 0
300.1
Large diameter parts
350
+0.089 0
350.1
Small diameter parts
300
+0.052 0
300.1
8
9
Inside diameter of seal ring contact face of clutch piston
Replace
Thickness
5
Inside diameter of seal ring contact surface of brake piston
Standard size
10 Brake spring
11 Clutch spring
Clearance between bevel gear 12 and reamer bolt
Repair limit
Free length
Installed length
Installed load
Free length
Installed 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
52.96 kN {5,400 kg}
Standard size
Shaft
Hole
Standard clearance
Clearance limit
+0.023 +0.002
+0.033 0
–0.023 – 0.031
Max. 0.031
20
Tolerance
Standard clearance
Clearance limit
0.4 – 0.7
1.0
Backlash between clutch hub and disc
0.4 – 0.7
1.0
15
Backlash between bevel pinion and bevel gear
0.30 – 0.40
0.75
16
Preload of bevel gear shaft taper roller bearing
17
Standard shim thickness of bearing cage
13
Backlash between brake hub and disc
14
D475A, D475ASD-5E0
Replace
Replace
Adjust or replace
Standard rotating torque: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
(When bevel pinion and gear are not meshed: 51 – 61.8 Nm {5.2 – 6.3 kgm} at bevel gear end) 2.0
Adjust
Adjust shim
27
SEN00212-02
10 Structure, function and maintenance standard
Unit: mm No.
Check item
18 Backlash between transfer gears 19
Thickness of collar between transfer gear and bearing
20
Standard shim thickness of bearing cage
28
Criteria
Remedy
Standard clearance
Clearance limit
0.26 – 0.67
0.75
Standard size
Tolerance
Repair limit
19.3
±0.1
18.9
2.0
Adjust or replace
Replace Adjust shim
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
Operation of steering clutch When steering clutch is turned “engaged”
q
q
q
q
When the PCCS lever is in the “neutral” position, the oil in the back side of clutch piston (1) is drained by the steering control valve. At this time, clutch piston (1) is pushed back to the right by the tension of clutch spring (2) to press discs (3) and plates (4) against stopper (5). The power from steering shaft (6) is transmitted through clutch hub (7), pressed discs (3) and plates (4) to housing (8). Since housing (8) is connected to brake hub (9) and output shaft (10), the power is transmitted through output shaft (10) to the final drive.
When steering clutch is turned “disengaged”
q
q
q
q
q
D475A, D475ASD-5E0
If the PCCS lever is operated to the left or right, the oil pressure is applied to the back of clutch piston (1) by the steering control valve. As the oil pressure rises, clutch piston (1) compress clutch spring (2) and moves to the left to eliminate the pressing force between discs (3) and plates (4). The power from steering shaft (6) is not transmitted after housing (8) and accordingly is not transmitted to the final drive. If the PCCS lever is released, the oil in the back side of clutch piston (1) is drained by the steering control valve, thus the steering clutch is turned “engaged”. If the L.H. steering clutch is turned “disengaged”, the power is transmitted only to the R.H. steering clutch, and consequently the machine turns to the left.
29
SEN00212-02
10 Structure, function and maintenance standard
Operation of steering brake When steering brake is “released”
q
q
q
When the PCCS lever is in the “neutral” position and the brake pedal is released, the steering control valve only sets the brake pressure to the maximum. Accordingly, the steering clutch is turned “engaged” and the oil pressure is applied to the back of brake piston (1). As the oil pressure rises, brake piston (1) compresses brake spring (2) and moves to the left to eliminate the pressing force between discs (3) and plates (4). The power transmitted from the steering shaft (6) through the steering clutch to brake hub (7) is further transmitted through output shaft (8) to the final drive.
When steering brake is “applied” (When PCCS lever is “operated”)
q
q
q q
q
30
If the PCCS lever is operated to the left or right, the steering control valve turns the steering clutch “disengaged” and the oil in the back side of piston (1) starts to be drained. At this time, brake piston (1) is pushed back to the right by the tension of brake spring (2) to press discs (3) and plates (4) against stopper (5). Brake piston (1) and stopper (5) are fixed to the steering case by the pin. Brake hub (7) and output shaft (8), which tend to rotate by the inertia force even after the steering clutch is turned “disengaged”, can be stopped by pressing discs (3) and plates (4) to each other. The turning radius and speed can be adjusted by the brake force controlled by the oil pressure in the back side of piston (1) according to the stroke of the PCCS lever to the left and right.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
When steering brake is “applied” (When PCCS lever is in “neutral” and brake pedal is “depressed”)
q
q
If the brake pedal is depressed while the PCCS lever is in the “neutral” position, the steering control valve starts to drain the oil in the back of brake piston (1). Then the steering brake operates with the steering clutch turned “engaged” and stops the rotation of output shaft (8). The brake force can be adjusted by controlling the oil pressure applied to the back side of brake piston (1) according to the stroke of the brake pedal.
D475A, D475ASD-5E0
31
SEN00212-02
Steering control valve
32
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
P: L: PS: LC: LL: LB: LBL:
From power train pump From power train oil cooler To pin puller solenoid valve To L.H. steering clutch To L.H. steering lubrication circuit To L.H. steering brake To L.H. bevel gear shaft bearing lubrication circuit RC: To R.H. steering clutch RL: To R.H. steering lubrication circuit RB: To R.H. steering brake RBL: To R.H. bevel gear shaft bearing lubrication circuit BPL: To bevel pinion bearing lubrication circuit DPS: From pin puller solenoid valve DLC: Drain (L.H. steering clutch) DLC: Drain (L.H. steering clutch pilot) DLB: Drain (L.H. steering brake) DRC:Drain (R.H. steering clutch) DRP: Drain (R.H. steering clutch pilot) DRB: Drain (R.H. steering brake) DB: Drain (Sudden stop prevention valve) DBP: Drain (Sudden stop prevention valve pilot) DPB: Drain (Parking brake)
1. 2. 3. 4. 5. 6. 7. 8.
Filter R.H. steering clutch ECMV L.H. steering clutch ECMV Sudden stop prevention valve R.H. steering brake ECMV L.H. steering brake ECMV Parking brake valve Valve seat
D475A, D475ASD-5E0
SEN00212-02
Outline q The steering control valve consists of 4 ECMV's installed on the valve seat, to control the steering clutch and steering brake. q The steering control valve is located in the circuit between the power train pump and pistons of the steering clutch and steering brake. It consists of 2 sets of the steering clutch ECMV (L.H. and R.H.) and 2 sets of the steering brake ECMV (L.H. and R.H.). q The steering control valve sends the oil from the power train pump to the steering clutch and steering brake to control each disc clutch. q If the PCCS lever is leaned to the right or left, the steering clutch is disengaged. The steering brake will operate by further leaning the PCCS lever. q The controller sends commands to each ECMV according to the right or left stroke of the PCCS lever and adjusts the gradual or sharp turns. q If the brake pedal is depressed, the controller sends commands to the steering brake ECMV according to the pedal stroke to apply the L.H. and R.H. brake, thus stopping the machine. q The controller, connected electrically to the PCCS lever and brake pedal operates the steering clutch and steering brake by controlling each ECMV. q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly, when an abnormality takes place in the electrical system. q When the parking brake lever is set in the “lock” position, the parking brake valve port is changed to drain the oil between the L.H. and R.H. steering brake ECMV and the brake piston to operate the brake. Also the parking brake valve is connected to the brake pedal by the linkage.
33
SEN00212-02
10 Structure, function and maintenance standard
Steering clutch ECMV, Steering brake ECMV
1
a a
ECMV: Abbreviation for Electronic Control Modulation Valve Don’t try to disassemble it since adjustment for maintaining the performance will be needed.
A: P: T: Dr: P1:
To clutch or brake From pump Drain Drain To clutch or brake pressure pickup port
1. 2. 3. 4. 5. 6. 7.
Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1)
34
*1: Clutch used
Stamp of the nameplate
Steering clutch, Steering brake
R*******
Outline q Each ECMV keeps the steering clutch oil pressure and steering brake oil pressure to the set pressure and furthermore changes the circuit to the piston chamber of the steering clutch and steering brake.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve A proportional solenoid in this valve receives a current sent from the steering controller and this valve converts it to an oil pressure. q Fill switch This is a switch to detect that a clutch or brake is filled with oil and has the following functions. 1. At the moment when the clutch or brake is filled with oil, the fill switch outputs the signal (fill signal) to the controller to notify the finishing of filling. 2. While the oil pressure is applied to the clutch or brake, the fill switch outputs the signal (fill signal) to the controller to notify the presence of the oil pressure. ECMV and proportional solenoid q One proportional solenoid is mounted for each ECMV. The propulsion force is generated according to the command current from the controller. The propulsion force generated by the proportional solenoid is actuated on the spool of the pressure control valve and generates the oil pressure. Accordingly, by controlling the amount of the command current, the propulsion force changes and the pressure control valve is actuated, then the oil flow and oil pressure is controlled. ECMV and fill switch For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned “engaged” by the pressure of the clutch. The oil pressure is built up according to this signal.
q
Operation of ECMV The ECMV is controlled by the command current from the controller to the proportional solenoid and the fill switch output signal.
q
D475A, D475ASD-5E0
35
SEN00212-02
10 Structure, function and maintenance standard
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in “free” position: Straight travel (L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “released”, and parking brake is “released”.)
q
q
q
q
36
When the PCCS lever is in “neutral” position and the brake pedal is “released”, proportional solenoid (1) of the clutch ECMV is de-energized and the sealing part of ball (2) is opened. The oil from the power train pump flows through port (Pc) of the clutch ECMV to orifice (a), then it is drained through the sealing part of ball (2). Valve (3) is moved to the right by the tension of spring (4) to disconnect port (Pc) from port (C), and connect port (C) with port (Dr). At this time, the oil from the back pressure port of the clutch piston is drained through port (C) and the clutch is turned “engaged” by the tension of the clutch spring. The oil pressure in the brake circuit, etc. is secured by orifice (a).
q
q
q
Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left to connect port (Pb) with port (B) and disconnect port (B) from port (Dr). At this time, the oil flows in the back pressure port of the brake piston. As the oil pressure rises, the brake piston is pushed to the left to compress the brake spring, then the brake is “released”. When the parking brake lever is in “free” position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
When PCCS lever is “operated to the left halfway”, brake pedal is “released”, and parking brake lever is in “free” position: Gradual left turn (L.H. clutch is turned “disengaged”, L.H. brake is “semi-released”, R.H. clutch is turned “engaged”, R.H. brake is “released”, and parking brake is “released”.)
q
q
q
q
When the PCCS lever is “operated to left halfway” and the brake pedal is “released”, proportional solenoid (1) of the L.H. clutch ECMV is energized and the sealing part of ball (2) is closed. The oil from the power train pump flows through port (Pc) of the clutch EMCV and orifice (a) to port (F) and pushes valve (3) to the left to connect port (Pc) with port (C) and disconnect port (C) from port (Dr). At this time, the oil flows in the back pressure port of the clutch piston. As the oil pressure rises, the clutch piston is pushed to the left to compress the clutch spring, then the clutch is turned “disengaged”. Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left. As for the oil pressure after port (B), the controller outputs the command current to proportional solenoid (5) according to the stroke of the PCCS lever.
D475A, D475ASD-5E0
q
q
q
Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. Accordingly, if the stroke of the PCCS lever is short, the oil pressure after port (B) is set high and the brake is turned from “released” to “semi-released”. If the stroke of the PCCS lever is long, the oil pressure after port (B) is set low and the brake is turned from “semireleased” to “applied”. When the parking brake lever is in “free” position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
37
SEN00212-02
10 Structure, function and maintenance standard
When PCCS lever is “operated fully to the left”, brake pedal is “released”, and parking brake lever is in “free” position: Sharp left turn (L.H. clutch is turned “disengaged”, L.H. brake is “applied”, R.H. clutch is turned “engaged”, R.H. brake is “released”, and parking brake is “released”.)
q
q
q
q
38
When the PCCS lever is shifted from “operated to left halfway” to “operated to left fully”, proportional solenoid (5) of the L.H. brake ECMV is de-energized and the sealing part of ball (6) is fully opened. Since the oil in port (E) is drained through the sealing part, valve (7) is moved to the right by the tension of spring (8) to disconnect port (Pb) from (B) and connect port (B) with port (Dr). At this time, the oil from the back pressure port of the brake piston is drained through port (B) and the brake is turned “applied” by the tension of the brake spring. The oil from the power train pump flows through port (Pb) of the brake ECMV and orifice (b), then it is drained through sealing part of ball (6). The oil pressure in the clutch circuit, etc. is secured by orifice (b).
q
When the parking brake lever is in “free” position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
When PCCS lever is in “neutral”, brake pedal is “depressed”, and parking brake lever is in “free” position: Stop (L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is “released”.)
q
q
q
q
When the brake pedal is depressed fully, proportional solenoids (5) of L.H. and R.H. brake ECMV are de-energized to open the sealing part of ball (6). The controller outputs the command current to proportional solenoid (5) according to the brake pedal stroke. Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. Since the PCCS lever is in “neutral” position, proportional solenoids (1) of L.H. and R.H. clutch ECMV are de-energized and L.H. and R.H. clutch are turned “engaged”.
D475A, D475ASD-5E0
q
If the brake pedal is depressed, the parking brake valve connected by the linkage operates to open the brake circuit and drain the oil.
39
SEN00212-02
10 Structure, function and maintenance standard
Parking brake valve
1
Unit: mm No.
1
Check item
Clearance between spool and valve body
Criteria Tolerance
Standard size 14
2
Outside diameter of dust seal contact surface of spool
Remedy
Shaft
Hole
Standard clearance
Clearance limit
–0.020 –0.030
+0.011 0
0.020 – 0.041
0.05
Standard size
Tolerance
Repair limit
14
–0.020 –0.030
13.9
Standard size
3
4. 5.
40
Return spring
Spool Valve body
Replace
Repair by hard chrome plating or replace
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
65
47.7
38.2 N {3.9 kg}
63
36.3 N {3.7 kg}
Replace
Outline q The parking brake valve is installed to the steering control valve, and spool (4) operates with the parking brake lever. q When the parking brake lever is in “lock” position, the brake operates by draining the operating pressure of the L.H. and R.H. steering brake.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00212-02
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in “lock” position : Parking (L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is “applied”.)
q
q
q
q
q
If the parking brake lever is turned to the “lock” position, spool (1) is moved to the left to open ports (A), (B) and (C). The oil which had flown into the brake piston back pressure port is drained through ports (A), (B) and (C). The oil pressure in the back pressure port of the brake piston continues to decrease, then the brake is fully “applied” and that situation is kept. When the engine is started again, as ports (A), (B) and (C) are still opened, the brake is continuously “applied”. If the parking brake lever is shifted to “free” position, spool (1) moves to the right to disconnect ports (A), (B) and (C). Then the oil pressure from the brake ECMV is applied to the back pressure port of the brake piston and the brake becomes “released”.
D475A, D475ASD-5E0
41
SEN00212-02
Sudden stop prevention valve
10 Structure, function and maintenance standard
1
Outline q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when an abnormality takes place in the electrical system. q Sudden stop prevention valve (1) is installed in the drain circuit of the brake ECMV so that the sudden oil pressure drop of port (DR) when brake ECMV coil (2) is de-energized, and consequently the sudden brake can be avoided. q If an abnormality takes place in the electrical system, also solenoid (3) of sudden stop prevention valve (1) is de-energized. Then, the oil of port (DR) is drained through orifice (a) so that the brake is applied gradually.
42
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00212-02
43
SEN00212-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN00212-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (01)
44
SEN00213-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Undercarriage and frame Track frame ..................................................................................................................................................... 2 Recoil spring ................................................................................................................................................... 4 Idler ................................................................................................................................................................. 6 Track roller ...................................................................................................................................................... 8 Carrier roller .................................................................................................................................................. 12 Track roller bogie .......................................................................................................................................... 13 Track shoe .................................................................................................................................................... 14 Main frame .................................................................................................................................................... 18 Suspension ................................................................................................................................................... 20
D475A, D475ASD-5E0
1
SEN00213-02
10 Structure, function and maintenance standard
Track frame
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
2
Idler Recoil spring assembly Carrier roller Track frame Sprocket Sprocket guard Track roller bogie Track roller Cap Idler yoke Cylinder Guide
1
Track roller, bogie (Semi U, full U, superdozer specification) Track roller flange type arrangement 1st
2nd
3rd
4th
5th
6th
7th
8th
S
D
D
D
D
D
D
S
S: Single D: Double
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00213-02
Outline q The track roller uses K-shape bogie mount to increase the ground contact area between the track shoe and ground surface on rough surfaces, thereby increasing the drawbar pull. q The K-shape bogie is fitted with rubber pads to absorb the shock from the ground surface. Unit: mm No.
4
13
Check item
Criteria Item
Repair limit
Curvature
7 (for length of 3,000)
Twisting
3 (for level length of 3,000)
Dents (cylinder portion)
12
Deformation of track frame outer cylinder
Clearance between inner cylinder and guide
Standard size 70
14
Clearance between idler bogie and guide
15
Press-fitting force for cartridge
D475A, D475ASD-5E0
Remedy
Tolerance Shaft
Hole
–0.15 –0.35
+0.3 +0.3
Standard clearance
Clearance limit
0.15 – 0.65
2.0
Standard clearance
Clearance limit
0 – 0.5
3.0
294.20 – 490.33 kN {30 – 50 ton}
Repair or Replace
Replace
Adjust —
3
SEN00213-02
Recoil spring
1. 2. 3. 4. 5. 6. 7. 8. 9.
4
Yoke Nut Retainer Rod Spring cylinder Retainer Piston Lubricator (for supplying and discharging grease) Grease chamber cylinder
10 Structure, function and maintenance standard
1
Outline q Recoil spring (10) damps sudden shocks applied to the idler. q The recoil spring is also used to adjust the track shoe tension by supplying or discharging grease through lubricator (8) and moving rod (4) forward or in reverse.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00213-02
Unit: mm No.
Check item
Criteria Standard size
10
11
Recoil spring
Clearance between inner cylinder and outer cylinder of outer cylinder bushing
Free length
Installation length
1,721
1,435
Standard size 445
Remedy Repair limit
Installation Installation Free length load load 788.2 kN {80,435 kg}
Tolerance
1,695
Shaft
Hole
Standard clearance
Clearance limit
–0.068 –0.165
+0.323 +0.600
0.128 – 0.488
0.8
12
Press-fitting force for outer cylinder bushing (inner cylinder side)
129.4 – 389.1 kN {13.2 – 39.7 ton}
13
Clearance between recoil spring mount nut and lock plate
0 – 1.0
D475A, D475ASD-5E0
717.4 kN {73,200 kg} Replace
Adjust
5
SEN00213-02
Idler
6
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00213-02
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
1,043
—
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
1
Outside diameter of protruding part
2
7
Clearance between shaft and bushing
Standard size 180
8
9
Width of shaft flange
Interference between ring and shaft
10
End play
D475A, D475ASD-5E0
Shaft
Hole
Standard clearance
–0.350 –0.413
+0.168 +0.003
0.353 – 0.581
Clearance limit —
Standard size
Repair limit
335.0
—
Standard size 115
Tolerance
Rebuild or replace
Tolerance Shaft
Hole
+0.046 +0.046
–0.15 –0.20
Replace bushing
Rebuild or replace
Standard Interference interference limit 0.15 – 0.246
Standard size
Repair limit
0.52 – 0.98
—
—
Replace ring
7
SEN00213-02
Track roller
8
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00213-02
2nd – 7th track rollers (double flanged roller) No.
Check item
1
Outside diameter of flange (outside)
2
Unit: mm Criteria
Remedy
Standard size
Repair limit
344
—
Outside diameter of flange (inside)
332
—
3
Outside diameter of tread
300
246
4
Thickness of tread
71.5
44.5
5
Overall width
423
—
6
Width of tread
99.5
—
7
Width of flange (Outside of flange)
34.5
19.5
8
Width of flange (Inside of flange)
27.5
12.5
9
Width of shaft flange
379
—
10
Clearance between shaft and bushing
Standard size 147
11
Interference between shaft and seal ring
Standard size 84
12
End play
D475A, D475ASD-5E0
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
–0.350 –0.413
+0.170 +0.170
0.350 – 0.583
—
Tolerance Shaft
Hole
+0.046 +0.046
–0.15 –0.20
Standard Interference interference limit 0.150 – 0.246
Standard size
Clearance limit
0.44 – 0.91
—
Replace bushing
Replace
— Adjust or replace
9
SEN00213-02
10 Structure, function and maintenance standard
1st and 8th track rollers (single flanged roller) No.
Unit: mm
Check item
Criteria
Remedy
Standard size
Repair limit
349
—
Outside diameter of tread
315
240
4
Thickness of tread
74
36.5
5
Overall width
423
—
6
Width of tread
99.5
—
7
Width of flange
34.5
19.5
9
Width of shaft flange
379
—
1
Outside diameter of flange
3
10
Clearance between shaft and bushing
Standard size 157
11
Interference between shaft and seal guide
Standard size 95
12
10
End play
Tolerance Shaft
Hole
Standard clearance
–0.350 –0.413
+0.171 +0.007
0.350 – 0.583
Tolerance Shaft
Hole
Standard interference
+0.046 0
–0.15 –0.20
0.15 – 0.246
0.44 – 0.91
—
Rebuild or replace
Clearance limit Replace bushing — Interference limit —
Replace
Adjust or replace
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00213-02
11
SEN00213-02
10 Structure, function and maintenance standard
Carrier roller
1
Unit: mm No.
Check item
1
Outside diameter of flange
2
Criteria
Remedy
Standard size
Repair limit
275
—
Outside diameter of carrier roller tread
240
215
3
Width of carrier roller tread
96
—
4
Thickness of tread
49.5
37
5
Width of flange
25
14
6
Interference between shaft and ring
7
Clearance between shaft and support
8
Play in axial direction of roller
12
Tolerance
Rebuild or replace
Shaft
Hole
Standard interference
Standard clearance
95
+0.046 +0.046
–0.15 –0.20
0.150 – 0.246
—
90
–0.2 –0.2
+0.35 +0.35
—
0 – 0.55
Standard size
Replace
Standard size
Clearance limit
0 – 0.22
—
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Track roller bogie
1
Outline q The track rollers are installed to small bogie (6). The track rollers and track shoes are always in contact. q The vibration of the machine from the ground surface is absorbed by rubber mount (5).
D475A, D475ASD-5E0
SEN00213-02
1. 2. 3. 4. 5. 6. 7. 8. 9.
Guide Cap Track roller assembly (double) Large bogie Rubber mount Small bogie Track roller assembly (single) Cover Cartridge pin
13
SEN00213-02
Track shoe
a
14
10 Structure, function and maintenance standard
1
Portion P shows the link on the side where the bushing is pressed fitted.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00213-02
Unit: mm No. 1
2
Check item Link pitch
Outside diameter of bushing
3
Thickness of bushing
4
Height of link
5
Thickness of link (bushing press-fitting portion)
6
Clearance between links
7
8
9
Criteria Standard size
Repair limit
317.8
320.8
Load
Heavy load
116
107.5
110
22.5
14
16.5 Repair limit
199
181 (*1)
53.5
35.5 (*2)
One side
1.6
—
Both sides
3.2
—
Interference between regular pin and link a. Regular link b. Master link
Standard size
Turn or replace
Turning
Standard size
Standard size
Interference between bushing and link
Shoe bolt
Remedy
Tolerance
Standard interference
Shaft
Hole
113
+0.652 +0.552
+0.087 +0.087
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
Retighten
*1: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit is 183 mm. *2: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit is 37.5 mm.
D475A, D475ASD-5E0
15
SEN00213-02
10 Structure, function and maintenance standard
Single grouser shoe
Unit: mm No.
Check item
1
Height of grouser
2
Overall height of shoe
16
Criteria
Remedy
Standard size
Repair limit
105
35
133
63
Repair by build-up welding or replace
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00213-02
17
SEN00213-02
Main frame
18
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00213-02
Unit: mm No.
Check item
Criteria Standard size
1
Interference between steering case and bushing
Repair limit
Tolerance
Standard size
Remedy
Standard clearance
Clearance limit
+0.052 +0.052
(Std.interference) 0.004 – 0.108
Min. 0
Shaft
Hole
315
–0.108 +0.056
2
Clearance between steering frame and final drive cage
390
–0.018 –0.075
+0.057 +0.057
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
4
Clearance between ripper arm mounting pin and bushing
140
–0.043 –0.106
+0.210 +0.050
0.093 – 0.316
1.5
5
Clearance between ripper cylinder mounting pin and bushing
110
–0.036 –0.090
+0.301 +0.118
0.154 – 0.371
1.5
6
Clearance between radiator guard mounting pin and bushing
Hole 100.2 Shaft 100
–0.036 –0.090
+0.164 +0.062
0.298 – 0.454
1.5
7
Clearance between radiator guard mounting pin and bushing
Hole 115.2 Shaft 115
–0.043 –0.106
+0.140 +0.031
0.274 – 0.446
1.5
8
Clearance between equalizer bar shaft and bushing
140
–0.043 –0.083
+0.208 +0.131
0.174 – 0.291
1.5
9
Protrusion of rubber at end face of seal
10
Standard size
Repair limit
1
0.5
Free height of front mount rubber
118
116
11
Free height of rear mount rubber
58
56
12
Press-fitting force for ripper arm mounting bushing
126.5 – 253 kN {12.9 – 25.8 ton}
13
Press-fitting force for ripper cylinder mounting bushing
111.8 – 267.7 kN {11.4 – 27.3 ton}
14
Press-fitting force for radiator guard mounting bushing
62.8 – 142.2 kN {6.4 – 14.5 ton}
15
Press-fitting force for radiator guard mounting bushing
53.9 – 106.9 kN {5.5 – 10.9 ton}
16
Press-fitting force for equalizer bar shaft mounting bushing
65.7 – 153 kN {6.7 – 15.6 ton}
D475A, D475ASD-5E0
Replace
Adjust
19
SEN00213-02
Suspension
20
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Equalizer bar Pivot shaft assembly Cover Thrust plate Thrust plate Pivot shaft Seal cage Cover Seal cage Side pin Center pin
D475A, D475ASD-5E0
SEN00213-02
Outline q The front part of the track frame moves up and down around pivot shaft (6) at its rear end. Equalizer bar (1) rocks around center pin (11) and is connected to the right and left track frames by side pins (10).
21
SEN00213-02
10 Structure, function and maintenance standard
Unit: mm No.
Check item
Criteria
12
Press-fitting force for side pin bushing
47.0 – 96.0 kN {4.8 – 9.8 ton}
13
Press-fitting force for side pin bushing
121.5– 294 kN {12.4 – 30 ton}
14
Press-fitting force for center pin bushing
68.6 – 232.2 kN {7 – 23.8 ton}
15
Clearance between center pin and bushing
Tolerance
Remedy
—
Shaft
Hole
Standard clearance
140
–0.043 –0.083
+0.225 +0.143
0.186 – 0.308
1.0
Standard size
Clearance limit
16
Clearance between side pin and bushing
115
–0.048 –0.078
+0.015 –0.015
0.033 – 0.093
1.0
17
Clearance between pivot shaft and bushing
260
–0.190 –0.271
+0.138 +0.026
0.216 – 0.409
1.0
18
Clearance between pivot shaft and bushing
220
–0.145 –0.208
+0.114 +0.038
0.204 – 0.340
1.0
19
Interference between side pin boss and bushing
Standard size
Tolerance
Standard Interference interference limit
Shaft
Hole
200
+0.051 +0.031
–0.033 –0.079
0.064 – 0.130
—
20
Interference between thrust washer and seal
270
+0.216 +0.086
–0.234 –0.286
0.320 – 0.502
—
21
Interference between thrust washer and seal
194
+0.096 +0.050
–0.075 –0.147
0.125 – 0.243
—
22
Interference between pivot shaft and seal
263
+0.108 +0.056
–0.122 –0.203
0.178 – 0.311
—
22
Replace bushing
Replace
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00213-02
23
SEN00213-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN00213-02
© 2016 KOMATSU All Rights Reserved Printed in Japan 02-16 (01)
24
SEN00214-00
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Hydraulic system, Part 1 Hydraulic system, Part 1 ................................................................................................................................. 2 Work equipment hydraulic equipment arrangement diagram............................................................... 2 PPC control piping diagram ................................................................................................................. 6 Work equipment control ....................................................................................................................... 8 Work equipment pump ....................................................................................................................... 10 PPC valve .......................................................................................................................................... 27 PCCS lever ........................................................................................................................................ 38
D475A, D475ASD-5E0
1
SEN00214-00
10 Structure, function and maintenance standard
Hydraulic system, Part 1
1
Work equipment hydraulic equipment arrangement diagram
1
Semi U-dozer (single tilt)
1. 2. 3. 4. 5. 6.
2
Blade tilt cylinder R.H. blade lift cylinder Main control valve Accumulator Dual tilt solenoid valve Hydraulic tank
7. 8. 9. 10. 11.
Fan pump Work equipment pump L.H. blade lift cylinder Fan motor Oil cooler
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Superdozer (full U-dozer + dual tilt)
1. 2. 3. 4. 5. 6.
Blade tilt cylinder R.H. blade lift cylinder Main control valve Accumulator Dual tilt solenoid valve Hydraulic tank
D475A, D475ASD-5E0
7. 8. 9. 10. 11. 12.
Fan pump Work equipment pump L.H. blade lift cylinder Blade pitch cylinder Fan motor Oil cooler
3
SEN00214-00
10 Structure, function and maintenance standard
Multi-shank ripper
1. 2. 3. 4. 5. 6.
4
Main control valve Divider block Ripper tilt cylinder (right) Ripper lift cylinder (right) Ripper lift cylinder (left) Ripper tift cylinder (left)
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Giant ripper q
The diagram shows a machine equipped with a pin puller cylinder
1. 2. 3. 4. 5.
Main control valve Divider block Ripper tilt cylinder (right) Ripper lift cylinder (right) Pin puller cylinder
D475A, D475ASD-5E0
6. 7. 8. 9.
Ripper lift cylinder (left) Ripper tilt cylinder (left) Pin puller solenoid valve Brake valve
5
SEN00214-00
PPC control piping diagram
10 Structure, function and maintenance standard
1
Blade and ripper control
1. 2. 3. 4. 5. 6. 7.
6
Blade control PPC valve Main control valve Accumulator Ripper control PPC valve PPC lock valve Work equipment lock lever Work equipment pump
D475A, D475ASD-5E0
SEN00214-00
10 Structure, function and maintenance standard
Work equipment control
1
q
The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
1. 2. 3. 4.
Work equipment lock lever Blade control lever Pitch button Tilt switch
8
5. 6. 7.
Ripper control lever Pin puller switch PPC lock valve
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Lever and switch positions A : Blade HOLD B : Blade LOWER C : Blade FLOAT D : Blade RAISE E : Blade LEFT TILT/PITCH F : Blade RIGHT TILT/PITCH G : Ripper HOLD H : Ripper RAISE J : Ripper LOWER K : Ripper TILT IN L : Ripper TILT BACK M : FREE N : LOCK P : Single tilt Q : Dual tilt R : Pitch OFF S : Pitch ON T : Pin puller switch PUSH IN U : Pin puller switch PUSH OUT
Outline q The work equipment control employs a PPC method which uses a PPC valve to move each control valve spool. q Work equipment lock lever (1) is interconnected with PPC lock valve (7), and at the LOCK position (N), the oil in the PPC circuit is stopped.
D475A, D475ASD-5E0
9
SEN00214-00
10 Structure, function and maintenance standard
Work equipment pump
1
3
Type: HPV125 + 125 (140 cm /rev specification)
DC: Discharge SC: Suction
10
Outline q This pump consists of two variable-capacity swash plate-type piston pumps, CO valve, LS valve, and EPC valve.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
A B C D E F G H J K 1. 2. 3. 4. 5. 6. 7. 8. 9.
PBF PAF PLSC PBR PENR PAR PENF PD1F PEPB PRC
: Front pump pressure input port : Front pump discharge port : LS set selector pressure pickup port : Rear pump pressure input port : Control pressure pickup port : Rear pump discharge port : Control pressure pickup port : Case drain port : EPC basic pressure pickup port : Rear pump discharge pressure pickup port
Front main pump Rear main pump LS valve CO valve LS-EPC valve Front shaft Cradle Front case Rocker cam
D475A, D475ASD-5E0
SEN00214-00
L PLSR : Load pressure input port M PLSRC: Load pressure pickup port N PLSFC : Load pressure pickup port P PLSF : Load pressure input port Q PEPC : EPC basic pressure port R PFC : Front pump discharge pressure pickup port S PD2F : Drain plug T ISIG : LS set selector current U PS : Pump suction port V PD2R : Air breather mounting port 10. 11. 12. 13. 14. 15. 16. 17.
Shoe Piston Cylinder block Valve plate End cap Rear shaft Rear case Servo piston
11
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Function q The rotation and torque transmitted to the pump shaft are converted into hydraulic pressure, and pressurized oil is discharged according to the load. q It is possible to change the discharge amount by changing the swash plate angle.
12
10 Structure, function and maintenance standard
Structure q Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. q The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) is always pressed against flat surface (A) of rocker cam (4) while sliding in a circular movement. q Rocker cam (4) brings high pressure oil at cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. q Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). q The cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8). D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Operation
1. Operation of pump q
Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle (a) is called the swash plate angle.)
q
Center line (X) of rocker cam (4) maintains swash plate angle (a) in relation to the axial direction of cylinder block (7), and flat surface (A) moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). The suction and discharge is carried out by this amount (F) – (E) per each piston. In other words, when cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber (F) becomes larger, and as the volume becomes bigger, the oil is sucked in.
q
q
D475A, D475ASD-5E0
SEN00214-00
q
If center line (X) of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)
13
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10 Structure, function and maintenance standard
2. Control of delivery amount q
q q
q
q
14
If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and delivery amount (Q) increases. Swash plate angle (a) is changed by servo piston (12). Servo piston (12) moves in a reciprocal movement according to the signal pressure from the CO valve and LS valve. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement. With servo piston (12), the area receiving the pressure is different on the left and the right, so main pump discharge pressure (self pressure) (PP) is always brought to the chamber receiving the pressure at the small diameter piston end. Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
3. LS valve
A. B. C. D. E. F. G.
PLS : LS pressure input port PP : Pump port PLP : LS control pressure output port PPL : CO control pressure input port PDP : Drain port PSIG : LS mode selection pilot port PA : Pump port
1. 2. 3. 4. 5. 6. 7. 8.
Sleeve Piston Spool Spring Seat Sleeve Plug Locknut
3. 4. 5. 6. 7. 8.
Ball Spool Spring Retainer Cover Spring
4. CO valve
A. PPL : CO control pressure output port B. PA : Pump port A. PDP : Drain port 1. 2.
Plug Servo piston assembly
D475A, D475ASD-5E0
15
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Function 1) LS valve q The LS (Load Sensing) valve detects the load and controls the discharge amount. q This valve controls main pump delivery amount (Q) according to differential pressure (dPLS) between main pump pressure (PP) and control valve outlet port pressure (PLS) (= PP – PLS) [called the LS differential pressure]. q Main pump pressure (PP), pressure (PLS) [called the LS pressure] from the control valve output, and pressure (PSIG) from the proportional solenoid valve [called the LS selector pressure] enter this valve. q The relationship between differential pressure (dPLS) between main pump pressure (PP) and LS pressure (PLS) (= PP – PLS) and delivery amount (Q) changes according to LS selector current (ISIG) of the LS-EPC valve as shown in the figure below. q As (ISIG) changes from 0 to 0.9 A, the set force of the spring changes. As a result, the median of the standard changing point of the pump delivery amount changes from 2.5 to 0.98 MPa {from 25 to 10 kg/cm2}.
16
10 Structure, function and maintenance standard
2) q
q
CO valve When the pump pressure in the hydraulic circuit becomes maximum, the CO (Cut-OFF) valve minimizes the pump swash plate angle to limit the pressure and protect the circuit. Since the pump swash plate angle is minimized, the pump absorption torque is reduced and the fuel consumption is reduced.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Operation
1) LS valve (1) When control valve is at neutral position
q
q
q
q
The LS valve is a three-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). The size of this LS pressure (PLS) + force of spring (4) and the main pump pressure (self pressure) (PP) determines the position of spool (6). However, the size of the output pressure (PSIG) (the LS selection pressure) of the EPC valve for the LS valve entering port (G) also changes the position of spool (6). (The set pressure of the spring changes). Before the engine is started, servo piston (12) is pushed to the right. (See the diagram on the right) When the engine is started and the control lever is at the neutral position, LS pressure (PLS) is 0 MPa {0 kg/cm2}. (It is interconnected with the drain circuit through the control valve spool.)
D475A, D475ASD-5E0
q
At this point, spool (6) is pushed to the right, and port (C) and port (D) are connected. Pump pressure (PP) enters the large diameter end of the piston from port (K) and the same pump pressure (PP) also enters port (J) at the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in the area of piston (12).
17
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10 Structure, function and maintenance standard
(2) Operation in direction of maximum pump delivery amount
q
q q
q
18
When the difference between main pump pressure (PP) and LS pressure (PLS), or LS differential pressure (dPLS), becomes smaller (for example, when the area of opening of the control valve becomes larger and LS pressure (PLS) increases), the combined force of LS pressure (PLS) and force of spring (4) pushes spool (6) to the right. As spool (6) moves, ports (D) and (E) are connected to each other and to the CO valve. At this time, the CO valve is connected to the drain port and the pressure in circuit (D) – (K) becomes drain pressure (PT). (Operation of the CO valve will be explained later.) Accordingly, the pressure on the large diameter end of servo piston (12) becomes drain pressure (PT). Since pump pressure (PP) is constantly applied to port (J) on the small diameter end, servo piston (12) is pushed to the left and the swash plate is moved in the direction for increasing the delivery amount.
q
q
If the output pressure of the EPC valve for the LS valve is applied to port (G) at this time, it pushes piston (7) to the left. If piston (7) is pushed to the left, the set force of spring (4) is reduced and LS differential pressure (dPLS) [the difference between oil pressures (PLS) and (PP)] changes when ports (D) and (E) of spool (6) are connected.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
(3) Operation in direction of minimum pump delivery amount
q
q
q
The following explains the case where servo piston (12) moves to the right (where the delivery amount becomes smaller). When LS differential pressure (dPLS) increases [for example, when the area of opening of the control valve becomes smaller and LS pressure (PLS) lowers], pump pressure (PP) pushes spool (6) to the left. As spool (6) moves, main pump pressure (PP) flows from port (C) to port (D), and then it enters the large diameter end of the piston through port (K). Main pump pressure (PP) also enters port (J) on the small diameter end of servo piston (12), but servo piston (12) is pushed to the right because of the difference in area between its large diameter end and small diameter end. As a result, the swash plate angle is reduced.
D475A, D475ASD-5E0
19
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10 Structure, function and maintenance standard
(4) When servo piston is balanced
q
q
q
20
Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). When main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS) and the force of spring (4) and their relationship is (A0) × (PP) = (A1) × (PEN), servo piston (12) stops in the current position. Then, swash plate is kept at an intermediate position. [It stops at a position where the opening between ports (D) and (E) of spool (6) and that between ports (C) and (D) are approximately the same.]
q
q
q
At this time, the relationship between the areas receiving the pressure at both ends of servo piston (12) is (A0) : (A1) = 1 : 2. Accordingly, the relationship between the pressures applied to both ends of the piston when the piston is balanced becomes (PP) : (PEN) C 2 : 1. The position where spool (6) is balanced and stopped is the standard center. The force of spring (4) is so adjusted that the standard center will be decided when (PP) – (PLS) = 2.5 MPa {25 kg/cm2}. When the input current to the LS-EPC valve changes from 0 to 0.9A and (PSIG) (the output pressure of the LS-EPC valve varying from 0 to 2.9 MPa {0 to 30 kg/cm2}) is applied to port (G), however, the balancing and stopping position changes in proportion to the (PSIG) pressure in the range from (PP) – (PLS) = 2.5 to 0.98 MPa {25 to 10 kg/cm2}.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
q
SEN00214-00
The operation of the LS valve is shown in the following table.
Solenoid drive table Single specification
Dual specification
Superdozer specification
q
q
q
Raise Lift Lower Left tilt
q
Left tilt limit Single tilt Right tilt
q
q
q
Right tilt limit Blade Left tilt
q
Left tilt limit
q
Right tilt
q
Right tilt limit
q
Rear pitch
q
Forward pitch
q
Dual tilt
Pitch
q
Raise Lift Lower Ripper Raise Tilt Lower
D475A, D475ASD-5E0
21
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10 Structure, function and maintenance standard
2) CO valve (1) When actuator load is small and pump pressure (PP) is low
q
q q
q
q
22
Spool (3) is a little to the left position. At this time, port (C) is connected to port (D) through the internal passage of spool (3). Port (C) of the CO valve is connected to port (E) of the LS valve. Pump pressure (PP) is applied to port (B) and small diameter side of servo piston (9). The pressure in port (E) of the LS valve is drain pressure (PT). If ports (E) and (G) of the LS valve are connected at this time, the pressure on the large diameter side of the piston becomes drain pressure (PT) and servo piston (9) moves to the left. As a result, the pump swash plate angle is increased to increase the pump delivery amount.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
(2) When actuator load is large and pump discharge pressure reaches maximum
q
q q q
q
q
q
When the load is large and pump discharge pressure (PP) is high, the force to push spool (3) to the right is increased and spool (3) is set in the position shown in the above figure. Port (C) of the CO valve is connected to port (E) of the LS valve. Pump pressure (PP) is applied to port (B) and small diameter side of servo piston (9). Then, the pressure applied through port (C) to the LS valve is main pump pressure (PP) from port (B). If ports (E) and (G) of the LS valve are connected at this time, main pump pressure (PP) is applied to the large diameter side of servo piston (9). Main pump pressure (PP) is applied to the small diameter side of the piston, too. Servo piston (9) is pushed to the right, however, because of the difference in area between the large diameter side and small diameter side of the piston. As a result, the pump swash plate angle is decreased to decrease the pump delivery amount.
D475A, D475ASD-5E0
23
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10 Structure, function and maintenance standard
5. LS-EPC valve
A. PSIG : To LS valve B. PT : To tank C. PEPC: From self pressure reducing valve
24
1. 2. 3. 4. 5. 6. 7.
Coil Body Spring Spool Rod Plunger Connector
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Function q The EPC valve consists of the solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.
SEN00214-00
Operation 1) q q q
q
D475A, D475ASD-5E0
When signal current is 0 (coil de-energized) When there is no signal current flowing from the controller to coil (1), coil (1) is de-energized. For this reason, spool (4) is pushed to the right in the direction of the arrow by spring (3). As a result, port (C) (PEPC) closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time, the pressurized oil from the LS valve passes from port (A) (PSIG) through port (B) (PT) and is drained to the tank.
25
SEN00214-00
2) q
q q
q
q
26
When signal current is small (Coil is energized) If a small signal current flows in coil (1), coil (1) is “energized” and a thrust to the right is generated in plunger (6). Rod (5) pushes spool (2) to the right and the oil from port (C) (PEPC) flows in port (A) (PSIG). The pressure in port (A) (PSIG) rises. If the total of the force applied to spool (2) and the load of spring (3) exceeds the thrust of plunger (6), spool (2) is pushed to the left. Then, port (C) (PEPC) and port (A) (PSIG) are disconnected and port (A) (PSIG) and port (B) (PT) are connected simultaneously. As a result, spool (2) moves up and down until the thrust of plunger (6) is balanced with the total of the pressure in port (A) (PSIG) and the load of spring (3). Accordingly, the pressure in the circuit between the EPC valve and LS valve is controlled in proportion to the signal current.
10 Structure, function and maintenance standard
3) q q q q
q
When signal current is maximum (Coil is energized) If the signal current flows in coil (1), coil (1) is “energized”. Since the signal current is at the maximum, the thrust in plunger (6) becomes maximum. Accordingly, rod (5) presses spool (2) to the right. As a result, the maximum oil flows from port (C) (PEPC) to port (A) (PSIG) and the pressure in the circuit between the EPC valve and LS valve becomes highest. At this time, port (C) (PT) is closed and the oil does not flow in the tank.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
PPC valve
1
1. Blade PPC valve
P : From self pressure reducing valve P1 : To blade lift valve (LOWER) PPC port P2 : To blade lift valve (RAISE) PPC port
D475A, D475ASD-5E0
P3 : To blade tilt valve (LEFT TILT) PPC port P4 : To blade tilt valve (RIGHT TILT) PPC port T : To hydraulic tank
27
SEN00214-00
1. 2. 3. 4. 5. 6.
28
Spool Metering spring Centering spring Piston Disc Nut (For connecting lever)
10 Structure, function and maintenance standard
7. 8. 9. 10. 11.
Joint Plate Retainer Body Filter
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Unit: mm No.
Check item
Criteria
Remedy
Standard size
12
Centering spring (For port P1)
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
34.0 x 15.5
31.9
94 N {9.6 kg}
—
75.2 N {7.68 kg}
13
Centering spring (For port P2)
43.2 x 15.5
34.0
78.5 N {8 kg}
—
62.8 N {6.4 kg}
14
Centering spring (For ports P3 and P4)
48.57 x 15.5
32.5
107.9 N {11 kg}
—
86.3 N {8.8 kg}
15
Metering spring (For port P1)
29.27 x 8.15
25.4
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
16
Metering spring (For port P2)
26.3 x 8.15
24.1
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
17
Metering spring (For ports P3 and P4)
26.53 x 8.15
24.9
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
D475A, D475ASD-5E0
If spring is damaged or deformed, replace it
29
SEN00214-00
10 Structure, function and maintenance standard
Operation
1) When in neutral (1) For lifting blade q Ports (A) and (B) of the blade lift valve of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
30
(2) For tilting blade q Ports (C) and (D) of the blade tilt valve of the control valve and ports (P3) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
2) When in fine control (Neutral o Fine control) q
q
q
q
q
q
q
If piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed down through metering spring (2). Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (B). If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). As a result, spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1). The positional relationship between spool (1) and body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). Since metering spring (2) is compressed in proportion to the stroke of the control lever, the pressure in port (P1) rises in proportion to the stroke of the control lever. Accordingly, the control valve spool moves to a position at which the pressure in port (B) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.
D475A, D475ASD-5E0
31
SEN00214-00
3) When in fine control (When control lever is returned) q
q
q
q
32
If lever (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f’) of the valve which is not in operation and then flows through port (P2) into port (A).
10 Structure, function and maintenance standard
4) When lever is operated to stroke end q
q
q
If disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes the control valve spool. The oil returning from port (A) flows through port (P2) and fine control (f’) into drain chamber (D).
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
5) When blade is “floated” q
q
q q
q
q q
If piston (4) on the “LOWER” side of port (P1) is pushed down by disc (5), ball (11) touches projection (a) of the piston in the middle of the stroke (The detent starts to operate). If piston (4) is pushed in further, ball (11) pushes up collar (12) supported on detent spring (13) and escapes out to go over projection (a) of the piston. At this time, piston (4') on the opposite side is pushed up by spring (14). As a result, the oil in chamber (F) flows through (b) and (c) to chamber (E) and piston (4') follows disc (5). Since passage (d) is connected to port (P1), almost the same pressure is applied to passage (d) and port (P1). Chamber (E) is normally connected to drain chamber (D). If ball (11) goes over projection (a) of the piston, passage (d) and chamber (E) are connected and the oil starts flowing. At this time, the control valve moves to the “FLOAT” position and the blade is floated. Since piston (4') is pushed up by the pressure in chamber (E), the “FLOAT” state is kept even if the lever is released.
D475A, D475ASD-5E0
SEN00214-00
6) When “FLOAT” state of blade is reset q
q
Disc (5) is pushed down with a force larger than the oil pressure in chamber (E) to return from the “FLOAT” position. As a result, chamber (E) is disconnected from passage (d) and connected to the drain chamber. Accordingly, the oil pressure in chamber (E) is lost and the “FLOAT” state is reset.
33
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10 Structure, function and maintenance standard
2. Ripper PPC valve
P P1 P2 P3 P4 T
34
: From self pressure reducing valve : To ripper tilt valve PPC port : To ripper tilt valve PPC port : To ripper lift valve PPC port : To ripper lift valve PPC port : To tank
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Spool Metering spring Centering spring Piston Disc Nut (For connecting lever) Joint Plate Retainer Body Filter
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Unit: mm No.
Check item
Criteria
Remedy
Standard size
12
Centering spring (For ports P3 and P4)
Free length x Outside diameter
Repair limit
Installed length
Installed load
50.4 x 15.5
Free length
Installed load
34.0
55.9 N {5.7 kg}
—
44.7 N {4.56 kg}
13
Centering spring (For ports P1 and P2)
50.1 x 15.5
34.0
71.4 N {7.28 kg}
—
56.9 N {5.8 kg}
14
Metering spring
26.5 x 8.20
24.9
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
D475A, D475ASD-5E0
If spring is damaged or deformed, replace it
35
SEN00214-00
Operation
10 Structure, function and maintenance standard
q
1) When in neutral q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
q
Since metering spring (2) is compressed in proportion to the stroke of the control lever, the pressure in port (P1) rises in proportion to the stroke of the control lever. Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.
2) When in fine control (Neutral o Fine control) q
q
q
q
36
If piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed down through metering spring (2). Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (A). If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). As a result, spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1). The positional relationship between spool (1) and body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). D475A, D475ASD-5E0
10 Structure, function and maintenance standard
3) When in fine control (When control lever is returned) q
q
q
q
If disc (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f’) of the valve which is not in operation and then flows through port (P2) into chamber (B).
D475A, D475ASD-5E0
SEN00214-00
4) When lever is operated to stroke end q
q
q
If disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into chamber (A) and pushes the control valve spool. The oil returning from chamber (B) flows through port (P2) and fine control (f’) into drain chamber (D).
37
SEN00214-00
10 Structure, function and maintenance standard
PCCS lever
1
Travel and steering PCCS lever a
Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operating effort characteristics will need to be adjusted.
1. 2. 3. 4.
Bellows Bracket Plate Bolt
38
5. 6. 7.
Screw Lever Connector
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00214-00
Function
1. Operating effort characteristics 1) q
Operation for forward and reverse travel The control lever is held at 3 positions of Forward, Neutral, and Reverse.
D475A, D475ASD-5E0
2) q
Operation for steering Free return.
39
SEN00214-00
10 Structure, function and maintenance standard
2. Output voltage characteristics q
q
q
40
The control unit is installed to the left control stand and the control lever is installed directly onto it. The operating angle (stroke) of the control lever is sensed with potentiometers and signal voltages are output to the transmission and steering controller. A potentiometer is installed in each of longitudinal direction and lateral direction. Each potentiometer outputs 2 signal voltages which are opposite to each other as shown in the figure at right.
D475A, D475ASD-5E0
SEN00214-00
D475A, D475ASD-5E0 Bulldozer Form No. SEN00214-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 01-06 (01)
42
SEN00215-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Hydraulic system, Part 2 Control valve ................................................................................................................................................... 2 CLSS............................................................................................................................................................. 17 Unload valve ................................................................................................................................................. 20 Introduction of LS pressure........................................................................................................................... 21 LS bypass plug ............................................................................................................................................. 22 Pressure compensation valve....................................................................................................................... 23 Blade lift valve............................................................................................................................................... 26 Merge-divider valve....................................................................................................................................... 34 Self pressure reducing valve......................................................................................................................... 36 Pilot solenoid valve ....................................................................................................................................... 40
D475A, D475ASD-5E0
1
SEN00215-01
Control valve
10 Structure, function and maintenance standard
1
Outline q This control valve consists of a 6-spool valve and a merge-divider valve. q Since the 6-spool valve and the merge-divider valve are assembled into 1 unit by connecting bolts and each passage is connected inside, the whole unit is compact and easy to maintain. A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 P1 P2 P3 P4 P7 P8 P9 1. 2. 3. 4.
2
: To ripper lift cylinder head : To blade tilt right cylinder head : To blade lift cylinder head : To blade lift cylinder head : To blade tilt left cylinder head : To ripper tilt cylinder head : To ripper lift cylinder bottom : To blade tilt right cylinder bottom : To blade lift cylinder bottom : To blade lift cylinder bottom : To blade tilt left cylinder bottom : To ripper tilt cylinder bottom : From ripper lift PPC valve : From ripper lift PPC valve : From blade tilt PPC valve : From blade tilt PPC valve : From blade lift PPC valve : From blade lift PPC valve : From blade tilt PPC valve
P10 : From blade tilt PPC valve P11 : From ripper tilt PPC valve P12 : From ripper tilt PPC valve PLS1 : To front pump control PLS2 : To rear pump control PP1 : From rear main pump PP2 : From front main pump PPS1: To front pump control PPS2: To rear pump control PR : To solenoid valve, PPC valve, and EPC valve PS : From merge-divider solenoid valve PST : From port PR SA : Pressure sensor mounting port SB : Pressure sensor mounting port T : To tank TS : To tank
6-spool valve Cover 1 Cover 2 Merge-divider valve
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
6-spool valve (1/8)
D475A, D475ASD-5E0
3
SEN00215-01
10 Structure, function and maintenance standard
(2/8)
4
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
(3/8)
1. 2. 3. 4. 5. 6. 7.
Unload valve Pressure compensation valve (on ripper tilt head side) Pressure compensation valve (on blade left tilt head side) Pressure compensation valve (on blade lift head side) Pressure compensation valve (on blade lift head side) Pressure compensation valve (on blade right tilt head side) Pressure compensation valve (on ripper lift head side)
D475A, D475ASD-5E0
8. 9. 10. 11. 12. 13. 14.
Pressure compensation valve (on ripper lift bottom side) Pressure compensation valve (on blade right tilt bottom side) Pressure compensation valve (on blade lift bottom side) Pressure compensation valve (on blade lift bottom side) Pressure compensation valve (on blade left tilt bottom side) Pressure compensation valve (on ripper tilt bottom side) Main relief valve
5
SEN00215-01
10 Structure, function and maintenance standard
(4/8)
6
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8.
SEN00215-01
Spool (Ripper tilt) Spool (Blade left tilt) Spool (Blade lift) Spool (Blade lift) Spool (Blade right tilt) Spool (Ripper lift) Unload valve Main relief valve Unit: mm
No.
Check item
Criteria
Remedy
Standard size
9
Spool return spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
54.5 x 34.8
51.2
393 N {40.1 kg}
—
315 N {32.1 kg}
—
301 N {30.7 kg}
10
Spool return spring
54 x 34.8
50.5
377 N {38.4 kg}
11
Spool return spring
69.9 x 34.8
65
390 N {39.8 kg}
—
312 N {31.8 kg}
12
Spool return spring
72.3 x 37.0
65.5
354 N {36.1 kg}
—
283 N {28.9 kg}
13
Spool return spring
52.9 x 22.3
33
274 N {27.9 kg}
—
219 N {22.3 kg}
D475A, D475ASD-5E0
If spring is damaged or deformed, replace it.
7
SEN00215-01
10 Structure, function and maintenance standard
(5/8)
8
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
SEN00215-01
Safety-suction valve (Blade left tilt head) Safety-suction valve (Blade lift head) Plug (Superdozer Spec.) Safety-suction valve (Blade lift head) Plug (Superdozer Spec.) Safety-suction valve (Blade right tilt head) Suction valve (Ripper lift head) Safety-suction valve (Ripper lift bottom) Safety-suction valve (Blade right tilt bottom) Safety valve (Blade lift bottom) Safety valve (Blade lift bottom) Safety-suction valve (Blade left tilt bottom) LS shuttle valve (Arm and right travel) LS shuttle valve (Boom, left travel, and bucket) LS check valve Pressure release plug Unit: mm
No.
Check item
Criteria
Remedy
Standard size
15
Check valve spring
D475A, D475ASD-5E0
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
If spring is damaged or deformed, replace it.
9
SEN00215-01
10 Structure, function and maintenance standard
(6/8)
10
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2.
SEN00215-01
Unload valve Main relief valve
Ripper tilt valve 3. Spool 4. Pressure compensation valve (Head) 5. LS shuttle valve 6. Pressure compensation valve (Bottom) Blade left tilt valve 7. Safety-suction valve 8. Spool 9. Pressure compensation valve (Head) 10. LS shuttle valve 11. Pressure compensation valve (Bottom) 12. Safety-suction valve Unit: mm No.
Check item
Criteria
Remedy
Standard size
13
Piston return spring
D475A, D475ASD-5E0
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
36.9 x 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
If spring is damaged or deformed, replace it.
11
SEN00215-01
10 Structure, function and maintenance standard
(7/8)
12
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Blade lift valve 1. Safety-suction valve Plug (Superdozer Spec.) 2. Spool 3. Pressure compensation valve (Right) 4. Pressure compensation valve (Left) 5. Suction valve Blade lift valve 6. Safety-suction valve Plug (Superdozer Spec.) 7. Spool 8. Pressure compensation valve (Raise) 9. LS shuttle valve 10. Pressure compensation valve (Lower) 11. Suction valve 12. Check valve for regeneration circuit Blade right tilt valve 13. Suction valve 14. Spool 15. Pressure compensation valve (Reverse) 16. LS shuttle valve 17. Pressure compensation valve (Forward) 18. Suction valve Ripper lift valve 19. Suction valve 20. Spool 21. Pressure compensation valve (Curl) 22. LS shuttle valve 23. Pressure compensation valve (Dump) 24. Safety-suction valve Unit: mm No.
Check item
Criteria
Remedy
Standard size
25
26
Regeneration valve spring
Piston return spring
D475A, D475ASD-5E0
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
31.5 x 10.3
19.5
6.2 N {0.6 kg}
—
4.9 N {0.5 kg}
36.9 x 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
If spring is damaged or deformed, replace it.
13
SEN00215-01
10 Structure, function and maintenance standard
(8/8)
14
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
SEN00215-01
Unload valve Main relief valve Merge-divider valve (For main) Spool return spring Merge-divider valve (For LS) Spool return spring Valve (Sequence valve) Spring (Sequence valve) LS bypass plug Spring (Safety valve) Ball Valve (Pressure reducing valve) Spring (Main pressure reducing valve) Spring (Pilot pressure reducing valve) Poppet Screw Spring (Safety valve) Ball Unit: mm
No.
Check item
Criteria
Remedy
Standard size
19
Check valve spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
20
Spool return spring
46.6 x 21.8
33
156.8 N {16.0 kg}
—
125.5 N {12.8 kg}
21
Spool return spring
64.5 x 32.3
63
177.5 N {18.1 kg}
—
142.0 N {14.5 kg}
22
Sequence valve spring
70.9 x 18
59
199.8 N {20.4 kg}
—
160.0 N {16.3 kg}
D475A, D475ASD-5E0
If spring is damaged or deformed, replace it.
15
SEN00215-01
10 Structure, function and maintenance standard
Main relief valve
1. 2.
Spring Poppet
Function q The main relief valve sets the maximum pump pressure of the main valve. Operation q The set pressure of the relief valve depends on the installed load of spring (1).
16
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
CLSS
SEN00215-01
1
1. Outline of CLSS
Features CLSS stands for Closed center Load Sensing System, and has the following features. q Fine control not influenced by load q Control enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q Energy saving using variable pump control
D475A, D475ASD-5E0
Structure q The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. q The work equipment pump body consists of the pump itself, CO valve and LS valve.
17
SEN00215-01
10 Structure, function and maintenance standard
2. Basic principle 1) q
18
Control of pump swash plate The pump swash plate angle (pump delivery amount) is controlled so that LS differential pressure (dPLS) [the difference between pump pressure (PP) and control valve outlet port LS pressure (PLS)] (load pressure of actuator) is constant. [LS pressure (dPLS) = Pump discharge pressure (PP) – LS pressure (PLS)]
q
If LS differential pressure (dPLS) becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
2) q
q
q
SEN00215-01
Pressure compensation A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When two actuators are operated together, this valve acts to make pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of openings (S1) and (S2) of each valve.
D475A, D475ASD-5E0
19
SEN00215-01
Unload valve
10 Structure, function and maintenance standard
1
Function q When the pump flow is merged and the control valve group on one side is actuated (with the remaining control valve group at neutral), the sub-unload valve drains the pump flow to the group that is at neutral. Operation q The pressure in pump passages (A) is received at the end portion of valve (1). The control valve is at neutral, so the pressure in LS circuit (B) is 0 MPa {0 kg/cm2}. q The pressurized oil in pump passage (A) is stopped by valve (1) and cannot escape, so the pr essur e r ises . When this pr essur e becomes larger than the force of spring (2), valve (1) moves to the left, ports (C) and (D) are interconnected, and the pump pressure flows to tank passsage (E). In addition, the pressurized oil in LS circuit (B) passes from orifice (f) through port (D) and is drained to tank passage (E). Therefore, in this operation, LS pressure C tank pressure. q In this unload operation, pump discharge pressure – LS circuit pressure is greater than the pump LS control pressure, so a signal is sent to set the pump swash plate to the minimum angle.
20
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Introduction of LS pressure
1
(LS shuttle valve)
1. 2. 3.
Main pump Main spool Pressure compensation valve
Function q LS pressure (PLS) is the actuator load pressure at the output side of the control valve. q The upstream pressure (= spool meter-in downstream pressure) of pressure compensation valve (3) is taken inside main spool (2) and goes to LS shuttle valve (5). q When this happens, it connects actuator circuit (A) and LS circcuit (PLS) through check valve (4), and sets so that LS pressure (PLS) C actuator load pressure. q Introduction hole (a) inside main spool (2) has a small diameter, so it also acts as a throttle.
D475A, D475ASD-5E0
4. 5.
Check valve LS shuttle valve
Operation q When main spool (2) is operated, pump discharge pressure (PP) starts to flow to actuator circuit (A). q First, this pump discharge pressure (PP) passes through introduction hole (a) of main spool (2), and is taken to LS circuit (PLS). q When actuator circuit pressure (A) rises to the necessary pressure, pump pressure (PP) rises and check valve (4) inside main spool (2) opens. The high pressure of LS circuit (PLS) then flows to actuator circuit (A). q In this way, LS pressure (PLS) becomes almost the same as actuator circuit pressure (A).
21
SEN00215-01
LS bypass plug
1. 2. 3. 4. 5.
22
Main pump Main spool Pressure compensation valve LS shuttle valve LS bypass plug
10 Structure, function and maintenance standard
1
Function q The residual pressure in LS circuit (PLS) is released from orifices (b) and (c). q This reduces the speed of the rise in the LS pressure, and prevents any sudden change in the oil pressure. Furthermore, a pressure loss is generated by the circuit resistance between LS shuttle valve (4) and throttle (a) of main spool (2) according to the bypass flow from LS bypass plug (5). As a result, the effective LS differential pressure drops, and the dynamic stability of the actuator is increased.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Pressure compensation valve
1
1. When the load pressure is higher than other actuators
1. 2. 3. 4. 5. 6.
Main pump Valve Shuttle valve Piston Spring LS shuttle valve
Function q When the maximum load pressure is generated during compound operations and during independent operations, and the load pressure is higher than other actuators, the pressure compensation valve acts as a load check valve to prevent reverse flow in the circuit. Operation If pump pressure (PP) and LS pressure (PLS) are lower than actuator circuit (B), shuttle valve (3) inside the pressure compensation valve moves to the left in the direction of the arrow to interconnect spring chamber (C). q When this happens, piston (4) is pushed to the right by spring (5), so pump outlet circuit (A) closes. This prevents the oil from flowing back from actuator circuit (B) to pump outlet circuit (A). q
D475A, D475ASD-5E0
23
SEN00215-01
10 Structure, function and maintenance standard
2. When the load pressure is lower than other actuators
Function q During compound operations, if the load pressure is lower than the other actuators and the flow of oil starts to increase, the pressure compensation valve carries out compensation. In this case, it tries to make the load pressure for the other actuators greater and reduce the flow of oil.
24
Operation q During compound operations, if the load pressure for the other actuators rises, the oil flow in actuator circuit (B) tries to increase. q When this happens, LS pressure (PLS) for the other actuator also increases, so this LS pressure (PLS) pushes shuttle valve (3) of the pressure compensation valve to the right in the direction of the arrow, passes through the passage inside piston (4), and flows to spring chamber (C). q As a results, piston (4) is pushed to the right in the direction of the arrow, and the outlet side of pump circuit (PP) is closed, so outlet port pressure (A) (spool meter-in downstream pressure) becomes the same as the outlet port pressure of the other actuators. q Pump pressure (PP) (spool meter-in upstream pressure) is the same between all actuators, so pump pressure (PP) and outlet port pressure (A) become the same between all spools that are being operated. Therefore, the pump flow is divided in proportion to the area of the opening of each valve.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00215-01
25
SEN00215-01
Blade lift valve
10 Structure, function and maintenance standard
1
Function q The blade lift valve supplies hydraulic oil to the blade lift cylinder according to the 4 operations of NEUTRAL, RAISE, LOWER, and FLOAT of the blade lift PPC valve lever.
1. When blade lift lever is in NEUTRAL
26
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Operation q When the blade lift lever is in NEUTRAL, spool (3) is held in the neutral position by springs (1) and (6) through retainers (2) and (4). q At this time, the oil does not flow in either of the head and bottom of the blade lift cylinder.
D475A, D475ASD-5E0
27
SEN00215-01
10 Structure, function and maintenance standard
2. When blade lift lever is set in RAISE position
28
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Operation q If the blade lift lever is set in the RAISE position, the pilot pressure is applied through the blade PPC valve to chamber (E) and spool (3) moves to the left. q The oil from the main pump flows through notch (11) of spool (3) and cylinder port (A) to the cylinder head. q The oil returning from the cylinder bottom flows through cylinder port (B) and notch (9) of spool (3) to drain port (D).
D475A, D475ASD-5E0
29
SEN00215-01
10 Structure, function and maintenance standard
3. When blade lift lever is set in LOWER position
30
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Operation q If the blade lift lever is set in the LOWER position, the pilot pressure is applied through the blade PPC valve to chamber (F) and spool (3) moves to the right. q If the blade lift lever is set to the LOWER stroke end, retainer (4) moves to retainer (5) and the load of spring (7) is added to the load of spring (6) and spool (3) stops moving. q At this time, the oil from the main pump flows through notch (10) of spool (3) and cylinder port (B) to the cylinder bottom. q The oil returning from the cylinder head flows through cylinder port (A) and notch (12) of spool (3) to drain port (C).
D475A, D475ASD-5E0
31
SEN00215-01
10 Structure, function and maintenance standard
4. When blade lift lever is set in FLOAT position
32
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00215-01
Operation q If the blade lift lever is moved from the LOWER position to the FLOAT position, the pilot pressure is applied through the blade PPC valve to chamber (F) and spool (3) moves further to the right. q At this time, retainer (5) moves against the total load of springs (6) and (7) until its right end touches plug (8). q Since cylinder ports (A) and (B) are connected to drain ports (C) and (D) respectively, both head and bottom of the blade lift cylinder are connected to the drain port and the blade is “FLOATED”.
D475A, D475ASD-5E0
33
SEN00215-01
Merge-divider valve
1. 2. 3. 4.
Main spool Spring LS spool Spring
Function q The merge-divider valve merges or divides oils (PP1) and (PP2) discharged from 2 pumps (It distributes those oils to each control valve group). q This valve also merges and divides the LS circuit pressures.
34
10 Structure, function and maintenance standard
1
Operation 1. When oils from pumps are merged (When pilot pressure (PS) is turned OFF) q Since pilot pressure (PS) is turned OFF, main spool (1) is pressed to the left by spring (2) and ports (E) and (F) are connected. q Accordingly, oils (PP1) and (PP2) discharged from the 2 pumps are merged in ports (E) and (F) and sent to the control valves which need them. q Similarly, LS spool (3) is pressed to the left by spring (4) and the connection of the LS circuit changes as follows. Connection of circuit: (A) is connected to (D). (B) is connected to (C). q As a result, the LS pressure transmitted from each control valve spool to LS circuit ports (A), (D), (B), and (C) is transmitted to all the pressure compensation valves and other hydraulic equipment.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
2. q
q
q
q
SEN00215-01
When oils from pumps are divided (When pilot pressure (PS) is turned ON) When pilot pressure (PS) is turned ON, main spool (1) is pressed to the right by the (PS) pressure and ports (E) and (F) are disconnected. Accordingly, oils discharged from the 2 pumps are sent to the set control valves respectively. Pressure (PP1): Blade right tilt valve Pressure (PP2): Blade left tilt valve Similarly, LS spool (3) is pressed to the right by the (PS) pressure and the connection of the LS circuit changes as follows. Connection of circuit: (B) is connected to (D). The other ports are disconnected. As a result, the pressures in LS circuit ports (A), (B), (C), and (D) are transmitted to the set control valves respectively.
D475A, D475ASD-5E0
35
SEN00215-01
10 Structure, function and maintenance standard
Self pressure reducing valve
1
Function q The self pressure reducing valve lowers the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valves, PPC valves, etc.
q
Operation 1. When engine is stopped
q
36
q
Poppet (11) is pressed by spring (12) against the seat and the passage between port (PR) and (TS) is closed. Valve (14) is pressed to the left by spring (13) and the passage between ports (P2) and (PR) is open. Valve (7) is pressed to the left by spring (8) and the passage between ports (P2) and (A2) is closed. D475A, D475ASD-5E0
10 Structure, function and maintenance standard
2.
SEN00215-01
When in neutral and when load pressure (P2) is low [When load pressure (A2) is lower than self pressure reducing valve output pressure (PR)]
Operation Valve (7) is pressed by spring (8) and (PR) pressure (which is 0 MPa {0 kg/cm2} while the engine is stopped) to close the passage between ports (P2) and (A2). If hydraulic oil flows in through port (P2), however, (ød area x pressure P2) = force of spring (8) + (ød area x PR pressure), and they are balanced. Then, the passage between ports (P2) and (A2) is so adjusted that the P2 pressure will be kept at a certain value higher than the PR pressure. q If the PR pressure rises higher than the set level, poppet (11) opens and the hydraulic oil flows from port (PR) through orifice (a) in spool (14) and opening of poppet (11) into seal drain port (TS). q
D475A, D475ASD-5E0
q
Accordingly, differential pressure is generated over orifice (a) in spool (14), and spool (14) moves in the direction to close the passage between ports (P2) and (PR). The P2 pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio of the passage at this time and supplied as the PR pressure.
37
SEN00215-01
3.
When load pressure (P2) is high
Operation q If load pressure (A2) is heightened and the pump delivery amount is increased because of digging operation, etc., the P2 pressure rises {(ød area × P2 pressure) > force of spring (8) + (ød area × PR pressure)}, then valve (7) moves to the right stroke end. q As a result, the opening ratio of the passage between ports (P2) and (A2) is increased and the passage resistance is reduced. Consequently, the loss of the engine horsepower is reduced. q If the PR pressure rises higher than the set level, poppet (11) opens and the hydraulic oil flows from port (PR) through orifice (a) in spool (14) and opening of poppet (11) into seal drain port (TS).
38
10 Structure, function and maintenance standard
q
Accordingly, differential pressure is generated over orifice (a) in spool (14) and spool (14) moves in the direction to close the passage between ports (P2) and (PR). The P2 pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio of the passage at this time and supplied as the PR pressure.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
4.
SEN00215-01
When abnormally high pressure is generated
Operation q If the PR pressure of the self pressure reducing valve is raised abnormally, ball (16) separates from the seat against the force of spring (15). As a result, the hydraulic oil flows from output port (PR) to (TS) and the PR pressure lowers. Accordingly, the devices receiving the oil pressure (PPC valves, solenoid valves, etc.) are protected from abnormally high pressure.
D475A, D475ASD-5E0
39
SEN00215-01
Pilot solenoid valve
PPB : PPD : TLL : TLR : PTH : DUL : PPV : MFD:
40
10 Structure, function and maintenance standard
1
Rear pitch solenoid Forward pitch solenoid Left tilt limit solenoid Right tilt limit solenoid Pitch changeover solenoid Dual changeover solenoid Pitch priority solenoid Merge-divider solenoid
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
q
SEN00215-01
The operation of the pilot solenoid valve is shown in the following table.
Solenoid drive table (Dual tilt specification) PPB Lift
Single tilt
PPD
TLL
TLR
PTH
Dual tilt
Lift Ripper Tilt
MFD
Lower Left tilt Right tilt
q
Left tilt limit Right tilt
q
Right tilt limit Pitch
PPV
Raise
Left tilt
Blade
DUL
q
q
q
q
q
q
q
q
Rear pitch
q
q
Forward pitch
q
q
Raise Lower Raise Lower
Solenoid drive table (Superdozer specification) PPB Lift
PPD
TLL
TLR
PTH
DUL
PPV
MFD
Raise Lower Left tilt
Blade
Single tilt
q
Left tilt limit Right tilt
q
Right tilt limit Pitch
Lift Ripper Tilt
Rear pitch Forward pitch
q
q q
q
q
q
q
q
Raise Lower Raise Lower
D475A, D475ASD-5E0
41
SEN00215-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN00215-01
© 2016 KOMATSU All Rights Reserved Printed in Japan 02-16 (01)
42
SEN00216-01
BULLDOZER 1SHOP MANUAL 2SHOP
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Hydraulic system, Part 3 Hydraulic tank, hydraulic filter ......................................................................................................................... 2 Accumulator .................................................................................................................................................... 4 Work equipment cylinder ................................................................................................................................ 6 Piston valve..................................................................................................................................................... 8 Quick drop valve ........................................................................................................................................... 10 Blade control knob (Dual tilt specification) .................................................................................................... 12 Blade control knob (Superdozer specification) ............................................................................................. 13 Pitch and dual solenoid valve ....................................................................................................................... 14 Pin puller hydraulic circuit diagram ............................................................................................................... 15 Pin puller solenoid valve ............................................................................................................................... 16
D475A, D475ASD-5E0
1
SEN00216-01
10 Structure, function and maintenance standard
Hydraulic tank, hydraulic filter
1. 2. 3. 4. 5. 6.
2
Cover Sight gauge Cover Hydraulic tank Oil filler cap Hydraulic filter element
1
7. 8. 9. 10. 11. 12.
Spring Suction valve Strainer Drain plug Drain valve Breather, with valve function
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00216-01
Specified value Tank capacity Hydraulic tank
Breather
(l)
310
High (l) Level inside Middle (l) tank Low (l)
210
140
Cracking pressure (kPa {kg/cm2})
17.0 ± 2.5 {0.17 ± 0.025}
Vacuum valve actuating pressure (kPa {kg/cm2})
2.0 ± 0.3 {0.02 ± 0.003 }
170
Specified value 150 ± 30 {1.53 ± 0.3}
Cracking pressure (kPa {kg/cm2}) Hydraulic Mesh size filter Filtering area Filtering oil flow Strainer
Mesh size Filtering area
D475A, D475ASD-5E0
(µm) 2
(cm )
30/8 17,600
(l/min)
703
(µm)
105
2
(cm )
3,600
3
SEN00216-01
Accumulator For PPC valve
1. 2. 3. 4. 5. 6.
10 Structure, function and maintenance standard
1 Operation q After the engine is stopped, when the PPC valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B). q When the PPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30 kg/cm2}, and the pressure of the nitrogen gas in chamber (A) expands the bladder, so the oil in chamber (B) acts as the pilot pressure and actuates the main control valve.
Glass plug Shell Poppet Holder Bladder Oil port
Specifications: Type of gas:Nitrogen Gas volume:300 cc Max. actuation pressure:3.1 MPa {32 kg/cm2} Min. actuation pressure: 1.2 MPa {12 kg/cm2} Function q The accumulator is installed between the pressure reducing valve and the PPC valve. Even if the engine is stopped with the work equipment still raised, the pressure of the nitrogen gas compressed inside the accumulator sends the pilot pressure to the main control valve to actuate it and enable the work equipment to move down under its own weight.
4
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00216-01
5
SEN00216-01
Work equipment cylinder q
Blade lift cylinder
q
Blade tilt cylinder, superdozer pitch cylinder
q
Ripper lift cylinder, ripper tilt cylinder
6
10 Structure, function and maintenance standard
1
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00216-01
Pin puller cylinder
q
Unit: mm No.
Check item
Criteria Standard size
1
2
3
4
5
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
Blade lift
110
–0.036 –0.090
+0.261 +0.047
0.083 – 0.351
0.65
Blade tilt
140
–0.043 –0.106
+0.263 +0.047
0.090 – 0.369
0.67
Ripper lift
120
–0.036 –0.090
+0.263 +0.048
0.084 – 0.353
0.65
Ripper tilt
140
–0.043 –0.106
+0.263 +0.047
0.090 – 0.369
0.67
Pin puller
30
–0.065 –0.117
+0.133 +0.007
0.072 – 0.250
0.55
Blade lift
65
—
+0.5 +0.2
—
1.0
Blade tilt
90
–0.300 –0.200
+0.100 +0.013
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
—
Ripper lift
110
+0.207 +0.120
1.0
Ripper tilt
110
+0.195 +0.122
1.0
Clearance between cylinder bottom support shaft and boss
26
+0.1
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
D475A, D475ASD-5E0
+0.457 +0.370
—
Replace
1.0
7
SEN00216-01
10 Structure, function and maintenance standard
Piston valve
1
For blade lift cylinder Outline q The piston valve is installed to the piston of the blade lift cylinder. When the piston moves to the stroke end, the piston valve relieves the oil sent from the work equipment pump to lower the oil pressure applied to the piston. The piston valve also relieves the oil before the piston reaches the bottom or head of the cylinder to reduce the impact made at the stroke end and lower the surge pressure generated by the impact.
2.
When piston valve is “open” The end of valve (6) touches the cylinder bottom before piston rod (1) reaches the stroke end, and then valve (6) and piston valve (3) do not move any more and only piston (2) continues moving. At this time, the oil on the cylinder head side which has been stopped by piston valve (3) is relieved through piston valve seats (4) and (5), thus the oil pressure in the cylinder does not rise any more.
Operation 1. When piston valve is “closed” The oil from the work equipment pump acts on piston (2) and piston valve (3). Then, piston valve (3) is pushed to the right to seal the tapered part of piston valve seat (4). As a result, the oil pressure in the cylinder rises to move piston (2) to the right.
8
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00216-01
9
SEN00216-01
10 Structure, function and maintenance standard
Quick drop valve
1
For blade lift cylinder
2.
Outline The quick drop valve is installed to each of the right and left blade lift cylinders. It increases the lowering speed of the blade and prevents a vacuum on the cylinder bottom side during the lowering stroke and shortens the time lag in starting digging. The blade lowering speed is almost determined by the pump delivery amount. It can be heightened, however, by the quick drop valve.
1. 2.
Valve body Spool
3. 4.
While lowering blade The oil pushed out of the cylinder head side flows through port (B) to port (C). At this time, a pressure difference is made between before and after orifice (a). If the pressure difference becomes larger than the tension of spring (4), it compresses the spring and moves spool (2) and check valve (3) to the right. Then, ports (B) and (A) are connected and a part of the oil which has been flowing from the head side to port (C) flows in port (A) on the bottom side and merges with the oil from the control valve and flows into the bottom side. Accordingly, the blade lowering speed is increased by the quantity of the oil flowing into the cylinder bottom side and a vacuum on the bottom side is prevented.
Check valve Spring
Operation 1. Start of lowering blade If the blade control lever is set in the LOWER position, the oil from the control valve flows through port (A) to the cylinder bottom side and pushes the piston. The oil on the cylinder head side is pushed out by the piston into port (B), and then flows through port (C) and control valve to the hydraulic tank.
10
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00216-01
Unit: mm No.
1
Check item
Clearance between spool and valve body
Criteria Standard size 38.0
Tolerance Shaft
Hole
Standard clearance
Clearance limit
–0.011 –0.016
+0.010 +0.016
0.011 – 0.026
0.03
Standard size 2
Valve spring
D475A, D475ASD-5E0
Remedy
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
75.2
55.9
136.3 N {13.9 kg}
67.7
122.6 N {12.5 kg}
Replace
11
SEN00216-01
10 Structure, function and maintenance standard
Blade control knob (Dual tilt specification)
1. 2. 3. 4. 5.
Switch (dual-single selector switch) Switch (pitch) Cover Connector (male) Connector (female)
q
q
Outline q If the blade control knob is tilted forward, backward, to the right, or to the left, the blade is raised, lowered, tilted to the right, or tilted to the left. If switch (1) is set to the “DUAL” position and the lever is tilted to the right or left, dual tilt operation is carried out. If the lever is tilted to the right or left while switch (2) is pressed and held, pitching operation is carried out.
12
q
1
If switch (2) is pressed and the lever is operated, the blade is pitched. If the lever is tilted to the left, the blade is pitched back. If the former is tilted to the right, the latter is pitched forward. If switch (1) is set to the “DUAL” position and the lever is operated, blade carries out dual tilt operation. If the lever is tilted to the left, the blade carries out left dual tilt operation. If the lever is tilted to the right, the blade carries out right dual tilt operation. If switch (1) is set in either “DUAL” or “SINGLE” position and the lever is tilted to the right or left while switch (2) is pressed and held, the blade is pitched.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00216-01
Blade control knob (Superdozer specification)
1. 2. 3. 4. 5.
Forward pitch switch Rear pitch switch Cover Connector (male) Connector (female)
D475A, D475ASD-5E0
1
Outline q The blade is raised and lowered by leaning the blade control knob forward and backward. q If switch (1) is pressed, the blade is pitched forward. If switch (2) is pressed, the blade is pitched back.
13
SEN00216-01
Pitch and dual solenoid valve
1. 2. 3. 4. 5.
Connector Solenoid (a) Valve Solenoid (b) Manual push pin
A: B: P: T:
Port A Port B Port P Port T
14
10 Structure, function and maintenance standard
1
Outline q The pitch and dual solenoid valve is installed between the PPC valve and main control valve and used to select the PPC pilot pressure. q Operation of the pitch switch of the blade control lever (or the rear pitch switch or forward pitch switch of the superdozer specification), pilot pressure can be applied so the right and left pitch cylinders will move similarly and the tilt operation can be changed to the pitch operation. q If the dual tilt specification is installed and the toggle switch of the blade control lever is set in the "dual" position, the pilot pressure is applied to both right and left tilt cylinder spools to change the single tilt operation to the dual tilt operation. q The pitch and dual tilt solenoid valve is operated by the controller.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00216-01
Pin puller hydraulic circuit diagram
1
1. 2. 3. 4. 5. 6. 7.
Power train oil tank Oil strainer Power train pump Oil filter Main relief valve (Set pressure: 2.45 MPa {25 kg/cm2}) Steering control valve Pin-puller solenoid valve
D475A, D475ASD-5E0
8. Pin-puller cylinder 9. Steering case 10. Scavenging pump A: To transmission lubrication circuit B: To torque converter circuit C: To transmission valve circuit and torque converter lockup circuit
15
SEN00216-01
10 Structure, function and maintenance standard
Pin puller solenoid valve
1. 2. 3. 4. 5. 6. 7. 8. 9.
16
Plug Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly
1
A. B. C. D.
To pin puller cylinder head From power train pump To pin puller cylinder bottom To steering case
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
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 (12).
D475A, D475ASD-5E0
SEN00216-01
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 pin puller 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 (12).
17
SEN00216-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN00216-01
© 2008 KOMATSU All Rights Reserved Printed in Japan 04-08 (01)
18
SEN00217-00
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Work equipment Work equipment .............................................................................................................................................. 2 Cylinder stay ........................................................................................................................................ 2 Blade .................................................................................................................................................... 4 Ripper equipment................................................................................................................................. 8
D475A, D475ASD-5E0
1
SEN00217-00
10 Structure, function and maintenance standard
Work equipment
1
Cylinder stay
1
Unit: mm No.
Criteria Tolerance 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 +0.016
0.145 – 0.285
0.5
Clearance between cylinder yoke and bushing
Standard size
Remedy
Shaft
1
2
Check item
Replace
D475A, D475ASD-5E0
SEN00217-00
Blade
10 Structure, function and maintenance standard
1
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
4
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
No.
1
SEN00217-00
Check item
Clearance between brace pin and brace
Criteria Standard size
Tolerance
Remedy Standard clearance
Clearance limit
Shaft
Hole
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 +0.6
0.3 – 0.5
1
4
Clearance between brace pin and bushing
90
–0.3 –0.4
+0.1 +0.6
0.3 – 0.5
1
5
Clearance between center brace and cap spherical surface
200
–0.2 –0.3
+0.3 +0.6
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 +0.6
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
9
Clearance between straight frame joint bushings
185
+0.206 +0.166
–0.014 –0.060
–0.152 – –0.266
—
10
Clearance between trunnion and cap spherical surface
250
–0.5 –1.0
+1.0 +0.6
0.5 – 2.0
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 +0.6
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 +0.6
0.2 – 1.1
2
17
Clearance between center brace spherical surface and cap
200
–0.2 –0.3
+0.3 +0.6
0.2 – 0.6
1
18
Clearance between lift cylinder head pin and cylinder
65
–0.3 –0.5
+0.5 +0.2
0.5 – 1.0
2
19
Clearance between lift cylinder head pin and cross joint
65
–0.3 –0.5
+0.3 +0.6
0.3 – 0.8
2
20
Clearance between bracket and lateral pin
65
–0.3 –0.5
+0.3 +0.6
0.3 – 0.8
2
21
Clearance between cross joint and lateral pin
65
–0.3 –0.5
+0.5 +0.2
0.5 – 1.0
2
D475A, D475ASD-5E0
Replace
Adjust shim or replace
Replace
Adjust shim or replace
Replace
5
SEN00217-00
10 Structure, function and maintenance standard
Cutting edge, end bit
Unit: mm No.
6
Check item
Criteria
Remedy
Standard size
Repair limit
510
383
Width of end bit
720
635
3
Height of end bit inside
393
330
4
Height of cutting edge
405
351 (240 after turned)
1
Height of end bit outside
2
Replace
Replace or turn
D475A, D475ASD-5E0
SEN00217-00
Ripper equipment
10 Structure, function and maintenance standard
1
Variable giant ripper
8
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00217-00
Unit: mm No.
Check item
1
Clearance between bushing and bracket and arm mount pin
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.193 +0.050
0.093 – 0.299
1.5
2
Clearance between bushing and beam and arm mount pin
140
–0.043 –0.106
+0.500 +0.300
0.343 – 0.606
1.5
3
Clearance between cylinder mount pin and bushing
110
–0.036 –0.090
+0.289 +0.123
0.159 – 0.379
1.5
4
Outside diameter of shank mount pin
5
Wear of point
6
Wear of protector
D475A, D475ASD-5E0
Standard size
Tolerance
Repair limit
100
±0.3
—
Standard size
Repair limit
460
300
224
184
Replace
9
SEN00217-00
D475A, D475ASD-5 Bulldozer Form No. SEN00217-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 01-06 (01)
10
SEN00218-00
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Cab and its attachments Cab and its attachments ................................................................................................................................. 2 Cab mount............................................................................................................................................ 2 Cab....................................................................................................................................................... 3 Air conditioner ...................................................................................................................................... 6
D475A, D475ASD-5E0
1
SEN00218-00
10 Structure, function and maintenance standard
Cab and its attachments
1
Cab mount
1
1. 2. 3.
2
Support Damper mount (front) Damper mount (rear)
Outline q Mounts are installed at two places at the front and two places at the rear to secure the floor frame and cab. q An oil-filled damper mount is used to absorb the vibration.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Cab
SEN00218-00
1
Cab assembly
1. 2. 3. 4.
Front wiper Front glass Rear wiper Door
D475A, D475ASD-5E0
3
SEN00218-00
10 Structure, function and maintenance standard
ROPS guard
1.
4
ROPS guard
D475A, D475ASD-5E0
SEN00218-00
Air conditioner
10 Structure, function and maintenance standard
1
Air conditioner piping
6
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Condenser Air conditioner compressor Refrigerant piping Window defroster Side defroster Vent Hot water pickup piping Valve (hot water outlet) Receiver tank Hot water return piping Valve (hot water inlet) Air conditioner unit Additional blower motor
A. B. C.
Fresh air Recirculated air Hot air/cold air
D475A, D475ASD-5E0
SEN00218-00
7
SEN00218-00
D475A, D475ASD-5E0 Bulldozer Form No. SEN00218-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 01-06 (01)
8
SEN00219-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
10 Structure, function and maintenance standard
1
Electrical system Engine control system..................................................................................................................................... 2 CRI engine control system.............................................................................................................................. 6 Monitor system.............................................................................................................................................. 10 Machine monitor ........................................................................................................................................... 12 Mode selection system ................................................................................................................................. 30 Electrical equipment...................................................................................................................................... 34 Palm command control system (PCCS) ....................................................................................................... 36 Sensors......................................................................................................................................................... 38 Vehicle health monitoring system (VHMS).................................................................................................... 45 ORBCOMM terminal ..................................................................................................................................... 51
D475A, D475ASD-5E0
1
SEN00219-02
Engine control system
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
2
Battery relay (Right) Steering controller Battery (Right) Transmission controller Engine throttle controller Decelerator pedal Starting switch Decelerator pedal potentiometer Fuel control dial Battery (left) Battery relay (left) Starting motor Fuel supply pump
10 Structure, function and maintenance standard
1
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 fuel control dial signal enter the machine controller, are processed together with other data, and are sent to the electronic engine throttle controller as the throttle command. The electronic engine throttle controller controls the fuel supply pump according to the command. This machine uses CRI system.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00219-02
System diagram
Note The design of the machine monitor differs by a machine. For details, see section “Machine monitor”. Outline q The engine throttle 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 fuel supply pump. The 3rd throttle control signals contain the following. 1) High idle speed control 2) SSC (Shoe Slip Control) 3) Automatic deceleration (F3, R3, R2)
D475A, D475ASD-5E0
q
q
q
The steering controller sends the most suitable for engine speed from informations 1) and 2) and transmits it as the 3rd throttle to the engine throttle controller. Information of the engine throttle controller is commonly used by all the controllers throughout the network, for 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).
3
SEN00219-02
10 Structure, function and maintenance standard
Deceleration potentiometer
1. 2. 3. 4. 5. 6. 7.
4
Connector Lever Body Potentiometer Coupling Shaft Stopper
Outline q The deceleration potentiometer is installed to the front lower part of the operator’s cab and connected to the decelerator pedal by linkage. q 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 throttle controller according to the position of the decelerator pedal.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
D475A, D475ASD-5E0
SEN00219-02
5
SEN00219-02
CRI engine control system a
10 Structure, function and maintenance standard
1
CRI: Abbreviation for Common Rail Injection.
System diagram 1.
6
STD specification
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. NE speed sensor 2. Engine throttle controller 3. Injector assembly 3A. Orifice 3B. Control chamber 3C. Hydraulic piston 3D. Injector 3E. Nozzle 4. Fuel tank 5. Strainer 6. Pre fuel filter (with water separator) 7. Priming pump (main) 8. Fuel filter 9. Engine throttle controller cooler 10. Pressure limiter 11. Flow damper 12. High pressure injection pipe 13. Common rail 14. Fuel supply pump assembly 14A. PCV 14B. High pressure pump 14C. Feed pump 14D. Bypass valve 14E. Bkup speed sensor (G sensor) 15. Overflow valve
D475A, D475ASD-5E0
SEN00219-02
Outline q The signals detected by various sensors are input to the engine controller. q The input signals are processed by the controller and output to each actuator to control the fuel injection rate and fuel injection timing. System configuration q The CRI system consists of fuel supply pump (14), common rail (13), injector (3), engine throttle controller (2) to control them, and sensors. q The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The discharge rate is controlled by turning on and off PCV (discharge control valve) (14A) of the fuel supply pump according to the electric signals from the engine throttle controller. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail and controlled by the feedback method so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to nozzle (3E) side of the injector and control chamber (3B) through the fuel injection pipe of each cylinder. q The injector controls the fuel injection rate and fuel injection timing by turning on and off the TWV (2-way solenoid valve). If the TWV is turned on, the fuel circuit is so changed that the high-pressure fuel in the control chamber will flow through orifice (3A). The needle valve is raised to start fuel injection by the nozzle cracking pressure applied as the high-pressure fuel on the nozzle side. If the TWV is turned off, the fuel circuit is so changed that the highpressure fuel will be applied to the control chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.
7
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2.
8
10 Structure, function and maintenance standard
Machine of poor fuel arrangement specification
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
1. NE speed sensor 2. Engine throttle controller 3. Injector assembly 3A. Orifice 3B. Control chamber 3C. Hydraulic piston 3D. Injector 3E. Nozzle 4. Orifice (For bleeding air) 5. Fuel tank 6. Strainer 7. Pre fuel filter (with water separator) 8. Priming pump 9. Fuel filter 10. Engine throttle controller cooler 11. Pressure limiter 12. Flow damper 13. High pressure injection pipe 14. Common rail 15. Fuel supply pump assembly 15A. PCV 15B. High pressure pump 15C. Feed pump 15D. Bypass valve 15E. Bkup speed sensor (G sensor) 16. Overflow valve 17. Air bleeding valve 18. Water separator
D475A, D475ASD-5E0
SEN00219-02
Outline q The signals detected by various sensors are input to the engine controller. q The input signals are processed by the controller and output to each actuator to control the fuel injection rate and fuel injection timing. System configuration q The CRI system consists of fuel supply pump (15), common rail (14), injector (3), engine throttle controller (2) to control them, and sensors. q The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The discharge rate is controlled by turning on and off PCV (discharge control valve) (15A) of the fuel supply pump according to the electric signals from the engine throttle controller. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail and controlled by the feedback method so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to nozzle (3E) side of the injector and control chamber (3B) through the fuel injection pipe of each cylinder. q The injector controls the fuel injection rate and fuel injection timing by turning on and off the TWV (2-way solenoid valve). If the TWV is turned on, the fuel circuit is so changed that the high-pressure fuel in the control chamber will flow through orifice (3A). The needle valve is raised to start fuel injection by the nozzle cracking pressure applied as the high-pressure fuel on the nozzle side. If the TWV is turned off, the fuel circuit is so changed that the highpressure fuel will be applied to the control chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.
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10 Structure, function and maintenance standard
Monitor system
1
Note The design of the machine monitor differs by a machine. For details, see section “Machine monitor”. Outline q The monitor system monitors the machine condition with sensors installed to various parts of the machine, and quickly processes and displays obtained information on the monitor panel, to notify the operator of machine condition. The function of the monitor system is as follows. 1) Function which turns on the alarm when the machine has a trouble on the monitor. 2) Function which constantly displays the machine condition (coolant temperature,
10
q
q
q
torque converter oil temperature, fuel level, hydraulic oil level, etc.) on the gauge. 3) Function of displaying error codes. 4) Function of monitoring the current and voltage of the sensors and solenoids. 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 (with SSC). The monitor panel has the functions of displaying data and selecting the SSC mode (with SSC). 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, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00219-02
Processing in machine monitor (Common to all specifications) Display of machine monitor Contents and conditions of processing
Method
Flow of signals
1) Display of travel direction and gear speed. F1, R3, etc. are notified by CAN signals according to information of transmission controller.
CAN
Transmission controller o Steering controller o Machine monitor
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 signals.
CAN
3) Display of failure When the machine has a failure, the corresponding CAN failure code is notified to the monitor panel by CAN signals. Which one should be turned on, the buzzer or the caution lamp, is notified, too. i) In normal state User code ii) In fault history display mode The service code (6-digit code) and the following items are displayed 1. Time after first occurrence 2. Time after latest occurrence 3. Number of past occurrence The machine monitor displays code on the multiinformation section.
Engine speed sensor o Steering controller o Machine monitor
Engine sensor/solenoid o Steering controller or transmission controller o Machine monitor
Sensors and solenoids o Engine throttle controller o Steering controller o Machine monitor
Display of monitoring condition Contents and conditions of processing
Method
Flow of signals
1) The communication conditions of each sensor, each solenoid, and CAN signals are displayed. The item Nos. and device conditions are notified to the machine monitor by CAN signals. The machine monitor displays the items and each value on its multi-information section.
CAN
Each sensor o Steering controller or transmission controller o Machine monitor Sensors o Engine throttle controller o Steering controller o Machine monitor
2) Each items is selected by using the cursor switches, selector switches, buzzer cancel switch, and shift UP/DOWN switches.
Machine monitor o Controller o Machine monitor
Other items Contents and conditions of processing
Method
Flow of signals
1) Function selection mode (Displayed each time cancel switch is turned to left) i) Replacement periods of oil filter and oil are displayed. ii) Engine speed, oil pressure in work equipment circuit, etc. are displayed. iii) Failure codes related to electronic control are displayed. iv) Brightness of display, etc. are adjusted. 2) Mode to change replacement periods of maintenance mode 3) Mode to display failure codes related to the machine such as overheating, abnormal coolant temperature, etc. 4) Mode to display service meter and information related to load on machine
CAN
Steering controller o Machine monitor
D475A, D475ASD-5E0
Note CAN is abbreviation for Controller Area Network, which is a communication standard name provided by ISO etc.
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10 Structure, function and maintenance standard
Machine monitor
1
Monitor portion Serial No.: 30001 – 30070
1. 2. 3. 4. 5. 6.
Engine speedometer Engine coolant temperature gauge Power train oil temperature gauge Hydraulic oil temperature gauge Fuel level gauge Display section A (Travel direction and gear speed and others) 7. Torque converter lock-up indicator lamp 8. Charging condition caution lamp 9. Engine oil pressure caution lamp 10. Engine coolant temperature caution lamp 11. Power train oil temperature caution lamp 12. Hydraulic oil temperature caution lamp
12
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Air cleaner clogging caution lamp Radiator coolant level caution lamp Hydraulic oil level caution lamp Engine oil level caution lamp Engine pre-heating indicator lamp Maintenance caution lamp Dual tilt selector indicator lamp Warning red lamp Radiator fan operation indicator orange lamp Display section B (Multi-information) Mode selection switches portion
q
No.15 and No.16 are optional.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00219-02
Serial No.: 30071 and up
1. 2. 3. 4. 5. 6.
Engine speedometer Engine coolant temperature gauge Power train oil temperature gauge Hydraulic oil temperature gauge Fuel level gauge Display section A (Travel direction and gear speed and others) 7. Torque converter lock-up indicator lamp 8. Charging condition caution lamp 9. Engine oil pressure caution lamp 10. Engine coolant temperature caution lamp 11. Power train oil temperature caution lamp 12. Hydraulic oil temperature caution lamp
D475A, D475ASD-5E0
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Air cleaner clogging caution lamp Radiator coolant level caution lamp Hydraulic oil level caution lamp Engine oil level caution lamp Engine pre-heating indicator lamp Maintenance caution lamp Dual tilt selector indicator lamp Warning red lamp Radiator fan operation indicator orange lamp Display section B (Multi-information) Mode selection switches portion Radiator fan operation indicator lamp/symbol (The indicator which admits change operation)
q
No.15 and No.16 are optional.
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Outline q The monitor section is an LCD screen which consists of the gauges that constantly indicate the machine condition, character screen that displays the current travel condition of the machine (travel direction and gear speed), caution lamps that indicate abnormalities of the machine, indicator lamps that show the operation guide, and multi-information unit that displays the service meter and maintenance information. The CPU in the machine monitor processes the signals from the sensors at various places of the machine and indicates the results on the screen.
10 Structure, function and maintenance standard
3.
a
Indicators The necessary timings of the operations of the machine are indicated by the indicator lamps in the monitor section. Indication items (type of the indicator lamps), their operations, and their indication methods are shown in the “List of display of cautions and indicators” which will appear later. The blinking intervals of the indicator lamps are the same with the caution lamps.
Operation 1. Operation check (Check before starting) While the engine is stopped (five or more seconds after the engine is stopped), if the power is turned ON (the starting switch is turned to the ON position), all items of the gauges, indicator lamps and caution lamps of the monitor section operate as follows to indicate that each of them operates normally. 1) All items of the gauges, indicator lamps and caution lamps light for about 3 seconds and then go off. 2) The alarm buzzer sounds for about 1 second, synchronizing with 1) above. 2.
a
a
14
Cautions If the machine has any trouble, the caution lamp corresponding to the trouble part in the monitor section blinks or lights and the alarm buzzer sounds as required. The caution items (types of the caution lamps), caution lamps corresponding to the caution items, and operation of the alarm buzzer are shown in the “List of display of cautions and indicators” which will appear later. All the items, except the items of indication category “Check before starting” in “List of display of cautions and indicators” shown later, are monitored while the engine is running, from the start to the stop of the engine. The items of display category “Check before starting” are monitored from when the starting switch is turned ON while the engine is stopped. The blinking intervals of the caution lamps and the sounding intervals of the alarm buzzer are set to about 0.8 seconds, which fluctuates more or less when the ambient temperature is low (below about –10°C), but that does not indicate trouble.
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10 Structure, function and maintenance standard
4.
Gauges The gauges display the typical drawing of the items that the operator monitors constantly before and during operation among the information items (signals) from the sensors at various parts of the machine. The gauges display constantly from when the starting switch is turned ON to when the starting switch is turned OFF and operates constantly while the engine is running. Each scale does not read values but indicates colored ranges. The pointer is indicated by changing (turning ON and OFF) the color of a narrow LCD segment. The operator checks in which range of each gauge the coloring segment is (or the position of the first segment when multiple coloring segments are displayed in the gauge). The types, designs and displayed color bands of the gauges are shown in the “List of display of gauges” which will appear later. The thermometer among the gauges, if the above segment indicates the red range, the caution lamp and the alarm buzzer described before operate, too. For the relationship between the gauge (thermometer), caution lamp and alarm buzzer, see the “List of display of cautions and indicators” which will appear later.
D475A, D475ASD-5E0
SEN00219-02
5.
Display section A Display section A displays the following. (1) Normal display (Operation mode display) T h e c u r r e n t tr av el o p e r a t i o n of t h e machine is indicated by alphanumerics. That is, travel in forward 1st gear is indicated by F1, travel at reverse 2nd gear is indicated by R2, and setting of the gear in neutral is indicated by N. If the parking brake is set in the parking position, P is displayed. The CPU of this monitor system processes and indicates the set information items (signals) of the PCCS lever and parking brake lever and those from the transmission controller. Note: PCCS: Abbreviation for Palm command control system. For details, see the Operation and Maintenance Manual. (2) Special display (Service mode choice display) T h is i s sp ec ia l d is pl ay wh ic h i s no t described in the Operation and Maintenance Manual. It is used by the servicemen for testing, adjusting, troubleshooting, etc. In this case, the display of display section B described later is changed to various service mode displays, and display section A is also changed to indicate which service mode is selected by display section B. The selected service mode is indicated by the service mode type code of 2 alphanumeric letters such as 1C, EE, bE, etc. For details, see “30 Testing and adjusting” of this manual.
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6.
16
Display section B (Multi-information) Display section B is called the multi-information unit, which is set in the operation mode when the starting switch is turned ON and which has the following 4 types of indicating function. (1) Default (Operation mode display) While the machine is in operation, display section B displays the service meter (integrated operating time of the machine) and the preset forward and reverse gear speeds. The service meter advances and the hourglass symbol at the service meter head blinks while the engine is running. This machine has the function of driving in the preset forward or reverse gear speed. The preset gear speed is indicated by F* for forward and R* for reverse on the left of the service meter to indicate that the transmission is preset and the preset gear speed. (2) Maintenance display The display can be changed with a specified switch to indicate the information related to the maintenance of the machine. The following modes can be selected by this function. For details of them and the operating procedure, see the Operation and Maintenance Manual or “30 Testing and adjusting” of this manual. q Maintenance mode q PM clinic auxiliary mode q Error code display mode q Adjustment mode (3) Action code display If a serious trouble occurs which should be notified to the operator while the machine is operating in the normal display mode, the action code is displayed instead of the normal display. Action codes are alphanumerics such as E01, E02, etc. The types and meanings of them and remedies for them are described in the Operation and Maintenance Manual or “30 Testing and adjusting” of this manual. If an action code other than E01 is displayed, the warning lamp (red) blinks and the alarm buzzer sounds, too.
10 Structure, function and maintenance standard
(4) Special display (Service mode display) This is the special display described in Display section A, (2). The modes corresponding to the various service modes displayed in Display section A are displayed. For the types and meanings of the various service modes and remedies for them, see “30 Testing and adjusting” of this manual. As explained in Display section A, (2), this display is not described either in the Operation and Maintenance Manual.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
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List of display of cautions and indicators Serial No.: 30001 – 30070 Display category
Symbol
Indicated item
Indication range
Indication method
Check before starting
Radiator coolant level
Engine oil level (If equipped)
Below low level
Displayed when starting switch is turned ON while engine is stopped or when abnormality occurs. When normal: OFF When abnormal: Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Hydraulic oil level (If equipped)
Charging condition
When charging is defective
Engine oil press.
Below 49.0 kPa {0.5 kg/cm2}
Radiator coolant level
Below low level
Air cleaner clogging
When clogged Reference: Below –650 mmH2O
Hydraulic oil level (If equipped)
Below low level
Cautions
SAP00522
Engine coolant temp.
D475A, D475ASD-5E0
When coolant temp. gauge is in red range (above 102°C)
Displayed when abnormality occurs while engine is running. When normal: OFF When abnormal: Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Displayed when abnormality occurs while engine is running. 102°C – 105°C (1st red segment): Blinking Above 105°C (2nd red segment): Blinking. Warning lamp blinks and alarm buzzer sounds, too.
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Display category
Symbol
10 Structure, function and maintenance standard
Indicated item
When power train oil temp. gauge is in red range (above 120°C)
Hydraulic oil temp.
When hydraulic oil temperature gauge is in red range (above 100°C)
Displayed when abnormality occurs while engine is running. 100°C – 110°C (1st red segment): Blinking Above 110°C (2nd red segment): Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Maintenance
After replacement period of filter or oil
Displayed when abnormality occurs while engine is running. When normal: OFF When abnormal: ON
Engine oil level (If equipped)
Alarm
—
Auxiliary caution
Red Non-symbol
The whole engine drive does not work.
Blinking: Blinks if caution having * in indicated item column blinks. Blinks if action code other than E01 is displayed in Display section A (Multi-information) OFF: Same as cautions having * in indicated item column.
When engine is preheated
During preheating period: ON Other than preheating period: OFF If engine controller judges from coolant temperature that preheating is necessary, automatic preheating starts. When starting switch is turned to preheating position (turned left), preheating starts, too.
When possible
When possible: ON When impossible: OFF Turned ON when tilt switch of blade (work equipment) control lever is turned to dual tilt operation position (dual tilt operation is possible) and turned OFF when returned.
Indicators
Engine preheater (Electric heater ONOFF)
Indication that dual tilt operation is possible
18
Indication method Displayed when abnormality occurs while engine is running. 120°C – 130°C (1st red segment): Blinking Above 130°C (2nd red segment): Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Power train oil temp.
Cautions
Indication range
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Display category
Symbol
Indicators
Orange Non-symbol
Indicated item
Indication that engine can be started with cooling fan in reserve direction for cleaning cooling device such as radiator and that cooling fan rotation direction cannot be changed while engine is running regardless of current cooling fan rotation direction
SEN00219-02
Indication range
Indication method ON: Turned ON when fan rotation selector switch is turned to CLN position.
ON: When cooling fan rotation direction is in reverse rotation mode Blinking: When cooling fan rotation direction cannot be changed
Blinking: Blinks for 3 seconds to notify that cooling fan rotation direction cannot be changed when fan rotation selector switch is operated while engine is running. OFF: Turned OFF when fan rotation selector switch is operated again while this lamp is ON (At this time, cooling fan rotation direction is set in forward rotation mode). Lamp position
Lock-up mode ONOFF
In lock-up mode
ON: In lock-up mode OFF: In torque converter drive mode
D475A, D475ASD-5E0
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List of display of cautions and indicators Serial No.: 30071 and up Display category
Symbol
Indicated item
Indication range
Indication method
Check before starting
Radiator coolant level
Engine oil level (If equipped)
Below low level
Displayed when starting switch is turned ON while engine is stopped or when abnormality occurs. When normal: OFF When abnormal: Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Hydraulic oil level (If equipped)
Charging condition
When charging is defective
Engine oil press.
Below 49.0 kPa {0.5 kg/cm2}
Radiator coolant level
Below low level
Air cleaner clogging
When clogged Reference: Below –650 mmH2O
Hydraulic oil level (If equipped)
Below low level
Engine coolant temp.
Displayed when abnormality occurs while engine is running. 102°C – 105°C (1st red segment and all segments under it): BlinkWhen coolant temperature gauge ing is in red range (above 102°C) Above 105°C (2nd red segment and all segments under it): Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Cautions
SAP00522
20
Displayed when abnormality occurs while engine is running. When normal: OFF When abnormal: Blinking. Warning lamp blinks and alarm buzzer sounds, too.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Display category
Symbol
Indicated item
Power train oil temp.
SEN00219-02
Indication range
Displayed when abnormality occurs while engine is running. 120°C – 130°C (1st red segment When power train oil temperature and all segments under it): Blinkgauge is in red range (above ing 120°C) Above 130°C (2nd red segment and all segments under it): Blinking. Warning lamp blinks and alarm buzzer sounds, too.
When hydraulic oil temperature gauge is in red range (above 100°C)
Maintenance
After replacement period of filter or oil
Displayed when abnormality occurs while engine is running. When normal: OFF When abnormal: ON
Cautions
Hydraulic oil temp.
Displayed when abnormality occurs while engine is running. 100°C – 110°C (1st red segment and all segments under it): Blinking Above 110°C (2nd red segment and all segments under it): Blinking. Warning lamp blinks and alarm buzzer sounds, too.
Engine oil level (If equipped)
Alarm
—
Auxiliary caution
Red Non-symbol
The whole engine drive does not work.
Blinking: Blinks if caution having * in indicated item column blinks. Blinks if action code other than E01 is displayed in Display section A (Multi-information) OFF: Same as cautions having * in indicated item column.
When engine is preheated
During preheating period: ON Other than preheating period: OFF If engine controller judges from coolant temperature that preheating is necessary, automatic preheating starts. When starting switch is turned to preheating position (turned left), preheating starts, too.
When possible
When possible: ON When impossible: OFF Turned ON when tilt switch of blade (work equipment) control lever is turned to dual tilt operation position (dual tilt operation is possible) and turned OFF when returned.
Indicators
Engine preheater (Electric heater ONOFF)
Indication that dual tilt operation is possible
D475A, D475ASD-5E0
Indication method
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Display category
Symbol
10 Structure, function and maintenance standard
Indicated item
Indication range
Indicators
Indication that cooling fan rotation direction is When cooling fan rotation in reserve rotation direction is in reserve rotation mode when cooling mode device such as radiator is being cleaned
Orange Non-symbol
Indication that cooling fan rotation direction cannot be changed When cooling fan rotation while engine is running direction cannot be changed regardless of current cooling fan rotation direction
Indication method ON: Turned ON when fan rotation selector switch is turned to CLN position. OFF: Turned OFF when fan rotation selector switch is operated again while this lamp is ON (At this time, cooling fan rotation direction is set in forward rotation mode). Blinking: Blinks for 3 seconds to notify that cooling fan rotation direction cannot be changed when fan rotation selector switch is operated while engine is running. Lamp position
Lock-up mode ONOFF
In lock-up mode ON: In lock-up mode OFF: In torque converter drive mode
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List of display of gauges Serial No.: 30001 – 30070 Display category
Symbol
Indicated item
Indication range
Indication method
Engine coolant temperature Corresponding segment (1 place) is turned ON. Power train oil temperature
Gauges
Hydraulic oil temperature
Corresponding segment and all segments under it are turned ON.
Fuel level
Engine speed
D475A, D475ASD-5E0
Corresponding segment and all segments under it are turned ON.
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Serial No.: 30071 and up Display category
Symbol
Indicated item
Indication range
Indication method
Engine coolant temperature
Gauges
Power train oil temperature
Hydraulic oil temperature
Corresponding segment and all segments under it are turned ON.
Fuel level
Engine speed
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10 Structure, function and maintenance standard
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Outline of display section A and display section B Display section
Form and position
Display section A
Serial No.: 30001 – 30070 Fig. reference of 12 page. Serial No.: 30071 and up Fig. reference of 13 page.
Indicated item 1) Normal display (Operation mode display) • Current travel direction and gear speed Forward 1st: F1 Reverse 2nd: R2, etc. Neutral: N, Parking: P
Indication method • Display unit consist of 18 segments and indicates various alphanumerics by turning on corresponding segments. Example of forward 1st gear
2) Special display (Service mode display) Selected service mode symbol when display section B is changed • For details of selection of normal disto special display play and special display, see “30 Testing and adjusting” of this manual.
Display section B (Multi-information)
1) Normal display • Display unit displays 2 16-alphanu(Operation mode display) meric lines. • Preset forward gear speed and Preset gear speed is displayed by verreverse gear speed. tically enlarged letters, however. • Service meter (Integrated oper- • For details of selection of this display ating hours of machine) and normal display, see “30 Testing and adjusting” of this manual.
D475A, D475ASD-5E0
2) Indication of maintenance 1) Example of normal display Following modes related to maintenance and indicated by selecting operation • Maintenance mode • PM clinic auxiliary mode • Failure indication mode 2) Example of maintenance display • Adjustment mode 3 Indication of action code If serious trouble occurs while machine is operating, action code is displayed automatically instead 3 Example of action code of normal display
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Display section B (Multi-information)
Display section
26
Form and position
10 Structure, function and maintenance standard
Indicated item 4) Special display (Service mode display) Machine information necessary to service is displayed by special selecting operation. Information is displayed in following modes. • 1C: Maintenance interval change mode • EE: Electric system error code display mode • bE: Mechanical system error code display mode • Cb: Adjustment mode • Ld: Load memory display mode • 5R: Real-time monitoring mode • dR: Dual display monitoring mode
Indication method 4) Example of special display
Note: Service mode symbols (1C, EE, etc.) shown in indicated item column are selected service mode symbols described in Display section A, which are displayed in Display section A.
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10 Structure, function and maintenance standard
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Mode selection switches portion The machine monitor has the “Mode selector switch section” to operate the “Mode selection system” described later. Serial No.: 30001 – 30070
Serial No.: 30071 and up
Note: The switch operations of the 2 “serial No.” group machines are the same.
D475A, D475ASD-5E0
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1.
Switch functions
a) b) c) q
ON-OFF switching in lock-up mode Economy mode setting – OFF, mode 1, mode 2 ON-OFF switching in reverse slow mode
Option The machine with SSC (Shoe slip control) fu nc t io n pu t on o pt io na l ly ha s t he n ex t switches.
a) b) c) d) e)
ON-OFF switching in lock-up mode Economy mode setting – OFF, mode 1, mode 2 ON-OFF switching in reverse slow mode ON-OFF switching in SSC mode SSC mode level setting – Mode 1 to 5
2.
Operation For the operation, see “Mode selection system”.
3.
Initial setting when key is turned ON When a new machine is shipped from the factory, all the functions are turned OFF as a rule so that the operator can select only the necessary functions depending on the job site condition.
28
10 Structure, function and maintenance standard
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10 Structure, function and maintenance standard
D475A, D475ASD-5E0
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29
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Mode selection system
10 Structure, function and maintenance standard
1
System diagram
Note The design of the machine monitor differs by a machine. For details, see section “Machine monitor”.
30
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Outline q In this section, SSC (Shoe slip control) which is an optional device, is also explained for reasons of compilation. q 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. q The following engine control modes are available; Economy mode control used for dozing, SSC used for ripping, reverse slow mode control for both dozing and ripping, and lock-up control to select the direct drive or torque converter drive.
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Function of engine controller q 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.
Function of mode selection system T he sy stem c onsists of the mode selec tion switches installed to machine monitor (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. Functions of steering controller and transmission controller 1. The steering controller calculates travel speed of the ground from signals of the acceleration sensor and inputs the transmission output speed sensor signal 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 mode selection switches, and speed information from the transmission controller, then sends it as the SSC command to the engine controller. 4. The transmission controller sends lock-up signal to the lock-up solenoid valve, judging from input gear speed information from the transmission controller. a See “Operation of torque converter Lockup control system”.
D475A, D475ASD-5E0
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10 Structure, function and maintenance standard
Operation of mode selection system q Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in accordance with the contents of work.
a a
32
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. Note 1: When the lock-up mode is not selected, the other Economy, Reverse slow, SSC, and Rock-bed selection modes can be selected simultaneously. Note 2: When the lock-up mode is selected, Reverse slow mode can be selected simultaneously, but Economy, SSC, and Rock-bed selection modes cannot be selected simultaneously.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
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Electrical equipment
10 Structure, function and maintenance standard
1
Operation of lamp system
Lamp system circuit diagram
34
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
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Engine preheating (Electrical intake air heater) control
Preheating circuit
D475A, D475ASD-5E0
35
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10 Structure, function and maintenance standard
Palm command control system (PCCS)
1. 2. 3. 4. 5. 6. 7. 8. 9.
36
Machine monitor Auto shift down switch Engine controller Transmission controller Steering controller Steering control valve Transmission output shaft speed sensor Transmission control valve Engine speed sensor
1
Note The design of the machine monitor differs by a machine. For details, see section “Machine monitor”.
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
Shift mode function Function If you shift the PCCS lever to the forward or reverse, the gear speed selected from the shift mode is turned on. PCCS lever is control lever of steering, directional and gear shift in joystick lever of left hand. PCCS is abbreviation of Palm command control system. Type of modes q F1-R1 (Manual mode) q F1-R2 (Shift mode 1) q F2-R2 (Shift mode 2) Selecting method Shift the PCCS lever to “N”. Select the shift mode using UP or DOWN switch.
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Auto-shift-down function Function If the load is increased while the machine is traveling or working at the 2nd or 3rd gear speed, the gear speed is shifted down automatically. q The drawbar pull (load on the machine) is calculated from the engine speed, travel speed, and throttle information from the steering controller, and the gear speed is shifted down automatically according to the load and travel speed. q Once the gear speed is automatically shifted down, it is not automatically shifted up to the former position. (Gear speed can be shifted up with the manual switch.) q This function is applicable to both forward and reverse travels. How to use Turn auto-shift-down switch (1) ON.
Manual mode
Down switch ON
Up switch ON Shift mode 1
Down switch ON
Up switch ON Shift mode 2
Display The selected shift mode is displayed on the Multiinformation. For the Multi-information, see “Machine monitor”.
D475A, D475ASD-5E0
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Sensors
1 Type of sensor
Sensor method
When normal
When abnormal
Engine oil pressure
Contact
OFF
ON
Engine coolant temperature
Resistance
—
—
Torque converter oil temperature
Resistance
—
—
Hydraulic oil temperature
Resistance
—
—
Radiator coolant level
Contact
ON
OFF
Fuel level
Resistance
—
—
Engine oil level
Contact
ON
OFF
Air cleaner clogging
Contact
ON
OFF
Transmission output shaft speed sensor
Resistance
—
—
Torque converter speed sensor
Resistance
—
—
Acceleration sensor
Resistance
—
—
Pitch angle sensor
Resistance
—
—
Engine oil pressure sensor
1. 2. 3.
38
Plug Contact ring Contact
4. 5. 6.
Diaphragm Spring Terminal
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
SEN00219-02
Engine coolant temperature sensor Torque converter oil temperature sensor Hydraulic oil temperature sensor
1. 2. 3.
Thermistor Body Tube
4. 5. 6.
Tube Wire Connector
4. 5.
Wire Connector
Radiator coolant level sensor
1. 2. 3.
Float Sensor Tube
D475A, D475ASD-5E0
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10 Structure, function and maintenance standard
Fuel level sensor
1. 2. 3. 4. 5. 6. 7.
40
Connector Float Arm Body Spring Contact Spacer
Function q The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm 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, D475ASD-5E0
10 Structure, function and maintenance standard
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Engine oil level sensor
1. 2. 3.
Float Sensor Tube
4. 5.
Wire Connector
4. 5.
Wire Connector
Air cleaner clogging sensor
1. 2. 3.
Boss Switch Conduit
D475A, D475ASD-5E0
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10 Structure, function and maintenance standard
Transmission output shaft speed sensor
1. 2. 3.
Magnet Terminal Case
4. 5.
Boots Connector
Torque converter speed sensor
1. 2. 3.
42
Connector Flange Sensor
D475A, D475ASD-5E0
10 Structure, function and maintenance standard
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Acceleration sensor
1. 2. 3.
Sensor portion Wire Connector
q
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 below.
q
q
q
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Pitch angle sensor
1. 2. 3. 4.
Body Tube Wire Connector
q
The sensor is filled with electrolyte. If sensor leans, the electrolyte surface slants. If electrolyte surface slants, the contact area of two electrodes installed in the sensor with electrolyte changes. As a result, electrostatic capacity between the two electrode changes. The change of electrostatic capacity is output as a change of voltage. The input and output characteristics of the sensor are shown in the figure at right.
q
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10 Structure, function and maintenance standard
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Vehicle health monitoring system (VHMS) Outline q The VHMS consists of the VHMS controller and various sensors (some of which are used by others systems, too) and records the operating condition of the machine. It collects and records the position information and operation information of the machine, data of measuring instruments, etc. for later maintenance and service. The data to be checked are downloaded to a personal computer.
q
1
If the “ORBCOMM terminal system” is installed to the machine, it can transmit the data recorded in the VHMS by satellite communication for the wireless management by the administrator or the service department. For the use of the VHMS, see “30 Testing and adjusting, Part 4” of this manual.
VHMS controller
D475A, D475ASD-5E0
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Input and output signals CN1 [CN 1] Pin No.
CN2 [CN2 A, B] Signal name
CN1-1 NC
Input/ Output
Pin No.
Signal name
Input/ Output
—
CN2-A1 NC
—
CN1-2 Sensor power supply (24V)
Output
CN2-A2 NC
—
CN1-3 Sensor power supply (12V)
Output
CN2-A3 NC
—
CN1-4 Sensor power supply (5V)
Output
CN2-A4 NC
—
CN1-5 Sensor power supply (5V)
Output
CN2-A5 Exhaust temperature (Right 1)
Input
CN2-A6 Exhaust temperature (Left 2)
Input
CN2-A7 Exhaust temperature (Left 1)
Input
Power supply (Constant power supply) (24V)
Input
Power supply (Constant power supply) CN1-7 (24V)
Input
CN1-8 BR power supply (24V)
Input
CN1-9 BR power supply (24V)
Input
CN1-6
CN1-10 NC
—
CN1-11 GND
Input
CN1-12 GND
Input
CN1-13 NC
—
CN1-14 NC
—
CN1-15 NC
—
CN1-16 NC
—
CN1-17 Start signal CN1-18 NC
Input —
CN1-19 GND
Input
CN1-20 GND
Input
CN2-A8 NC
—
CN2-A9 DIS_SELO (OPEN)
Input
CN2-A10 NC
—
CN2-A11 NC
—
CN2-A12 Sensor GND
Input
CN2-A13 Sensor GND
Input
CN2-A14 NC
—
CN2-A15 Transmission, main oil pressure
Input
CN2-A16 Exhaust temperature (Right 2)
Input
CN2-A17 WAKE UP (Low)
Input
CN2-A18 Blow-by pressure
Input
CN2-B1 NC
—
CN2-B2 NC
—
CN2-B3 NC
—
CN2-B4 NC
—
CN2-B5 NC
—
CN2-B6 Wake up HI
Input
CN2-B7 NC
—
CN2-B8 NC
—
CN2-B9 GND
Input
CN2-B10 NC
—
CN2-B11 NC
—
CN2-B12 CONNECTOR Selection 1 (GND)
46
Input
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10 Structure, function and maintenance standard
CN3 [CN 3 A, B] Pin No.
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CN4 [CN 4 A, B] Signal name
CN3-A1 NC CN3-A2 CAB out D/L Sw
Input/ Output
Pin No.
Signal name
—
CN4-A1 NC
—
Input
CN4-A2 NC
— —
CN3-A3 NC
—
CN4-A3 GND
CN3-A4 NC
—
CN4-A4 CAN (1) H (KOM-NET/c)
CN3-A5
Model selection (See ORB connection)
Input
CN3-A6 NC
—
CN3-A7 NC
—
CN3-A8 NC
—
CN3-A9
CONNECTOR SELECTION 2 (OPEN)
Input/ Output
Input
CN4-A5 CAN (0) shield CGC CN4-A6 CAN (0) H CGC
Input/ Output Input Input/ Output
CN4-A7 NC
—
CN4-A8 NC
—
CN4-A9 GND
Input
CN3-A10 NC
—
CN4-A10 RS232C RX0 (PC Tool)
Input
CN3-A11 NC
—
CN4-A11 RS232C TX0 (PC Tool)
Output
CN3-A12 NC
—
CN4-A12 CAN (1) L (KOM-NET/c)
Input/ Output
CN3-A13 GND
Input
CN4-A13 CAN (1) SH (KOM-NET/c)
Input
CN3-A14 NC
—
CN3-A15 NC
—
CN4-A14 CAN (0) L CGC
CN3-A16 NC
—
CN4-B1 NC
—
CN3-A17 NC
Input
CN4-B2 NC
—
CN3-A18 NC
—
CN4-B3 RS232C GND
CN3-B1 NC
—
CN4-B4 RS232C TX1 (Orbcomm)
CN3-B2 NC
—
CN4-B5 NC
—
CN3-B3 NC
—
CN4-B6 NC
—
CN3-B4 NC
—
CN4-B7 NC
—
CN3-B5 NC
—
CN4-B8 NC
—
CN3-B6 Snap shot Sw
Input
CN3-B7 NC
—
CN3-B8 NC
—
CN3-B9 GND
Input
CN3-B10 NC
—
CN3-B11 NC
—
CONNECTOR SELECTION 3 CN3-B12 (OPEN)
D475A, D475ASD-5E0
Input
Input/ Output
Input Output
CN4-B9 GND
Input
CN4-B10 RS232C RX1 (Orbcomm)
Input
CN5 Pin No.
Signal name
Input/ Output
1
TX +
Output
2
TX –
Output
3
RX +
Input
4
RT 3
Input
5
RT 4
Input
6
RX –
Input
7
RT 1
Input
8
RT 2
Input
9
NC
10
GND
11
5 V POWER SUPPLY
12
GND
— — Output Input
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10 Structure, function and maintenance standard
Sensors Engine oil temperature sensor
Exhaust temperature sensor/amplifier
Specifications
Specifications
Type of sensor:
Thermistor
Rated voltage:
Measurement range:
40 – 130°C 80 – 130°C (Assured accuracy: ±2°C)
Sensed temperature range: 100 – 1,000°C 300 – 800°C (Assured accuracy: ±10°C)
Max. power consumption: 0.5 mW Pressure resistance:
4.9 MPa {50 kg/cm²}
Using temperature:
–30°C to +140°C
Performance table Temper- Resis- Temper- Resis- Temper- Resisature tance ature tance ature tance (°C) (kz) (°C) (kz) (°C) (kz) 30
35.27
80
6.571
110
2.887
40
24.28
85
5.682
115
2.544
50
17.05
90
4.931
120
2.248
60
12.20
95
4.293
125
1.992
70
8.884
100
3.750
130
1.769
a:
Heat sensing part of sensor – Outside diameter of mounting part: R1/4
Function The engine oil temperature sensor is installed to the engine oil filter. It inputs the change of the temperature as the change of the thermistor resistance to the VHMS controller.
48
DC 24 V
Output voltage characteristics (Ambient temperature: 20°C) – Reference values Sensed temperature (°C)
50
Output voltage 1.191 (V)
100
400
700
800
1.397
2.626
3.899
4.316
Operating temperature range: –40 to +110°C Current consumption: Max. 30 mA a: b: c: d:
Heat sensing part of sensor – Outside diameter of mounting part: R1/8 Amplifier Connector (Power supply side) Connector (Sensor side)
Function The exhaust temperature sensor/amplifier is a thermocouple-type temperature sensor, which is installed to the turbocharger inlet. It outputs the exhaust temperature data to the VHMS controller.
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10 Structure, function and maintenance standard
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Atmospheric temperature sensor Specifications Power consumption:
Max. 0.5 mW
Pressure resistance:
0.98 MPa {10 kg/cm2}
Sensed temperature range (ambient): –30 to +120°C Storage temperature range: –50 to +140°C Performance table Sensed temperature (°C) Resistance (kz)
a.
–20
–10
0
10
20
50
30.32 18.58 11.74 7.623 5.077 1.712
Heat sensing part of sensor – Outside diameter of mounting part: 16 x 1.5
Function The atmospheric temperature sensor inputs the change of the atmospheric temperature as the change of the thermistor resistance to the VHMS controller.
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Engine blow-by pressure sensor
1. 2. 3.
Sensor Connector Atmospheric pressure intake tube
A. B. C.
GND (Black) Power supply (Red) Output (White)
Specifications and function Pressure range: 0 – 20 kPa {0 – 2,040 mmH2O} Allowable pressure:
–20 to 100 kPa {–2,040 to 10,200 mmH2O}
Source voltage:
5 ± 0.25 V
Output characteristics:See graph. q
q
The blow-by pressure sensor is a fine relative pressure sensor which measures the difference between the pressure in the crankcase and the atmospheric pressure. The pressure in the crankcase is applied to the tip side of the sensor and the atmospheric pressure is applied to the wiring harness side.
Transmission main oil pressure sensor 1. 2.
50
Sensor Connector
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10 Structure, function and maintenance standard
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ORBCOMM terminal
1. 2.
1
Communication antenna connection DRC connector (40-pole) connection
Outline q The ORBCOMM terminal obtains various kinds of machine information recorded in the VHMS controller and transmits them via the wireless communication antenna. It has a CPU (Central Processing Unit) and wireless communication function. q This terminal has an LED lamp and a 7-segment display lamp used for inspection and troubleshooting. Input/Output signals q
DRC connector Pin No.
Input/Output
Pin No.
1
NC
Signal name
—
16
NC
Signal name
Input/Output —
2
NC
—
17
NC
—
3
NC
—
18
NC
4
COMM 232C RXD
Input
19
PWR_CTR_EXT
5
COMM 232C TXD
Output
20
NC
—
6
NC
—
21
NC
—
7
NC
—
22
NC
—
8
NC
—
23
NC
—
9
NC
—
24
NC
—
10
NC
—
25
NC
—
— Output
11
GND_RS232C
—
26
NC
—
12
NC
—
27
NC
—
13
NC
—
28
NC
14
NC
—
29
DOUT (GND)
15
NC
—
30
GND
—
31
NC
—
32
NC
—
33
NC
—
34
NC
—
35
NC
—
36
PWR_CTR_KEY
37
GND_PWR
—
38
GND_PWR
—
39
PWR_IN_BATT
Input
40
PWR_IN_BATT
Input
D475A, D475ASD-5E0
— Output
Input
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Antenna Specifications Type: Helical whip antenna (1) Impedance: 50 z Input terminal: N-P type Length: 165 ± 20 mm a. Communication antenna mounting part Function The communication controller transmits the data collected and stored by the VHMS controller to the computer center via the communication satellite.
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D475A, D475ASD-5E0 Bulldozer Form No. SEN00219-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (01)
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SEN01816-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
20 Standard value table
1
Standard service value table Standard value table for engine ...................................................................................................................... 2 Standard value table for chassis ..................................................................................................................... 3
D475A, D475ASD-5E0
1
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20 Standard value table
Standard value table for engine
Item
Machine model
D475A, D475ASD-5E0
Engine
SAA12V140E-3
Measurement conditions
Speed
High idle (*1) Low idle Rated speed
Intake air pressure (Boost pressure)
At rated output
Exhaust temperature
Whole speed range (Outside air temperature: 20°C)
Exhaust gas color
At sudden acceleration At high idle (*1)
Valve clearance (At normal temperature)
Intake valve Exhaust valve
Compression pressure (Engine oil: SAE15W-40 or SAE30)
Oil temperature: 40 – 60 °C (Engine speed)
Blow-by pressure (Engine oil: SAE15W-40 or SAE30)
Coolant temperature: Within operating range At rated output
Oil pressure (oil temperature: 90 – 110°C)
1
At high idle SAE0W30EOS SAE5W40EOS SAE10W30DH SAE15W40DH SAE30DH At low idle SAE0W30EOS SAE5W40EOS SAE10W30DH SAE15W40DH SAF30DH
Unit
Standard value for new machine
Service limit value
rpm
2,150 (+25/–50) 650 ± 50 2,000
2,150 (+25/–50) 650 ± 50 —
kPa {mmHg}
Min. 132.30 {1000}
—
°C
Max. 650
Max. 700
Bosch index
Max. 4.5 Max. 1.0
Max. 5.5 Max. 2.0
mm
0.35 ± 0.02 0.57 ± 0.02
— —
MPa {kg/cm2} (rpm)
Min. 4.1 {42} (200 – 250)
Min. 2.0 {20} (200 – 250)
kPa {mmH2O}
Max. 2.94 {300}
Max. 5.88 {600}
0.29 – 0.44 {3.0 – 4.5}
Min. 0.20 {2.0}
Min. 0.08 {0.8}
Min. 0.07 {0.7}
MPa {kg/cm2}
Oil temperature
Whole speed range (In oil pan)
ºC
80 – 110
Max. 120
Tension of alternator belt
Deflection under finger pressure of 58.8 N {6 kg}
mm
20 ± 2
—
Tension of air conditioner compressor belt
Deflection under finger pressure of 58.8 N {6 kg}
mm
20 ± 2
—
(*1): Refer to the item 3. of “Measuring engine speed” in Testing and adjusting, Part 1.
2
D475A, D475ASD-5E0
20 Standard value table
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Standard value table for chassis
1
Category
Machine model Measurement item
Engine speed
Deceleration low idle speed Deceleration high idle speed Torque converter stall speed
D475A, D475ASD-5E0 Standard value for new machine
Service limit value
900 ± 50
900 ± 50
2,000 ± 50
2,000 ± 50
1,690 ± 50
Min. 1,590
1,615 ± 75
Min. 1,450
45 ± 15
45 ± 15
Neutral o Forward
30 ± 5
30 ± 5
Neutral o Reverse
30 ± 5
30 ± 5
40 ± 5 (Play: Max. 3)
40 ± 5 (Play: Max. 3)
40 ± 5 (Play: Max. 3)
40 ± 5 (Play: Max. 3)
78 ± 10
78 ± 10
58 ± 10
58 ± 10
90 ± 10
90 ± 10
60 ± 10
60 ± 10
60 ± 10
60 ± 10
78 ± 10
78 ± 10
81 ± 10
81 ± 10
59 ± 9.8 {6.0 ± 1.0}
59 ± 9.8 {6.0 ± 1.0}
Neutral o Forward, Reverse
56.9 ± 6.9 {5.8 ± 0.7}
56.9 ± 6.9 {5.8 ± 0.7}
Forward, Reverse o Neutral
51 ± 6.9 {5.2 ± 0.7}
51 ± 6.9 {5.2 ± 0.7}
Neutral o Left
25.5 ± 4.9 {2.6 ± 0.5}
25.5 ± 4.9 {2.6 ± 0.5}
Neutral o Right
28.4 ± 4.9 {2.9 ± 0.5}
28.4 ± 4.9 {2.9 ± 0.5}
Measurement conditions
Unit
• Engine coolant temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range • Deceleration low idle: Press decelerator pedal • Deceleration high idle: Set forward-reverse rpm lever in neutral + Set work equipment control lever in neutral • Torque converter stall: Stall at F3
Torque converter stall + • Torque converter stall + Work equipment relief Work equipment relief speed: Stall at F3 + Raise ripper or relieve pitch back circuit speed Decelerator pedal
• Stop engine • Press pedal to center
Forward, reverse
Control lever and pedal stroke
PCCS lever
• Stop engine • Set lever to center
Neutral o Left
mm
Steering Neutral o Right Full stroke Brake pedal
• Run engine at low idle • Press pedal to center
Blade control lever
• Run engine at low idle • Hydraulic oil temperature: Within operating range • Set lever to center
Neutral o Raise/Lower
• Run engine at low idle • Hydraulic oil temperature: Within operating range • Set lever to center
Neutral o Raise/Lower
Stroke to oil pressure of 0
mm
Neutral o Float
Ripper control lever
Control lever and pedal operating effort
mm
Decelerator pedal
PCCS lever
Neutral o Left/Right tilt
Neutral o Tilt in/out
• Stop engine • Press pedal to center
Forward, reverse • Stop engine • Set lever to center
mm
mm
N{kg}
N{kg}
Steering
D475A, D475ASD-5E0
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20 Standard value table
Control lever and pedal operating effort
Category
Machine model Unit
Standard value for new machine
Service limit value
N{kg}
490.3 ± 49.0 {50.0 ± 5.0}
490.3 ± 49.0 {50.0 ± 5.0}
Neutral o Raise
39.2 ± 9.8 {4.0 ± 1.0}
39.2 ± 9.8 {4.0 ± 1.0}
• Run engine at low idle • Hydraulic oil tempera- Neutral o Lower ture: Within operating range Neutral o Float • Set lever to center
39.2 ± 9.8 {4.0 ± 1.0}
39.2 ± 9.8 {4.0 ± 1.0}
82.4 ± 13.7 {8.4 ± 1.4}
82.4 ± 13.7 {8.4 ± 1.4}
Neutral o Left/Right tilt
28.4 ± 9.8 {2.9 ± 1.0}
28.4 ± 9.8 {2.9 ± 1.0}
Neutral o Raise/Lower
21.6 ± 4.9 {2.2 ± 0.5}
21.6 ± 4.9 {2.2 ± 0.5}
20.6 ± 4.9 {2.1 ± 0.5}
20.6 ± 4.9 {2.1 ± 0.5}
400 ± 30
Min. 350
980 ± 50
Min. 880
15.2 ± 2.5 {155 ± 25}
15.2 ± 2.5 {155 ± 25}
High idle
0.78 – 0.98 {8 – 10}
0.78 – 0.98 {8 – 10}
Low idle
0.03 – 0.20 {0.3 – 2}
0.03 – 0.20 {0.3 – 2}
High idle
0.39 – 0.64 {4 – 6.5}
0.39 – 0.64 {4 – 6.5}
Low idle
0.03 – 0.15 {0.3 – 0.15}
0.03 – 0.15 {0.3 – 0.15}
High idle
1.3 – 1.42 {11.5 – 14.5}
1.3 – 1.42 {11.5 – 14.5}
High idle
2.55 – 2.74 {26.0 – 28.0}
Min. 2.55 {Min. 26.0}
2.55 – 2.74 {26.0 – 28.0}
Min. 2.45 {Min. 25.0}
High idle
2.65 – 2.98 {27.0 – 30.4}
2.55 – 3.04 {26.0 – 31.0}
Low idle
2.35– 2.89 {24.0 – 29.5}
2.45 – 3.04 {25.0 – 31.0}
Transmission F clutch pressure
Low idle
2.35 – 2.74 {24.0 – 28.0}
2.25 – 2.74 {23.0 – 28.0}
Transmission R clutch pressure
Low idle
2.35 – 2.74 {24.0 – 28.0}
2.25 – 2.74 {23.0 – 28.0}
Transmission 1st clutch pressure
Low idle
1.96 – 2.35 {20.0 – 24.0}
1.86 – 2.35 {19.0 – 24.0}
Transmission 2nd clutch pressure
Low idle
2.35 – 2.74 {24.0 – 28.0}
2.25 – 2.74 {23.0 – 28.0}
Measurement item
Brake pedal
Blade control lever
Ripper control lever
Fan
Min. speed Max. speed Circuit oil pressure
Torque converter inlet pressure
Power train oil pressure
Torque converter outlet pressure
4
D475A, D475ASD-5E0
Torque converter lock-up clutch pressure Torque converter stator clutch pressure
Transmission main relief pressure
Measurement conditions • Run engine at low idle • Press pedal to center
• Run engine at low idle • Hydraulic oil temperature: Within operating range • Set lever to center
Neutral o Tilt in/out Engine at low idle
• Hydraulic oil temperature: Within operating Engine at high range idle • Fan 100% mode Engine at high idle
• Power train oil temperature: Within operating Low idle range
N{kg}
N{kg}
rpm
MPa {kg/cm2}
MPa {kg/cm2}
D475A, D475ASD-5E0
20 Standard value table
SEN01816-01
Category
Machine model Measurement item
D475A, D475ASD-5E0
Measurement conditions
Unit
Low idle
2.35 – 2.74 {24.0 – 28.0}
2.25 – 2.74 {23.0 – 28.0}
Transmission lubricating pressure
High idle
0.15 – 0.29 {1.5 – 3.0}
0.15 – 0.29 {1.5 – 3.0}
High idle
2.65 – 2.98 {27.0 – 30.4}
Min. 2.45 Min. {25}
Low idle
2.35 – 2.89 {24.0 – 29.5}
2.26 – 2.89 {23.0 – 29.5}
High idle
2.65 – 2.98 {27.0 – 30.4}
Min. 2.45 {Min. 25}
2.35 – 2.89 {24.0 – 29.5}
2.26 – 2.89 {23.0 – 29.5}
High idle
2.65 – 2.98 {27.0 – 30.4}
Min. 2.45 {Min. 25}
Low idle
2.35 – 2.89 {24.0 – 29.5}
2.26 – 2.89 {23.0 – 29.5}
High idle
2.65 – 2.98 {27.0 – 30.4}
Min. 2.45 {Min. 25}
Low idle
2.35 – 2.89 {24.0 – 29.5}
2.26 – 2.89 {23.0 – 29.5}
Low idle
2.65 – 3.03 {27.0 – 30.9}
Min. 2.55 {Min. 26}
Forward 1st
3.3 ± 0.3
3.3 ± 0.3
Forward 2nd
6.2 ± 0.3
6.2 ± 0.3
Forward 3rd
11.2 ± 0.6
11.2 ± 0.6
Reverse 1st
4.2 ± 0.3
4.2 ± 0.3
Reverse 2nd
8.0 ± 0.4
8.0 ± 0.4
14.0 ± 0.7
14.0 ± 0.7
3.4 ± 0.3
3.4 ± 0.3
Forward 2nd
6.3 ± 0.3
6.3 ± 0.3
Forward 3rd
11.6 ± 0.6
11.6 ± 0.6
Reverse 1st
4.4 ± 0.3
4.4 ± 0.3
Reverse 2nd
8.4 ± 0.4
8.4 ± 0.4
Reverse 3rd
14.3 ± 0.7
14.3 ± 0.7
• Power train oil temperature: Within Low idle operating range
Steering right clutch pressure
Steering right brake pressure
Ripper pin puller pressure
Travel speed
D475A, D475ASD-5E0
• Stop machine on flat and level place • Run engine at high idle • Engine coolant temperature: Within operating range • Economy mode: OFF • Reverse slow mode: OFF • Run-up distance: 10 – 30 m • Measuring distance: 20 m
When lockup switch is OFF
Steering left brake pressure
When lockup switch is ON
Power train oil pressure
Service limit value
Transmission 3rd clutch pressure
Steering left clutch pressure
Power train
Standard value for new machine
Reverse 3rd Forward 1st
MPa {kg/cm2}
km/h
5
SEN01816-01
20 Standard value table
Machine model
Work equipment
Pump merge Measurement /divide conditions (ReferRelieving ence) method
Raise relief
Standard value for new machine Engine speed
Specification
Measurement
Category
Item
D475A, D475ASD-5E0
Right steering tilt
Blade dual tilt
Pitch back
Raise relief
Low
22.1 ± 1.4 22.1 ± 1.4 22.1 ± 1.4 22.1 ± 1.4 {225 ± 14} {225 ± 14} {225 ± 14} {225 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 {250 ± 14} {250 ± 14} {250 ± 14} {250 ± 14}
Low
23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 {235 ± 14} {235 ± 14} {235 ± 14} {235 ± 14}
High
24.0 ± 1.4 24.0 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {245 ± 14} {245 ± 14} {280 ± 14} {280 ± 14}
Merge
Merge
Merge
6
21.1 ± 1.4 21.1 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {215 ± 14} {215 ± 14} {280 ± 14} {280 ± 14} 27.4 ± 1.4 27.4 ± 1.4 24.0 ± 1.4 24.0 ± 1.4 {280 ± 14} {280 ± 14} {245 ± 14} {245 ± 14} 27.4 ± 1.4 27.4 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 {280 ± 14} {280 ± 14} {215 ± 14} {215 ± 14}
High
24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 {250 ± 14} {250 ± 14} {250 ± 14} {250 ± 14}
Low
21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 {215 ± 14} {215 ± 14} {215 ± 14} {215 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Divide
Divide
Merge
Ripper Lower relief
Work equipment pump Work equipment pump outlet pressure (F) outlet pressure (R)
26.5 ± 1.4 26.5 ± 1.4 26.5 ± 1.4 26.5 ± 1.4 {270 ± 14} {270 ± 14} {270 ± 14} {270 ± 14}
Divide • Hydraulic oil temperature: Low MPa 45 – 55°C • Relieve {kg/cm2} only circuit High Right dual to be meaDivide sured tilt Low
Pitch dump
Service limit value
High Merge
Left dual tilt Dual tilt
Relief pressure
Work equipment oil pressure
Blade single tilt
Left steering tilt
Standard value for new machine
Unit
Blade Lower relief
Service limit value
Merge
D475A, D475ASD-5E0
20 Standard value table
SEN01816-01
Machine model
Work equipment
Pump merge Measurement /divide conditions (ReferRelieving ence) method
Dual tilt
Tilt in
Standard value for new machine Engine speed
Specification
Measurement
Category
Item
D475A, D475ASD-5E0
Raise relief
Relief pressure Single tilt
Work equipment oil pressure
Blade single tilt
Left steering tilt
Right steering tilt
Raise relief
Lower relief
Tilt back
D475A, D475ASD-5E0
Work equipment pump Work equipment pump outlet pressure (F) outlet pressure (R)
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
26.5 ± 1.4 26.5 ± 1.4 26.5 ± 1.4 26.5 ± 1.4 {270 ± 14} {270 ± 14} {270 ± 14} {270 ± 14}
Low
22.1 ± 1.4 22.1 ± 1.4 22.1 ± 1.4 22.1 ± 1.4 {225 ± 14} {225 ± 14} {225 ± 14} {225 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Merge
Merge
Merge
Merge
High • Hydraulic Merge oil temperature: Low MPa 45 – 55°C • Relieve {kg/cm2} only circuit High to be meaMerge sured Low
24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 {250 ± 14} {250 ± 14} {250 ± 14} {250 ± 14} 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 {235 ± 14} {235 ± 14} {235 ± 14} {235 ± 14} 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14} 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Merge
Merge
Ripper Tilt in
Service limit value
High
Blade Lower relief
Standard value for new machine
Unit
Ripper Tilt back
Service limit value
Merge
Merge
7
SEN01816-01
20 Standard value table
Machine model
Work equipment
Pump merge Measurement /divide conditions (ReferRelieving ence) method
Raise relief
Standard value for new machine Engine speed
Specification
Measurement
Category
Item
D475A, D475ASD-5E0
Right steering tilt
Pitch dump Super
Relief pressure
Work equipment oil pressure
Blade single tilt
Blade dual tilt Pitch back
Raise relief
Lower relief
Tilt back
8
Work equipment pump Work equipment pump outlet pressure (F) outlet pressure (R)
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 24.5 ± 1.4 {250 ± 14} {250 ± 14} {250 ± 14} {250 ± 14}
Low
23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 {235 ± 14} {235 ± 14} {235 ± 14} {235 ± 14}
High
25.0 ± 1.4 25.0 ± 1.4 25.0 ± 1.4 25.0 ± 1.4 {255 ± 14} {255 ± 14} {255 ± 14} {255 ± 14}
Merge
Merge
Divide • Hydraulic oil temperature: Low MPa 45 – 55°C • Relieve {kg/cm2} only circuit High to be meaDivide sured Low
21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 {215 ± 14} {215 ± 14} {215 ± 14} {215 ± 14} 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14} 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
High
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Low
27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Merge
Merge
Ripper Tilt in
Service limit value
High Merge
Left steerMerge ing tilt
Standard value for new machine
Unit
Blade Lower relief
Service limit value
Merge
Merge
D475A, D475ASD-5E0
20 Standard value table
SEN01816-01
Machine model
D475A, D475ASD-5E0
Specification
Measurement
Category
Item Work equipment
Blade
LS differential pressure
Work equipment oil pressure
Dual tilt
Blade single tilt
Blade dual tilt
Ripper
Standard value for new machine
Service limit value
Raise relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Lower relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Left steering tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Right steering tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Left dual tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Right dual tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Pitch dump
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Pitch back
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Raise relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Tilt back
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Raise relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Lower relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Left steering tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Right steering tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Raise relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Lower relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Tilt in
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Tilt back
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Relieving method
Lower relief Tilt in
Single tilt
Blade
Blade single tilt
Ripper
D475A, D475ASD-5E0
Measurement conditions
• Hydraulic oil temperature: Within operating range • Run engine at high idle
Unit
MPa {kg/cm2}
9
SEN01816-01
20 Standard value table
Machine model
D475A, D475ASD-5E0
Specification
Measurement
Category
Item Work equipment
Work equipment
10
Blade single tilt
Super
LS differential pressure
Work equipment oil pressure
Blade
Blade dual tilt
Standard value for new machine
Service limit value
Raise relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Lower relief
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Left steering tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
Right steering tilt
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
1.76 ± 0.2 {18 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Tilt in
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Tilt back
2.45 ± 0.2 {25 ± 2}
2.45 ± 0.2 {25 ± 2}
Relieving method
Pitch dump Pitch back
Measurement conditions
Unit
• Hydraulic oil temperature: Within operating range • Run engine at high idle
Raise relief
Ripper
Lower relief
MPa {kg/cm2}
Unload pressure
• Hydraulic oil temperature: 45 – 55 °C • Set all work equipment control levers in neutral
2.94 – 4.9 {30 – 50}
2.94 – 4.9 {30 – 50}
Work equipment control oil pressure
• Hydraulic oil temperature: Within operating range • Set all work equipment control levers in neutral • Engine at high idle
3.92 – 4.51 {40 – 46}
Min. 3.72 {Min. 38}
PPC valve output pressure
• Hydraulic oil temperature: Within operating range • Set lever at stroke end • Engine at high idle
3.92 – 4.51 {40 – 46}
Min. 3.72 {Min. 38}
Blade tilt cylinder Leakage Blade pitch cylinder from Ripper shift cylinder cylinder Ripper tilt cylinder
• Hydraulic oil temperature: Within operating range • Run engine at high idle • Measure leakage for 1 minute while relieving cylinder
5
20
5
20
5
20
5
20
cc/min
D475A, D475ASD-5E0
20 Standard value table
SEN01816-01
Category
Machine model Measurement item
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine
Measurement conditions Measuring posture
Low idle
14 ± 3.5
Max. 20.0
High idle
5.0 ± 0.5
Max. 6.0
Low idle
1.8 ± 0.3
Max. 2.5
High idle
1.8 ± 0.3
Max. 2.5
Low idle
15.8 ± 3.5
Max. 22.0
High idle
5.1 ± 0.5
Max. 7.0
Low idle
1.7 ± 0.3
Max. 3.0
High idle
1.7 ± 0.3
Max. 2.2
Low idle
4.0 ± 1.5
Max. 6.5
High idle
3.3 ± 0.5
Max. 6.0
Low idle
4.4 ± 1.5
Max. 6.0
High idle
3.6 ± 0.5
Max. 6.0
Low idle
5.5 ± 1.5
Max. 8.0
High idle
3.1 ± 0.5
Max. 5.0
Low idle
5.5 ± 1.5
Max. 8.0
High idle
3.1 ± 0.5
Max. 5.0
Raise Blade lift (Single tiltdozer specification) (Dual tiltdozer specification)
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between blade on ground and raising stroke end
Lower
Measuring posture Raise
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between blade on ground and raising stroke end
Blade speed
Work equipment
Blade lift (Superdozer specification) Lower
Measuring posture Left tilt Blade tilt (Single tiltdozer specification)
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between left tilt end and right tilt end
Right tilt
Measuring posture Left tilt Blade tilt (Dual tiltdozer specification)
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between left tilt end and right tilt end
D475A, D475ASD-5E0
Right tilt
11
SEN01816-01
20 Standard value table
Category
Machine model Measurement item
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine
Measurement conditions Measuring posture
Low idle
4.0 ± 1.5
High idle
3.3
Max. 6.0
Left tilt Blade tilt (Superdozer specification)
Low idle
4.4 ± 1.5
High idle
3.6
Low idle
9.6 ± 1.5
13.0
High idle
4.4 ± 0.5
6.0
Low idle
6.6 ± 1.6
Max. 10.0
High idle
4.1 ± 0.5
Max. 6.0
Low idle
23.0 ± 3.0
Max. 30
High idle
7.8 ± 1.0
Max. 10
Low idle
16.0 ± 2.0
Max. 23.0
High idle
7.2 ± 1.0
Max. 9.5
Low idle
7.7 ± 1.0
Max. 12.0
High idle
3.0 ± 0.5
Max. 4.0
Low idle
3.0 ± 0.5
Max. 5.0
High idle
3.0 ± 0.5
Max. 4.0
Max. 6.5
Right tilt
Measuring posture Pitch dump Blade speed
Max. 6.0
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between left tilt end and right tilt end
Blade pitch (Dual tiltdozer specification)
+0.5 -0.8
Max. 6.0
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between pitch back end and pitch dump end
Work equipment
+0.5 -0.8
Pitch back
Measuring posture Pitch dump Blade pitch (Superdozer specification)
sec • Hydraulic oil temperature: Within operating range • Apply no load on blade. • Between pitch back end and pitch dump end
Pitch back
Measuring posture
Ripper speed
Raise
12
sec
Ripper lift • Hydraulic oil temperature: Within operating range Lower • Select lowest shank hole. • Between ripper on ground and raising stroke end
D475A, D475ASD-5E0
20 Standard value table
SEN01816-01
Category
Machine model Measurement item
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine
Measurement conditions
Measuring posture
Low idle
15.6 ± 1.5
Max. 22.0
High idle
5.2 ± 0.5
Max. 7.0
Low idle
9.1 ± 1.5
Max. 14.0
High idle
3.3 ± 0.5
Max. 4.5
Low idle
—
—
Max. 2.5
3.2
Low idle
—
—
High idle
Max. 2.7
3.5
Max. 1.0
1.5
Work equipment
Time lag
Ripper speed
Tilt in
Ripper tilt
sec • Hydraulic oil temperature: Within operating range • Select lowest shank hole. • Between forward tilt end and rear tilt end
Tilt out
Blade (Single tiltdozer specification) (Dual tiltdozer specification)
• Hydraulic oil temperature: Within operating range • Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted.
Blade (Superdozer specification)
• Hydraulic oil temperature: Within operating range • Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted.
Ripper
• Hydraulic oil temperature: Within operating range • Lower ripper from max. rising position and measure time after ripper comes in contact with ground until sprocket is lifted.
High idle sec
High idle
sec
Measuring posture
Hydraulic drift of lifted blade
mm/ Max. 150/15 Max. 300/15 min
Hydraulic drift
• Hydraulic oil temperature: Within operating range • Stop engine. • Raise blade to max. rising position and then measure reduction of blade bottom height (h) in 15 minutes. Measuring posture
Hydraulic drift of machine tilted by blade
mm/ min
Max. 50/5
Max. 100/5
• Hydraulic oil temperature: Within operating range • Stop engine. • Tilt blade to maximum to push up shoe on either side and then measure reduction of shoe height (h) in 5 minutes.
D475A, D475ASD-5E0
13
SEN01816-01
20 Standard value table
Category
Machine model Measurement item
Measurement conditions
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine
Measuring posture
Hydraulic drift of machine lifted by blade
mm/ min
Max. 50/5
Max. 100/5
mm/ Max. 80/15 min
Max. 160/15
• Hydraulic oil temperature: Within operating range • Stop engine. • Push up front part of machine with blade and then measure reduction of idler center height (h) in 5 minutes.
Hydraulic drift
Work equipment
Measuring posture
Hydraulic drift of lifted ripper • Hydraulic oil temperature: Within operating range • Stop engine. • Raise ripper to max. rising position and then measure reduction of shank bottom height (h) in 15 minutes. Measuring posture
Hydraulic drift of machine lifted by ripper
mm/ min
Max. 30/5
Max. 60/5
• Hydraulic oil temperature: Within operating range • Stop engine. • Push up rear part of machine with ripper and then measure reduction of sprocket center height (h) in 5 minutes.
14
D475A, D475ASD-5E0
20 Standard value table
D475A, D475ASD-5E0
SEN01816-01
15
SEN01816-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN01816-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 08-07 (01)
16
SEN01817-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting............................................................................................. 3 Measuring engine speed................................................................................................................................. 6 Measuring intake air pressure (boost pressure) ........................................................................................... 10 Measuring exhaust temperature ................................................................................................................... 12 Measuring exhaust gas color ........................................................................................................................ 14 Adjusting valve clearance ............................................................................................................................. 16 Testing compression pressure ...................................................................................................................... 18 Measuring blow-by pressure......................................................................................................................... 20 Measuring engine oil pressure...................................................................................................................... 22 Handling of fuel system devices ................................................................................................................... 23 Releasing residual pressure from fuel system .............................................................................................. 23 Testing fuel pressure..................................................................................................................................... 24 Handling of reduced cylinder mode operation .............................................................................................. 25 Handling of no injection cranking operation .................................................................................................. 25 Testing fuel return and leak amount.............................................................................................................. 26 Bleeding air from fuel circuit.......................................................................................................................... 29
D475A, D475ASD-5E0
1
SEN01817-03
30 Testing and adjusting
Bleeding air from fuel circuit (Low-grade fuel specification).......................................................................... 31 Testing fuel circuit for leakage....................................................................................................................... 33 Testing and adjusting alternator belt tension................................................................................................. 34 Testing and adjusting belt tension for air conditioner compressor ................................................................ 35 Adjusting fuel control dial and decelerator pedal .......................................................................................... 36
2
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01817-03
Testing or adjusting item Air boost pressure (boost pressure)
A
Coolant temperature, oil temperature and exhaust temperature
B
Part No.
1 Exhaust gas color
C
Valve clearance
Compression pressure
D
E
Blow-by pressure
Engine oil pressure
2
799-401-2220 Hose
1
799-101-1502 Digital temperature gauge
1 –99.9 – 1,299°C
799-201-9001 Handy smoke checker
1
Commercial item
Smoke meter
1
Commercial item
Thickness gauge
1
Bosch index: 0 – 9
0 – 7 MPa {0 – 70 kg/cm2} KIT Part No.: 795-502-1205
795-471-1310 Adapter
1
3
6217-71-6150 Gasket
1
799-201-1504 Blow-by checker
1 0 – 5 kPa {0 – 500 mmH2O}
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1 Pressure gauge: 60 MPa {600 kg/cm2}
799-401-2320 Hydraulic tester
1 Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-401-2320 Hydraulic tester
1 *As common as G2
3
795-471-1450 Adapter
1
4
07005-00812 Gasket
1
1
6151-51-8490 Spacer
1
2
6141-71-1710 Joint
1
1
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
*As common as G1
3
Commercial item
Hose
1
4
Commercial item
Hose
1
5
Commercial item
Measuring cylinder
1
6
Commercial item
Stopwatch
1
7
07376-70315 Plug
1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-401-2320 Hydraulic tester
1 *As common as G2
799-101-5220 Nipple (10 x 1.25 mm)
1
07002-11023
1
1 Power train oil pressure K 2 3
D475A, D475ASD-5E0
1 –101 – 200 kPa {–760 – 1,500 mmHg}
2
H 2
J
799-201-2202 Boost gauge kit
1
1
Testing fuel return and leak amount
Remarks
795-502-1590 Compression gauge
2
Testing fuel pressure
1
1
F
G
Part name
Quantity
Symbol
Tools for testing, adjusting, and troubleshooting
O-ring
*As common as G1
3
Testing or adjusting item
Emergency escape method when power train has trouble
Part No.
1
L
2 1
Testing and adjusting work equipment and HSS oil pressure
2 M
Measuring ripper pin puller solenoid valve output pressure
1
790-261-1204 Digital hydraulic tester
1
566-35-43561 Nipple (18 x 1.5 mm)
1
07002-11823
O-ring
799-101-5220 Nipple (10 x 1.25 mm) 07002-11023
O-ring
1 1 1 1
1
790-261-1204 Digital hydraulic tester
1
2
799-401-3100 Adapter (size 02)
1
3
799-401-3200 Adapter (size 03)
1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-401-3200 Adapter (size 03)
1 *As common as P3
Measuring fan pump circuit pressure
T 1
Commercial item
Measuring cylinder
799-205-1100 Tachometer KIT
1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
799-402-3800 Angle gauge
1
79A-264-0021 0 – 294 N {0 – 30 kg}
1
79A-264-0091 0 – 490 N {0 – 50 kg}
1
W
Scale
1
Work equipment speed
X
Commercial item
Stopwatch
1
Voltage and resistance
Y
Commercial item
Tester
1
Z
1
799-608-3211 Diskette
1
2
799-608-3220 Harness
1
3
4
Commercial item
Notebook type personal computer
*As common as G1 *As common as G1
*As common as G1
1
Commercial item
Initializing VHMS controller
*As common as G1
799-101-5002 Hydraulic tester
S
Stroke and hydraulic drift
1
799-101-5002 Hydraulic tester
1
Measuring fan motor speed
V
790-190-1601 Pump assembly
790-261-1204 Digital hydraulic tester
R
Operating effort
1
1
Measuring internal leakage of work equipment cylinder
U
195-06-71220 Wiring harness
Remarks
799-101-5002 Hydraulic tester
2
Adjusting blade tilt angle control
1
799-401-2701 Differential pressure gauge 1
1
Q
7824-66-6430 Resistor
4
N 1
P
1
799-101-5160 Nipple (R1/8)
1 Measuring PPC valve output pressure
19M-06-32820 Switch assembly
3
5 Testing control circuit basic pressure
Part name
Quantity
30 Testing and adjusting
Symbol
SEN01817-03
1
*As common as G1
OS: Windows 98/2000/Me/XP Terminal "RS232C" is with it
D475A, D475ASD-5E0
Diagnosis of sensor and harness
D475A, D475ASD-5E0
—
SEN01817-03
Part No.
Part name
Quantity
Testing or adjusting item
Symbol
30 Testing and adjusting
Remarks
799-601-7400 T-adapter assembly
1 For AMP040
799-601-7500 T-adapter assembly
1 For AMP070
799-601-9100 T-adapter assembly
1 For HD30
799-601-9200 T-adapter assembly
1 For DT connector
799-601-9300 T-adapter assembly
1 For DRC26-24 (40 pins)
799-601-7310 Adapter
1 For SWP 12 pins
799-601-7320 Adapter
1 For SWP 16 pins
799-601-7360 Adapter
1 For relay (5 pins)
799-601-3450 Adapter
1 For VHMS download harness
799-601-4101 T-adapter assembly
1 Connector for engine
799-601-4130 • T-adapter
1 Ne sensor
799-601-4150 • T-adapter
1 Oil pressure sensor
799-601-4211 • T-adapter
1 Controller (50-pole)
799-601-4220 • T-adapter
1 Controller (60-pole)
799-601-4240 • Socket
1 Ambient pressure sensor
799-601-4250 • Socket
1 Boost pressure sensor
799-601-4260 • T-adapter
1 Controller (4-pole)
799-601-4330 • Socket
1 G (Bkup) sensor
799-601-4350 • T-adapter box
1 60-pole
799-601-9020 • T-adapter
1 Injector
799-601-9420 • T-adapter
1 Common rail pressure
799-601-9430 • Socket
1 Supply pump PCV
795-799-5530 • Socket
1
795-799-5540 • Socket
1 Boost and intake temperature sensor
799-601-9310 Plate
1 For 24-pole
799-601-9320 T-adapter box
1 For 24-pole
Coolant, fuel and oil temperature sensor
5
SEN01817-03
Measuring engine speed a
30 Testing and adjusting
1
Measure the engine speed under the following condition. q Coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q Power train oil temperature: Within operating range
1.
Preparatory work Turn the starting switch ON and set the monitor panel in the “Monitoring mode” to prepare for measurement of the engine speed. a For the operating method, see “Special functions of monitor panel (EMMS)”. q Monitoring code: 01002 (Left bank engine speed) 01004 (Right bank engine speed) a Usually, confirm the left bank engine speed. Serial numbers: 30001 – 30070
3.
Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. a The high idle speed measured in the “Monitoring mode” or in the “Pm Clinic auxiliary mode” is the auto-deceleration speed. a When measuring the high idle speed of the engine, use the “Adjustment mode”. Adjustment code: 0007 (Engine decelerator cut mode) Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
Serial numbers: 30071 and up
4.
2.
6
Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idle position. 2) Set the PCCS lever and work equipment control lever in neutral, and measure the engine speed with the decelerator pedal depressed.
Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. D475A, D475ASD-5E0
30 Testing and adjusting
5.
Measuring torque converter stall speed a Use Adjustment mode to measure. q Adjustment mode: 0530 (Stall speed check mode) k This machine is equipped with the cooling fan speed control function to protect the radiator when the engine is not fully warmed up. Since that function does not work while this mode is used, warm up the engine fully before using this mode. 1) Start the engine and set the fuel control dial in the low idle position. 2) With the brake pedal depressed securely and the parking brake lever in the “free” position, set the PCCS lever in the “forward” and 3rd gear speed position. a Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. a Keep the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idle position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 5) Just after the power train oil temperature gauge reaches position (a) of the green range, return the direction of the PCCS lever into neutral.
D475A, D475ASD-5E0
SEN01817-03
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
6) 7)
Repeat above steps 2) – 5) 3 times. Perform steps 2) – 4) again and measure the engine speed when the power train oil temperature gauge reaches position (a) of the green range. a After finishing measurement, return the direction of the PCCS lever into neutral and lower the power train oil temperature with the engine at high idle. a After finishing measurement, finish the Adjustment mode.
7
SEN01817-03
6.
8
Measuring torque converter stall + work equipment relief speed (full stall speed) a Use Adjustment mode to measure. q Adjustment mode: 0530 (Stall speed check mode) 1) Start the engine and set the fuel control dial in the low idle position. 2) With the brake pedal depressed securely and the parking brake lever in the “free” position, set the PCCS lever in the “forward” and 3rd gear speed position. a Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. a Keep the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idle position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 5) Operate the ripper lever to raise the ripper lift cylinder to the stroke end or pitch back stroke end. 6) Just after the power train oil temperature gauge reaches position (a) of the green range, return the direction of the PCCS lever into neutral.
30 Testing and adjusting
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
D475A, D475ASD-5E0
30 Testing and adjusting
7) 8)
Repeat above steps 2) – 6) 3 times. Perform steps 2) – 4) and also operate ripper RAISE relief and pitch back relief and measure the engine speed when the power train oil temperature gauge reaches position (a) of the green range. a After finishing measurement, return the direction of the PCCS lever into neutral and lower the power train oil temperature with the engine at high idle. a After finishing measurement, finish the Adjustment mode. a The engine speed can be measured by the following operation: q “Pm clinic auxiliary mode” of the monitor panel q Each time the information switch is set to the right or left when the monitor panel is in the normal display state, the display in the multi information section turns to the display of service meter or engine speed. (However, measure the high idle speed of the engine in the “Adjustment mode”).
D475A, D475ASD-5E0
SEN01817-03
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
9
SEN01817-03
30 Testing and adjusting
Measuring intake air pressure (boost pressure) a
2.
Remove air intake connector boost pressure pickup plugs (2) and (3) (R1/8). a If nipple [1] is installed as standard to the intake air pressure (boost pressure) measuring port, install gauge [2] without installing anything to the port. q Plug (2): For left bank q Plug (3): For right bank
3.
Install nipple [1] of boost gauge kit A and connect gauge [2]. q Left bank
1
Measuring instruments for intake air pressure (boost pressure)
Symbol A k
a
1.
10
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
When installing and removing the measuring instrument, take care not to touch a hot part of the engine. Measure the intake air pressure (boost pressure) under the following condition. q Coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q Power train oil temperature: Within operating range Open the left and right side covers of the engine.
D475A, D475ASD-5E0
30 Testing and adjusting
q
Right bank
4.
Run the engine at medium or higher speed and drain the oil from the hose. a Insert the joint of the gauge and hose halfway and open the self-seal on the hose side repeatedly, and the oil is drained. a If Pm kit (A) is available, the air bleeding coupling (790-261-1130) in it may be used. a If any oil is left in the hose, the gauge does not move. Accordingly, be sure to drain the oil.
5.
Measure the intake air pressure (boost pressure) while the engine is running at high idle and the torque converter is stalling. a For the procedure for stalling the torque converter, see “Measuring engine speed”. a Normally, the intake air pressure (boost pressure) should be measured while the engine is running at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter.
D475A, D475ASD-5E0
SEN01817-03
6.
After finishing test, remove the testing instrument and return the removed parts. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: LT2 or LG-5 a The boost pressure can be tested in the “Pm Clinic auxiliary mode: 05” of the machine monitor. a The boost pressure displayed in the Pm clinic auxiliary mode is absolute pressure. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
11
SEN01817-03
30 Testing and adjusting
Measuring exhaust temperature 1 a
Measuring instrument for exhaust temperature Symbol
Part No.
B
799-101-1502
Name Digital thermometer
a
Measure the exhaust temperature under the following condition. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Check the exhaust temperature with the monitor panel since the machine is equipped with exhaust temperature sensors for the VHMS. q Monitoring code (Right bank front): 42602 q Monitoring code (Right bank rear): 42601 q Monitoring code (Left bank front): 42600 q Monitoring code (Left bank rear): 42606 q Unit: °C a For the operating method, see “Special functions of monitor panel”.
2.
12
2)
3.
Remove exhaust temperature measuring plugs. q Plug (2): For left bank front q Plug (3): For left bank rear q Plug (4): For right bank front q Plug (5): For right bank rear
Install sensor [1] to the measuring plugs and connect them to digital thermometer B. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement. a Example of the right bank rear
If the monitor panel is not used, measure the exhaust temperature according to the following procedure. k Remove and install the measuring instruments after the exhaust manifold is cooled down. a Measure the exhaust temperatures of the right and left banks separately. 1) Open the right and left side covers (1) of the engine.
D475A, D475ASD-5E0
30 Testing and adjusting
4.
5.
SEN01817-03
Procedure for measuring maximum exhaust temperature for troubleshooting. Operate the machine and measure the maximum exhaust temperature. a Use the PEAK mode of the digital thermometer. a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. q Corrected value [°C] = Measured value + 2 x (20 – Outside air temperature)
Procedure for measuring exhaust temperature periodically for preventive maintenance a If the torque converter is stalled, the torque converter oil temperature is overheated before the exhaust temperature is stabilized. Measure according to the following procedure. 1) Completely stall the torque converter to raise the exhaust temperature to about 650°C according to the following procedure (Condition (a) in the figure). i) Start the engine and set the fuel control dial to the low idle position. ii) Press the brake pedal and set the PCCS lever in the FORWARD 3rd gear speed position. iii) Press the decelerator pedal and set the fuel control dial to the high idle position. iv) Return the decelerator pedal slowly to stall the torque converter and relieve the ripper in raising direction or pitch back with the engine at high idle. k Press the brake pedal and keep your right foot on the decelerator pedal for safety until the work is finished.
D475A, D475ASD-5E0
2)
3) k
6.
Stop relieving the ripper or pitch back, and lower the exhaust temperature by only stalling the torque converter (Condition (b) in the figure). a If the temperature does not lower but rises, set the temperature to high in step 1). After the temperature lowers and is stabilized, measure it (Condition (c) in the figure). Just after the power train oil temperature gauge reads the red range, return the direction of the PCCS lever into neutral and lower the power train oil temperature.
After finishing measurement, remove the measuring instrument and return the removed parts. q Remove the gasket sealant remaining on the threads of the removed plug with a wire brush and apply new adhesive or gasket sealant to the plug before installing. 2 Plug: LC-G
13
SEN01817-03
30 Testing and adjusting
Measuring exhaust gas color a
Measuring instrument for exhaust gas color
Symbol C k
a
a
1.
1
Part No.
1
799-201-9001
2
Commercial item
Part name
2.
Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.
Handy smoke checker Smoke meter
When installing and removing the measuring instrument, take care not to touch a hot part. If an air source and a electric power source are not available in the field, use handy smoke checker C1. When recording official data, etc., use smoke meter C2. Measure the exhaust gas color under the following condition. q Coolant temperature: Within operating range Measuring with handy smoke checker C1 1) Stock a sheet of filter paper to smoke checker C1. 2) Insert the exhaust gas intake pipe in the exhaust pipe. 3) Start the engine. 4) As increasing the engine speed rapidly or running it at high idle, operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.
2)
3)
4)
5)
5)
6)
14
Remove the filter paper and compare it with the attached scale to make a judgement. After finishing measurement, remove the measuring instrument and reinstall the removed parts.
6) 7)
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Restrict the supplied air pressure below 1.5 MPa {15 kg/cm2}. Connect the power cable to a receptacle of AC100V power source. a Before connecting the cable, check that the power switch of the smoke meter is turned off. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter C2.
Start the engine. As increasing the engine speed rapidly or running it at high idle, press the accelerator pedal of smoke meter C2 and collect the exhaust gas with the filter paper.
D475A, D475ASD-5E0
30 Testing and adjusting
8)
9)
SEN01817-03
Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing measurement, remove the measuring instrument and reinstall the removed parts.
D475A, D475ASD-5E0
15
SEN01817-03
30 Testing and adjusting
Adjusting valve clearance a
a
1
Adjusting tool for valve clearance
Symbol
Part No.
D
Commercially available
Part name Thickness gauge
1.
Remove cylinder head cover. a For details, see “Removal and installation of cylinder head assembly” in Disassembly and assembly.
2.
Rotate the crankshaft forward and match stamped line of R1.6 TOP on vibration damper (1) to pointer (2), by setting RH No. 1 cylinder to the compression top dead center while watching the movement of the intake valve of RH No. 6 cylinder.
a
16
At near the compression top dead center of the RH No. 1 cylinder, the intake valve of RH No. 6 cylinder moves.(opens).
3.
Loosen locknut (6) of RH No. 1 cylinder adjust screw (5). Insert a clearance gauge D of specified clearance between the crosshead (4) and rocker arm (3) and adjust the adjustment screw to the degree that the clearance gauge can be moved lightly. a Valve clearance Air Intake valve: 0.35 mm, Exhaust valve: 0.57 mm
Crank the engine using the barring tool (B) mounted to the front right-hand side of the flywheel housing.
D475A, D475ASD-5E0
30 Testing and adjusting
4.
Tighten locknut (6) to secure adjustment screw. 3 Locknut tightening torque: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.
5.
Hereafter crank the engine similar way in the firing order. Match the stamped line of the damper to the pointer and adjust the valve clearance of each cylinder. a Firing order R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 – L4
6.
After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
D475A, D475ASD-5E0
SEN01817-03
17
SEN01817-03
30 Testing and adjusting
Testing compression pressure a
1
k
a
4.
Install adapter E2 to the mounting hole on the injector and compression gauge E1. a Fit the gasket to the injector end without fail a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily.
5.
Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See “Adjusting valve clearance”.
6.
Disconnect engine controller connectors (1) (PW R) and (2) (PW L).
Testing tools for compression pressure
Symbol E
1
2
Part No.
Part name
795-502-1590
Compression gauge
795-471-1310
Adapter
6261-71-6150
Gasket
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C).
1.
Remove cylinder head cover of the cylinder to be tested for compression pressure. a For details, see “Removal and installation of cylinder head assembly” in Disassembly and assembly.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See “Adjusting valve clearance”.
3.
Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s (Loosen the 2 terminal nuts alternately) from the injector. a Pass injector under the fuel path projected sideways and pull up the injector through wire (Do not pry the injector top up).
k
k
18
If these connectors are not disconnected, the engine may start while you are measuring, and that is dangerous. Accordingly, be sure to disconnect these connectors. Since connectors (1) and (2) are in the power supply circuit, cover them on the wiring harness side with vinyl sheets etc. to prevent electric leakage and grounding fault.
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30 Testing and adjusting
7.
Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. a Measure the engine speed at this time, referring to “Special functions of monitor panel (EMMS)”. q Monitoring code: 01002
8.
After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. 2) Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}
SEN01817-03
4)
Tighten the clamp and spacer with the bolt. 5) Install rocker arm assembly. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Adjust the valve clearance. For details, see “Adjusting valve clearance”. 6) Install head cover. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a
Install the injector wiring harness according to the following procedure 1) Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate. Install O-ring (16). 2) Install cap (17) with clip on the injector side of wiring harness. Press wiring harness (18) between the injector top and cap to the injector main body without slack. 3) Tighten nut (19) on the injector side. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
D475A, D475ASD-5E0
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30 Testing and adjusting
Measuring blow-by pressure a
a
1
Measuring instrument for blow-by pressure Symbol
Part No.
F
799-201-1504
Name Blow-by checker
Measure the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Check the blow-by pressure with the monitor panel since the machine of standard specification is equipped with crankcase pressure sensors for the VHMS. q Monitoring code: 42800 (Blow-by pressure) q Unit: kPa a For the operating method, see “Special functions of monitor panel (EMMS)”. a The monitor indicates the absolute value.
2.
If the VHMS is not installed, measure by the following method. 1) Remove right and left covers (2) of engine undercover (1).
2)
20
Install nozzle [1] of blow-by checker F to blow-by hose (3) of the right bank and block the hose joint. a Connect a short hose and tie the outlet. a Either of the right and left blow-by hoses may be blocked.
3)
Install nozzle [2] of blow-by checker F and hose [3] to blow-by hose (4) of the left bank and connect blow-by checker F.
4)
Run the engine at high idle and measure the blow-by pressure when the torque converter is stalled. a For details of the procedure for torque c o n v e r t e r s ta l l , s e e “ M e a s u r i n g engine speed”. a The blow-by pressure should be measured with the engine running at rated output. However, when measuring in the field, a similar value can be obtained at torque converter stall. a If it is impossible to check at rated output or stall speed, measure at high idle. In this case, the blow-by value will be about 80% of the value at rated output.
D475A, D475ASD-5E0
30 Testing and adjusting a
5)
SEN01817-03
Blow-by pressure varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.
After finishing measurement, remove the measuring instrument and return the removed parts.
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30 Testing and adjusting
Measuring engine oil pressure a
1
Measuring instruments for engine oil pressure Symbol G
1 2
Part No.
4)
Name
799-101-5002 Hydraulic tester
Install nipple [1] and joint (M14 × 1.5 mm) of hydraulic tester G1 and connect them to hydraulic tester G2. Run the engine at low idle and high idle and measure the engine oil pressure at each speed.
790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester
a
Measure the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range
1.
Check the engine oil pressure with the monitor panel since the machine is equipped with engine oil pressure sensors for the VHMS. q Monitoring code: 37200 (Engine oil pressure) q Unit: MPa a For the operating method, see “Special functions of monitor panel (EMMS)”.
2.
3)
If the monitor panel is not used, measure the engine oil pressure according to the following procedure. 1) Open the engine left upper side cover. 2) Remove oil temperature sensor (1) on the LH side of the cylinder block. Keep the removed oil temperature sensor and the wiring harness connector connected to each other. a Don’t remove the oil pressure sensor from the block because the engine controller detects abnormal low pressure error of the oil pressure sensor.
5)
After finishing measurement, remove the measuring instruments and return the removed parts. a The boost pressure can be tested in the “Pm Clinic auxiliary mode: 03” of the machine monitor. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
22
D475A, D475ASD-5E0
30 Testing and adjusting
Handling of fuel system devices 1 a
a
Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
D475A, D475ASD-5E0
SEN01817-03
Releasing residual pressure from fuel system 1 a
a
a
k
Pressure is generated in the low pressure circuit and high pressure circuit of the fuel system while the engine is running. Low pressure circuit: Feed pump – Fuel main filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector The pressure in both low pressure circuit and high pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed or installed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system, or removing or installing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
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30 Testing and adjusting
Testing fuel pressure a
k
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
2
799-401-2320
Hydraulic tester
3
795-471-1450
Adapter
4
07005-00812
Gasket
1
a
Start the engine and inspect the fuel pressure with the engine running at high idle or at the equivalent of rated output speed (stall load). a If the fuel pressure is in the following range, it is normal. Engine speed
Fuel pressure
At high idle or at the equivalent of rated output speed
0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
Measure the fuel pressure only for the low pressure circuit between the feed pump – fuel filter – fuel supply pump. Since the pressure in the high pressure circuit from the fuel supply pump through the common rail to the injector is very high, it cannot be measured. Open the left upper side cover of the engine and remove fuel pressure inspection plug (1) (M8 X 1.25) of fuel filter head.
2.
Install adapter H3 and gasket H4 to the plug hole.
3.
Install nipple [1] of hydraulic tester H1, and connect to hydraulic tester H2.
24
4.
Measuring tools for fuel pressure
Symbol
H
1
5.
Since the fuel circuits of the right and left banks after the priming pump are independent from each other, check them separately.
6.
After finishing testing, remove the testing tools and return the removed parts.
D475A, D475ASD-5E0
30 Testing and adjusting
Handling of reduced cylinder mode operation a
1.
2.
3.
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1
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When engine speed and output do not change from the normal operation (all cylinder operating mode) even though the fuel injection has been cut out for any cylinder, the cylinder is suspected to be defective. The following problems can be considered: q Leaking of cylinder head gasket q Defective injection of injector q Defective piston, piston ring or cylinder liner q Defective valve mechanism (valve system) q Defective electrical system Since the injector of each cylinder is separately controlled electronically in the common rail fuel injection system, the reduced cylinder mode operation can be obtained by easier operations of the switches when compared with the mechanical fuel injection system. This allows to narrow down the causes of the incident easily. a To implement reduced cylinder mode operation, see “Special functions of monitor panel (EMMS)”. a Use the reduced cylinder mode for only the purpose of troubleshooting.
D475A, D475ASD-5E0
Handling of no injection cranking operation 1 a
q
a a
No injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the engine unit has been stored for a long period, the no injection cranking is performed to lubricate the engine parts and protect them from seizure. Use the no-injection cranking function for only the above purposes while the engine is mounted on the machine. To implement no injection cranking operation, see “Special functions of monitor panel (EMMS)”.
25
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30 Testing and adjusting
Testing fuel return and leak amount
a
Testing tools for fuel return and leak amount
Symbol
J
a
26
Part No.
Part name
1
6151-51-8490
Spacer
2
6141-71-1710
Joint
3
Commercially available
Hose
4
Commercially available
Hose
5
Commercially available
Measuring cylinder
6
Commercially available
Stopwatch
7
07376-70315
Plug
1
1.
Preparation work (example for left bank) 1) Remove tube (3) between common rail (1) and supply pump (2). 2) Insert spacer J1 to supply pump (2) side and retighten it with the currently removed joint bolt. a Be sure to fit the gaskets to both ends of the spacer. 3) Connect the return piping to the fuel tank side again. a Be sure to fit the gaskets to both ends of the spacer.
Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.
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30 Testing and adjusting
4)
5)
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Insert joint J2 to common rail (1) side and retighten it with the currently removed joint bolt. a Be sure to fit the gaskets to both ends of the joint. Connect inspection hose J3 to the tip of joint J2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter. 5) 3.
2.
After finishing testing, stop the engine.
Testing return rate from injector a During testing injector return amount, keep the end of hose J3 connected to pressure limiter and insert the other end to oil pan (receiver). 1) Disconnect fuel return hose (4) and install plug J7 to hose (4) side and fix it to the frame.
Testing leakage from pressure limiter 1) Adjust routing to prevent its slacking of inspection hose J3 and insert the hose end to the oil pan (saucer). 2) Referencing “Measuring engine speed”, set up the condition necessary for checking the engine speed. 3) Start the engine and operate at the equivalent to rated operation (torque converter stall load). 4) After making sure that the engine speed is stabilized, measure leakage volume per minute by use of measuring cylinder J5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal. Engine speed (rpm)
Leaking amount (cc/min)
Equivalent to rated operation
Max. 10
D475A, D475ASD-5E0
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2)
3)
30 Testing and adjusting
Connect inspection hose J4 to joint (5) side. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. Adjust routing to prevent its slacking of inspection hose J4 and insert the hose end to the oil pan (container).
7)
4)
5)
6)
28
Rated output speed (rpm)
Return (Spill) limit (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
After finishing testing, stop the engine.
4.
Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts.
5.
Check the right bank similarly.
Referencing “Measuring engine speed”, set up the condition necessary for checking the engine speed. Start the engine and operate at the equivalent to rated operation (torque converter stall load). After making sure that the engine speed is stabilized, measure return rate per minute by use of measuring cylinder J5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal.
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30 Testing and adjusting
Bleeding air from fuel circuit
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1
a
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure.
1.
Remove fuel pre-filter (1) and fill it with fuel. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel pre-filter (1), and then add fuel through part (b) (holes around the central hole). a After filling the fuel pre-filter (1) with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the filter but fill it with the fuel by operating priming pump (3).
D475A, D475ASD-5E0
a
Don't fill fuel directly after removing main filter (2).
29
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2.
Install fuel pre-filter (1) to the filter head. a Apply engine oil thinly over the packing on the fuel pre-filter side. a After the packing of the fuel pre-filter touches the sealing face of the filter head, tighten the fuel filter 1/2 – 3/4 turns.
3.
Loosen air bleed plug (3) (plug on the outlet side) of the fuel main filter and operate priming pump (4). a Operate the priming pump until the fuel flows out of the plug hole and tighten the plug after checking the fuel. 3 Air bleeding plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4.
Loosen air bleeder (5) of the fuel supply pump and operate priming pump (4) 90 - 100 times. a Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then, operate the priming pump several times more until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5.
Bleed the air from the RH bank according to the above procedure.
6.
Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 2.
30
30 Testing and adjusting
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30 Testing and adjusting
Bleeding air from fuel circuit (Low-grade fuel specification) a
SEN01817-03
q
1
1.
Bleed air according to this procedure in the following cases. q When the fuel filter was replaced q When fuel ran out q When starting the engine for the first time after replacing the fuel piping or supply pump When replacing the fuel filter, do not add fuel to the main filter. It is not necessary either to add fuel to the pre-filter. Set the starting switch to OFF position.
2.
Open the right and left side covers.
3.
Open air bleeding valves (4) (right and left). a Set the valve levers in parallel with the piping. a See the operating procedure sticker stuck near the valves of the air bleeding piping.
k
4.
q
Right bank
Set switch (2) of electric priming pump switch (1) installed in the engine compartment to the “ON” position. a Lamp (3) will start flashing and operation of the electric priming pump will be started. q Release switch (2), and it automatically returns to its original position.
Left bank
D475A, D475ASD-5E0
31
SEN01817-03 a a a k
The buit-in timer of this switch automatically starts or stops operation of the electric priming pump. (See the figure below) Operation of the electric priming pump is stopped as long as flashing of the lamp is continued. It is not an error. Shifting the switch to “OFF” while the lamp is flashing turns off the lamp and stops the electric priming pump, too. Pressure is constantly applied to the fuel circuit as long as operation of the electric priming pump is continued. Loosening the air bleeding plug from this state might allow fuel to burst out. Thus, don’t try to loosen the plug while the pump is in operation.
5.
As the specified duration (about 6.5 minutes) is expired, lamp (3) automatically goes off, stopping the electric priming pump. a When the fuel filter alone was replaced, above completes bleeding air.
6.
When fuel is not provided in the fuel circuit such as when run out of fuel occurred or when replacement of the fuel pipe or supply pump was done, set switch (2) to “ON” again after the electric priming pump is automatically stopped.
7.
Bleeding air, in this case, completes as lamp (3) went off.
8.
Close air bleeding valve (4). a Set the valve levers at right angles to the piping.
32
30 Testing and adjusting
9.
Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, the air in the low-pressure circuit may have not been bled. In this case, start the engine according to the following procedure. 1) Turn electric priming pump switch (2) to the ON position. 2) While the electric priming pump is operating, crank the engine to start with the starting motor. If the engine still does not start, wait for about 2 minutes and repeat steps 1) and 2). 3) After the engine starts, keep it running for at least 5 minutes to bleed all air from the fuel circuit. a Do not operate the starting motor continuously for more than 20 seconds. a For the filter replacement procedure, see the standard specification.
D475A, D475ASD-5E0
30 Testing and adjusting
Testing fuel circuit for leakage k
a
SEN01817-03
1
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing and installing its components, check for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at a speed less than 1,000 rpm and stop it after its rotation is stabilized.
3.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
4.
Run the engine at low idle.
5.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
6.
Run the engine at high idle.
7.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
8.
Run the engine at high idle to apply load to the engine. a Relieve by tilting the blade or raising the ripper.
D475A, D475ASD-5E0
9.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If any fuel leakage is not detected, inspection is completed.
33
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30 Testing and adjusting
Testing and adjusting alternator belt tension 1
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure.
Testing Press the intermediate point of the belt between alternator pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 59 Nm {Approx. 6 kg} a Deflection (a): 20 ± 2 mm
1.
Loosen nut (B) and bolt (2) alternately.
2.
Adjust belt tension using nut (A).
3.
Tighten bolt (2) to have adjust bolt (1) and plate (3) made orthogonal to each other. 3 Bolt: 53.9 – 122.6 Nm {5.5 – 12.5 kgm}
4.
Tighten nut (B) to fix plate (3). a After adjusting, test the belt tension again.
34
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01817-03
Testing and adjusting belt tension for air conditioner compressor 1 Testing q Measure deflection (a) of the belt when it is p ushed with a finge r a t a p oint midway between the compressor pulley and the engine drive pulley. q Pushing force: Approx. 59 N {approx. 6 kg} q Deflection (a) of belt: 20 ± 2 mm
Adjusting a If the belt deflection is outside the standard value, adjust as follows. 1.
Loosen 3 mounting bolts and nuts (1) and locknuts (2) and (3).
2.
Turn locknut (3) and move air conditioner compressor (4) together with the bracket to adjust the tension of the belt.
3.
Tighten locknuts (2), (3) and 3 mounting bolts and nuts (1).
D475A, D475ASD-5E0
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30 Testing and adjusting
Adjusting fuel control dial and decelerator pedal
1.
36
Outline of fuel control system q The following signals are inputted as rotation command signals to the engine controller. q Decelerator pedal potentiometer signal q 3rd throttle signal The engine controller controls the fuel control system of the engine (CRI system) according to the lowest engine speed signal among those input signals. q Adjust the deceleration slow speed by adjusting the decelerator pedal linkage.
1
[1] [2] [3] [4] [5] [6] [7]
Fuel control dial (2nd throttle signal) Engine controller Steering controller Decelerator pedal (1st throttle signal) Decelerator potentiometer Engine (CRI system) Machine control signal (3rd throttle signal) [8] Rod [9] Stopper bolt
D475A, D475ASD-5E0
30 Testing and adjusting
2.
Preparatory work 1) Start the engine, set the monitor panel in the “Adjustment mode”, and prepare to measure the engine speed. a For the operation method, see “Special functions of monitor panel (EMMS)”. q Adjustment code: 0007 (Engine deceleration cut mode) a The engine speed is displayed by 1 rpm. Serial numbers: 30001 – 30070
SEN01817-03
4.
Adjusting high idle speed Set the fuel control dial to the high idle position and check that the high idle speed is correct. q High idle speed: 2000 ± 50 rpm a When engine speed is high: Lower the engine speed to below 1,900 rpm temporarily with stopper bolt (9) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idle speed. a When engine speed is low: Adjust the engine speed to the high idle speed with stopper bolt (9).
5.
Check of decelerator position (decelerator potentiometer signal) a Measure the decelerator position in the monitoring mode. q Monitoring mode: 31701 (Decelerator position) Check that displayed position is 100% while the decelerator pedal is released. If the displayed position is less than 100%, adjust it to 100% with the pedal linkage. If this adjustment is not made perfectly, the engine control function etc. may not operate normally. Accordingly, be sure to check the displayed position. q The decelerator position can be checked while the engine is stopped.
6.
Check of final accelerator position a Measure the final accelerator position in the monitoring mode. q Monitoring mode: 31706 (Final accelerator position) While the decelerator pedal is released, set the fuel control dial to the MAX position, set the parking brake lever in the FREE position, set the PCCS lever in the F or R position, and check that the displayed position is 100%. (Finish the check in 5 above in advance.) If the displayed position is less than 100%, check the voltage signal of the fuel circuit for error. If this adjustment is not made perfectly, the engine control function etc. may not operate normally. Accordingly, be sure to check the displayed position. q The accelerator position can be checked while the engine is stopped.
Serial numbers: 30071 and up
3.
Adjusting decelerator pedal speed Set the fuel control dial at the high idle position, depress decelerator pedal (4) until it contacts the stopper, and check that the decelerator pedal speed is normal. q Decelerator pedal speed: 900 ± 50 rpm a If the engine speed is not correct, adjust installation dimension (a) of rod (8). q Installation dimension (a): 283 mm q Installation dimension (b): 67.5 mm
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SEN01817-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01817-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
38
SEN01818-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 2 Measuring power train oil pressure................................................................................................................. 3 Adjusting transmission speed sensor ........................................................................................................... 12 Simple method to test brake performance .................................................................................................... 13 Adjusting brake pedal and parking brake lever ............................................................................................. 14 Adjusting PCCS lever console position......................................................................................................... 17 Emergency escape method when power train has trouble ........................................................................... 18 Inspecting wear of sprocket .......................................................................................................................... 20 Testing and adjusting track shoe tension ...................................................................................................... 21 Testing and adjusting work equipment oil pressure ...................................................................................... 22 Testing and adjusting control circuit basic pressure...................................................................................... 33 Measuring PPC valve output pressure and solenoid valve output pressure................................................. 34 Adjusting play of PPC valve.......................................................................................................................... 40 Measuring outlet pressure of ripper pin puller solenoid valve ....................................................................... 41 Checking parts which caused hydraulic drift of blade and ripper .................................................................. 42 Measuring internal leakage of work equipment cylinder ............................................................................... 43 Releasing residual pressure from work equipment cylinder ......................................................................... 44
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30 Testing and adjusting
Bleeding air from work equipment cylinder ................................................................................................... 44 Adjusting ripper lever position ....................................................................................................................... 45 Adjusting work equipment lock lever............................................................................................................. 46 Measuring fan motor speed .......................................................................................................................... 47 Measuring fan circuit oil pressure ................................................................................................................. 48 Bleeding air from fan pump ........................................................................................................................... 49 Measurement procedure for blade tilt control angle (Dual tiltdozer specification)......................................... 50 Measurement procedure for blade tilt control angle (Superdozer specification) ........................................... 53 Testing and adjusting operator's cab............................................................................................................. 55 Adjusting blade.............................................................................................................................................. 59 Testing and adjusting operator's seat isolator ............................................................................................... 61
2
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30 Testing and adjusting
SEN01818-03
Measuring power train oil pressure a
Measuring instruments for power train oil pressure Symbol 1 K
2 3
k
a
a
a
2 3
Part No.
Name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester 799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring
Stop the machine on level ground and lower the work equipment to the ground, then set the parking brake lever and work equipment lock lever in the lock position. Measure the power train oil pressure under the following condition. q Power train oil temperature: Within operating range Centralized pressure pickup ports (1) – (14) are installed inside the inspection cover on the right outside of the operator’s cab and transmission lubricating oil pressure pickup port (15) is installed to the top of the power train filter. Table of locations of centralized pressure pickup points for measuring oil pressure and gauges to use
No. Stamp 1
1
IN
Measured oil pressure T/C inlet pressure
OUT T/C outlet pressure SC
Gauge (MPa {kg/cm2}) 2.5 {25} 1.0 {10}
T/C stator clutch pressure
6 {60} 2.5 {25}
4
LU
T/C lockup clutch pressure
5
TM
T/M main relief pressure
6 {60}
6
FWD T/M F clutch pressure
6 {60}
7
REV T/M R clutch pressure
6 {60}
8
1ST T/M 1st clutch pressure
6 {60}
9
2ND T/M 2nd clutch pressure
6 {60}
10
3RD T/M 3rd clutch pressure
6 {60}
11
LB
S/T left brake pressure
6 {60}
12
RB
S/T right brake pressure
6 {60}
13
LC
Left clutch pressure
6 {60}
14
RC
Right clutch pressure
6 {60}
15
—
T/M lubricating pressure
D475A, D475ASD-5E0
1.0 {10}
3
SEN01818-03
1.
Measuring torque converter inlet pressure (IN) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (1). a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
30 Testing and adjusting
2.
Measuring torque converter outlet pressure (OUT) 1) Connect hydraulic tester K2 to oil pressure pick-up nipple (2). a Use an oil pressure gauge of 1.0 MPa {10 kg/cm2}.
2) 2) 3)
4)
4
Start the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
After finishing measurement, remove the measuring instrument and return the removed parts.
3)
4)
Start the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
After finishing measurement, remove the measuring instrument and return the removed parts.
D475A, D475ASD-5E0
30 Testing and adjusting
3.
Measuring torque converter stator clutch pressure (SC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (3). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
4)
Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
SEN01818-03
4.
Measuring torque converter lock-up clutch pressure (LU) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (4). a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
2)
Start the engine and set the monitor panel in the “Adjustment mode” and disengage both steering clutches. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 5535 (Disengagement of both steering clutches) a The transmission speed is displayed on the lower display section (Unit: 1 rpm).
3) 4)
Turn on the lock-up mode switch. Set the PCCS lever in the FORWARD and 2nd gear speed position and make the transmission run idle. Raise the engine speed gradually and measure the oil pressure when the lock-up pilot lamp lights up. After finishing measurement, remove the measuring instrument and return the removed parts.
After finishing measurement, remove the measuring instrument and return the removed parts.
5)
6)
D475A, D475ASD-5E0
5
SEN01818-03
5.
Measuring transmission main relief pressure (TM) a Check the transmission main relief pressure with the monitor panel since the machine is equipped with a transmission main relief pressure sensor for the VHMS. q Monitoring code: 43000 (Transmission main relief pressure) q Unit: MPa a For the operating method, see “Special functions of monitor panel (EMMS)”. a If the machine is not equipped with the VHMS, measure the transmission main relief pressure according to the following procedure. 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (5). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
30 Testing and adjusting
6.
Measuring transmission F clutch pressure (FWD) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (6). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2)
3) 4) 2) 3)
4)
6
Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
After finishing measurement, remove the measuring instrument and return the removed parts.
5)
6)
Run the engine, set the monitor panel in the “Adjustment mode”, and disengage both steering clutches. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (Unit: 1 rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 3rd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
After finishing measurement, remove the measuring instrument and return the removed parts. D475A, D475ASD-5E0
30 Testing and adjusting
7.
Measuring transmission R clutch pressure (R) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (7). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2)
3) 4)
5)
6)
SEN01818-03
8.
Measuring transmission 1st clutch pressure (1ST) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (8). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
Run the engine, set the monitor panel in the “Adjustment mode”, and disengage both steering clutches. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (in rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the REVERSE 3rd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
2)
After finishing measurement, remove the measuring instrument and return the removed parts.
6)
D475A, D475ASD-5E0
3) 4)
5)
Run the engine, set the monitor panel in the “Adjustment mode”, and disengage both steering clutches. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (Unit: 1 rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 1st gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
After finishing measurement, remove the measuring instrument and return the removed parts.
7
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9.
Measuring transmission 2nd clutch pressure (2ND) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (9). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2)
3) 4)
5)
6)
8
30 Testing and adjusting
10. Measuring transmission 3rd clutch pressure (3RD) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (10). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
Run the engine, set the monitor panel in the “Adjustment mode”, and disengage both steering clutches. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (in rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 2nd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
2)
After finishing measurement, remove the measuring instrument and return the removed parts.
6)
3) 4)
5)
Run the engine, set the monitor panel in the “Adjustment mode”, and disengage both steering clutches. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 5535 (Both steering clutches disengagement) a The message display displays the transmission speed (in rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 3rd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
After finishing measurement, remove the measuring instrument and return the removed parts. D475A, D475ASD-5E0
30 Testing and adjusting
11. Measuring steering left brake pressure (LB) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (11). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
4)
Run the engine and set the parking brake lever in the FREE position. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever is set to the steering left stroke end. a Check that the oil pressure becomes 0 when the brake pedal is pressed fully or when the parking brake lever is set in the LOCK position.
After finishing measurement, remove the measuring instrument and return the removed parts.
D475A, D475ASD-5E0
SEN01818-03
12. Measuring steering right brake pressure (RB) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (12). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
4)
Run the engine and set the parking brake lever in the FREE position. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever is set to the steering right stroke end. a Check that the oil pressure becomes 0 when the brake pedal is pressed fully or when the parking brake lever is set in the LOCK position.
After finishing measurement, remove the measuring instrument and return the removed parts.
9
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13. Measuring steering left clutch pressure (LC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (13). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
4)
5)
10
30 Testing and adjusting
14. Measuring steering right clutch pressure (RC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (14). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
Run the engine and set the parking brake lever in the FREE position. Set the PCCS lever to the steering left stroke end. a Set the direction of the PCCS lever in neutral. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the steering of the PCCS lever is returned to the neutral position.
2)
After finishing measurement, remove the measuring instrument and return the removed parts.
5)
3)
4)
Run the engine and set the parking brake lever in the FREE position. Set the PCCS lever to the steering right stroke end. a Set the direction of the PCCS lever in neutral. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the steering of the PCCS lever is returned to the neutral position.
After finishing measurement, remove the measuring instrument and return the removed parts.
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01818-03
15. Measuring transmission lubricating oil pressure 1) Connect hydraulic tester K2 to oil pressure pickup nipple (15). a Use an oil pressure gauge of 1.0 MPa {10 kg/cm2}.
2)
Run the engine at high idle and measure the oil pressure.
3)
After finishing measurement, remove the measuring instrument and return the removed parts.
D475A, D475ASD-5E0
11
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Adjusting transmission speed sensor
30 Testing and adjusting
Remove sensor (1) and flange (2) together and secure them with nut (3). a Take care that the adjustment angle of the sensor will not change. 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
7.
Install flange (2) and the sensor together to the steering case. 2 Flange and mounting bolt: Gasket sealant (LG-6) 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
8.
After finishing adjustment, set the monitor panel in the “Monitoring display mode” and check that the transmission speed is displayed normally. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Monitoring code: 31400 (Transmission speed)
1
a
The torque converter output speed sensor for the VHMS is not adjustable.
1.
Remove the fuel tank undercover, and then remove transmission output speed sensor (1) and the flange together. a Before adjusting transmission speed sensor (1), remove it temporarily and check that its tip is free from a steel chip and a flaw. a Before installing the transmission speed sensor, separate sensor (1), flange (2), and nut (3).
2.
Install flange (2) to the steering case temporarily.
3.
Looking at bevel gear (4) through the hole of flange (2), check that the tooth tip is at the center of the hole. a If the tooth tip is not at the center, run the engine and move the machine forward or in reverse a little to set the tooth tip to the center.
4.
Tighten sensor (1) until its tip touches the tooth tip of gear (4). 2 Threads of sensor: Gasket sealant (LG-6)
5.
Return sensor (1) from the above position by the specified angle. a Returning angle of sensor: 1/2 – 1 turn a Adjust clearance (b) between the sensor tip and gear tooth tip to 0.75 – 1.50 mm.
12
6.
D475A, D475ASD-5E0
30 Testing and adjusting
Simple method to test brake performance
SEN01818-03
1
a
Implement simple method to test brake performance under the following condition. q Power train oil temperature: Within operating range
1.
Set the blade and ripper in the travel posture on a level place.
2.
Run the engine and set the parking brake lever in free position.
3.
While the engine is running at low idle and the brake pedal is depressed securely, set PCCS lever in the forward and 2nd gear speed position. k If this test is carried out in the 1st gear position, the brake is overloaded. Therefore, be sure to carry it out in 2nd gear speed. a Set the steering unit in neutral.
4.
Press the decelerator pedal and set the fuel control dial in the high idle position.
5.
Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idle level. k Since the torque converter is stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
D475A, D475ASD-5E0
13
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Adjusting brake pedal and parking brake lever
30 Testing and adjusting
1
Brake pedal side
14
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01818-03
Parking brake lever side
Adjusting brake pedal side 1.
Adjusting brake pedal stroke Adjust stroke (a) of brake pedal (1) by adjusting installed dimension (b) of stopper bolt (2). a Adjust the brake pedal stroke with the brake rod separated from the pedal. q Pedal stroke (a): 78 mm q Installed dimension (b) of stopper bolt: 36.5 mm
2.
Adjusting installed length of brake rod 1) Connect small rod (3), brake rod (4), and turnbuckle (6). q Screwing distance (c), (d), (e), and (f): 23 mm 2) Adjust the installed length of brake rod (4) with turnbuckle (6) so that the spool of brake valve (5) will be at the OFF position. a The threads on the brake pedal side of the turnbuckle locknut are inverted. 3 Locknut: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
D475A, D475ASD-5E0
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 (7). 3) Press brake pedal (1) and check that spool stroke (g) of brake valve (5) is in the normal range. q Spool stroke (g): 20 – 24 mm
4.
Checking brake oil pressure 1) Start the engine and set the monitor panel in the adjustment mode. a For the operating method in the adjustment mode, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 9996 (Mechanical brake release mode) 2) With the parking brake lever in the FREE position, press the brake pedal fully and check that the brake oil pressures on both sides become 0. a For the measuring points of the brake oil pressure, see “Measuring power train oil pressure”.
15
SEN01818-03
5.
16
Initializing brake potentiometer Turn the starting switch ON, set the monitor panel to the “Adjustment mode”, and initialize the brake potentiometer. a For the operating method in the adjustment mode, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 0005 (Initialization of brake potentiometer)
30 Testing and adjusting
Adjusting parking brake lever side 6.
Assembly and installation of lever assembly 1) Assemble lever assembly (7) and adjust the operation of limit switch (8). a Assemble the lever assembly with the parking cable disconnected from the lever. q When lever is at upper position: OFF, at lower position: ON q Operating stroke of limit switch: 3 mm 2) Install lever assembly (7).
7.
Adjusting installed length of parking brake cable 1) Connect parking brake cable (9) to the lever side, and then adjust installed dimensions (h) and (j). q Installed dimension (h) of cable: 22.5 mm q Installed dimension (j) of cable: 14.5 mm 2) Connect parking brake cable (9) to the valve side. q Installed dimension (m) of cable: 15 mm q Installed dimension (k) of cable: 20.5 mm 3) Operate parking brake lever (10) between the FREE position and LOCK position and adjust the position of rod end (11) so that spool stroke (n) of brake valve (4) will be normal. q Spool stroke (n): 23.0 mm
8.
Checking brake oil pressure Run the engine and set the parking brake lever in the FREE position and LOCK position and check that the brake oil pressure will be as follows. a For the measuring point of the brake oil pressure, see “Measuring power train oil pressure”. q LOCK position: 0, FREE position: Specified pressure
9.
Checking limit switch 1) Turn the starting switch ON, set the monitor panel to the “Monitoring display mode”. a For the operating method in the monitoring display mode, see “Special functions of monitor panel (EMMS)”. q Monitoring code: 40910 (Steering controller input signal 1) 2) Set the parking brake lever in the FREE position and LOCK position and check that the limit switch signals are input normally.
D475A, D475ASD-5E0
30 Testing and adjusting
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). a If the console is not parallel with the operator’s seat, adjust dimension (a) of rod (4). q Standard dimensions (a): 179 mm (Machine with operator’s seat isolator: 178.5 mm) a The locknut on the rear side of the turnbuckle is a left-handed (reversing) screw.
D475A, D475ASD-5E0
SEN01818-03
1
17
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30 Testing and adjusting a
Emergency escape method when power train has trouble 1 a
a Devices used for emergency escape Symbol
Part No.
Since the female side of connector PL2 is kept disconnected, mask it with a vinyl sheet, etc. Put switch assembly [1] in the cab through the cab window.
Part name
19M-06-32820 Switch assembly L
1
195-06-71220 Wiring harness 2
1.
790-190-1601 Pump assembly
Emergency escape method with switch box (Use L1) a 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. a 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 register [2] to wiring harness [3] of emergency escape device L1. k Since register [2] controls the drive voltage of the solenoid, connect it to the wiring harness before connecting to the machine. k 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.
2)
18
7824-66-6430 Register
3)
Disconnect neutral safety relay (NSF) in the fuse room and connect pins [3] and [5] of the connector on the wiring harness side. a Perform this operation only when the engine does not start electrically because of a trouble in the neutral safety relay or the transmission controller. k 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. k 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.
Open the left fender inspection cover and connect wiring harness [3] to connectors PL1 (1) and PL2 (2). q Connector PL1 (1): Connect to male side and female side. q Connector PL2 (2): Connect to male side. D475A, D475ASD-5E0
30 Testing and adjusting
4) 5)
SEN01818-03
Start the engine and set the parking brake lever in the FREE position. Operate switch assembly [1] and move the machine to a safe place. a The gear speed switch is so made that the switch on the lower gear speed will be operated first. k Take care when the machine travels in reverse, since the steering direction is reversed.
3)
4)
2.
Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller solenoid valve. Connect end hose of pump assembly L2 to the supply hose. (Use the nipple of face seal type.) a Block the solenoid valve side with plug. Plug: 02789-00315
Emergency escape method with brake releasing device (Use L2) a If the engine cannot be started and the parking brake cannot be released, escape according to the following procedure. 1) Assemble pump assembly L2.
5) 6)
2)
Install volume pump [4] of pump assembly L2 to the outside of the operator’s cab.
D475A, D475ASD-5E0
Turn the starting switch ON and set the parking brake lever in the FREE position. Operate the volume pump to raise the brake releasing oil pressure to the initial pressure. q Initial pressure: Approx. 2.74 MPa {28 kg/cm2} a Since an accumulator is installed in the circuit, the handle must be operated 30 – 50 times to raise the oil pressure. a If the oil pressure does not rise above a certain level, the relief valve may be set to low pressure. In this case, adjust the set pressure of the relief valve.
19
SEN01818-03
7)
20
Tow the machine to a safe place. a The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again about 1 minutes after. Accordingly, work quickly. a If the brake releasing pressure lowers to about 1.57 MPa {16 kg/cm 2 }, the brake is applied. In this case, operate the volume pump again to raise the brake releasing pressure to the initial pressure.
30 Testing and adjusting
Inspecting wear of sprocket a
a
1
Use the “Full-scale dimensions drawing of sprocket profile” in “Sprocket” in “Structure, function, and maintenance standard” as a gauge for measuring wear of the sprocket. Make a copy of the “Full-scale dimensions drawing of sprocket profile” on a transparent paper or sheet and apply it directly to the sprocket to see if the sprocket can be used.
D475A, D475ASD-5E0
30 Testing and adjusting
Testing and adjusting track shoe tension 1 Testing 1. Move the machine slowly on a level place, then stop it. a Do not apply the brake when stopping. 2.
Place straight steel bar (1) between the idler and front carrier roller and measure clearance (a) between the bottom of the steel bar and shoe grouser. q Standard clearance (a): 20 – 30 mm
D475A, D475ASD-5E0
SEN01818-03
Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1.
Remove cover (2).
2.
When the tension is too high Loosen plug (3) to discharge the grease. k Since the high-pressure grease may spout out, do not loosen the plug more than 1 turn. 3 Plug: 59 – 88 Nm {6 – 9 kgm}
3.
When tension is low Add grease through grease fitting (4). a If the track shoe is not tensed well, move the machine forward and in reverse slowly. a After the adjustment is finished, check the track tension again.
21
SEN01818-03
30 Testing and adjusting
Testing and adjusting work equipment oil pressure a
1 2 M
4)
Run the engine at high idle and set the blade lever and ripper lever in neutral, and measure the oil pressure.
5)
After finishing measurement, remove the measuring instrument and return the removed parts.
1
Part No.
Name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 566-35-43561 Nipple (18 x 1.5 mm) 07002-11823 O-ring
3
799-101-5160 Nipple (R1/8)
4
799-401-2701 Differential pressure gauge
5
799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring
Measuring k Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. a Measure the work equipment oil pressure under the following condition. q Hydraulic oil temperature: Within operating range
22
Install nipples M2, M3, and connect them to oil pressure gauge [1] of hydraulic tester M1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
Testing and adjusting instruments for work equipment oil pressure Symbol
1.
3)
Measuring unload pressure 1) Remove the main valve cover above the right fender. 2) Remove work equipment oil pressure sensors (1) and (2) from the work equipment control valve. q (1): Front pump oil pressure sensor q (2): Rear pump oil pressure sensor
D475A, D475ASD-5E0
30 Testing and adjusting
2.
Measuring main relief pressure (Single tilt specification) a Measure the main relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a Since the oils from the 2 pumps are merged in the work equipment circuit of the single tilt specification, the oil pressure of the divided oil cannot be measured. 1) Start the engine and set the work equipment lock lever in the FREE position. 2) Run the engine at high idle, raise or tilt the ripper to relieve the cylinder at a stroke end, and measure the oil pressure.
SEN01818-03
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
3) a
a
After finishing measurement, remove the measuring instrument and return the removed parts. The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the “PM clinic auxiliary mode” of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the “Dual display monitoring mode” of the service mode.
D475A, D475ASD-5E0
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SEN01818-03
3.
Measuring main relief pressure (Dual tilt specification and superdozer specification) a Measure the main relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a The oil pressure of the divided oil can be measured by measuring while pitching back the ripper. 1) Start the engine and set the work equipment lock lever in the FREE position. 2) Run the engine at high idle, raise or pitch back the ripper to relieve the cylinder at a stroke end, and measure the oil pressure.
30 Testing and adjusting
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
3)
a
a
24
After finishing measurement, remove the measuring instrument and return the removed parts.
The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the “PM clinic auxiliary mode” of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the “Dual display monitoring mode” of the service mode.
D475A, D475ASD-5E0
30 Testing and adjusting
4.
Measuring blade tilt relief pressure (Single tilt specification) a Measure the blade tilt relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a Since all of the oils from the 2 pumps are merged in the work equipment circuit of the single tilt specification, the oil pressure of the divided oil cannot be measured. 1) Start the engine and set the work equipment lock lever in the FREE position. 2) Run the engine at high idle, tilt the blade to the left to relieve the cylinder at a stroke end, and measure the oil pressure.
SEN01818-03
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
3)
a
a
After finishing measurement, remove the measuring instrument and return the removed parts.
The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the “PM clinic auxiliary mode” of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the “Dual display monitoring mode” of the service mode.
D475A, D475ASD-5E0
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SEN01818-03
5.
Measuring blade pitch relief pressure (Dual tilt specification and superdozer specification) a Measure the blade pitch dump relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a Measure the pressure of the divided oil from the 2 pumps during pitch dump operation. 1) Start the engine and set the work equipment lock lever in the FREE position. 2) Run the engine at high idle, pitch dump the blade to relieve the cylinder at a stroke end, and measure the oil pressure.
3)
a
a
26
30 Testing and adjusting
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
After finishing measurement, remove the measuring instrument and return the removed parts.
The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the “PM clinic auxiliary mode” of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the “Dual display monitoring mode” of the service mode.
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30 Testing and adjusting
6.
Measuring blade raise relief pressure a Measure the blade raise relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. 1) Block the return side hose of the blade lift cylinder. 2) Start the engine and set the work equipment lock lever in the FREE position.
SEN01818-03
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
3)
4)
a
a
Run the engine at high idle, raise the blade to relieve the cylinder at a stroke end, and measure the oil pressure. After finishing measurement, remove the measuring instrument and return the removed parts. a When measuring the oil pressure of the single tilt specification and dual tilt specification, relieve the oil through the blade raise relief valve. When measuring the oil pressure of the superdozer specification, relieve the oil through the main relief valve.
The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the “PM clinic auxiliary mode” of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the “Dual display monitoring mode” of the service mode.
D475A, D475ASD-5E0
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SEN01818-03
7.
Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time and calculate the difference between them. 1) Remove work equipment oil pressure sensors (1) and (2) from the work equipment control valve.
2)
Remove oil pressure pickup plugs (3) and (4) from the work equipment pump. q (1): Front pump discharge oil pressure sensor q (2): Rear pump discharge oil pressure sensor q (3): Front pump LS pressure plug q (4): Rear pump LS pressure plug
3)
Install nipple M2, M3 to the work equipment control valve and connect it to oil pressure gauge [1] of hydraulic tester M1 or differential pressure gauge M4. (Pump discharge pressure) Install nipple M5 to the work equipment pump side and connect it to oil pressure gauge [1] of hydraulic tester M1 or differential pressure gauge M4. (LS pressure: Low pressure side)
4)
28
30 Testing and adjusting a
When using differential pressure gauge: Connect the pump discharge pressure side to the high pressure side (back side) and connect the LS pressure side to the low pressure side (lower side). Since the differential pressure gauge needs a 12 V power source, connect it to a battery.
D475A, D475ASD-5E0
30 Testing and adjusting a
5)
a
6)
When using oil pressure gauge: Use the oil pressure gauge of 40 MPa {400 kg/cm2}. Since the differential pressure is about 3.9 MPa {40 kg/cm2} at maximum, measure it by installing the same gauge to the pickup plugs alternately.
Operate the blade lever and ripper lever and measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time while each cylinder is moving. Calculation of LS differential pressure: LS differential pressure = Pump discharge pressure – LS pressure After finishing measurement, remove the measuring instruments and return the removed parts.
D475A, D475ASD-5E0
SEN01818-03
8.
Measuring LS valve output pressure (servo piston inlet pressure) 1) Open the inspection cover of the cross bar front undercover. 2) Remove oil pressure pickup plugs (5) and (6) from the work equipment pump. q (5):For front pump LS valve output pressure q (6):For rear pump LS valve output pressure
3)
Install nipple M5 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauge of 40 MPa {400 kg/cm2}.
4)
Start the engine and set the work equipment lock lever in the FREE position.
29
SEN01818-03
5)
30 Testing and adjusting
Run the engine at high idle, perform the operations shown in the following table, and measure the LS valve output pressure.
Specification
Operation
Common to all Raise blade specifications Dual tilt and superdozer
Raise ripper or pitch back to relieve
Single tilt
Raise ripper or tilt to right to relieve
6)
LS valve output pressure (MPa {kg/cm2}) 0 {0}
1.4 27.4 +– 2.74 + 14 {280 – 28}
Adjusting a The unload valve cannot be adjusted. 1.
Adjusting main relief pressure a If the work equipment relief pressure is abnormal, adjust main relief valve (7) or (8) according to the following procedure. a When the main relief pressure of the dual tilt specification and superdozer specification is measured, if it is abnormal in either or both of the front pump circuit and rear pump circuit, adjust the ma in re lief valve(s) of the abnormal circuit(s). a The main relief pressure of the divided oil of the single tilt specification cannot be measured. Accordingly, measure the main relief pressure on either side or both sides. q (7): Main relief valve for front pump circuit q (8): Main relief valve for rear pump circuit
After finishing measurement, remove the measuring instrument and return the removed parts.
1)
30
Loosen locknut (9) and turn adjustment screw (10) to adjust the pressure. a If the adjustment screw is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. a Quantity of adjustment per turn of adjustment screw: 12.6 MPa {128 kg/ cm2} 3 Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
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30 Testing and adjusting
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q
a a
2)
2.
Loosen locknut (18) of the blade tilt relief valve and turn adjustment nut (17) to adjust the pressure. If the adjustment nut is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. Quantity of adjustment per turn of adjustment nut: 25.3 MPa {258 kg/cm2} 3 Locknut: 39 – 49 Nm {4 – 5 kgm}
After finishing adjustment, check again that the oil pressure is normal according to the procedure for measurement described above.
Adjusting blade pitch/tilt relief pressure a If the blade left tilt relief pressure (single tilt specification) or the blade pitch dump relief pressure (dual tilt specification and superdozer specification) is abnormal, adjust blade tilt relief valve (15) or (16) according to the following procedure. a When the blade tilt relief pressure of the dual tilt specification and superdozer specification is measured, if it is abnormal in either or both of the front pump circuit and rear pump circuit, adjust the blade tilt relief valve(s) of the abnormal circuit(s). a The blade tilt relief pressure of the divided oil of the single tilt specification cannot be measured. Accordingly, measure the blade tilt relief pressure on either side or both sides. q (15): Blade tilt relief valve for front pump circuit q (16): Blade tilt relief valve for rear pump circuit
3.
Adjusting blade lift relief pressure a If the blade lift relief pressure is abnormal, adjust blade lift relief valve (19) or (20) according to the following procedure. a The blade lift relief pressure of the divided oil cannot be measured. Accordingly, measure the blade lift relief pressure on either side or both sides. q (19): Blade lift relief valve for front pump circuit q (20): Blade lift relief valve for rear pump circuit
q
a
D475A, D475ASD-5E0
Loosen locknut (21) of the blade tilt relief valve and turn adjustment nut (22) to adjust the pressure. If the adjustment nut is q turned to the right, the pressure rises. q turned to the left, the pressure lowers.
31
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30 Testing and adjusting
Quantity of adjustment per turn of adjustment nut: 25.3 MPa {258 kg/cm2} 3 Locknut: 39 – 49 Nm {4 – 5 kgm}
2)
4.
Adjusting LS differential pressure a If the LS differential pressure is abnormal, adjust LS valves (11) and (12) according to the following procedure. q (11): LS valve for front pump circuit q (12): LS valve for rear pump circuit
1)
32
After finishing adjustment, check again that the oil pressure is normal according to the procedure for measurement described above.
Loosen locknut (13) and turn adjustment screw (14) to adjust the differential pressure. a If the adjustment screw is q turned to the right, the LS differential pressure rises. q turned to the left, the LS differential pressure lowers. a Quantity of adjustment per turn of adjustment screw: 1.3 MPa {13.3 kg/ cm2} 3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
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30 Testing and adjusting
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Testing and adjusting control circuit basic pressure a
Run the engine at high idle, set the blade lever and ripper lever in neutral, and measure the oil pressure.
4.
After finishing measurement, remove the measuring instrument and return the removed parts.
1
Measuring instruments for control circuit basic pressure Symbol N
a
3.
1
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
The control circuit basic pressure is the pressure reduced by the self-pressure reducing valve of the control valve. It is used commonly for the work equipment PPC, fan pump control, and work equipment pump control.
Measuring k Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. a Measure the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range 1.
Remove the right ROPS front cover.
2.
Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure pickup nipple (1). a Use the oil pressure gauge of 6 MPa {60 kg/cm2}.
D475A, D475ASD-5E0
Adjusting a The self-pressure reducing valve cannot be adjusted.
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30 Testing and adjusting
Measuring PPC valve output pressure and solenoid valve output pressure a
a
1
Measuring instruments for PPC valve output pressure and solenoid valve output pressure Symbol 1 P
Part No.
The PPC valve output pressure of the following circuits is the basic pressure of the solenoid valve (Dual tilt specification and superdozer specification). q Blade right tilt/left tilt: Pitch/Tilt solenoid valve basic pressure
Part name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (02) 3 799-401-3200 Adapter (03)
k
a
a
1.
34
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. Before measuring the PPC valve output pressure and pitch/tilt control valve pressure, check that the control circuit basic pressure is normal. Measure the PPC valve output pressure and pitch/tilt control valve pressure under the following condition. q Hydraulic oil temperature: Within operating range Measuring PPC valve output pressure (solenoid valve basic pressure) a Measure the pressure of the following circuits at the PPC valve. q Blade lift raise circuit q Blade tilt circuit before entering pitch/ tilt solenoid valve q Ripper raise circuit and ripper tilt back circuit 1) Remove pressure switch (1) of the circuit to be measured from the blade and ripper PPC valve. 2) Install nipple [1] of hydraulic tester K1 and connect oil pressure gauge [2]. 3) Start the engine and set the work equipment lock lever in the FREE position. 4) Run the engine at high idle, operate the control lever of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a The blade-lower circuit, ripper-lower circuit, and tilt-in circuit may be measured on the work equipment control side. a When measuring the blade-lower circuit, operate the lever until the blade floats.
2.
Measuring solenoid valve output pressure (Dual tilt specification and superdozer specification) a Measure the following solenoid valve output pressures on the solenoid valve block (3) side. (It is difficult to measure on the work equipment control valve side.) q Blade left tilt circuit (Left tilt/pitch back circuit) (4) after passing through solenoid valve q Blade right tilt circuit (Right dual tilt/ pitch back circuit) (5) after passing through solenoid valve
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30 Testing and adjusting
1)
2)
3) 4)
Disconnect the piping of the circuit to be measured and install oil pressure pickup adapter P2 or P3. Install nipple [1] of hydraulic tester P1 and connect oil pressure gauge [2].
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a
Measure the following solenoid valve output pressures on the work equipment control side. q Blade left tilt circuit (Left tilt/pitch dump circuit) (6) after passing through solenoid valve q Blade lower circuit (7) after passing through solenoid valve q Blade right tilt circuit (Right tilt/pitch dump circuit) (8) after passing through solenoid valve
Start the engine and set the work equipment lock lever in the FREE position. Run the engine at high idle, operate the control lever or knob switch of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a When measuring the output pressure of the pitch dump solenoid valve or pitch back solenoid valve of the superdozer specification, set the blade lever in neutral and operate the knob switch. a Measure the output pressure of the tilt limit solenoid valve while checking the tilting direction of the blade lever. When the blade is set at the tilt limit angle, the output pressure from the PPC valve is stopped.
D475A, D475ASD-5E0
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1)
2)
3) 4)
36
30 Testing and adjusting
Disconnect the piping of the circuit to be measured and install oil pressure pickup adapter P2 or P3. Install nipple [1] of hydraulic tester P1 and connect oil pressure gauge [2].
Start the engine and set the work equipment lock lever in the FREE position. Run the engine at high idle, operate the control lever or knob switch of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a When measuring the output pressure of the pitch dump solenoid valve or pitch back solenoid valve of the superdozer specification, set the blade lever in neutral and operate the knob switch. a Measure the output pressure of the tilt limit solenoid valve while checking the tilting direction of the blade lever. When the blade is set at the tilt limit angle, the output pressure from the PPC valve is stopped.
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30 Testing and adjusting
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Single tilt specification
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37
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30 Testing and adjusting
Dual tilt specification and superdozer specification
38
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30 Testing and adjusting
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39
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Adjusting play of PPC valve a a q
30 Testing and adjusting
1
If the end play of the blade lever and ripper lever is excessive, adjust it with their PPC valves according to the following procedure. This figure shows the PPC valve for the ripper. Standard play (a): 0.5 – 3.0mm at 200mm from revolution center of lever (in both longitudinal and lateral directions)
1.
Remove boot (1).
2.
Loosen locknut (2) and turn disc (3) to adjust the play. a Do not move the piston at this time.
3.
Fix disc (3) and tighten locknut (2). 3 Locknut: 98 – 127 Nm {10 – 13 kgm}
4.
Install boot (1).
40
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30 Testing and adjusting
SEN01818-03
Measuring outlet pressure of ripper pin puller solenoid valve 1 a
Measuring instruments for outlet pressure of ripper pin puller solenoid valve Symbol 1 Q
Part No.
790-261-1204 Digital hydraulic tester
2 799-401-3200 k
Name
799-101-5002 Hydraulic tester Oil pressure pickup adapter (Size 03)
a
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the outlet pressure of the ripper pin puller solenoid valve under the following condition. q Power train oil temperature: Within operating range
1.
Disconnect pin puller cylinder hose (1) or (2).
2.
Install oil pressure pickup adapter Q2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester Q1 and connect oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
D475A, D475ASD-5E0
4.
Run the engine at high idle and operate the ripper pin puller switch and measure the oil pressure.
5.
After finishing measurement, remove the measuring instrument and return the removed parts.
41
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30 Testing and adjusting
Checking parts which caused hydraulic drift of blade and ripper a
When a hydraulic drift of blade or ripper occurred, check if the parts causing the drift is located in cylinder packing side or in control valve side according to the following procedure.
1.
Stop the engine with the cylinder at the following positions. 1) Blade lift cylinder Tense blade to push up the front of machine. a Do not extend the blade lift cylinder to the stroke end since it is equipped with the piston valve.
3)
2.
2)
42
Blade tilt cylinder Retract the tilt cylinder to the stroke end and tense blade further to push up the right side of the machine.
Ripper lift cylinder Te nse rippe r to push u p the rea r of machine.
Move the control lever of cylinder to be checked to the direction of extending cylinder and validate the movement of cylinder. q If the drift speed becomes faster, a cylinder packing is defective. q If the speed does not change, a control valve is defective. a If the pressure of the accumulator is lost, run the engine for approx. 10 seconds to build up the pressure.
[Reference] In case of the hydraulic drift is caused by defective cylinder packing, the reason why the drift speed becomes faster by above mentioned operation is as follows: 1) When work equipment is set in the above mentioned position, where the holding pressure is applied to the bottom side, the oil leaks from bottom side to head side. Since the volume of head side is smaller than that of bottom side by the volume of the rod, the inner pressure of head side rises by the oil leak from bottom side. 2) If the inner pressure of head side rises, cylinder is balanced at certain pressure (depending on the amount of leakage) which is in proportion to the inner press u r e . T h e r e f o r e , t h e d r i ft i n g s p e e d becomes slower. 3) At this time, if the circuit in the head side is opened (bottom side is closed by check valve) to drain circuit by above mentioned lever operation, the oil in the head side flows into the drain circuit causing the lost of the pressure balance. Then the drift speed becomes faster.
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30 Testing and adjusting
SEN01818-03
Measuring internal leakage of work equipment cylinder a
a a
3.
Run the engine at high idle and apply the relief pressure to the cylinder bottom side. q Blade tilt cylinder: Operate to extend the cylinder to be measured. q Ripper lift cylinder: Operate to lower ripper. q Ripper Tilt cylinder: Operate to tilt ripper forward.
4.
After 30 seconds, measure leakage for 1 minute.
5.
After finishing removed parts.
1
Measuring instruments for internal leakage of work equipment cylinder Symbol
Part No.
L
Purchased
Name Measuring cylinder
Measure the internal leakage of work equipment cylinder under the following condition. q Hydraulic oil temperature: 45 – 55ºC Since the blade lift cylinder is equipped with a piston valve, its internal leakage cannot be measured.
1.
Extend the cylinder to be measured to the stroke end and set the machine in the measuring position. 1) Blade tilt cylinder Extend the cylinder to be measured to the stroke end. 2) Ripper lift cylinder Pull out the shank pin and lower the ripper to the end. 3) Ripper tilt cylinder Tilt the ripper forward to the end.
2.
Disconnect hose on the cylinder head side and block the hose side with a plug. a Remove the hose cover of the blade tilt cylinder. k Take care not to disconnect the hose on the bottom side.
D475A, D475ASD-5E0
measurement,
return
the
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30 Testing and adjusting
Releasing residual pressure from work equipment cylinder 1
Bleeding air from work equipment cylinder 1
a
When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure from the circuit according to the following procedure.
a
If the work equipment cylinder is removed and installed or its piping is disconnected and connected, bleed air from its circuit according to the following procedure.
1.
Loosen the hydraulic tank oil filler cap gradually to release the residual pressure from the tank.
1.
Run the engine at low idle for about 5 minutes.
2.
Running the engine at low idle, extend and retract the cylinder to be bled 4 – 5 times. a Move the piston rod to about 100mm before the stroke end and never relieve the oil.
3.
Running the engine at high idle and carry out the operation in 2.
4.
Running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
2.
Set the work equipment lock lever in the FREE position and operate the work equipment control lever to each direction. a If the work equipment control lever is operated 2 – 3 times, the residual pressure in the accumulator is released.
3.
Run the engine at low idle for about 5 seconds, then stop it.
4.
Repeat steps 2 – 3 above 2 – 3 times.
44
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30 Testing and adjusting
Adjusting ripper lever position
a a
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1
Adjust the ripper lever to the best position according to the following procedure. The ripper lever can be adjusted forward and in reverse within the range of ±40mm from the center of the lever shaft.
1.
Adjusting within range of backward 40mm 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 40mm 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). 5) Loosen nut (3). 6) Reverse knob (4). 7) Tighten nut (3) to secure knob (4).
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Adjusting work equipment lock lever
1.
30 Testing and adjusting
1
Adjust dimension (a) between pins of rod (1). Dimension (a) between pins: 442.6 mm
q
2.
46
Connect rod (1) to work equipment lock lever (2) and PPC lock valve (3). a Install connecting pin (4) on the lock lever side with the cotter pin on the outside of the machine.
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30 Testing and adjusting
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Measuring fan motor speed a
1.
2.
3.
1
4.
Insert probe [2] of tachometer kit S through the radiator mask and set it out of the fan net with stand [3] and connect it to multi-tachometer [4]. a The probe tip cannot be inserted in an opening of the fan net, but it can measure the fan motor speed. Remove all obstacles between the lighting part of the probe and the reflecting tape.
5.
Start the engine and set the monitor panel in the adjustment mode. a For the operating method in the adjustment mode, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 1005 (Fan 100% speed mode)
6.
Run the engine at low idle and high idle and measure the fan motor speed.
7.
After finishing measurement, remove the measuring instrument and return the removed parts.
Measuring instruments for fan motor speed Symbol
Part No.
S
799-205-1100
Name Tachometer kit
Open the radiator mask and remove the mounting bolts of fan net (1) under the fan motor. a Fan net (1) cannot be removed since the fan motor piping is installed.
Make clearance (a) by shifting fan net (1) and stick reflecting tape [1] to the fan through clearance (a). a Stick the reflecting tape near the outside of the fan (where the distance between the fan net and fan is short).
Install fan net (1) and close the radiator mask. k Be sure to close the fan net and the radiator mask before starting measurement. Do not start the engine with the radiator mask open.
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30 Testing and adjusting
Measuring fan circuit oil pressure a
Measuring instruments for fan circuit oil pressure Symbol T
k
1
1
Part No.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
a
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the fan circuit oil pressure under the following condition. q Hydraulic oil temperature: Within operating range
1.
Open the radiator mask.
2.
Connect oil pressure gauge [1] of hydraulic tester T1 to the oil pressure pickup nipple installed to the underside of fan motor (1). a Use the oil pressure gauge of 40 MPa {400 kg/cm2}.
3.
Start the engine and set the monitor panel in the adjustment mode. a For the operating method in the adjustment mode, see “Special functions of monitor panel (EMMS)”. a Adjustment code: 1005 (Fan 100% speed mode)
4.
Run the engine at high idle and measure the fan circuit oil pressure.
48
5.
After finishing measurement, remove the measuring instrument and return the removed parts.
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30 Testing and adjusting
Bleeding air from fan pump a
a
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1
If the fan pump is removed and installed or its piping is disconnected and connected, bleed air from the pump case according to the following procedure. Before bleeding air, check that the hydraulic oil level is proper.
1.
Remove the floor inspection cover.
2.
Loosen air bleeders (1) and (2), and leave it for 15 minutes.
3.
After 15 minutes, run the engine at low idle.
4.
After oil flows out of air bleeder, tighten air bleeders (1) and (2).
D475A, D475ASD-5E0
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30 Testing and adjusting
Measurement procedure for blade tilt control angle (Dual tiltdozer specification) 1 a
a
a
a 1.
50
2.
Run the engine at low idle, set the toggle switch of the blade lever to the dual tilt position, and set the blade in the following standard posture. 1) Set the blade horizontally (Set it to 0°). 2) Pitch back the blade to the maximum. 3) Raise the blade at 100 mm above the ground.
3.
Hold the buzzer cancel switch in the select position [U] for 2.5 seconds to display the maintenance mode.
4.
Set the information switch in the [>] position to select the adjustment mode.
5.
Set the buzzer cancel switch in the select position [U] to select the adjustment selection screen.
Measuring instrument for blade tilt control angle Symbol
Part No.
U
799-402-3800
Name Angle gauge
When the blade and blade cylinder potentiometer are removed and installed or when the machine controller is replaced, adjust the blade tilt limit angle according to the following procedure. If this adjustment is not performed, the blade may not tilt sufficiently or may tilt too much and interfere with the track shoe. Be sure to perform this adjustment. Perform this adjustment on a level ground. Adjust installed length (a) of rod (1) and connect it to potentiometer lever (2) and yoke (3). q Installed length (a): 425 mm
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30 Testing and adjusting
6.
Operate information switches [<] and [>] to select the tilt limit setting screen.
7.
Set the buzzer cancel switch in the select position [U] to select the tilt limit adjustment mode.
8.
Press the pitch switch of the blade lever, and the buzzer sounds and the work equipment position in the standard posture is saved.
9.
Raise the blade tip to about 1 m above the ground.
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10. Operate the blade lever to tilt the blade to the left and set the left tilting angle to 12°. a Since the tilt limiting function does not work at this time, operate the lever slowly and take care not to increase the tilting angle too much. a Adjust the tilting angle accurately with angle gauge U.
11. Set the toggle switch of the blade lever in the single tilt position and then set it in the dual tilt position again to save the left tilt limit value in the system. a When saving is finished, the buzzer sounds. 12. Set the buzzer cancel switch in the cancel position [t] once to cancel the tilt limit adjustment mode temporarily. 13. Set the blade in the maximum pitch dump posture (Keep the work equipment horizontal).
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30 Testing and adjusting
14. Set the buzzer cancel switch in the select position [U] again to select the tilt limit adjustment mode. 15. Operate the blade lever to tilt the blade to the right and set the right tilting angle to 12°. a Since the tilt limiting function does not work at this time, operate the lever slowly and take care not to increase the tilting angle too much. a Adjust the tilting angle accurately with angle gauge U.
16. Set the toggle switch of the blade lever in the signal tilt position and then set it in the dual tilt position again to save the right tilt limit value in the system. a When saving is finished, the buzzer sounds. 17. Set the buzzer cancel switch in the cancel position [t] to cancel the tilt limit adjustment mode. 18. Lower the work equipment to the ground and stop the engine. 19. Start the engine again, tilt the blade to the right and left, and check that the blade does not interfere with the track shoe at any height.
52
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Measurement procedure for blade tilt control angle (Superdozer specification) 1 a
a
a
a 1.
2.
Measuring instrument for blade tilt control angle Symbol
Part No.
U
799-402-3800
Name Angle gauge
When the blade and blade cylinder potentiometer are removed and installed or when the machine controller is replaced, adjust the blade tilt limit angle according to the following procedure. If this adjustment is not performed, the blade may not tilt sufficiently or may tilt too much and interfere with the track shoe. Be sure to perform this adjustment. Perform this adjustment on a level ground.
3.
Hold the buzzer cancel switch in the select position [U] for 2.5 seconds to display the maintenance mode.
4.
Set the information switch in the [>] position to select the adjustment mode.
5.
Set the buzzer cancel switch in the select position [U] to select the adjustment selection screen.
6.
Operate information switches [<] and [>] to select the tilt limit setting screen.
Adjust installed length (a) of rod (1) and connect it to potentiometer lever (2) and yoke (3). q Installed length (a): 425 mm
Run the engine at low idle and set the blade in the following standard posture. 1) Set the blade horizontally (Set it to 0°). 2) Pitch back the blade to the maximum. 3) Raise the blade at 100 mm above the ground.
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7.
Set the buzzer cancel switch in the select position [U] to select the tilt limit adjustment mode.
8.
Press the pitch back button (lower button) of the work equipment lever, and the buzzer sounds and the work equipment position in the standard posture is saved.
9.
Set the buzzer cancel switch in the cancel position [t] once to cancel the tilt limit adjustment mode temporarily.
30 Testing and adjusting
13. Press the pitch dump button (upper button), and the buzzer sounds and the left limit position is saved. a Since the tilt limiting function does not work at this time, operate the lever slowly and take care not to increase the tilting angle too much. a Adjust the tilting angle accurately with angle gauge U. 14. Tilt the work equipment to the right by 7°.
10. Operate the blade according to the following procedure so that it can be tilted. 1) Raise the blade tip to 200 – 300 mm above the ground. 2) Set the blade angle to 52°. a Adjust the blade angle accurately with angle gauge U.
11. Set the buzzer cancel switch in the select position [U] again to select the tilt limit adjustment mode. 12. Raise the work equipment tip to about 1 m above the ground and tilt it to the left by 7°.
15. Press the pitch dump button (upper button), and the buzzer sounds and the right limit position is saved. a Since the tilt limiting function does not work at this time, operate the lever slowly and take care not to increase the tilting angle too much. a Adjust the tilting angle accurately with angle gauge U. 16. Set the buzzer cancel switch in the cancel position [t] to cancel the tilt limit adjustment mode. 17. Lower the work equipment to the ground and stop the engine. 18. Start the engine again, tilt the blade to the right and left, and check that the blade stops automatically in the following range at any height. q Automatic tilt stopping angle: 7 ± 1°
54
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30 Testing and adjusting
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Testing and adjusting operator's cab 1 Check after installing cab assembly 1. Measuring pressure in cab q Criterion: Measured value X 98.1 Pa {10 mmH2O} q Engine speed: High idle q Blower speed: High (Hi) q Fresh/Recirculation switch: Fresh air position q Fan: Adjustment code:1005 (Fan 100% mode) a If the measured value is lower than the standard value, check the following. (1) Plug of control box (2) Air filters (recirculated air filter and fresh air filter) of air conditioner for clogging 1) A simple method of measuring the internal pressure is as follows. 1] Prepare a transparent vinyl hose. q Outside diameter: 10 mm, Length: 3,000 mm 2] Secure the end of hose [1] to the top of the back of operator's seat with a tape. 3] Pour coolant in the hose up to about half. 4] Remove slide glass lever lock (1) and insert the other end of vinyl hose [1].
5]
Seal the mounting holes of lock lever (1) with tape (2).
6]
Set the coolant level in the vinyl hose out of the cab to that in the cab. Run the engine at high idle and measure coolant level difference (c). (Value (c): Pa {mmH2O}) a [a] side: Inside of cab (Pressurized) [b] side: Out of cab (Atmospheric pressure)
7]
a
Secure the end of hose [1] to the operator's seat with tape.
D475A, D475ASD-5E0
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2.
56
Check of sealing performance 1) Close the all openings of the cab. 2) Splash coolant around the hatched part of the cab at the rate of about 19 l/min for 10 minutes. q At this time, it is not necessary to splash pressurized coolant. 3) Splash coolant horizontally from a hose over sealing surface (3). 4) Check around the dashboard carefully. a If coolant leaks, caulk the leaking part and check again.
30 Testing and adjusting
3.
Testing door lock Close the door and check the relationship between the operator's cab and door. If there is any fault, repair it. 1) Check of condition 1] Check the installed height of damper rubbers (4). (Check 4 pieces on each side.) Stick adhesive tape [1] to the contact face of damper rubber (4), open and close the door 2 – 3 times. Then, check the contact face of adhesive tape [1] against the operator's cab. Normal: When the door is closed, the damper rubbers come in contact lightly. Abnormal: When the door is closed, the damper rubbers do not come in contact or come in contact so strongly that the adhesive tapes are removed.
D475A, D475ASD-5E0
30 Testing and adjusting
2]
Check the relationship between the door latch and striker (on both sides). q Close door (5) and check the engaging condition of latch (6) and striker (7). q Normal: Deviation (a) is 0.5 mm or less. a Check deviation (a) of latch center (y) and striker center (x) from each other from the direction of (A).
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2)
Adjusting 1] Adjusting height of damper rubbers q Loosen the mounting bolt of damper rubber (4). q The shim can be removed or installed without removing the mounting bolt. q Increase or decrease the number of shim (8) installed at the bottom of damper rubber (4) to properly adjust the height of damper rubber (4).
2]
3]
D475A, D475ASD-5E0
Adjusting height of latch and striker (1) Temporarily tighten the mounting bolt of striker (7), open and close the door 2 - 3 times to align latch (6) and striker (7) to each other. (2) Check the engaging condition of latch (6) and striker (7). (3) Securely tighten the mounting bolt of striker (7). (4) Open and close the door and check that it is locked and unlocked smoothly. If the door is not locked and unlocked smoothly (If the knob is heavy), perform the adjustment procedure from the first. a Operating effort of door unlock lever: 68.6 ± 19.6 N {7 ± 2 kg} Apply grease (G2-LI) to latch (6). a If latch (6) is not sufficiently greased, the knob becomes heavy.
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4.
30 Testing and adjusting
ii)
Testing open lock Lock the door open and check the relationship between the operator's cab and door. If there is any fault, repair it. 1) Check of condition 1] Check the relationship between open lock latch (9) and striker (10) from the direction of B.
q
q
2)
a
q
q
Open the door and check the engaging condition of the open latch and striker. Check that the claw of open latch (9) does not ride over the bent part of striker (10). Check that the body of open latch (9) does not interfere with striker (10).
Adjusting 1] Adjusting latch and striker q Loosen the adjustment nut of striker (10) and adjust striker (10) so that it will not interfere with or ride over open latch (9), then tighten the nut. q If interference cannot be eliminated by adjusting striker (10), loosen the mounting bolt of open latch (9) and adjust open latch (9). q Push the door. If it moves until clearance (b) between striker (7) and open latch (9) is reduced to “0”, loosen mounting nut (12) of stopper rubber (11) and extend stopper rubber (11) in the pushing direction to adjust.
2]
58
Check the installed height of the stopper rubbers. (Check both sides, 4 pieces on each.) Lock the door open and shake it in the forward and reverse directions to see if it has any play. Check that the operating effort of the unlock lever is not heavy.
Adjusting installed height of stopper rubber (1) Loosen locknut (12) of stopper rubber (11). (2) If there is any play, adjust stopper rubber (11) until dimension (c) is as follows. a If the door is not locked easily or the unlock lever is heavy, return stopper rubber (11) in the range that the door does not have any play. q Dimension (c) of stopper rubber above cab: 35 ± 0.5 mm q Dimension (c) of stopper rubber under cab: 32 ± 0.5 mm q Operating effort of door unlock lever: 68.6 ± 19.6 Nm {7 ± 2 kgm} (3) After adjusting, tighten locknut (12). D475A, D475ASD-5E0
30 Testing and adjusting
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Adjusting blade
1
a
If the blade is removed and installed or disassembled and reassemble, adjust it according to the following procedure.
1.
Adjusting shims for assembly 1) Adjust the shim of center (1).
2)
Adjust the shim of trunnion (2) (shim adjustment type).
Adjusted point
Adjusted point
Adjusted clearance
Standard clearance
Standard shim thickness
1
a
See note
4.5 mm
2
Adjusted Standard clearclearance ance c
1.56 ± 0.65 mm (Total thickness clearance)
Standard shim thickness 12 mm
Note: Adjust the shim so that the play of the ball in the axial direction will be less than 1 mm and the ball can rotate smoothly.
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2.
Adjusting blade tilt distance 1) Adjust dimension (d) of brace (4) with the handle. q Dimension (d) of brace: 1,844.5 mm 2) Measure right and left tilt distances (e1) and (e2). Blade
U
Semi-U
Right tilt distance (e1)
Approx. 900 mm
Approx. 750 mm
Left tilt distance (e2)
Approx. 900 mm
Approx. 750 mm
3)
60
30 Testing and adjusting
If both tilt distances are not the same, adjust dimension (d) of brace (4) according to the following procedure. q (e1) > (e2): Increase dimension (d) finely. q (e1) < (e2): Decrease dimension (d) finely.
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30 Testing and adjusting
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Testing and adjusting operator's seat isolator a
Machine with operator's seat isolator
1.
Breakage of rubber q Criterion: When the operator's seat is pressed with the hand, it must not touch the stopper of operator's seat isolator. a When the criterion is not satisfied. q Remove and disassemble the operator's seat isolator and check the rubber for breakage. q If the rubber is broken, replace the operator's seat isolator assembly. 1) Pull slide (1) and move the operator's seat to the forward end.
2)
Pull turning lever (2) and rotate turntable (3) by 13 degrees.
D475A, D475ASD-5E0
1
3)
Stand backrest (4) of the operator's seat upright.
4)
Open window (5) on the left side of the operator's cab.
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5)
2.
62
Press the seat surface through the window.
Oil leakage from damper q Criterion: No oil leakage from damper. a When the criterion is not satisfied. q Replace the operator's seat isolator assembly.
30 Testing and adjusting
1)
Remove bolts (7) of front cover (6) of the operator's seat and remove the front cover.
2)
Check damper (8) for oil leakage.
D475A, D475ASD-5E0
30 Testing and adjusting
3.
SEN01818-03
Breakage of stopper rubber q Criterion: The stopper must not come off. a When the criterion is not satisfied. q Replace the operator's seat isolator assembly. 1) Put your feet on foot rest (9) and brace your legs.
2)
Check that stopper (10) touches stopper rubber (11) and does not the steel portion.
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D475A, D475ASD-5E0 Bulldozer Form No. SEN01818-03
© 2011 KOMATSU All Rights Reserved Printed in Japan 06-11
64
SEN01819-04
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 3 Special functions of monitor panel (EMMS) .................................................................................................... 2
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30 Testing and adjusting
Special functions of monitor panel (EMMS)
Display section of special functions
Operation section 1 of special functions (Basic operation)
1.
3.
2.
a
2
Upper panel (Gear speed display section) Lower panel (Multi-information section)
Service switch
1
Operation section 2 of special functions (Changeover operation) 4. Buzzer cancel switch 5. Information switch 6. Shift-up switch (STD steering lever) Shift switch (ONE-WAY steering lever) 7. Shift-down switch (STD steering lever) Neutral switch (ONE-WAY steering lever)
EMMS: Equipment Management Monitoring System
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30 Testing and adjusting
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Normal function and special functions of monitor panel (EMMS) The monitor panel (EMMS) has the normal and special functions, and displays information of various types at the gear speed display section and the multi-information section of the center of the monitor panel. 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, an operator can view and change the items displayed normally or displayed by the operation of the switches. 2. Special function 1: Service mode With this function, a serviceman can display and change the displayed items by the specified switching operation for testing, adjusting and troubleshooting. Flow of each mode and function
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Operation and display in operator mode (Outline) a
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 and maintenance manual”.
Normal display mode (Default) The monitor panel displays the following information normally. Gear speed display section (1): q Left side: Travel direction (P·N·F·R) q Right side: Gear speed (1·2·3) q Graphics: Engine speed Multi-information section (2): a Information is displayed in 2 lines of 16 characters each. q Left side: Gear shift mode (F1-R1·F1-R2·F2-R2) q Right side: Service meter (Unit: 0.1h) a To change the normal display mode to the operator mode, hold buzzer cancel switch (4) in the [U] position for 2.5 seconds. Serial numbers: 30001 – 30070
30 Testing and adjusting
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 multi-information section (2) and reset after the replacement. a Gear speed display section (1) keeps displayed normally. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
Serial numbers: 30071 and up
4
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30 Testing and adjusting
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Maintenance item list Replacement interval (h) No.
Display
Maintenance item
1st time (fixed)
2nd time and more (changeable)
1
ENG OIL
Engine oil
500
500
2
ENG FILT
Engine oil filter
500
500
3
FUEL FILT
Fuel main filter
1000
1000
4
HYD FILT
Hydraulic oil filter
250
2000
5
CORR RES
Corrosion resistor
1000
1000
5
DAMP OIL
Damper oil
2000
2000
7
FNL OIL
Final drive oil
250
2000
8
HYD OIL
Hydraulic oil
250
2000
9
HSS FILT
Charge filter (*1)
10
POWL OIL
Power train oil
0
0
250
1000
11
POWL FLT
Power train oil filter
250
500
12
F. PRE FLT
Fuel pre-filter
500
500
(*1): Displayed on D475A-5 but not set.
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. a Gear speed display section (1) keeps displayed normally. Serial numbers: 30001 – 30070
Order
Display
Item
01
01-ENG. SPEED
02
02-COOLANT TEMP Coolant temperature
03
03-ENG OIL PRESS Engine oil pressure
04
04-AMB PRESS
Ambient pressure
05
05-BOOST PRESS
Engine boost pressure
06
06-BOOST TEMP
Engine boost temperature
07
07-T/C TEMP
Power train oil temperature
08
08-HYD TEMP
Hydraulic oil temperature
09
09-HYD. PRESS F
Hydraulic oil pressure (F pump)
10
10-HYD. PRESS R
Hydraulic oil pressure (R pump)
13
13-BATTERY VOLT
Battery voltage
a
Engine speed
The ambient pressure and boost pressure is displayed in absolute value.
Serial numbers: 30071 and up
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3.
Failure code display mode (3-FAULT CODE DISPLAY MODE) In this mode, the contents of each fault in the machine are displayed by a 6-character failure code on the multi-information section (2). When the user or the operator needs to be notified of the failure code of each fault, this mode is applied. a Gear speed display section (1) keeps displayed normally. Serial numbers: 30001 – 30070
30 Testing and adjusting
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). a Gear speed display section (1) keeps displaying normally. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
Serial numbers: 30071 and up
a
a
6
When a serviceman needs to check the failure codes for troubleshooting, the “Electrical system failure code display mode” and the “Mechanical system failure code display mode” should be used for more detailed information. Method of checking failure code: Turn buzzer cancel switch (4) to the [U] position on the screen shown above, and the all failure codes detected currently are displayed at the interval of about 2 seconds. (To finish displaying, turn the buzzer cancel switch to the [ t ] position.)
No.
Display
Item
1
01:LCD BRIGHTNESS
Adjustment of LCD brightness
2
02:DSP BRIGHTNESS
Adjustment of display brightness
3
03:DSP CONTRAST
Adjustment of display contrast
4
04:FAN 100% SPEED
Fan 100% speed mode (For cleaning radiator)
5
05:NO INJECTION
No injection cranking mode
6
06:TILT LIMIT
Tilt limit adjustment mode
7
07:PRE_LUB ON
Pre-lubrication reset mode against prelubrication trouble
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30 Testing and adjusting
1)
Brightness of LCD This mode is to adjust brightness of the backup lamp at the liquid crystal gauge section. (See “Operation and maintenance manual”.)
2)
Brightness of display This mode is to adjust brightness of the backup lamp at the multi-information section. (See “Operation and maintenance manual”.)
3)
Contrast of display This mode is to adjust contrast of the liquid crystal at the multi-information section. (See “Operation and maintenance manual”.)
4)
Fan 100% mode This function is to control rotation speed of the cooling fan forcedly at approximately 100% of the maximum speed. 1] This mode is selected by operating the information switch. 2] The mode is selected by turning the buzzer cancel switch to the [U] position. 3] The function is effective under this condition and the rotation speed of the cooling fan is controlled to approximately 100% of the maximum speed. a Exiting this mode disables the function.
SEN01819-04
5)
No injection cranking mode This mode is to circulate the engine oil easily while applying no injection conditions to all engine cylinders before staring engine after an extended machine storage. 1] This mode is selected by operating the information switch. 2] The mode is selected by turning the buzzer cancel switch to the [U] position.
3]
In above 3 seconds, “WAIT” displayed on the lower line changes to “ACTIVE” and the mode becomes effective.
4]
In this condition, turn the starting switch to START position to apply no injection cranking. The mode is released by moving the starting switch to ON position and turning the buzzer cancel switch to the [t] position. Do not continue no injection cracking for more than 20 seconds in order to protect the starting motor. For safety, this mode cannot be operated while the engine is running.
5]
k
k
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SEN01819-04 a
At this time, “NOT AVAILABLE” is displayed on the lower line to indicate that the mode is ineffective.
30 Testing and adjusting
7)
Pre-lubrication mode On this screen, operate the information switch to display the Skip on the lower line of the display section. If this mode is finished under this condition, the engine can be started without using the pre-lubrication system. a This mode becomes ineffective once the engine is stopped.
a
6)
8
Exiting from this mode disables this function. Tilt limit adjustment mode a Refer to the section “Measurement procedure for blade tilt control angle” in Testing and adjusting, Part 2.
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30 Testing and adjusting
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Action code display function If a failure occurs in the machine during work which the operator should be notified of, an action code and a phone number are displayed on the multiinformation section (2). a Gear speed display section (1) keeps displayed normally. a 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.) a 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 “Electrical system failure code display mode” and “Mechanical system failure code display mode” of the service mode.
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
Action codes table Action code
Indication method of fault
E01
• Only action code is displayed.
E02
• Gear is not shifted up or down. • Action code is displayed. • Blade tilt is not limited. • Caution lamp flashes. • Blade pitch mechanism does not • Caution buzzer sounds. work.
Contents of fault • Torque converter is not locked up. • Blade dual tilt mechanism does not work.
Remedy • Automatic function stops or normal function stops partially but machine can work. • Call your Komatsu distributor for repair. • 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.
• Engine boost pressure is defective. • Move machine to safe place. • Action code is displayed. • Usable gear speeds are limited. • Call your Komatsu distributor for • Engine speed does not rise fully. CALL E03 • Caution lamp flashes. repair. • Caution buzzer sounds. • Gear shifting shocks become large. • Steering performance lowers. • Action code is displayed. • Engine cannot be controlled. CALL E04 • Caution lamp flashes. • Machine cannot travel. • Caution buzzer sounds. • Machine stops.
D475A, D475ASD-5E0
• Stop machine immediately. • Call your Komatsu distributor for repair.
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30 Testing and adjusting
Operation and display in service mode Method of changing to service mode a 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). a Keeping the service switch in the ON position, hold the buzzer cancel switch in the [U] position for 2.5 seconds. a If the monitor panel is set in the service mode, [1C] or [55] is displayed on the gear speed display section (1). Serial numbers: 30001 – 30070
Gear Order speed display
1
1C
Display and item 5-EXCHG. INTVAL. INTERVAL MODE Maintenance interval change mode 6-ELEC. FAULT CODE MODE
2
EE
Electrical system failure code display mode 7-MACHINE CHECK CODE MODE
3
bE
4
Cb
5
Ld
6
5R
7
dR
8
55
Mechanical system failure code display mode 8-SERVICE ADJUST MODE Adjustment mode 9-LOAD MAP DISPLEY MODE Load memory display mode 10-REAL TIME MONITORING MODE Real time monitoring mode 11-DUAL DISPLAY MONITORING MODE Dual display monitoring mode 12-SNAP SHOT MODE Snap shot mode *
* VHMS specification only
Serial numbers: 30071 and up
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). q [ > ]: Next mode No. q [ < ]: Previous mode No. q [U]: Execute mode. a 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). q [t]: Screen returns. (2) When finishing the all operation: Turn off the starting switch.
10
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30 Testing and adjusting
5.
Maintenance interval change mode (5-EXCHG. INTVAL. INTERVAL 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.
SEN01819-04
2)
Selecting and displaying maintenance item 1] Operate information switch (5) on the maintenance item selection screen to select a maintenance item. q [ > ]: Next code q [ < ]: Previous code 2] Display the maintenance item selection screen by operating buzzer cancel switch (4). q [U]: 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) a The items shown below are examples. a If the replacement interval does not need to be changed, finish the operation on this screen. a If the replacement interval needs to be changed, go to step 4).
1)
Selecting and executing mode 1] Select “Maintenance interval change mode” on the mode selection screen. a 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). 2] Display the maintenance item selection screen by operating buzzer cancel switch (4). q [U]: Execute mode. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
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4)
Changing replacement interval time 1] Change the set time by operating information switch (5), shift-up switch (6), and shift-down switch (7). q [ > ]: Move cursor to right. q [ < ]: Move cursor to left. q [UP]: Increase number. q [DOWN]: Decrease number.
a
12
30 Testing and adjusting
If you do not use the maintenance function, set the all times to 0.
2]
If the input time is correct, enter the change of setting by operating buzzer cancel switch (4). q [U]: Enter change. a If the change is finished normally, the information display screen appears after the screen shown below.
a
If the change does not finish normally, above message “SETTING NOW!!” is not displayed but the replacement interval change screen is kept displayed. (The screen does not return to the information display screen.)
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30 Testing and adjusting
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Maintenance item list Replacement interval (h) No.
Display
Maintenance item
1st time (fixed)
2nd time and more (changeable)
1
01: ENG OIL
Engine oil
500
500
2
02: ENG FILT
Engine oil filter
500
500
3
03: FUEL FILT
Fuel main filter
1000
1000
4
04: HYD FILT
Hydraulic oil filter
250
2000
5
06: CORR RES Corrosion resistor
1000
1000
6
07: DAMP OIL
Damper oil
2000
2000
7
08: FNL OIL
Final drive oil
250
2000
8
10: HYD OIL
Hydraulic oil
250
2000
9
12: HSS FILT
Charge filter (*1)
10
19: POWL OIL
Power train oil
0
0
250
1000
11
20: POWL FILT Power train oil filter
250
500
12
41: F. PRE-FLT Fuel pre-filter
500
500
(*1): Displayed on D475A-5 but not set.
a
The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd and after interval times.
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Electrical system failure code display mode (6-ELEC. FAULT CODE MODE) In this mode, you can check the past electrical system failure codes. a Refer to the item “Failure code list” in Troubleshooting, General. 1) Selecting and executing mode 1] Select “Electric system failure code display mode” on the mode selection screen. a 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). 2] Display the failure code display screen by operating buzzer cancel switch (4). q [U]: Execute mode. Serial numbers: 30001 – 30070
30 Testing and adjusting
6.
3)
Display in the case where 1 or more codes are recorded If any failure code has been output up to now, the information section displays as shown below. [1] Record No. (Up to 20) [2] Failure 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 a The items shown below are examples.
Serial numbers: 30071 and up
a
2)
14
Flashing and lighting of failure code Flashing: Code is being output currently. Lighting: Code is not being output currently.
Display in the case where no codes are recorded If no failure codes have been output up to now, the information section displays as shown below.
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30 Testing and adjusting a
Condition for detecting and keeping failure code If a failure code of any item other than communication and engine is output, it keeps flashing until the starting switch is turned off. After the starting switch is turn on or the engine is started again, the failure code keeps lighting until the same fault is detected. A failure codes of communication and engine start lighting when the fault is solved, even if the starting switch is not 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). q [ > ]: Next code q [ < ]: Previous code a The failure codes are displayed from the oldest one in order of length of time after they were output.
5)
Method of deleting failure code While displaying a failure code to be deleted, operate shift-up switch (6) or shift-down switch (7). q [UP] or [DOWN]: Delete failure code. a A failure code which is being output currently (which is flashing) cannot be deleted.
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7.
Mechanical system failure code display mode (7-MACHINE CHECK CODE MODE) In this mode, you can check the past mechanical system error codes. a Refer to the item “Failure code list” in Troubleshooting, General. 1)
Selecting and executing mode 1] Select “Mechanical system failure code display mode” on the mode selection screen. a 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). 2] Display the failure code display screen by operating buzzer cancel switch (4). q [U]: Execute mode. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
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2)
3)
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30 Testing and adjusting a
Display in the case where no codes are recorded If no failure codes have been output up to now, the information section displays as shown below.
Display in the case where 1 or more codes are recorded If any failure code has been output up to now, the information section displays as shown at right. [1] Record No. (Up to 15) [2] Failure code (Code being output currently is flashing) [3] Number of past occurrences [4] Service meter reading at first occurrence [5] Service meter reading at last occurrence a The item shown below is example.
a
Flashing and lighting of failure code Flashing: Code is being output currently. Lighting: Code is not being output currently. Condition for detecting and keeping failure code A failure code of mechanical system starts lighting when the fault is solved, even if the starting switch is not turned off.
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) described in the monitor illustration on page 2. q [ > ]: Next code q [ < ]: Previous code a All the failure codes, including ones which have not been displayed, are displayed in numeric order.
5)
Method of deleting failure code The mechanical system failure codes cannot be deleted.
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30 Testing and adjusting
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. a 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). q [U]: Execute mode. Serial numbers: 30001 – 30070
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2)
Selecting adjustment items 1] On the adjustment code input screen, input the 4-digit code of the item to be adjusted by operating information switch (5), shift up switch (6) and shift down switch (7). q [>]: Moves cursor rightward. q [<]: Moves cursor leftward. q [UP]: Increases number. q [DOWN]: Decreases number. 2] After inputting the code, operate buzzer cancel switch (4) to display the monitoring screen. q [U]: Enters input mode.
a Serial numbers: 30071 and up
D475A, D475ASD-5E0
If an incorrect code is input, the adjustment code input screen appears again after showing the below screen. In this case, execute the above operation again.
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3)
Contents of display on adjustment screen [1] Code [2] Adjustment item [3] Related information a For the detailed information and adjustment procedure, see “Adjustment modes list and adjustment procedure”.
30 Testing and adjusting
Serial numbers: 30071 and up
5)
4)
When operating machine in adjustment 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. a At this time, even if the shift up or shift down switch is pressed with the PCCS lever in the neutral position, the shift cannot be changed. (The displayed number is the code of adjustment mode selection.) To change the shift, shift the PCCS lever to the “forward” or “reverse” position and press the shift up or shift down switch while the machine is traveling. a To select another screen, return the parking brake lever to the LOCK position and perform the necessary procedure. Serial numbers: 30001 – 30070
18
Automatic selection of adjustment item (Limited function) After one of some adjustment items is selected, if the information switch is operated, the next adjustment item is selected automatically, even if the code of the next adjustment item is not input. q [ > ]: Code is increased q [ < ]: Code is decreased a This function is applied to only the items having numbers in the Automatic selection column of the “Adjustment mode table and adjustment procedure”. Those items are selected in the order of their numbers. a Note that this operation is not effective while the parking brake lever is in the RESET position. a You may return to the screen for inputting codes and enter a code without using this function.
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Adjustment modes list and adjustment procedure No. Code
Adjustment item
Related information
Disassembly Sending and assembly in order
[1] 0001 INP TEL NO.
Phone No. input mode
Numerals and symbols
[2] 0002 S/T S. CODE
Steering controller specification set
Code
q
1
[3] 0003 T/M S. CODE
Transmission controller specification set
Code
q
2
[4] 0004 BODY TYPE
Machine specification set
Code
q
3
[5] 0005 BRAKE BASE
Brake potentiometer zero point adjustVoltage ment
q
4
[6] 0007 ENG. FULL CH
Engine deceleration cut mode
Engine speed
[7] 0008 INT-> 123456
Common rail reduced cylinder mode
Speed/Fuel injection rate
[8] 0009 PITCH SENS.
Pitch angle sensor initialization set
Voltage
[9] 0010 FAN 70%MODE
Fan speed 70% speed mode
(Adjustment amount)
8 7
[10] 0022 VHMS INST
VHMS specification set
Set state
[11] 0530 STALL CHECK
Stall speed check mode
Engine speed
[12] 1005 FAN 100%MODE Fan speed 100% mode
(Date of adjustment in factory)
[13] 1012 S/T N-SET
Steering lever neutral set
Voltage
[14] 1013 S/T M. L-SET
Steering lever left set
Voltage
[15] 1014 S/T M. R-SET
Steering lever right set
Voltage
[16] 1015 BRKLH. OFST
Left brake oil pressure offset (set)
Oil pressure
[17] 1016 BRKRH. OFST
Right brake oil pressure offset (set)
Oil pressure
[18] 1112 PRE LUB SEL
Pre-lubrication set
Set state
[19] 2223 R SLOW CUT
Reverse slow stop set
Set state
[20] 5535 CLUTCH OPEN
Clutch disengagement mode
Transmission speed
[21] 5537 CLT LH. OFST
Left clutch oil pressure offset (set)
Oil pressure
[22] 5538 CLT RH. OFST
Right clutch oil pressure offset (set)
Oil pressure
[23] 9801 ENG. LEVEL
Engine oil level display mode (if equipped)
Set state
[24] 9993 HYD. LEVEL
Hydraulic oil level display mode (if equipped)
Set state
[25] 9995 LOCK BRAKE
Electrical brake constantly ON mode
Voltage
[26] 9996 MECHA BRAKE Electrical brake release mode
Voltage
[27] 9997 HI IDLE SET
High idle limit mode
Revolving speed
[28] 9998 SFT INHIBIT
3rd speed cut set
Permit
a a
5
q
6
9
After assembling the machine or replacing each controller, be sure to adjust the items marked with q in the “Disassembly and assembly” column of the above table. (For the adjustment procedure, see “Adjustment procedure after replacement of controller”.) The numbers in “Sending in order” column can be displayed in order by setting the information switch in [>] or [<] position.
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[1] 0001: Phone number input mode q This code inputs or changes a phone number to be displayed simultaneously when the user code is displayed. q The lower part displays a phone number and symbols. q Available characters: 0123456789:;<=>? q Instructions for use: 1) By operating the information switch (5), shift up switch (6), and shift down switch (7), input a phone number and symbols. q [ > ]: Moves the cursor rightward. q [ < ]: Moves the cursor leftward. q [UP]: Advance the numeric character or character (in the order of available characters). q [DOMN]: Reverse the numeric character or character (in the reverse order of available characters). 2) Set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. a Sixteen digits of numeric characters are provided. To avoid confusion, input symbols other than numeric characters at digits you will not use. a 0 (zero) is input at all places of the lower part before shipment from our factory. (No phone number is displayed under this condition.) a The setting is enabled even after ending this code.
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30 Testing and adjusting
[2] 0002: Steering controller specification set q This code is used to initialize the specification codes recognized by the steering controller and the set values of the memory in the controller. q The specification code is displayed on the lower line. q Adjustment method 1) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. 2) Check that the displayed specification code has changed from [2*2] to [222]. a If specification code [222] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this code is turned off, the setting is effective.
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[3] 0003: Transmission controller specification set q This code is used to initialize the specification codes recognized by the transmission controller and the set values of the memory in the controller. q The specification code is displayed on the lower line. q Adjustment method: 1) Set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. 2) Check that the displayed specification code has changed from [1*1] to [111]. a If specification code [111] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this code is turned off, the setting is effective.
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2)
3)
[4] 0004: Machine specification code setting q This code is used to have the machine specification recognized by the controllers which compose the system. q The specification of the work equipment, SSC and travel lever are set with this code. q Adjustment method a Since setting of this code is reset when “Transmission controller specification setting” is executed, adjust it after that. 1) Select code 0004 in the adjustment mode. (a): Indicates specification of travel lever (1st place) (b): Indicates specification of work equipment (2nd place) (c): Indicates specification of SSC (3rd place)
No.
Type of work equipment
800
Single tilt
801
Single tilt
SSC power set 1
802
Single tilt
SSC power set 2
810
Dual tilt
Specification
811
Dual tilt
SSC power set 1
812
Dual tilt
SSC power set 2
820
Superdozer
a a 4)
a
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Each time shift-down switch (7) is pressed, display of the 1st place changes. Select a proper specification (standard specification or optional specification) of the travel lever. Each time shift-up switch (6) is pressed, display of the 2nd place and 3rd place changes. Select proper specifications of the work equipment and SSC. a If the SSC is installed to the machine, be sure to select Power setting 1.
Number “8” at the leftmost place of the machine specification code indicates the travel lever type. If the optional-type travel lever is employed, set “9” at the above place. Set buzzer cancel switch (4) in the [U] position to save the machine specification. a When the buzzer cancel switch is operated, the alarm buzzer sounds. k If the actual machine specification is different from the setting in the controller, the machine may move unexpectedly or an error may be made. Accordingly, be sure to set the machine specification correctly. Even if this code is turned OFF, the setting is effective.
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[5] 0005: Brake potentiometer zero-point adjustment q This code is used to adjust the zero point of the brake pedal potentiometer. q The deviation from the standard value is indicated by voltage on the lower line (Indication range: -2500 to 2500 mV). q Adjustment method: 1) Check that the brake pedal is in neutral (it is not pressed). 2) Set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. a This adjustment is performed to have the zero point of the potentiometer recognized by the controller. It is not performed to adjust the effect of the brake. a Even if this adjustment is performed, the indication on the lower line does not change. a Even if this code is turned off, the setting is effective.
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30 Testing and adjusting
[6] 0007: Engine deceleration-cut mode q This code is used to stop the auto-deceleration function of the engine and check the high idle speed of the engine singly. q The engine speed is displayed on the lower line (Display range: 0 – 3000 rpm). q Using method: q While this code is displayed, its function is turned on and the auto-deceleration function is turned off. a If this code is turned off, its function is turned off.
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[7] 0008: Common rail reduced cylinder mode a When the engine common rail system seems to be defective, this code is used to stop injecting fuel into 1 or more cylinders (reduce the number of effective cylinders) while the engine is running and find out a defective cylinder from the change of the engine speed and the fuel injection rate. a Since this function diagnoses a failure based on the differences of the engine speed and the fuel injection rate in the reduced cylinder mode operation from that in the normal mode operation, use this function while the engine is running. q Engine speed (A) and fuel injection rate (B) are displayed on the lower line. q How to use: Select the cylinders to be turned off for the reduced cylinder mode operation by operating information switch (5) and buzzer cancel switch (4). Use this method to turn on the selected cylinders again, too. q [>]: Moves cursor rightward. q [<]: Moves cursor leftward. q [U]: Executes or stops reduced cylinder mode operation.
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[8] 0009: Pitch angle sensor initial set q This code is used to adjust the zero point and installation error of the pitch angle sensor. q The deviation from the standard neutral position is displayed by voltage on the lower line (Display range: -2500 to 2500 mV). q Adjustment method: Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
[9] 0010: Fan 70% speed mode This code forcedly sets the rpm of cooling fan at 70% of the maximum rotation. q The lower part displays data for factory adjustment. q Instructions for use: q The function is enabled with this code displayed to control the rpm of cooling fan to approximately 70% of the maximum rotation. a Ending this code disables the function. q
a
When the cursor is at cylinder “6”, if information switch (5) is operated to the right [>], the rig ht ban k cylin ders can be reduced. (L 1,2,3,4,5,6 o R 1,2,3,4,5,6)
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[10] 0022: Setting of VHMS specification q This code is used to set the installation of VHMS terminal. If the installation is not set, the VHMS operation data is not set normally and the data related to the VHMS cannot be monitored. q The installation condition of the terminal is displayed on the lower line. q ACTIVE: Setting of installation of VHMS q DEACTIVE: Setting of non-installation of VHMS q Setting method 1) Select an installation condition of the VHMS terminal with shift-up switch (6) and shift-down switch (7). 2) After selecting the condition of the terminal, set buzzer cancel switch (4) in the [?] position. 3) The buzzer sounds and the set condition is saved. a The setting is effective even after this code is finished. a After the control is replaced, be sure to set (check) the condition.
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30 Testing and adjusting
[11] 0530: Stall speed check mode q This code is the function to make the cooling fan speed maximum to check the torque converter stall speed. k In this machine the cooling fan speed control function is installed in order to protect the radiator when the engine is not yet warmed up enough. However, in case that this mode is in use, the protecting function does not work. So use the machine after carrying out enough warming up. q The engine speed is displayed on the lower line. (Display range: 0 – 3000) q How to use While this code is displayed, its function is enabled and the cooling fan speed becomes maximum. a If this code is turned off, its function is disabled.
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30 Testing and adjusting
[12] 1005: Fan 100% mode q This code forcedly sets the speed of cooling fan at approximately 100% of the maximum speed. Also by this code, the adjustment value for the maximum speed can be set. q The adjustment data is displayed on the lower line. q How to use: a The function is effective with this code displayed to control the speed of cooling fan to approximately 100% of the maximum speed. i) When changing the adjustment value, operate shift up switch (6) and shift down switch (7) to set the adjustment value for the maximum speed. q [UP]: Adjustment value increases. q [DOWN]: Adjustment value decreases. ii) For confirming the adjustment value, set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. a If this code is turned off, its function is disabled. However, the adjustment value once set is still effective.
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[13] 1012: Steering lever neutral set q This code is used to adjust the steering neutral position of the PCCS lever. q The deviation of the steering potentiometer from the standard neutral position is displayed by voltage on the lower line (Display range: -2500 – 2500 mV). q Adjustment method: 1) Set the PCCS lever to the neutral position. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if adjustment is carried out, the display on the lower line does not change. a Even if this code is turned off, the setting is effective. a This code is not for adjusting the steering performance.
[14] 1013: Steering lever left set This code is used to adjust the maximum left steering position of the PCCS lever. q The deviation of the steering potentiometer from the standard maximum left position is displayed by voltage on the lower line (Display range: -2500 – 2500 mV). q Adjustment method: 1) Set the PCCS lever to the left steering stroke end. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if adjustment is carried out, the display on the lower line does not change. a Even if this code is turned off, the setting is effective. a This code is not for adjusting the steering performance. q
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[15] 1014: Steering lever right set q This code is used to adjust the maximum right steering position of the PCCS lever. q The deviation of the steering potentiometer from the standard maximum right position is displayed by voltage on the lower line (Display range: -2500 – 2500 mV). q Adjustment method: 1) Set the PCCS lever to the right steering stroke end. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if adjustment is carried out, the display on the lower line does not change. a Even if this code is turned off, the setting is effective. a This code is not for adjusting the steering performance.
30 Testing and adjusting
[16] 1015: Left brake oil pressure offset q This code is used to adjust the left brake oil pressure manually. q The offset oil pressure (Unit: MPa) is displayed on the lower line (If it has been adjusted, its value is displayed. It can be adjusted further within the allowable range). q Adjustment method: a The allowable adjustment range is ± 0.3 MPa {3 kg/cm2} (Displayed value: 0.3) 1) Operate the shift switch to set the offset oil pressure. q Shiftup switch (6): Increase oil pressure q Shiftdown switch (7): Decrease oil pressure a The offset pressure is increased or decreased by 0.05 MPa {0.5 kg/cm2} (Displayed value: 0.05). 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
[17] 1016: Right brake oil pressure offset q This code is used to adjust the right brake oil pressure manually. q The offset oil pressure (Unit: MPa) is displayed on the lower line (If it has been adjusted, its value is displayed. It can be adjusted further within the allowable range). q Adjustment method: a The allowable adjustment range is ± 0.3 MPa {3 kg/cm2} (Displayed value: 0.3) 1) Operate the shift switch to set the offset oil pressure. q Shiftup switch (6): Increase oil pressure q Shiftdown switch (7): Decrease oil pressure a The offset pressure is increased or decreased by 0.05 MPa {0.5 kg/cm2} (Displayed value: 0.05).
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2) a
Operate the buzzer cancel switch to [U] side and check that the caution buzzer sounds. Even if this code is turned off, the setting is effective.
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[19] 2223: Reverse slow stop set q This code is used to turn off the reverse slow function forcibly, regardless of the operation of the switches on the monitor panel. q The state of the reverse slow function is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [DEACTIVE]: Turn reverse slow function OFF q [ACTIVE]: Turn reverse slow function ON a Once the reverse slow function is turned OFF, the reverse speed is not lowered, even if the reverse slow mode switch on the monitor panel is turned ON. a Even if this code is turned off, the setting is effective.
[18] 1112: Pre-lubrication set (if equipped) This code is used to set the machine equipped with the pre-lubrication system. q Installation or non-installation of the pre-lubrication system is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [Pre-Lub ON]: Machine is equipped with pre-lubrication system q [Pre-Lub OFF]: Machine is not equipped with pre-lubrication system a If setting of installation and non-installation of the pre-lubrication system is wrong, an error may be detected. a Even if this code is turned off, the setting is effective. q
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[20] 5535: Both steering clutches disengagement q This code is used to engage the transmission clutch without driving the machine for testing, adjusting, troubleshooting, Pm Clinic, etc. q The transmission speed (Unit: rpm) is displayed on the lower line. q Using method: While this code is displayed, the function is effective and steering clutches on both sides are disengaged. Accordingly, the machine does not travel even if the PCCS lever is operated. a If this code is turned off, the function becomes ineffective.
28
30 Testing and adjusting
[21] 5537: Left steering clutch oil pressure offset q This code is used to adjust the left clutch oil pressure manually. q The offset oil pressure (Unit: MPa) is displayed on the lower line (If it has been adjusted, its value is displayed. It can be adjusted further within the allowable range). q Adjustment method: a The allowable adjustment range is ± 0.3 MPa {3 kg/cm2} (Displayed value: 0.3) 1) Operate the shift switch to set the offset oil pressure. q Shiftup switch (6): Increase oil pressure q Shiftdown switch (7): Decrease oil pressure a The offset pressure is increased or decreased by 0.05 MPa {0.5 kg/cm2} (Displayed value: 0.05). 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
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30 Testing and adjusting
[22] 5538: Right steering clutch oil pressure offset q This code is used to adjust the right clutch oil pressure manually. q The offset oil pressure (Unit: MPa) is displayed on the lower line (If it has been adjusted, its value is displayed. It can be adjusted further within the allowable range). q Adjustment method: a The allowable adjustment range is ± 0.3 MPa {3 kg/cm2} (Displayed value: 0.3) 1) Operate the shift switch to set the offset oil pressure. q Shiftup switch (6): Increase oil pressure q Shiftdown switch (7): Decrease oil pressure a The offset pressure is increased or decreased by 0.05 MPa {0.5 kg/cm2} (Displayed value: 0.05). 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
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[23] 9801: Engine oil level set (if equipped) q This code is used to set the machine equipped with the engine oil level switch. q Installation or non-installation of the engine oil level switch is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [ACTIVE]: Machine is equipped with engine oil level switch q [DEACTIVE]: Machine is not equipped with engine oil level switch a To use this function, the engine oil level switch must be installed. a If [ACTIVE] is selected while the engine oil level switch is not installed, the caution buzzer sounds. Take care.
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[24] 9993: Hydraulic oil level set (if equipped) q This code is used to set the hydraulic oil level caution. q The setting of the hydraulic oil level caution is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [ACTIVE]: Turn hydraulic oil level caution function ON q [DEACTIVE]: Turn hydraulic oil level caution function OFF a To use this function, the hydraulic oil level switch must be installed. a If [ACTIVE] is selected while the hydraulic oil level switch is not installed, the caution buzzer sounds. Take care. a Even if this code is turned off, the setting is effective.
30 Testing and adjusting
[25] 9995: Electric brake constantly ON mode q This code is used to see if the sudden stop prevent valve operates normally. q The voltage of the brake potentiometer is displayed on the lower line. q Using method: While this code is displayed, the function is effective and the electric brake is constantly turned on. a If this code is turned off, the function becomes ineffective.
[26] 9996: Electric brake release mode This code is used to check the operation of the mechanical brake. q The voltage of the brake potentiometer is displayed on the lower line. q Using method: While this code is displayed, the function is effective and the electric brake is constantly turned off. a If this code is turned off, the function becomes ineffective. q
30
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30 Testing and adjusting
[27] 9997: High idle limit mode q This code is used to limit the high idle speed. q The engine speed (set value) is displayed on the lower line. q Possible limiting range: High idle speed –400 rpm q Using method: 1) Set information switch (5) in the [ > ] or [ < ] position to select the limit speed. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Once the high idle speed is limited, the engine speed does not reach the original high idle speed, even if the fuel control dial is operated. a Even if this code is turned off, the setting is effective.
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[28] 9998: 3rd speed cut set q This code is used to prevent the gear from shifting up to the 3rd gear speed. q Available gear speeds are displayed on the lower line by bits (in the order of the 3rd, 2nd, and 1st from the left). q Using method: Operate information switch (5) and buzzer cancel switch (4) to limit or reset the maximum gear speed. q [ > ]: Move cursor to right q [ < ]: Move cursor to left q [U] Change setting q Display of lower line [o]: Gear speed is effective q Display of lower line [_]: Gear speed is ineffective a Once a gear speed is limited, the gear does not shift up to that gear speed, even if the shiftup switch is operated. a Even if this code is turned off, the setting is effective.
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9.
Load memory display mode (9-LOAD MAP DISPLAY MODE) In this mode, you can check the load on the machine, forward odometer, and reverse odometer. 1)
Selecting and executing mode 1] Select “Load memory display mode” on the mode selection screen. a 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). 2] Display the information screen by operating buzzer cancel switch (4). q [U]: Execute mode. Serial numbers: 30001 – 30070
30 Testing and adjusting
2)
No.
Changing information screen Change the information screen by operating information switch (5). q [ > ]: Next screen. q [ < ]: Previous screen. Display
Item
1
01-1000 rpm SMR
1000 rpm service data
2
02-FOWARD ODO M
Forward travel distance
3
03-REVERSE ODO M
Reverse travel distance
4
04-F1 ODO Meter
F1 travel distance
5
05-F2 ODO Meter
F2 travel distance
6
06-F3 ODO Meter
F3 travel distance
7
07-R1 ODO Meter
R1 travel distance
8
08-R2 ODO Meter
R2 travel distance
9
09-R3 ODO Meter
R3 travel distance
3)
Display of 1,000rpm 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 1,000rpm. a The data cannot be reset.
Serial numbers: 30071 and up
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4)
Display of forward odometer (02) On this screen, the integrated forward travel distance is displayed. a The data cannot be reset.
7)
Display of F2 odometer (05) On this screen, the integrated F2 (Forward 2nd gear) travel distance is displayed. a The data cannot be reset.
5)
Display of reverse odometer (03) On this screen, the integrated reverse travel distance is displayed. a The data cannot be reset.
8)
Display of F3 odometer (06) On this screen, the integrated F3 (Forward 3rd gear) travel distance is displayed. a The data cannot be reset.
6)
Display of F1 odometer (04) On this screen, the integrated F1 (Forward 1st gear) travel distance is displayed. a The data cannot be reset.
9)
Display of R1 odometer (07) On this screen, the integrated R1 (Reverse 1st gear) travel distance is displayed. a The data cannot be reset.
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10) Display of R2 odometer (08) On this screen, the integrated R2 (Reverse 2nd gear) travel distance is displayed. a The data cannot be reset.
11) Display of R3 odometer (09) On this screen, the integrated R3 (Reverse 3rd gear) travel distance is displayed. a The data cannot be reset.
30 Testing and adjusting
12) Moving machine with saved load displayed If the parking brake lever is set in the FREE position, gear speed display unit (1) is set in the normal display mode again and the machine can operate normally. a At this time, even if the shift up or shift down switch is pressed with the PCCS lever in the neutral position, the shift cannot be changed. (The displayed number is the code of load saving display mode.) To change the shift, shift the PCCS lever to the “forward” or “reverse” position and press the shift up or shift down switch while the machine is traveling. a To select another screen, return the parking brake lever to the LOCK position temporarily, and then start the operation. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
34
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01819-04
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. a This mode is used to monitor 1 item. When monitoring 2 items simultaneously, use the “Dual display monitoring mode”. Selecting and executing mode 1] Select “Real-time monitoring mode” on the mode selection screen. a 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). 2] Display the monitoring code input screen by operating buzzer cancel switch (4). q [U]: Execute mode. Serial numbers: 30001 – 30070
q q q q
[ > ]: Move cursor to right. [ < ]: Move cursor to left. [UP]: Increase number. [DOWN]: Decrease number.
1)
2]
After inputting the code, display the m on ito ring scree n by op erating buzzer cancel switch (4). q [ ]: Enter input code. a If the input code is normal, the monitoring screen shown at right appears.
Serial numbers: 30071 and up
a
2)
If the input code is abnormal, the code input screen appears again after the screen shown at right.
Selecting and entering monitored items 1] On the code input screen, input the 5digit code of the item to be monitored by operating information switch (5), shift-up switch (6), and shift-down switch (7).
D475A, D475ASD-5E0
35
SEN01819-04
3)
Contents of display on monitoring screen (Figure below shows examples) [1] Code [2] Monitoring item [3] Information [4] Unit (Not displayed for some items) a 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). q [U]: Hold and release. a While the monitored item is held, the letter “H” is displayed at the left end of the lower line.
30 Testing and adjusting
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. a At this time, even if the shift up or shift down switch is pressed with the PCCS lever in the neutral position, the shift cannot be changed. (The displayed number is the code of monitoring mode.) To change the shift, shift the PCCS lever to the “forward” or “reverse” position and press the shift up or shift down switch while the machine is traveling. a To select another screen, return the parking brake lever to the LOCK position and perform the necessary procedure. Serial numbers: 30001 – 30070 5)
Serial numbers: 30071 and up
36
D475A, D475ASD-5E0
30 Testing and adjusting
6)
SEN01819-04
Automatic selection of monitoring item (Limited function) After one of some monitoring items is selected, if the information switch is operated, the next monitoring item is selected automatically, even if the code of the next monitoring item is not input. q [ > ]: Code is increased q [ < ]: Code is decreased a This function is applied to only the items having numbers in the “Sending in order” column of the Monitoring mode table. Those items are selected in the order of their numbers. a Note that this operation is not effective while the parking brake lever is in the RESET position. a You may return to the screen for inputting codes and enter a code without using this function.
D475A, D475ASD-5E0
37
SEN01819-04
30 Testing and adjusting
Monitoring mode table No. Code
Monitoring item
Unit
Remarks
Automatic selection
1
00201 ENG M ID L
Engine controller model selection name, left bank
Letter
—
—
2
00203 ENG M ID R
Engine controller model selection name, right bank
Letter
—
—
3
01002 ENG REV L
Engine speed, left bank
rpm
—
1
4
01004 ENG REV R
Engine speed, right bank
rpm
—
2
5
01603 Remote Th
2nd throttle position
%
—
—
6
03000 FUEL DIAL
Fuel control dial voltage
mV
—
25
7
03200 BATTERY
Battery voltage
mV
—
39
8
03201 S/T ACC
Steering controller ACC input voltage
mV
—
—
9
03202 S/T PWR2
Steering controller load power supply voltage
mV
—
—
10 03203 E-ECM PW L
Engine controller power supply voltage, left bank
mV
—
—
11 03206 E-ECM PW R
Engine controller power supply voltage, right bank
mV
—
—
12 03207 S/T PWR1
Steering controller unswitched power supply voltage
mV
—
—
13 03208 T/M PWR1
Transmission controller unswitched power supply voltage
mV
—
—
14 03212 T/M ACC
Transmission controller ACC input voltage
mV
—
—
15 03216 T/M PWR2
Transmission controller load power supply voltage
mV
—
—
16 04104 COOLANT TP
Engine coolant temperature
°C
—
6
17 04105 COOLANT TP
Engine coolant temperature sensor voltage
mV
—
—
18 04200 FUEL SENS
Fuel level sensor voltage
mV
—
37
19 04401 HYD.TEMP
Hydraulic oil temperature
°C
—
7
20 08100 HSI BREAK
HSI line break point
rpm
—
—
21 08200 TQ Sel
Torque curve selection
Letter
—
—
22 08300 Droop Type
Droop type selection
Letter
—
—
23 08400 Droop SW
Droop switch selection
Letter
—
—
24 08500 Droop Trim
Droop trim selection
Letter
—
—
25 10500 S/T 5V PW1
Steering controller sensor 5V power supply voltage 1
mV
—
—
26 10501 T/M 5V PW1
Transmission controller sensor 5V power supply voltage 1
mV
—
—
27 10505 S/T 5V PW2
Steering controller sensor 5V power supply voltage 2
mV
—
—
28 10506 T/M 5V PW2
Transmission controller sensor 5V power supply voltage 2
mV
—
—
29 10700 S/T 24V PW
Steering controller sensor 24V power supply voltage
mV
—
—
30 10701 T/M 24V PW
Transmission controller sensor 24V power supply voltage
mV
—
—
31 14200 FUEL TMP L
Fuel temperature, left bank
°C
—
—
32 14201 FUEL TMP L
Fuel temperature sensor voltage, left bank
mV
—
—
33 14202 FUEL TMP R
Fuel temperature, right bank
°C
—
—
34 14203 FUEL TMP R
Fuel temperature sensor voltage, right bank
mV
—
—
35 17201 PCV TMG L
PCV closing timing, left bank
CA
—
—
36 17202 PCV TMG R
PCV closing timing, right bank
CA
—
—
37 17500 ENG MODE
Engine controller mode selection
Letter
—
—
38 18300 ENG IVSW 1
Engine controller idle validation switch 1
bit
(See detailed information)
—
39 18301 ENG IVSW 1
Engine controller idle validation switch 2
bit
(See detailed information)
—
38
D475A, D475ASD-5E0
30 Testing and adjusting
No. Code
SEN01819-04
Monitoring item
Unit
Remarks
Automatic selection
40 18400 INTAKE TEMP Intake air temperature
°C
—
—
41 18401 INTAKE TEMP Intake air temperature sensor voltage
mV
—
—
42 18500 BOOST TEMP Boost temperature
°C
—
—
43 18501 BOOST TEMP Boost temperature sensor voltage
mV
—
—
mg/st
—
—
45 18700 ENG TRUQUE Engine output torque
Nm
—
—
46 18900 E-ECM TP L
Engine controller ECM inside temperature, left bank
°C
—
—
47 18902 E-ECM TP R
Engine controller ECM inside temperature, right bank
°C
—
—
48 20201 T/M. PROGRM
Transmission controller program version
Letter
—
—
44 18600 INJECT CMD
Final injection rate command
49 20202 S/T. PROGRM
Steering controller program version
Letter
—
—
50 20216 ENG BLD L
Engine controller build version, left bank
Letter
—
—
51 20217 ENG CAL L
Engine controller calibration data version, left bank
Letter
—
—
52 20218 ENG CAL R
Engine controller calibration data version, right bank
Letter
—
—
53 20219 ENG BLD R
Engine controller build version, right bank
Letter
—
—
54 20301 VHMS
VHMS LED monitor
LED
—
40
55 20400 E-ECM SN L
Engine controller ECM serial No., left bank
Letter
—
—
56 20401 E-ECM SN R
Engine controller ECM serial No., right bank
Letter
—
57 30100 T/C TEMP.
Torque converter oil temperature
°C
—
58 31200 T/M IN
Transmission input speed
rpm
—
59 31400 T/M OUT
Transmission output speed
rpm
—
3 — —
60 31520 T/M-FILL
Transmission-related fill switch input state
bit
(See detailed information)
61 31521 S/T FILL
Steering-related fill switch input state
bit
(See detailed information)
8
62 31602 1st CLUTCH
1st clutch ECMV current command value
mA
—
—
63 31603 2nd CLUTCH
2nd clutch ECMV current command value
mA
—
—
64 31604 3rd CLUTCH
3rd clutch ECMV current command value
mA
—
—
65 31606 Rev CLUTCH
Reverse clutch ECMV current command value
mA
—
—
66 31608 Frd CLUTCH
Forward clutch ECMV current command value
mA
—
—
67 31612 1 CLUTCH F
1st clutch ECMV output feedback current
mA
—
33
68 31613 2 CLUTCH F
2nd clutch ECMV output feedback current
mA
—
34
69 31614 3 CLUTCH F
3rd clutch ECMV output feedback current
mA
—
35
70 31616 R CLUTCH F
Reverse clutch ECMV output feedback current
mA
—
32
71 31618 BRAKE R.H.
Right brake ECMV output feedback current
mA
—
27
72 31619 BRAKE L.H.
Left brake ECMV output feedback current
mA
—
26
73 31620 BRAKE R.H.
Right brake ECMV current command value
mA
—
—
74 31621 BRAKE L.H.
Left brake ECMV current command value
mA
—
—
75 31622 F CLUTCH F
Forward clutch ECMV output feedback current
mA
76 31623 FAN PUMP. O
Cooling fan pump solenoid output command current
mA
—
—
77 31624 FAN PUMP. F
Cooling fan pump solenoid output feedback current
mA
—
—
78 31625 PITCH SOL.
Blade pitch solenoid output feedback current
mA
—
—
79 31627 L/U SOL
Torque converter lockup solenoid output feedback current
mA
—
36
80 31628 E. BRAKE SL
Sudden stop prevention solenoid output feedback current
mA
—
28
81 31633 FAN PMP2. O
Cooling fan pump 2 solenoid output command current
mA
—
—
D475A, D475ASD-5E0
31
39
SEN01819-04
30 Testing and adjusting
No. Code
Monitoring item
Unit
Remarks
Automatic selection
mA
—
—
%
—
9
mV
—
24
82 31634 FAN PMP2. F
Cooling fan pump 2 solenoid output feedback current
83 31701 DECEL
Decelerator position
84 31703 DECEL
Decelerator pedal potentiometer voltage
85 31706 F THROTTLE
Final accelerator position
%
—
10
86 32900 BODY ANGLE Machine pitch angle
°
—
18
87 36001 Accel Adj
Throttle correction value data
%
—
—
88 36200 PRESS CMD
Final common rail pressure command
MPa
—
—
89 36300 INJECT CMD
Final injection timing command
CA
—
—
90 36400 RAIL PR L
Common rail pressure, left bank
MPa
—
12
91 36401 RAIL PR L
Common rail pressure sensor voltage, left bank
mV
—
—
92 36403 RAIL PR R
Common rail pressure, right bank
MPa
—
13
93 36404 RAIL PR R
Common rail pressure sensor voltage, right bank
mV
—
—
94 36500 BOOST PRS
Boost pressure
kPa
(Absolute pressure)
14
95 36501 BOOST PRS
Boost pressure sensor voltage
mV
—
—
96 36700 ENG TORQUE Engine converted torque
%
—
15
97 37200 ENG OIL PRS
Engine oil pressure
kPa
—
11
98 37201 ENG OIL PRS
Engine oil pressure sensor voltage
mV
—
—
99 37301 FUEL RATE
Fuel injection rate
L/h
—
—
(Absolute pressure)
—
100 37400 ABM PRESS
Ambient pressure
kPa
101 37401 ABM PRESS
Ambient pressure sensor voltage
mV
—
—
102 37500 ATM TEMP
Ambient temperature
°C
—
—
103 40001 VEHICLE SP
Travel speed (Theoretical value)
km/h
—
4
104 40905 T/M-SW1
Transmission-related controller input signal 1
bit
(See detailed information)
—
105 40906 T/M-SW2
Transmission-related controller input signal 2
bit
(See detailed information)
—
106 40907 T/M OP SIG
Transmission-related controller operation input signal
bit
(See detailed information)
—
107 40908 T/M HYD SW
Blade lever oil pressure switch input signal
bit
(See detailed information)
—
108 40909 T/M SOL. 2
Transmission-related controller ON/OFF output 2
bit
(See detailed information)
—
109 40910 S/T-SW1
Steering-related controller switch input signal 1
bit
(See detailed information)
—
110 40911 S/T-SW2
Steering-related controller switch input signal 2
bit
(See detailed information)
—
111 40913 S/T-SW5
Steering-related controller switch input signal 5
bit
(See detailed information)
—
112 40914 S/T SOL. 1
Transmission-related controller ON/OFF output 1
bit
(See detailed information)
—
113 40915 S/T SOL. 2
Steering-related controller output signal 2
bit
(See detailed information)
—
114 42600 EXH TEMP LF
Exhaust temperature, left front
°C
—
—
115 42601 EXH TEMP RR Exhaust temperature, right rear
°C
—
—
116 42602 EXH TEMP RF Exhaust temperature, right front
°C
—
—
117 42603 EXH TEMP RF Exhaust temperature sensor voltage, right front
mV
—
—
40
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01819-04
No. Code
Monitoring item
118 42604 EXH TEMP LF
Exhaust temperature sensor voltage, left front
Unit
Remarks
Automatic selection
mV
—
—
119 42605 EXH TEMP RR Exhaust temperature sensor voltage, right rear
mV
—
—
120 42606 EXH TEMP LR Exhaust temperature, left rear
°C
—
—
121 42607 EXH TEMP LR Exhaust temperature sensor voltage, left rear
mV
—
—
122 42700 ENG OIL TMP
Engine oil temperature
°C
—
—
123 42701 ENG OIL TMP
Engine oil pressure sensor voltage
mV
—
—
124 42800 BLOWBY PRS
Blow-by pressure
kPa
—
—
125 43000 T/M PRESS
Transmission main relief pressure
MPa
—
—
126 43502 IdleCancel
Warm-up operation cancel flag
bit
(See detailed information)
—
127 44202 Accel Up
Throttle upper limit value data
%
—
128 44203 Accel low
Throttle lower limit value data
%
—
129 50200 T/M LEVR 1
Directional lever potentiometer 1 voltage
mV
19
130 50201 T/M LEVR 2
Directional lever potentiometer 2 voltage
mV
20
131 50300 S/T LEVR 1
Steering potentiometer 1 voltage
mV
21
132 50301 S/T LEVR 2
Steering potentiometer 2 voltage
mV
22
133 50400 BRAKE PEDL
Brake pedal potentiometer voltage
mV
23
134 50900 N-SAFTY
Neutral safety relay drive voltage
mV
38 —
135 51000 ENG REG
Regulation command speed
rpm
136 51100 FUEL DIAL
Fuel control dial command speed
rpm
137 60000 TRACTION
Traction force (Theoretical value)
W
138 60100 BODY ANGLE
Machine pitch angle sensor voltage
mV
—
139 60200 ACCELERATN
Acceleration sensor voltage
mV
—
140 60300 SSC ORDER
SSC command speed
rpm
—
141 60400 S/T-SW6
Steering-related controller input signal 6
bit
(See detailed information)
—
142 60500 ENG.CON. PW
Engine controller drive voltage
mV
—
—
143 60600 BR HOLD
Battery relay drive voltage
mV
—
—
144 60700 S/T MODE
Steering state code
Letter
—
—
145 60800 FILL MODE
Fill condition setting variable
Letter
—
—
5
146 60909 MOD MODE
Modulation condition setting variable
Letter
—
—
147 70000 CHG.P. MODE
Gearshift point condition setting variable
Letter
—
—
148 70200 T/M OUT
Transmission speed sensor voltage
mV
—
—
149 70300 B. KNOB SW
Blade lever knob switch input signal
bit
(See detailed information)
—
150 70305 T/M RIPER2
Ripper lever oil pressure switch input signal
bit
(See detailed information)
—
151 70400 BACK ALARM
Backup alarm relay drive voltage
mV
—
—
152 70600 DUAL SOL.
Dual tilt solenoid drive current
mA
—
—
153 70700 HYD. PUMP 1
Work equipment pump oil pressure 1
MPa
—
16
154 70701 HYD. PUMP 1
Work equipment oil pressure sensor 1 voltage
mV
—
—
155 70702 HYD. PUMP 2
Work equipment pump oil pressure 2
MPa
—
17
156 70703 HYD. PUMP 2
Work equipment oil pressure sensor 2 voltage
mV
—
— — —
157 90000 T/M SOL. 3
Tilt and pitch solenoid output 3 bit output signal
bit
(See detailed information)
158 90001 T/M SOL. 4
Dual tilt and pitch solenoid output 4 bit output signal
bit
(See detailed information)
D475A, D475ASD-5E0
41
SEN01819-04
No. Code
30 Testing and adjusting
Monitoring item
Unit
Remarks
Automatic selection
159 90002 BL YOKE L
Left yoke angle sensor voltage
mV
—
—
160 90003 BL YOKE R
Right yoke angle sensor voltage
mV
—
—
161 90600 S/T CLT LH
Left clutch ECMV output feedback current
mA
—
29
162 90601 S/T CLT RH
Right clutch ECMV output feedback current
mA
—
30
163 90602 S/T CLT LH
Left clutch ECMV output current
mA
—
—
164 90603 S/T CLT RH
Right clutch ECMV output current
mA
—
—
165 92100 F1 SMR
F1 integrated travel hours
h
—
—
166 92101 F2 SMR
F2 integrated travel hours
h
—
—
167 92102 F3 SMR
F3 integrated travel hours
h
—
—
168 92200 R1 SMR
R1 integrated travel hours
h
—
—
169 92201 R2 SMR
R2 integrated travel hours
h
—
—
170 92202 R3 SMR
R3 integrated travel hours
h
—
—
171 99901 TRIG T F
Trigger time F
msec
—
—
172 99902 TRIG T R
Trigger time R
msec
—
—
173 99903 TRIG T 1
Trigger time 1
msec
—
—
174 99904 TRIG T 2
Trigger time 2
msec
—
—
175 99905 TRIG T 3
Trigger time 3
msec
—
—
176 99906 TM SFT
Transmission shift
Letter
—
—
177 99907 LU
Lockup state
bit
(See detailed information)
—
178 99908 TM IN TRQ
Transmission input torque
Nm
—
—
179 99909 DOZING h
Dozing hours
h
—
—
180 99910 RIPPING h
Ripping hours
h
—
—
181 99911 PATH NUM
Number of path
path
—
—
182 99913 TC IN TRQ
Torque converter input torque
Nm
—
—
183 99914 H. P 1 TRQ
Work equipment pump 1 input torque
Nm
—
—
184 99915 H. P 2 TRQ
Work equipment pump 2 input torque
Nm
—
—
185 99917 BR L PRESS
Left brake oil pressure
MPa
—
—
186 99918 BR R PRESS
Right brake oil pressure
MPa
—
—
187 99919 CL L PRESS
Left clutch oil pressure
MPa
—
—
188 99920 CL R PRESS
Right clutch oil pressure
MPa
—
—
a
42
The numbers in the Automatic selection column can be displayed in numeric order by setting the information switch in the “>” or “<” position.
D475A, D475ASD-5E0
30 Testing and adjusting
Detailed information on bit display codes Examples of display of bit information a The display position of the bit information in the “Real-time monitoring mode (Display of only 1 item)” is different from that in the “Dual display monitoring mode (Simultaneous display of 2 items)”. a The bit information is displayed by [ ] for OFF and [o] for ON in the places 1 – 8. a The state of each item shown below is the condition for turning on the bit.
18300: Engine controller idle validation switch 1 1: Idle validation switch 1: ON 2: (Unused) 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
D475A, D475ASD-5E0
SEN01819-04
18301: Engine controller idle validation switch 2 1: Idle validation switch 2: ON 2: (Unused) 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
31520: Input state of transmission related fill switch 1: Forward clutch fill switch: ON 2: Reverse clutch fill switch: ON 3: 1st clutch fill switch: ON 4: 2nd clutch fill switch: ON 5: 3rd clutch fill switch: ON 6: (Unused) 7: (Unused) 8: (Unused)
43
SEN01819-04
30 Testing and adjusting
31521: Input state of steering related fill switch 1: Left brake fill switch: ON 2: Left clutch fill switch: ON 3: (Unused) 4: (Unused) 5: Right clutch fill switch: ON 6: Right brake fill switch: ON 7: (Unused) 8: (Unused)
40906: Transmission related controller input signal 2 1: Automatic gear shift-down switch: ON 2: Neutral switch (OPT-type travel lever): OFF 3: Neutral switch (OPT-type travel lever): ON 4: Neutral switch (OPT-type travel lever): OFF 5: Neutral switch (OPT-type travel lever): ON 6: Automatic pitch back switch: ON 7: (Unused) 8: (Unused)
40905: Transmission related controller input signal 1 1: Shift-up switch: OFF 2: Shift-up switch: ON 3: Shift-down switch: OFF 4: Shift-down switch: ON 5: Parking brake switch: FREE 6: Parking brake switch: LOCK 7: (Unused) 8: (Unused)
40907: Transmission related controller function input signal 1: ACC signal switch: ON 2: (Unused) 3: R signal: ON 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
44
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01819-04
40908: Blade lever oil pressure switch input signal 1: Blade lift raise oil pressure switch: ON 2: Blade lift lower oil pressure switch: ON 3: (Unused) 4: (Unused) 5: Blade left tilt oil pressure switch: ON 6: Blade right tilt oil pressure switch: ON 7: (Unused) 8: (Unused)
40910: Steering related controller input signal 1 1: (Unused) 2: (Unused) 3: (Unused) 4: (Unused) 5: Parking brake lever switch: FREE 6: Parking brake lever switch: LOCK 7: (Unused) 8: (Unused)
40909: Transmission related controller output signal 2 1: (Unused) 2: (Unused) 3: (Unused) 4: Backup alarm relay: ON 5: Neutral safety relay: ON 6: Lockup: ON 7: (Unused) 8: (Unused)
40911: Steering related controller input signal 2 1: Buzzer cancel switch: t position 2: Buzzer cancel switch: U position 3: Information switch: > position 4: Information switch: < position 5: Service switch: ON 6: (Unused) 7: (Unused) 8: (Unused)
D475A, D475ASD-5E0
45
SEN01819-04
40913: Steering related controller input signal 5 1: ACC signal: ON 2: Pre-lubrication oil pressure switch: ON 3: R signal: ON 4: (Unused) 5: Fan reverse switch: ON 6: Fan cleaning switch: ON 7: (Unused) 8: (Unused)
40914: Steering related controller output signal 1 1: Pre-heater relay drive: ON 2: Snap shot switch: ON 3: Fan reverse solenoid: ON 4: Merge-divider selector solenoid valve: ON 5: Battery relay drive: ON 6: Sudden stop prevent solenoid: ON 7: LS solenoid: ON 8: (Unused)
46
30 Testing and adjusting
40915: Steering related controller ON-OFF output signal 2 1: Pre-lubrication motor relay: ON 2: Engine stop relay: ON 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
43502: Warm-up cancel flag 1: Warm-up cancel flag: ON 2: (Unused) 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
D475A, D475ASD-5E0
30 Testing and adjusting
60400: Steering related controller input signal 6 1: (Unused) 2: C signal: ON 3: Engine low idle signal: ON 4: Engine stop command signal: ON 5: Hydraulic oil level switch signal: ON 6: Pre-lubrication motor drive signal: ON 7: (Unused) 8: (Unused)
70300: Blade lever knob switch input signal 1: Blade lever tilt switch: SINGLE 2: Blade lever tilt switch: DUAL 3: Blade lever pitch switch: OFF 4: Blade lever pitch switch: ON 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
D475A, D475ASD-5E0
SEN01819-04
70305: Ripper lever oil pressure switch input signal 1: (Unused) 2: Ripper lift raise oil pressure switch: ON (Operated) 3: Ripper lift lower oil pressure switch: ON (Operated) 4: Ripper tilt in oil pressure switch: ON (Operated) 5: Ripper tilt out oil pressure switch: ON (Operated) 6: (Unused) 7: (Unused) 8: (Unused)
90000: Tilt/Pitch solenoid output 3 bit output signal (Superdozer specification) 1: Left tilt limit solenoid: ON 2: Right tilt limit solenoid: ON 3: Pitch solenoid: ON 4: (Unused) 5: Pitch dump solenoid: ON 6: Pitch back solenoid: ON 7: (Unused) 8: (Unused)
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90000: Dual/Pitch dump solenoid output 4 bit output signal (Other than superdozer specification) 1: Left tilt limit solenoid: ON 2: Right tilt limit solenoid: ON 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
30 Testing and adjusting
99907: Lockup state 1: Forward clutch output: ON 2: Reverse clutch output: ON 3: 1st clutch output: ON 4: 2nd clutch output: ON 5: 3rd clutch output: ON 6: Clutch modulation: Modulating 7: Lockup clutch output: ON 8: Clutch state: Neutral
90001: Transmission controller output signal 1: Dual tilt solenoid: ON 2: Pitch solenoid: ON 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
48
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30 Testing and adjusting
11. Dual display monitoring mode (11-DUAL DISPLAY MONITORING MODE) In this mode, 2 monitored items can be displayed simultaneously. a 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 1] Select “Dual display monitoring mode” on the mode selection screen. a 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). 2] Display the monitoring code input screen by operating buzzer cancel switch (4). q [U]: Execute mode. Serial numbers: 30001 – 30070
SEN01819-04
2)
Selecting and entering monitored items 1] 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), shiftup switch (6), and shift-down switch (7). q [ > ]: Move cursor to right. q [ < ]: Move cursor to left. q [UP]: Increase number. q [DOWN]: Decrease number. 2] After inputting the codes, display the m on ito ring scree n by op erating buzzer cancel switch (4). q [U]: Enter input code.
a
If the input codes are normal, the monitoring screen shown below appears.
Serial numbers: 30071 and up
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3)
30 Testing and adjusting
If the input codes are incorrect, the code input screen appears again after the screen shown below.
Contents of display on monitoring screen (Figure below shows examples) [1] Code 1 [2] Information 1 [3] Code 2 [4] Information 2 a 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. a At this time, even if the shift up or shift down switch is pressed with the PCCS lever in the neutral position, the shift cannot be changed. (The displayed number is the code of monitoring mode.) To change the shift, shift the PCCS lever to the “forward” or “reverse” position and press the shift up or shift down switch while the machine is traveling. a To select another screen, return the parking brake lever to the LOCK position and perform the necessary procedure. Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
50
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30 Testing and adjusting
12. Snap shot mode (12-SNAPSHOT MODE) The VHMS specification has the manual snap shot function and automatic snap shot function. While the manual snap shot function is turned ON, various data in 7 minutes 30 seconds for the Pm clinic, testing, and adjusting can be saved in the VHMS controller. 1) Select “Snap shot mode” on the mode selection screen. a If the mode is selected, code (55) is displayed on gear speed display unit (1) and the title is displayed on multi-information unit (2). For details of the operating method in the snap shot mode, see “Execution method of quick PM”. (1) Manual snap shot function q To collect data periodically for the Pm clinic, the machine must be operated as specified by the Quick Pm. When data is required and collected for testing, adjusting, etc., the operations of the machine are not limited. q To use the data saved with the manual snap shot function, a personal computer must be connected. For the procedure for connecting the personal computer, see “Initialization procedure for VHMS controller”. (The personal computer may be connected either before or after the snap shot operation.) (2) Automatic snap shot function q While the automatic snap shot function is turned ON, if an item which the VHMS controller monitors constantly becomes abnormal (if the corresponding failure code is displayed), the snap shot data of that item in 7 minutes 30 seconds are saved in the VHMS controller automatically. q Since the VHMS controller automatically performs the automatic snap shot function according to the monitoring item data, the operator does not need to operate the monitor. q How to collect snap shot data If the value of a monitoring item data becomes abnormal, that data is recorded and saved for 7 minutes 30 seconds from 5 minutes 30 seconds ago. a The data is recorded at 10 second intervals for the first 5 minutes, and at 1 second intervals for 2 minutes 30 seconds after the first 5 minutes.
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Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
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D475A, D475ASD-5E0 Bulldozer Form No. SEN01819-04
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
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BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
30 Testing and adjusting
1
Testing and adjusting, Part 4 Adjustment method when controller has been replaced ................................................................................. 2 Preparation work for troubleshooting for electrical equipment system ........................................................... 4 Inspection procedure of diode......................................................................................................................... 8 Handling of optional devices ........................................................................................................................... 9 Initialization procedures for VHMS controller................................................................................................ 10 Precautions for replacing VHMS controller ................................................................................................... 31 Pm Clinic service .......................................................................................................................................... 36
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Adjustment method when controller has been replaced a
k
a
a a
1.
30 Testing and adjusting
Adjusting transmission controller Select Transmission controller specification set (0003) and adjust the transmission controller. a Execute this code only when the steering controller is also replaced.
5.
Turning power on again Turn the starting switch off (battery relay off) and leave it for 1 minute. Then turn the starting switch on, then reset the monitor panel in the “Adjustment Mode” of the service mode.
6.
Adjusting machine specification Select Machine specification set (0004) and adjust the machine specification.
1
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. 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. Precautions for replacing a controller: When replacing a controller, stop the machine in a safe place and turn the starting switch OFF. Adjust the controller referring to the item 8. Adjusting mode in "Special functions of monitor panel (EMMS)". Controller initial setting After replacing controller, turn the switch ON temporarily (ACC position) and after approx. 10 seconds, turn the switch OFF. q After turning the switch OFF, the controller is initialized. Therefore leave it for approx. 1 minute after turning the switch OFF even if the battery relay shuts down.
2.
Setting system in service mode After step 1, turn the starting switch ON again and set the monitor panel in the “Adjustment mode” of the service mode.
3.
Adjusting steering controller Select Steering controller specification set (0002) and adjust the steering controller. a Execute this code only when the transmission controller is also replaced.
2
4.
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30 Testing and adjusting
7.
Adjusting brake potentiometer Select Brake potentiometer initial set (0005) and adjust the brake potentiometer.
8.
Adjusting pitch angle sensor Select the initial setting (0009) of the pitch angle sensor and adjust the pitch angle sensor.
9.
VHMS system set Set VHMS system using Adjustment mode (0022). (If not, take care that default is not-equipped set.)
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10. Turning power on again Turn the starting switch OFF (battery relay off) and after leaving it for 1 minute, turn it ON again. 11. Checking failure codes 1) Set the monitor panel in the “Electrical system failure code display mode” of the service mode. 2) Check if any active failure codes exist. If not, delete all the failure codes recorded. a If any active failure codes exist, eliminate the cause of the incident by troubleshooting, then carry out steps 10 and 11 again. a Precautions after replacing controller: If any controller is replaced, the service meter in the oil and filter maintenance mode is reset to 0. As a result, the replacement period displayed on the monitor panel may be different from the actual operating hours. To solve this problem, determine the first replacement periods of the oils and filters after the replacement of the controller according to the replacement periods recorded before the replacement of the controller.
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Preparation work for troubleshooting for electrical equipment system a
30 Testing and adjusting
3)
1
Insert or connect T-adapters in or to connectors S01, S02, S03, and S04 of monitor panel (2).
When performing troubleshooting for an electrical circuit related to the monitor panel, engine controller, transmission controller, steering controller, or VHMS terminal, expose the related connectors according to the following procedure.
1.
Monitor panel 1) Remove cover (1). 2) Remove the 2 mounting bolts and pull out monitor panel (2) toward the operator’s seat. Serial numbers: 30001 – 30070 2.
Engine controller 1) Open left and right side covers (1) and remove side covers (2) and (3).
Serial numbers: 30071 and up
2)
4
Remove cover (4) of engine controller.
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30 Testing and adjusting
3)
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Insert or connect the diagnostic T-adapter in or to the connector (PWP, PWL, ENG, OEMR or OEML) of engine controller (5). a When disconnecting the connector, loosen its screw. a When connecting the connector, tighten its screw to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
k
In order to prevent malfunction and mistaken system error warning, be sure to completely remove foreign object (b) such as sand, dust, water, etc., from inside of controller side connector (a) with air blow etc., before connecting to harness connector.
D475A, D475ASD-5E0
3.
Transmission controller 1) Remove dashboard cover (1).
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2)
Insert or connect T-adapters in or to connectors TMC1, TMC2, and TMC3 of transmission controller (2). a If the connectors cannot be disconnected and connected easily, remove the controller from the dashboard. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
30 Testing and adjusting
4.
Steering controller 1) Remove dashboard undercover (1).
2)
6
Insert or connect T-adapters in or to connectors STCN1, STCN2, and STCN3 of steering controller (2). a If the connectors cannot be disconnected and connected easily, remove the controller from the dashboard. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
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5.
VHMS controller 1) Open the floor left side cover and remove cover (1).
2)
Remove amplifier mounting cover (2).
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6.
ORBCOMM terminal 1) Open the floor left side cover and remove cover (1).
2) 3)
3)
Referring to 5 above, remove VHMS controller (3). Insert or connect T-adapters in or to connectors KOM1 of ORBCOMM terminal (4). a If it is difficult to remove and install the connectors, remove the terminal for the ease of work.
Insert or connect T-adapters in or to connectors V1, V2A, V2B, V3A, and V3B of VHMS controller (3). a If it is difficult to remove and install the connectors, remove the controller for the ease of work.
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Inspection procedure of diode
30 Testing and adjusting
1
a
The direction of continuity of diode is marked on the surface of the diode.
1.
When using digital tester 1) Switch to diode range and check displayed value. a Voltage of internal battery is displayed by normal tester. 2) Set red (+) test lead to diode anode (P) side and black (–) test lead to cathode (N) side. Check displayed value. 3) Judge quality of diode from displayed value. q Displayed value does not change: No continuity (defect) q Displayed value changes: Continue (normal) (note) Note: In the case of silicon diode, the value between 460 – 600 mV is displayed. q Displayed value becomes 0 or near 0: Short-circuiting of diode internal part (defect)
8
2.
When using analog tester 1) Switch to resistance range. 2) Check the deflection of needle while connecting as follows. i) Set red (+) test lead to diode anode (P) side and black (–) test lead to cathode (N) side. ii) Set red (+) test lead to diode cathode (N) side and black (–) test lead to anode (P) side. 3) Based on the deflection of needle, judge the quality of diode. q Needle does not deflect with connection i) but deflects with connection ii): Normal. (However deflection range (resistance value) varies depending on the type of tester and measuring range.) q Needle deflects with both connection i) and ii): Defective (internal short circuit) q Needle does not deflect with either connection i) or ii): Defective (internal disconnection)
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Handling of optional devices a
D475A-5E0 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.
Connecting the ACC signal of starting switch If the ACC signal (ON signal) of the starting switch is necessary for a optional device such as the turbocharger timer, connect it through the following connector pin. q Pin (B) of CN-ESD (3-pole heavy duty wire connector) a A 20A fuse is installed on the upstream side of this connector pin.
2.
Inputting engine low-idle command If it is required to keep the engine speed at low idle for an optional device such as the engine protector, connect the following connector pin to the chassis ground. q Pin (C) of CN-ESD (3-pole heavy duty wire connector) a While this connector pin is connected to the chassis ground, the engine speed is kept at low idle, regardless of the fuel control dial position.
3.
Connecting C signal of starting switch If the C signal (starting signal) of the starting switch is necessary for a optional device such as the pre-lubricator, connect it through the following connector pin. q CN-PRS (2-pole heavy duty wire connector) a Remove the connector installed when the machine is shipped, and connector pin (1) to the starting signal to be finally output by the pre-lubricator and connector pin (2) to the input signal from the starting switch.
4.
Connecting external power source If an external power source is necessary, connect it through the following connectors. q AUX1 (Plug connector) q AUX2 (Plug connector) a A 20A fuse is installed on the upstream side of each of these connectors.
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1
9
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30 Testing and adjusting
Initialization procedures for VHMS controller 1 a
Initialization tools for VHMS controller
Symbol
Part No. 799-608-3211
Diskette
2
799-608-3220
Wiring harness
Commercially available
Notebook type personal computer (OS: Windows98/2000/ NT/Me/XP Terminal "RS232C" is with it)
3
a
a
a
a
a
10
Part name
1
Z
a
1.
Before starting full operation after completion of local assembly or before resuming operation after storage for a long period, initialize the VHMS controller according to the following procedure. Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the initialization. For the method of installing the VHMS Initialization Program to the personal computer, refer to the Operation and Maintenance Manual contained in the package of diskette Z1. Since the service menu of the monitor panel will be used in the following procedure, read “Special functions of monitor panel” and understand the operating procedure in advance. The initialization procedures cover both “ORBCOMM Specification” and “ORBCOMM-less Specification”. In case of “ORBCOMM-less” Specification”, omit the procedures necessary for “ORBCOMM Specification” only. During the initialization work, confirm each work according to the “VHMS Initialization Work Checklist”.
Check of machine information, engine information and controller information a This step is a work performed on the whole machine. Check and record the machine information, engine information, VHMS controller information and ORBCOMM terminal information. No. 1
Machine model
2
Machine serial No.
3
Current service meter reading
4
Engine serial No.
5
Transmission serial No.
6
VHMS controller serial No.
7
ORBCOMM terminal serial No. [For ORBCOMM specification only]
a
2.
Information to be checked
The VHMS controller and ORBCOMM terminal are in the VHMS controller box under the left side cover of the floor.
Connection of personal computer 1) Make sure that the starting switch is in the OFF position. k Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Z3 and download connectors VDW and DL1 by wiring harness Z2. a The download connectors are installed to the following places. q VDW: Inside of cab (Left rear lower part) q DL1: Rear side of chassis (Hull frame) a Connect the personal computer to the RS232C terminal.
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SEN01820-03
2)
3) 4)
a a
Execute initialization of VHMS from the connector in the cab. Use the ground download connector for only downloading.
5)
6)
3.
Select “Service mode” and “Real-time monitoring mode” in order on the monitor panel. Input ID = 20301. If the central part of the lower line of the multi-information display unit counts up, the VHMS controller is normal.
Check of operation and satellite capturing condition of VHMS controller a This step is a work performed in the operator's cab. a Check of satellite capturing condition is necessary o only [ORBCOMM specification]. 1) Set the starting switch in the ON position.
D475A, D475ASD-5E0
7)
Judge the operation of the ORBCOMM controller by the state of the dot at the right bottom of the LED digit of the VHMS controller. The dot at the right bottom of the LED digit of the VHMS controller can be checked in the multi-information display unit of the monitor by the following method. 1] Set the starting switch in the ON position. 2] For monitor panel specification: Referring to 10. “Real-time monitoring mode” or 11. “Dual display monitoring mode”, input ID = 20301.
At least 3 minutes after starting the VHMS, check the decimal point at the right bottom of the LED of the VHMS controller or the decimal point at the right bottom of the central part of the lower line of the multiinformation display unit.
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30 Testing and adjusting
9)
Right decimal point
12
Display
OFF
• Power is not supplied to ORBCOMM controller. • Communication line to VHMS controller is abnormal.
ON
• Satellite is not captured. • Power is supplied to ORBCOMM controller. • Communication line to VHMS controller is normal.
Blinking
• Power is supplied to ORBCOMM controller. • Communication line to VHMS controller is normal. • Satellite is captured.
8)
Watch the decimal point LED on the right of the right-hand 7 segments of the VHMS controller to check that the ORBCOMM controller is capturing the satellite [ORBCOMM specification]. a Check the communication satellite capturing condition of the ORBCOMM controller on the VHMS controller side. a If the ORBCOMM controller is normal, the decimal point LED of the right-hand 7 segments flashes.
Check the controller for normal operation referencing 7-segment LED of VHMS controller. a VHMS controller is fed with switch power supply. Thus, its operation is judged normal if its 7-segment LED starts flashing while rotating as the starting switch is turned on and then if the controller starts counting in the ascending order.
4.
Startup of VHMS initialization tool a This step is a work performed in the operator's cab (on the personal computer). 1) Turn on the personal computer and start the OS. 2) Click the icon of [VHMS Initialization Tool] on the personal computer screen to start the VHMS initialization tool. a The setting screen varies with the version No. of the VHMS setting tool. a When using a tool before Ver. 3.5.2.1 (CD-ROM), set the VHMS in step 5. a When using an updated tool (Ver. 3.5.2.1 or after), set the VHMS in step 6. a It is recommended to download the latest VHMS setting tool from the WebCARE and update your tool. (Related material: Servicemate SMP623) 3) Input the 10-digit service ID in [Service ID]. a Service ID: 7826146000 4) Select [Data clear and Set up] in the [Select Function] column. 5) Press the [OK] button to go to the setup screen.
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5.
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3)
If information in the [Date/Time] box is not correct, change it according to the following procedures: 1] Press [Edit] button (1) on the right lower part of the [Date/Time] box to display the correction screen. 2] Correct the information and press the [OK] button.
4)
If information in the [Machine information] box is not correct, change it according to the following procedures: 1] Press the [Edit] button (2) on the right lower part of the [Machine information] box to display the correction screen. 2] Correct the information and press the [OK] button.
5)
After checking/changing all the data in [Machine information], press [Apply] button (3) to settle the setting. a Press the [Apply] button (3), and the screen for checking the setting will appear. Check the setting again and press the [OK] button if the setting is correct. a In case of the ORBCOMM Specification, execute [Communication Setting] first and then settle the setting.
Initialization of VHMS controller (Tool before Ver. 3.5.2.1) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR]. [Machine information] 1) Open the [Machine information] tab. a The [Machine information] tab is displayed first in the [Data clear and Set up] menu. 2) Check all the data.
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[Communication Setting] [For ORBCOMM specification only] a Execute this setting after requesting for opening of the ORBCOMM terminal and finishing the opening procedure. 6) Open the [Communication Setting] tab. 7) Check all the data.
8)
14
To change the setting in [SHORT FAULT HISTRY], follow the procedure below: 1] Select [SHORT FAULT HISTRY] on the screen and press [Edit] button (5) on the left lower part of the [File Transfer Setting] block to display the setting screen. 2] Change the setting and then press the [OK] button. a At initialization, select [Occurrence] at [Timing] and set the function to [ON].
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9)
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To change setting in [SHORT TREND ANALYSIS], follow the procedures below: 1] Select [SHORT TREND ANALYSIS] on the screen and press [Edit] button on the left lower part of the [File Transfer Setting] block to display the setting screen. 2] Change the setting and then press the [OK] button. a At initialization, input [20h] to [SMR] and set the function to [ON].
10) To change the setting of [Satellite Setting], follow the procedure below. 1] Press the [Edit] button in the [Satellite Setting] block to display the setting screen. 2] Set the GCC Code to the applicable area and then press the [OK] button.
GCC Code 1
120
130
Area N.America (*1) C.S.Americas Faroe lslands Europe (*2) Middle East Asia (*3) Africa Oceania CLS Japan
D475A, D475ASD-5E0
11) After checking/changing all the data in [Communication Setting], press [Apply] button to settle the setting. a If the [Apply] button is pressed, the s c r e e n f o r c h e c k in g t h e s e t t i n g appears. Check the setting again and press the [OK] button if the setting is correct.
12) After checking/changing the data of [Machine Information] and [Communication Setting], press the [Exit] button at the right lower part of the screen to finish [VHMS Initialization Tool].
Remarks *1: Except U.S. Territories in Micronesia and Midway lsland
*2: Except Faroe lslands *3: Except Japan
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6.
Initialization of VHMS controller (Ver. 3.5.2.1 or after) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR]. 1) Select [VHMS Setting] and press the “Next” button.
30 Testing and adjusting
3)
Check the machine information. If it does not need to be corrected, press the “Next” button.
a
2)
16
If the VHMS was installed additionally, the information of [Serial No.] etc. must be input.
Select [Set up & All clear] and press the “Next” button.
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4) 5) 6)
7)
Select the time zone. Input the local time. If the DST (Daylight Saving Time) is used now, select it and press the “Next” button. a If the DST is selected, the clock is advanced 1 hour automatically, thus the time must be corrected again.
120
130
8)
The contents of the setting are displayed finally. If there is not a problem, press the “Apply” button.
9)
The system asks you if you save the data before changing the setting. If you do not need to save, select “NO”.
Set the GCC Code to the applicable area and then press the “Next” button.
GCC Code 1
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Area N.America (*1) C.S.Americas Faroe lslands Europe (*2) Middle East Asia (*3) Africa Oceania CLS Japan
Remarks *1: Except U.S. Territories in Micronesia and Midway lsland
*2: Except Faroe lslands *3: Except Japan
10) After finishing the work of changing the contents of initialization, press the “OK” button to finish the program.
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7.
Procedures for executing Quick Pm a The Quick Pm means the Pm Clinic executed with the manual snap shot function of the monitor panel. a Data in 7 minutes 30 seconds are saved in the VHMS controller. k Stop the machine on a flat place.
30 Testing and adjusting
2] 3]
Set the buzzer cancel switch in the [U] position. “READY” is displayed and the system is ready to start. a On the lower line, 15 pieces of “-” are displayed.
1) 2)
Start the engine. Set the monitor panel to display the service menu. a For the operating method, see “Special functions of monitor panel”. 3) Selection and execution of mode. 1] Select “Snap shot mode” on the mode selection screen. a If the mode is selected, code (55) is displayed in gear speed display unit (1) and the title is displayed in multi-information unit (2). Serial numbers: 30001 – 30070 4]
Set the buzzer cancel switch in the [U] position, and the snap shot operation starts. a After the snap shot operation starts, the elapsed time is displayed on the upper line. a On the lower line, 1 “ ” is added every 30 seconds. While multiple “ ” are displayed, the one at the right end blinks. a To interrupt the snap shot operation, set the buzzer cancel switch in the [t] position.
Serial numbers: 30071 and up
18
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5]
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After starting the snap shot operation, operate the machine according to Table 1. a Check that the engine coolant temperature and torque converter oil temperature are in the operating range. a After 10 “ ” are displayed (After 5 minutes), “#” is added up to 5. a “ ”: The data sampling interval is 10 seconds. a “#”: The data sampling interval is 1 second.
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Time (sec)
Finish
Start
No.
Table 1 Operations of machine to be executed while snap shot is operated Operation of machine State of machine
1
0:00 0:25 25
2
0:25 0:50 25
3
0:50 1:40 50
4
1:40 2:30 50 Deceleration slow
5
2:30 3:00 30
6
Transmission
Fuel SteerWork equipment control ing dial
Decelerator pedal
Brake pedal
Parking brake
N
LH
N
LOW
HI
Released Released
N
RH
N
LOW
HI
Released Released
N
N
N
HI
HI
Released Released
N
N
N
HI
LOW
Released Released
High-pressure relief & high idle
N
N
HI
HI
Released Released
3:00 3:30 30
High-pressure relief & low idle
N
N
Right tilt (or pitch back in case of dual tilt model)
LOW
HI
Released Released
7
3:30 4:00 30
Port relief & high idle
N
N
8
4:00 4:30 30
Port relief & low idle
N
9
4:30 5:10 40
Torque converter stall & low idle
Torque converter 10 5:10 6:00 50 stall (F3) & high idle (Note 1) 11 6:00 6:30 30
Low idle High idle
High idle
Torque converter 12 6:30 7:10 40 stall + High-pressure relief 13 7:10 7:30 20
High idleo Low idle (Note 2)
HI
HI
Released Released
N
Left tilt (or pitch dump in case of dual tilt model)
LOW
HI
Released Released
NoF1oF2oF 3oNoR1oR2 oR3oN
N
N
LOW
HI
ON
Released
NoF3 (Shift to F3, then run engine at full throttle)
N
N
HI
LOWo Shift to F3, then HI
ON
Released
N
N
N
HI
HI
NoF3 (Shift to F3, then run engine at high idle)
N
Left tilt (or pitch dump in case of dual tilt model)
HI
LOWo Shift to F3, then HI
ON
Released
N
N
N
HIo LOW
HI
Released
ON
Released Released
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle. (Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level. a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine speed to high idle. a After stalling the torque converter, watch the power train oil temperature gauge and take care not to overheat the power train oil. (The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the engine at high idle to lower the oil temperature.)
20
D475A, D475ASD-5E0
30 Testing and adjusting
6]
The screen shown below appears 7 minutes 30 seconds after the snap shot is started, and then the initial screen appears 5 seconds after. (End of snap shot)
SEN01820-03
q q
q
q q q q q
q
q
Important The data of the Quick Pm is recorded only once. If the Quick Pm is executed again, the current data are overwritten. Accordingly, be sure to save the data in the personal computer after executing the Quick Pm, referring to “8. Downloading of set data”. 7] a 8] a
Using the analysis tool, read the data of the Quick Pm. For the usage of the analysis tool, see the operation manual. Open the data of the Quick Pm and translate them into a graph. Set the time to the X-axis and set the following items to the Y-axis. q Engine Speed q Fuel Inject
D475A, D475ASD-5E0
q q
q q q q
q
q
Blowby Press Exhaust Temp RB (Exhaust temperature of right bank: 1, 2, 3, 4, 5, 6) Exhaust Temp LB (Exhaust temperature of left bank: 1, 2, 3, 4, 5, 6) Engine Oil Press Engine Oil Temp Eng Coolant Temp Ambient Temp Demand Eng Speed (Engine speed demanded by controller) T/C Oil Temp (Torque converter oil temperature) T/M Main Press (Transmission main relief pressure) T/M Output Speed (Transmission output speed) Shift Position ( Tr a n s m i s s i o n , t r a v e l , g e a r speed) S/T Clutch Pos. (Steering clutch position) S/T Brake Pos. (Steering brake position) Hydr Oil Temp (Hydraulic oil temperature) Pump 1 Press (Work equipment pump 1 oil pressure) Pump 2 Press (Work equipment pump 2 oil pressure) Body Pitch Angle (Pitch angle)
21
SEN01820-03
9]
22
30 Testing and adjusting
Check “Click position graphic value display”.
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
10] Click a point in the graph, and the value of each measurement item at that point on the X-axis is displayed under the graph. (Example of displayed graph: This is different from the actual graph.)
D475A, D475ASD-5E0
23
SEN01820-03
30 Testing and adjusting
11] Enter the above value in the Pm Clinic Inspection Sheet. a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as follows.
Engine at high idle
Q
Q
Q
Deceleration slow
Q
High-pressure relief & engine at full throttle
Q
Q
Q
Q
Q
Q Q
High-pressure relief & engine at slow Port relief & engine at full throttle
Q
Q Q
Port relief & engine at slow Q
Torque converter stall & engine at slow Torque converter stall (F3) & engine at full throttle
Work equipment pump (FR)
3rd clutch fill switch
2nd clutch fill switch
1st clutch fill switch
Rear clutch fill switch
Steering right brake fill switch
Q
Steering left brake fill switch
Q
Steering right clutch fill switch
Q
Steering left clutch fill switch
Engine at low idle
Front clutch fill switch
Transmission main relief pressure
Exhaust temperature
Blow-by pressure
Engine speed
State of machine
Engine oil pressure
Measurement items
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Engine at full throttle Torque converter stall & high-pressure relief Engine at high idle o Engine at low idle
24
Q
D475A, D475ASD-5E0
30 Testing and adjusting
8.
SEN01820-03
Downloading of set data 1) Connect personal computer Z3 and download connectors VDW in the cab or ground download connector DL1 by wiring harness Z2.
2)
3) a
Download connector VDW in the cab is installed to the left rear lower part of the operator's seat.
4)
When using download connector VDW in the cab, set the starting switch in the ON position. When using ground download connector DL1, turn switch (2) ON. a The green LED lights up. Operate the icon of [VHMS Technical Analysis Tool] on the personal computer to start the VHMS technical analysis tool.
a a a
Ground download connector DL1 is installed in frame (1) at the rear of the machine.
D475A, D475ASD-5E0
Input [User Name] and [Password]. For the operation procedures, see the Operation and Maintenance Manual for VHMS Technical Analysis Tool.
25
SEN01820-03
5)
9.
Check of downloaded data a This step is a work performed in the operator's cab (on the personal computer). 1) Check the set data with the [View] function. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that the [MFA0] code at the time when the snapshot was operated is displayed in [Fault History]. a Make sure that the snap shot data is recorded.
2)
26
Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. a For the operation procedures, see the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that downloading has completed before proceeding to the next step.
After checking the set data, terminate [VHMS Technical Analysis Tool].
30 Testing and adjusting
10. Disconnection of Personal Computer 1) Make sure that the starting switch is in the OFF position. k Be sure to turn off the starting switch before connecting or disconnecting the personal computer. 2) Finish the OS of the personal computer and then turn the personal computer OFF.
3)
If the data was downloaded in the cab, disconnect wiring harness Z2 from download connector VDW.
4)
If the data was downloaded on the ground, turn switch (2) OFF and disconnect wiring harness Z2 from download connector DL1.
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
11. Communication to Komatsu After completing steps 1 to 9 successfully, send the “VHMS/WebCARE setting notification form” to VHMS/WebCARE Support Center of Komatsu, Tokyo. a Since Komatsu has to set the receiving side of the satellite communication, be sure to inform Komatsu of the completion of the setting. a Send the VHMS data by Notes (LAN) or E-mail (WAN). Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) FAX: 03-5561-4766 (Domestic user) E-mail: [email protected]
D475A, D475ASD-5E0
27
SEN01820-03
30 Testing and adjusting
(Objective model: D475A-5E0 Bulldozer)
28
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
(Objective model: D475A-5E0 Bulldozer)
D475A, D475ASD-5E0
29
SEN01820-03
30
30 Testing and adjusting
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
Precautions for replacing VHMS controller 1 a
Part No. 799-608-3211
Diskette
2
799-608-3220
Wiring harness
Commercially available
Notebook type personal computer (OS: Windows98/2000/NT/ Me/XP Terminal "RS232C" is with it)
3
a a
3)
Check all the information before replacing the VHMS controller. Select [Save] from [File] in the menu.
Name
1
Z
a
Select “Save/Load” and press the “OK” button.
Tools for replacing VHMS controller Symbol
a
2)
When the VHMS controller needs to be replaced, set it before removing it and the installed new VHMS controller according to the following procedure. Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the initialization. During the initialization work, confirm each work according to the “VHMS Initialization Work Checklist”. The information of model name etc. shown in the figures is different from the actual machine.
4)
[Work before replacing VHMS controller] 1. Downloading of remaining data a This step is a work performed in the operator's cab (on the personal computer). a Using the [Download] function, download the data currently recorded in the VHMS controller to the personal computer. a For the operating procedures, see Initialization procedures for VHMS controller, “8. Downloading of set data”. 2.
Check, saving and writing of information set in VHMS controller (Before Ver. 3.5.2.1) a This step is a work performed in the operator's cab (on the personal computer). a Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly installed VHMS controller. 2-1. Check and saving of information set in VHMS controller to be replaced 1) Connect the personal computer and start the VHMS technical analysis tool. a See “Initialization procedures for VHMS controller”.
D475A, D475ASD-5E0
31
SEN01820-03
5)
6) 7)
8) 9)
Check the information again and press the “OK” button to save it.
3)
Select [Load] from [File] in the menu.
4)
The saved information is displayed. Press the “OK” button.
5)
The saved information is displayed on another screen. Press the [Edit] button to set the time.
Select [Exit] from [File] in the menu to finish the VHMS technical analysis tool. Disconnect the personal computer. a See Initialization procedures for VHMS controller, “9. Disconnection of Personal Computer”. Turn the personal computer OFF. Replace the VHMS controller.
2-2. Writing of set information in new VHMS controller 1) Connect the personal computer again and start the VHMS technical analysis tool. a See “Initialization procedures for VHMS controller”. 2) Select “Save/Load” and press the “OK” button.
32
30 Testing and adjusting
6)
D475A, D475ASD-5E0
30 Testing and adjusting
7)
After setting the time, press the “OK” button.
8)
Press the [Apply] button, and the contents of the setting are displayed. Check the contents again and press the [OK] button if there is not a problem.
SEN01820-03
9)
The system asks you if you will save the previous data. Press the “NO” button. a Usually, you do not need to save the previous data.
10) Select [Exit] from [File] in the menu to finish the VHMS setting tool. 3.
Check, saving and writing of information set in VHMS controller (Ver. 3.5.2.1 or after) a This step is a work performed in the operator's cab (on the personal computer). a Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly installed VHMS controller.
3-1. Check and saving of information set in VHMS controller to be replaced 1) Connect the personal computer and start the VHMS technical analysis tool. a See “Initialization procedures for VHMS controller”. 2) Select [When VHMS needs to be replaced] and press the “Next” button.
D475A, D475ASD-5E0
33
SEN01820-03
3)
Select [Save Current Setting before replacement of VHMS controller] and press the “Next” button.
4)
Check all the information before replacing the VHMS controller and press the “Save” button.
30 Testing and adjusting
3-2. Writing of set information in new VHMS controller 1) Connect the personal computer again and start the VHMS technical analysis tool. a See “Initialization procedures for VHMS controller”. 2) Select [When VHMS needs to be replaced] and press the “Next” button.
3)
5) 6)
7) 8)
34
Select [Use Previous setting after replacement of VHMS controller] and press the “Next” button.
Select [Exit] from [File] in the menu to finish the VHMS setting tool. Disconnect the personal computer. a See Initialization procedures for VHMS controller, “9. Disconnection of Personal Computer”. Turn the personal computer OFF. Replace the VHMS controller.
D475A, D475ASD-5E0
30 Testing and adjusting
4)
5)
The saved information is displayed. Press the “Next” button.
Set the time and press the “Apply” button.
SEN01820-03
7)
The above completes modification of the setting. Press [OK] button to end the VHMS initial setting tool.
[Work after replacing VHMS controller] a After replacing the VHMS controller, carry out initialization according to the “Initialization Procedure for VHMS Controller”. a Change the data to the information recorded before the VHMS controller was replaced. (Input the date and time when the VHMS controller was replaced.) a After completing the setting after the replacement, send the check sheet to VHMS/WebCARE Support Center of Komatsu, Tokyo. a Send the data downloaded before and after replacing the VHMS controller by Notes (LAN) or E-mail (WAN). Komatsu VHMS/WebCARE Support Center 2-3-6, Akasaka Minato-ku Tokyo, Japan FAX:
81-3-5561-4766 (from outside of Japan)
E-mail: [email protected]
6)
The system asks you if you will save the previous data. Press the “NO” button. a Usually, you do not need to save the previous data.
D475A, D475ASD-5E0
35
SEN01820-03
30 Testing and adjusting
Pm Clinic service
1
Model
Serial No.
Service meter
T D475A-5E0 T D475ASD-5E0
h
User name
Date of clinic /
Serviceman
/
Specifications Blade
Attachment
T Semi U blade T U blade T Super blade T
Shoe width
T Variable Multi-shank ripper T Variable giant ripper T Counterweight ( kg) T
T 710 mm T 810 mm T 910 mm T
% % % %
Operating conditions Quarry, mine
Construction
Type of soil (specific gravity)
Type of work
T Coal
T Construction, civil engineering
T Rock
T Dozing
T Gold
T Roads
T Gravel
T Side cutting
T Limestone
T Tunnels
T Sand
T Ripping
T
T
T Clay
T Travel
Existence of abnormalities Oil, coolant level check T Engine coolant level
When necessary
T Engine oil level
T Power train
T Damper case
T Hydraulic oil level
T Final drive
T(
Ambient temperature Max. Min.
)
Height above sea level °C
m
Operator's opinion Visual check results Failure code history [
]
h
Content: [
]
h
Content:
a
]
h
[
]
h
Content:
Engine coolant temperature: Max. range
Serial numbers: 30001 – 30070
36
[ Content:
Serial numbers: 30071 and up
a
Power train oil temperature: Max. range
Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
Measuring points for Pm clinic (1/3)
Reference pages for measurement procedures 1. Engine speed: Testing and adjusting, Part 1, Pages 6 – 9 2. Blow-by pressure: Testing and adjusting, Part 1, Pages 20, 21 3. Engine oil pressure: Testing and adjusting, Part 1, Page 22 4. Boost pressure: Testing and adjusting, Part 1, Pages 10, 11 5. Exhaust temperature: Testing and adjusting, Part 1, Pages 12, 13
D475A, D475ASD-5E0
37
SEN01820-03
30 Testing and adjusting
Measuring points for Pm clinic (2/3)
Reference pages for measurement procedures 6. Torque converter parts: Testing and adjusting, Part 2, Pages 4 – 5 7. Transmission parts: Testing and adjusting, Part 2, Pages 6 – 8 8. Steering brake parts: Testing and adjusting, Part 2, Pages 9 – 10
38
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
Measuring points for Pm clinic (3/3)
Reference pages for measurement procedures 9. Work equipment and HSS parts: Testing and adjusting, Part 2, Pages 22 – 32 10. Control circuits: Testing and adjusting, Part 2, Pages 33 – 39 11. Fan parts: Testing and adjusting, Part 2, Pages 48 – 49
D475A, D475ASD-5E0
39
SEN01820-03
30 Testing and adjusting
Decelerator low idle Decelerator high idle
Low idle High idle
Low idle
Transmission: Neutral Oil temperature: Within operating range High idle
Low idle Transmission: Neutral
High idle High idle
40
Transmission: F3 (Adjustment code: 5535)
Low idle
Transmission: R3 (Adjustment code: 5535)
Low idle
Transmission: F1 (Adjustment code: 5535)
Low idle
Transmission: F2 (Adjustment code: 5535)
Low idle
Transmission: F3 (Adjustment code: 5535)
Low idle
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
Low idle
High idle Transmission: Neutral Low idle
High idle
Engine speed high idle, F2, brake applied
Low idle
High idle
Low idle
High idle
High idle
Low idle High idle High idle
D475A, D475ASD-5E0
41
SEN01820-03
30 Testing and adjusting
Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle
42
D475A, D475ASD-5E0
30 Testing and adjusting
SEN01820-03
Pm clinic Undercarriage check sheet
Serial number
Work order
Date /
T D475A-5E0 # T D475ASD-5E0 #
Service meter /
Serviceman h
Measure the bushing temperature immediately after operations Left side of machine
q
Right side of machine
a
Measurement results Pass
Fail
Left side of machine Right side of machine q
Opening of track link
D475A, D475ASD-5E0
Left track
A: Clearance between links
Right track
A: Clearance between links
Pin No.
1.6
Pin No.
1.6
43
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) (Program form No.: SELA195001)
44
D475A, D475ASD-5E0
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) (Program form No.: SELA195001)
IMPACT
D475A, D475ASD-5E0
45
SEN01820-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01820-03
© 2010 KOMATSU All Rights Reserved Printed in Japan 04-10
46
SEN01821-04
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Failure code table and fuse locations Failure code table ........................................................................................................................................... 2 Fuse locations............................................................................................................................................... 12
D475A, D475ASD-5E0
1
SEN01821-04
40 Troubleshooting
Failure code table Failure code
Transmission clutch
15E0MW Transmission clutch 15SAL1 Forward clutch oil pressure 15SALH Forward clutch oil pressure 15SBL1 Reverse clutch oil pressure 15SBLH Reverse clutch oil pressure 15SEL1 1st clutch oil pressure 15SELH 1st clutch oil pressure 15SFL1 2nd clutch oil pressure 15SFLH 2nd clutch oil pressure 15SGL1 3rd clutch oil pressure 15SGLH 3rd clutch oil pressure 1800MW Power train clutch 2201L1
Right clutch oil pressure
2201LH Right clutch oil pressure 2202L1
Left clutch oil pressure
2202LH Left clutch oil pressure 2300NR Brake thermal load 2301L1
Right brake oil pressure
2301LH Right brake oil pressure 2301NR Right steering brake thermal load 2302L1
Component in charge
Action code
Category of record
Clutch slip
T/M
—
Electrical system
Double engagement
T/M
Clutch slip
T/M
Troubled part
1380MW Lockup clutch 1500L0
1
Left brake oil pressure
2302LH Left brake oil pressure 2302NR Left steering brake thermal load
Trouble
Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Clutch slip Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Abnormal heating Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Abnormal heating Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Abnormal heating
6001ZK Failure code for design
—
CALL E03 Electrical system —
Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E03 Electrical system
S/T
—
Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T
TroubleshootCALL E04 Electrical system ing by failure code, Part 1 CALL E04 Electrical system SEN01823-02 — Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T S/T
—
—
—
A000NS Engine
Overheat
MON
—
Mechanical system
AA10NX Air cleaner
Clogging
MON
—
Mechanical system
AB00MA Battery charge abnormality
Malfunction
MON
—
Mechanical system
B@BAZG Engine oil
Oil pressure reduction
ENG
—
Mechanical system
B@BAZK Engine oil
Oil level reduction
MON
—
Mechanical system
B@BCNS Engine coolant
Overheat
ENG
—
Mechanical system
B@BCZK Engine coolant
Coolant level reduction
MON
—
Mechanical system
B@BEBF Fuel
Water in fuel
MON
—
Mechanical system
2
Reference manual
D475A, D475ASD-5E0
40 Troubleshooting
Failure code
SEN01821-04
Troubled part
Trouble
Component in charge
Action code
Category of record
Reference manual
B@BFZK Fuel level
Reduction
MON
—
Mechanical system
B@CENS Power train oil
Overheat
MON
—
Mechanical system
B@CHZG HSS charge oil pressure
Low oil pressure
MON
—
B@CHZK Power train
Oil level reduction
MON
—
Mechanical system Troubleshooting by failure Mechanical system code, Part 1
B@GAZK Battery electrolyte level
Electrolyte level reduction
MON
—
Mechanical system SEN01823-02
B@HANS Hydraulic oil
Overheat
MON
—
Mechanical system
B@HAZK Hydraulic oil
Oil level reduction
S/T
—
Mechanical system
CA111
Engine controller (Left bank)
Internal abnormality
ENG CALL E04 Electrical system
CB111
Engine controller (Right bank)
Internal abnormality
ENG CALL E04 Electrical system
Speed sensor signal error
ENG CALL E04 Electrical system
Speed sensor signal error
ENG CALL E04 Electrical system
High voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
High voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
High voltage detection
ENG CALL E02 Electrical system
Low voltage detection
ENG CALL E02 Electrical system
High voltage detection
ENG CALL E02 Electrical system
Low voltage detection
ENG CALL E02 Electrical system
High voltage detection
ENG CALL E01 Electrical system
CA115 CB115 CA122 CA123 CA131 CA132 CA135 CA141 CA144 CA145 CA153 CA154 CA187 CB187 CA212 CA213 CA221 CA222 CA227 CB227 CA234 CA238 CB238 CA263 CB263 CA265
Engine NE/Bkup speed sensor abnormality (Left bank) Engine NE/Bkup speed sensor abnormality (Right bank) Charge pressure sensor abnormally high level (Only left bank) Charge pressure sensor abnormally low level (Only left bank) Decelerator pedal sensor abnormally high level (Only left bank) Decelerator pedal sensor abnormally low level (Only left bank) Oil pressure sensor abnormally high level (Only left bank) Oil pressure sensor abnormally low level (Only left bank) Coolant temperature sensor abnormally high level (Only left bank) Coolant temperature sensor abnormally low level (Only left bank) Charge temperature sensor abnormally high level (Only left bank) Charge temperature sensor abnormally low level (Only left bank) Sensor power supply (2) abnormally low level (Left bank) Sensor power supply (2) abnormally low level (Right bank) Engine oil temperature sensor abnormally high level (Only left bank) Engine oil temperature sensor abnormally low level (Only left bank) Ambient temperature sensor abnormally high level (Only left bank) Ambient temperature sensor abnormally low level (Only left bank) Sensor power supply (2) abnormally high level (Left bank) Sensor power supply (2) abnormally high level (Right bank) Engine overspeed (Only left bank) Ne speed sensor power supply abnormality (Left bank) Ne speed sensor power supply abnormality (Right bank) Fuel temperature sensor abnormally high level (Left bank) Fuel temperature sensor abnormally high level (Right bank) Fuel temperature sensor abnormally low level (Left bank)
D475A, D475ASD-5E0
Low voltage detection
TroubleshootENG CALL E01 Electrical system ing by failure code, Part 2 ENG CALL E03 Electrical system SEN01824-01 ENG CALL E03 Electrical system
High voltage detection
ENG CALL E01 Electrical system
Low voltage detection
ENG CALL E01 Electrical system
High voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
High voltage detection
ENG CALL E03 Electrical system
High voltage detection
ENG CALL E03 Electrical system
Abnormally high speed
ENG
Low voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
Abnormally high speed
ENG CALL E01 Electrical system
Abnormally high speed
ENG CALL E01 Electrical system
Low voltage detection
ENG CALL E01 Electrical system
Low voltage detection Low voltage detection
—
Mechanical system
3
SEN01821-04
Failure code
40 Troubleshooting
Troubled part
Trouble
Component in charge
Action code
Category of record
Reference manual
CB265
Fuel temperature sensor abnormally Low voltage detection low level (Right bank)
ENG CALL E01 Electrical system
CA271
PCV1 short circuit (Left bank)
Short circuit
ENG CALL E03 Electrical system
CB271
PCV1 short circuit (Right bank)
Short circuit
ENG CALL E03 Electrical system
CA272
PCV1 disconnection (Left bank)
Disconnection
CB272
PCV1 disconnection (Right bank)
Disconnection
ENG CALL E03 Electrical system Troubleshooting by failure ENG CALL E03 Electrical system code, Part 2
CA273
PCV2 short circuit (Left bank)
Short circuit
ENG CALL E03 Electrical system SEN01824-01
CB273
PCV2 short circuit (Right bank)
Short circuit
ENG CALL E03 Electrical system
CA274
PCV2 disconnection (Left bank)
Disconnection
ENG CALL E03 Electrical system
CB274
PCV2 disconnection (Right bank)
Disconnection
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Mismatch
ENG CALL E03 Electrical system
Mismatch
ENG CALL E03 Electrical system
Circuit abnormality
ENG CALL E03 Electrical system
Circuit abnormality
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
CA322 CA323 CA324 CA325 CA331 CA332 CA342 CB342 CA351 CB351 CA352 CB352 CA386 CB386 CA441 CB441 CA442 CB442 CA449 CB449 CA451 CB451 CA452 CB452 CA553 CB553
4
Injector #1 (L/B#1) system disconnection/short circuit (Left bank) Injector #5 (L/B#5) system disconnection/short circuit (Left bank) Injector #3 (L/B#3) system disconnection/short circuit (Left bank) Injector #6 (L/B#6) system disconnection/short circuit (Left bank) Injector #2 (L/B#2) system disconnection/short circuit (Left bank) Injector #4 (L/B#4) system disconnection/short circuit (Left bank) Engine controller data mismatch (Left bank) Engine controller data mismatch (Right bank) Injector drive circuit abnormality (Left bank) Injector drive circuit abnormality (Right bank) Sensor power supply (1) abnormally low level (Left bank) Sensor power supply (1) abnormally low level (Right bank) Sensor power supply (1) abnormally high level (Left bank) Sensor power supply (1) abnormally high level (Right bank) Power supply voltage abnormally low level (Left bank) Power supply voltage abnormally low level (Right bank) Power supply voltage abnormally high level (Left bank) Power supply voltage abnormally high level (Right bank) Common rail abnormally high pressure (2) (Left bank) Common rail abnormally high pressure (2) (Right bank) Common rail pressure sensor abnormally high level (Left bank) Common rail pressure sensor abnormally high level (Right bank) Common rail pressure sensor abnormally low level (Left bank) Common rail pressure sensor abnormally low level (Right bank) Common rail abnormally high pressure (1) (Left bank) Common rail abnormally high pressure (1) (Right bank)
Low voltage detection
TroubleshootENG CALL E03 Electrical system ing by failure code, Part 3 ENG CALL E03 Electrical system SEN01825-03 ENG CALL E04 Electrical system
Low voltage detection
ENG CALL E04 Electrical system
High voltage detection
ENG CALL E04 Electrical system
High voltage detection
ENG CALL E04 Electrical system
High voltage detection High voltage detection
Abnormally high pressure occurrence Abnormally high pressure occurrence
ENG CALL E03 Electrical system ENG CALL E03 Electrical system
High voltage detection
ENG CALL E03 Electrical system
High voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
Abnormally high pressure occurrence Abnormally high pressure occurrence
ENG
E02
Electrical system
ENG
E02
Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
Failure code CA554 CB554 CA559 CB559 CA689 CB689 CA691 CA692 CA731 CB731 CA757 CB757 CA778 CB778 CA781 CB781 CA1257 CB1257 CB1548 CB1549 CB1551 CB1552 CB1553 CB1622
Troubled part Common rail pressure sensor inrange error (Left bank) Common rail pressure sensor inrange error (Right bank) Supply pump low pressure (1) (Left bank) Supply pump low pressure (1) (Right bank) Engine Ne speed sensor abnormality (Left bank) Engine Ne speed sensor abnormality (Right bank) Intake air temperature sensor abnormally high level (Only left bank) Intake air temperature sensor abnormally low level (Only left bank) Engine Bkup speed sensor abnormal phase (Left bank) Engine Bkup speed sensor abnormal phase (Right bank) Engine controller all data loss (Left bank) Engine controller all data loss (Right bank) Engine Bkup speed sensor abnormality (Left bank) Engine Bkup speed sensor abnormality (Right bank) Inter-multicontroller communication error (Left bank) Inter-multicontroller communication error (Right bank) Multicontroller distinction wiring harness key error (Left bank) Multicontroller distinction wiring harness key error (Right bank) Injector #7 (R/B#1) system disconnection/short circuit (Right bank) Injector #8 (R/B#2) system disconnection/short circuit (Right bank) Injector #10 (R/B#4) system disconnection/short circuit (Right bank) Injector #11 (R/B#5) system disconnection/short circuit (Right bank) Injector #12 (R/B#6) system disconnection/short circuit (Right bank) Injector #19 (R/B#3) system disconnection/short circuit (Right bank)
CA1633 KOMNET abnormality (Left bank) Decelerator pedal sensor power supCA2185 ply abnormally high level (Only left bank) Decelerator pedal sensor power supCA2186 ply abnormally low level (Only left bank) Supply pump low pressure (2) CA2249 (Left bank) Supply pump low pressure (2) CB2249 (Right bank)
SEN01821-04
Trouble
Component in charge
Action code
Category of record
In-range error occurrence
ENG CALL E03 Electrical system
In-range error occurrence
ENG CALL E03 Electrical system
Low pressure occurrence
ENG
E02
Electrical system
Low pressure occurrence
ENG
E02
Electrical system
High voltage detection
TroubleshootENG CALL E03 Electrical system ing by failure code, Part 3 ENG CALL E03 Electrical system SEN01825-03 ENG E01 Electrical system
Low voltage detection
ENG
Phase error
ENG CALL E03 Electrical system
Phase error
ENG CALL E03 Electrical system
All data loss
ENG CALL E04 Electrical system
All data loss
ENG CALL E04 Electrical system
Bkup signal error
ENG CALL E03 Electrical system
Bkup signal error
ENG CALL E03 Electrical system
Communication error
ENG CALL E03 Electrical system
Communication error
ENG CALL E03 Electrical system
Distinction error
ENG CALL E03 Electrical system
Distinction error
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit
ENG CALL E03 Electrical system
Disconnection/Short circuit Disconnection/Short circuit
ENG CALL E03 Electrical system Troubleshooting by failure ENG CALL E03 Electrical system code, Part 4
Disconnection/Short circuit
ENG CALL E03 Electrical system SEN01826-01
Communication error
ENG CALL E03 Electrical system
High voltage detection
ENG CALL E03 Electrical system
Low voltage detection
ENG CALL E03 Electrical system
Low pressure occurrence
ENG CALL E03 Electrical system
Low pressure occurrence
ENG CALL E03 Electrical system
Signal error Signal error
E01
Electrical system
D110KA Battery relay
Disconnection
S/T
—
Electrical system
D110KB Battery relay
Short circuit
S/T
—
Electrical system
D130KA Neutral safety relay
Disconnection
T/M
E02
Electrical system
D130KB Neutral safety relay
Short circuit
T/M
E02
Electrical system
D161KA Backup alarm relay
Disconnection
T/M
E01
Electrical system
D475A, D475ASD-5E0
Reference manual
5
SEN01821-04
Failure code
40 Troubleshooting
Troubled part
Trouble
Component in charge
Action code
Category of record
D161KB Backup alarm relay
Short circuit
T/M
E01
Electrical system
D182KZ Preheater relay
Disconnection/short circuit
S/T
E01
Electrical system
Disconnection
S/T
—
Electrical system
Short circuit
S/T
—
Electrical system
D5ZRKA Snap shot switch
Disconnection
S/T
—
Electrical system
D5ZRKB Snap shot switch
Short circuit
S/T
—
Electrical system
Engine controller ACC signal cut relay Engine controller ACC signal cut D190KB relay D190KA
Monitor panel CAN communication (MON) Monitor panel CAN communication dAFRKR (T/M) Monitor panel CAN communication daFRKR (S/T)
DAFRKR
DAQ0KT Transmission controller DAQ1KK DAQ2KK DAQ5KK DAQ6KK DAQ7KK DAQ9KQ DAQRKR DAQSKR DB2RKR dB2RKR db2RKR
Transmission controller main power supply Transmission controller load power supply Transmission controller potentiometer power supply Transmission controller sensor power supply Transmission controller sensor power supply Transmission controller model selection Transmission controller CAN communication Transmission controller S-NET communication Engine controller (Left bank) CAN communication Engine controller (Left bank) CAN communication Engine controller (Right bank) CAN communication
DB30KT Steering controller DB31KK DB32KK DB35KK DB36KK DB37KK DB39KQ dB3RKR DB3SKR
MON CALL E03 Electrical system
Communication error
T/M
Communication error
S/T
Controller internal abnormality
T/M
Power supply voltage reduction (Input) Power supply voltage reduction (Input) Power supply voltage reduction (Input) Power supply voltage reduction (Input) Power supply voltage reduction (Input) Model selection signal disagreement
CALL E03 Electrical system
T/M
TroubleshootCALL E03 Electrical system ing by failure code, Part 4 E01 Electrical system SEN01826-01 CALL E04 Electrical system
T/M
CALL E04 Electrical system
T/M
CALL E03 Electrical system
T/M
E01
Electrical system
T/M
CALL E03 Electrical system
T/M
CALL E04 Electrical system
Communication error
T/M
CALL E03 Electrical system
Communication error
T/M
Communication error
S/T
CALL E03 Electrical system
Communication error
T/M
CALL E03 Electrical system
Communication error
S/T
CALL E03 Electrical system
Controller internal abnormality
S/T
Steering controller main power sup- Power supply voltage reduction (Input) ply Power supply voltage reducSteering controller load power supply tion (Input) Steering controller potentiometer Power supply voltage reducpower supply tion (Input) Steering controller sensor power Power supply voltage reducsupply tion (Input) Steering controller sensor power Power supply voltage reducsupply tion (Input) Model selection signal disSteering controller model selection agreement Steering controller CAN communicaCommunication error tion (T/M) Steering controller S-NET communiCommunication error cation Power supply voltage reducVHMS controller tion Model selection signal disVHMS controller model selection agreement Direct source voltage reducVHMS controller tion
DBB0KK [n9 o 01] DBB0KQ [nF o 11] DBB3KK [n9 o 05] DBB5KP VHMS sensor power supply (5 V) [n9 o 04] DBB6KP VHMS sensor power supply (24 V) [n9 o 02]
6
Communication error
Reference manual
E01
E01
Electrical system
Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E04 Electrical system
S/T
CALL E03 Electrical system
S/T S/T
CALL E03 Electrical system Troubleshooting by failure CALL E03 Electrical system code, Part 5
S/T
CALL E04 Electrical system SEN01827-02
S/T
CALL E03 Electrical system
S/T
E01
Electrical system
VHMS
—
—
VHMS
—
—
VHMS
—
—
Output voltage reduction
VHMS
—
—
Output voltage reduction
VHMS
—
—
D475A, D475ASD-5E0
40 Troubleshooting
Failure code
Troubled part
SEN01821-04
Trouble
Component in charge
Action code
Category of record
Reference manual
DBB7KP VHMS sensor power supply (12 V) [n9 o 03] DBBQKR VHMS KOM-NET [n8 o 02] VHMS controller CAN communicadbBRKR tion
Output voltage reduction
VHMS
—
—
Communication error
VHMS
—
—
Communication error
S/T
—
Electrical system
DD12KA Shift-up switch
Disconnection
T/M
E02
Electrical system
DD12KB Shift-up switch
Short circuit
T/M
E02
Electrical system
DD13KA Shift-down switch
Disconnection
T/M
E02
Electrical system
DD13KB Shift-down switch
Short circuit
T/M
E02
Electrical system
DD14KA Parking brake lever switch
Disconnection
T/M
CALL E03 Electrical system
DD14KB Parking brake lever switch
Short circuit
T/M
CALL E03 Electrical system
DDB9L4 Reverse switch
Signal disagreement
T/M
E02
Electrical system
DDK3L4 Forward switch
Signal disagreement
T/M
E02
Electrical system
DDK5KA Shift switch
Disconnection
T/M
E02
DDK5KB Shift switch
Short circuit
T/M
E02
Electrical system Troubleshooting by failure Electrical system code, Part 5
T/M
E02
Electrical system SEN01827-02
T/M
E02
Electrical system
Blade tilt right oil pressure switch Switch ON for long time system Blade tilt left oil pressure switch sysDDN3LD Switch ON for long time tem DDN2LD
DDN7KA Blade pitch switch
Disconnection
T/M
E02
Electrical system
DDN7KB Blade pitch switch
Short circuit
T/M
E02
Electrical system
DDN9KA Blade tilt switch
Disconnection
T/M
E01
Electrical system
DDN9KB Blade tilt switch
Short circuit
T/M
E01
Electrical system
DDNALD Blade lift raise full oil pressure switch Switch ON for long time
T/M
—
Electrical system
DDNBLD Ripper lift raise oil pressure switch
Switch ON for long time
T/M
—
Electrical system
DDNCLD Ripper lift lower oil pressure switch
Switch ON for long time
T/M
—
Electrical system
DDNDLD Ripper tilt in oil pressure switch
Switch ON for long time
T/M
—
Electrical system
DDNELD Ripper tilt back oil pressure switch
Switch ON for long time
T/M
—
Electrical system
Switch ON for long time
T/M
—
Electrical system
DDQ2KA Parking brake lever switch
Disconnection
S/T
CALL E03 Electrical system
DDQ2KB Parking brake lever switch
Short circuit
S/T
CALL E03 Electrical system
DDQ2L4 Parking brake lever switch (S/T)
Signal disagreement
S/T
CALL E03 Electrical system
dDQ2L4 Parking brake lever switch (T/M)
Signal disagreement
T/M
CALL E03 Electrical system
DDT5KA Neutral switch
Disconnection
T/M
DDT5KB Neutral switch
Short circuit
T/M
DDT5KQ Lever specification selection error
Model selection signal disagreement
T/M
DGS1KX Hydraulic oil temperature sensor
Out of input signal range
T/M
—
Electrical system
DGT1KA Power train oil temperature sensor
Disconnection
MON
E01
Electrical system
DGT1KX Power train oil temperature sensor
Out of input signal range
MON
E01
Electrical system
DDNFLD
Ripper lift lower full oil pressure switch
D475A, D475ASD-5E0
TroubleshootCALL E04 Electrical system ing by failure code, Part 6 CALL E04 Electrical system SEN01828-03 CALL E04 Electrical system
7
SEN01821-04
Failure code DGT5KA [n3 o 12] dGT5KA [n3 o 22] DGT5KB [n3 o 11] dGT5KB [n3 o 21] DGT6KA [n3 o 24] dGT6KA [n3 o 26] DGT6KB [n3 o 23] dGT6KB [n3 o 25] DH22KA DH22KB DH23KA DH23KB
40 Troubleshooting
Component in charge
Action code
Category of record
Disconnection
VHMS
—
—
Disconnection
VHMS
—
—
Short circuit
VHMS
—
—
Short circuit
VHMS
—
—
Disconnection
VHMS
—
—
Disconnection
VHMS
—
—
Short circuit
VHMS
—
—
Short circuit
VHMS
—
—
Disconnection
T/M
—
Electrical system
Short circuit
T/M
—
Electrical system
Disconnection
T/M
—
Electrical system
Short circuit
T/M
—
Electrical system
Troubled part Left bank exhaust temperature sensor system (Front) Left bank exhaust temperature sensor system (Rear) Left bank exhaust temperature sensor system (Front) Left bank exhaust temperature sensor system (Rear) Right bank exhaust temperature sensor system (Front) Right bank exhaust temperature sensor system (Rear) Right bank exhaust temperature sensor system (Front) Right bank exhaust temperature sensor system (Rear) Work equipment pump oil pressure sensor (F) Work equipment pump oil pressure sensor (F) Work equipment pump oil pressure sensor (R) Work equipment pump oil pressure sensor (R)
Trouble
Reference manual
DHE5KB Blow-by pressure sensor system [n3 o 32] DHE5KY Blow-by pressure sensor system [n3 o 31] DHT3KX Transmission oil pressure sensor [n6 o 14]
Disconnection
VHMS
—
—
Hot short
VHMS
—
—
Out of input signal range
VHMS
—
—
DK01KA Left yoke angle sensor
Disconnection
T/M
E02
Electrical system
DK01KB Left yoke angle sensor
Short circuit
T/M
E02
Electrical system
DK03KA Right yoke angle sensor
Disconnection
T/M
E02
Electrical system
DK03KB Right yoke angle sensor
Short circuit
T/M
E02
Electrical system
DK10KA Fuel control dial
Disconnection
S/T
CALL E03 Electrical system
DK10KB Fuel control dial
Short circuit
S/T
CALL E03 Electrical system
DK30KA Steering potentiometer (1)
Disconnection
S/T
CALL E03 Electrical system
DK30KB Steering potentiometer (1)
Short circuit
S/T
CALL E03 Electrical system
DK30KX Steering potentiometer (1)
Out of input signal range
S/T
CALL E04 Electrical system
DK30KZ Steering potentiometer (1)
Disconnection or short circuit
S/T
CALL E04 Electrical system
DK30L8 Steering potentiometer (1)
Analog signal disagreement
S/T
CALL E03 Electrical system
DK31KA Steering potentiometer (2)
Disconnection
S/T
CALL E03 Electrical system
DK31KB Steering potentiometer (2)
Short circuit
S/T
CALL E03 Electrical system
DK40KA Brake potentiometer
Disconnection
S/T
CALL E03 Electrical system
DK40KB Brake potentiometer
Short circuit
S/T
CALL E03 Electrical system
DK55KX Forward-reverse potentiometer
Out of input signal range
T/M
DK55KZ Forward-reverse potentiometer
Disconnection or short circuit
T/M
CALL E04 Electrical system Troubleshooting by failure code (Display CALL E04 Electrical system of code), Part 7
DK55L8 Forward-reverse potentiometer
Analog signal disagreement
T/M
CALL E03 Electrical system SEN01829-02
DK56KA Forward-reverse potentiometer (1)
Disconnection
T/M
CALL E03 Electrical system
DK56KB Forward-reverse potentiometer (1)
Short circuit
T/M
CALL E03 Electrical system
8
Troubleshooting by failure code, Part 6 SEN01828-03
D475A, D475ASD-5E0
40 Troubleshooting
Failure code
SEN01821-04
Troubled part
Trouble
Component in charge
Action code
Category of record
DK57KA Forward-reverse potentiometer (2)
Disconnection
T/M
CALL E03 Electrical system
DK57KB Forward-reverse potentiometer (2)
Short circuit
T/M
CALL E03 Electrical system
DK60KA Acceleration sensor
Disconnection
S/T
E01
Electrical system
DK60KB Acceleration sensor
Short circuit
S/T
E01
Electrical system
DKH1KA Pitch angle sensor
Disconnection
S/T
CALL E03 Electrical system
DKH1KB Pitch angle sensor
Short circuit
S/T
CALL E03 Electrical system
DKH1KX Pitch angle sensor
Out of input signal range
Reference manual
S/T
E01
Electrical system
Torque converter output speed senDLF1KA Disconnection sor
T/M
—
Electrical system
DLT3KA Transmission output speed sensor
Disconnection
T/M
E01
Electrical system
dLT3KA Transmission output speed sensor
Disconnection
T/M
E01
Electrical system
DLT3KB Transmission output speed sensor
Short circuit
T/M
E01
Electrical system
DV00KB Alarm buzzer
Short circuit
MON
E02
Electrical system
DW55KA Blade pitch back solenoid
Disconnection
T/M
CALL E03 Electrical system
DW55KB Blade pitch back solenoid
Short circuit
T/M
CALL E03 Electrical system
DW56KA Blade pitch dump solenoid
Disconnection
T/M
CALL E03 Electrical system
DW56KB Blade pitch dump solenoid
Short circuit
T/M
CALL E03 Electrical system
DW56KY Blade pitch dump solenoid
Hot short
T/M
DW57KA Left tilt limit solenoid
Disconnection
T/M
CALL E03 Electrical system Troubleshooting by failure code (Display E02 Electrical system of code), Part 7
DW57KB Left tilt limit solenoid
Short circuit
T/M
E02
Electrical system SEN01829-02
DW57KY Left tilt limit solenoid
Hot short
T/M
E02
Electrical system
DW58KA Right tilt limit solenoid
Disconnection
T/M
E02
Electrical system
DW58KB Right tilt limit solenoid
Short circuit
T/M
E02
Electrical system
DW58KY Right tilt limit solenoid
Hot short
T/M
E02
Electrical system
DW59KA Dual tilt selector solenoid
Disconnection
T/M
E01
Electrical system
DW59KB Dual tilt selector solenoid
Short circuit
T/M
E01
Electrical system
DW59KY Dual tilt selector solenoid
Hot short
T/M
E01
Electrical system
DW5AKA Blade pitch selector solenoid
Disconnection
T/M
E02
Electrical system
DW5AKB Blade pitch selector solenoid
Short circuit
T/M
E02
Electrical system
DW5AKY Blade pitch selector solenoid
Hot short
T/M
E02
Electrical system
Disconnection
T/M
CALL E03 Electrical system
Short circuit
T/M
CALL E03 Electrical system
Hot short
T/M
CALL E03 Electrical system
DW7BKA Fan reverse solenoid
Disconnection
T/M
E01
Electrical system
DW7BKB Fan reverse solenoid
Short circuit
T/M
E01
Electrical system
DW7BKY Fan reverse solenoid
Hot short
T/M
E01
Electrical system
Blade pitch dump solenoid (Superdozer specification) Blade pitch dump solenoid DW5DKB (Superdozer specification) Blade pitch dump solenoid DW5DKY (Superdozer specification) DW5DKA
D475A, D475ASD-5E0
9
SEN01821-04
Failure code
40 Troubleshooting
Troubled part
Trouble
Component in charge
Action code
Category of record
Reference manual
DWJ0KA Pump merge-divider solenoid
Disconnection
S/T
E02
Electrical system
DWJ0KB Pump merge-divider solenoid
Short circuit
S/T
E02
Electrical system
DWJ0KY Pump merge-divider solenoid
Hot short
S/T
E02
Electrical system
DWN3KA Sudden stop prevention solenoid
Disconnection
S/T
CALL E04 Electrical system
DWN3KB Sudden stop prevention solenoid
Short circuit
S/T
CALL E04 Electrical system
DWN3KY Sudden stop prevention solenoid
Hot short
S/T
DWN5KA Fan pump solenoid (1)
Disconnection
T/M
DWN5KB Fan pump solenoid (1)
Short circuit
T/M
DWN5KY Fan pump solenoid (1)
Hot short
T/M
E02
Electrical system
DWNCKA Fan pump solenoid (2)
Disconnection
T/M
E01
Electrical system
DWNCKB Fan pump solenoid (2)
Short circuit
T/M
E01
Electrical system
DWNCKY Fan pump solenoid (2)
Hot short
T/M
E02
Electrical system
DXE0KA LS set solenoid
Disconnection
T/M
E02
Electrical system
DXE0KB LS set solenoid
Short circuit
T/M
E02
Electrical system
DXE0KY LS set solenoid
Hot short
T/M
E02
Electrical system
DXH1KA Lockup solenoid
Disconnection
T/M
E01
Electrical system
DXH1KB Lockup solenoid
Short circuit
T/M
E01
Electrical system
DXH1KY Lockup solenoid
Hot short
T/M
CALL E03 Electrical system
DXH4KA 1st clutch ECMV
Disconnection
T/M
CALL E03 Electrical system
DXH4KB 1st clutch ECMV
Short circuit
T/M
CALL E03 Electrical system
DXH4KY 1st clutch ECMV
Hot short
T/M
CALL E03 Electrical system
DXH5KA 2nd clutch ECMV
Disconnection
T/M
CALL E03 Electrical system
DXH5KB 2nd clutch ECMV
Short circuit
T/M
DXH5KY 2nd clutch ECMV
Hot short
T/M
CALL E03 Electrical system Troubleshooting by failure code (Display CALL E03 Electrical system of code), Part 8
DXH6KA 3rd clutch ECMV
Disconnection
T/M
CALL E03 Electrical system SEN01830-01
DXH6KB 3rd clutch ECMV
Short circuit
T/M
CALL E03 Electrical system
DXH6KY 3rd clutch ECMV
Hot short
T/M
CALL E03 Electrical system
DXH7KA Reverse clutch ECMV
Disconnection
T/M
CALL E03 Electrical system
DXH7KB Reverse clutch ECMV
Short circuit
T/M
CALL E03 Electrical system
DXH7KY Reverse clutch ECMV
Hot short
T/M
CALL E03 Electrical system
DXH8KA Forward clutch ECMV
Disconnection
T/M
CALL E03 Electrical system
DXH8KB Forward clutch ECMV
Short circuit
T/M
CALL E03 Electrical system
DXH8KY Forward clutch ECMV
Hot short
T/M
CALL E03 Electrical system
DXH9KA Right steering clutch ECMV
Disconnection
S/T
CALL E03 Electrical system
DXH9KB Right steering clutch ECMV
Short circuit
S/T
CALL E03 Electrical system
10
TroubleshootCALL E04 Electrical system ing by failure code (Display of code), Part 7 E01 Electrical system SEN01829-02 E01 Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
Failure code
SEN01821-04
Troubled part
Trouble
Component in charge
Action code
Category of record
Reference manual
DXH9KY Right steering clutch ECMV
Hot short
S/T
CALL E04 Electrical system
DXHAKA Left steering clutch ECMV
Disconnection
S/T
CALL E03 Electrical system
DXHAKB Left steering clutch ECMV
Short circuit
S/T
CALL E03 Electrical system
DXHAKY Left steering clutch ECMV
Hot short
S/T
CALL E04 Electrical system
DXHBKA Right brake ECMV
Disconnection
S/T
CALL E04 Electrical system
DXHBKB Right brake ECMV
Short circuit
S/T
CALL E04 Electrical system
DXHBKY Right brake ECMV
Hot short
S/T
CALL E04 Electrical system
DXHCKA Left brake ECMV
Disconnection
S/T
CALL E04 Electrical system
DXHCKB Left brake ECMV
Short circuit
S/T
DXHCKY Left brake ECMV
Hot short
S/T
CALL E04 Electrical system Troubleshooting by failure code (Display CALL E04 Electrical system of code), Part 8
F@BBZL [n3 o 38] F@BYNS [n3 o 61] f@BYNS [n3 o 71] F@BZNS [n3 o 81] f@BZNS [n3 o 91] F@BYNR [n3 o 62] f@BYNR [n3 o 72] F@BZNR [n3 o 82] f@BZNR [n3 o 92]
Abnormality high pressure occurrence Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise
a a
a a
a
Engine blow-by pressure sensor Left front exhaust temperature sensor (1) Left rear exhaust temperature sensor (1) Right front exhaust temperature sensor (1) Right rear exhaust temperature sensor (1) Left front exhaust temperature sensor (2) Left rear exhaust temperature sensor (2) Right front exhaust temperature sensor (2) Right rear exhaust temperature sensor (2)
VHMS
—
—
VHMS
—
—
VHMS
—
—
VHMS
—
—
VHMS
—
—
VHMS
—
—
VHMS
—
—
VHMS
—
—
VHMS
—
—
SEN01830-01
The items in this table are arranged in the order of the failure codes. A component in charge is a controller or the monitor panel in charge of the system check. MON : Monitor panel ENG : Engine controller T/M : Transmission controller S/T : Steering controller VHMS : VHMS controller The failure codes having no numbers in the action code column are not displayed on the ordinary screen when abnormality related to them occurs. They are simply recorded in the fault history of the service menu (Electrical equipment system or mechanical equipment system). The history classification column shows in which system each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history. Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS controller, however, they are not recorded in the fault history. The 4-letter codes in [ ] among the VHMS codes are the failure codes displayed on the 7-segment LED of the VHMS controller (They are divided into 2 2-letter codes). Blinking and lighting of failure code q Blinking : The trouble has not been repaired. q Lighting : The trouble has been repaired.
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40 Troubleshooting
Fuse locations
1
Connection table of fuse boxes a This connection table shows the devices to which each power supply of the fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally.
Fuse box A [FS12] Fuse No.
Type of power supply
Fuse capacity (A)
1
Accessory power supply
20
2 3
20
VHMS controller
Unswitched power supply
20
Cab power supply
10
Converter operation support center
Accessory power supply
20
Converter operation support center
4 5
Destination of power VHMS controller
Fuse box B [FS22] Fuse No.
Type of power supply
Fuse capacity (A)
Destination of power
1
5
Backup alarm
2
20
Preheater power supply, pin puller, air suspension seat
3
20
Additional heater power supply
4
Accessory power supply
20
Working lamp
5
20
Rear lamp
Fuse box C [FS32] Fuse No.
Type of power supply
Fuse capacity (A)
Destination of power
1
5
ACC signal
2
20
Horn
3
20
Spare power supply (1)
4
Accessory power supply
20
Spare power supply (2)
5
20
Spare ACC signal
Cab fuse box D Fuse No.
Fuse capacity (A)
Destination of power
10
2
10
Rear wiper
3
10
Right wiper
4
10
Front wiper
5
10
Left wiper
6
12
Type of power supply
1
Accessory power supply
Radio, cigarette lighter, room lamp
20
Additional headlamp
7
20
Additional rear lamp, rotary lamp
8
—
Spare
9
—
Spare
10
10
Radio memory
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40 Troubleshooting
SEN01821-04
Fuse locations and fuse Nos. Inside of left console box in cab
Lower right part of cab overhead
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40 Troubleshooting
Circuit breaker No
Connector No.
1
F30
30
Cab unswitched power supply
2
F96
105
Main power supply
3
B105H2L
105
4
B105H1L
105
Electrical intake air heater main power supply Installed in battery box at (Right bank) left of operator's seat Electrical intake air heater main power supply
6
B7L
30
Engine controller unswitched power supply
7
B8L
30
Engine controller unswitched power supply
8
CB1
20
Steering controller
9
CB2
20
Monitor panel
10
CB3
20
Transmission controller
11
CB4
20
Air conditioner
12
CB5
20
Headlamp
13
CB6
20
Starting switch unswitched power supply
a
14
Capacity (A)
Circuit
Remarks
Installed in console box at left of operator's seat
Resetting operation of circuit breaker Turn the starting switch OFF and push in projected reset button (14). If the reset button returns immediately, carry out troubleshooting to repair failed part.
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40 Troubleshooting
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SEN01821-04
15
SEN01821-04
D475A, D475ASD-5E0 Bulldozer Form No. SEN01821-04
© 2011 KOMATSU All Rights Reserved Printed in Japan 11-11
16
SEN01822-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 Sequence of events in troubleshooting ........................................................................................................... 3 Checks before troubleshooting ....................................................................................................................... 4 Classification and procedures of troubleshooting ........................................................................................... 5 Contents of troubleshooting table ................................................................................................................... 8 Connection table for connector pin numbers ................................................................................................ 10 T- branch box and T- branch adapter table ................................................................................................... 46
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Points to remember when troubleshooting k k k k k k
40 Troubleshooting
1
Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant 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, an important point is of course to understand the structure and function. However, a shortcut 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.
4.
5.
6.
2
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 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) Are abnormal symptoms detected in the machine? 2) Make checks before starting day's work. 3) Make checks of other items. 4) Check other maintenance items which can be visually checked and are considered necessary. Confirming failure Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a problem of handling, operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. Measures to remove root cause of failure Even if the immediate failure is repaired, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.
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Sequence of events in troubleshooting
1
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3
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40 Troubleshooting
Checks before troubleshooting 1 Judgement Value
Action
1. Check fuel level
—
Add fuel
2. Check for impurities in fuel
—
Clean, drain
3. Check fuel filter
—
Replace
4. Check hydraulic oil level
—
Add oil
5. Check oil level in damper case
—
Add oil
6. Check power train oil level
—
Add oil
7. Check engine oil level (engine oil pan level)
—
Add oil
8. Check coolant level
—
Add water
9. Check dust indicator for clogging
—
Clean or replace
10.Check travel of brake pedal
—
Adjust
1. Check for abnormal noise, smell
—
Repair
2. Check for oil leakage
—
Repair
3. Carry out air bleeding
—
Bleed air
1. Check for looseness, corrosion of battery terminal, wiring
20 – 30 V
Tighten or replace
2. Check for looseness, corrosion of alternator terminal, wiring
—
Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring
—
Tighten or replace
4. Check battery voltage (engine stopped)
—
Replace
5. Check battery electrolyte level
—
Add or replace
6. Check for discolored, burnt, exposed wiring
—
Replace
7. Check for missing wiring clamps, hanging wire
—
Repair
8. Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals)
—
Disconnect connector and dry
9. Check for blown, corroded fuses
—
Replace
10.Check alternator voltage (engine running at 1/2 throttle or above)
After running for several minutes: 27.5 – 29.5 V
Replace
11. Check operating sound of battery relay (starting switch ON, OFF)
—
Replace
4
Lubricating oil, coolant Electrical equipment
Other check items
Hydraulic, mechanical equipment
Checks before starting
Item
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40 Troubleshooting
SEN01822-03
Classification and procedures of troubleshooting
1
Classification of troubleshooting Mode Display of code
Contents Troubleshooting by failure code (Display of code)
E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1.
Procedure for troubleshooting to be taken when action code is displayed on machine monitor: If an action code is displayed on the machine monitor, display the failure code in the failure code display mode (for the electrical system and the mechanical system) of the machine monitor (EMMS). Carry out troubleshooting in [Display of failure code] according to the displayed failure code. a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code “lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may not have been repaired (Some troubles can be detected by simply turning the starting switch ON). a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble corresponding to it has been repaired (For the method of reproducing the failure code, see the troubleshooting in [Display of code]).
2.
Procedure for troubleshooting to be taken when failure code is recorded: If an action code is not displayed on the machine monitor, check for a failure code in the failure code display mode (for the electrical system and the mechanical system) of the machine monitor (EMMS). If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code. a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code “lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may not have been repaired (Some troubles can be detected by simply turning the starting switch ON). a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble corresponding to it has been repaired (For the method of reproducing the failure code, see the troubleshooting in [Display of code]).
3.
Procedure of troubleshooting to be taken when action code is not displayed and failure code is not recorded: If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out troubleshooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
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40 Troubleshooting
Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.
Phenomena looking like trouble
Code display
E-mode
H-mode
S-mode
Phenomena related to action code or error code 1 Action codes are displayed on the monitor panel 2 Error codes are displayed in the error code display mode
Check the error code q
Phenomena related to engine 3 The engine does not start easily (It always takes time to start) 4
The engine does not crank
S-1 E-1
S-2a)
The engine cranks but exhaust smoke does 5 The engine does not not come out start Exhaust smoke comes out but the engine does 6 not start 7
S-2b) S-2c)
The engine speed does not rise sharply (Follow-up performance is low)
S-3
8 The engine stops during operation
S-4
9 Engine rotation is abnormal (The engine hunts)
S-5
10 Output is insufficient or power is low
S-6
11 Exhaust gas color is bad (Incomplete combustion)
S-7
12 Oil is consumed much or exhaust gas color is bad
S-8
13 Oil becomes dirty quickly
S-9
14 Fuel is consumed much
S-10
15 Coolant contains oil (or it blows back or reduces)
S-11
16 The engine oil pressure caution lamp lights up (Oil pressure lowers)
S-12
17 Oil level rises
S-13
18 Coolant temperature rises too high (Overheating)
S-14
19 Abnormal sound comes out
S-15
20 Vibration is excessive
S-16
21 The preheater does not operate
E-2 Phenomena related to power train
22 Power is low (Drawbar pull is low)
H-1
23 The machine does not travel (in the 2nd or 3rd gear speed)
H-2
24 The machine does not travel start in any gear speed
H-3
25 The machine can travel in only forward or reverse direction
H-4
Time lag is large in shifting the gear speed or changing the travel 26 direction
H-5
27 The machine cannot be steered
H-6
28 The machine can be steered in only 1 direction
H-7
29 The machine overruns when steered
H-8
30 The brake does not operate
H-9
31 The torque converter is not locked up
H-10
32 The torque converter oil is overheated
H-11
S-6
Phenomena related to work equipment 33 Speed of the whole work equipment is low
H-12
34 Any part of the equipment does not move
H-13
35 Blade lifting speed or power is low
H-14
36 Blade tilting speed or power is low
H-15
37 Ripper lifting speed or power is low
H-16
6
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40 Troubleshooting
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Troubleshooting No.
Phenomena looking like trouble
Code display
E-mode
H-mode
38 Ripper tilting speed or power is low
H-17
39 Hydraulic drift of blade lifting is large
H-18
40 Hydraulic drift of blade tilting is large
H-19
41 Hydraulic drift of ripper lifting is large
H-20
The ripper pin puller cylinder does not operate (if the giant ripper is 42 installed)
H-21
43 The blade does not pitch (if the dual tilt system installed)
H-22
44 Abnormal sound comes out from around hydraulic pump
H-23
S-mode
Phenomena related to monitor panel (Operator mode: Ordinary screen) 45
When the starting switch is turned ON, no items are displayed on monitor panel
E-4
46
When the starting switch is turned ON, all items are kept displayed on monitor panel
E-5
47 When the starting switch is turned ON, the basic check items flash
E-6
48 Caution items flash while the engine is running
E-7
49 Emergency warning items flash while the engine is started
E-8
50
When the preheater is operated, the preheater pilot lamp does not light up
E-9
51
When the dual tilt is selected, the dual/single tilt selector lamp does not light up (if the dual tilt system is equipped)
E-10
52
When the torque converter is locked up, the torque converter lockup pilot lamp does not light up
E-11
53 Display of the engine coolant temperature gauge is abnormal
E-12
54 Display of the power train oil temperature gauge is abnormal
E-13
55 Display of the hydraulic oil temperature gauge is abnormal
E-14
56 Display of the fuel level gauge is abnormal
E-15
57 Display of the gear speed and engine speed is abnormal
E-16
58 Display of the shift mode and service meter is abnormal
E-17
59 The switch module cannot be operated
E-18
60 The caution lamp does not flash or go off
E-19
61 The caution buzzer does not sound or go off
E-20
62 The auto shift-down system does not operate or reset
E-21
63 The auto pitch-back system does not operate or reset
E-22
64 The caution buzzer cannot be canceled
E-23
65 The operator mode does not operate
E-24
Phenomena related to monitor panel (Service mode: Special function screen) 66 The service mode does not operate
E-25 Other phenomena
67 The backup alarm does not sound
E-26
The night lamp of the panel, headlamp, working lamp, and rear lamp 68 do not light up
E-27
69 The air conditioner does not operate
E-28
70 The ORBCOMM terminal does not operate normally
E-29
71 Fan does not reverse
E-30
72 Gear cannot be shifted
E-31
73 Electric priming pump does not operate or does not stop
E-32
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40 Troubleshooting
Contents of troubleshooting table a
1
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Action code
Failure code
Display of panel
Display of panel
Failure Trouble that appears in the machine symptom
Failure content State where the monitor panel or controller detects the trouble Controller's action
Action to be taken to protect the system and equipment when the monitor panel or controller detects a trouble
Symptoms that Problem that appears as an abnormality in the main unit by the action taken by the monitor appears panel or controller (above) on machine General information
Information related to troubles 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
Possible causes and standard value in normal state
8
• Disconnection in wiring The connector connection is defective or wiring harness is disconnected. • Ground fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. • Hot short circuit A harness not connected to the power (24 V) circuit comes 2 into contact with the power (24 V) circuit. • Short circuit Causes by which a trouble A harness of an independent circuit abnormally comes into is assumed to be defected contact with one of another circuit. (The order number indicates a serial number, not (1) Method of indicating connector numbers and handling of Ta priority sequence.) adapter For troubleshooting, insert or connect T-adapter shown 3 below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the Tadapters in both the male and female. • When “male” or “female” is indicated for a connector number, disconnect connector, and insert the T-adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. 4 • 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.
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40 Troubleshooting
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Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting. • Connector No.: Indicates (model – number of pins) (color) • Arrow (io): Indicates the approximate mounting place on machine
D475A, D475ASD-5E0
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SEN01822-03
Connection table for connector pin numbers a
10
40 Troubleshooting
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
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40 Troubleshooting
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T- branch box and T- branch adapter table a
(Rev. 2009.03) 1
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q
799-601-3200 T-box (for MS)
37
q q
799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q q
799-601-3470 Case 799-601-2710 Adapter for MIC
5
MIC-5P
q q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
799-601-2950 Adapter for MIC
9
MIC-9P
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q q q
q
q q
q
q q q
q
q
q
799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO)
q
q
60
q
799-601-4360 Case 799-601-7010 Adapter for X (T-adapter)
1
q
q
799-601-7020 Adapter for X
2
X2P
q q q
q
799-601-7030 Adapter for X
3
X3P
q q q
q q
799-601-7040 Adapter for X
4
X4P
q q q
799-601-7050 Adapter for SWP
6
SW6P
q q q q q q
799-601-7060 Adapter for SWP
8
SW8P
799-601-7310 Adapter for SWP
12
SW12P q
q
q
q
M2P
q q q
q
M3P
q q q
q
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
799-601-7090 Adapter for M
2
799-601-7110 Adapter for M
3
46
q q
D475A, D475ASD-5E0
40 Troubleshooting
SEN01822-03
q
Out of kit
q
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
8
799-601-9200
799-601-7140 Adapter for S
799-601-9100
M8P
799-601-9000
8
799-601-8000 q
799-601-7340 Adapter for M
799-601-7500
q
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
6
799-601-7000
4
799-601-7130 Adapter for M
799-601-2800
799-601-7120 Adapter for M
Part name
799-601-2700
Identification symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
q
799-601-7190 Adapter for AMP040
12
A12P
q
q q q q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
q q
799-601-7240 Case
q
799-601-7270 Case 799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
799-601-9010 Adapter for DTM
2
DTM2
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
D475A, D475ASD-5E0
24
q q q q
q q
q
q q
q
47
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN01822-03
q
799-601-9330 Case
q
799-601-9340 Case 799-601-9350 Adapter for DRC
40
DRC-40
q
799-601-9360 Adapter for DRC
24
DRC-24
q
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor
3
A3
q q
2
P
q q
799-601-9440* Socket for engine (CRI-T2)
3
1,2,3
q
795-799-5520* Socket for engine (HPI-T2)
2
S
q
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
q q
2
A
q q
795-799-5460 Cable for engine (HPI-T2)
3
—
q
795-799-5470 Cable for engine (HPI-T2)
3
—
q
795-799-5480 Cable for engine (HPI-T2)
3
—
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
3
FCIN
q q
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure
3
1,2,3L
q q
4
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-9430*
795-799-5540*
799-601-4140
799-601-4230*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
Adapter for engine (CRI-T3) Atomosphere pressure
Socket for engine (CRI-T3) Air intake pressure/temperature
q
q
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3,G
q q
Socket for engine (CRI-T3) 799-601-4340* Pump actuator
2
2,PA
q q
4
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
4
DTP4
799-601-4380*
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
q q q
799-601-4211 Adapter for controller (ENG)
50
DRC50
q
799-601-4220 Adapter for controller (ENG)
60
DRC60
q
799-601-4390* Socket for controller (95 ENG)
60
—
q
799-601-4280* Box for controller (PUMP)
121
—
q
799-601-9720 Adapter for controller (HST)
16
HST16A
q
799-601-9710 Adapter for controller (HST)
16
HST16B
q
799-601-9730 Adapter for controller (HST)
26
HST26A
q
2, 3, 4,
—
q
799-601-9890
Multi-adapter for DT2 – 4 and DTM2
“*” Shows not T-adapter but socket.
48
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01822-03
49
SEN01822-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01822-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
50
SEN01823-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 1 Failure code [1380MW] Lockup clutch: Clutch slip ......................................................................................... 3 Failure code [1500L0] Transmission clutch: Dual engagement ...................................................................... 4 Failure code [15E0MW] Transmission clutch: Clutch slip ............................................................................... 5 Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON ..................... 6 Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF .................... 7 Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ........................................ 8 Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF .................... 9 Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON ........................... 10 Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF ............................11 Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON .......................... 12 Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF.......................... 13 Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON........................... 14 Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF .......................... 15 Failure code [1800MW] Power train clutch: Slip ........................................................................................... 16 Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON......................... 17 Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF ........................ 18
D475A, D475ASD-5E0
1
SEN01823-03
40 Troubleshooting
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON ........................... 19 Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF........................... 20 Failure code [2300NR] Brake thermal load: Abnormal heating..................................................................... 21 Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON ......................... 22 Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF......................... 23 Failure code [2301NR] Right steering brake thermal load: Abnormal heating .............................................. 24 Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON............................ 25 Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF ........................... 26 Failure code [2302NR] Left steering brake thermal load: Abnormal heating ................................................ 27 Failure code [6001ZK] Failure code for design ............................................................................................. 28 Failure code [A000NS] Engine: Overheat ..................................................................................................... 29 Failure code [AA10NX] Air cleaner: Clogging ............................................................................................... 30 Failure code [AB00MA] Battery charge abnormality: Malfunction................................................................. 31 Failure code [B@BAZG] Engine oil: Oil pressure too low ............................................................................. 32 Failure code [B@BAZK] Engine oil: Oil level reduction................................................................................. 33 Failure code [B@BCNS] Engine coolant: Overheat...................................................................................... 34 Failure code [B@BCZK] Engine coolant: Level too low ................................................................................ 35 Failure code [B@BEBF] Fuel: Water in fuel .................................................................................................. 36 Failure code [B@BFZK] Fuel level: Reduction.............................................................................................. 37 Failure code [B@CENS] Power train oil: Overheat....................................................................................... 38 Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure ........................................................... 39 Failure code [B@CHZK] Power train oil: Oil level reduction ......................................................................... 39 Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction .............................................. 40 Failure code [B@HANS] Hydraulic oil: Overheat .......................................................................................... 40 Failure code [B@HAZK] Hydraulic oil: Level reduction................................................................................. 41
2
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [1380MW] Lockup clutch: Clutch slip Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Lockup clutch: Clutch slip failure (Transmission controller system) 1380MW • When torque converter is locked up, sensed engine speed does not match with sensed torque converter output speed. • None in particular. • None in particular. • Engine speed and torque converter speed can be checked in real-time monitoring mode. (Code 01002: Engine speed (Left bank), Code 01004: Engine speed (Right bank)) (Code 31200: Transmission input speed (Torque converter output speed)) • Method of reproducing failure code: Start engine, turn lockup clutch ON and drive machine.
1 Possible causes and the standard values when normal
2 3 4
Cause Lockup clutch slip (When system is normal) Defective engine speed sensor system Defective torque converter speed sensor Defective transmission controller
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting Check for cause of lockup clutch slip and damage of machine. If failure code [CA689], [CB689] or [CA778], [CB778] is displayed, carry out troubleshooting for it. If failure code [DLF1KA] is displayed, carry out troubleshooting for it. Since trouble is in system, troubleshooting cannot be carried out.
3
SEN01823-03
40 Troubleshooting
Failure code [1500L0] Transmission clutch: Dual engagement Action code
Failure code
CALL E03
1500L0
Symptom Transmission clutch: Dual engagement of failure (Transmission controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the same time. (Gear speed is limited.) (1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB] • Of the failure codes related to the transmission clutch, the following codes were displayed at the same time. (Machine can not travel.) (2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB] Failure content (3) Either of [DXH6KA] or [DXH6KB] and (1) above (4) [15SALH] and [15SBLH] (5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY] (6) [15SELH], [15SFLH], and [15SGLH] (7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY] (8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY] (9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY] Controller's action
• Flashes warning lamp and turns on alarm buzzer. • Limits operation of engine and transmission.
Symptoms that • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, traveling is limited to specific gear speeds. appear on machine • Machine cannot travel. General information
• Duplication of failure code: Engine start + travel
Cause Possible causes and the standard values when normal
4
Standard values when normal and remarks for troubleshooting
Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes. [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH] [DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA, [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB], [DXH6KY], [DXH7KA, [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [15E0MW] Transmission clutch: Clutch slip Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Transmission clutch: Clutch slip failure (Transmission controller system) 15E0MW • Sensed torque converter output speed does not match with sensed transmission output speed. • None in particular. • None in particular. • Torque converter speed and transmission speed can be checked in real-time monitoring mode. (Code 31200: Transmission input speed (Torque converter output speed)) (Code 31400: Transmission output speed) • Method of reproducing failure code: Start engine and drive machine.
1 Possible causes and the standard values when normal
2 3 4
Cause Transmission clutch slip (When system is normal) Defective torque converter speed sensor system Defective transmission speed sensor Defective transmission controller
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting Check for cause of transmission clutch slip and damage of machine. If failure code [DLF1KA] is displayed, carry out troubleshooting for it. If failure code [DLT3KA], [dLT3KA] or [DLT3KB] is displayed, carry out troubleshooting for it. Since trouble is in system, troubleshooting cannot be carried out.
5
SEN01823-03
40 Troubleshooting
Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
Failure code Symptom of Forward clutch oil pressure: Command current OFF and fill signal failure ON (Transmission controller system) 15SAL1 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. Becomes N (neutral) 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 failure code: Engine start + Neutral running Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective forward clutch fill FFT2 (male) PCCS lever Resistance 1 switch (Internal short) N Min. 1 Mz Between (1) – chassis ground F (Forward) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. 2 ing (Contact with ground Wiring harness between TMC1 (female) (5) – Resiscircuit) Min. 1 Mz FFT2 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller N 5 – 11 V Between (5) – chassis ground F (Forward) Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
6
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Forward clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SALH 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. Becomes 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 failure code: Engine start + Forward running Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a 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. 1 Mz Between (1) – chassis ground F (Forward) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between TMC1 (female) (5) – ResisMax. 1 z in connector) FFT2 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller N 5 – 11 V Between (5) – chassis ground F (Forward) Max. 1 V 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
D475A, D475ASD-5E0
7
SEN01823-03
40 Troubleshooting
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
Failure code Symptom of Reverse clutch: Command current OFF and fill signal ON failure (Transmission controller system) 15SBL1 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. Becomes 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 failure code: Engine start + Neutral running Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective reverse clutch fill FRT2 (male) PCCS lever Resistance 1 switch (Internal short) N Min. 1 Mz Between (1) – chassis ground R (Reverse) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. 2 ing (Contact with ground Wiring harness between TMC1 (female) (24) Resiscircuit) Min. 1 Mz – FRT2 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller N 5 – 11 V Between (24) – chassis ground R (Reverse) Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission reverse clutch ECMV
8
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Reverse clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SBLH The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Becomes 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 failure code: Engine start + Reverse running Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a 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. 1 Mz Between (1) – chassis ground R (Reverse) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between TMC1 (female) (24) ResisMax. 1 z in connector) – FRT2 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller N 5 – 11 V Between (24) – chassis ground R (Reverse) Max. 1 V 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
D475A, D475ASD-5E0
9
SEN01823-03
40 Troubleshooting
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 1st clutch oil pressure: Command current OFF and fill signal ON failure (Transmission controller system) 15SEL1 • 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 failure code: Engine start + F1 or R1 o Neutral running Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a 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. 1 Mz Between (1) – chassis ground F1 · R1 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between TMC1 (female) (23) Resiscircuit) Min. 1 Mz – F1T8 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller Other than F1/R1 5 – 11 V Between (23) – chassis ground F1 · R1 Max. 1 V 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
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 1st clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SELH • 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. • 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 failure code: Engine start + F1 or R1 running Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 1st clutch fill F1T8 (male) PCCS lever Resistance 1 switch (Internal short) Other than F1/R1 Min. 1 Mz Between (1) – chassis ground F1 · R1 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between TMC1 (female) (23) ResisMax. 1 z in connector) – F1T8 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller Other than F1/R1 5 – 11 V Between (23) – chassis ground F1 · R1 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 1st clutch ECMV
D475A, D475ASD-5E0
11
SEN01823-03
40 Troubleshooting
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 2nd clutch oil pressure: Command current OFF and fill signal ON failure (Transmission controller system) 15SFL1 • The fill switch signal is not set off at stop of output of the transmission 2nd 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 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 failure code: Engine start + F2 or R2 running o Neutral running Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a 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. 1 Mz Between (1) – chassis ground F2 · R2 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between TMC1 (female) (17) Resiscircuit) Min. 1 Mz – F2T6 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller Other than F2/R2 5 – 11 V Between (17) – chassis ground F2 · R2 Max. 1 V 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
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 2nd clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SFLH • The fill switch signal is not set on 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 failure code: Engine start + F2 or R2 running Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance 1 switch (Internal short) Other than F2/R2 Min. 1 Mz Between (1) – chassis ground F2 · R2 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between TMC1 (female) (17) ResisMax. 1 z in connector) – F2T6 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller Other than F2/R2 5 – 11 V Between (17) – chassis ground F2 · R2 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
D475A, D475ASD-5E0
13
SEN01823-03
40 Troubleshooting
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 3rd clutch oil pressure: Command current OFF and fill signal ON failure (Transmission controller system) 15SGL1 • 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. • 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 failure code: Engine start + F3 or R3 running o Neutral running Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a 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. 1 Mz Between (1) – chassis ground F3 · R3 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between TMC1 (female) (11) Resiscircuit) Min. 1 Mz – F3T4 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller Other than F3/R3 5 – 11 V Between (11) – chassis ground F3 · R3 Max. 1 V 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
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 3rd clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SGLH • 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 failure code: Engine start + F3 or R3 running Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance 1 switch (Internal short) Other than F3/R3 Min. 1 Mz Between (1) – chassis ground F3 · R3 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between TMC1 (female) (11) ResisMax. 1 z in connector) – F3T4 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller Other than F3/R3 5 – 11 V Between (11) – chassis ground F3 · R3 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
D475A, D475ASD-5E0
15
SEN01823-03
40 Troubleshooting
Failure code [1800MW] Power train clutch: Slip Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Power train clutch slip failure (Transmission controller system) 1800MW • At lock-up of the torque converter, the engine rotation is different from the torque converter rotation by 500 rpm or more. • None in particular. • None in particular. • The engine rotation and the torque converter rotation can be checked in monitoring mode. (Code 01002: Engine rotation L, code 01004: Number of engine rotation R, code 31200: Transmission input rotation (torque converter rotation) • Method of reproducing failure code: Engine start + Lock-up switch ON + Actual running
1 Possible causes and the standard values when normal
2 3 4
16
Cause Power train clutch slip (When the system is normal) Defective engine rotation sensor Defective torque converter rotation sensor system Defective transmission controller
Standard values when normal and remarks for troubleshooting a Clutch slip was detected; check the cause and machine damage state, then repair the machine. Check whether failure codes [CA689], [CB689], [CA778] and [CB778] are displayed. If they are displayed, carry out the troubleshooting. Check whether failure codes [DLT3KA], [DLT3KB] are displayed. If they are displayed, carry out the troubleshooting. Since this is an internal defect, it cannot be diagnosed.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Right clutch oil pressure: Command current OFF and fill signal OFF failure (Steering controller system) 2201L1 • The fill switch signal is not set off at output stop of 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 failure code: Engine start Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective right steering FRC8 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) – (Internal short) chassis ground Right steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN3 (female) (39) Resiscircuit) Min. 1 Mz – FRC8 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective steering controlSTCN3 PCCS lever Voltage ler N (Neutral) 5 – 11 V Between (39) – chassis ground Right steering Max. 1 V 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, D475ASD-5E0
17
SEN01823-03
40 Troubleshooting
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Right clutch oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2201LH • 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 failure code: Engine start + Parking brake lever release + PCCS lever operated (right steering) Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective right steering FRC8 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) – (Internal short) chassis ground Right steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN3 (female) ResisMax. 1 z in connector) (39) – FRC8 (female) (1) tance a Prepare with starting switch OFF. Engine start for troubleshooting. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 5 – 11 V Between (39) – chassis ground Right steering Max. 1 V 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
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left clutch oil pressure: Command current OFF and fill signal ON failure (Steering controller system) 2202L1 • 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 failure code: Engine start Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective left steering FLC6 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) – (Internal short) chassis ground Left steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN3 (female) (29) Resiscircuit) Min. 1 Mz – FLC6 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start for troubleshooting. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 5 – 11 V Between (29) – chassis ground Left steering Max. 1 V 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 clutch ECMV
D475A, D475ASD-5E0
19
SEN01823-03
40 Troubleshooting
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left clutch oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2202LH • 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 failure code: Engine start + Parking brake lever release + PCCS lever operated (left steering) Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective left steering FLC6 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) – (Internal short) chassis ground Left steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN3 (female) (29) ResisMax. 1 z in connector) – FLC6 (female) (1) tance a Prepare with starting switch OFF. Engine start for troubleshooting. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 5 – 11 V Between (29) – chassis ground Left steering Max. 1 V 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 clutch ECMV
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [2300NR] Brake thermal load: Abnormal heating Action code — Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Brake thermal load: abnormal heating failure (Steering controller system) 2300NR • The steering controller added together the continuous operating times of the pitch angle sensor, travel speed, and brake potentiometer, and then judged that the brake was heating abnormally. • None in particular.
Cause Standard values when normal and remarks for troubleshooting 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed) Defective steering control2 When the operation in cause 1 is not performed ler
D475A, D475ASD-5E0
21
SEN01823-03
40 Troubleshooting
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Right brake oil pressure: Command current OFF and fill signal ON failure (Steering controller system) 2301L1 • 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. • 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 failure code: Engine start Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective right steering FR84 (male) PCCS lever Resistance brake fill switch (Internal short) N (Neutral) Max. 1 z Between (1) – chassis ground Right steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN2 (female) (25) Resiscircuit) Min. 1 Mz – FR84 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1V Between (25) – chassis ground Right steering 5 – 11 V 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
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Right brake oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2301LH • 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. • 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 failure code: Engine start + Parking bake lever release Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective right steering FR84 (male) PCCS lever Resistance clutch fill switch (Internal short) N (Neutral) Max. 1 z Between (1) – chassis ground Right steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN2 (female) (25) ResisMax. 1 in connector) – FR84 (female) (1) tance Mz a Prepare with starting switch OFF. Engine start + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1V Between (25) – chassis ground Right steering 5 – 11 V 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, D475ASD-5E0
23
SEN01823-03
40 Troubleshooting
Failure code [2301NR] Right steering brake thermal load: Abnormal heating Action code — Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
24
Failure code Symptom of Right steering brake thermal load: Abnormal heating failure (Steering controller system) 2301NR • The steering controller added together the continuous operating times of the pitch angle sensor, travel speed and right steering potentiometer, and then judged that the right steering brake was heating abnormally (Machine traveled down with brake pedal pressed). • None in particular.
Cause Standard values when normal and remarks for troubleshooting Improper steering during downslope travel (Machine traveled down and was steered to right con1 tinuously) Defective steering control2 When the operation in cause 1 is not performed ler
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left brake oil pressure: Command current OFF and fill signal ON failure (Steering controller system) 2302L1 • 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. • 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 failure code: Engine start Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective left steering FL82 (male) PCCS lever Resistance brake fill switch (Internal short) N (Neutral) Max. 1 z Between (1) – chassis ground Right steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN2 (female) (35) Resiscircuit) Min. 1 Mz – FL82 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1 V Between (35) – chassis ground Left steering 5 – 11 V 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, D475ASD-5E0
25
SEN01823-03
40 Troubleshooting
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left brake oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2302LH • The fill switch signal is not set on 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. • 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 failure code: Engine start + Parking brake lever release Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective left steering FL82 (male) PCCS lever Resistance brake fill switch (Internal short) N (Neutral) Max. 1 z Between (1) – chassis ground Left steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN2 (female) (35) ResisMax. 1 z in connector) – FL82 (female) (1) tance a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1 V Between (35) – chassis ground Left steering 5 – 11 V 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
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [2302NR] Left steering brake thermal load: Abnormal heating Action code — Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Left steering brake thermal load: Abnormal heating failure (Steering controller system) 2302NR • The steering controller added together the continuous operating times of the pitch angle sensor, travel speed and left steering potentiometer, and then judged that the left steering brake was heating abnormally (The machine traveled down with the foot brake pressed). • None in particular.
Cause Standard values when normal and remarks for troubleshooting Improper steering during downslope travel (Machine traveled down and was steered to left con1 tinuously) Defective steering control2 When the operation in cause 1 is not performed ler
D475A, D475ASD-5E0
27
SEN01823-03
40 Troubleshooting
Failure code [6001ZK] Failure code for design Action code — Failure content Controller's action Symptoms that appear on machine General information
28
Failure code 6001ZK
Symptom of Failure code for design failure
• None in particular. • None in particular. • Since this failure code is for design, it does not occur actually. It appears in mechanical system error code list, however.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [A000NS] Engine: Overheat Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine: Overheat failure (Mechanical system) A000NS • While engine was running, engine overheat lamp blinked. • None in particular. • None in particular. • Since lighting of above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table [B@BCNS], however.
D475A, D475ASD-5E0
29
SEN01823-03
40 Troubleshooting
Failure code [AA10NX] Air cleaner: Clogging Action code Failure code Symptom of Air cleaner: Clogging failure (Mechanical system) — AA10NX Failure content • Clogging of air cleaner was detected while engine is running. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that appear on • If machine is used as it is, engine output may lower or engine may be damaged. machine General • Air cleaner clogging caution symbol on monitor panel blinks and this failure code is recorded. information Cause Clogged air cleaner 1 (When system is normal) Defective air cleaner clog2 ging sensor (Internal disconnection)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 3 wiring or defective contact in connector)
4 Defective machine monitor
Standard values when normal and remarks for troubleshooting a Check air cleaner. If it is clogged, clean or replace it. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. AF1, AF2 (male) Air cleaner Resistance When normal Max. 1z Between (1) – (2) When clogged Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S03 (female) (13) – ResisMax. 1z AF1 (female) (1) tance Wiring harness between AF1 (female) (2) – ResisMax. 1z AF2 (female) (1) tance Wiring harness between AF2 (female) (2) – ResisMax. 1z chassis ground tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. S03 Air cleaner Voltage When normal Max. 1V Between (13) – chassis ground When clogged Min. 7 V
Electric circuit diagram related to air cleaner clogging
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [AB00MA] Battery charge abnormality: Malfunction Action code — Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Battery charge abnormality: Malfunction failure (Mechanical system) AB00MA • Charge level circuit voltage lowered while engine is running. • Blinks warning lamp. • If machine is used as it is, battery may be discharged. • Charge level caution symbol on machine monitor blinks and this failure code is recorded. • Method of reproducing failure code: Start engine + Turn fuel control dial to full. Cause Battery charge defect 1 (When system is normal) Defective charge level 2 caution lamp system
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting Phenomenon causing battery charge defect may be occurring or may have occurred. Check cause and damage condition and repair. Carry out troubleshooting for "Battery charge level caution lamp blinks while engine is running" in E-mode.
31
SEN01823-03
40 Troubleshooting
Failure code [B@BAZG] Engine oil: Oil pressure too low Action code
Failure code
—
B@BAZG
Failure content Controller's action
Symptom of Engine oil: Oil pressure too low failure (Mechanical system)
• The engine oil pressure abnormality takes place during the engine running. • Flashes warning lamp and turns on alarm buzzer. (Function of machine monitor) • Limits operation of engine.
Symptoms that appear on machine
• If the machine is operated in such a condition, the engine output may decrease and the engine may be damaged. • After warning, engine speed is limited to medium (half).
General information
• The engine oil pressure caution symbol on the machine monitor flashes and this failure code is recorded. • Duplication of failure code: Start the engine.
Possible causes and the standard values when normal
Cause
Standard values when normal and remarks for troubleshooting
Reduction of engine oil 1 pressure (When system is normal)
It can be suspected that the problem causing the detection of engine oil pressure reduction is currently occurring or occurred in the past. Investigate the cause and damage condition, and correct it.
Defective engine oil pressure caution lamp circuit
If cause 1 is not detected, engine oil sensor system may be detective. Carry out troubleshooting for the failure codes [CA135] and [CA141].
2
32
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40 Troubleshooting
SEN01823-03
Failure code [B@BAZK] Engine oil: Oil level reduction Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Engine oil: Oil level reduction failure (Mechanical system) B@BAZK • During rotation of engine, engine oil level caution lamp flashes. • Flashes warning lamp and turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is, engine may be damaged. • The engine oil level caution symbol on the machine monitor flashes and this failure code is recorded. • Method of reproducing failure code: Start engine. Cause Standard values when normal and remarks for troubleshooting Engine oil level reduction It is suspected that problem causing engine oil level reduction is 1 (When system is in normal occurring at present or occurred in past. Investigate cause and damstate) age condition, and correct it. Carry out troubleshooting of engine oil level caution lamp system in Defective engine oil level 2 accordance with “During running of engine, emergency caution item caution lamp system flashes” in E mode.
D475A, D475ASD-5E0
33
SEN01823-03
40 Troubleshooting
Failure code [B@BCNS] Engine coolant: Overheat Action code
Failure code
—
B@BCNS
Failure content Controller's action Symptoms that appear on machine General information
Symptom of Engine coolant: Overheat failure (Mechanical system)
• Engine coolant overheats while engine is running. • Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel) • Limits output and continues operation. • Engine output lowers. • If the machine is operated in such a condition, engine may be damaged. • The engine coolant temperature caution symbol on the monitor panel flashes and this failure code is recorded. • Duplication of failure code: Start the engine. Cause
Possible causes and the standard values when normal
34
1 Engine coolant overheat
2
Standard values when normal and remarks for troubleshooting Engine coolant may be overheating. Check it directly and remove cause if it is overheating.
If cause 1 is not detected, coolant temperature sensor system may Defective coolant be detective. Carry out troubleshooting for the failure codes [CA144] temperature sensor system and [CA145].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [B@BCZK] Engine coolant: Level too low Action code
Failure code
—
B@BCZK
Failure content Controller's action Symptoms that appear on machine General information
Symptom of Engine coolant: Level too low failure (Mechanical system)
• Engine coolant level decreases when starting switch is turned ON. • Flashes warning lamp and turns on alarm buzzer.
• If the machine is operated in such a condition, engine may be damaged. • The engine coolant level caution symbol on the monitor panel flashes and this failure code is recorded. • Duplication of failure code: turn ON the starting switch. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting
Engine coolant level is too It can be suspected that the problem causing the detection of engine 1 low. coolant level too low is currently occurring or occurred in the past. (When system is normal) Investigate the cause and damage condition, and correct it. 2
Defective radiator coolant Since the float may be stuck by clogging of dirt, check and clean the level sensor coolant level sensor directly.
3
Defective engine coolant level caution lamp circuit
D475A, D475ASD-5E0
Carry out troubleshooting in accordance with “When starting switch is turned ON, engine coolant level caution flashes” in E mode.
35
SEN01823-03
40 Troubleshooting
Failure code [B@BEBF] Fuel: Water in fuel Action code Failure code Symptom of Fuel: Water in fuel failure (Mechanical system) — B@BEBF Failure content • There was water in fuel and water separator lamp lighted up. Controller's • None in particular. action Symptoms that appear on • None in particular. machine General • Since above caution lamp is not set for this machine, above failure code is not displayed. information Above failure code is listed in the mechanical system failure code table, however.
36
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40 Troubleshooting
SEN01823-03
Failure code [B@BFZK] Fuel level: Reduction Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Fuel level: Reduction failure (Mechanical system) B@BFZK • Fuel level reduced and fuel level caution lamp lighted up. • None in particular. • None in particular. • Since above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table, however.
D475A, D475ASD-5E0
37
SEN01823-03
40 Troubleshooting
Failure code [B@CENS] Power train oil: Overheat Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
38
Failure code Symptom of Power train oil: Overheat failure (Mechanical system) B@CENS • During rotation of engine, power train oil temperature caution lamp flashes. • Flashes warning lamp and turns on caution buzzer. (Function of machine monitor) • If machine is operated as it is, power train may be damaged. • Method of reproducing failure code: Start engine. Cause Power train oil temperature 1 overheat (When system is in normal state) Defective power train oil 2 temperature overheat caution lamp system
Standard values when normal and remarks for 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 “During running of engine, emergency caution item flashes” in E mode.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of HSS charge oil pressure: Low oil pressure failure (Mechanical system) B@CHZG • HSS charge oil pressure is reduced and HSS charge oil pressure caution lamp lights up. • None in particular. • None in particular. • Since above caution lamp is not set on this machine, above failure code not occur. Above failure code is listed up in mechanical system failure code table, however.
Failure code [B@CHZK] Power train oil: Oil level reduction Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Power train oil: Oil level reduction failure (Mechanical system) B@CHZK • While engine was running, power train oil caution lamp blinked. • None in particular. • None in particular. • Since above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table, however.
D475A, D475ASD-5E0
39
SEN01823-03
40 Troubleshooting
Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Battery electrolyte level: Electrolyte level reduction failure (Mechanical system) B@GAZK • Battery electrolyte level reducted and battery electrolyte level reduction lamp lighted. • None in particular. • None in particular. • Since above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table, however.
Failure code [B@HANS] Hydraulic oil: Overheat Action code Failure code Symptom of Hydraulic oil: Overheat failure (Mechanical system) — B@HANS Failure content • During rotation of engine, hydraulic oil caution lamp flashes. Controller's • Flashes warning lamp and turns on caution buzzer. (Function of machine monitor)) action Symptoms that appear on • If machine is operated as it is, work equipment circuit units may be damaged. machine • The hydraulic oil temperature caution symbol of the machine monitor flashes and this failure code General is recorded. information • Method of reproducing failure code: Start engine.
Possible causes and the standard values when normal
40
Cause Hydraulic oil temperature 1 overheat (When system is in normal state) Defective hydraulic oil tem2 perature caution lamp system
Standard values when normal and remarks for 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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-03
Failure code [B@HAZK] Hydraulic oil: Level reduction Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Hydraulic oil: Level reduction failure (Mechanical system) B@HAZK • During rotation of engine, hydraulic oil caution lamp flashes. • Flashes warning lamp and 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 failure code: During rotation of engine, hydraulic oil temperature caution lamp on machine monitor blinks and this failure code is recorded. Cause Hydraulic oil level reduc1 tion (When system is in normal state)
Standard values when normal and remarks for 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 Defective hydraulic oil 2 accordance with “During running of engine, emergency caution item level caution lamp system flashes” in E mode.
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SEN01823-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01823-03
© 2015 KOMATSU All Rights Reserved Printed in Japan 06-15 (02)
42
SEN01824-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 2 Failure code [CA111] Engine controller (Left bank): Internal abnormality ....................................................... 4 Failure code [CB111] Engine controller (Right bank): Internal abnormality..................................................... 6 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal ................................................................................................................ 8 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal ................................................................................................................ 9 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 10 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 12 Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection ........................................................................................................................... 13 Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 15 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 16
D475A, D475ASD-5E0
1
SEN01824-01
40 Troubleshooting
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 18 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 20 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 22 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 24 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 26 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection ............................................................................................................................ 28 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection ............................................................................................................................ 29 Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection ........................................................................................................................... 30 Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection ............................................................................................................................ 31 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 32 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 34 Failure code [CA227] Sensor power source 2 too high (At left bank): Excessively high voltage detected ......................................................................................................... 36 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection ........................................................................................................................... 38 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ................................. 40 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected .......................................................................................................... 42 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected .......................................................................................................... 44 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected ......................................................................................................... 46 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected ......................................................................................................... 48 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection ............................................................................................................................ 49 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection ............................................................................................................................ 49 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit ............................................................... 50 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ............................................................. 51 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ........................................................ 52 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection...................................................... 53 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ............................................................... 54 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ............................................................. 55 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ........................................................ 56 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection...................................................... 57
2
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40 Troubleshooting
D475A, D475ASD-5E0
SEN01824-01
3
SEN01824-01
40 Troubleshooting
Failure code [CA111] Engine controller (Left bank): Internal abnormality Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine controller (Left bank): Internal abnormality failure (Engine controller system) CA111 • Controller has abnormality in it. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause 1 Defective circuit breaker
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Ground fault in wiring 3 harness (Contact with GND circuit)
4
4
Defective engine controller
Standard values when normal and remarks for troubleshooting Circuit breaker may be defective. Check it directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW L (female) (3), ResisMax. 1 z (4) – battery (+) tance Wiring harness between PW L (female) (1), ResisMax. 1 z (2) – ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz PW L (female) (3), (4) – battery (+) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW L Voltage Between (3), (4) – (1), (2) 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to engine controller power supply
D475A, D475ASD-5E0
5
SEN01824-01
40 Troubleshooting
Failure code [CB111] Engine controller (Right bank): Internal abnormality Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine controller (Right bank): Internal abnormality failure (Engine controller system) CB111 • Controller has abnormality in it. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause 1 Defective circuit breaker
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Ground fault in wiring 3 harness (Contact with GND circuit)
4
6
Defective engine controller
Standard values when normal and remarks for troubleshooting Circuit breaker may be defective. Check it directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW R (female) (3), ResisMax. 1 z (4) – battery (+) tance Wiring harness between PW R (female) (1), ResisMax. 1 z (2) – ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz PW R (female) (3), (4) – battery (+) and tance ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW R Voltage Between (3), (4) – (1), (2) 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to engine controller power supply
D475A, D475ASD-5E0
7
SEN01824-01
40 Troubleshooting
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At left bank): Abnorfailure mal speed sensor signal (Engine controller system) CA115 • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit. • Flashes warning lamp and turns on alarm buzzer. • Engine does not start (during engine stop). • Engine stops (during engine running).
Cause Defective Ne speed 1 sensor circuit Defective Bkup speed 2 sensor circuit Possible causes and the standard values when normal
8
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA689]. Carry out troubleshooting of [CA778].
Since a mounting section of Ne speed sensor can be suspected to be Defective Ne speed defective, directly check the mounting section. (Defective installation sensor mounting section of sensor itself, internal defect of flywheel, etc.) Since a mounting section of Bkup speed sensor can be suspected to Bkup speed sensor 4 be defective, directly check the mounting section. (Defective installamounting section tion of sensor itself, internal defect of supply pump, etc.) Defective connection of The defective (wrong) connections of Ne speed sensor and Bkup 5 sensor speed sensor can be suspected. Directly check them. (wrong connection) Engine controller can be suspected to be defective if no problem is Defective engine 6 found in causes 1 – 5 (since this is an internal defect, it cannot be controller diagnosed). 3
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At right bank): Abnorfailure mal speed sensor signal (Engine controller system) CB115 • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit. • Flashes warning lamp and turns on alarm buzzer. • Engine does not start (during engine stop). • Engine stops (during engine running).
Cause Defective Ne speed 1 sensor circuit Defective Bkup speed 2 sensor circuit Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB689]. Carry out troubleshooting of [CB778].
Since a mounting section of Ne speed sensor can be suspected to be Defective Ne speed defective, directly check the mounting section. (Defective installation sensor mounting section of sensor itself, internal defect of flywheel, etc.) Since a mounting section of Bkup speed sensor can be suspected to Bkup speed sensor 4 be defective, directly check the mounting section. (Defective installamounting section tion of sensor itself, internal defect of supply pump, etc.) Defective connection of The defective (wrong) connections of Ne speed sensor and Bkup 5 sensor speed sensor can be suspected. Directly check them. (wrong connection) Engine controller can be suspected to be defective if no problem is Defective engine 6 found in causes 1 – 5 (since this is an internal defect, it cannot be controller diagnosed). 3
D475A, D475ASD-5E0
9
SEN01824-01
40 Troubleshooting
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Charge pressure sensor too high (At left bank only): Excessively high failure voltage detected (Engine controller system) CA122 • Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor. • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Acceleration performance of engine deteriorates. • The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring function. (Code: 36501 Boost pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source circuit
Defective charge pres2 sure (boost pressure) sensor (internal defect)
Disconnection in wiring harness 3 (disconnection or defective contact of connectors)
Possible causes and the standard values when normal
10
Defective harness grounding 4 (contact with ground circuit)
5
Harness short (Harness internal short)
6
Defective engine controller
Standard values when normal and remarks for troubleshooting If failure code [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. PIM Voltage Between (1) – (2) Power source 4.75 – 5.25 V Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (37) – ResisMax. 1 z PIM (female) (1) tance Wiring harness between ENG (female) (44) – ResisMax. 1 z PIM (female) (3) tance Wiring harness between ENG (female) (47) – ResisMax. 1 z PIM (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (37) – PIM (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (44) – PIM (female) (3) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – PIM (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) Resis(37) to PIM (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (44) to PIM (female) (3) Between wiring harness from ENG (female) Resis(37) to PIM (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (47) to PIM (female) (2) Between wiring harness from ENG (female) Resis(44) to PIM (female) (3) and wiring harness Min. 1 Mz tance from ENG (female) (47) to PIM (female) (2) a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG Voltage Between (37) – (47) Power source 4.75 – 5.25 V
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40 Troubleshooting
SEN01824-01
Circuit diagram related to charge pressure sensor
D475A, D475ASD-5E0
11
SEN01824-01
40 Troubleshooting
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
12
Failure code Symptom of Charge pressure sensor too low (At left bank only): Excessively low failure voltage detected (Engine controller system) CA123 • Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor. • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Acceleration performance of engine deteriorates. • The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring function. (Code: 36501 Boost pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause 1
Defective sensor power source circuit
Standard values when normal and remarks for troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection Action code CALL E03 Failure content Controller's action
• • • •
Symptoms that appear on machine General information
Failure code Symptom of Decelerator pedal sensor abnormally high level (Only left bank): High failure voltage detection (Engine controller system) CA131 High voltage was detected in decelerator pedal signal circuit. If abnormality occurs while starting switch is ON, controller fixes sensor to value just before occurrence of abnormality and continues operation. If starting switch is turned ON while there is abnormality, controller fixes sensor to 100% value and continues operation. Blinks warning lamp and sounds alarm buzzer.
• Engine speed cannot be controlled with decelerator pedal. • Decelerator pedal signal voltage can be checked with monitoring function (Code: 31703 Decelerator voltage) • Method of reproducing failure code: Turn starting switch ON. Cause Defective decelerator 1 sensor power supply system
2
Possible causes and the standard values when normal
3
4
5
Standard values when normal and remarks for troubleshooting If failure code [CA2185] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. DEC (male) Resistance Defective decelerator sensor (Internal defect) Between (A) – (C) 4.0 – 6.0 kz Between (B) – (A) 0.25 – 5.0 kz Between (B) – (C) 0.25 – 5.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) ResisDisconnection in wiring Max. 1z tance harness (Disconnection – DEC (female) (A) in wiring or defective con- Wiring harness between OEM L (female) (9) – ResisMax. 1z tact in connector) DEC (female) (B) tance Wiring harness between OEM L (female) (23) ResisMax. 1z – DEC (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring OEM L (female) (22) – DEC (female) (A) tance harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz OEM L (female) (9) – DEC (female) (B) tance Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (23) – DEC (female) (C) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine OEM L Voltage controller Between (22) – (23) Power supply 4.75 – 5.25 V Between (9) – (23) Signal 0.5 – 4.5 V
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13
SEN01824-01
40 Troubleshooting
Circuit diagram related to decelerator pedal sensor
14
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SEN01824-01
Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected Action code CALL E03 Failure content Controller's action
• • • •
Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Decelerator pedal sensor too low: excessively low voltage detected failure (At left bank only) (Engine controller system) CA132 Excessively low voltage is detected at signal circuit of decelerator pedal. Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates with 100% value. Flashes warning lamp and turns on alarm buzzer.
• Engine speed cannot be controlled by decelerator pedal. • The signal voltage of decelerator pedal can be checked in monitoring mode. (Code: 31703 Decelerator voltage) • Duplication of failure code: turn ON the starting switch. Cause Standard values when normal and remarks for troubleshooting Defective decelerator If failure code [CA2186] is displayed at the same time, carry out trou1 pedal sensor power supbleshooting for it first. ply circuit
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15
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Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected Action code CALL E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Oil pressure sensor too high (At left bank only): Excessively high voltfailure age detected (Engine controller system) CA135 • Excessively high voltage is detected at oil pressure sensor circuit. • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2}) • Flashes warning lamp and turns on alarm buzzer.
• The signal voltage of engine oil pressure sensor can be checked in monitoring function. (Code: 37201 Engine oil pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source circuit
2
3
Possible causes and the standard values when normal 4
5
6
16
Standard values when normal and remarks for troubleshooting If failure code [CA187] or [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. POIL Voltage Defective oil pressure Between (1) – (2) Power source 4.75 – 5.25 V sensor Since the sensor voltage is measured with the harness being con(internal defect) nected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring Wiring harness between ENG (female) (37) – ResisMax. 1 z harness POIL (female) (1) tance (disconnection or defecWiring harness between ENG (female) (47) – Resistive contact of connecMax. 1 z POIL (female) (2) tance tors) Wiring harness between ENG (female) (13) – ResisMax. 1 z POIL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisDefective harness Min. 1 Mz ENG (female) (37) – POIL (female) (1) tance grounding (contact with ground cir- Between ground and wiring harness between ResisMin. 1 Mz cuit) ENG (female) (47) – POIL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (13) – POIL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) Resis(37) to POIL (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (47) to POIL (female) (2) Harness short (Harness internal short) Between wiring harness from ENG (female) Resis(37) to POIL (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (13) to POIL (female) (3) Between wiring harness from ENG (female) Resis(47) to POIL (female) (2) and wiring harness Min. 1 Mz tance from ENG (female) (13) to POIL (female) (3) a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. Defective engine controller ENG Voltage Between (37) – (47) Power source 4.75 – 5.25 V
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Circuit diagram related to oil pressure sensor
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17
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Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
18
Failure code Symptom of Oil pressure sensor too low (At left bank only): Excessively low voltfailure age detected (At left bank only) (Engine controller system) CA132 • Excessively low voltage is detected at oil pressure sensor circuit. • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2}) • Flashes warning lamp and turns on alarm buzzer.
• The signal voltage of engine oil pressure sensor can be checked in monitoring function. (Code: 37201 Engine oil pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause 1
Defective sensor power source circuit
Standard values when normal and remarks for troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first.
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40 Troubleshooting
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Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Coolant temperature sensor too high: Excessively high voltage failure detected (Engine controller system) CA144 • Excessively high voltage is detected at signal circuit of coolant temperature sensor. • Operates with a fixed coolant temperature (90°C). • Flashes warning lamp and turns on alarm buzzer. • Exhaust gas color becomes white. • The signal voltage of coolant temperature sensor can be checked in monitoring function. (Code: 04105 Coolant temperature sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause
Possible causes and the standard values when normal
20
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective coolant still OFF. 1 temperature sensor TWTR (male) Coolant temperature Resistance (Internal defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (15) – Resis2 (disconnection or Max. 1 z TWTR (female) (A) tance defective contact of Wiring harness among ENG (female) (38) – Resisconnectors) Max. 1 z JB – TWTR (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (15) – all pins of ENG (Harness internal short) ResisMin. 1 Mz (female) (with all connectors in the harness tance disconnected) Since the connections among coolant temperature sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring harness • Connector is loose, lock is broken, seal is broken 4 connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations 5 than engine controller ENG (female) Coolant temperature Resistance Between (15) – (38) 10 – 100°C 0.6 – 20 kz Defective engine Engine controller is possibly defective if no problem is found in causes 6 controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
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Circuit diagram related to coolant temperature sensor
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21
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40 Troubleshooting
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Coolant temperature sensor too low (At left bank only): Excessively failure low voltage detected (Engine controller system) CA145 • Excessively low voltage is detected at signal circuit of coolant temperature sensor. • Operates with a fixed coolant temperature (90°C). • Flashes warning lamp and turns on alarm buzzer. • Exhaust gas color becomes white. • The signal voltage of coolant temperature sensor can be checked in monitoring function. (Code: 04105 Coolant temperature sensor voltage) Cause
Possible causes and the standard values when normal
22
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective coolant still OFF. 1 temperature sensor TWTR (male) Coolant temperature Resistance (Internal defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch Defective harness still OFF. 2 grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz ENG (female) (15) – TWTR (female) (A) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (15) – all pins of ENG (Harness internal short) Resis(female) (with all connectors in the harness Min. 1 Mz tance disconnected) Since the connections among coolant temperature sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring harness 4 • Connector is loose, lock is broken, seal is broken connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations 5 than engine controller ENG (female) Coolant temperature Resistance Between (15) – (38) 10 – 100°C 0.6 – 20 kz Defective engine Engine controller is possibly defective if no problem is found in causes 6 controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
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Circuit diagram related to coolant temperature sensor
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23
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Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Charge temperature sensor too high (At left bank only): Excessively failure high voltage detected. (Engine controller system) CA153 • Excessively high voltage is detected at signal circuit of charge temperature (boost temperature) sensor. • Operates with a fixed charge temperature (boost temperature) (70°C). • Exhaust gas color becomes white. • The signal voltage of the charge temperature (boost temperature) sensor can be checked with the monitoring function. (Code: 18501 Boost temperature sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause
Possible causes and the standard values when normal
24
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective charge temperTIM (male) Air boost temperature Resistance 1 ature (boost temperature) sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz Between (A) – ground In all range Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness (disconnection Wiring harness between ENG (female) (23) – Resis2 Max. 1 z or defective contact of TIM (female) (A) tance connectors) Wiring harness between ENG (female) (47) – ResisMax. 1 z JB – TIM (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (23) – all pins of ENG (Harness internal short) ResisMin. 1 Mz (female) (with all connectors in the harness tance disconnected) Since the connections among charge temperature (boost temperature) sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring harness 4 • Connector is loose, lock is broken, seal is broken connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations 5 ENG (female) Air boost temperature Resistance than engine controller Between (23) – (47) 10 – 100°C 0.5 – 20 kz Defective engine Engine controller is possibly defective if no problem is found in causes 6 controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
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Circuit diagram related to charge temperature sensor
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25
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Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Charge temperature sensor too low (At left bank only): Excessively failure low voltage detected (Engine controller system) CA154 • Excessively low voltage is detected at signal circuit of charge temperature (boost temperature) sensor. • Operates with a fixed charge temperature (boost temperature) (70°C). • Exhaust gas color becomes white. • The signal voltage of the charge temperature (boost temperature) sensor can be checked with the monitoring function. (Code: 18501 Boost temperature sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause
Possible causes and the standard values when normal
26
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective charge temperTIM (male) Air boost temperature Resistance 1 ature (boost temperature) sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz Between (A) – ground In all range Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch Defective harness still OFF. 2 grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz ENG (female) (23) – TIM (female) (A) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (23) – all pins of ENG (Harness internal short) ResisMin. 1 Mz (female) (with all connectors in the harness tance disconnected) Since the connections among charge temperature (boost temperature) sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. Defective wiring harness • Connector is loose, lock is broken, seal is broken 4 connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations ENG (female) Air boost temperature Resistance 5 than engine controller Between (23) – (47) 10 – 100°C 0.5 – 20 kz Between (23) – ground In all range Min. 1 Mz Defective engine Engine controller is possibly defective if no problem is found in causes 6 controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
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Circuit diagram related to charge temperature sensor
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Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection Action code CALL E03 Failure content
Controller's action
Symptoms that appear on machine General information Possible causes and the standard values when normal
28
• • • • • •
Failure code Symptom of Sensor power supply (2) abnormally low level (Left bank): Low voltage failure detection (Engine controller system) CA187 Low voltage was detected in sensor power supply (2) (5 V) circuit. Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and continues operation. Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation. Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation. Bkup sensor operates with Ne speed sensor signal. Blinks warning lamp and sounds alarm buzzer.
• Output lowers.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA227].
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Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low voltfailure age detection (Engine controller system) CA187 • Low voltage was detected in sensor power supply (2) (5 V) circuit. • Bkup sensor operates with Ne speed sensor signal. • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB227].
29
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Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine oil temperature sensor abnormally high level (Only left bank): failure High voltage detection (Engine controller system) CA212 • High voltage was detected in engine oil temperature sensor circuit. • Sets oil temperature to default value (100°C) and continues operation.
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective oil temperature 1 sensor (Internal defect) TOIL (male) Oil temperature Resistance Between (A) – (B) 0 – 100°C 0.5 – 36 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) (17) – Resis2 Max. 1 z in wiring or defective con- TOIL (female) (A) tance tact in connector) Wiring harness between ENG (female) (47) – ResisMax. 1 z TOIL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring without turning starting switch ON. 3 harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz ENG (female) (17) – TOIL (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control4 ENG Oil temperature Resistance ler (17) – (47) 0 – 100°C 0.5 – 36 kz
Circuit diagram related to engine oil temperature sensor
30
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Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine oil temperature sensor abnormally low level (Only left bank): failure Low voltage detection (Engine controller system) CA213 • Low voltage was detected in engine oil temperature sensor circuit. • Sets oil temperature to default value (100°C) and continues operation.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA212].
31
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Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Atmospheric pressure sensor too high (At left bank only): Excessively failure high voltage detected (Engine controller system) CA213 • Excessively high voltage is detected at signal circuit of atmospheric pressure sensor. • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source circuit
Defective atmospheric 2 pressure sensor (internal defect)
Possible causes and the standard values when normal
Disconnection in wiring harness (disconnection 3 or defective contact of connectors)
Defective harness 4 grounding (contact with ground circuit)
5
32
Harness short (Harness internal short)
Standard values when normal and remarks for troubleshooting If failure code [CA352] or [CA386] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. PAMB Voltage Between (1) – (3) Power source 4.75 – 5.25 V Between (2) – (3) Signal 0.5 – 4.5 V Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (37) – ResisMax. 1 z PAMB (female) (1) tance Wiring harness between ENG (female) (3) – ResisMax. 1 z PAMB (female) (2) tance Wiring harness between ENG (female) (38) – ResisMax. 1 z PAMB (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (37) – PAMB (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (3) – PAMB (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (38) – PAMB (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) Resis(37) to PAMB (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (3) to PAMB (female) (2) Between wiring harness from ENG (female) Resis(37) to PAMB (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (38) to PAMB (female) (3) Between wiring harness from ENG (female) Resis(3) to PAMB (female) (2) and wiring harness Min. 1 Mz tance from ENG (female) (38) to PAMB (female) (3)
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Cause Possible causes and the standard values when normal
6
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG Voltage Between (37) – (38) 4.75 – 5.25 V Between (3) – (38) 0.5 – 4.5 V
Circuit diagram related to atmospheric pressure sensor
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Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
34
Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively failure low voltage detected (Engine controller system) CA222 • Excessively low voltage is detected at signal circuit of atmospheric pressure sensor. • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}). • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of failure code [CA221].
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35
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Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
Failure code Symptom of Sensor power source (2) too high (At left bank): Excessively high voltfailure age detected (Engine controller system) CA227 Excessively high voltage is detected in sensor power source (2) (5V) circuit. Operates using Ne speed sensor signal instead of Bkup speed sensor signal. Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2}) Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2}) Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}). Flashes warning lamp and turns on alarm buzzer.
• Output decreases.
Cause
Possible causes and the standard values when normal
36
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other 1 Defective related circuits codes are displayed, carry out troubleshooting for those codes. a Prepare with starting switch OFF and diagnose with starting switch ON. Bkup speed sensor G connector Disconnect the Engine oil pressure Defective sensor POIL connector devices on the right 2 sensor (internal defect) one at a time. Atmospheric pressure If the code disapPAMB connector sensor pears, that device is Charge pressure seninternally defective. PIM connector sor a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (37) – Resis3 (disconnection or defecMax. 1 z each sensor (female) tance tive contact of connecWiring harness between ENG (female) (47) – Resistors) Max. 1 z each sensor (female) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between Resis4 Min. 1 Mz tance (contact with ground cir- ENG (female) (37) – each sensor (female) cuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – each sensor (female) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short Between wiring harness from ENG (female) 5 (Harness internal short) (37) to each sensor (female) and wiring harResisMin. 1 Mz ness from ENG (female) (47) to each sensor tance (female) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine control6 ENG Voltage ler Between (37) – (47) 4.75 – 5.25 V
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Circuit diagram related to sensor power source (2) (5V)
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Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection Action code Failure code Symptom of Sensor power supply (2) abnormally high level (Right bank): High voltfailure age detection (Engine controller system) CALL E03 CB227 Failure content • High voltage was detected in sensor power supply (2) (5 V) circuit. Controller's • Bkup speed sensor operates with Ne speed sensor signal. action Symptoms that appear on • Output lowers. machine General information
Possible causes and the standard values when normal
38
Cause Standard values when normal and remarks for troubleshooting 1 Related defective system If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right Defective sensor (Inter2 is disconnected, if nal defect) Bkup speed error code disappears, G connector sensor that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) (37) – Resis3 Max. 1 z in wiring or defective con- each sensor (female) tance tact in connector) Wiring harness between ENG (female) (47) – ResisMax. 1 z each sensor (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resis4 harness (Contact with Min. 1 Mz ENG (female) (37) – each sensor (female) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – each sensor (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness from ENG (female) 5 ness (with another wiring (37) to each sensor (female) and wiring harResisharness) Min. 1 Mz ness from ENG (female) (47) to each sensor tance (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine control6 ENG Voltage ler Between (37) – (47) 4.75 – 5.25 V
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Circuit diagram related to sensor power source (2) (At right bank)
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39
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Failure code [CA234] Engine over speed (At left bank only): Excessively high speed Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine over speed (At left bank only): Excessively high speed failure (Engine controller system) CA234 • The engine speed exceeds upper control limit speed. • Flashes warning lamp and turns on alarm buzzer. • Stops operation of injector until the engine speed drops to the normal speed. • Engine speed fluctuates. • The engine speed can be checked in monitoring function. (Code: 01000 Engine speed) • Duplication of failure code: Start engine and operate at high idle. Cause
Possible causes and the standard values when normal
40
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other 1 Defective related circuits codes are displayed, carry out troubleshooting for those codes. The improper usage of equipped machine can be suspected. Instruct 2 Improper usage the proper usage. Engine controller can be suspected to be defective if no problem is Defective engine 3 found in causes 1 – 2 (since this is an internal defect, it cannot be controller diagnosed).
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Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal power source for Ne speed sensor (At left bank only): failure Excessively low voltage detected (Engine controller system) CA238 • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit. • Controls using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Cause
Possible causes and the standard values when normal
42
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective Ne speed sen- Disconnect a device 1 sor shown on the right. (internal defect) If the failure code disNe speed sensor Ne connector appears, that device is internally defective. a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between left bank ENG Resis2 (disconnection or defecMax. 1 z (female) (16) – Ne (female) (1) tance tive contact of connecWiring harness between left bank ENG Resistors) Max. 1 z (female) (48) – Ne (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resisgrounding Min. 1 Mz 3 tance (contact with ground cir- left bank ENG (female) (16) – Ne (female) (1) cuit) Between ground and wiring harness between ResisMin. 1 Mz left bank ENG (female) (48) – Ne (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short Between wiring harness from left bank ENG 4 (Harness internal short) (female) (16) to Ne (female) (1) and wiring ResisMin. 1 Mz harness from left bank ENG (female) (48) to tance Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine control5 ler Left bank ENG Voltage Between (16) – (48) 4.75 – 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0
43
SEN01824-01
40 Troubleshooting
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal power source for Ne speed sensor (At right bank only): failure Excessively low voltage detected (Engine controller system) CB238 • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit. • Controls using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Cause
Possible causes and the standard values when normal
44
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective Ne speed sen- Disconnect a device 1 sor shown on the right. (internal defect) If the failure code disNe speed sensor Ne connector appears, that device is internally defective. a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between left bank ENG Resis2 (disconnection or defecMax. 1 z (female) (16) – Ne (female) (1) tance tive contact of connecWiring harness between right bank ENG Resistors) Max. 1 z (female) (48) – Ne (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resisgrounding Min. 1 Mz left bank ENG (female) (16) – Ne (female) (1) tance 3 (contact with ground cirBetween ground and wiring harness between cuit) Resisright bank ENG (female) (48) – Ne (female) Min. 1 Mz tance (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short Between wiring harness from left bank ENG 4 (Harness internal short) (female) (16) to Ne (female) (1) and wiring ResisMin. 1 Mz harness from right bank ENG (female) (48) to tance Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine control5 ler Voltage Between left bank ENG (16) – right bank ENG (48) 4.75 – 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0
45
SEN01824-01
40 Troubleshooting
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Fuel temperature sensor too high (At left bank): Excessively high voltfailure age detected (Engine controller system) CA263 • Excessively high voltage is detected at fuel temperature sensor circuit. • Operates with a fixed fuel temperature (95°C).
• The signal voltage of engine fuel temperature sensor can be checked in monitoring function. (Code: 14201 Engine fuel temperature sensor voltage) Cause
1
Possible causes and the standard values when normal
2
3
4
46
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective fuel temperastill OFF. ture sensor (internal TFUEL (male) Fuel temperature Resistance defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (30) – Resis(disconnection or defecMax. 1 z TFUEL (female) (A) tance tive contact of connecWiring harness between ENG (female) (47) – Resistors) Max. 1 z TFUEL (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between ResisMin. 1 Mz (contact with ground cir- ENG (female) (30) – TFUEL (female) (A) tance cuit) a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Fuel temperature Resistance Defective engine controller Between (30) – (47) 10 – 100°C 0.6 – 20 kz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to fuel temperature sensor
D475A, D475ASD-5E0
47
SEN01824-01
40 Troubleshooting
Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Fuel temperature sensor too high (At right bank): Excessively high failure voltage detected (Engine controller system) CB263 • Excessively high voltage is detected at fuel temperature sensor circuit. • Operates with a fixed fuel temperature (95°C).
• The signal voltage of engine fuel temperature sensor can be checked in monitoring function. (Code: 14201 Engine fuel temperature sensor voltage) Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective fuel temperastill OFF. ture sensor (internal TFUEL (male) Fuel temperature Resistance defect) Between (A) – (B) 10 – 100°C 0.6 – 20 kz a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (30) – Resis(disconnection or defecMax. 1 z TFUEL (female) (A) tance tive contact of connecWiring harness between ENG (female) (47) – Resistors) Max. 1 z TFUEL (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between ResisMin. 1 Mz (contact with ground cir- ENG (female) (30) – TFUEL (female) (A) tance cuit) a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Fuel temperature Resistance Defective engine controller Between (30) – (47) 10 – 100°C 0.6 – 20 kz
Circuit diagram related to fuel temperature sensor
48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection Action code E01 Failure content Controller's action
Failure code Symptom of Fuel temperature sensor abnormally low level (Left bank): Low voltfailure age detection (Engine controller system) CA265 • Low voltage was detected in fuel temperature sensor circuit. • Substitutes coolant temperature sensor. • If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and continues operation.
Symptoms that appear on machine General information Possible causes and the standard values when normal
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA263].
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection Action code E01 Failure content Controller's action
Failure code Symptom of Fuel temperature sensor abnormally low level (Right bank): Low voltfailure age detection (Engine controller system) CB265 • Low voltage was detected in fuel temperature sensor circuit. • Substitutes coolant temperature sensor. • If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and continues operation.
Symptoms that appear on machine General information Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB263].
49
SEN01824-01
40 Troubleshooting
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit Action code Failure code Symptom of PCV1 short circuit (Left bank): Short circuit failure (Engine controller system) CALL E03 CA271 Failure content • Short circuit occurred in supply pump PCV1 circuit. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that appear on machine General • While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse information voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal short circuit)
Possible causes and the standard values when normal
Ground fault in wiring 2 harness (Contact with GND circuit)
Hot short (Contact with 3 24V circuit) in wiring harness
4
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) – PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) – PCV1 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (4) – PCV1 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (5) – PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV1
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of PCV1 short circuit (Right bank): Short circuit failure (Engine controller system) CB271 • Short circuit occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.
• While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal short circuit)
Possible causes and the standard values when normal
Ground fault in wiring 2 harness (Contact with GND circuit)
Hot short (Contact with 3 24V circuit) in wiring harness
4
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) – PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) – PCV1 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (4) – PCV1 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (5) – PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV1
D475A, D475ASD-5E0
51
SEN01824-01
40 Troubleshooting
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of PCV1 disconnection (Left bank): Disconnection failure (Engine controller system) CA272 • Disconnection occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.
• While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal disconnection)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Ground fault in wiring 3 harness (Contact with GND circuit)
4
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (4) – ResisMax. 1 z PCV1 (female) (1) tance Wiring harness between ENG (female) (5) – ResisMax. 1 z PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) – PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) – PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV1
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of PCV1 disconnection (Right bank): Disconnection failure (Engine controller system) CB272 • Disconnection occurred in supply pump PCV1 circuit. • Blinks warning lamp and sounds alarm buzzer.
• While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal disconnection)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Ground fault in wiring 3 harness (Contact with GND circuit)
4
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (4) – ResisMax. 1 z PCV1 (female) (1) tance Wiring harness between ENG (female) (5) – ResisMax. 1 z PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) – PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) – PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) – (5) 2.3 – 5.3 z Between (4), (5) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV1
D475A, D475ASD-5E0
53
SEN01824-01
40 Troubleshooting
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit Action code Failure code Symptom of PCV2 short circuit (Left bank): Short circuit failure (Engine controller system) CALL E03 CA273 Failure content • Short circuit occurred in supply pump PCV2 circuit. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that appear on machine General • While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse information voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV2 (Internal short circuit)
Possible causes and the standard values when normal
Ground fault in wiring 2 harness (Contact with GND circuit)
Hot short (Contact with 3 24V circuit) in wiring harness
4
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male) Resistance Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (9) – PCV2 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) – PCV2 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (9) – PCV2 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (10) – PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV2
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of PCV2 short circuit (Right bank): Short circuit failure (Engine controller system) CB273 • Short circuit occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.
• While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV2 (Internal short circuit)
Possible causes and the standard values when normal
Ground fault in wiring 2 harness (Contact with GND circuit)
Hot short (Contact with 3 24V circuit) in wiring harness
4
Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male) Resistance Between (1) – (2) 2.3 – 5.3 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (9) – PCV2 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) – PCV2 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (9) – PCV2 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (10) – PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV2
D475A, D475ASD-5E0
55
SEN01824-01
40 Troubleshooting
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of PCV2 disconnection (Left bank): Disconnection failure (Engine controller system) CA274 • Disconnection occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.
• While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective supply pump without turning starting switch ON. PCV2 (Internal disconPCV2 (male) Resistance nection) Between (1) – (2) 2.3 – 5.3 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection Wiring harness between ENG (female) (9) – Max. 1 z tance in wiring or defective con- PCV2 (female) (1) tact in connector) Wiring harness between ENG (female) (10) – ResisMax. 1 z PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resisharness (Contact with Min. 1 Mz ENG (female) (9) – PCV2 (female) (1) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) – PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine controlENG (female) Resistance ler Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV2
56
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of PCV2 disconnection (Right bank): Disconnection failure (Engine controller system) CB274 • Disconnection occurred in supply pump PCV2 circuit. • Blinks warning lamp and sounds alarm buzzer.
• While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective supply pump without turning starting switch ON. PCV2 (Internal disconPCV2 (male) Resistance nection) Between (1) – (2) 2.3 – 5.3 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection Wiring harness between ENG (female) (9) – Max. 1 z tance in wiring or defective con- PCV2 (female) (1) tact in connector) Wiring harness between ENG (female) (10) – ResisMax. 1 z PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resisharness (Contact with Min. 1 Mz ENG (female) (9) – PCV2 (female) (1) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) – PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine controlENG (female) Resistance ler Between (9) – (10) 2.3 – 5.3 z Between (9), (10) – ground Min. 1 Mz
Circuit diagram related to supply pump PCV2
D475A, D475ASD-5E0
57
SEN01824-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN01824-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 08-07 (01)
58
SEN01825-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 3 Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit ......................................................................................................................... 4 Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit ......................................................................................................................... 6 Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit ......................................................................................................................... 8 Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit ....................................................................................................................... 10 Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit ....................................................................................................................... 12 Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit ....................................................................................................................... 14 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ............................................... 16 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch............................................. 17 Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit...................................... 18 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ............................... 20
D475A, D475ASD-5E0
1
SEN01825-03
40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection.......22 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection ....23 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection ....24 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection ..26 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection............28 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection .........28 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection .........29 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection .......29 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence.......................................................................................................30 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence.......................................................................................................30 Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected ............................................................................................................32 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection...............................................................................................................................34 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection..............................................................................................................36 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection..............................................................................................................36 Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected..........................................................................................................37 Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected..........................................................................................................38 Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error................39 Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error .............39 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected.................................................................................................................40 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification) ................................................................44 Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected.................................................................................................................48 Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal..............................52 Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ...........................54 Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection...............................................................................................................................56 Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection................................................................................................................................58 Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase...............59 Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase ............59
2
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01825-03
3
SEN01825-03
40 Troubleshooting
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #1 (L/B #1) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CA322 • A disconnection or short circuit has occurred in injector #1 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector #1 CN1 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness Wiring harness between ENG (female) (45) – ResisMax. 1 z (disconnection or defective CN1 (female) (1) tance contact of connectors) Wiring harness between ENG (female) (53) – ResisMax. 1 z CN1 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resisgrounding (contact with Min. 1 Mz ENG (female) (45) – CN1 (female) (1) tance ground circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (53) – CN1 (female) (2) tance Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry injector or wiring harness out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Defective engine controller Between (45) – (53) 0.4 – 1.1 z Between (45), (53) and ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #1
D475A, D475ASD-5E0
5
SEN01825-03
40 Troubleshooting
Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #5 (L/B #5) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CA323 • A disconnection or short circuit has occurred in injector #5 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
6
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector #5 CN5 (male) Resistance (internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness Wiring harness between ENG (female) (46) – ResisMax. 1 z (disconnection or defective CN5 (female) (1) tance contact of connectors) Wiring harness between ENG (female) (60) – ResisMax. 1 z CN5 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resisgrounding (contact with Min. 1 Mz ENG (female) (46) – CN5 (female) (1) tance ground circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (60) – CN5 (female) (2) tance Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry injector or wiring harness out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Defective engine controller Between (46) – (60) 0.4 – 1.1 z Between (46), (60) and ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #5
D475A, D475ASD-5E0
7
SEN01825-03
40 Troubleshooting
Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #3 (L/B #3) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CA324 • A disconnection or short circuit has occurred in injector #3 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
Defective injector #3 (internal defect)
Disconnection in wiring harness 2 (disconnection or defective contact of connectors) Possible causes and the standard values when normal
Defective harness ground3 ing (contact with ground circuit)
4
Defective another cylinder injector or wiring harness
5 Defective engine controller
8
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. CN3 (male) Resistance Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (55) – ResisMax. 1 z CN3 (female) (1) tance Wiring harness between ENG (female) (52) – ResisMax. 1 z CN3 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (55) – CN3 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (52) – CN3 (female) (2) tance If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Between (55) – (52) 0.4 – 1.1 z Between (55), (52) and ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #3
D475A, D475ASD-5E0
9
SEN01825-03
40 Troubleshooting
Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #6 (L/B #6) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CA325 • A disconnection or short circuit has occurred in injector #6 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
Defective injector #6 (internal defect)
Disconnection in wiring harness 2 (disconnection or defective contact of connectors) Possible causes and the standard values when normal
Defective harness ground3 ing (contact with ground circuit)
4
Defective another cylinder injector or wiring harness
5 Defective engine controller
10
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. CN6 (male) Resistance Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (57) – ResisMax. 1 z CN6 (female) (1) tance Wiring harness between ENG (female) (59) – ResisMax. 1 z CN6 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (57) – CN6 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (59) – CN6 (female) (2) tance If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Between (57) – (59) 0.4 – 1.1 z Between (57), (59) and ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #6
D475A, D475ASD-5E0
11
SEN01825-03
40 Troubleshooting
Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #2 (L/B #2) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CA331 • A disconnection or short circuit has occurred in injector #2 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
Defective injector #2 (internal defect)
Disconnection in wiring harness 2 (disconnection or defective contact of connectors) Possible causes and the standard values when normal
Defective harness ground3 ing (contact with ground circuit)
4
Defective another cylinder injector or wiring harness
5 Defective engine controller
12
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. CN2 (male) Resistance Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (54) – ResisMax. 1 z CN2 (female) (1) tance Wiring harness between ENG (female) (51) – ResisMax. 1 z CN2 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (54) – CN2 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (51) – CN2 (female) (2) tance If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Between (54) – (51) 0.4 – 1.1 z Between (54), (51) and ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #2
D475A, D475ASD-5E0
13
SEN01825-03
40 Troubleshooting
Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #4 (L/B #4) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CA332 • A disconnection or short circuit has occurred in injector #4 circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Speed is not stable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
Defective injector #4 (internal defect)
Disconnection in wiring harness 2 (disconnection or defective contact of connectors) Possible causes and the standard values when normal
Defective harness ground3 ing (contact with ground circuit)
4
Defective another cylinder injector or wiring harness
5 Defective engine controller
14
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. CN4 (male) Resistance Between (1) – (2) 0.4 – 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (56) – ResisMax. 1 z CN4 (female) (1) tance Wiring harness between ENG (female) (58) – ResisMax. 1 z CN4 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (56) – CN4 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (58) – CN4 (female) (2) tance If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Between (56) – (58) 0.4 – 1.1 z Between (56), (58) and ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #4
D475A, D475ASD-5E0
15
SEN01825-03
40 Troubleshooting
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
16
Failure code Symptom of Engine controller data mismatch (Left bank): Mismatch failure (Engine controller system) CA342 • Data mismatch occurred in engine controller. • Blinks warning lamp and sounds alarm buzzer. • Engine cannot be started or operated.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA111].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine controller data mismatch (Right bank): Mismatch failure (Engine controller system) CB342 • Data mismatch occurred in engine controller. • Blinks warning lamp and sounds alarm buzzer. • Engine cannot be started or operated.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB111].
17
SEN01825-03
40 Troubleshooting
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit failure (Engine controller system) CA351 • Abnormality has occurred in injector drive circuit. • Operates with limited output. (Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases.
Cause
1
2
Possible causes and the standard values when normal
3
4
5
18
Standard values when normal and remarks for troubleshooting Check the failure codes (codes for injector system trouble) that are Defective related circuits displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since a fuse or breaker of equipped machine side can be suspected to be defective, directly check them. Defective breaker (If fuse is blown, or breaker is shut off, it is highly possible that a defective grounding, etc. has occurred in the circuit.) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness Wiring harness between PW L (female) (3) ResisMax. 1 z (disconnection or defective (4) – battery (+) tance contact of connectors) Wiring harness between PW L (female) (1) ResisMax. 1 z (2) and ground tance a Prepare with starting switch OFF and diagnose with starting Defective harness switch still OFF. grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz PW L (female) (3) (4) – battery (+)Resistance tance a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine controller PW L Voltage Between (3), (4) – (1), (2) 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to controller power source
D475A, D475ASD-5E0
19
SEN01825-03
40 Troubleshooting
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector drive circuit abnormality (Right bank): Circuit abnormality failure (Engine controller system) CB351 • Abnormality occurred in injector drive circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Cause
1 2
Possible causes and the standard values when normal
3
4
5
20
Standard values when normal and remarks for troubleshooting If another code (code of injector system abnormality) is also disRelated defective system played, carry out troubleshooting for it. Fuse or circuit breaker on applicable machine side may be defective. Defective circuit breaker Check them directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between PW R (female) (3), ResisMax. 1 z wiring or defective contact (4) – battery (+) tance in connector) Wiring harness between PW R (female) (1), ResisMax. 1 z (2) – ground tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring without turning starting switch ON. harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz PW R (female) (3), (4) – battery (+) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller PW R Voltage Between (3), (4) – (1), (2) 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to engine controller power supply
D475A, D475ASD-5E0
21
SEN01825-03
40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
22
Failure code Symptom of Sensor power supply (1) abnormally low level (Left bank): Low voltfailure age detection (Engine controller system) CA352 • Low voltage was detected in sensor power supply (1) (5 V) circuit. • Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA386].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code
Sensor power supply (1) abnormally low level (Right bank): Low voltSymptom of age detection failure CB352 (Engine controller system) • Low voltage was detected in sensor power supply (1) (5 V) circuit. • Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB386].
23
SEN01825-03
40 Troubleshooting
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Sensor power supply (1) abnormally high level (Left bank): High voltfailure age detection (Engine controller system) CA386 • High voltage was detected in sensor power supply (1) (5 V) circuit. • Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Cause 1 Related defective system
2
3
Possible causes and the standard values when normal
4
5
6
24
Standard values when normal and remarks for troubleshooting If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right Defective sensor is disconnected, if (Internal defect) Left common rail error code disapPFUEL connector pressure sensor pears, that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in PFUEL (female) (1) wiring or defective contact Wiring harness between ENG (female) (25) – ResisMax. 1 z in connector) PFUEL (female) (2) tance Wiring harness between ENG (female) (47) – ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring ENG (female) (33) – PFUEL (female) (1) tance harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz ENG (female) (25) – PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (female) (33) – PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (25) – tance PFUEL (female) (2) Short circuit in wiring Between wiring harness between ENG harness (with another Resis(female) (33) – PFUEL (female) (1) and wirwiring harness) Min. 1 Mz ing harness between ENG (female) (47) – tance PFUEL (female) (3) Between wiring harness between ENG (female) (25) – PFUEL (female) (2) and wirResisMin. 1 Mz ing harness between ENG (female) (47) – tance PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller ENG Voltage Between (33) – (47) 4.75 – 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to sensor power supply 1 (5V)
D475A, D475ASD-5E0
25
SEN01825-03
40 Troubleshooting
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code
Sensor power supply (1) abnormally high level (Right bank): High Symptom of voltage detection failure CB386 (Engine controller system) • High voltage was detected in sensor power supply (1) (5 V) circuit. • Common rail pressure sensor limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Cause 1 Related defective system
2
Defective sensor (Internal defect)
Disconnection in wiring harness (Disconnection in 3 wiring or defective contact in connector)
Possible causes and the standard values when normal
Ground fault in wiring har4 ness (Contact with GND circuit)
Short circuit in wiring har5 ness (with another wiring harness)
6 Defective engine controller
26
Standard values when normal and remarks for troubleshooting If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right is disconnected, if Right common rail error code disapPFUEL connector pressure sensor pears, that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – ResisMax. 1 z PFUEL (female) (1) tance Wiring harness between ENG (female) (25) – ResisMax. 1 z PFUEL (female) (2) tance Wiring harness between ENG (female) (47) – ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (33) – PFUEL (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (25) – PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (female) (33) – PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (25) – tance PFUEL (female) (2) Between wiring harness between ENG (female) (33) – PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (47) – tance PFUEL (female) (3) Between wiring harness between ENG (female) (25) – PFUEL (female) (2) and wirResisMin. 1 Mz ing harness between ENG (female) (47) – tance PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG Voltage Between (33) – (47) 4.75 – 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to sensor power supply (1) (5V)
D475A, D475ASD-5E0
27
SEN01825-03
40 Troubleshooting
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Power supply voltage abnormally low level (Left bank): Low voltage failure detection (Engine controller system) CA441 • Low voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA111].
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
28
Failure code Symptom of Power supply voltage abnormally low level (Right bank): Low voltage failure detection (Engine controller system) CB441 • Low voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB111].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Power supply voltage abnormally high level (Left bank): High voltage failure detection (Engine controller system) CA442 • High voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Possible causes and the standard values when normal
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA111].
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Power supply voltage abnormally high level (Right bank): High voltfailure age detection (Engine controller system) CB442 • High voltage was detected in power supply voltage circuit. • Blinks warning lamp and sounds alarm buzzer. • Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB111].
29
SEN01825-03
40 Troubleshooting
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Common rail abnormally high pressure (2) (Left bank): Abnormally failure high pressure occurrence (Engine controller system) CA449 • Common rail pressure sensor circuit detected abnormally high pressure (Level 2). • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA2249].
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
30
Failure code Symptom of Common rail abnormally high pressure (2) (Right bank): Abnormally failure high pressure occurrence (Engine controller system) CB449 • Common rail pressure sensor circuit detected abnormally high pressure (Level 2). • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA2249].
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01825-03
31
SEN01825-03
40 Troubleshooting
Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Common rail pressure sensor too high (At left bank): Excessively failure high voltage detected (Engine controller system) CA451 • Excessively high voltage has occurred in the common rail pressure sensor circuit. • Operates with limited output.(Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36401 Common rail pressure sensor voltage) Cause Defective sensor power 1 source circuit
2
3
Possible causes and the standard values when normal 4
5
32
Standard values when normal and remarks for troubleshooting If failure code [CA352] or [CA386] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. PFUEL Voltage Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V (internal defect) Since the sensor voltage is measured with the harness being connected, if the voltage is abnormal, first check the harness and the controller to make it sure if there is no other cause of the trouble, and then judge the sensor voltage. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (33) – ResisDisconnection in wiring Max. 1 z tance harness (disconnection or PFUEL (female) (1) defective contact of con- Wiring harness between ENG (female) (25) – ResisMax. 1 z nectors) PFUEL (female) (2) tance Wiring harness between ENG (female) (47) – ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz Defective harness groundENG (female) (33) – PFUEL (female) (1) tance ing (contact with ground Between ground and wiring harness between Resiscircuit) Min. 1 Mz ENG (female) (25) – PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – PFUEL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) (33) to PFUEL (female) (1) and wiring harResisMin. 1 Mz ness from ENG (female) (25) to PFUEL tance (female) (2) Harness short Between wiring harness from ENG (female) (Harness internal short) (33) to PFUEL (female) (1) and wiring harResisMin. 1 Mz ness from ENG (female) (47) to PFUEL tance (female) (3) Between wiring harness from ENG (female) (25) to PFUEL (female) (2) and wiring harResisMin. 1 Mz ness from ENG (female) (47) to PFUEL tance (female) (3)
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40 Troubleshooting
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Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG Voltage 6 Defective engine controller Between (33) – (47) 4.75 – 5.25 V Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0
33
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40 Troubleshooting
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Common rail pressure sensor abnormally high level (Right bank): failure High voltage detection (Engine controller system) CB451 • High voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36404: Common rail pressure sensor voltage). Cause Defective sensor power 1 supply system
2
3
Possible causes and the standard values when normal 4
5
34
Standard values when normal and remarks for troubleshooting If code [CB352] or [CB386] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL Voltage Defective common rail Between (1) – (3) Power supply 4.75 – 5.25 V pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V (Internal defect) Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in PFUEL (female) (1) wiring or defective contact Wiring harness between ENG (female) (25) – ResisMax. 1 z in connector) PFUEL (female) (2) tance Wiring harness between ENG (female) (47) – ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring harENG (female) (33) – PFUEL (female) (1) tance ness (Contact with GND Between ground and wiring harness between Resiscircuit) Min. 1 Mz ENG (female) (25) – PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) – PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (female) (33) – PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (25) – tance PFUEL (female) (2) Short circuit in wiring harness (with another wiring Between wiring harness between ENG (female) (33) – PFUEL (female) (1) and wirResisharness) Min. 1 Mz ing harness between ENG (female) (47) – tance PFUEL (female) (3) Between wiring harness between ENG (female) (25) – PFUEL (female) (2) and wirResisMin. 1 Mz ing harness between ENG (female) (47) – tance PFUEL (female) (3)
D475A, D475ASD-5E0
40 Troubleshooting
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Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG Voltage 6 Defective engine controller Between (33) – (47) 4.75 – 5.25 V Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0
35
SEN01825-03
40 Troubleshooting
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Common rail pressure sensor abnormally low level (Left bank): failure Abnormally low voltage detection (Engine controller system) CA452 • Low voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36401: Common rail pressure sensor voltage). Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA451].
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
36
Failure code Symptom of Common rail pressure sensor abnormally low level (Right bank): failure Abnormally low voltage detection (Engine controller system) CB452 • Low voltage was detected in common rail pressure sensor circuit. • Limits output and continues operation (Limits common rail pressure). • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36404: Common rail pressure sensor voltage). Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB451].
D475A, D475ASD-5E0
40 Troubleshooting
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Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Common rail pressure high trouble (1) (At left bank): Excessively failure high pressure trouble occurred (Engine controller system) CA553 • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure) Cause
1 2
Possible causes and the standard values when normal
3
4 5 6 7
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other Defective related circuits codes are displayed, carry out troubleshooting for those codes. Improper fuel has been Since the use of improper fuel can be suspected, check the fuel. used. (Viscosity is too high) Defective electrical system Since an electrical defect of common rail pressure sensor is susof common rail pressure pected, carry out troubleshooting for the following code. [CA451] sensor Defective mechanical sysSince a mechanical defect of common rail pressure sensor is sustem of common rail prespected, directly check the sensor. sure sensor Since a damage of spring, wear of seat or sticking of ball is susDefective overflow valve pected, directly check them. Since an overflow piping is suspected to be clogged, directly check Clogged overflow piping it. Since a mechanical defect of pressure limiter is suspected, directly Defective pressure limiter check the limiter.
D475A, D475ASD-5E0
37
SEN01825-03
40 Troubleshooting
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Common rail pressure high trouble (1) (At right bank): Excessively failure high pressure trouble occurred (Engine controller system) CB553 • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit. • Flashes warning lamp and turns on alarm buzzer. • Output decreases. • Common rail pressure can be checked with the monitoring function. (Code: 36403 Common rail pressure) Cause
1 2
Possible causes and the standard values when normal
3
4 5 6 7
38
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other Defective related circuits codes are displayed, carry out troubleshooting for those codes. Improper fuel has been Since the use of improper fuel can be suspected, check the fuel. used. (Viscosity is too high) Defective electrical system Since an electrical defect of common rail pressure sensor is susof common rail pressure pected, carry out troubleshooting for the following code. [CB451] sensor Defective mechanical sysSince a mechanical defect of common rail pressure sensor is sustem of common rail prespected, directly check the sensor. sure sensor Since a damage of spring, wear of seat or sticking of ball is susDefective overflow valve pected, directly check them. Since an overflow piping is suspected to be clogged, directly check Clogged overflow piping it. Since a mechanical defect of pressure limiter is suspected, directly Defective pressure limiter check the limiter.
D475A, D475ASD-5E0
40 Troubleshooting
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Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of In-range error in common rail pressure sensor (At left bank): Infailure range error occurred (Engine controller system) CA554 • In-range error has occurred in common rail pressure sensor circuit. • Operates with limited output.(Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases.
Possible causes and the standard values when normal
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA451].
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of In-range error in common rail pressure sensor (At right bank): Infailure range error occurred (Engine controller system) CB554 • In-range error has occurred in common rail pressure sensor circuit. • Operates with limited output.(Limits common rail pressure.) • Flashes warning lamp and turns on alarm buzzer. • Output decreases.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB451].
39
SEN01825-03
40 Troubleshooting
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of failure pressure feed detected (Engine controller system) CA559 • Loss of pressure feed (level 1) from supply pump has occurred. • Limits common rail pressure. • Flashes warning lamp and turns on alarm buzzer. • Output decreases.
Cause 1 Defective related circuits 2
Possible causes and the standard values when normal
Improper fuel has been used.
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel is suspected, directly check the fuel.
a See “Note 1” for the contents of diagnosis. See Testing and adjusting “Testing fuel pressure” for the pressure inspection of the fuel low pressure circuit. Defective low pressure 3 Pressure in fuel low pressure circuit device 0.15 – 0.3 MPa circuit (At high idle or under the load {1.5 – 3.0 kg/cm2} equivalent to rating (stalling)) 4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis. Since an electrical defect of supply pump PCV is suspected, carry Defective electrical system 5 out troubleshooting for the following codes. of supply pump PCV [CA271], [CA272], [CA273], and [CA274] Defective common rail Since a defect of common rail pressure sensor is suspected, check 6 pressure sensor for a damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and adjusting “Testing fuel return and leak amount”. 7 Defective pressure limiter Max. 10 cc/min. Pressure limiter leak amount [Equivalent to rated operation (stalling)] a As for the test relating to return (spill) limit amount of injector, see Testing and adjusting “Testing fuel return and leak amount”. Speed under the conditions which are equivalent to rated operation Injector return (spill) limit amount (stalling) 8 Defective injector 1,600 rpm 960 cc/min 1,700 rpm 1,020 cc/min 1,800 rpm 1,080 cc/min 1,900 rpm 1,140 cc/min 2,000 rpm 1,200 cc/min Supply pump can be suspected to be defective if no problem is 9 Defective supply pump found in causes 1 – 8.
Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed”.
40
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40 Troubleshooting
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Note 1: When low-pressure circuit equipment is defective, check the following: 1) Fuel level 2) Clogged fuel tank breather 3) Stuck or worn feed pump, clogged filter 4) Leaked or clogged low-pressure fuel pipe 5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.) 6) Clogged fuel filter 7) Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check. If clogged, clean. 2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0
41
SEN01825-03
40 Troubleshooting
Check sheet for no-pressure feed Model Model and serial No.
Operation No. #
Date inspected
Engine Engine serial No.
/
#
h
Worker's name
A. Visual inspections 1
Fuel leakage to outside
2
Clogged fuel tank breather
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) 3
/
Service meter
Checking failure codes
/
/
/
Pass Fail /
Checking monitoring information Code
*1
4
Display item
Engine speed
Condition for inspection
Unit
Standard value (reference value)
Low idle
rpm
600 – 700
High idle
rpm
2,100 – 2,200
Equivalent to rating
rpm
2,000
Measured value
Pass Fail
Low idle
%
0
High idle
%
100
Equivalent to rating
mm3
—
—
Command for common rail pressure
Equivalent to rating
MPa
*5
Fuel pressure in common rail
Equivalent to rating
MPa
Low idle
CA
—
—
—
*6
Command for fuel injection timing
High idle
CA
—
—
—
Equivalent to rating
CA
—
—
—
kPa
—
—
—
*2
Throttle speed
*3
Command for fuel injection rate
*4
—
*7
Boost pressure
Equivalent to rating
*8
Coolant temperature (high temperature)
Low idle
°C
—
—
—
*9
Coolant temperature (low temperature)
Low idle
°C
—
—
—
*10
Fuel temperature
Low idle
°C
—
—
—
Unit
Standard value (reference value)
Checking reduced cylinder mode operation (engine speed) Function
5 *11
Cut-out cylinder
42
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
—
—
—
Cylinder No. 2
Low idle
rpm
—
—
—
Cylinder No. 3
Low idle
rpm
—
—
—
Cylinder No. 4
Low idle
rpm
—
—
—
Cylinder No. 5
Low idle
rpm
—
—
—
Cylinder No. 6
Low idle
rpm
—
—
—
Condition for inspection
Unit
Standard value (reference value)
At high idle or under the load equivalent to rating (stalling)
MPa {kg/cm2}
0.15 – 0.3 {1.5 – 3.0}
C. Inspection of pressure in fuel circuit 6
Condition for inspection
Pressure in fuel low pressure circuit
Measured value
Pass Fail
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40 Troubleshooting
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D. Inspection of strainer and filter 7
Visual inspection of strainer
8
Visual inspection of gauze filter
9
Visual inspection of fuel filter
Pass Fail
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return amount 11
Pressure limiter leak amount
12 Injector return amount
Unit
Standard value (reference value)
Under the load equivalent to rating (stalling)
cc/min
Max 10
Equivalent to rating: 1,600 rpm
cc/min
960
Equivalent to rating: 1,700 rpm
cc/min
1,020
Equivalent to rating: 1,800 rpm
cc/min
1,080
Equivalent to rating: 1,900 rpm
cc/min
1,140
Equivalent to rating: 2,000 rpm
cc/min
1,200
Condition for inspection
Measured value
Pass Fail
Rotation speed:
Return amount:
Inspection items *1 – *10 of B-4: When inspecting with the monitoring function, see “Monitoring code table”. Inspection items *11 of B-5: When inspecting with the monitoring function, see “Adjustment mode table”. Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
D475A, D475ASD-5E0
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SEN01825-03
40 Troubleshooting
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification) Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code
Loss of pressure feed from supply pump (1) (At left bank): Loss of Symptom of pressure feed detected (Low-grade fuel specification) failure CA559 (Engine controller system) • Loss of pressure feed (level 1) from supply pump has occurred. • Limits common rail pressure. • Output decreases. • Flashes warning lamp and turns on alarm buzzer.
Cause 1 Defective related circuits 2
Possible causes and the standard values when normal
Improper fuel has been used.
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel is suspected, directly check the fuel.
a See “Note 1” for the contents of diagnosis. See Testing and adjusting “Testing fuel pressure” for the pressure inspection of the fuel low pressure circuit. Defective low pressure 3 Pressure in fuel low pressure circuit device 0.15 – 0.3 MPa circuit (At high idle or under the load {1.5 – 3.0 kg/cm2} equivalent to rating (stalling)) 4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis. Since an electrical defect of supply pump PCV is suspected, carry Defective electrical system 5 out troubleshooting for the following codes. of supply pump PCV [CA271], [CA272], [CA273], and [CA274] Defective common rail Since a defect of common rail pressure sensor is suspected, check 6 pressure sensor for a damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and adjusting “Testing fuel return and leak amount”. 7 Defective pressure limiter Max. 10 cc/min. Pressure limiter leak amount [Equivalent to rated operation (stalling)] a As for the test relating to return (spill) limit amount of injector, see Testing and adjusting “Testing fuel return and leak amount”. Speed under the conditions which are equivalent to rated operation Injector return (spill) limit amount (stalling) 8 Defective injector 1,600 rpm 960 cc/min 1,700 rpm 1,020 cc/min 1,800 rpm 1,080 cc/min 1,900 rpm 1,140 cc/min 2,000 rpm 1,200 cc/min Supply pump can be suspected to be defective if no problem is 9 Defective supply pump found in causes 1 – 8.
Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed”.
44
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40 Troubleshooting
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Note 1: When low-pressure circuit equipment is defective, check the following: 1) Fuel level 2) Clogged fuel tank breather 3) Water separator and pre-filter filled with water 4) Stuck or worn feed pump, clogged filter 5) Leaked or clogged low-pressure fuel pipe 6) Bypass valve malfunction, defective assembly of other parts (See Fig.1.) 7) Clogged fuel filter 8) Clogged screen in water separator 9) Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Water separator: Disassemble, check, and clean screen (4) if clogged. 2) Gauze filter: Disassemble and check. If clogged, clean. 3) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 4) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0
45
SEN01825-03
40 Troubleshooting
Check sheet for no-pressure feed Model Model and serial No.
Operation No. #
Date inspected
Engine Engine serial No.
/
#
h
Worker's name
A. Visual inspections 1
Fuel leakage to outside
2
Clogged fuel tank breather
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) 3
/
Service meter
Checking failure codes
/
/
/
Pass Fail /
Checking monitoring information Code
*1
4
Display item
Engine speed
Condition for inspection
Unit
Standard value (reference value)
Low idle
rpm
600 – 700
High idle
rpm
2,100 – 2,200
Equivalent to rating
rpm
2,000
Measured value
Pass Fail
Low idle
%
0
High idle
%
100
Equivalent to rating
mm3
—
—
Command for common rail pressure
Equivalent to rating
MPa
*5
Fuel pressure in common rail
Equivalent to rating
MPa
Low idle
CA
—
—
—
*6
Command for fuel injection timing
High idle
CA
—
—
—
Equivalent to rating
CA
—
—
—
kPa
—
—
—
*2
Throttle speed
*3
Command for fuel injection rate
*4
—
*7
Boost pressure
Equivalent to rating
*8
Coolant temperature (high temperature)
Low idle
°C
—
—
—
*9
Coolant temperature (low temperature)
Low idle
°C
—
—
—
*10
Fuel temperature
Low idle
°C
—
—
—
Unit
Standard value (reference value)
Checking reduced cylinder mode operation (engine speed) Function
5 *11
Cut-out cylinder
46
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
—
—
—
Cylinder No. 2
Low idle
rpm
—
—
—
Cylinder No. 3
Low idle
rpm
—
—
—
Cylinder No. 4
Low idle
rpm
—
—
—
Cylinder No. 5
Low idle
rpm
—
—
—
Cylinder No. 6
Low idle
rpm
—
—
—
Condition for inspection
Unit
Standard value (reference value)
At high idle or under the load equivalent to rating (stalling)
MPa {kg/cm2}
0.15 – 0.3 {1.5 – 3.0}
C. Inspection of pressure in fuel circuit 6
Condition for inspection
Pressure in fuel low pressure circuit
Measured value
Pass Fail
D475A, D475ASD-5E0
40 Troubleshooting
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D. Inspection of strainer and filter 7
Visual inspection of strainer
8
Visual inspection of gauze filter
9
Visual inspection of fuel filter
Pass Fail
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return amount 11
Pressure limiter leak amount
12 Injector return amount
Unit
Standard value (reference value)
Under the load equivalent to rating (stalling)
cc/min
Max 10
Equivalent to rating: 1,600 rpm
cc/min
960
Equivalent to rating: 1,700 rpm
cc/min
1,020
Equivalent to rating: 1,800 rpm
cc/min
1,080
Equivalent to rating: 1,900 rpm
cc/min
1,140
Equivalent to rating: 2,000 rpm
cc/min
1,200
Condition for inspection
Measured value
Pass Fail
Rotation speed:
Return amount:
Inspection items *1 – *10 of B-4: When inspecting with the monitoring function, see “Monitoring code table”. Inspection items *11 of B-5: When inspecting with the monitoring function, see “Adjustment mode table”. Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
D475A, D475ASD-5E0
47
SEN01825-03
40 Troubleshooting
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of failure pressure feed detected (Engine controller system) CB559 • Loss of pressure feed (level 1) from supply pump has occurred. • Limits common rail pressure. • Output decreases. • Flashes warning lamp and turns on alarm buzzer.
Cause 1 Defective related circuits 2
Possible causes and the standard values when normal
Improper fuel has been used.
Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel is suspected, directly check the fuel.
a See “Note 1” for the contents of diagnosis. See Testing and adjusting “Testing fuel pressure” for the pressure inspection of the fuel low pressure circuit. Defective low pressure 3 Pressure in fuel low pressure circuit device 0.15 – 0.3 MPa circuit (At high idle or under the load {1.5 – 3.0 kg/cm2} equivalent to rating (stalling)) 4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis. Since an electrical defect of supply pump PCV is suspected, carry Defective electrical system 5 out troubleshooting for the following codes. of supply pump PCV [CB271], [CB272], [CB273], and [CB274] Defective common rail Since a defect of common rail pressure sensor is suspected, check 6 pressure sensor for a damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and adjusting “Testing fuel return and leak amount”. 7 Defective pressure limiter Max. 10 cc/min. Pressure limiter leak amount [Equivalent to rated operation (stalling)] a As for the test relating to return (spill) limit amount of injector, see Testing and adjusting “Testing fuel return and leak amount”. Speed under the conditions which are equivalent to rated operation Injector return (spill) limit amount (stalling) 8 Defective injector 1,600 rpm 960 cc/min 1,700 rpm 1,020 cc/min 1,800 rpm 1,080 cc/min 1,900 rpm 1,140 cc/min 2,000 rpm 1,200 cc/min Supply pump can be suspected to be defective if no problem is 9 Defective supply pump found in causes 1 – 8.
Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed”.
48
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40 Troubleshooting
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Note 1: When low-pressure circuit equipment is defective, check the following: 1) Fuel level 2) Clogged fuel tank breather 3) Stuck or worn feed pump, clogged filter 4) Leaked or clogged low-pressure fuel pipe 5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.) 6) Clogged fuel filter 7) Fuel in oil pan (fuel leakage in head cover) Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) q Overflow valve (1): Spring is seen through both holes. q Bypass valve (2): Spring is seen through hole on nut side. q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check. If clogged, clean. 2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
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40 Troubleshooting
Check sheet for no-pressure feed Model Model and serial No.
Operation No. #
Date inspected
Engine Engine serial No.
/
#
h
Worker's name
A. Visual inspections 1
Fuel leakage to outside
2
Clogged fuel tank breather
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) 3
/
Service meter
Checking failure codes
/
/
/
Pass Fail /
Checking monitoring information Code
*1
4
Display item
Engine speed
Condition for inspection
Unit
Standard value (reference value)
Low idle
rpm
600 – 700
High idle
rpm
2,100 – 2,200
Equivalent to rating
rpm
2,000
Measured value
Pass Fail
Low idle
%
0
High idle
%
100
Equivalent to rating
mm3
—
—
Command for common rail pressure
Equivalent to rating
MPa
*5
Fuel pressure in common rail
Equivalent to rating
MPa
Low idle
CA
—
—
—
*6
Command for fuel injection timing
High idle
CA
—
—
—
Equivalent to rating
CA
—
—
—
kPa
—
—
—
*2
Throttle speed
*3
Command for fuel injection rate
*4
—
*7
Boost pressure
Equivalent to rating
*8
Coolant temperature (high temperature)
Low idle
°C
—
—
—
*9
Coolant temperature (low temperature)
Low idle
°C
—
—
—
*10
Fuel temperature
Low idle
°C
—
—
—
Unit
Standard value (reference value)
Checking reduced cylinder mode operation (engine speed) Function
5 *11
Cut-out cylinder
50
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
—
—
—
Cylinder No. 2
Low idle
rpm
—
—
—
Cylinder No. 3
Low idle
rpm
—
—
—
Cylinder No. 4
Low idle
rpm
—
—
—
Cylinder No. 5
Low idle
rpm
—
—
—
Cylinder No. 6
Low idle
rpm
—
—
—
Condition for inspection
Unit
Standard value (reference value)
At high idle or under the load equivalent to rating (stalling)
MPa {kg/cm2}
0.15 – 0.3 {1.5 – 3.0}
C. Inspection of pressure in fuel circuit 6
Condition for inspection
Pressure in fuel low pressure circuit
Measured value
Pass Fail
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D. Inspection of strainer and filter 7
Visual inspection of strainer
8
Visual inspection of gauze filter
9
Visual inspection of fuel filter
Pass Fail
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return amount 11
Pressure limiter leak amount
12 Injector return amount
Unit
Standard value (reference value)
Under the load equivalent to rating (stalling)
cc/min
Max 10
Equivalent to rating: 1,600 rpm
cc/min
960
Equivalent to rating: 1,700 rpm
cc/min
1,020
Equivalent to rating: 1,800 rpm
cc/min
1,080
Equivalent to rating: 1,900 rpm
cc/min
1,140
Equivalent to rating: 2,000 rpm
cc/min
1,200
Condition for inspection
Measured value
Pass Fail
Rotation speed:
Return amount:
Inspection items *1 – *10 of B-4: When inspecting with the monitoring function, see “Monitoring code table”. Inspection items *11 of B-5: When inspecting with the monitoring function, see “Adjustment mode table”. Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
D475A, D475ASD-5E0
51
SEN01825-03
40 Troubleshooting
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Ne speed sensor (At left bank): Abnormal signal failure (Engine controller system) CA689 • Abnormal signal of the engine Ne speed sensor has been detected. • Operates using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Causes Defective sensor power 1 source circuit
Disconnection in wiring harness 2 (disconnection or defective contact of connectors)
Defective harness grounding 3 (contact with ground circuit)
Possible causes and the standard values when normal
4
Harness short (Harness internal short)
Defective mounting of sen5 sor or defective parts for speed detection 6
Defective engine Ne speed sensor
7 Defective engine controller
52
Standard values when normal and remarks for troubleshooting If failure code [CA238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between left ENG (female) ResisMax. 1 z (16) – NE (female) (1) tance Wiring harness between left ENG (female) ResisMax. 1 z (48) – NE (female) (2) tance Wiring harness between left ENG (female) ResisMax. 1 z (27) – NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (16) – NE (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (48) – NE (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (27) – NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from left ENG Resis(female) (16) to NE (female) (1) and wiring Min. 1 Mz tance harness from left ENG (female) (48) to NE (female) (2) Between wiring harness from left ENG (female) (16) to NE (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (27) to NE tance (female) (3) Between wiring harness from left ENG (female) (48) to NE (female) (2) and wiring ResisMin. 1 Mz harness from left ENG (female) (27) to NE tance (female) (3) Since defective mounting of Ne speed sensor (improper gap) or defective parts for speed detection (flywheel) can be suspected, directly check it. Engine Ne speed sensor can be suspected to be defective if no problem is found in causes 1 – 5 (since this is an internal defect, it cannot be diagnosed). Engine controller can be suspected to be defective if no problem is found in causes 1 – 6 (since this is an internal defect, it cannot be diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to engine Ne speed sensor
D475A, D475ASD-5E0
53
SEN01825-03
40 Troubleshooting
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Ne speed sensor (At right bank): Abnormal signal failure (Engine controller system) CB689 • Abnormal signal of the engine Ne speed sensor has been detected. • Operates using Bkup speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Bkup speed sensor is defective at the same time). • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Causes Defective sensor power 1 source circuit
Disconnection in wiring harness 2 (disconnection or defective contact of connectors)
Defective harness grounding 3 (contact with ground circuit)
Possible causes and the standard values when normal
4
Harness short (Harness internal short)
Defective mounting of sen5 sor or defective parts for speed detection 6
Defective engine Ne speed sensor
7 Defective engine controller
54
Standard values when normal and remarks for troubleshooting If failure code [CB238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between left ENG (female) ResisMax. 1 z (16) – NE (female) (1) tance Wiring harness between right ENG (female) ResisMax. 1 z (48) – NE (female) (2) tance Wiring harness between right ENG (female) ResisMax. 1 z (27) – NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (16) – NE (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (48) – NE (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (27) – NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from left ENG Resis(female) (16) to NE (female) (1) and wiring Min. 1 Mz tance harness from right ENG (female) (48) to NE (female) (2) Between wiring harness from left ENG (female) (16) to NE (female) (1) and wiring ResisMin. 1 Mz harness from right ENG (female) (27) to NE tance (female) (3) Between wiring harness from right ENG (female) (48) to NE (female) (2) and wiring ResisMin. 1 Mz harness from right ENG (female) (27) to NE tance (female) (3) Since defective mounting of Ne speed sensor (improper gap) or defective parts for speed detection (flywheel) can be suspected, directly check it. Engine Ne speed sensor can be suspected to be defective if no problem is found in causes 1 – 5 (since this is an internal defect, it cannot be diagnosed). Engine controller can be suspected to be defective if no problem is found in causes 1 – 6 (since this is an internal defect, it cannot be diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to engine Ne speed sensor
D475A, D475ASD-5E0
55
SEN01825-03
40 Troubleshooting
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Intake air temperature sensor abnormally high level (Only left bank): failure High voltage detection (Engine controller system) CA691 • Intake air temperature sensor circuit detected high voltage. • Fixes intake air temperature (25°C) and continues operation.
Cause Defective charge tempera1 ture sensor (Internal defect)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
Ground fault in wiring har3 ness (Contact with GND circuit)
4 Defective engine controller
56
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TAM1 Intake air temperature Resistance Between (A) – (B) 10 – 100°C 0.5 – 20 kz Between (A) – ground All range Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (43) – ResisMax. 1z TAM1 (female) (A) tance Wiring harness between ENG (female) (47) – ResisMax. 1z TAM1 (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (43) – TAM1 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Intake air temperature Resistance Between (43) – (47) 10 – 100°C 0.5 – 20 kz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to intake air temperature sensor
D475A, D475ASD-5E0
57
SEN01825-03
40 Troubleshooting
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
58
Failure code Symptom of Intake air temperature sensor abnormally low level (Only left bank): failure Low voltage detection (Engine controller system) CA692 • Intake air temperature sensor circuit detected low voltage. • Fixes intake air temperature (25°C) and continues operation.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA691].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Bkup speed sensor phase (At left bank): Abnormal failure phase (Engine controller system) CA731 • Abnormal phase has been detected in the engine Bkup sensor circuit. • Operates using engine Ne speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Ne speed sensor is defective at the same time). • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Cause Possible causes and the standard values when normal
1
Defective engine Ne speed sensor circuit
2
Defective engine Bkup speed sensor system
Standard values when normal and remarks for troubleshooting Since a defect of engine Ne speed sensor can be suspected, carry out troubleshooting for the following code. [CA689] Since a defect of engine Bkup speed sensor can be suspected, carry out troubleshooting for the following code. [CA778]
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Bkup speed sensor phase (At right bank): Abnorfailure mal phase (Engine controller system) CB731 • Abnormal phase has been detected in the engine Bkup sensor circuit. • Operates using engine Ne speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Ne speed sensor is defective at the same time). • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Cause Possible causes and the standard values when normal
1
Defective engine Ne speed sensor circuit
2
Defective engine Bkup speed sensor system
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting Since a defect of engine Ne speed sensor can be suspected, carry out troubleshooting for the following code. [CB689] Since a defect of engine Bkup speed sensor can be suspected, carry out troubleshooting for the following code. [CB778]
59
SEN01825-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01825-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
60
SEN01826-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 4 Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data .................................. 3 Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data................................ 3 Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal ................ 4 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error..................... 6 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error ............... 8 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error .......... 10 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error ......11 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error... 12 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 14 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 16 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 18 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 20
D475A, D475ASD-5E0
1
SEN01826-01
40 Troubleshooting
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 22 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 24 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error......................................... 26 Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection ........................................................................................................................... 28 Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected .......................................................................................................... 30 Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected.............................................................................................................. 31 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected.............................................................................................................. 31 Failure code [D110KA] Battery relay: Disconnection .................................................................................... 32 Failure code [D110KB] Battery relay: Short circuit ........................................................................................ 34 Failure code [D130KA] Neutral safety relay: Disconnection ......................................................................... 36 Failure code [D130KB] Neutral safety relay: Short circuit ............................................................................. 38 Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 40 Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 42 Failure code [D182KZ] Preheater relay: Disconnection or short circuit ........................................................ 44 Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection....................................... 46 Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit .......................................... 48 Failure code [D5ZRKA] Snap shot switch: Disconnection ............................................................................ 50 Failure code [D5ZRKB] Snap shot switch: Short circuit ................................................................................ 51 Failure code [DAFRKR] Monitor panel CAN communication: Communication error .................................... 52 Failure code [dAFRKR] Monitor panel CAN communication: Communication error ..................................... 54 Failure code [daFRKR] Monitor panel CAN communication: Communication error ..................................... 56 Failure code [DAQ0KT] Transmission controller: Abnormality in controller .................................................. 58 Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input).................................................................................................. 60 Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input).................................................................................................. 62 Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) ............................................................................................................ 64 Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) ............................................................................................................ 65 Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input).................................................................................................. 66 Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency ............... 67 Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality) ........................................................ 68 Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system) .............................................. 70
2
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40 Troubleshooting
SEN01826-01
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Loss of all engine controller data (At left bank): Loss of all data failure (Engine controller system) CA757 • Loss of all data in engine controller has been detected. • Flashes warning lamp and turns on alarm buzzer. • The engine cannot be started, or cannot be operated.
Possible causes and the standard values when normal
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA111].
Failure code [CB757] Loss of all engine controller data (At right bank): 1 Loss of all data Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Loss of all engine controller data (At right bank): Loss of all data failure (Engine controller system) CB757 • Loss of all data in engine controller has been detected. • Flashes warning lamp and turns on alarm buzzer. • The engine cannot be started, or cannot be operated.
Possible causes and the standard values when normal
D475A, D475ASD-5E0
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB111].
3
SEN01826-01
40 Troubleshooting
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup failure signal (Engine controller system) CA778 • Abnormal engine Bkup speed sensor signal has been detected. • Operates using Ne speed sensor signal. • Flashes warning lamp and turns on alarm buzzer. • Engine stops during operation (when Ne speed sensor is defective at the same time). • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Cause Defective sensor power 1 source circuit
Possible causes and the standard values when normal
4
Standard values when normal and remarks for troubleshooting If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between left ENG (female) ResisDisconnection in wiring Max. 1 z (37) – left G (female) (1) tance harness 2 (disconnection or defective Wiring harness between left ENG (female) ResisMax. 1 z contact of connectors) (47) – left G (female) (2) tance Wiring harness between left ENG (female) ResisMax. 1 z (26) – left G (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz Defective harness left ENG (female) (37) – left G (female) (1) tance 3 grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz left ENG (female) (47) – left G (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (26) – left G (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from left ENG (female) (37) to left G (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (47) to left G tance (female) (2) Harness short Between wiring harness from left ENG 4 (Harness internal short) (female) (37) to left G (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (26) to left G tance (female) (3) Between wiring harness from left ENG (female) (47) to left G (female) (2) and wiring ResisMin. 1 Mz harness from left ENG (female) (26) to left G tance (female) (3) Defective mounting of sen- Since defective mounting of Bkup speed sensor (improper gap) or 5 sor or defective parts for defective parts for speed detection (in supply pump) can be susspeed detection pected, directly check it. Engine Bkup speed sensor can be suspected to be defective if no Defective engine Bkup 6 problem is found in causes 1 – 5 (since this is an internal defect, it speed sensor cannot be diagnosed). Engine controller can be suspected to be defective if no problem is 7 Defective engine controller found in causes 1 – 6 (since this is an internal defect, it cannot be diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine Bkup speed sensor
D475A, D475ASD-5E0
5
SEN01826-01
40 Troubleshooting
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Engine Bkup speed sensor abnormality (Right bank): Bkup signal failure error (Engine controller system) CB778 • Engine Bkup speed sensor signal detected abnormality. • Operates with Ne speed sensor signal • Blinks warning lamp and sounds alarm buzzer. • If engine has been running, it stops (when Ne speed sensor is also defective). • If engine has been stopped, it cannot start (when Ne speed sensor is also defective).
Cause Defective sensor power 1 supply system
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
Ground fault in wiring har3 ness (Contact with GND circuit)
Possible causes and the standard values when normal
Short circuit in wiring har4 ness (with another wiring harness)
Defective sensor installa5 tion or defective speed sensing part 6
Defective engine Bkup speed sensor
7 Defective engine controller
6
1
Standard values when normal and remarks for troubleshooting If failure code [CB187] or [CB227] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between right ENG (female) ResisMax. 1 z (37) – right G (female) (1) tance Wiring harness between right ENG (female) ResisMax. 1 z (47) – right G (female) (2) tance Wiring harness between right ENG (female) ResisMax. 1 z (26) – right G (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (37) – right G (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (47) – right G (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (26) – right G (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between right ENG (female) (37) – right G (female) (1) and wiring ResisMin. 1 Mz harness between right ENG (female) (47) – tance right G (female) (2) Between wiring harness between right ENG (female) (37) – right G (female) (1) and wiring ResisMin. 1 Mz harness between right ENG (female) (26) – tance right G (female) (3) Between wiring harness between right ENG (female) (47) – right G (female) (2) and wiring ResisMin. 1 Mz harness between right ENG (female) (26) – tance right G (female) (3) Bkup speed sensor may be installed defectively (improper clearance) or speed sensing part (in supply pump) may be defective. Check them directly. If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine Bkup speed sensor
D475A, D475ASD-5E0
7
SEN01826-01
40 Troubleshooting
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error
1
Action code Failure code Symptom of Inter-multicontroller communication error (Left bank): Communicafailure tion error (Engine controller system) CALL E03 CA781 Failure content • Communication error occurred between engine controllers (Left bank). Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that • During operation: Engine continues operation with 1 bank. appear on • When key is ON: Engine cannot be started. machine General information Cause
Possible causes and the standard values when normal
8
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between left ENG (female) Resis1 Max. 1 z wiring or defective contact (8) – right ENG (female) (8) tance in connector) Wiring harness between left ENG (female) ResisMax. 1 z (6) – right ENG (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resis2 harness (Contact with Min. 1 Mz left ENG (female) (8) – right ENG (female) (8) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (6) – right ENG (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Left ENG (female) Resistance 3 Defective engine controller Between (8) – (6) 108 – 132 z Between (8), (6) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to communication between multiple controller
D475A, D475ASD-5E0
9
SEN01826-01
40 Troubleshooting
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error 1 Action code Failure code Symptom of Inter-multicontroller communication error (Right bank): Communicafailure tion error (Engine controller system) CALL E03 CB781 Failure content • Communication error occurred between engine controllers (Right bank). Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that • During operation: Engine continues operation with 1 bank. appear on • When key is ON: Engine cannot be started. machine General information Possible causes and the standard values when normal
10
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA781].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
1
Failure code Symptom of Multicontroller distinction wiring harness key error (Left bank): Disfailure tinction error (Engine controller system) CA1257 • Controller of each bank disagrees with distinction wiring harness (Left bank). • Stops operation. • Blinks warning lamp and sounds alarm buzzer. • When key is ON: Engine cannot be started.
Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between OEM L (female) (7) ResisMax. 1 z in connector) – OEM L (female) (34) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Resiscircuit) Between OEM L (female) (8) – ground Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisMin. 1 Mz 3 Defective engine controller Between OEM L (female) (7) – ground tance ResisBetween OEM L (female) (8) – ground Min. 1 Mz tance
Circuit diagram related to multicontroller distinction wiring harness key
D475A, D475ASD-5E0
11
SEN01826-01
40 Troubleshooting
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
1
Failure code Symptom of Multicontroller distinction wiring harness key error (Right bank): Disfailure tinction error (Engine controller system) CB1257 • Controller of each bank disagrees with distinction wiring harness (Right bank). • Stops operation. • Blinks warning lamp and sounds alarm buzzer. • When key is ON: Engine cannot be started.
Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between OEM R (female) (7) ResisMin. 1 Mz in connector) – OEM R (female) (34) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Resiscircuit) Between OEM R (female) (8) – ground Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisMin. 1 Mz 3 Defective engine controller Between OEM R (female) (7) – ground tance ResisBetween OEM R (female) (8) – ground Min. 1 Mz tance
Circuit diagram related to multicontroller distinction wiring harness key
12
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01826-01
13
SEN01826-01
40 Troubleshooting
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1 Action code Failure code Symptom of Injector #7 (R/B #1) system disconnection/short circuit (Right bank): failure Disconnection/Short circuit (Engine controller system) CALL E03 CB1548 Failure content • Disconnection or short circuit occurred in injector #7 circuit. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that • Output lowers. appear on • Engine speed is unstable. machine General • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
14
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #7 CN1 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (45) – Max. 1 z tance wiring or defective contact CN1 (female) (1) in connector) Wiring harness between ENG (female) (53) – ResisMax. 1 z CN1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resisness (Contact with GND Min. 1 Mz ENG (female) (45) – CN1 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (53) – CN1 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (45) – (53) 0.4 – 1.1 z Between (45), (53) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #7 (R/B #1)
D475A, D475ASD-5E0
15
SEN01826-01
40 Troubleshooting
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1 Action code Failure code Symptom of Injector #8 (R/B #2) system disconnection/short circuit (Right bank): failure Disconnection/Short circuit (Engine controller system) CALL E03 CB1549 Failure content • Disconnection or short circuit occurred in injector #8 circuit. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that • Output lowers. appear on • Engine speed is unstable. machine General • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
16
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #8 CN2 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (54) – Max. 1 z tance wiring or defective contact CN2 (female) (1) in connector) Wiring harness between ENG (female) (51) – ResisMax. 1 z CN2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resisness (Contact with GND Min. 1 Mz ENG (female) (54) – CN2 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (51) – CN2 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (54) – (51) 0.4 – 1.1 z Between (54), (51) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #8 (R/B #2)
D475A, D475ASD-5E0
17
SEN01826-01
40 Troubleshooting
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #10 (R/B #4) system disconnection/short circuit (Right failure bank): Disconnection/Short circuit (Engine controller system) CB1551 • Disconnection or short circuit occurred in injector #10 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
18
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #10 CN4 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (56) – Max. 1 z tance wiring or defective contact CN4 (female) (1) in connector) Wiring harness between ENG (female) (58) – ResisMax. 1 z CN4 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resisness (Contact with GND Min. 1 Mz ENG (female) (56) – CN4 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (58) – CN4 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (56) – (58) 0.4 – 1.1 z Between (56), (58) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #10 (R/B #4)
D475A, D475ASD-5E0
19
SEN01826-01
40 Troubleshooting
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1 Action code Failure code Symptom of Injector #11 (R/B #5) system disconnection/short circuit (Right bank): failure Disconnection/Short circuit (Engine controller system) CALL E03 CB1552 Failure content • Disconnection or short circuit occurred in injector #11 circuit. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that • Output lowers. appear on • Engine speed is unstable. machine General • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
20
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #11 CN5 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (46) – Max. 1 z tance wiring or defective contact CN5 (female) (1) in connector) Wiring harness between ENG (female) (60) – ResisMax. 1 z CN5 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resisness (Contact with GND Min. 1 Mz ENG (female) (46) – CN5 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (60) – CN5 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (46) – (60) 0.4 – 1.1 z Between (46), (60) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #11 (R/B #5)
D475A, D475ASD-5E0
21
SEN01826-01
40 Troubleshooting
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Injector #12 (R/B #6) system disconnection/short circuit (Right failure bank): Disconnection/Short circuit (Engine controller system) CB1553 • Disconnection or short circuit occurred in injector #12 circuit. • Blinks warning lamp and sounds alarm buzzer. • Output lowers. • Engine speed is unstable. • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
22
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #12 CN6 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (57) – Max. 1 z tance wiring or defective contact CN6 (female) (1) in connector) Wiring harness between ENG (female) (59) – ResisMax. 1 z CN6 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resisness (Contact with GND Min. 1 Mz ENG (female) (57) – CN6 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (59) – CN6 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (57) – (59) 0.4 – 1.1 z Between (57), (59) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #12 (R/B #6)
D475A, D475ASD-5E0
23
SEN01826-01
40 Troubleshooting
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit 1 Action code Failure code Symptom of Injector #9 (R/B #3) system disconnection/short circuit (Right bank): failure Disconnection/Short circuit (Engine controller system) CALL E03 CB1622 Failure content • Disconnection or short circuit occurred in injector #9 circuit. Controller's • Blinks warning lamp and sounds alarm buzzer. action Symptoms that • Output lowers. appear on • Engine speed is unstable. machine General • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Cause
1
2 Possible causes and the standard values when normal 3
4
5
24
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #9 CN3 (male) Resistance (Internal defect) Between (1) – (2) 0.4 – 1.1 z Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (55) – Max. 1 z tance wiring or defective contact CN3 (female) (1) in connector) Wiring harness between ENG (female) (52) – ResisMax. 1 z CN3 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resisness (Contact with GND Min. 1 Mz ENG (female) (55) – CN3 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (52) – CN3 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (55) – (52) 0.4 – 1.1 z Between (55), (52) – ground Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #9 (R/B #3)
D475A, D475ASD-5E0
25
SEN01826-01
40 Troubleshooting
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error
1
Action code Failure code Symptom of KOMNET abnormality (Left bank): Communication error failure (Engine controller system) CALL E03 CA1633 Failure content • Abnormality occurred in KOMNET communication circuit to engine controller (Left bank). Controller's • Continues normal control (Communication function cannot be used). action • Blinks warning lamp and sounds alarm buzzer. Symptoms that • Information may not be transmitted or received normally through KOMNET communication system appear on and machine may not operate normally. machine General information Cause
Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector)
Possible causes and the standard values when normal
Ground fault in wiring har2 ness (Contact with GND circuit)
3 Defective engine controller
26
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) ResisMax. 1 z – OEM R (female) (46) tance Wiring harness between OEM L (female) (47) ResisMax. 1 z – OEM R (female) (47) tance Wiring harness between OEM L (female) (46) Resis108 – – OEM L (female) (47) tance 132 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (46) – OEM R (female) (46) tance Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (47) – OEM R (female) (47) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) Resis108 – – OEM L (female) (47) tance 132 z Wiring harness between OEM R (female) Resis108 – (46) – OEM R (female) (47) tance 132 z
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to KOMNET
D475A, D475ASD-5E0
27
SEN01826-01
40 Troubleshooting
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Decelerator pedal sensor power supply abnormally high level (Only failure left bank): High voltage detection CA2185 High voltage (above 5.25 V) was detected in decelerator pedal sensor power supply circuit. If trouble occurs while starting switch is ON, controller fixes sensor to value just before occurrence of abnormality and continues operation. If starting switch is turned ON while there is trouble, controller operates at 100% value. Blinks warning lamp and sounds alarm buzzer.
• • • •
• Engine speed cannot be controlled with decelerator pedal.
Cause
1
Defective decelerator sensor (Internal defect)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal
Ground fault in wiring har3 ness (Contact with GND circuit)
Short circuit in wiring har4 ness (with another wiring harness)
5 Defective engine controller
28
1
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right is disconnected, if code disappears, that Decelerator sensor DEC connector device has trouble in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) ResisMax. 1 z – DEC (female) (A) tance Wiring harness between OEM L (female) (23) ResisMax. 1 z – DEC (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (22) – DEC (female) (A) tance Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (23) – DEC (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between OEM L (female) (22) – DEC (female) (A) and wiring Resis108 – harness between OEM L (female) (23) – DEC tance 132 z (female) (C) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OEM L Voltage Between (22) – (23) 4.75 – 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to decelerator pedal sensor power supply
D475A, D475ASD-5E0
29
SEN01826-01
40 Troubleshooting
Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected 1 Action code CALL E03 Failure content Controller's action
Failure code Symptom of Decelerator pedal sensor power source too low (At left bank only): failure Excessively low voltage detected (Engine controller system) CA2186 Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit. Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates with 100% value. Flashes warning lamp and turns on alarm buzzer.
• • • •
Symptoms that appear on machine General information Possible causes and the standard values when normal
30
• Engine speed cannot be controlled by decelerator pedal.
Cause 1
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA2185].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of failure pressure feed detected (Engine controller system) CA2249 Loss of pressure feed (level 2) occurred in the common rail circuit. Operates with limited output. Flashes warning lamp and turns on alarm buzzer. Engine is hard to start. Exhaust gas color becomes black. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure)
• • • • • • •
Possible causes and the standard values when normal
Cause 1
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA559].
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
Failure code Symptom of Loss of pressure feed from supply pump (2) (At right bank): Loss of failure pressure feed detected (Engine controller system) CB2249 Loss of pressure feed (level 2) occurred in the common rail circuit. Operates with limited output. Flashes warning lamp and turns on alarm buzzer. Engine is hard to start. Exhaust gas color becomes black. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure)
• • • • • • •
Cause 1
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB559].
31
SEN01826-01
40 Troubleshooting
Failure code [D110KA] Battery relay: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Battery relay: Disconnection failure (Steering controller system) D110KA • 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 failure code: Switch starting switch from ON to OFF. Cause
1
Possible causes and the standard values when normal
2
3
4
32
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective battery relay Battery relay Continuity (Internal disconnection) Between terminals BR – Continue ground terminal (E) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) (4) ResisMax. 1 z wiring or defective contact – battery relay SW tance in connector) Wiring harness between battery relay ground ResisMax. 1 z terminal – chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisMin. 1 Mz STCN3 (female) (4) – battery relay SW – cuit) tance KEY (female) (4) with chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering controlSTCN3 (female) Continuity ler Between (4) – chassis ground Continue
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to battery relay
D475A, D475ASD-5E0
33
SEN01826-01
40 Troubleshooting
Failure code [D110KB] Battery relay: Short circuit
1
Action code Failure code Symptom of Battery relay: Short circuit failure (Steering controller system) — D110KB Failure content • Abnormal current flowed to battery relay circuit when outputting it. Controller's • Stops output to battery relay circuit. action Symptoms that appear on • Problem may occur in data writing to ROM (nonvolatile storage) of each controller. machine • Output state (voltage) to battery relay can be checked in monitoring mode. General (Code 60600: Battery relay drive voltage) information • Method of reproducing failure code: Switch starting switch from ON to OFF. Cause
Possible causes and the standard values when normal
34
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery relay Continuity/resistance Defective battery relay 1 Between terminals BR – (Internal short circuit) Continue ground terminal (E) Between terminal BR – Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24V circuit) STCN3 (female) (4) – battery relay SW – Voltage Max. 1 V KEY (female) (4) with chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlSTCN3 Starting switch Voltage 3 ler Between (4) – ON 20 – 30 V chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to battery relay
D475A, D475ASD-5E0
35
SEN01826-01
40 Troubleshooting
Failure code [D130KA] Neutral safety relay: Disconnection
1
Action code Failure code Symptom of Neutral safety relay: Disconnection failure (Transmission controller system) E02 D130KA Failure content • 24 V is not generated when ground of neutral safety relay circuit is interrupted. Controller's • Flashes caution lamp and turns on caution buzzer. action • Stops ground output to neutral safety relay circuit. Symptoms that appear on • Engine does not start. machine • Output state (voltage) to neutral safety relay can be checked in monitoring mode. (Code 50900: Neutral safety relay drive voltage) General • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (Lock information position). a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side) Cause
Possible causes and the standard values when normal
36
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective neutral safety without turning starting switch ON. 1 relay (Internal disconnecNSF (male) Resistance tion) Between (1) – (2) 200 – 400 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective disconnection in wiring harness (DisconWiring harness between TMC2 (female) (8) – Resis2 Max. 1 z nection in wiring or defec- NSF (female) (2) tance tive contact in connector) Wiring harness between NSF (female) (1) – ResisMax. 1 z starting switch ACC (270) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness TMC2 (female) (8) – NSF (female) (2) with Min. 1 Mz 3 tance (Contact with ground cir- chassis ground cuit) Short circuit of wiring harness between NSF ResisMin. 1 Mz (female) (1) – starting switch ACC (270) with tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 Parking brake lever Voltage 4 controller Lock position Max. 1 V Between (8) – chassis ground Free position 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0
37
SEN01826-01
40 Troubleshooting
Failure code [D130KB] Neutral safety relay: Short circuit
1
Action code Failure code Symptom of Neutral safety relay: Short circuit failure (Transmission controller system) E02 D130KB Failure content • Abnormal current flowed in neutral safety relay circuit at the time of ground output. Controller's • Flashes caution lamp and turns on caution buzzer. action • Stops ground output to neutral safety relay circuit. Symptoms that appear on • Engine does not start. machine • Output state (voltage) to neutral safety relay can be checked in monitoring mode. (Code 50900: Neutral safety relay drive voltage) General • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (Free information position). a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side) Cause
Possible causes and the standard values when normal
38
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective neutral safety 1 relay (Internal short circuit) NSF (male) Resistance Between (1) – (2) 200 – 400 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMC2 (female) (8) – NSF (female) (2) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 Parking brake lever Voltage 3 controller Lock position Max. 1 V Between (8) – chassis ground Free position 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0
39
SEN01826-01
40 Troubleshooting
Failure code [D161KA] Back-up alarm relay: Disconnection
1
Action code Failure code Symptom of Back-up alarm relay: Disconnection failure (Transmission controller system) E01 D161KA Failure content • 24 V is not generated when ground output of neutral safety relay circuit is interrupted. Controller's • Stops output to back-up alarm relay circuit. action Symptoms that appear on • Back-up alarm is not turned on. machine • Output state (voltage) to back-up alarm relay can be checked in monitoring mode. (Code 70900: Back-up alarm relay drive voltage) General • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (reverse). information a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side) Cause
Possible causes and the standard values when normal
40
Standard values when normal and remarks for troubleshooting If fuse is burnout, circuit probably has short circuit with chassis 1 Defective fuse FS22-1 ground. a Prepare with starting switch OFF, then carry out troubleshooting Defective back-up alarm without turning starting switch ON. 2 relay (Internal disconnecBKA (male) Resistance tion) Between (1) – (2) 200 – 400 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective disconnection in Wiring harness between TMC2 (female) (18) Resiswiring harness (DisconMax. 1 z 3 tance nection in wiring or defec- –BKA (female) (2) tive contact in connector) Wiring harness between BKA (female) (1) – ResisMax. 1 z FS22-1 outlet port tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness TMC2 (female) (18) – BKA (female) (2) with Min. 1 Mz tance 4 (Contact with ground cir- chassis ground cuit) Short circuit of wiring harness between BKA Resis(female) (1) – FS22-1 outlet port with chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 PCCS lever Voltage 5 controller Neutral position 20 – 30 V Between (18) – chassis ground Reverse position Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0
41
SEN01826-01
40 Troubleshooting
Failure code [D161KB] Back-up alarm relay: Short circuit
1
Action code Failure code Symptom of Back-up alarm relay: Short circuit failure (Transmission controller system) E01 D161KB Failure content • Abnormal current flowed in back-up alarm relay circuit at the time of ground output. Controller's • Stops output to back-up alarm relay circuit. action Symptoms that appear on • Back-up alarm is not turned on. machine • Output state (voltage) to back-up alarm relay can be checked in monitoring mode. (Code 70400: Back-up alarm relay drive voltage) General • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (Reverse information position). a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side) Cause
Possible causes and the standard values when normal
42
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective back-up alarm 1 relay (Internal short circuit) BKA (male) Resistance Between (1) – (2) 200 – 400 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMC2 (female) (18) – BKA (female) (2) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 PCCS lever Voltage 3 controller Neutral position 20 – 30 V Between (18) – chassis ground Reverse position Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0
43
SEN01826-01
40 Troubleshooting
Failure code [D182KZ] Preheater relay: Disconnection or short circuit 1 Action code Failure code Symptom of Preheater relay: Disconnection or short circuit failure (Steering controller system) E01 D182KZ Failure content • The upstream relay of the preheater relay does not operate. Controller's action Symptoms that • Automatic preheater system does not operate. appear on • The preheater can be operated manually. machine • The output state to the preheater relay can be checked in the monitoring mode. (Code 40914: Steering controller output signal) General • Method of reproducing failure code: Turn the starting switch ON. information a This failure code detects abnormality on the primary (coil) side of the preheater relay and cannot detect abnormality on the secondary (contact) side. Cause
1
2 Possible causes and the standard values when normal 3
4
44
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective preheater relay PHR (male) Resistance (Internal disconnection) Between (1) and (2) 200 – 400 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness Wiring harness between STCN2 (female) Resis(Disconnection in wiring Max. 1 z (19) and PHR (female) (2) tance harness or defective conWiring harness between PHR (female) (1) Resistact in connector) Max. 1 z and starting switch ACC (270) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Between wiring harness between STCN2 Resisground in wiring harness (female) (19) and RHR (female) (2) and Min. 1 Mz tance (Contact with ground cir- chassis ground cuit) Between wiring harness between PHR Resis(female) (1) and starting switch ACC (270) Min. 1 Mz tance and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlSTCN2 Starting switch Voltage ler ON 20 – 30 V Between (19) chassis ground OFF Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to preheater relay
D475A, D475ASD-5E0
45
SEN01826-01
40 Troubleshooting
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Engine controller ACC signal cutout relay: Disconnection failure (Steering controller system) D190KA • Voltage of engine controller ACC cut relay circuit does not match controller output. • Stops outputting signal to engine controller ACC cut relay. • Engine stop function of steering controller does not work. • Output state (voltage) to engine controller ACC cut relay can be checked in real-time monitoring mode (Code 60500: Engine controller ACC cut relay voltage). • Method of reproducing failure code: Turn starting switch ON. a This failure code detects abnormality on primary side (coil side) of engine controller ACC cut relay but does not detect abnormality on secondary side (contact side). Cause 1 Defective fuse FS31 (1)
2
3 Possible causes and the standard values when normal 4
5
46
Standard values when normal and remarks for troubleshooting If fuse is broken, circuit probably has ground fault etc. a Prepare with starting switch OFF, then carry out troubleshooting Defective engine controller without turning starting switch ON. ACC cut relay ACT (male) Resistance (Internal disconnection) Between (1) – (2) 200 – 400 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness Wiring harness between STCN2 (female) (8) Resis(Disconnection in wiring Max. 1 z – ACT (female) (2) tance harness or defective Wiring harness between ACT (female) (1) – Resiscontact in connector) Max. 1 z starting switch ACC (270) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Resisground in wiring harness Between ground and wiring harness between Min. 1 Mz STCN2 (female) (8) – ACT (female) (2) tance (Contact with ground circuit) Between ground and wiring harness between ResisMin. 1 Mz ACT (female) (1) – starting switch ACC (270) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering STCN2 Starting switch Voltage controller Between (8) – ON Max. 1 V chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0
47
SEN01826-01
40 Troubleshooting
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit 1 Action code Failure code Symptom of Engine controller ACC signal cutout relay: Short circuit failure (Steering controller system) — D190KA Failure content • When signal was output to engine controller ACC cut relay, abnormal current flowed. Controller's • Stops outputting signal to engine controller ACC cut relay. action Symptoms that appear on • Engine stop function of steering controller does not work. machine • Output state (voltage) to engine controller ACC cut relay can be checked in real-time monitoring mode (Code 60500: Engine controller ACC cut relay voltage). General • Method of reproducing failure code: Turn starting switch ON. information a This failure code detects abnormality on primary side (coil side) of engine controller ACC cut relay but does not detect abnormality on secondary side (contact side). Cause
Possible causes and the standard values when normal
48
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective engine controller without turning starting switch ON. 1 ACC cut relay ACT (male) Resistance (Internal disconnection) Between (1) – (2) 200 – 400 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 2 V circuit) in wiring harness Wiring harness between STCN2 (female) (8) Voltage Max. 1 V – ACT (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 3 STCN2 Starting switch Voltage controller Between (8) – ON Max. 1 V chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0
49
SEN01826-01
40 Troubleshooting
Failure code [D5ZRKA] Snap shot switch: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Snap shot switch: Disconnection failure (Steering controller system) D5ZRKA • When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated. • None in particular.
• Enter the snap shot mode and apply a trigger. Cause
1
2 Possible causes and the standard values when normal 3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring harness or defective Wiring harness between STCN2 (female) (9) Voltage Max. 1 V contact in connector) and V3B (female) (6) a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Between wiring harness between STCN2 (Contact with ground cirResisMin. 1 Mz (female) (9) and V3B (female) (6) and chascuit) tance sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Snap shot switch Voltage Defective steering controller Trigger Max. 1 V Between (9) and Out of period just chassis ground 20 – 30 V after trigger a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS controller V3B Voltage Between (6) and chassis ground 20 – 30 V
Circuit diagram related to snap shot switch
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [D5ZRKB] Snap shot switch: Short circuit Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Snap shot switch: Short circuit failure (Steering controller system) D5ZRKB • Abnormal current flowed in snap shot switch circuit at the time of ground output. • None in particular.
• Enter the snap shot mode and apply a trigger. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 1 source in wiring harness Between wiring harness between STCN2 (Contact with 24-V circuit) (female) (9) and V3B (female) (6) and chasVoltage Max. 1 V sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Snap shot switch Voltage Defective steering control2 ler Trigger Max. 1 V Between (9) and Out of period chassis ground 20 – 30 V just after trigger a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller V3B Voltage Between (6) and chassis ground 20 – 30 V
Circuit diagram related to snap shot switch
D475A, D475ASD-5E0
51
SEN01826-01
40 Troubleshooting
Failure code [DAFRKR] Monitor panel CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Monitor panel CAN communication: Communication error failure (Machine monitor system) DAFRKR Monitor panel cannot recognize steering controller in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
52
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Min. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z If causes 1 – 4 are not detected, monitor panel or steering controller Defective monitor panel or 5 may be defective. (Since trouble is in system, troubleshooting cansteering controller not be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
53
SEN01826-01
40 Troubleshooting
Failure code [dAFRKR] Monitor panel CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Monitor panel CAN communication: Communication error failure (Transmission controller system) dAFRKR Transmission cannot recognize monitor panel in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
54
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Min. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z If causes 1 – 4 are not detected, monitor panel or transmission conDefective monitor panel or 5 troller may be defective. (Since trouble is in system, troubleshooting transmission controller cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
55
SEN01826-01
40 Troubleshooting
Failure code [daFRKR] Monitor panel CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Monitor panel CAN communication: Communication error failure (Steering controller system) daFRKR Steering controller cannot recognize monitor panel in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
56
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Min. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z If causes 1 – 4 are not detected, monitor panel or steering controller Defective monitor panel or 5 may be defective. (Since trouble is in system, troubleshooting cansteering controller not be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
57
SEN01826-01
40 Troubleshooting
Failure code [DAQ0KT] Transmission controller: Abnormality in controller
1
Action code Failure code Symptom of Transmission controller: Abnormality in controller failure (Transmission controller system) E01 DAQ0KT Failure content • Information of ROM (nonvolatile storage) of transmission controller is not normal. Controller's action Symptoms that appear on • Gear shift feeling of transmission may become worse. machine General • Method of reproducing error code: Turn starting switch ON. information Possible causes and the standard values when normal
58
Cause 1
Defective transmission controller
Standard values when normal and remarks for troubleshooting Troubleshooting cannot be carried out since it is internal defect. (It is no problem even if you use controller unless no visible problem appears on machine.)
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01826-01
59
SEN01826-01
40 Troubleshooting
Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input) Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of Transmission controller main power supply: Power supply voltage failure reduction (Input) (Transmission controller system) DAQ1KK Transmission controller power supply voltage is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Monitor panel may not display normally. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON. Cause Defective circuit breaker 1 CB6 (20 A) Defective circuit breaker 2 CB30 (30 A)
Possible causes and the standard values when normal
60
Standard values when normal and remarks for troubleshooting If circuit breaker CB6 is turned OFF, circuit probably has ground fault. If circuit breaker CB30 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (1), ResisMax. 1 z (11) – CB6 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB6 (1) – F30 Max. 1 z wiring or defective contact tance in connector) ResisWiring harness between B30S – battery relay Max. 1 z BRB terminal tance Wiring harness between TMC3 (female) (21), ResisMax. 1 z (31), (32), (33) – ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring harTMC3 (female) (1), (11) – CB6 (2) tance 4 ness (Contact with GND Between ground and wiring harness between Resiscircuit) Min. 1 Mz CB6 (1) – F30 tance Between ground and wiring harness between ResisMin. 1 Mz B30S – battery relay BRB terminal tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 5 TMC3 Voltage controller Between (1), (11) – (21), (31), 20 – 30 V (32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0
61
SEN01826-01
40 Troubleshooting
Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input) Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • •
1
Failure code Symptom of Transmission controller load power supply: Power supply voltage failure reduction (Input) (Transmission controller system) DAQ2KK Power supply voltage of transmission controller load (relays, solenoids, etc.) is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON. Cause Defective circuit breaker 1 CB3 (20 A) Defective circuit breaker 2 CB105 (105 A)
Possible causes and the standard values when normal
62
Standard values when normal and remarks for troubleshooting If circuit breaker CB3 is turned OFF, circuit probably has ground fault. If circuit breaker CB105 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (2), ResisMax. 1 z (12), (22) – CB3 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB3 (1) – F96 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B105S – battery ResisMax. 1 z relay BRC terminal tance Wiring harness between TMC3 (female) (21), ResisMax. 1 z (31), (32), (33) – ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring harTMC3 (female) (2), (12), (22) – CB3 (2) tance 4 ness (Contact with GND Between ground and wiring harness between Resiscircuit) Min. 1 Mz CB3 (1) – F96 tance Between ground and wiring harness between ResisMin. 1 Mz B105S – battery relay BRC terminal tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 5 TMC3 Voltage controller Between (2), (12), (22) – (21), 20 – 30 V (31), (32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0
63
SEN01826-01
40 Troubleshooting
Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Transmission controller potentiometer power supply: Source voltage failure reduction (input) (Transmission controller system) DAQ5KK Voltage of 5 V power supply circuit of transmission controller sensor is below 4.5 V or above 5.5 V. Abnormal current flowed in 5 V power supply circuit of transmission controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output to 5 V 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 failure code: Turn starting switch ON. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward-reverse TL2 (male) Resistance potentiometer (Internal Between (4) – (1) 3.2 kz ± 20% short circuit) Sensor Between (1) – Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisTMC1 (female) (22) – TL2 (female) (4) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) TMC1 (female) (22) – TL2 (female) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC1 Voltage controller Between (22) – (21) 4.5 – 5.5 V
Circuit diagram related to transmission controller potentiometer power supply
64
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) 1 Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Transmission controller sensor power supply: Source voltage reducfailure tion (input) (Transmission controller system) DAQ6KK • Voltage of 24 V power supply circuit of transmission controller sensor is below 12 V or above 30 V. • Abnormal current flowed in 24 V power supply circuit of transmission controller sensor. • Stops output to 24 V power supply circuit if abnormal voltage flows
• Method of reproducing failure code: Turn starting switch ON (Then wire is not connected since this power supply is not used). Cause
Possible causes and the standard values when normal
1
Defective transmission controller
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage (16) – (21) 20 – 30 V
65
SEN01826-01
40 Troubleshooting
Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input) 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Transmission controller sensor power supply: Power supply voltage failure reduction (Input) (Transmission controller system) DAQ7KK • Voltage of 5V power supply circuit for transmission controller sensors is below 4.5 V or above 5.5 V. • Abnormal current flowed in 5V power supply circuit for transmission controller sensors. • If abnormal current flows, controller stops output of 5V power supply circuit. • System may not operate normally. • Method of reproducing failure code: Turn starting switch ON. Cause Defective work equipment pump oil pressure 1 sensor (Internal short circuit)
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting When device at right is disconnected, if failure code HP1 or lights up (to indicate resetting), sensor has trouble in it. HP2 cona Turn starting switch OFF, disconnect connector, turn nector starting switch ON and carry out troubleshooting. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har2 ness (Contact with GND Between ground and wiring harness between Resiscircuit) TMC3 (female) (34) – HP1 or HP2 (female) Min. 1 Mz tance (B) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 3 24V circuit) in wiring har- Between ground and wiring harness between ness TMC3 (female) (34) – HP1 or HP2 (female) Voltage Max. 1 V (B) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering or 4 TMC3, TMC1 Voltage transmission controller Between TMC3 (34) – TMC1 (21) 4.5 – 5.5 V
Circuit diagram related to transmission controller sensor power supply
66
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Transmission controller type collation: Type select signal inconsisfailure tency (Transmission controller system) DAQ9KQ Internal spec. setting of transmission controller is inconsistent with spec. set signal. Flashes caution lamp and turns on caution buzzer. Limits operations 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 failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting It is normal if error code lights on (reset display) after carrying out Defective transmission 1 adjustment mode. controller adjustment • Adjustment code: 0003: Transmission controller spec. a Prepare with starting switch OFF, carry out troubleshooting withDisconnection in wiring out turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Short circuit of wiring harness between ResisMax. 1 z in connector) TMC3 (female) (10) with chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 3 controller TMC3 Voltage Between (10) – chassis ground Max. 1 V
Circuit diagram related to transmission controller type select
D475A, D475ASD-5E0
67
SEN01826-01
40 Troubleshooting
Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality) 1 Action code
Failure code
CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
Transmission controller CAN communication: Communication error Symptom of (Objective component system abnormality) failure DAQRKR (Transmission controller system) Transmission controller cannot recognize monitor panel, steering controller, engine controller or VHMS controller in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
68
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z tance (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible causes and the standard values when normal
4
Defective CAN terminal resistor
Defective monitor panel, engine controller, trans5 mission controller, steering controller or VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z If causes 1 – 4 are not detected, monitor panel, engine controller, transmission controller, steering controller or VHMS controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
69
SEN01826-01
40 Troubleshooting
Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system) 1 Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code
Transmission controller S-NET communication: Defective communiSymptom of cation (Abnormality in objective component system) failure DAQSKR (Transmission controller system) • 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 failure code: Turn starting switch ON. Cause Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector) Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
Possible causes and the standard values when normal
70
3
Hot short in wiring harness (Contact with 24 V circuit)
4
Defective monitor panel (Switch module)
5
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (21) ResisMax. 1 z – S01 (female) (8) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC2 (female) (21) – S01 (female) (8) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 (female) (21) – S01 (female) (8) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S01 Voltage Between (8) – chassis ground 6–9V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC2 Voltage Between (21) – (31) 6–9V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0
71
SEN01826-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN01826-01
© 2007 KOMATSU All Rights Reserved Printed in Japan 08-07 (01)
72
SEN01827-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 5 Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error ............... 4 Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error................ 6 Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error.............. 8 Failure code [DB30KT] Steering controller: Abnormality in controller ........................................................... 10 Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input) ..... 12 Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input) ...... 14 Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input) ................................................................................................. 16 Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) ............ 18 Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) ............ 19 Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency....................... 20 Failure code [dB3RKR] Steering controller CAN communication: Communication error.............................. 22 Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) .............................................. 24 Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage........................................................................................ 26
D475A, D475ASD-5E0
1
SEN01827-03
40 Troubleshooting
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection .................................................... 27 Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage .............................................................................. 28 Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage.............................................................. 29 Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" o "02") VHMS sensor power supply (24 V): Lowering of output voltage............................................................ 30 Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" o "03") VHMS sensor power supply (12 V): Lowering of output voltage............................................................ 32 Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error ..... 34 Failure code [dbBRKR] VHMS controller CAN communication: Communication error................................. 36 Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 38 Failure code [DD12KB] Shift up switch: Short circuit .................................................................................... 40 Failure code [DD13KA] Shift down switch: Disconnection ............................................................................ 42 Failure code [DD13KB] Shift down switch: Short circuit................................................................................ 44 Failure code [DD14KA] Parking brake lever switch: Disconnection.............................................................. 46 Failure code [DD14KB] Parking brake lever switch: Short circuit ................................................................. 48 Failure code [DDB9L4] Reverse switch: Signal disagreement...................................................................... 50 Failure code [DDK3L4] Forward switch: Signal disagreement...................................................................... 52 Failure code [DDK5KA] Gearshift switch: Disconnection .............................................................................. 54 Failure code [DDK5KB] Gearshift switch: Short circuit ................................................................................. 56 Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time................... 58 Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time ...................... 59 Failure code [DDN7KA] Blade pitch switch: Disconnection .......................................................................... 60 Failure code [DDN7KB] Blade pitch switch: Short circuit .............................................................................. 62 Failure code [DDN9KA] Blade tilt switch: Disconnection .............................................................................. 64 Failure code [DDN9KB] Blade tilt switch: Short circuit .................................................................................. 66 Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ........................ 68 Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time.............................. 69 Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time............................. 70 Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time .................................. 71 Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time............................. 72 Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time ......................... 73
2
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
3
SEN01827-03
40 Troubleshooting
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Engine controller CAN communication: Communication error failure (Steering controller system) DB2RKR Steering controller cannot recognize engine controller (Left bank) in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) – CT1 (female) (A) – STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Max. 1 z tance S04 (female) (1), (2) or V4A (female) (4) or Disconnection in wiring harness (Disconnection in SRV (male) (3) 1 wiring or defective contact Wiring harness between OEM L (female) (47) in connector) – CT1 (female) (B) – STCN2 (female) (22) or ResisTMC2 (female) (22) or RES (female) (B) or Max. 1 z tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) Wiring harness between OEM L (female) (39) ResisMax. 1 z – ACT (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) – CT1 (female) (A) – STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Min. 1 Mz tance S04 (female) (1), (2) or V4A (female) (4) or Ground fault in wiring SRV (male) (3) and ground 2 harness (Contact with GND circuit) Wiring harness between OEM L (female) (47) – CT1 (female) (B) – STCN2 (female) (22) or ResisTMC2 (female) (22) or RES (female) (B) or Min. 1 Mz tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Wiring harness between OEM L (female) (39) ResisMin. 1 Mz – ACT (female) (6) and ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between OEM L (female) (46) – CT1 (female) (A) – STCN2 (female) (32) or Voltage Max. 1 V TMC2 (female) (32) or RES (female) (A) or Hot short (Contact with S04 (female) (1), (2) or V4A (female) (4) or 3 24V circuit) in wiring SRV (male) (3) and ground harness Wiring harness between OEM L (female) (47) – CT1 (female) (B) – STCN2 (female) (22) or Voltage Max. 1 V TMC2 (female) (22) or RES (female) (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z Defective engine controller If engine cannot be started, engine controller power supply may be 5 power supply defective. Carry out troubleshooting for failure code [CA111]. If causes 1 – 5 are not detected, engine controller or steering conDefective engine controller 6 troller may be defective. (Since trouble is in system, troubleshooting or steering controller cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
5
SEN01827-03
40 Troubleshooting
Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Engine controller CAN communication: Communication error failure (Transmission controller system) dB2RKR Transmission controller cannot recognize engine controller (Left bank) in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
6
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) – CT1 (female) (A) – STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Max. 1 z tance S04 (female) (1), (2) or V4A (female) (4) or Disconnection in wiring harness (Disconnection in SRV (male) (3) 1 wiring or defective contact Wiring harness between OEM L (female) (47) in connector) – CT1 (female) (B) – STCN2 (female) (22) or ResisTMC2 (female) (22) or RES (female) (B) or Max. 1 z tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) Wiring harness between OEM L (female) (39) ResisMax. 1 z – ACT (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) – CT1 (female) (A) – STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Min. 1 Mz tance S04 (female) (1), (2) or V4A (female) (4) or Ground fault in wiring SRV (male) (3) and ground 2 harness Wiring harness between OEM L (female) (47) (Contact with GND circuit) – CT1 (female) (B) – STCN2 (female) (22) or ResisTMC2 (female) (22) or RES (female) (B) or Min. 1 Mz tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Wiring harness between OEM L (female) (39) ResisMin. 1 Mz – ACT (female) (6) and ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between OEM L (female) (46) – CT1 (female) (A) – STCN2 (female) (32) or Voltage Max. 1 V TMC2 (female) (32) or RES (female) (A) or Hot short (Contact with S04 (female) (1), (2) or V4A (female) (4) or 3 24V circuit) in wiring SRV (male) (3) and ground harness Wiring harness between OEM L (female) (47) – CT1 (female) (B) – STCN2 (female) (22) or TMC2 (female) (22) or RES (female) (B) or Voltage Max. 1 V S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z Defective engine controller If engine cannot be started, engine controller power supply may be 5 power supply defective. Carry out troubleshooting for failure code [CA111]. If causes 1 – 5 are not detected, engine controller or transmission Defective engine controller 6 controller may be defective. (Since trouble is in system, troubleor transmission controller shooting cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
7
SEN01827-03
40 Troubleshooting
Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Engine controller CAN communication: Communication error failure (Steering controller system) db2RKR • Steering controller cannot recognize engine controller (Right bank) in CAN communication circuit. • Takes no particular action. • System may not operate normally. • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
8
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM R (female) (46) – CT1 (female) (A) – STCN2 (female) ResisDisconnection in wiring (32) or TMC2 (female) (32) or RES (female) Max. 1 z tance harness (Disconnection in (A) or S04 (female) (1), (2) or V4A (female) 1 wiring or defective contact (4) or SRV (male) (3) in connector) Wiring harness between OEM R (female) (47) – CT1 (female) (B) – STCN2 (female) Resis(22) or TMC2 (female) (22) or RES (female) Max. 1 z tance (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM R (female) (46) – CT1 (female) (A) – STCN2 (female) Resis(32) or TMC2 (female) (32) or RES (female) Min. 1 Mz Ground fault in wiring tance (A) or S04 (female) (1), (2) or V4A (female) 2 harness (4) or SRV (male) (3) and ground (Contact with GND circuit) Wiring harness between OEM R (female) (47) – CT1 (female) (B) – STCN2 (female) Resis(22) or TMC2 (female) (22) or RES (female) Min. 1 Mz tance (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between OEM R (female) (46) – CT1 (female) (A) – STCN2 (female) Voltage Max. 1 V (32) or TMC2 (female) (32) or RES (female) Hot short (Contact with (A) or S04 (female) (1), (2) or V4A (female) 3 24V circuit) in wiring (4) or SRV (male) (3) and ground harness Wiring harness between OEM R (female) (47) – CT1 (female) (B) – STCN2 (female) Voltage Max. 1 V (22) or TMC2 (female) (22) or RES (female) (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z Defective engine controller If engine cannot be started, engine controller power supply may be 5 power supply defective. Carry out troubleshooting for failure code [CB111]. If causes 1 – 5 are not detected, engine controller or steering conDefective engine controller 6 troller may be defective. (Since trouble is in system, troubleshooting or steering controller cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
9
SEN01827-03
40 Troubleshooting
Failure code [DB30KT] Steering controller: Abnormality in controller Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
10
1
Failure code Symptom of Steering controller: Abnormality in controller failure DB30KT • Information of ROM (nonvolatile storage) of steering controller is not normal. • Take no particular action. • Steering performance may be reduced. • Brake performance may be reduced. • Method of reproducing failure code: Turn starting switch ON. Cause 1
Defective steering controller
Standard values when normal and remarks for troubleshooting Troubleshooting cannot be carried out since it is internal defect. (It is no problem even if you use controller unless no visible problem appears on machine.)
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
11
SEN01827-03
40 Troubleshooting
Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input) 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
Failure code Symptom of Steering controller main power supply: Power supply voltage reducfailure tion (Input) (Steering controller system) DB31KK Steering controller power supply voltage is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Monitor panel may not display normally. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON. Cause Defective circuit breaker 1 CB6 (20 A) Defective circuit breaker 2 CB30 (30 A)
Possible causes and the standard values when normal
12
Standard values when normal and remarks for troubleshooting If circuit breaker CB6 is turned OFF, circuit probably has ground fault. If circuit breaker CB30 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) (1), ResisMax. 1 z (11) – CB6 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB6 (1) – F30 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B30S – battery relay ResisMax. 1 z BRB terminal tance Wiring harness between STCN3 (female) ResisMax. 1 z (21), (31), (32), (33) – ground tance Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring STCN3 (female) (1), (11) – CB6 (2) tance 4 harness Resis(Contact with GND circuit) Between ground and wiring harness between Min. 1 Mz CB6 (1) – F30 tance Between ground and wiring harness between ResisMin. 1 Mz B30S – battery relay BRB terminal tance Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 5 STCN3 Voltage controller Between (1), (11) – (21), (31), 20 – 30 V (32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0
13
SEN01827-03
40 Troubleshooting
Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input) 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • •
Failure code Symptom of Steering controller load power supply: Power supply voltage reducfailure tion (Input) (Steering controller system) DB32KK Power supply voltage of steering controller load (relays, solenoids, etc.) is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON. Cause Defective circuit breaker 1 CB1 (20 A) Defective circuit breaker 2 CB105 (105 A)
Possible causes and the standard values when normal
14
Standard values when normal and remarks for troubleshooting If circuit breaker CB1 is turned OFF, circuit probably has ground fault. If circuit breaker CB105 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) (2), ResisMax. 1 z (12), (22) – CB1 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB1 (1) – F96 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B105S – battery ResisMax. 1 z relay BRC terminal tance Wiring harness between STCN3 (female) ResisMax. 1 z (21), (31), (32), (33) – ground tance Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring STCN3 (female) (2), (12), (22) – CB1 (2) tance 4 harness Resis(Contact with GND circuit) Between ground and wiring harness between Min. 1 Mz CB1 (1) – F96 tance Between ground and wiring harness between ResisMin. 1 Mz B105S – battery relay BRC terminal tance Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering STCN3 Voltage 5 controller Between (2), (12), (22) – (21), 20 – 30 V (31), (32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0
15
SEN01827-03
40 Troubleshooting
Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input) 1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • •
Failure code Symptom of Steering controller potentiometer power supply: Power supply voltfailure age reduction (Input) (Steering controller system) DB35KK Voltage of 5V power supply circuit for steering controller sensors is below 4.5 V or above 5.5 V. Abnormal current flowed in 5V power supply circuit for steering controller sensors. Blinks warning lamp and sounds alarm buzzer. If abnormal current flows, controller stops output of 5V power supply circuit. Limits operations of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
16
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake BRK (male) Resistance 1 potentiometer (Internal short circuit) Between (C) – (A) 5 kz ± 20% Sensor Between (C) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fuel control dial DIAL (male) Resistance 2 potentiometer (Internal short circuit) Between (1) – (3) 5 kz ± 15% Sensor Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering TL2 (male) Resistance 3 potentiometer (Internal short circuit) Between (5) – (8) 3.2 kz ± 20% Between (8) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness Between ground and wiring harness between Resis(Contact with GND circuit) STCN1 (female) (22) – TL2 (female) (5) or Min. 1 Mz tance BRK (female) (C) or DIAL (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 24V circuit) in wiring Between ground and wiring harness between harness STCN1 (female) (22) – TL2 (female) (5) or Voltage Max. 1 V BRK (female) (C) or DIAL (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 6 controller STCN1 Voltage Between (22) – (21) 4.5 – 5.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to steering controller potentiometer power supply
D475A, D475ASD-5E0
17
SEN01827-03
40 Troubleshooting
Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • •
1
Failure code Symptom of Steering controller sensor power supply: Source voltage reduction failure (input) (Steering controller system) DB36KK Voltage of 24 V power supply circuit of steering controller sensor is below 12 V or above 30 V. Abnormal current flowed in 24 V power supply circuit of steering controller sensor. 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 failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting It is internal defect if error code lights on (reset display) Defective blade pitch when disconnecting right connector. PT1 1 angle sensor (Internal a Disconnect connector with starting switch OFF, then connector short circuit) turn starting switch ON and carry out troubleshooting. a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground cirResisSTCN1 (female) (16) – PT1 (female) (C) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering control3 STCN1 Voltage ler Between (16) – (21) 20 – 30 V
Circuit diagram related to steering controller sensor power supply
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Steering controller sensor power supply: Source voltage reduction failure (input) (Steering controller system) DB37KK Voltage of 5 V power supply circuit of steering controller sensor is below 4.5 V or above 5.5 V. Abnormal current flowed in 5 V power supply circuit of steering controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output of 5 V power supply circuit if abnormal voltage flows.
• System may not operate normally. • Method of reproducing failure code: Turn starting switch ON. Cause
1
2 Possible causes and the standard values when normal 3
4
Standard values when normal and remarks for troubleshooting It is internal defect if error code lights on (reset display) Defective acceleration when disconnecting right connector. SSA sensor a Disconnect connector with starting switch OFF, then connector (Internal short circuit) turn starting switch ON and carry out troubleshooting. a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (34) – SSA (female) (C) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) (34) – SSA (female) (1) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering STCN1, STCN3 Voltage controller Between STCN3 (34) – 20 – 30 V STCN1 (21)
Circuit diagram related to steering controller sensor power supply
D475A, D475ASD-5E0
19
SEN01827-03
40 Troubleshooting
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • •
Failure code Symptom of Steering controller type selection: Type select signal inconsistency failure (Steering controller system) DB39KQ Internal spec. setting of steering controller is inconsistent with spec. set signal. (Steering controller may not recognize normally) Flashes caution lamp and turns on caution buzzer. Stops all outputs of steering controller. Limits operation of engine, transmission, and brake. Problem that appears on machineMachine 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 failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting It is normal if failure code indicates (reset display) after carrying out Defective steering 1 adjustment mode. controller adjustment • Adjustment code: 0002 (Steering controller spec. set) a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between STCN3 (female) ResisMax. 1 z in connector) (20) – chassis ground tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering 3 controller STCN3 Voltage Between (20) – chassis ground Max. 1 V
Circuit diagram related to steering controller type select
20
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
21
SEN01827-03
40 Troubleshooting
Failure code [dB3RKR] Steering controller CAN communication: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • •
1
Failure code Symptom of Steering controller CAN communication: Communication error failure (Transmission controller system) dB3RKR Transmission controller cannot recognize steering controller in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
• Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
22
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Max. 1 z tance (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring (female) (4) or RES (female) (A) or SRV 2 harness (male) (3) and ground (Contact with GND circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Min. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring (male) (3) and ground harness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause Possible causes and the standard values when normal
4
Defective CAN terminal resistor
Defective steering 5 controller or transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z If causes 1 – 4 are not detected, steering controller or transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
23
SEN01827-03
40 Troubleshooting
Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code
Steering controller S-NET communication: Defective communication Symptom of (Abnormality in objective component system) failure DB3SKR (Steering controller system) • 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 failure code: Turn starting switch ON. Cause Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector) Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
Possible causes and the standard values when normal
24
1
3
Hot short in wiring harness (Contact with 24 V circuit)
4
Defective monitor panel (Switch module)
5
Defective steering controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN2 (female) ResisMax. 1 z (21) – S01 (female) (8) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisSTCN2 (female) (21) – S01 (female) (8) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN2 (female) (21) – S01 (female) (8) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. S01 Voltage Between (8) – chassis ground 6–9V a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. STCN2 Voltage Between (21) – (31) 6–9V
D475A, D475ASD-5E0
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Circuit diagram related to S-NET communication
D475A, D475ASD-5E0
25
SEN01827-03
40 Troubleshooting
Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of VHMS controller: Lowering of source voltage failure (VHMS controller system) DBB0KK • The switch source voltage is below 19.5 V. • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n9" o "01". Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between V1 (female) (8), (9) Resis1 Max. 1 z wiring harness or defective and FS12 (fuse) (1) tance contact in connector) Wiring harness between V1 (female) (11) and ResisMax. 1 z GND 01 tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Between wiring harness between V1 (Contact with ground Resis(female) (8), (9) and FS12 (fuse) (1) and Min. 1 Mz circuit) tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (female) (8), (9) and V1 (female) Voltage 20 – 30 V (11), (12) or chassis ground
Circuit diagram related to VHMS controller power supply
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of VHMS controller model selection: Disagreement of model selection failure signals (VHMS controller system) DBB0KQ • Wrong connection of connectors is displayed. • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "nF" o "11". Cause Standard values when normal and remarks for troubleshooting Wrong connection of VHMS controller connec- Check that the couple of connectors V2A and V3A and that of con1 tors (When system is nor- nectors V2B and V3B are connected correctly. If not, correct. mal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Between wiring harness V1 (female) (11), Resis2 Max. 1 z wiring harness or defective (12) and chassis ground tance contact in connector) Between wiring harness V3A (female) (9) ResisMax. 1 z and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between V1 (female) (11), (12) and chassis 3 Defective VHMS controller Voltage Max. 1 V ground Between V3A (female) (9) and chassis Voltage Max. 1 V ground
Circuit diagram related to model selection power supply
D475A, D475ASD-5E0
27
SEN01827-03
40 Troubleshooting
Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of VHMS controller: Lowering of direct source voltage failure (VHMS controller system) DBB3KK • The direct source voltage is below 19.5 V. • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n9" o "05". Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between V1 (female) (6), (7) Resis1 Max. 1 z wiring harness or defective and FS12 (fuse) (2) tance contact in connector) Wiring harness between V1 (female) (11) and ResisMax. 1 z GND 01 tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Between wiring harness between V1 (Contact with ground Resis(female) (6), (7) and FS12 (fuse) (2) and Min. 1 Mz circuit) tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (female) (6), (7) and V1 (female) Voltage 20 – 30 V (11), (12) or chassis ground
Circuit diagram related to VHMS controller power supply
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Sensor power supply (5 V): Lowering of output voltage failure (Disconnection or short circuit) DBB5KP • The sensor source voltage (5 V) is out of the normal range (4.5 – 5.5 V). • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n9" o "04". Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 1 Short circuit of wiring harness between V1 (Contact with ground cirResis(female) (4) – ENBP (female) (B) and chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring harness or defective Between wiring harness V1 (female) (4) and ResisMax. 1 z contact in connector) ENBP (female) (B) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (female) (4) and V2A (female) 4.5 – Voltage (12) 5.5 V
Circuit diagram related to sensor power supply 5 V
D475A, D475ASD-5E0
29
SEN01827-03
40 Troubleshooting
Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" o "02") VHMS sensor power supply (24 V): Lowering of output voltage Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of VHMS sensor power supply (24 V): Lowering of output voltage failure (Disconnection or short circuit) (VHMS controller system) DBB6KP • The sensor source voltage (24 V) is out of the normal range (20 – 30 V). • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n9" o "02". Cause
Possible causes and the standard values when normal
30
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between V1 (female) (2) – 1 wiring harness or defective EXA1 (female) (A), V1 (female) (2) – EXA2 Resis(female) (A), V1 (female) (2) – EXA3 (female) Max. 1 z contact in connector) tance (A), V1 (female) (2) – EXA4 (female) (A) – V1 (female) (2) – TMMD (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between V1 ground in wiring harness (female) (2) – EXA1 (female) (A), V1 (female) 2 (Contact with ground cir- (2) – EXA2 (female) (A), V1 (female) (2) – ResisMin. 1 Mz cuit) tance EXA3 (female) (A), V1 (female) (2) – EXA4 (female) (A) – V1 (female) (2) – TMMD (female) (B) with chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (2) and V2A (13) Voltage 20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to sensor power supply 24 V
D475A, D475ASD-5E0
31
SEN01827-03
40 Troubleshooting
Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" o "03") VHMS sensor power supply (12 V): Lowering of output voltage Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of VHMS sensor power supply (12 V): Lowering of output voltage failure (Disconnection or short circuit) (VHMS controller system) DBB7KP • The sensor source voltage (12 V) is out of the normal range (11.5 – 12.5 V). • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n9" o "03". Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring harness or defecBetween wiring harness V1 (female) (3) and ResisMax. 1 z tive contact in connector) DLT (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between V1 (Contact with ground cirResis(female) (3) and DLT (female) (1) with chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller V1 Voltage Between (3) and (11), (12) 11.5 – 12.5 V
Circuit diagram related to sensor power supply 12 V
32
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
33
SEN01827-03
40 Troubleshooting
Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of VHMS KOM-NET: Communication error failure (VHMS controller system) DBBQKR • Communication (CAN) information cannot be received from each controller. • None in particular. • System may not operate normally. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n8" on VHMS controller LED changes from "n8" to "02". Cause
Possible causes and the standard values when normal
34
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Max. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause Possible causes and the standard values when normal
4
Defective CAN terminal resistor
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CT1 (male), RES (male), RES L (male), RES R (male), Resistance CTV (male) Between (A) – (B) 100 – 140 z
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
35
SEN01827-03
40 Troubleshooting
Failure code [dbBRKR] VHMS controller CAN communication: Communication error Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of VHMS controller CAN communication: Communication error failure (Steering controller system) dbBRKR • Steering controller cannot recognize VHMS controller in CAN communication circuit. • None in particular. • Data related to VHMS cannot be monitored. • Data related to VHMS may not be obtained normally. • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
36
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 1 z Disconnection in wiring tance (female) (46) or CT1 (female) (A) or V4A harness (Disconnection in (female) (4) or RES (female) (A) or SRV 1 wiring or defective contact (male) (3) in connector) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Max. 1 z tance (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) Resis(32) or OEM L (female) (46) or OEM R Min. 1 Mz tance (female) (46) or CT1 (female) (A) or V4A Ground fault in wiring (female) (4) or RES (female) (A) or SRV 2 harness (Contact with (male) (3) and ground GND circuit) Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Min. 1 Mz tance (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) – STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring (male) (3) and ground harness Wiring harness between S04 (female) (3), (4) – STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) – (B) 100 – 140 z If causes 1 – 4 are not detected, steering controller or VHMS controlDefective steering control5 ler may be defective. (Since trouble is in system, troubleshooting ler or VHMS controller cannot be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
37
SEN01827-03
40 Troubleshooting
Failure code [DD12KA] Shift up switch: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Shift up switch: Disconnection (Transmission controller system) failure DD12KA • Signals of two systems of shift up 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 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 up switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing failure code: Turn starting switch ON and operate shift up switch. Cause
1
Defective shift up switch (Internal disconnection)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal
38
1
3
Hot short in wiring harness (Contact with 24 V circuit)
4
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift up switch TL3 (male) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (2) – (3) Resistance between Min. 1 Mz Max. 1 z (2) – (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (6) – ResisMax. 1 z TL3 (female) (3) tance Wiring harness between TMC2 (female) (37) ResisMax. 1 z – TL3 (female) (1) tance Wiring harness between TMC1 (female) (4) – ResisMax. 1 z TL3 (female) (2) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC1 (female) (6) – TL3 (female) (3) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC2 (female) (37) – TL3 (female) (1) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMCN1,TMCN2 OFF (Release) ON (Press) Voltage between TMC1 (6) – TMC1 Max. 1 V 5 – 11 V (10) Voltage between TMC2 (37) – TMC1 5 – 11 V Max. 1 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0
39
SEN01827-03
40 Troubleshooting
Failure code [DD12KB] Shift up switch: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Shift up switch: Short circuit (Transmission controller system) failure DD12KB • Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • 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 up switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing failure code: Turn starting switch ON and operate shift up switch. Cause
1
Possible causes and the standard values when normal
Defective shift up switch (Internal disconnection)
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
3
40
1
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift up switch TL3 (male) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (2) – (3) Resistance between Min. 1 Mz Max. 1 z (2) – (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC1 (female) (6) – TL3 (female) (3) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisTMC2 (female) (37) – TL3 (female) (1) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMC1,TMC2 OFF (Release) ON (Press) Voltage between TMC1 (6) – TMC1 Max. 1 V 5 – 11 V (10) Voltage between TMC2 (37) – TMC1 5 – 11 V Max. 1 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0
41
SEN01827-03
40 Troubleshooting
Failure code [DD13KA] Shift down switch: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Shift down switch: Disconnection failure (Transmission controller system) DD13KA • Signals of two systems of shift down 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 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 40905:Transmission controller input signal 1) • Method of reproducing failure code: Turn starting switch ON and operate shift down switch. Cause
Defective shift down 1 switch (Internal disconnection)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal
42
1
3
Hot short in wiring harness (Contact with 24 V circuit)
4
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift down switch TL3 (male) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (5) – (6) Resistance between Min. 1 Mz Max. 1 z (5) – (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (19) ResisMax. 1 z – TL3 (male) (6) tance Wiring harness between TMC3 (female) (29) ResisMax. 1 z – TL3 (male) (4) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z – TL3 (male) (5) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC3 (female) (19) – TL3 (male) (6) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC3 (female) (29) – TL3 (male) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift down switch TMC1, TMC3 OFF (Release) ON (Press) Voltage between TMC3 (29) – TMC1 Max. 1 V 5 – 11 V (10) Voltage between TMC3 (29) – TMC1 5 – 11 V Max. 1 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0
43
SEN01827-03
40 Troubleshooting
Failure code [DD13KB] Shift down switch: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Shift down switch: Short circuit failure (Transmission controller system) DD13KB • Signals of two systems of shift down switch circuit were turned ON (CLOSE) • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is not pressed. • Shift down 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 40905: Transmission controller input signal 1) • Method of reproducing failure code: Turn starting switch ON and operate shift up switch. Cause
Possible causes and the standard values when normal
44
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift down switch TL3 (male) Defective shift down switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (5) – (6) Resistance between Min. 1 Mz Max. 1 z (5) – (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness TMC3 (female) (19) – TL3 (male) (6) with Min. 1 Mz 2 tance (Contact with ground cir- chassis ground cuit) Short circuit of wiring harness between ResisTMC3 (female) (29) – TL3 (male) (4) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift down switch TMC1, TMC3 OFF (Release) ON (Press) Defective transmission Voltage between 3 controller TMC3 (19) – TMC1 Max. 1 V 5 – 11 V (10) Voltage between TMC3 (29) – TMC1 5 – 11 V Max. 1 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0
45
SEN01827-03
40 Troubleshooting
Failure code [DD14KA] Parking brake lever switch: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine
General information
Possible causes and the standard values when normal
Possible causes and the standard values when normal
46
• • • •
1
Failure code Symptom of Parking brake lever switch: Disconnection failure (Transmission controller system) DD14KA Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes parking brake 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. a 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, NC is for operation detection and NO 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 failure code: Turn starting switch ON and operate parking brake lever. When failure code [DD14KA] occurred alone Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC1 (female) (18) Resis1 Max. 1 z wiring or defective contact – branched point of circuit JF2 tance in connector) Wiring harness between TMC1 (female) (12) ResisMax. 1 z – branched point of circuit JF1 tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever TMC1 Defective transmission Free position Lock position 2 controller Between (18) – Max. 1 V 5 – 11 V chassis ground Between (12) – 5 – 11 V Max. 1 V chassis ground When failure codes [DD14KA] and [DDQ2KA] occurred at the same time Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking brake lever Parking brake lever switch NSW (male) 1 (Internal disconnection) Free position Lock position Between (A) – (B) Max. 1 z Min. 1 Mz Between (A) – (B) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NSW (female) (B) – ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in TMC1 (female) (18), – STCN2 (female) (5) 2 wiring or defective contact Wiring harness between NSW (female) (C) – ResisMax. 1 z in connector) TMC1 (female) (12), – STCN2 (female) (15) tance Wiring harness between NSW (female) (A) – ResisMax. 1 z chassis ground tance
D475A, D475ASD-5E0
40 Troubleshooting
Possible causes and the standard values when normal
SEN01827-03
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Hot short in wiring harness (female) (B) – TMC1 (female) (18), – STCN2 Voltage Max. 1 V 3 (Contact with 24 V circuit) (female) (5) with chassis ground Short circuit of wiring harness between NSW (female) (C) – TMC1 (female) (12), – STCN2 Voltage Max. 1 V (female) (15) with chassis ground
Circuit diagram related to parking brake switch
D475A, D475ASD-5E0
47
SEN01827-03
40 Troubleshooting
Failure code [DD14KB] Parking brake lever switch: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine
General information
• • • •
1
Failure code Symptom of Parking brake lever switch: Short circuit failure (Transmission controller system) DD14KB Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes parking brake 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. a 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, NC is for operation detection and NO 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 failure code: Turn starting switch ON and operate parking brake lever. Cause
Possible causes and the standard values when normal
48
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking brake lever Parking brake lever switch NSW (male) 1 (Internal disconnection) Free position Lock position Between (A) – (B) Max. 1 z Min. 1 Mz Between (A) – (C) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with chassis Wiring harness between NSW (female) (B) – Resisground in wiring harness TMC1 (female) (18), – STCN2 (female) (5) with Min. 1 Mz 2 tance (Contact with ground circhassis ground cuit) Wiring harness between NSW (female) (C) – ResisTMC1 (female) (12), – STCN2 (female) (15) Min. 1 Mz tance with chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever TMC1 Defective transmission conFree position Lock position 3 troller Between (18) – Max. 1 V 5 – 11 V chassis ground Between (12) – 5 – 11 V Max. 1 V chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to parking brake switch
D475A, D475ASD-5E0
49
SEN01827-03
40 Troubleshooting
Failure code [DDB9L4] Reverse switch: Signal disagreement Action code E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Reverse switch: Signal disagreement failure (Transmission controller system) DDB9L4 Signals of 2 reverse switch circuit systems disagree with each other. Blinks warning lamp and sounds alarm buzzer. Assumes that switch is not pressed. Limits operations of engine, transmission and brake.
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, gear speed is limited to F1. • Input state (ON/OFF) from reverse switch can be checked in monitoring mode (Code 40905: Transmission controller input signal 1). • Method of reproducing failure code: Turn starting switch ON (+ Operate reverse switch). Cause
1
2
Possible causes and the standard values when normal
3
4
5
50
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Reverse switch TL3 (male) Defective reverse switch OFF (Released) ON (Pressed) (Internal disconnection) Resistance between Min. 1 Mz Max. 1 z (6) – (5) Resistance between Min. 1 Mz Max. 1 z (4) – (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (19) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in – TL3 (female) (6) wiring or defective contact Wiring harness between TMC3 (female) (29) ResisMax. 1 z in connector) – TL3 (female) (4) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z – TL3 (female) (5) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resisharness (Contact with Min. 1 Mz TMC3 (female) (19) – TL3 (female) (6) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz TMC3 (female) (29) – TL3 (female) (4) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Between ground and wiring harness between Voltage Max. 1 V 24V circuit) in wiring TMC3 (female) (19) – TL3 (female) (6) harness Between ground and wiring harness between Voltage Max. 1 V TMC3 (female) (29) – TL3 (female) (4) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Reverse switch Reverse switch OFF (Released) ON (Pushed) Defective transmission Voltage between controller TMC3 (19) – TMC1 5 – 11 V Max. 1 V (10) Voltage between TMC3 (29) – TMC1 5 – 11 V Max. 1 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0
51
SEN01827-03
40 Troubleshooting
Failure code [DDK3L4] Forward switch: Signal disagreement Action code E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Forward switch: Signal disagreement failure (Transmission controller system) DDK3L4 Signals of 2 forward switch circuit systems disagree with each other. Blinks warning lamp and sounds alarm buzzer. Assumes that switch is not pressed. Limits operations of engine, transmission and brake.
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, gear speed is limited to F1. • Input state (ON/OFF) from forward switch can be checked in monitoring mode (Code 40905: Transmission controller input signal 1). • Method of reproducing failure code: Turn starting switch ON (+ Operate forward) switch. Cause
Possible causes and the standard values when normal
52
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Forward switch TL3 (male) Defective forward switch OFF (Released) ON (Pressed) 1 (Internal disconnection) Resistance between Min. 1 Mz Max. 1 z (3) – (5) Resistance between Min. 1 Mz Max. 1 z (1) – (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (6) – ResisDisconnection in wiring TL3 (female) (3) Max. 1 z tance harness (Disconnection in 19–1. Resistance 2 wiring or defective contact Wiring harness between TMC2 (female) (37) Resisin connector) Max. 1 z – TL3 (female) (1) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z – TL3 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between Resis3 ness (Contact with GND Min. 1 Mz TMC1 (female) (6) – TL3 (female) (3) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz TMC2 (female) (37) – TL3 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Between ground and wiring harness between Voltage Max. 1 V 4 24V circuit) in wiring harTMC1 (female) (6) – TL3 (female) (3) ness Between ground and wiring harness between Voltage Max. 1 V TMC2 (female) (37) – TL3 (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Forward switch TMC1, TMC2 OFF (Released) ON (Pushed) Defective transmission Voltage between 5 controller TMC1 (6) – TMC1 5 – 11 V Max. 1 V (10) Voltage between TMC2 (37) – TMC1 5 – 11 V Max. 1 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0
53
SEN01827-03
40 Troubleshooting
Failure code [DDK5KA] Gearshift switch: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Gearshift switch: Disconnection failure (Transmission controller system) DDK5KA • Signals of 2 gearshift switch circuit systems are turned OFF (opened) simultaneously. • Blinks warning lamp and sounds alarm buzzer. • Assumes that switch is not pressed. • Gear cannot be shifted up or down (1st o 2nd). • Auto shift-down function does not work. • Input state (ON/OFF) from gearshift switch can be checked in monitoring mode (40906: Transmission controller input signal 2). • Method of reproducing failure code: Turn starting switch ON (+ operate gearshift switch). Cause
1
Defective shift up switch (Internal disconnection)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal
54
1
3
Hot short in wiring harness (Contact with 24 V circuit)
4
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift switch SNC (female) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (3) – (1) Resistance between Min. 1 Mz Max. 1 z (2) – (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (7) – ResisMax. 1 z SNL (male) (2) tance Wiring harness between TMC2 (female) (10) ResisMax. 1 z – SNC (male) (3) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z – SNC (male) (1) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 (female) (7) – SNC (male) (2) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC2 (female) (10) – SNC (male) (3) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift switch TMC1,TMC2 OFF (Release) ON (Press) Voltage between Max. 1 V 5 – 11 V TMC2 (7) – TMC1 (10) Voltage between TMC2 (10) – TMC1 Max. 1 V 5 – 11 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift switch
D475A, D475ASD-5E0
55
SEN01827-03
40 Troubleshooting
Failure code [DDK5KB] Gearshift switch: Short circuit Action code E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Gearshift switch: Short circuit failure (Transmission controller system) DDK5KB • Signals of 2 gearshift switch circuit systems are turned ON (closed) simultaneously. • Blinks warning lamp and sounds alarm buzzer. • Assumes that switch is not pressed. • Gear cannot be shifted up or down (1st o 2nd). • Auto shift-down function does not work. • Input state (ON/OFF) from gearshift switch can be checked in monitoring mode (40906: Transmission controller input signal 2). • Method of reproducing failure code: Turn starting switch ON (+ operate gearshift switch). Cause
1
Possible causes and the standard values when normal
Defective shift up switch (Internal disconnection)
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
3
56
1
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift switch SNC (female) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (3) – (1) Resistance between Min. 1 Mz Max. 1 z (2) – (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC2 (female) (7) – SNC (male) (2) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisTMC2 (female) (10) – SNC (male) (3) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift switch TMC1,TMC2 OFF (Release) ON (Press) Voltage between TMC2 (7) – TMC1 5 – 11 V Max. 1 V (10) Voltage between TMC2 (10) – TMC1 Max. 1 V 5 – 11 V (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift switch
D475A, D475ASD-5E0
57
SEN01827-03
40 Troubleshooting
Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
• • • • • • • •
1
Failure code Symptom of Blade tilt right oil pressure switch system: Switch is ON for long time failure (Transmission controller system) DDN2LD The signal of the blade tilt right oil pressure switch circuit is kept turned ON for 60 seconds. Flashes the caution lamp and turns on the caution buzzer. Recognizes that the oil pressure switch is turned OFF. During right dual tilt operation, tilting is not limited. Blade tilt right operation becomes slow. VHMS data is not always correct. The input state (ON/OFF) from the blade tilt right oil pressure switch can be checked in the monitoring mode. (Code 40908: Blade lever oil pressure switch input state) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the error code lamp still lights up (resetting is still urged) after the 1 (When electrical system is reproductive operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade tilt right oil TRS (male) Blade lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Right tilt Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (6) and TRS (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC2, TMC1 Blade lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (6) and TMC1 (4) Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
58
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time 1 Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
• • • • • • • •
Failure code Symptom of Blade tilt left oil pressure switch system: Switch is ON for long time failure (Transmission controller system) DDN3LD The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds. Flashes the caution lamp and turns on the caution buzzer. Recognizes that the oil pressure switch is turned OFF. During left dual tilt operation, tilting is not limited. Blade tilt left operation becomes slow. VHMS data is not always correct. The input state (ON/OFF) from the blade tilt left oil pressure switch can be checked in the monitoring mode. (Code 40908: Blade lever oil pressure switch input state) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the error code lamp still lights up (resetting is still urged) after the 1 (When electrical system is reproductive operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade tilt left oil TLS (male) Blade lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Left tilt Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (16) and TLS (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC2, TMC1 Blade lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (16) and TMC1 (4) Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
D475A, D475ASD-5E0
59
SEN01827-03
40 Troubleshooting
Failure code [DDN7KA] Blade pitch switch: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch switch: Disconnection failure (Transmission controller system) DDN7KA • The signals of the 2 blade pitch switch circuit systems are turned OFF (opened) simultaneously. • Flashes the caution lamp and turns on the caution buzzer. • Recognizes that the switch is not pressed. • The blade is not pitched (When pitching operation is performed, the blade is tilted). • "NO" of the 2 switch system signals is for detection of operations and "NC" is for detection of errors. • The input state (ON/OFF) from the blade pitch switch can be checked in the monitoring mode. (Code 70300: Blade lever knob switch input signal) • Method of reproducing failure code: Turn the starting switch ON + (Operate blade tilt switch). Cause
Possible causes and the standard values when normal
60
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade pitch OFF (Released) ON (Pressed) 1 switch (Internal disconnecResistance between tion) Max. 1 z Min. 1 Mz (1) and (5) Resistance between Min. 1 Mz Max. 1 z (1) and (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (15) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in and P03 (female) (5) 2 wiring harness or defecWiring harness between TMC2 (female) (5) ResisMax. 1 z tive contact in connector) and P03 (female) (2) tance Wiring harness between TMC2 (female) (4) ResisMax. 1 z and P03 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between TMC2 Short circuit with power (female) (15) and P03 (female) (5) and chas- Voltage Max. 1 V 3 source in wiring harness sis ground (Contact with 24-V circuit) Between wiring harness between TMC2 (female) (5) and P03 (female) (2) and chasVoltage Max. 1 V sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Blade pitch switch TMC1, TMC2 OFF (Released) ON (Pressed) Defective transmission Voltage between 4 controller TMC2 (15) and Max. 1 V 5 – 11 V TMC1 (4) Voltage between TMC2 (5) and 5 – 11 V Max. 1 V TMC1 (4)
D475A, D475ASD-5E0
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SEN01827-03
Circuit diagram related to blade pitch switch and blade tilt switch
D475A, D475ASD-5E0
61
SEN01827-03
40 Troubleshooting
Failure code [DDN7KB] Blade pitch switch: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch switch: Short circuit failure (Transmission controller system) DDN7KB • 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 failure code: Turn starting switch ON and operate blade tilt switch. Cause
Possible causes and the standard values when normal
62
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade pitch OFF (Release) ON (Press) 1 switch (Internal disconnecResistance between tion) Max. 1 z Min. 1 Mz (1) – (5) Resistance between Min. 1 Mz Max. 1 z (1) – (2) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with chassis Short circuit of wiring harness between ground in wiring harness TMC2 (female) (15) – P03 (female) (5) with Voltage Max. 1 V 2 (Contact with ground circhassis ground cuit) Short circuit of wiring harness between TMC2 (female) (5) – P03 (female) (2) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade pitch switch TMC1, TMC2 OFF (Release) ON (Press) Defective transmission 3 Voltage between controller TMC2 (15) – Max. 1 V 5 – 11 V TMC1 (4) Voltage between 5 – 11 V Max. 1 V TMC2 (5) – TMC1 (4)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0
63
SEN01827-03
40 Troubleshooting
Failure code [DDN9KA] Blade tilt switch: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade tilt switch: Disconnection failure (Transmission controller system) DDN9KA • 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 failure code: Turn starting switch ON (and operate blade tilt switch). Cause
1
2
Possible causes and the standard values when normal 3
4
64
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade tilt switch P03 (male) Defective blade tilt switch SINGLE DUAL (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (3) – (6) Resistance between Min. 1 Mz Max. 1 z (3) – (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (35) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in – P03 (female) (6) wiring or defective contact Wiring harness between TMC2 (female) (25) ResisMax. 1 z in connector) – P03 (female) (4) tance Wiring harness between TMC1 (female) (4) – ResisMax. 1 z P03 (female) (3) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short in wiring harness TMC2 (female) (35) – P03 (female) (6) with Voltage Max. 1 V (Contact with 24 V circuit) chassis ground Short circuit of wiring harness between TMC2 (female) (25) – P03 (female) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade tilt switch TMC1, TMC2 SINGLE DUAL Defective transmission Voltage between controller TMC2 (35) – Max. 1 V 5 – 11 V TMC1 (4) Voltage between TMC2 (25) – 5 – 11 V Max. 1 V TMC1 (4)
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Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0
65
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40 Troubleshooting
Failure code [DDN9KB] Blade tilt switch: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Blade tilt switch: Short circuit (Transmission controller system) failure DDN9KB • 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 failure code: Turn starting switch ON (and operate blade tilt switch). Cause
1
Possible causes and the standard values when normal
Defective blade tilt switch (Internal disconnection)
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
3
66
1
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade tilt switch P03 (male) SINGLE DUAL Resistance between Max. 1 z Min. 1 Mz (3) – (6) Resistance between Min. 1 Mz Max. 1 z (3) – (4) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 (female) (35) – P03 (female) (6) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC2 (female) (25) – P03 (female) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade tilt switch TMC1, TMC2 SINGLE DUAL Voltage between TMC2 (35) – Max. 1 V 5 – 11 V TMC1 (4) Voltage between TMC2 (25) – 5 – 11 V Max. 1 V TMC1 (4)
D475A, D475ASD-5E0
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Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0
67
SEN01827-03
40 Troubleshooting
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Blade lift raise full oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNALD • The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 60 seconds. • Recognizes that the oil pressure switch is turned OFF. • The data of the VHMS may become abnormal. • Blade lift raise operation becomes slow. • The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal) • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after 1 (When electrical system is the resetting operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade lift raise BLU (male) Blade lever Resistance 2 full oil pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Raise Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between STCN2 (Contact with ground cirResis(female) (36) and BLU (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (36) and TMC1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift raise full oil pressure switch
68
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Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Ripper lift raise oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNBLD • The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds. • Recognizes that the oil pressure switch is turned OFF. • • • •
The shoe slip control (SSC) function does not operate normally. Ripper lift raise operation becomes slow. The data of the VHMS may become abnormal. The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the monitoring mode. (Code 70305: Steering controller input signal 3) • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the error code lamp still lights up (resetting is still urged) after the 1 (When electrical system is resetting operation is performed, it is suspected that the lever was normal) operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper lift raise oil RPU (male) Ripper lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Raise Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (13) and RPU (female) (1) and Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC2, TMC1 Ripper lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (13) and TMC1 (4) Raise Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
D475A, D475ASD-5E0
69
SEN01827-03
40 Troubleshooting
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Ripper lift lower oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNCLD • The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds. • Recognizes that the oil pressure switch is turned OFF. • • • •
The shoe slip control (SSC) function does not operate normally. The data of the VHMS may become abnormal. Ripper lift lower operation becomes slow. The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the monitoring mode. (Code 70305: Steering controller input signal 3) • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after 1 (When electrical system is the resetting operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper lift lower RPD (male) Ripper lever Resistance 2 oil pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Lower Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (3) and RPD (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (3) and TMC1 (4) Lower Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
70
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SEN01827-03
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Ripper tilt in oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNDLD • The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds. • Recognizes that the oil pressure switch is turned OFF. • • • •
The shoe slip control (SSC) function does not operate normally. The data of the VHMS may become abnormal. Ripper tilt in operation becomes slow. The input state (ON/OFF) from the ripper tilt in oil pressure switch can be checked in the monitoring mode. (Code 70305: Ripper lever oil pressure switch input signal) • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after 1 (When electrical system is the resetting operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper tilt in oil RT1 (male) Ripper lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Tilt in Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (2) and RT1 (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (2) and TMC1 (4) Tilt in Max. 1 V
Circuit diagram related to ripper tilt in oil pressure switch
D475A, D475ASD-5E0
71
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Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Ripper tilt back oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNELD • The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds. • Recognizes that the oil pressure switch is turned OFF. • • • •
The shoe slip control (SSC) function does not operate normally. The tilt back speed of the ripper lowers. The data of the VHMS may become abnormal. The input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked in the monitoring mode. (Code 70305: Ripper lever oil pressure switch input signal) • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after 1 (When electrical system is the resetting operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper tilt back oil RT8 (male) Ripper lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Tilt back Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (38) and RT8 (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 – 11 V Between TMC2 (38) and TMC1 (4) Tilt back Max. 1 V
Circuit diagram related to ripper tilt back oil pressure switch
72
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time 1 Action code — Failure content Controller's action Symptoms that appear on machine
Failure code Symptom of Blade lift lower full pressure switch: Switch is ON for long time failure (Transmission controller system) DDNFLD • The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds. • Recognizes that the oil pressure switch is turned OFF. • The lift lower speed of the blade lowers. • The data of the VHMS may become abnormal.
General information
• The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal) • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 180 seconds).
Possible causes and the standard values when normal
Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after 1 (When electrical system is the resetting operation is performed, it is suspected that the lever normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade lift lower BLD (male) Blade lever Resistance 2 full oil pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Lower full Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (26) and BLD (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 – 11 V TMC2 (26) – TMC1 (4) Tilt in Max. 1 V
Circuit diagram related to blade lift lower full oil pressure switch
D475A, D475ASD-5E0
73
SEN01827-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01827-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
74
SEN01828-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code, Part 6 Failure code [DDQ2KA] Parking brake lever switch: Disconnection ............................................................... 4 Failure code [DDQ2KB] Parking brake lever switch: Short circuit .................................................................. 6 Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals................................................ 8 Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals ................................................ 9 Failure code [DDT5KA] Neutral switch: Disconnection ................................................................................. 10 Failure code [DDT5KB] Neutral switch: Short circuit .................................................................................... 12 Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement ...................... 14 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range.................... 15 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection................................................. 16 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ................. 17 Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates "n3" o "12")........................................................ 18 Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates "n3" o "22")........................................................ 20 Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates "n3" o "11")............................................................ 22
D475A, D475ASD-5E0
1
SEN01828-03
40 Troubleshooting
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21") Left bank exhaust temperature sensor system (Rear): Short circuit...................................................... 24 Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24") Right bank exhaust temperature sensor system (Front): Disconnection ............................................... 26 Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26") Right bank exhaust temperature sensor system (Rear): Disconnection................................................ 28 Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23") Right bank exhaust temperature sensor system (Front): Short circuit................................................... 30 Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") Right bank exhaust temperature sensor system (Rear): Short circuit ................................................... 32 Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection............................... 34 Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit .................................. 35 Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection .............................. 36 Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit .................................. 37 Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32") Blow-by pressure sensor system: Disconnection .................................................................................. 38 Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31") Blow-by pressure sensor system: Hot short .......................................................................................... 39 Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14") Transmission oil pressure sensor: Out of input signal range ................................................................. 40 Failure code [DK01KA] Left yoke angle sensor: Disconnection .................................................................... 41 Failure code [DK01KB] Left yoke angle sensor: Short circuit ....................................................................... 42 Failure code [DK03KA] Right yoke angle sensor: Disconnection ................................................................. 43 Failure code [DK03KB] Right yoke angle sensor: Short circuit ..................................................................... 44 Failure code [DK10KA] Fuel dial: Disconnection .......................................................................................... 45 Failure code [DK10KB] Fuel dial: Short circuit .............................................................................................. 46 Failure code [DK30KA] Steering potentiometer (1): Disconnection .............................................................. 48 Failure code [DK30KB] Steering potentiometer (1): Short circuit .................................................................. 50 Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range............................... 52 Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit ....................................... 52 Failure code [DK30L8] Steering potentiometer (1): See table....................................................................... 53 Failure code [DK31KA] Steering potentiometer (2): Disconnection .............................................................. 54 Failure code [DK31KB] Steering potentiometer (2): Short circuit .................................................................. 56
2
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40 Troubleshooting
D475A, D475ASD-5E0
SEN01828-03
3
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40 Troubleshooting
Failure code [DDQ2KA] Parking brake lever switch: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine
General information
Possible causes and the standard values when normal
Possible causes and the standard values when normal
4
• • • •
1
Failure code Symptom of Parking brake lever switch: Disconnection failure (Steering controller system) DDQ2KA Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes parking brake 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. a 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, NC is for operation detection and NO is for error detection. • Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. (Code 40910: Steering controller input signal 1) • Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever). When failure code [DDQ2KA] occurred alone Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between STCN2 (female) (5) Resis1 Max. 1 z in wiring or defective con- – branched point of circuit JF2 tance tact in connector) Wiring harness between STCN2 (female) (15) ResisMax. 1 z – branched point of circuit JF1 tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever STCN2 Defective steering Free position Lock position 2 controller Between (5) – Max. 1 V 5 – 11 V chassis ground Between (15) – 5 – 11 V Max. 1 V chassis ground When failure codes [DDQ2KA] and [DD14KA] occurred at the same time Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking brake lever Parking brake lever NSW 1 switch Free position Lock position (Internal disconnection) Between (A) – (B) Max. 1 z Min. 1 Mz Min. 1 Mz Max. 1 z Between (A) – (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NSW (female) (B) – ResisDisconnection in wiring Max. 1 z tance harness (Disconnection TMC1 (female) (18), – STCN2 (female) (5) 2 in wiring or defective con- Wiring harness between NSW (female) (C) – ResisMax. 1 z tact in connector) TMC1 (female) (12), – STCN2 (female) (15) tance Wiring harness between NSW (female) (A) – ResisMax. 1 z chassis ground tance
D475A, D475ASD-5E0
40 Troubleshooting
Possible causes and the standard values when normal
SEN01828-03
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Hot short in wiring har(female) (B) – TMC1 (female) (18) – STCN2 Voltage Max. 1 V 3 ness (Contact with 24 V (female) (5) with chassis ground circuit) Short circuit of wiring harness between NSW (female) (C) – TMC1 (female) (12) – STCN2 Voltage Max. 1 V (female) (15) with chassis ground
Circuit diagram related to parking brake switch
D475A, D475ASD-5E0
5
SEN01828-03
40 Troubleshooting
Failure code [DDQ2KB] Parking brake lever switch: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine
General information
Possible causes and the standard values when normal
6
• • • •
1
Failure code Symptom of Parking brake lever switch: Short circuit failure (Steering controller system) DDQ2KB 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. a 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) • NC and NO 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 40910: Steering controller input signal 1) • Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever). When failure codes [DDQ2KA] and [DD14KA] are displayed simultaneously Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective parking brake Parking brake lever NSW (male) 1 lever switch (Internal At FREE At LOCK short circuit) Between (A) – (B) Max. 1 z Min. 1 Mz Between (A) – (B) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with chassis Short circuit of wiring harness between NSW Resisground in wiring harness (female) (B) – TMC1 (female) (18) – STCN2 Min. 1 Mz 2 tance (Contact with ground cir- (female) (5) with chassis ground cuit) Short circuit of wiring harness between NSW Resis(female) (C) – TMC1 (female) (12) – STCN2 Min. 1 Mz tance (female) (15) with chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever STCN2 Defective steering At FREE At LOCK 3 controller Between (5) – Max. 1 V 5 – 11 V chassis ground Between (15) – 5 – 11 V Max. 1 V chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to parking brake switch
D475A, D475ASD-5E0
7
SEN01828-03
40 Troubleshooting
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals Action code CALL E03 Failure content Controller's action Symptoms that appear on machine
General information
1
Failure code Symptom of Parking brake lever switch: Disagreement of signals failure (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. a 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, DDQ2KB) • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code 40910: Steering controller input signal 1) • Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever). Cause
Possible causes and the standard values when normal
8
Standard values when normal and remarks for troubleshooting See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and Defective CAN communi1 [DAQRKR] are displayed. If they are displayed, carry out troublecation signal system shooting for them first. Defective parking brake See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and 2 lever switch signal sys[DDQ2KB] are displayed. If they are displayed, carry out troubletem shooting for them first. Defective steering con3 Since trouble is in system, troubleshooting cannot be carried out. troller
D475A, D475ASD-5E0
40 Troubleshooting
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Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals Action code CALL E03 Failure content Controller's action Symptoms that appear on machine
General information
1
Failure code Symptom of Parking brake lever switch: Disagreement of signals failure (Transmission 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. a 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, DDQ2KB) • Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever). Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and Defective CAN communi1 [DAQRKR] are displayed. If they are displayed, carry out troublecation signal system shooting for them first. Defective parking brake See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and 2 lever switch signal sys[DDQ2KB] are displayed. If they are displayed, carry out troubletem shooting for them first. Defective steering con3 Since trouble is in system, troubleshooting cannot be carried out. troller
D475A, D475ASD-5E0
9
SEN01828-03
40 Troubleshooting
Failure code [DDT5KA] Neutral switch: Disconnection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Neutral switch: Disconnection (Transmission controller system) failure DDT5KA • 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 pressed. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Input state (ON/OFF) from neutral switch can be checked in monitoring mode. (Code 40906: Transmission controller input signal 2) • Method of reproducing failure code: Turn starting switch ON (and operate neutral switch). Cause
1
2
Possible causes and the standard values when normal 3
4
10
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Neutral switch SNC (male) Defective neutral switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (4) – (6) Resistance between Min. 1 Mz Max. 1 z (4) – (5) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (27) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection – SNC (female) (6) in wiring or defective con- Wiring harness between TMC2 (female) (17) ResisMax. 1 z tact in connector) – SNC (female) (5) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z – SNC (female) (4) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 Hot short in wiring har(female) (27) – SNC (female) (6) with chassis Voltage Max. 1 V ness (Contact with 24 V ground circuit) Short circuit of wiring harness between TMC2 (female) (17) – SNC (female) (5) with chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMC1,TMC2 OFF (Release) ON (Press) Defective transmission Voltage between controller Max. 1 V 5 – 11 V TMC2 (27) – TMC1 (10) Voltage between TMC2 (17) – 5 – 11 V Max. 1 V TMC1 (10)
D475A, D475ASD-5E0
40 Troubleshooting
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Circuit diagram related to neutral switch
D475A, D475ASD-5E0
11
SEN01828-03
40 Troubleshooting
Failure code [DDT5KB] Neutral switch: Short circuit Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Neutral switch: Short circuit (Transmission controller system) failure DDT5KB • Signals of two systems of neutral switch circuit were turned ON (CLOSE) at the same time. • Flashes caution lamp and turns on caution buzzer. • Recognizes that switch is pressed. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel any more. • Input state (ON/OFF) from neutral switch can be checked in monitoring mode. (Code 40906: Transmission controller input signal 2) • Method of reproducing failure code: Turn starting switch ON (and operate neutral switch). Cause
Possible causes and the standard values when normal
12
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Neutral switch SNC (male) Defective neutral switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (4) – (6) Resistance between Min. 1 Mz Max. 1 z (4) – (5) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between TMC2 Resisground in wiring harness (female) (27) – SNC (female) (6) with chassis Min. 1 Mz 2 tance (Contact with ground cir- ground cuit) Short circuit of wiring harness between TMC2 Resis(female) (17) – SNC (female) (5) with chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMC1, TMC2 OFF (Release) ON (Press) Defective transmission Voltage between 3 controller TMC2 (27) – Max. 1 V 5 – 11 V TMC1 (10) Voltage between TMC2 (17) – 5 – 11 V Max. 1 V TMC1 (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to neutral switch
D475A, D475ASD-5E0
13
SEN01828-03
40 Troubleshooting
Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Lever specification selection: Model selection signal disagreement failure (Transmission controller system) DDT5KQ • Travel lever cannot select PCCS standard specification. • Blinks warning lamp and sounds alarm buzzer. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it cannot travel at all. • Input state (ON/OFF) from neutral switch can be checked in monitoring mode (Code 40906: Transmission controller input signal 2) • Method of reproducing failure code: Turn starting switch ON. Cause Standard values when normal and remarks for troubleshooting Worng selection of travel a Check type of travel lever in adjustment Select optional travel 1 lever mode: 0004 lever a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between ResisMin. 1 Mz 2 harness (Contact with TMC2 (female) (17) – SNC (female) (5) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz TMC2 (female) (27) – SNC (female) (6) tance If causes 1 and 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to lever specification selection
14
D475A, D475ASD-5E0
40 Troubleshooting
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Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Hydraulic oil temperature sensor: Input signal is out of normal range failure (Transmission controller system) DGS1KX • 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 failure code: Turn starting switch ON or start engine. Cause Defective hydraulic oil temperature sensor 1 (Internal disconnection or short circuit)
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector) Possible causes and the standard values when normal
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Short circuit with power 4 source in wiring harness (Contact with 24 V circuit)
5
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDS (male) Resistance Between (1) – (2) 3.5 k – 90 kz (10 – 100°C) Between (1), (2) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (14) ResisMax. 1 z – SDS (female) (1) tance Wiring harness between TMC1 (female) (21) ResisMax. 1 z – SDS (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMC1 Resis(female) (14) – SDS (female) (1) with chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC1 (female) (14) – SDS (female) (1) with chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMC1 (female) Resistance Between (14) – (21) 3.5 k – 90 kz (10 – 100°C) Between (14) – chassis ground Min. 1 Mz
Circuit diagram related to hydraulic oil temperature sensor
D475A, D475ASD-5E0
15
SEN01828-03
40 Troubleshooting
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Power train oil temperature sensor: Disconnection failure (Machine monitor system) DGT1KA • The power train temperature sensor signal is lower than the specified value. • Nothing particular. • • • •
Power train oil temperature on machine monitor is not displayed properly. Fan speed is limited to half. Gear shift shock of transmission is large. Power train temperature state (temperature) can be checked in monitoring mode. (Code 30100: Power train oil temperature) • Duplication of failure code: Turn starting switch ON or start engine. Causes Defective power train oil 1 temperature sensor (Short circuit)
Possible causes and the standard values when normal
1
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Defective harness 3 grounding (contact with ground circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. 453 (male) Resistance Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C) Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between S04 (female) (12) – ResisMax. 1 z 453 (female) (1) tance Wiring harness between S03 (female) (3) – ResisMax. 1 z 453 (female) (2) tance Wiring harness between S03 (female) (4) – 453 (female) (2)
Resistance
Max. 1 z
a Prepare with starting switch OFF and diagnose with starting switch Hot short of wiring still OFF. 4 harness Between ground and wiring harness between Resis(contact with 24 V circuit) Min. 1 Mz S04 (female) (12) – 453 (female) (1) tance Machine monitor can be suspected to defective if no problem is found Defective machine 5 in causes 1 – 4 (since this is an internal defect, it cannot be diagmonitor nosed).
Circuit diagram related to power train oil temperature sensor
16
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40 Troubleshooting
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Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range 1 Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Power train oil temperature sensor: Input signal out of range failure (Machine monitor system) DGT1KX • Power train temperature sensor signal is out of normal range. • Nothing particular. • • • •
Power train oil temperature on machine monitor is not displayed properly. Fan speed is limited to half. Gear shift shock of transmission is large. Power train temperature state (temperature) can be checked in monitoring mode. (Code 30100: Power train oil temperature) • Duplication of failure code: Turn starting switch ON or start engine. Causes Defective power train oil 1 temperature sensor (Short circuit)
Possible causes and the standard values when normal
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Defective harness 3 grounding (contact with ground circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. 453 (male) Resistance Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C) Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between S04 (female) (12) – ResisMax. 1 z 453 (female) (1) tance Wiring harness between S03 (female) (3) – ResisMax. 1 z 453 (female) (2) tance Wiring harness between S03 (female) (4) – 453 (female) (2)
Resistance
Max. 1 z
a Prepare with starting switch OFF and diagnose with starting switch Hot short of wiring still OFF. 4 harness Between ground and wiring harness between Resis(contact with 24 V circuit) Min. 1 Mz S04 (female) (12) – 453 (female) (1) tance Machine monitor can be suspected to defective if no problem is found Defective machine 5 in causes 1 – 4 (since this is an internal defect, it cannot be diagmonitor nosed).
Circuit diagram related to power train oil temperature sensor
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Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates "n3" o "12") Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
18
Failure code Symptom of Left bank exhaust temperature sensor system (Front): Disconnection failure (VHMS controller system) DGT5KA • The signal voltage of the left bank exhaust temperature sensor is below 0.5 V. • None in particular. • The left bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "12". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of left bank 1 exhaust temperature Check the engine, then repair it if it has any abnormality. (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senDefective left bank Exhaust temperature sor (Front) is replaced, the condition does not 2 exhaust temperature sensor is normal become normal. sensor When the left bank exhaust temperature senExhaust temperature sor (Front) is replaced, the condition becomes sensor is defective normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Defective left bank Approx. engine is 20°C Voltage exhaust temperature 0.9 – 1.2 V 3 EXA2 – started sensor Between V1, V2A After amplifier (B) and line engine is (C) Approx. 500°C Voltage started 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA2 (female) (A) tance Wiring harness between V2A (female) (7) and ResisDisconnection in wiring Max. 1 z tance harness (Disconnection EXA2 (female) (B) 4 in wiring harness or ResisWiring harness between V2A (female) (13) Max. 1 z defective contact) and EXA2 (female) (C) tance Wiring harness between EXT2 (female) (1) ResisMax. 1 z and EXTLF (female) (1) tance Wiring harness between EXT2 (female) (2) ResisMax. 1 z and EXTLF (female) (2) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
5
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (7) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
19
SEN01828-03
40 Troubleshooting
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates "n3" o "22") 1 Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
20
Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Disconnection failure (VHMS controller system) dGT5KA • The signal voltage of the left bank exhaust temperature sensor is below 0.5 V. • None in particular. • The left bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "12". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of left bank 1 exhaust temperature Check the engine, then repair it if it has any abnormality. (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senDefective left bank Exhaust temperature sor (Rear) is replaced, the condition does not 2 exhaust temperature sensor is normal become normal. sensor When the left bank exhaust temperature senExhaust temperature sor (Rear) is replaced, the condition becomes sensor is defective normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Defective left bank Approx. engine is 20°C Voltage exhaust temperature 0.9 – 1.2 V 3 EXA4 – started sensor Between V1, V2A After amplifier (B) and line engine is (C) Approx. 500°C Voltage started 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA4 (female) (A) tance Wiring harness between V2A (female) (6) and ResisDisconnection in wiring Max. 1 z tance harness (Disconnection EXA4 (female) (B) 4 in wiring harness or ResisWiring harness between V2A (female) (13) Max. 1 z defective contact) and EXA4 (female) (C) tance Wiring harness between EXT4 (male) (1) and ResisMax. 1 z EXTLR (female) (1) tance Wiring harness between EXT4 (male) (2) and ResisMax. 1 z EXTLR (female) (2) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
5
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (6) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
21
SEN01828-03
40 Troubleshooting
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates "n3" o "11")1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left bank exhaust temperature sensor system (Front): Short circuit failure (VHMS controller system) DGT5KB • The signal voltage of the left bank exhaust temperature sensor is above 4.9 V. • None in particular. • The left bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "11". Causes
Defective left bank 1 exhaust temperature sensor
Defective left bank exhaust temperature 2 sensor amplifier Possible causes and the standard values when normal
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Short circuit with power source in wiring harness 4 (Contact with 24-V circuit)
22
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition does not sensor is normal become normal. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition becomes norsensor is defective mal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Approx. engine is 20°C Voltage 0.9 – 1.2 V EXA2 – started V1, V2A Between After (B) and line engine is (C) Approx. 500°C Voltage started 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA2 (female) (A) and chassis ground tance Between wiring harness between V2A Resis(female) (7) and EXA2 (female) (B) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT2 Resis(male) (1) and EXTLF (female) (1) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT2 ResisMin. 1 Mz (male) (2) and EXTLF (female) (2) and chastance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA2 (female) (B), (C) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective VHMS control5 ler V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (7) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
23
SEN01828-03
40 Troubleshooting
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21") Left bank exhaust temperature sensor system (Rear): Short circuit1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Short circuit failure (VHMS controller system) dGT5KB • The signal voltage of the left bank exhaust temperature sensor is above 4.9 V. • None in particular. • The left bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "21". Causes
Defective left bank 1 exhaust temperature sensor
Defective left bank exhaust temperature 2 sensor amplifier Possible causes and the standard values when normal
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Short circuit with power source in wiring harness 4 (Contact with 24-V circuit)
24
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition does not sensor is normal become normal. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition becomes norsensor is defective mal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Approx. engine is 20°C Voltage 0.9 – 1.2 V EXA4 – started V1, V2A Between After (B) and line engine is (C) Approx. 500°C Voltage started 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA4 (female) (A) and chassis ground tance Between wiring harness between V2A Resis(female) (6) and EXA4 (female) (B) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT4 Resis(male) (1) and EXTLR (female) (1) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT4 Resis(male) (2) and EXTLR (female) (2) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA4 (female) (B), (C) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective VHMS control5 ler V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (6) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
25
SEN01828-03
40 Troubleshooting
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24") Right bank exhaust temperature sensor system (Front): Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
26
1
Failure code Symptom of Right bank exhaust temperature sensor system (Front): Disconnecfailure tion (VHMS controller system) DGT6KA • The signal voltage of the right bank exhaust temperature sensor is below 0.5 V. • None in particular. • The right bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "24". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of right bank exhaust tempera1 Check the engine, then repair it if it has any abnormality. ture (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Front) is replaced, the condition does 2 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Front) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Approx. Defective right bank engine is 20°C Voltage 0.9 – 1.2 V 3 exhaust temperature EXA1 – started Between sensor amplifier V1, V2A After (B) and line engine is (C) Approx. 500°C Voltage started 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA1 (female) (A) tance Wiring harness between V2A (female) (5) and ResisDisconnection in wiring Max. 1 z tance harness (Disconnection EXA1 (female) (B) 4 in wiring harness or ResisWiring harness between V2A (female) (13) Max. 1 z defective contact) tance and EXA1 (female) (C) Wiring harness between EXT1 (male) (1) and ResisMax. 1 z EXTRF (female) (1) tance Wiring harness between EXT1 (male) (2) and ResisMax. 1 z EXTRF (female) (2) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
5
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (5) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
27
SEN01828-03
40 Troubleshooting
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26") Right bank exhaust temperature sensor system (Rear): Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
28
1
Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Disconnection failure (VHMS controller system) dGT6KA • The signal voltage of the right bank exhaust temperature sensor is below 0.5 V. • None in particular. • The right bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "26". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of right bank exhaust tempera1 Check the engine, then repair it if it has any abnormality. ture (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Rear) is replaced, the condition does 2 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Rear) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Approx. Defective right bank engine is 20°C Voltage 0.9 – 1.2 V 3 exhaust temperature EXA3 – started Between sensor amplifier V1, V2A After (B) and line engine is (C) Approx. 500°C Voltage started 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA3 (female) (A) tance Wiring harness between V2A (female) (16) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection and EXA3 (female) (B) 4 in wiring harness or ResisWiring harness between V2A (female) (13) Max. 1 z defective contact) tance and EXA3 (female) (C) Wiring harness between EXT3 (male) (1) and ResisMax. 1 z EXTRR (female) (1) tance Wiring harness between EXT3 (male) (2) and ResisMax. 1 z EXTRR (female) (2) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
5
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (16) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
29
SEN01828-03
40 Troubleshooting
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23") Right bank exhaust temperature sensor system (Front): Short circuit Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right bank exhaust temperature sensor system (Front): Short circuit failure (VHMS controller system) DGT6KB • The signal voltage of the right bank exhaust temperature sensor is above 4.9 V. • None in particular. • The right bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "23". Causes
Possible causes and the standard values when normal
30
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Front) is replaced, the condition does 1 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Front) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Approx. Defective right bank engine is 20°C Voltage 0.9 – 1.2 V 2 exhaust temperature started EXA1 – sensor amplifier V1, V2A Between After (B) and line engine is (C) Approx. started 500°C Voltage 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA1 (female) (A) and chassis ground tance Between wiring harness between V2A Short circuit with chassis Resis(female) (5) and EXA1 (female) (B) and chasMin. 1 Mz ground in wiring harness tance 3 sis ground (Contact with ground cirBetween wiring harness between EXT1 cuit) ResisMin. 1 Mz (male) (1) and EXTRF (female) (1) and chastance sis ground Between wiring harness between EXT1 Resis(male) (2) and EXTRF (female) (2) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harwithout turning starting switch ON. 4 ness (Contact with 24-V Between wiring harness between V1 (female) Resiscircuit) Min. 1 Mz (2) and EXA1 (female) (B), (C) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
5
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and chassis ground Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (5) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
31
SEN01828-03
40 Troubleshooting
Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") Right bank exhaust temperature sensor system (Rear): Short circuit Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Short circuit failure (VHMS controller system) dGT6KB • The signal voltage of the right bank exhaust temperature sensor is above 4.9 V. • None in particular. • The right bank exhaust temperature cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n3" o "25". Causes
Possible causes and the standard values when normal
32
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Rear) is replaced, the condition does 1 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Rear) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 – 30 V Before Approx. Defective right bank engine is 20°C Voltage 0.9 – 1.2 V 2 exhaust temperature started EXA3 – sensor amplifier V1, V2A Between After (B) and line engine is (C) Approx. started 500°C Voltage 2.6 – 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA3 (female) (A) and chassis ground tance Between wiring harness between V2A Short circuit with chassis Resis(female) (16) and EXA3 (female) (B) and Min. 1 Mz ground in wiring harness tance 3 chassis ground (Contact with ground cirBetween wiring harness between EXT3 cuit) ResisMin. 1 Mz (male) (1) and EXTRR (female) (1) and chastance sis ground Between wiring harness between EXT3 Resis(male) (2) and EXTRR (female) (2) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harwithout turning starting switch ON. 4 ness (Contact with 24-V Between wiring harness between V1 (female) Resiscircuit) Min. 1 Mz (2) and EXA3 (female) (B), (C) tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible causes and the standard values when normal
5
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and chassis ground Voltage 20 – 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20°C Approx. 0.9 – 1.2 V Between started (16) and After engine is started (13) 500°C Approx. 2.6 – 3.5 V (with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
33
SEN01828-03
40 Troubleshooting
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Work equipment pump oil pressure sensor (F): Disconnection failure (Transmission controller system) DH22KA • Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.2 V. • Recognizes hydraulic pump (F) oil pressure to be 0. • Work equipment pump (F) oil pressure cannot be monitored. • Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring mode. (Code 70701: Voltage of work equipment pump oil sensor (F)) • Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system Defective work equipment pump oil pressure 2 sensor (F) (Internal trouble)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5
Defective transmission controller
Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. HP1 Voltage Between (C) – (A) 0.5 – 6.0 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (34) ResisMax. 1 z – HP1 (female) (B) tance Wiring harness between TMC1 (female) (9) – ResisMax. 1 z HP1 (female) (C) tance Wiring harness between TMC1 (female) (21) ResisMax. 1 z – HP1 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMC1 Resis(female) (9) – HP1 (female) (C) with chassis Min. 1 Mz tance ground Transmission controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (F)
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Work equipment pump oil pressure sensor (F): Short circuit failure (Transmission controller system) DH22KB • Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 4.8 V • Recognizes hydraulic pump (F) oil pressure to be 0. • Work equipment pump (F) oil pressure cannot be monitored. • Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring mode. (Code 70701: Voltage of work equipment pump oil pressure sensor (F)) • Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipout troubleshooting. ment pump oil pressure 2 sensor (F) (Internal trouHP1 Voltage ble) Between (C) – (A) 0.5 – 6.0 V a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring har3 ness (Contact with 24 V Short circuit of wiring harness between TMC1 circuit) (female) (9) – HP1 (female) (C) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (F)
D475A, D475ASD-5E0
35
SEN01828-03
40 Troubleshooting
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Work equipment pump oil pressure sensor (R): Disconnection failure (Transmission controller system) DH23KA • Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.2 V. • Recognizes hydraulic pump (R) oil pressure to be 0. • Work equipment pump (R) oil pressure cannot be monitored. • Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring mode. (Code 70703: Voltage of work equipment pump oil sensor (R)) • Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system Defective work equipment pump oil pressure 2 sensor (R) (Internal trouble)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5
Defective transmission controller
Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. HP2 Voltage Between (C) – (A) 0.5 – 6.0 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (34) ResisMax. 1 z – HP2 (female) (B) tance Wiring harness between TMC1 (female) (3) – ResisMax. 1 z HP2 (female) (C) tance Wiring harness between TMC1 (female) (21) ResisMax. 1 z – HP2 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMC1 Resis(female) (3) – HP2 (female) (C) with chassis Min. 1 Mz tance ground Transmission controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Work equipment pump oil pressure sensor (R): Short circuit failure (Transmission controller system) DH23KB • Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 4.8 V • Recognizes hydraulic pump (R) oil pressure to be 0. • Work equipment pump (R) oil pressure cannot be monitored. • Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring mode. (Code 70703: Voltage of work equipment pump oil pressure sensor (R)) • Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipout troubleshooting. ment pump oil pressure 2 sensor (R) (Internal trouHP2 Voltage ble) Between (C) – (A) 0.5 – 6.0 V a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring har3 ness (Contact with 24 V Short circuit of wiring harness between TMC1 circuit) (female) (3) – HP2 (female) (C) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A, D475ASD-5E0
37
SEN01828-03
40 Troubleshooting
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32") Blow-by pressure sensor system: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blow-by pressure sensor system: Disconnection failure (VHMS controller system) DHE5KB • The signal voltage of the blow-by pressure sensor is below 0.1 V. • None in particular. • The blow-by pressure cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the error code can be checked.) • The LED of the VHMS controller indicates "n3" o "32". Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blow-by presENBP Voltage 1 sure sensor Between (B) and (A) 4.5 – 5.5 V Between (C) and (A) 0.3 – 0.7 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between V1 (female) (4) and Resis2 Max. 1 z in wiring harness or ENBP (female) (B) tance defective contact) Wiring harness between 2A (female) (18) and ResisMax. 1 z ENBP (female) (C) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS control- Between V1 (female) (4) and V2A (female) 3 Voltage 4.5 – 5.5 V ler (12) Between V2A (female) (18) and V2A (female) Voltage 0.3 – 0.7 V (12)
Circuit diagram related to blow-by pressure sensor
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31") Blow-by pressure sensor system: Hot short Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blow-by pressure sensor system: Hot short failure (VHMS controller system) DHE5KY • The signal voltage of the blow-by pressure sensor is above 4.7 V. • None in particular. • The blow-by pressure cannot be monitored with the monitoring function. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the error code can be checked.) • The LED of the VHMS controller indicates "n3" o "31". Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blow-by presENBP Voltage 1 sure sensor Between (B) and (A) 4.5 – 5.5 V Between (C) and (A) 0.3 – 0.7 V a Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harwithout turning starting switch ON. 2 ness (Contact with 24-V Between ground and wiring harness between circuit) Voltage Max. 1 V V2 (female) (18) and ENBP (female) (C) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS control- Between V1 (female) (4) and V2A (female) 3 Voltage 4.5 – 5.5 V ler (12) Between V2A (female) (18) and V2A (female) Voltage 0.3 – 0.7 V (12)
Circuit diagram related to blow-by pressure sensor
D475A, D475ASD-5E0
39
SEN01828-03
40 Troubleshooting
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14") Transmission oil pressure sensor: Out of input signal range Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Transmission oil pressure sensor: Out of input signal range failure (VHMS controller system) DHT3KX • Transmission oil pressure signals cannot be obtained. • None in particular. • The system may not operate normally. • The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) • The LED of the VHMS controller indicates "n6" o "14". Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between V1 (female) (2) and Resis1 Max. 1 z in wiring harness or TMMD (female) (B) tance defective contact) Wiring harness between V2A (female) (15) ResisMax. 1 z and TMMD (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Between wiring harness between V1 (female) Resisground in wiring harness (2) and TMMD (female) (B) and chassis Min. 1 Mz 2 tance (Contact with ground cir- ground cuit) Between wiring harness between V2A Resis(female) (15) and TMMD (female) (C) and Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring har3 ness (Contact with 24-V Short circuit of wiring harness between V2A circuit) (female) (15) and TMMD (female) (C) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS 4 controller V1 and V2A Voltage Between V1 (2) and V2A (12) Below 20 – 30 V
Circuit diagram related to transmission oil pressure sensor
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DK01KA] Left yoke angle sensor: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Left yoke angle sensor: Disconnection failure (Transmission controller system) DK01KA • The signal voltage of the left yoke angle sensor circuit is lower than the specified value. • Flashes the caution lamp and turns on the caution buzzer. • The tilt limiting system does not function. • The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode. (Code 90002: Left yoke angle sensor voltage) • Method of reproducing failure code: Turn the starting switch ON. Causes Defective sensor 5-V 1 power supply system Defective left yoke angle sensor 2 (Internal disconnection or short circuit)
Possible causes and the standard values when normal
1
Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector) Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5
Defective transmission controller
Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CSL (male) Resistance Between (A) and (C) 4.0 – 6.0 kz Between (A) and (B) 0.25 – 7.0 kz Between (B) and (C) 0.25 – 7.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (34) ResisMax. 1 z and CSL (female) (A) tance Wiring harness between TMC1 (female) (7) ResisMax. 1 z and CSL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC1 Resis(female) (7) and CSL (female) (B) and chassis Min. 1 Mz tance ground Transmission controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to left yoke angle sensor
D475A, D475ASD-5E0
41
SEN01828-03
40 Troubleshooting
Failure code [DK01KB] Left yoke angle sensor: Short circuit Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Left yoke angle sensor: Short circuit failure (Transmission controller system) DK01KB • The signal voltage of the left yoke angle sensor circuit is higher than the specified value. • Flashes the caution lamp and turns on the caution buzzer. • The tilt limiting system does not function. • The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode. (Code 90002: Left yoke angle sensor voltage) • Method of reproducing failure code: Turn the starting switch ON. Causes Defective sensor 5-V 1 power supply system
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left yoke angle CSL (male) Resistance sensor 2 (Internal disconnection or Between (A) and (C) 4.0 – 6.0 kz short circuit) Between (A) and (B) 0.25 – 7.0 kz Between (B) and (C) 0.25 – 7.0 kz a Prepare with starting switch OFF, then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness 3 Between wiring harness between TMC1 (Contact with 24-V cir(female) (7) and CSL (female) (B) and chassis Voltage Max. 1 V cuit) ground Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to left yoke angle sensor
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DK03KA] Right yoke angle sensor: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Right yoke angle sensor: Disconnection failure (Transmission controller system) DK03KA • The signal voltage of the right yoke angle sensor circuit is lower than the specified value. • Flashes the caution lamp and turns on the caution buzzer. • The tilt limiting system does not function. • The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode. (Code 90003: Right yoke angle sensor voltage) • Method of reproducing failure code: Turn the starting switch ON. Causes Defective sensor 5-V 1 power supply system Defective right yoke angle sensor 2 (Internal disconnection or short circuit)
Possible causes and the standard values when normal
1
Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector) Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5
Defective transmission controller
Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CSR (male) Resistance Between (A) and (C) 4.0 – 6.0 kz Between (A) and (B) 0.25 – 7.0 kz Between (B) and (C) 0.25 – 7.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (34) ResisMax. 1 z and CSR (female) (A) tance Wiring harness between TMC1 (female) (13) ResisMax. 1 z and CSR (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC1 Resis(female) (13) and CSR (female) (B) and chasMin. 1 Mz tance sis ground Transmission controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to right yoke angle sensor
D475A, D475ASD-5E0
43
SEN01828-03
40 Troubleshooting
Failure code [DK03KB] Right yoke angle sensor: Short circuit Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right yoke angle sensor: Short circuit failure (Transmission controller system) DK03KB • The signal voltage of the right yoke angle sensor circuit is higher than the specified value. • Flashes the caution lamp and turns on the caution buzzer. • The tilt limiting system does not function. • The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode. (Code 90003: Right yoke angle sensor voltage) • Method of reproducing failure code: Turn the starting switch ON. Causes Defective sensor 5-V 1 power supply system
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right yoke CSR (male) Resistance angle sensor 2 (Internal disconnection or Between (A) and (C) 4.0 – 6.0 kz short circuit) Between (A) and (B) 0.25 – 7.0 kz Between (B) and (C) 0.25 – 7.0 kz a Prepare with starting switch OFF, then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness 3 Between wiring harness between TMC1 (Contact with 24-V cir(female) (13) and CSR (female) (B) and chas- Voltage Max. 1 V cuit) sis ground Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to right yoke angle sensor
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DK10KA] Fuel dial: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
Failure code Symptom of Fuel dial: Disconnection failure (Steering controller system) DK10KA Signal voltage of fuel dial circuit is lower than the specified value. Flashes warning lamp and turns on alarm buzzer. Continues to control with decelerator pedal potentiometer signal. Operation of engine and transmission is limited.
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input state (voltage) from fuel dial can be checked in monitoring mode. (Code 03000: Fuel dial voltage) • Duplication of failure code: turn ON the starting switch. Causes Defective sensor 5V 1 power supply circuit
Defective fuel dial 2 (internal disconnection and short circuit)
Possible causes and the standard values when normal
1
Disconnection in wiring harness 3 (disconnection or defective contact of connectors)
Defective harness grounding 4 (contact with ground circuit)
5
Defective steering and transmission controller
Standard values when normal and remarks for troubleshooting Check if failure code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. DIAL (male) Resistance Between (1) – (3) 4.0 – 6.0 kz Between (1) – (2) 0.5 – 4.5 kz Between (2) – (3) 0.5 – 4.5 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between STCN1 (female) (22) ResisMax. 1 z – DIAL (female) (1) tance Wiring harness between STCN1 (female) (8) ResisMax. 1 z – DIAL (female) (2) tance Wiring harness between STCN1 (female) (21) ResisMax. 1 z – DIAL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz STCN1 (female) (22) – DIAL (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz STCN1 (female) (8) – DIAL (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch ON. Voltage STCN1 Between (22) – (21) 4.6 – 5.4 V Between (8) – (21) 0.5 – 4.5 V
Circuit diagram related to fuel dial
D475A, D475ASD-5E0
45
SEN01828-03
40 Troubleshooting
Failure code [DK10KB] Fuel dial: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
Failure code Symptom of Fuel dial: Short circuit failure (Steering controller system) DK10KB Signal voltage of fuel dial circuit is higher than the specified value. Flashes warning lamp and turns on alarm buzzer. Continues to control with decelerator pedal potentiometer signal. Operation of engine and transmission is limited.
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1. • Input state (voltage) from fuel dial can be checked in monitoring mode. (Code 03000: Fuel dial voltage) • Duplication of failure code: turn ON the starting switch. Causes Defective sensor 5 V 1 power supply circuit
Defective fuel dial 2 (internal disconnection and short circuit)
Possible causes and the standard values when normal
1
Disconnection in wiring harness 3 (disconnection or defective contact of connectors)
Standard values when normal and remarks for troubleshooting Check if failure code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. DIAL (male) Resistance Between (1) – (3) 4.0 – 6.0 kz Between (1) – (2) 0.5 – 4.5 kz Between (2) – (3) 0.5 – 4.5 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between STCN1 (female) (21) – DIAL (female) (3)
Resistance
Max. 1 z
a Prepare with starting switch OFF and diagnose with starting switch ON. Between ground and wiring harness between Voltage Max. 1V Hot short of wiring harSTCN1 (female) (22) – DIAL (female) (1) 4 ness (contact with 24 V circuit) Between ground and wiring harness between Voltage Max. 1V STCN1 (female) (8) – DIAL (female) (2) Between ground and wiring harness between Voltage Max. 1V STCN1 (female) (21) – DIAL (female) (3) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective steering and STCN1 Voltage 5 transmission controller Between (22) – (21) 4.6 – 5.4 V Between (8) – (21) 0.5 – 4.5 V
Circuit diagram related to fuel dial
46
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01828-03
47
SEN01828-03
40 Troubleshooting
Failure code [DK30KA] Steering potentiometer (1): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Steering potentiometer (1): Disconnection failure (Steering controller system) DK30KA Signal voltage of steering potentiometer (1) system (L) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (2) system (R). 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) (L) can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective 5 V sensor 1 power source system
Possible causes and the standard values when normal
48
Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and perform troubleshooting. Defective PCCS lever a If power supply voltage is normal and sensor output voltage is steering potentiometer 2 abnormal (0.5 V or lower), internal open circuit and ground fault 2 (internal open circuit) or cannot be identified. In this case, go to cause 4. ground fault If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective. Sensor 0.96 to Between TL2 (female) (6) and (8) Voltage output 4.04 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between STCN1 (female) (22) Resis3 Max. 1 z in wiring or defective – TL2 (female) (5) tance contact in connector) Wiring harness between STCN1 (female) (2) ResisMax. 1 z – TL2 (female) (7) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness STCN1 (female) (22) – TL2 (female) (5) with Min. 1 Mz 4 tance (Contact with ground chassis ground circuit) Short circuit of wiring harness between ResisSTCN1 (female) (2) – TL2 (female) (7) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 5 STCN1 Voltage controller Between (2) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0
49
SEN01828-03
40 Troubleshooting
Failure code [DK30KB] Steering potentiometer (1): Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Steering potentiometer (1): Short circuit failure (Steering controller system) DK30KB Signal voltage of steering potentiometer (1) system (L) is higher than specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (2) system (R). 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) (L) can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective 5 V sensor 1 power source system
Possible causes and the standard values when normal
50
Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and perform troubleshooting. Defective PCCS lever a If power supply voltage is normal and sensor output voltage is steering potentiometer 2 abnormal (0.5 V or lower), internal open circuit and ground fault 2 (internal open circuit) or cannot be identified. In this case, go to cause 4. ground fault If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective. Sensor 0.96 to Between TL2 (female) (6) and (8) Voltage output 4.04 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Short circuit with power STCN1 (female) (22) – TL2 (female) (5) with Voltage Max. 1 V 3 source in wiring harness chassis ground (Contact with 24 V circuit) Short circuit of wiring harness between STCN1 (female) (2) – TL2 (female) (7) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 4 controller STCN1 Voltage Between (2) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0
51
SEN01828-03
40 Troubleshooting
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Steering potentiometer (1): Input signal is out of normal range failure (Steering controller system) DK30KX • Either of failure codes [DK30KA] and [DK30KB] of steering potentiometer systems (1) and (2) and failure 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 failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes
Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
52
1
Failure code Symptom of Steering potentiometer (1): Disconnection or short circuit failure (Steering controller system) DK30KZ • When starting switch is turned ON, either of steering potentiometer systems (1) and (2) is abnormal, then either of failure codes [DK30KA] and [DK30KB] and failure 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 failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes
Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DK30L8] Steering potentiometer (1): See table Action code CALL E03 Failure content Controller's action
• • • •
Symptoms that appear on machine General information
Possible causes and the standard values when normal
1
Failure code Symptom of Steering potentiometer (1): See table failure (Steering controller system) DK30L8 Total signal voltage of each of steering potentiometer (1) system (ST1) and (2) system (ST2) is out of the specified range. 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 failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes
Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D475A, D475ASD-5E0
53
SEN01828-03
40 Troubleshooting
Failure code [DK31KA] Steering potentiometer (2): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Steering potentiometer (2): Disconnection failure (Steering controller system) DK31KA Signal voltage of steering potentiometer (2) system (R) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (1) system (L). 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) (R) can be checked in monitoring mode. (Code 50301: Voltage of steering potentiometer (2)) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective sensor 5V 1 power source system
Possible causes and the standard values when normal
54
Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and perform troubleshooting. Defective PCCS lever a If power supply voltage is normal and sensor output voltage is steering potentiometer 2 abnormal (0.5 V or lower), internal open circuit and ground fault 2 (internal open circuit) or cannot be identified. In this case, go to cause 4. ground fault If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective. Sensor 0.96 to Between TL2 (female) (6) and (8) Voltage output 4.04 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between STCN1 (female) (22) Resis3 Max. 1 z in wiring or defective – TL2 (female) (5) tance contact in connector) Wiring harness between STCN1 (female) (19) ResisMax. 1 z – TL2 (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness STCN1 (female) (22) – TL2 (female) (5) with Min. 1 Mz 4 tance (Contact with ground chassis ground circuit) Short circuit of wiring harness between ResisSTCN1 (female) (19) – TL2 (female) (6) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 5 STCN1 Voltage controller Between (19) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
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Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0
55
SEN01828-03
40 Troubleshooting
Failure code [DK31KB] Steering potentiometer (2): Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Steering potentiometer (2): Short circuit failure (Steering controller system) DK31KB Signal voltage of steering potentiometer (2) system (R) is higher than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (1) system (L). 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) (R) can be checked in monitoring mode. (Code 50301: Voltage of steering potentiometer (2)) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective sensor power 1 source system
Possible causes and the standard values when normal
56
Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (steering) and perform troubleshooting. Defective PCCS lever a If power supply voltage is normal and sensor output voltage is steering potentiometer 2 abnormal (0.5 V or lower), internal open circuit and ground fault 2 (internal open circuit) or cannot be identified. In this case, go to cause 4. ground fault If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective. Sensor 0.96 to Between TL2 (female) (6) and (8) Voltage output 4.04 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short in wiring harSTCN1 (female) (22) – TL2 (female) (5) with Voltage Max. 1 V 3 ness (Contact with 24 V chassis ground circuit) Short circuit of wiring harness between STCN1 (female) (19) – TL2 (female) (6) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering con4 troller STCN1 Voltage Between (19) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0
57
SEN01828-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN01828-03
© 2011 KOMATSU All Rights Reserved Printed in Japan 11-11
58
SEN01829-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code (Display of code), Part 7 Failure code [DK40KA] Brake potentiometer: Disconnection ......................................................................... 3 Failure code [DK40KB] Brake potentiometer: Short circuit ............................................................................. 4 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range ......................... 5 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit ................................. 6 Failure code [DK55L8] Forward-reverse potentiometer: See table................................................................. 7 Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection ................................................... 8 Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit ................................................... 10 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ................................................. 12 Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit ................................................... 14 Failure code [DK60KA] Acceleration sensor: Disconnection ........................................................................ 16 Failure code [DK60KB] Acceleration sensor: Short circuit............................................................................ 18 Failure code [DKH1KA] Pitch angle sensor: disconnection .......................................................................... 19 Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................. 20 Failure code [DKH1KX] Pitch angle sensor: Out of input signal range ......................................................... 21
D475A, D475ASD-5E0
1
SEN01829-02
40 Troubleshooting
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection............................................ 22 Failure code [DLT3KA] Transmission output speed sensor: Disconnection.................................................. 23 Failure code [dLT3KA] Transmission output speed sensor: Disconnection .................................................. 24 Failure code [DLT3KB] Transmission output speed sensor: Short circuit ..................................................... 26 Failure code [DV00KB] Caution buzzer: Short circuit ................................................................................... 27 Failure code [DW55KA] Blade pitch back solenoid: Disconnection .............................................................. 28 Failure code [DW55KB] Blade pitch back solenoid: Short circuit.................................................................. 29 Failure code [DW56KA] Blade pitch dump solenoid: Disconnection............................................................. 30 Failure code [DW56KB] Blade pitch dump solenoid: Short circuit ................................................................ 31 Failure code [DW56KY] Blade pitch dump solenoid: Hot short..................................................................... 32 Failure code [DW57KA] Left tilt limit solenoid: Disconnection....................................................................... 33 Failure code [DW57KB] Left tilt limit solenoid: Short circuit .......................................................................... 34 Failure code [DW57KY] Left tilt limit solenoid: Hot short............................................................................... 35 Failure code [DW58KA] Right tilt limit solenoid: Disconnection .................................................................... 36 Failure code [DW58KB] Right tilt limit solenoid: Short circuit........................................................................ 37 Failure code [DW58KY] Right tilt limit solenoid: Hot short ............................................................................ 38 Failure code [DW59KA] Dual tilt selector solenoid: Disconnection ............................................................... 39 Failure code [DW59KB] Dual tilt selector solenoid: Short circuit................................................................... 40 Failure code [DW59KY] Dual tilt selector solenoid: Hot short ....................................................................... 41 Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection......................................................... 42 Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit ............................................................ 43 Failure code [DW5AKY] Blade pitch selector solenoid: Hot short................................................................. 44 Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection .............. 45 Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit ................. 46 Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short...................... 47 Failure code [DW7BKA] Fan reverse solenoid: Disconnection ..................................................................... 48 Failure code [DW7BKB] Fan reverse solenoid: Short circuit......................................................................... 49 Failure code [DW7BKY] Fan reverse solenoid: Hot short ............................................................................. 50 Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection ........................................................ 51 Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit ............................................................ 52 Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short ................................................................ 53 Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection .................................................. 54 Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit...................................................... 55 Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short .......................................................... 56 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection..................................................................... 57 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ........................................................................ 58 Failure code [DWN5KY] Fan pump solenoid 1: Hot short............................................................................. 59 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection .................................................................... 60 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit........................................................................ 61 Failure code [DWNCKY] Fan pump solenoid 2: Hot short ............................................................................ 62
2
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40 Troubleshooting
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Failure code [DK40KA] Brake potentiometer: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Brake potentiometer: Disconnection failure (Steering controller system) DK40KA Signal voltage of brake potentiometer circuit is lower than the specified value. 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 failure code: Turn starting switch ON and operate brake pedal.
• • • • • • • • •
Cause Defective 5 V sensor 1 power source system
2
Possible causes and the standard values when normal
3
4
5
Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake potentiBRK (male) Resistance ometer (Internal disconBetween (A) – (C) 4.0 – 6.0 kz nection or short circuit) Between (A) – (B) 1.5 – 4.5 kz (Free – full stroke) Between (B) – (C) 4.5 – 1.5 kz (Free – full stroke) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN1 (female) ResisMax. 1 z wiring or defective contact (22) – BRK (female) (C) tance in connector) Wiring harness between STCN1 (female) (3) ResisMax. 1 z – BRK (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness STCN1 (female) (22) – BRK (female) (C) with Min. 1 Mz tance (Contact with ground cir- chassis ground cuit) Short circuit of wiring harness between ResisSTCN1 (female) (3) – BRK (female) (B) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlVoltage STCN1 ler 1.5 – 4.5 V Between (3) – (21)
Circuit diagram related to brake potentiometer
D475A, D475ASD-5E0
3
SEN01829-02
40 Troubleshooting
Failure code [DK40KB] Brake potentiometer: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Brake potentiometer: Short circuit failure (Steering controller system) DK40KB Signal voltage of brake potentiometer circuit is higher than specification value. Blinks warning lamp and sounds alarm buzzer. Does not control brake with brake potentiometer signal (Brake can be controlled with pedal). Limits operations of engine and transmission. Brake cannot be controlled well with brake pedal. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1. Input state (Voltage) from brake potentiometer can be checked in monitoring mode (Code 50400: Brake potentiometer voltage). Method of reproducing failure code: Turn starting switch ON (+ Operate brake pedal).
• • • • • • • • •
Cause Defective sensor 5V 1 power supply system
2
Possible causes and the standard values when normal
3
4
5
Standard values when normal and remarks for troubleshooting If failure code [DB35KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake potentiBRK (male) Resistance ometer (Internal disconBetween (A) – (C) 4.0 – 6.0 kz nection or short circuit) Between (A) – (B) 1.5 – 4.5 kz (Free – full stroke) Between (B) – (C) 4.5 – 1.5 kz (Free – full stroke) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Wiring harness between STCN1 (female) 24V circuit) in wiring harVoltage Max. 1 V (22) – BRK (female) (C) ness Wiring harness between STCN1 (female) (3) ResisMax. 1 V – BRK (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN1 (female) ResisMax. 1 z in connector) (21) – BRK (female) (A) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
4
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range 1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Forward-reverse potentiometer: Input signal is out of normal range failure (Transmission controller system) DK55KX • Either of failure codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and either of failure 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 failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause
Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
D475A, D475ASD-5E0
5
SEN01829-02
40 Troubleshooting
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit 1 Action code CALL E04 • Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal
6
• • • •
•
Failure code Symptom of Forward-reverse potentiometer: Disconnection or short circuit failure (Transmission controller system) DK55KZ When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnormal, then either of failure codes [DK56KA] and [DK56KB] and either of failure 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 failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause
Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
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40 Troubleshooting
SEN01829-02
Failure code [DK55L8] Forward-reverse potentiometer: See table Action code CALL E03 Failure content Controller's action
• • • •
Symptoms that appear on machine General information
Possible causes and the standard values when normal
1
Failure code Symptom of Forward-reverse potentiometer: See table failure (Transmission controller system) DK55L8 Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is out of the specified range. 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 failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause
Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
D475A, D475ASD-5E0
7
SEN01829-02
40 Troubleshooting
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Forward-reverse potentiometer (1): Disconnection failure (Transmission controller system) DK56KA Signal voltage of forward-reverse potentiometer (1) system (R) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of forward-reverse potentiometer (2) system (F). 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) (R) can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer (1)) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Defective 5 V sensor 1 power source system
Defective PCCS lever Forward-reverse potentiome2 ter 1 (internal open circuit) or ground fault
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 3 wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)
5
8
1
Defective transmission controller
Standard values when normal and remarks for troubleshooting See if error code [DAQ5KK] is displayed. If it is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (Forward-reverse) and perform troubleshooting. a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), internal open circuit and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, PCCS lever Forward-reverse potentiometer 1 is defective. Sensor 0.96 to Between TL2 (female) (2) and (4) Voltage output 4.04 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (22) ResisMax. 1 z – TL2 (female) (4) tance Wiring harness between TMC1 (female) (2) – ResisMax. 1 z TL2 (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC1 (female) (2) – TL2 (female) (3) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisMin. 1 Mz TMC1 (female) (22) – TL2 (female) (4) with tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage Between (2) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0
9
SEN01829-02
40 Troubleshooting
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit1 Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Forward-Reverse potentiometer (1): Short circuit failure (Transmission controller system) DK56KB Signal voltage of forward-reverse potentiometer (1) system (R) circuit is higher than specified value. Blinks warning lamp and sounds alarm buzzer. Continues control with signal of forward-reverse potentiometer (2) system (F). Limits operations of engine and transmission.
• • • •
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, gear speed is limited to F1 and R1. • Input state (Voltage) from forward-reverse potentiometer (1) (R) can be checked in monitoring mode (Code 50200: Forward-Reverse potentiometer (1) voltage). • Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and reverse)). Cause Defective sensor 5V 1 power supply system
Defective PCCS lever Forward-reverse potentiome2 ter 1 (internal open circuit) or ground fault
Possible causes and the standard values when normal Hot short (Contact with 3 24V circuit) in wiring harness
Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector)
5
10
Defective transmission controller
Standard values when normal and remarks for troubleshooting If failure code [DAQ5KK] is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (Forward-reverse) and perform troubleshooting. a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), internal open circuit and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, PCCS lever Forward-reverse potentiometer 1 is defective. Sensor 0.96 to Between TL2 (female) (2) and (4) Voltage output 4.04 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC1 (female) (2) – Voltage Max. 1 V TL2 (female) (3) Wiring harness between TMC1 (female) (22) Voltage Max. 1 V – TL2 (female) (4) Wiring harness between TMC1 (female) (21) Voltage Max. 1 V – TL2 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (21) ResisMax. 1 z – TL2 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage TMC1 Between (2) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0
11
SEN01829-02
40 Troubleshooting
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Forward-reverse potentiometer (2): Disconnection failure (Transmission controller system) DK57KA Signal voltage of forward-reverse potentiometer (2) system (F) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of forward-reverse potentiometer (1) system (R). 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) (F) can be checked in monitoring mode. (Code 50201: Voltage of forward-reverse potentiometer (2)) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Defective 5 V sensor 1 power source system
Defective PCCS lever Forward-reverse potentiome2 ter 1 (internal open circuit) or ground fault
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 3 wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)
5
12
1
Defective transmission controller
Standard values when normal and remarks for troubleshooting See if error code [DAQ5KK] is displayed. If it is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (Forward-reverse) and perform troubleshooting. a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), internal open circuit and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, PCCS lever Forward-reverse potentiometer 1 is defective. Sensor 0.96 to Between TL2 (female) (2) and (4) Voltage output 4.04 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (22) ResisMax. 1 z – TL2 (female) (4) tance Wiring harness between TMC1 (female) (19) ResisMax. 1 z – TL2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC1 (female) (19) – TL2(female) (2) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisTMC1 (female) (22) – TL2 (female) (4) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage Between (19) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0
13
SEN01829-02
40 Troubleshooting
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Forward-Reverse potentiometer (2): Short circuit failure (Transmission controller system) DK57KB Signal voltage of forward-reverse potentiometer (2) system (F) circuit is higher than specified value. Blinks warning lamp and sounds alarm buzzer. Continues control with signal of forward-reverse potentiometer (1) system (R). Limits operations of engine and transmission.
• • • •
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, gear speed is limited to F1 and R1. • Input state (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring mode (Code 50201: Forward-Reverse potentiometer (2) voltage). • Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and reverse)). Cause Defective sensor 5V 1 power supply system
Defective PCCS lever Forward-reverse potentiome2 ter 1 (internal open circuit) or ground fault
Possible causes and the standard values when normal Hot short (Contact with 3 24V circuit) in wiring harness
Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector)
5
14
1
Defective transmission controller
Standard values when normal and remarks for troubleshooting If failure code [DAQ5KK] is displayed, carry out troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector TL2. 3. Turn starting switch to ON position. 4. Operate PCCS lever (Forward-reverse) and perform troubleshooting. a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), internal open circuit and ground fault cannot be identified. In this case, go to cause 4. If check result of cause 4 is normal, PCCS lever Forward-reverse potentiometer 1 is defective. Sensor 0.96 to Between TL2 (female) (2) and (4) Voltage output 4.04 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC1 (female) (19) Voltage Max. 1 V – TL2 (female) (2) Wiring harness between TMC1 (female) (22) Voltage Max. 1 V – TL2 (female) (4) Wiring harness between TMC1 (female) (21) Voltage Max. 1 V – TL2 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (21) ResisMax. 1 z – TL2 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Voltage TCM1 Between (19) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0
15
SEN01829-02
40 Troubleshooting
Failure code [DK60KA] Acceleration sensor: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Acceleration sensor: Disconnection failure (Steering controller system) DK60KA • Signal voltage of acceleration sensor is below 0.5 V. • 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 failure code: Turn starting switch ON. Cause Defective 5 V power 1 source system
2
Possible causes and the standard values when normal
3
4
5
16
Standard values when normal and remarks for troubleshooting See if failure code [DB37KK] is displayed. If it is displayed, carry out troubleshooting for it first. a 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 – 4.25 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) ResisMax. 1 z wiring or defective contact (34) – SSA (female) (1) tance in connector) Wiring harness between STCN1 (female) (1) ResisMax. 1 z – SSA (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness STCN3 (female) (34) – SSA (female) (1) with Min. 1 Mz tance (Contact with ground cir- chassis ground cuit) Short circuit of wiring harness between ResisSTCN1 (female) (1) – SS3 (female) (2) with Min. 1 Mz tance chassis ground Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 – 4 (since this is an internal defect, it cannot be ler diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to acceleration sensor
D475A, D475ASD-5E0
17
SEN01829-02
40 Troubleshooting
Failure code [DK60KB] Acceleration sensor: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
1
Failure code Symptom of Acceleration sensor: Short circuit failure (Steering controller system) DK60KB • Acceleration sensor signal voltage is above 4.5 V. • Stops shoe slip control (SSC) function. • Engine speed does not change even if shoe slips. • Input state (Voltage) from acceleration sensor can be checked in monitoring mode (Code 60200: Acceleration sensor voltage). • Method of reproducing failure code: Turn starting switch ON. Cause Standard values when normal and remarks for troubleshooting Defective 5V power supply If failure code [DB37KK] is displayed, carry out troubleshooting for it 1 system first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective acceleration 2 sensor (Internal defect) SSA Voltage Between (2) – (3) 0.75 – 4.25 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between STCN1 (female) (1) Voltage Max. 1 V Hot short (Contact with – SSA (female) (2) 3 24V circuit) in wiring harWiring harness between STCN3 (female) ness Voltage Max. 1 V (34) – SSA (female) (1) Wiring harness between STCN1 (female) Voltage Max. 1 V (21) – SSA (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 4 wiring or defective contact Wiring harness between STCN1 (female) ResisMax. 1 z in connector) (21) – SSA (female) (3) tance Steering controller can be suspected to be defective if no problem is Defective steering control5 found in causes 1 – 4 (since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to acceleration sensor
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DKH1KA] Pitch angle sensor: disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Pitch angle sensor: Disconnection failure (Steering controller system) DKH1KA Signal voltage of pitch angle sensor is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Cannot recognize pitch angle. Limits operation of engine and transmission. Gear shift shock is large. 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 failure code: Turn starting switch ON.
• • • • • • • • •
Cause Defective 24 V power 1 source system
2
Possible causes and the standard values when normal
1
Defective pitch angle sensor (Internal trouble)
Disconnection in wiring harness (Disconnection in 3 wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)
5
Defective steering controller
Standard values when normal and remarks for troubleshooting See if failure code [DB36KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PT1 Voltage Between (B) – (A) 0.15 – 4.85 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) ResisMax. 1 z (16) – PT1 (female) (C) tance Wiring harness between STCN1 (female) ResisMax. 1 z (13) – PT1 (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisSTCN1 (female) (16) – PT1 (female) (C) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisSTCN1 (female) (13) – PT1 (female) (B) with Min. 1 Mz tance chassis ground Steering controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to pitch angle sensor
D475A, D475ASD-5E0
19
SEN01829-02
40 Troubleshooting
Failure code [DKH1KB] Pitch angle sensor: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Pitch angle sensor: Short circuit failure (Steering controller system) DKH1KB Signal voltage of pitch angle sensor is higher than the specified value. Flashes caution lamp and turns on caution buzzer. Cannot recognize pitch angle. Limits operation of engine and transmission. Gear shift shock is large. 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 failure code: Turn starting switch ON.
• • • • • • • • •
Cause Defective 24 V power 1 source system
Possible causes and the standard values when normal
1
2
Defective pitch angle sensor (Internal trouble)
3
Hot short in wiring harness (Contact with 24 V circuit)
Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector) 5
Defective steering controller
Standard values when normal and remarks for troubleshooting See if failure code [DB36KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PT1 Voltage Between (B) – (A) 0.15 – 4.85 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN1 (female) (13) – PT1 (female) (B) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between STCN1 (female) (21) – PT1 (female) (A) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) ResisMax. 1 z (21) – PT1 (female) (A) tance Steering controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to pitch angle sensor
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range 1 Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Pitch angle sensor: Out of input signal range failure (Steering controller system) DKH1KX • Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN communication error [DB3RKR] occurred. • Cannot recognize pitch angle. • Gear speed is not changed automatically. • Input state (Voltage) from pitch angle sensor can be checked in monitoring mode (Code 60100: Pitch angle sensor voltage). • Method of reproducing failure code: Turn starting switch ON.
Possible Cause Standard values when normal and remarks for troubleshooting causes and the Carry out troubleshooting for disconnection [DKH1KA] and short circuit [DKH1KB] in pitch angle standard values sensor and steering controller CAN communication [DB3RKR]. when normal
D475A, D475ASD-5E0
21
SEN01829-02
40 Troubleshooting
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection Action code — Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Torque converter output speed sensor: Disconnection failure (Transmission controller system) DLF1KA • Signals from the torque converter output speed sensor are not input. • Recognizes torque converter output speed is 0 rpm. • The torque converter speed cannot be monitored. •
The input state (rpm) from the torque converter output speed sensor can be checked in the monitoring mode. (Code 31200: Torque converter speed) • Method of reproducing failure code: Start the engine + Drive the machine actually. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective torque conwithout turning starting switch ON. verter output speed sensor TC1 (male) Resistance (Internal disconnection or Between (1) and (2) 500 – 1,000 z short circuit) Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC2 (female) (20) ResisMax. 1 z wiring harness or defective and TC1 (female) (1) tance contact in connector) Wiring harness between TMC2 (female) (39) ResisMax. 1 z and TC1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Between wiring harness between TMC2 (Contact with ground cirResis(female) (20) and TC1 (female) (1) and chasMin. 1 Mz cuit) tance sis ground If causes 1 – 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to torque converter output speed sensor
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DLT3KA] Transmission output speed sensor: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Transmission output speed sensor: Disconnection failure (Transmission controller system) DLT3KA • Transmission output speed sensor error [dLT3KA] occurred or transmission CAN communication error [DAQRKR] occurred. • Assumes transmission output speed to be 0 rpm. • • • • •
Transmission speed cannot be monitored. Traction force cannot be calculated. Auto-shift down operation is defective. Gear shift shock is large. Input voltage from transmission output speed sensor can be checked in monitoring mode (Code 31400: Transmission output speed). • Method of reproducing failure code: Turn starting switch ON + Drive machine actually.
Possible Cause Standard values when normal and remarks for troubleshooting causes and the standard values Carry out troubleshooting for disconnection [dLT3KA] and transmission CAN communication error when normal [DAQRKR].
D475A, D475ASD-5E0
23
SEN01829-02
40 Troubleshooting
Failure code [dLT3KA] Transmission output speed sensor: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Transmission output speed sensor: Disconnection failure (Transmission controller system) dLT3KA • Signal is not input from transmission output speed sensor. • Assumes that transmission output speed is 0 rpm. • • • • •
Transmission speed cannot be monitored. Traction force cannot be calculated. Auto-shift down operation is defective. Gear shift shock is large. Input (rpm) from transmission output speed sensor can be checked in monitoring mode. (Code 31400: Transmission speed • Method of reproducing failure code: Start engine and travel machine actually. Cause Defective transmission output speed sensor 1 (Internal disconnection or short circuit)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal
24
1
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
4
Hot short in wiring harness (Contact with 24-V circuit)
5
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TM1 (male) Resistance Between (1) – (2) 500 – 1,000 z Between (1), (2) – chassis Min. 1 Mz ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (30) ResisMax. 1 z – TM1 (female) (1) tance Wiring harness between TMC2 (female) (29) ResisMax. 1 z – TM1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC2 (female) (30) – TM1 (female) (1) with Min. 1 Mz tance chassis ground Wiring harness between TMC2 (female) (29) ResisMin. 1 Mz and TM1 (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC2 (female) (30) Voltage Max. 1 V and TM1 (female) (1) and chassis ground Wiring harness between TMC2 (female) (29) Voltage Max. 1 V and TM1 (female) (2) and chassis ground Transmission controller can be suspected to be defective if no problem is found in causes 1 – 4 (since this is an internal defect, it cannot be diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to transmission output speed sensor
D475A, D475ASD-5E0
25
SEN01829-02
40 Troubleshooting
Failure code [DLT3KB] Transmission output speed sensor: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
1
Failure code Symptom of Transmission output speed sensor: Short circuit failure (Transmission controller system) DLT3KB • Signal from transmission output speed sensor does not change while machine is traveling. • Assumes transmission output speed to be 0 rpm. • • • • •
Transmission speed cannot be monitored. Traction force cannot be calculated. Auto shift-down function does not work. Gearshift shocks are increased. Input voltage from transmission output speed sensor can be checked in monitoring mode (Code 31400: Transmission output speed). • Method of reproducing failure code: Turn starting switch ON + Drive machine actually. Cause Standard values when normal and remarks for troubleshooting Defective installation of Carry out adjustment according to Testing and adjusting, "Adjusting 1 transmission output speed transmission speed sensor". sensor a Prepare with starting switch OFF, then carry out troubleshooting Defective transmission without turning starting switch ON. output speed sensor TM1 (male) Resistance 2 (Internal disconnection or Between (1) – (2) 500 – 1,000 z short circuit) Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between TMC2 (female) (30) Resis3 ness (Contact with GND Min. 1 Mz – TM1 (female) (1) tance circuit) Wiring harness between TMC2 (female) (29) ResisMin. 1 Mz and TM1 (female) (1) and chassis ground tance If causes 1 – 3 are not detected, transmission controller may be Defective transmission 4 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to transmission output speed sensor
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DV00KB] Caution buzzer: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Caution buzzer: Short circuit failure (Machine monitor system) DV00KB • 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 failure code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1 second). Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective caution buzzer 1 (Internal short circuit) 217 (male) Resistance Between (1) – (2) 200 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between 217 (Contact with 24 V circuit) (female) (1) – S03 (female) (18) with chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness (Contact with GND Wiring harness between 217 (female) (1) and Resiscircuit) Min. 1 Mz S03 (female) (18) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S03 Caution buzzer Voltage 4 Defective monitor panel When turned OFF 20 – 30 V Between (18) – When turned ON chassis ground Max. 3 V (sounding)
Circuit diagram related to caution buzzer
D475A, D475ASD-5E0
27
SEN01829-02
40 Troubleshooting
Failure code [DW55KA] Blade pitch back solenoid: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch back solenoid: Disconnection failure (Transmission controller system) DW55KA • Flashes warning lamp and turns on warning alarm. • When the signal is output to the blade pitch back solenoid circuit, no current flows. • Stops outputting the signal to the blade pitch back solenoid circuit. • The blade is not pitched back. • The output state (ON/OFF) to the blade pitch back solenoid can be checked in the monitoring mode. (Code 90000: Tilt pitch solenoid output 3) • Method of reproducing failure code: Turn the starting switch ON. + Pitch back blade. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch back without turning starting switch ON. 1 solenoid PPB (male) Resistance (Internal disconnection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (26) Resis2 Max. 1 z wiring harness or defective and PPB (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and PPB (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch back solenoid
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW55KB] Blade pitch back solenoid: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch back solenoid: Short circuit failure (Transmission controller system) DW55KB • When signal was output to blade pitch back solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch back solenoid. • Blade does not pitch back. • Output state (ON/OFF) to blade pitch back solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch back PPB (male) Resistance 1 solenoid (Internal short circuit) Between (1) – (2) 20 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Wiring harness between TMC3 (female) (26) Resiscircuit) Min. 1 Mz – PPB (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 3 ness (with another wiring Resis(female) (26) – PPB (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (3) – PPB (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission 4 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch back solenoid
D475A, D475ASD-5E0
29
SEN01829-02
40 Troubleshooting
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch dump solenoid: Disconnection failure (Transmission controller system) DW56KA • Flashes warning lamp and turns on warning alarm. • When the signal is output to the blade pitch dump solenoid circuit, no current flows. • Stops outputting the signal to the blade pitch dump solenoid circuit. • The blade is not pitched forward. • The output state (ON/OFF) to the blade pitch dump solenoid can be checked in the monitoring mode. (Code 90000: Tilt/pitch solenoid output 3) • Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade forward. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 dump solenoid PPD (male) Resistance (Internal disconnection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between TMC3 (female) (16) 2 Max. 1 z tance wiring harness or defective and PPD (female) (1) contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and PPD (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch dump solenoid
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch dump solenoid: Short circuit failure (Transmission controller system) DW56KB • When signal was output to blade pitch dump solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch dump solenoid circuit. • Blade does not pitch dump. • Output state (ON/OFF) to blade pitch dump solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch PPD (male) Resistance dump solenoid (Internal short circuit) Between (1) – (2) 20 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (16) Resiscircuit) Min. 1 Mz – PPD (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness (with another wiring Between wiring harness between TMC3 Resis(female) (16) – PPD (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (3) – PPD (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch dump solenoid
D475A, D475ASD-5E0
31
SEN01829-02
40 Troubleshooting
Failure code [DW56KY] Blade pitch dump solenoid: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Blade pitch dump solenoid: Hot short failure (Transmission controller system) DW56KY • Some current keeps flowing to blade pitch dump solenoid circuit. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch dump solenoid circuit. • Blade pitch dump solenoid keeps operating. • Output state (ON/OFF) to blade pitch dump solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation. Cause
Possible causes and the standard values when normal
1
Defective blade pitch 1 dump solenoid (Internal short circuit) Hot short (Contact with 2 24V circuit) in wiring harness 3
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PPD (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC3 (female) (16) Voltage Max. 1 V – PPD (female) (1). If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to blade pitch dump solenoid
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW57KA] Left tilt limit solenoid: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Left tilt limit solenoid: Disconnection failure (Transmission controller system) DW57KA • When the signal is output to the left tilt limit solenoid circuit, no current flows. • Flashes the caution lamp and turns on the caution buzzer. • Stops outputting the signal to the left tilt limit solenoid circuit. • The blade is not pitched forward. • The left tilt limit function does not operate. • The output state (ON/OFF) to the left tilt limit solenoid can be checked in the monitoring mode. (Code 90000: Tilt/pitch solenoid output 3) • Method of reproducing failure code: Turn the starting switch ON. + Execute the left tilt mode. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left tilt limit without turning starting switch ON. 1 solenoid TLL (male) Resistance (Internal disconnection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (27) Resis2 Max. 1 z wiring harness or defective and TLL (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and TLL (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to left tilt limit solenoid
D475A, D475ASD-5E0
33
SEN01829-02
40 Troubleshooting
Failure code [DW57KB] Left tilt limit solenoid: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Left tilt limit solenoid: Short circuit failure (Transmission controller system) DW57KB • When signal was output to left tilt limit solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to left tilt limit solenoid circuit. • Left tilt limit function does not work. • Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform left tilt limit mode. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a 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 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (27) Resiscircuit) Min. 1 Mz – TLL (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring Resis(female) (27) – TLL (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (3) – TLL (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to left tilt limit solenoid
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW57KY] Left tilt limit solenoid: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Left tilt limit solenoid: Hot short failure (Transmission controller system) DW57KY • Some current keeps flowing to left tilt limit solenoid circuit. • Blinks waring lamp and sounds alarm buzzer. • Stops outputting signal to left tilt limit solenoid circuit. • Left tilt limit solenoid keeps operating. • Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform left tilt mode. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left tilt limit sole1 noid (Internal short circuit) TLL (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (27) ness Voltage Max. 1 V – TLL (female) (1). If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to left tilt limit solenoid
D475A, D475ASD-5E0
35
SEN01829-02
40 Troubleshooting
Failure code [DW58KA] Right tilt limit solenoid: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right tilt limit solenoid: Disconnection failure (Transmission controller system) DW58KA • When the signal is output to the right tilt limit solenoid circuit, no current flows. • Flashes the caution lamp and turns on the caution buzzer. • Stops outputting the signal to the right tilt limit solenoid circuit. • The right tilt limit function does not operate. • The output state (ON/OFF) to the right tilt limit solenoid can be checked in the monitoring mode. (Code 90000: Tilt/pitch solenoid output 3) • Method of reproducing failure code: Turn the starting switch ON. + Execute the right tilt mode. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right tilt limit without turning starting switch ON. 1 solenoid TLR (male) Resistance (Internal disconnection) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (37) Resis2 Max. 1 z wiring harness or defective and TLR (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and TLR (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to right tilt limit solenoid
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW58KB] Right tilt limit solenoid: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right tilt limit solenoid: Short circuit failure (Transmission controller system) DW58KB • When signal was output to right tilt limit solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to right tilt limit solenoid circuit. • The right tilt limit function does not operate. • Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform right tilt limit mode. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right tilt limit TLR (male) Resistance 1 solenoid (Internal short circuit) Between (1) – (2) 20 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Wiring harness between TMC3 (female) (37) Resiscircuit) Min. 1 Mz – TLR (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 3 ness (with another wiring Resis(female) (37) – TLR (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (3) – TLR (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission 4 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to right tilt limit solenoid
D475A, D475ASD-5E0
37
SEN01829-02
40 Troubleshooting
Failure code [DW58KY] Right tilt limit solenoid: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Right tilt limit solenoid: Hot short failure (Transmission controller system) DW58KY • Some current keeps flowing to right tilt limit solenoid circuit. • Blinks waring lamp and sounds alarm buzzer. • Stops outputting signal to right tilt limit solenoid circuit. • Right tilt limit solenoid keeps operating. • Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). • Method of reproducing failure code: Turn starting switch ON + Perform right tilt mode. Cause
Possible causes and the standard values when normal
1
Defective right tilt limit 1 solenoid (Internal disconnection) Hot short (Contact with 2 24V circuit) in wiring harness 3
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TLR (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC3 (female) (37) Voltage Max. 1 V – TLR (female) (1). If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to right tilt limit solenoid
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Dual tilt selector solenoid: Disconnection failure (Transmission controller system) DW59KA • When signal is output to dual tilt selector solenoid circuit, any current does not flow. • Stops outputting to dual tilt selector solenoid circuit. • Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works). • Output (Current) to dual tilt selector solenoid can be checked in monitoring mode.] (Code 70600: Dual tilt solenoid drive current) • Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective dual tilt selector without turning starting switch ON. 1 solenoid (Internal disconDUL (male) Resistance nection) Between (1) – (2) 10 – 40 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (6) – Resis2 Max. 1 z wiring or defective contact DUL (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z – DUL (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to dual tilt selector solenoid
D475A, D475ASD-5E0
39
SEN01829-02
40 Troubleshooting
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Dual tilt selector solenoid: Short circuit failure (Transmission controller system) DW59KB • When signal was output to dual tilt selector solenoid circuit, abnormal current flowed. • Stops outputting signal to dual tilt selector solenoid circuit. • Dual tilt unit does not operate (When dual tilt operation is performed, single tilt unit operates). • Output state (Current) to dual tilt selector solenoid can be checked in monitoring mode (Code 70600: Dual tilt solenoid drive current). • Method of reproducing failure code: Turn starting switch ON + Perform dual tilt operation. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective dual tilt selector DUL (male) Resistance 1 solenoid (Internal short circuit) Between (1) – (2) 10 – 40 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Wiring harness between TMC3 (female) (6) – Resiscircuit) Min. 1 Mz DUL (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 3 ness (with another wiring Resis(female) (6) – DUL (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (13) – DUL (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission 4 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to dual tilt selector solenoid
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW59KY] Dual tilt selector solenoid: Hot short Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Dual tilt selector solenoid: Hot short failure (Transmission controller system) DW59KY • Some current keeps flowing to dual tilt selector solenoid circuit. • Stops outputting signal to dual tilt selector solenoid circuit. • Dual tilt selector solenoid keeps operating. • Output state (Current) to dual tilt selector solenoid can be checked in monitoring mode (Code 70600: Dual tilt solenoid drive current). • Method of reproducing failure code: Turn starting switch ON + Perform dual tilt operation. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective dual tilt selector without turning starting switch ON. 1 solenoid (Internal disconDUL (male) Resistance nection) Between (1) – (2) 10 – 40 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (6) – ness Voltage Max. 1 V DUL (female) (1). If causes 1 – 2 are not detected, steering or transmission controller Defective steering or 3 may be defective. (Since trouble is in system, troubleshooting cantransmission controller not be carried out.)
Circuit diagram related to dual tilt selector solenoid
D475A, D475ASD-5E0
41
SEN01829-02
40 Troubleshooting
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection 1 Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Blade pitch selector solenoid: Disconnection failure (Transmission controller system) DW5AKA • When the signal is output to the blade pitch selector solenoid circuit, no current flows. • Flashes the caution lamp and turns on the caution buzzer. • Stops outputting the signal to the blade pitch selector solenoid circuit. • The blade is not pitched back. (When the pitch back operation is performed, the blade may be tilted.) • The output state (current) to the blade pitch selector solenoid can be checked in the monitoring mode. (Code 31625: Pitch solenoid current) • Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade back. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 selector solenoid PTH (male) Resistance (Internal short circuit) Between (1) and (2) 10 – 40 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (28) Resis2 Max. 1 z wiring harness or defective and PTH (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z and PTH (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch selector solenoid
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch selector solenoid: Short circuit failure (Transmission controller system) DW5AKB • When signal was output to blade pitch selector solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch selector solenoid circuit. • Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates). • Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch PTH (male) Resistance selector solenoid (Internal short circuit) Between (1) – (2) 10 – 40 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (28) Resiscircuit) Min. 1 Mz – PTH (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring Resis(female) (28) – PTH (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (13) – PTH (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch selector solenoid
D475A, D475ASD-5E0
43
SEN01829-02
40 Troubleshooting
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch selector solenoid: Hot short failure (Transmission controller system) DW5AKY • Some current keeps flowing to blade pitch selector solenoid circuit. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch selector solenoid circuit. • Blade pitch selector solenoid keeps operating. • Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 selector solenoid (Internal PTH (male) Resistance short circuit) Between (1) – (2) 10 – 40 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (28) ness Voltage Max. 1 V – PTH (female) (1). If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch selector solenoid
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Disconnecfailure tion (Transmission controller system) DW5DKA • When the signal is output to the blade pitch selector solenoid circuit, no current flows. • Flashes the caution lamp and turns on the caution buzzer. • Stops outputting the signal to the blade pitch selector solenoid circuit. • The blade is not pitched back. (When the pitch back operation is performed, the blade may be tilted.) • The output state (current) to the blade pitch selector solenoid can be checked in the monitoring mode. (Code 31625: Pitch solenoid current) • Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade back. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 dump solenoid PTH (male) Resistance (Internal disconnection) Between (1) and (2) 10 – 40 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between TMC3 (female) (28) 2 Max. 1 z tance wiring harness or defective and PTH (female) (1) contact in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z and PTH (female) (2) tance If causes 1 – 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer)
D475A, D475ASD-5E0
45
SEN01829-02
40 Troubleshooting
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Short cirfailure cuit (Transmission controller system) DW5DKB • When signal was output to blade pitch selector solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch selector solenoid circuit. • Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates). • Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch PTH (male) Resistance dump solenoid (Internal short circuit) Between (1) – (2) 10 – 40 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (28) Resiscircuit) Min. 1 Mz – PTH (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring Resis(female) (28) – PTH (female) (1) and wiring harness) Min. 1 Mz tance harness between TMC3 (female) (13) – PTH (female) (2) If causes 1 – 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
46
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Hot short failure (Transmission controller system) DW5DKY • Some current keeps flowing to blade pitch dump solenoid circuit. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to blade pitch dump solenoid circuit. • Blade pitch dump solenoid keeps operating. • Output state (Current) to blade pitch dump solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation. Cause
Possible causes and the standard values when normal
1
Defective blade pitch 1 dump solenoid (Internal short circuit) Hot short (Contact with 2 24V circuit) in wiring harness 3
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PTH (male) Resistance Between (1) – (2) 10 – 40 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC3 (female) (28) Voltage Max. 1 V – PTH (female) (1). If causes 1 – 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
D475A, D475ASD-5E0
47
SEN01829-02
40 Troubleshooting
Failure code [DW7BKA] Fan reverse solenoid: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan reverse solenoid: Disconnection failure (Steering controller system) DW7BKA • When the signal is output to the fan reverse solenoid circuit, no current flows. • Stops outputting the signal to the fan reverse solenoid circuit. • The fan reverse function cannot be used. • The output state (ON/OFF) to the fan reverse solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) • Method of reproducing failure code: Turn the starting switch ON. + Reverse the fan rotation direction. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan reverse without turning starting switch ON. 1 solenoid FAR (male) Resistance (Internal disconnection) Between (1) and (2) 34 – 44 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) Resis2 Max. 1 z wiring harness or defective (17) and FAR (female) (1) tance contact in connector) Wiring harness between STCN3 (female) (3) ResisMax. 1 z and FAR (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering 3 found in causes 1 – 2 (Since this is an internal defect, it cannot be controller diagnosed).
Circuit diagram related to fan reverse solenoid
48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW7BKB] Fan reverse solenoid: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Fan reverse solenoid: Short circuit failure (Steering controller system) DW7BKB • When the signal is output to the fan reverse solenoid circuit, an abnormal current flows. • Stops outputting the signal to the fan reverse solenoid. • The fan reverse function cannot be used. • The output state (ON/OFF) to the fan reverse solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) • Method of reproducing error code: Turn the starting switch ON. + Reverse the fan rotation direction. Cause Defective fan reverse 1 solenoid (Internal short circuit)
Possible causes and the standard values when normal
1
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
Short circuit in wiring harness 3 (Short circuit between wiring harnesses)
4
Defective steering controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAR (male) Resistance Between (1) and (2) 34 – 44 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between STCN3 Resis(female) (17) and FAR (female) (1) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between STCN3 Resis(female) (17) and FAR (female) (1) and wirMin. 1 Mz tance ing harness between STCN3 (female) (13) and FAR (female) (2) Steering controller can be suspected to be defective if no problem is found in causes 1 – 3 (Since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to fan reverse solenoid
D475A, D475ASD-5E0
49
SEN01829-02
40 Troubleshooting
Failure code [DW7BKY] Fan reverse solenoid: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan reverse solenoid: Hot short failure (Steering controller system) DW7BKY • Some current keeps flowing to fan reverse solenoid circuit. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to fan reverse solenoid circuit. • Fan keeps running in reverse. • Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode (Code 40914: Steering-related controller ON/OFF output 1). • Method of reproducing failure code: Turn starting switch ON + Operate fan in reverse. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan reverse solewithout turning starting switch ON. 1 noid (Internal disconnecFAR (male) Resistance tion) Between (1) – (2) 34 – 44 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between STCN3 (female) ness Voltage Max. 1 V (17) – FAR (female) (1). If causes 1 – 2 are not detected, steering controller may be defecDefective steering control3 tive. (Since trouble is in system, troubleshooting cannot be carried ler out.)
Circuit diagram related to fan reverse solenoid
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection 1 Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Pump merge-divider solenoid: Disconnection failure (Steering controller system) DWJ0KA • When the signal is output to the pump merge-divider solenoid circuit, no current flows. • Flashes the caution lamp and turns on the caution buzzer. • Stops outputting the signal to the pump merge-divider solenoid circuit. • Blade tilt/pitch work may not be performed normally. • The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) • Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective pump without turning starting switch ON. 1 merge-divider solenoid MFD (male) Resistance (Internal short circuit) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) Resis2 Max. 1 z wiring harness or defective (27) and MFD (female) (1) tance contact in connector) Wiring harness between STCN3 (female) (3) ResisMax. 1 z and MFD (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to pump merge-divider solenoid
D475A, D475ASD-5E0
51
SEN01829-02
40 Troubleshooting
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Pump merge-divider solenoid: Short circuit failure (Steering controller system) DWJ0KB • When signal was output to pump merge-divider solenoid circuit, abnormal current flowed. • Blinks warning lamp and sounds alarm buzzer. • Stops outputting signal to pump merge-divider solenoid circuit. • Blade may not be tilted or pitched normally. • Output state (ON/OFF) to pump merge-divider solenoid can be checked in monitoring mode (Code 40914: Steering-related controller ON/OFF output 1). • Method of reproducing failure code: Turn starting switch ON + Perform dual tilt mode. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective pump mergeMFD (male) Resistance divider solenoid (Internal short circuit) Between (1) – (2) 20 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between STCN3 (female) Resiscircuit) Min. 1 Mz (27) – MFD (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between STCN3 ness (with another wiring Resis(female) (27) – MFD (female) (1) and wiring harness) Min. 1 Mz tance harness between STCN3 (female) (3) – MFD (female) (2) If causes 1 – 3 are not detected, steering controller may be defecDefective steering controltive. (Since trouble is in system, troubleshooting cannot be carried ler out.)
Circuit diagram related to pump merge-divider solenoid
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Pump merge-divider solenoid: Hot short failure (Steering controller system) DWJ0KY • Current keeps flowing to the pump merge-divider solenoid circuit. • Flashes the caution lamp and turns on the caution buzzer. • Stops outputting the signal to the pump merge-divider solenoid circuit. • Blade tilt/pitch work may not be performed normally. • The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) • Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective pump without turning starting switch ON. 1 merge-divider solenoid MFD (male) Resistance (Internal short circuit) Between (1) and (2) 20 – 60 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Between wiring harness between STCN3 (Contact with 24-V circuit) (female) (27) and MFD (female) (1) and Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to pump merge-divider solenoid
D475A, D475ASD-5E0
53
SEN01829-02
40 Troubleshooting
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Sudden stop prevention solenoid: Disconnection failure (Steering controller system) DWN3KA • 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. • 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 failure code: Turn starting switch ON. Cause Defective sudden stop 1 prevention solenoid (Internal disconnection)
Possible causes and the standard values when normal
1
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Defective steering controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ST8 (male) Resistance Between (1) – (2) 5 – 25 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) (7) ResisMax. 1 z – ST8 (female) (1) tance Wiring harness between STCN3 (female) ResisMax. 1 z (13) – ST8 (female) (2) tance Steering controller can be suspected to be defective if no problem is found in causes 1 – 2 (Since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to sudden stop prevention solenoid
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit1 Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Sudden stop prevention solenoid: Short circuit failure (Steering controller system) DWN3KB • 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. • 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 failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective sudden stop ST8 (male) Resistance 1 prevention solenoid (Internal short circuit) Between (1) – (2) 5 – 25 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (7) – ST8 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Short circuit in wiring harness between ResisSTCN3 (female) (7) – ST8 (female) (1) with harness) Min. 1 Mz tance wiring harness between STCN3 (female) (13) – ST8 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering control4 found in causes 1 – 3 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to sudden stop prevention solenoid
D475A, D475ASD-5E0
55
SEN01829-02
40 Troubleshooting
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Sudden stop prevention solenoid: Hot short failure (Steering controller system) DWN3KY Current keeps flowing to sudden stop prevention solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Function of emergency sudden stop prevention does not operate. 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 failure code: Turn starting switch ON.
• • • • • • • •
Cause Defective sudden stop 1 prevention solenoid (Internal disconnection) Possible causes and the standard values when normal
1
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Defective steering controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ST8 (male) Resistance Between (1) – (2) 5 – 25 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN3 (female) (7) – ST8 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is found in causes 1 – 2 (Since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to sudden stop prevention solenoid
56
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan pump solenoid 1: Disconnection failure (Transmission controller system) DWN5KA • When signal is output to fan pump solenoid circuit, any current does not flow. • Stops outputting to fan pump solenoid circuit. • Output of the fan pump (LPV90) becomes maximum. • Output (Current) to fan pump solenoid can be checked in monitoring mode. (Code 31623, 31624: Cooling fan solenoid output command current, output current) • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump solewithout turning starting switch ON. 1 noid (Internal disconnecFA1 (male) Resistance tion) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (17) Resis2 Max. 1 z wiring or defective contact – FA1 (female) (1) tance in connector) Wiring harness between TMC3 (female) (23) ResisMax. 1 z – FA1 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to fan pump solenoid
D475A, D475ASD-5E0
57
SEN01829-02
40 Troubleshooting
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan pump solenoid 1: Short circuit failure (Transmission controller system) DWN5KB • When signal was output to fan pump solenoid circuit, abnormal current flowed. • Stops outputting to fan pump solenoid circuit. • Output of the fan pump (LPV90) becomes maximum. • Output (Current) to fan pump solenoid can be checked in monitoring mode. (Code 31623, 31624: Cooling fan solenoid output command current, output current) • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fan pump soleFA1 (male) Resistance 1 noid (Internal short circuit) Between (1) – (2) 15 – 25 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground cirResisTMC3 (female) (17) – FA1 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Short circuit in wiring harness between TMC3 Resis(female) (17) – FA1 (female) (1) with wiring harness) Min. 1 Mz tance harness between TMC3 (female) (23) – FA1 (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to fan pump solenoid
58
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DWN5KY] Fan pump solenoid 1: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan pump solenoid 1: Hot short failure (Transmission controller system) DWN5KY • Current keeps flowing to fan pump solenoid circuit. • Flashes warning lamp and turns on warning alarm. • Stops outputting to fan pump solenoid circuit. • Output of the fan pump (LPV90) becomes minimum. • Fan speed does not increase. • Output (Current) to fan pump solenoid can be checked in monitoring mode. (Code 31623, 31624: Cooling fan solenoid output command current, output current) • Method of reproducing failure code: Turn starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump solewithout turning starting switch ON. 1 noid (Internal disconnecFA1 (male) Resistance tion) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit) Short circuit of wiring harness between TMC3 (female) (17) – FA1 (female) (1) with Voltage Max. 1 V chassis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to fan pump solenoid
D475A, D475ASD-5E0
59
SEN01829-02
40 Troubleshooting
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan pump solenoid 2: Disconnection failure (Transmission controller system) DWNCKA • When the signal is output to the fan pump solenoid circuit, no current flows. • Stops outputting the signal to the fan pump solenoid circuit. • Output of the fan pump (LPV30) becomes maximum. • The output state (current) to the fan pump solenoid can be checked in the monitoring mode. (Code 31633, 31634: Cooling fan solenoid output command current, output current) • Method of reproducing failure code: Turn the starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump without turning starting switch ON. 1 solenoid 2 FA2 (male) Resistance (Internal short circuit) Between (1) and (2) 5 – 15 z Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (7) Resis2 Max. 1 z wiring harness or defective and FA2 (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (23) ResisMax. 1 z and FA2 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to fan pump solenoid
60
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Fan pump solenoid 2: Short circuit failure (Transmission controller system) DWNCKB • When the signal is output to the fan pump solenoid circuit, an abnormal current flows. • Stops outputting the signal to the fan pump solenoid. • Output of the fan pump (LPV30) becomes maximum. • The output state (ON/OFF) to the fan pump solenoid can be checked in the monitoring mode. (Code 31633, 31634: Cooling fan solenoid output command current, output current) • Method of reproducing failure code: Turn the starting switch ON. Cause Defective fan pump 1 solenoid 2 (Internal short circuit)
Possible causes and the standard values when normal
1
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
Short circuit in wiring harness 3 (Short circuit between wiring harnesses)
4
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FA2 (male) Resistance Between (1) and (2) 5 – 15 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC3 Resis(female) (7) and FA2 (female) (1) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC3 Resis(female) (7) and FA2 (female) (1) and wiring Min. 1 Mz tance harness between TMC3 (female) (23) and FA2 (female) (2) Transmission controller can be suspected to be defective if no problem is found in causes 1 – 3 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to fan pump solenoid
D475A, D475ASD-5E0
61
SEN01829-02
40 Troubleshooting
Failure code [DWNCKY] Fan pump solenoid 2: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Fan pump solenoid 2: Hot short failure (Transmission controller system) DWNCKY • Current keeps flowing to the fan pump solenoid circuit. • Flashes warning lamp and turns on warning alarm. • Stops outputting the signal to the fan pump solenoid circuit. • Output of the fan pump (LPV30) becomes minimum. • Fan speed does not increase. • The output state (current) to the fan pump solenoid can be checked in the monitoring mode. (Code 31633, 31634: Cooling fan solenoid output command current, output current) • Method of reproducing failure code: Turn the starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump without turning starting switch ON. 1 solenoid 2 FA2 (male) Resistance (Internal short circuit) Between (1) and (2) 15 – 25 z Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24-V circuit) Between wiring harness between TMC3 (female) (7) and FA2 (female) (1) and chasVoltage Max. 1 V sis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to fan pump solenoid
62
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01829-02
63
SEN01829-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN01829-02
© 2011 KOMATSU All Rights Reserved Printed in Japan 11-11
64
SEN01830-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting by failure code (Display of code), Part 8 Failure code [DXE0KA] LS set solenoid: Disconnection................................................................................. 3 Failure code [DXE0KB] LS set solenoid: Short circuit .................................................................................... 4 Failure code [DXE0KY] LS set solenoid: Hot short......................................................................................... 5 Failure code [DXH1KA] Lock-up solenoid: Disconnection .............................................................................. 6 Failure code [DXH1KB] Lock-up solenoid: Short circuit.................................................................................. 7 Failure code [DXH1KY] Lockup solenoid: Hot short ....................................................................................... 8 Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................... 9 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................ 10 Failure code [DXH4KY] 1st clutch ECMV: Hot short......................................................................................11 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection............................................................................ 12 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 13 Failure code [DXH5KY] 2nd clutch ECMV: Hot short.................................................................................... 14 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ............................................................................ 15 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 16
D475A, D475ASD-5E0
1
SEN01830-01
40 Troubleshooting
Failure code [DXH6KY] 3rd clutch ECMV: Hot short..................................................................................... 17 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection .................................................................... 18 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit ........................................................................ 19 Failure code [DXH7KY] Reverse clutch ECMV: Hot short ............................................................................ 20 Failure code [DXH8KA] Forward clutch ECMV: Disconnection..................................................................... 21 Failure code [DXH8KB] Forward clutch ECMV: Short circuit ........................................................................ 22 Failure code [DXH8KY] Forward clutch ECMV: Hot short............................................................................. 23 Failure code [DXH9KA] Right steering clutch ECMV: Disconnection............................................................ 24 Failure code [DXH9KB] Right steering clutch ECMV: Short circuit ............................................................... 25 Failure code [DXH9KY] Right steering clutch ECMV: Hot short.................................................................... 26 Failure code [DXHAKA] Left steering clutch ECMV: Disconnection.............................................................. 27 Failure code [DXHAKB] Left steering clutch ECMV: Short circuit ................................................................. 28 Failure code [DXHAKY] Left steering clutch ECMV: Hot short...................................................................... 29 Failure code [DXHBKA] Right brake ECMV: Disconnection ......................................................................... 30 Failure code [DXHBKB] Right brake ECMV: Short circuit ............................................................................. 31 Failure code [DXHBKY] Right brake ECMV: Hot short ................................................................................. 32 Failure code [DXHCKA] Left brake ECMV: Disconnection............................................................................ 33 Failure code [DXHCKB] Left brake ECMV: Short circuit ............................................................................... 34 Failure code [DXHCKY] Left brake ECMV: Hot short.................................................................................... 35 Failure code [F@BBZL] (or VHMS_LED display "n3" o "38") Engine blow-by pressure sensor: Abnormally high pressure occurrence ........................................... 36 Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise ................................ 38 Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ................................. 40 Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise .............................. 42 Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise............................... 44 Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise ................................ 46 Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ................................. 48 Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise .............................. 50 Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise............................... 52
2
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXE0KA] LS set solenoid: Disconnection Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of LS set solenoid: Disconnection failure (Steering controller system) DXE0KA • When the signal is output to the LS set solenoid circuit, no current flows. • Stops outputting the signal to the LS set solenoid circuit. • Flashes the caution lamp and turns on the caution buzzer. • Pitching and tilting speed of the work equipment may become too high. • The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output signal 1) • Method of reproducing failure code: Turn the starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective LS set solenoid 1 (Internal short circuit) LSV (male) Resistance Between (1) and (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) (37) Resis2 Max. 1 z wiring harness or defective and LSV (female) (1) tance contact in connector) Wiring harness between STCN3 (female) (3) ResisMax. 1 z and LSV (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to LS set solenoid
D475A, D475ASD-5E0
3
SEN01830-01
40 Troubleshooting
Failure code [DXE0KB] LS set solenoid: Short circuit Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of LS set solenoid: Short circuit failure (Steering controller system) DXE0KB • When the signal is output to the LS set solenoid circuit, an abnormal current flows. • Stops outputting the signal to the LS set solenoid circuit. • Flashes the caution lamp and turns on the caution buzzer. • Pitching and tilting speed of the work equipment may become too high. • The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output signal 1) • Method of reproducing failure code: Turn the starting switch ON. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective LS set solenoid LSV (male) Resistance (Internal short circuit) Between (1) and (2) 5 – 15 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Between wiring harness between STCN3 (Contact with ground cirResis(female) (37) and LSV (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness Between wiring harness between STCN3 (Short circuit between Resis(female) (37) and LSV (female) (1) and wiring Min. 1 Mz wiring harnesses) tance harness between STCN3 (female) (3) and LSV (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 – 3 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to LS set solenoid
4
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXE0KY] LS set solenoid: Hot short Action code E02 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of LS set solenoid: Hot short failure (Steering controller system) DXE0KY • Current keeps flowing to the LS set solenoid circuit. • Stops outputting the signal to the LS set solenoid circuit. • Flashes the caution lamp and turns on the caution buzzer. • Pitching and tilting speed of the work equipment may become too high. • The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output signal 1) • Method of reproducing failure code: Turn the starting switch ON. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective LS set solenoid 1 (Internal short circuit) LSV (male) Resistance Between (1) and (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Between wiring harness between STCN3 (Contact with 24-V circuit) (female) (37) and LSV (female) (1) and chas- Voltage Max. 1 V sis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to LS set solenoid
D475A, D475ASD-5E0
5
SEN01830-01
40 Troubleshooting
Failure code [DXH1KA] Lock-up solenoid: Disconnection Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Lock-up solenoid: Disconnection failure (Transmission controller system) DXH1KA • 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 failure code: Start engine and turn lock-up switch ON and drive machine. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective torque converter without turning starting switch ON. 1 lock-up solenoid (Internal 653 (male) Resistance short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (38) Resis2 Max. 1 z wiring or defective contact – 653 (female) (1) tance in connector) Wiring harness between TMC3 (female) (23) ResisMax. 1 z – 653 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to torque converter lock-up solenoid
6
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH1KB] Lock-up solenoid: Short circuit Action code E01 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Lock-up solenoid: Short circuit failure (Transmission controller system) DXH1KB • 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 failure code: Start engine and turn lock-up switch ON and drive machine. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective torque converter 653 (male) Resistance 1 lock-up solenoid (Internal short circuit) Between (1) – (2) 30 – 80 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (38) – 653 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Short circuit in wiring harness between TMC3 Resis(female) (38) – 653 (female) (1) with wiring harness) Min. 1 Mz tance harness between TMC3 (female) (23) – 653 (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to torque converter lock-up solenoid
D475A, D475ASD-5E0
7
SEN01830-01
40 Troubleshooting
Failure code [DXH1KY] Lockup solenoid: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • •
1
Failure code Symptom of Lockup solenoid: Hot short failure (Transmission controller system) DXH1KY Some current keeps flowing to torque converter lockup solenoid circuit. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to torque converter lockup solenoid circuit. Torque converter lockup solenoid keeps operating. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1 (Engine may stop). Output state (Current) to torque converter lockup solenoid can be checked in monitoring mode (Code 31627: Torque converter lockup solenoid drive current). Method of reproducing failure code: Turn starting switch ON + Turn lockup switch ON + Drive machine. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective torque converter without turning starting switch ON. 1 lockup solenoid (Internal 653 (male) Resistance short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (38) ness Voltage Max. 1 V – 653 (female) (1). If causes 1 – 2 are not detected, transmission controller may be Defective transmission 4 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Circuit diagram related to torque converter lockup solenoid
8
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH4KA] 1st clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of 1st clutch ECMV: Disconnection failure (Transmission controller system) DXH4KA 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 command current, output current of 1st clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F1 or R1. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective 1st clutch solewithout turning starting switch ON. 1 noid (Internal disconnecS1T7 (male) Resistance tion) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (15) Resis2 Max. 1 z wiring or defective contact – S1T7 (female) (1) tance in connector) Wiring harness between TMC3 (female) (3) – ResisMax. 1 z S1T7 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission 1st clutch ECMV
D475A, D475ASD-5E0
9
SEN01830-01
40 Troubleshooting
Failure code [DXH4KB] 1st clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of 1st clutch ECMV: Short circuit failure (Transmission controller system) DXH4KB 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 command current, output current of 1st clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F1 or R1. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch soleS1T7 (male) Resistance 1 noid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (15) – S1T7 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (15) – S1T7 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) – S1T7 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission 1st clutch ECMV
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH4KY] 1st clutch ECMV: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of 1st clutch ECMV: Hot short failure (Transmission controller system) DXH4KY Current keeps flowing to 1st clutch solenoid circuit. 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 F1 and R1. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. (Code 31602, 31612: Output command current, output current of 1st clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F2 or R2. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch sole1 noid (Internal short circuit) S1T7 (male) Resistance Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with 24 V circuit) (female) (15) – S1T7 (female) (1) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission 1st clutch ECMV
D475A, D475ASD-5E0
11
SEN01830-01
40 Troubleshooting
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of 2nd clutch ECMV: Disconnection failure (Transmission controller system) DXH5KA 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 command current, output current of 2nd clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in F2 or R2. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective 2nd clutch solewithout turning starting switch ON. 1 noid (Internal disconnecS2T5 (male) Resistance tion) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (36) Resis2 Max. 1 z wiring or defective contact – S2T5 (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z – S2T5 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission 2nd clutch ECMV
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of 2nd clutch ECMV: Short circuit failure (Transmission controller system) DXH5KB 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 command current, output current of 2nd clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in F2 or R2. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 2nd clutch soleS2T5 (male) Resistance 1 noid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (36) – S2T5 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (36) – S2T5 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) – S2T5 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission 2nd clutch ECMV
D475A, D475ASD-5E0
13
SEN01830-01
40 Troubleshooting
Failure code [DXH5KY] 2nd clutch ECMV: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of 2nd clutch ECMV: Hot short failure (Transmission controller system) DXH5KY Current keeps flowing to 2nd clutch solenoid circuit. 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 F2 and R2. • Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. (Code 31603, 31613: Output command current, output current of 2nd clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in F1 or R1. Cause
Possible causes and the standard values when normal
1
1
Defective 2nd clutch solenoid (Internal short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
3
Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S2T5 (male) Resistance Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC3 (female) (36) – S2T5 (female) (1) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no problem is found in causes 1 – 2 (Since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to transmission 2nd clutch ECMV
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of 3rd clutch ECMV: Disconnection failure (Transmission controller system) DXH6KA 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 command current, output current of 3rd clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in F3 or R3. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective 3rd clutch solewithout turning starting switch ON. 1 noid (Internal disconnecS3T3 (male) Resistance tion) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (5) – Resis2 Max. 1 z wiring or defective contact S3T3 (female) (1) tance in connector) Wiring harness between TMC3 (female) (3) – ResisMax. 1 z S3T3 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission 3rd clutch ECMV
D475A, D475ASD-5E0
15
SEN01830-01
40 Troubleshooting
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of 3rd clutch ECMV: Short circuit failure (Transmission controller system) DXH6KB 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 command current, output current of 3rd clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in F3 or R3. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch soleS3T3 (male) Resistance 1 noid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (5) – S3T3 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (5) – S3T3 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) – S3T3 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission 3rd clutch ECMV
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH6KY] 3rd clutch ECMV: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of 3rd clutch ECMV: Hot short failure (Transmission controller system) DXH6KY Current keeps flowing to 3rd clutch solenoid circuit. 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 F3 and R3. • Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. (Code 31604, 31614: Output command current, output current of 3rd clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in F1 or R1. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch sole1 S3T3 (male) Resistance noid (Internal short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMCN3 (female) (5) – S3T3 (female) (1) with Voltage Max. 1 V chassis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission 3rd clutch ECMV
D475A, D475ASD-5E0
17
SEN01830-01
40 Troubleshooting
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Reverse clutch ECMV: Disconnection failure (Transmission controller system) DXH7KA 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 command current, output current of reverse clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in reverse. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective reverse clutch without turning starting switch ON. 1 solenoid (Internal disconSRT1 (male) Resistance nection) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (25) Resis2 Max. 1 z wiring or defective contact – SRT1 (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z – SRT1 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission reverse clutch ECMV
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Reverse clutch ECMV: Short circuit failure (Transmission controller system) DXH7KB 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 command current, output current of reverse clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in reverse. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective reverse clutch SRT1 (male) Resistance solenoid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (25) – SRT1 (female) (1) with chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 ness (with another wiring (female) (25) – SRT1 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) – SRT1 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission reverse clutch ECMV
D475A, D475ASD-5E0
19
SEN01830-01
40 Troubleshooting
Failure code [DXH7KY] Reverse clutch ECMV: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Reverse clutch ECMV: Hot short failure (Transmission controller system) DXH7KY Current keeps flowing to reverse clutch solenoid circuit. 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 R1. • Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606, 31616: Output command current, output current of reverse clutch ECMV) • Method of reproducing failure code: Start engine and drive machine in forward. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective reverse clutch without turning starting switch ON. 1 solenoid (Internal short cirSRT1 (male) Resistance cuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with 24 V circuit) (female) (25) – SRT1 (female) (1) with chas- Voltage Max. 1 V sis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission reverse clutch ECMV
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH8KA] Forward clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Forward clutch ECMV: Disconnection failure (Transmission controller system) DXH8KA 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 command current, output current of forward clutch ECMV) • Method of reproducing failure code: Start engine and drive machine forward. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective forward clutch without turning starting switch ON. 1 solenoid (Internal disconSFT1 (male) Resistance nection) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (35) Resis2 Max. 1 z wiring or defective contact – SFT1 (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z – SFT1 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission forward clutch ECMV
D475A, D475ASD-5E0
21
SEN01830-01
40 Troubleshooting
Failure code [DXH8KB] Forward clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Forward clutch ECMV: Short circuit failure (Transmission controller system) DXH8KB 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 command current, output current of forward clutch ECMV) • Method of reproducing failure code: Start engine and drive machine forward. Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward clutch SFT1 (male) Resistance solenoid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (35) – SFT1 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 ness (with another wiring (female) (35) – SFT1 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) – SFT1 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 – 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to transmission forward clutch ECMV
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH8KY] Forward clutch ECMV: Hot short Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • •
1
Failure code Symptom of Forward clutch ECMV: Hot short failure (Transmission controller system) DXH8KY Current keeps flowing to forward clutch solenoid circuit. 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 F1. • Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output command current, output current of forward clutch ECMV) • Method of reproducing failure code: Start engine and drive machine reverse. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective forward clutch without turning starting switch ON. 1 solenoid (Internal short cirSFT1 (male) Resistance cuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with 24 V circuit) (female) (35) – SFT1 (female) (1) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 – 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Circuit diagram related to transmission forward clutch ECMV
D475A, D475ASD-5E0
23
SEN01830-01
40 Troubleshooting
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of Right steering clutch ECMV: Disconnection failure (Steering controller system) DXH9KA When signal is output to right steering clutch solenoid circuit, current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to right. Once machine is stopped, engine speed is limited to medium (half). 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 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right). Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 clutch solenoid SRC7 (male) Resistance (Internal disconnection) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN3 (female) (35) 2 Max. 1 z tance wiring or defective contact – SRC7 (female) (1) in connector) Wiring harness between STCN3 (female) (23) ResisMax. 1 z – SRC7 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to right steering clutch ECMV
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right steering clutch ECMV: Short circuit failure (Steering controller system) DXH9KB When signal was output to right steering clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to right. Once machine is stopped, engine speed is limited to medium (half). 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 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).
• • • • • • • • •
Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right steering SRC7 (male) Resistance clutch solenoid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (35) – SRC7 (female) (1) Min. 1 Mz cuit) tance with chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring Short circuit of wiring harness between harness (with another wirResisSTCN3 (female) (35) – SRC7 (female) (1) ing harness) Min. 1 Mz tance with wiring harness between STCN3 (female) (23) – SRC7 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 – 3 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to right steering clutch ECMV
D475A, D475ASD-5E0
25
SEN01830-01
40 Troubleshooting
Failure code [DXH9KY] Right steering clutch ECMV: Hot short Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of Right steering clutch ECMV: Hot short failure (Steering controller system) DXH9KY Current keeps flowing to right steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to right. (Right clutch cannot be disconnected.) Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, machine cannot travel any more. Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right). Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 clutch solenoid SRC7 (male) Resistance (Internal short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) (35) – SRC7 (female) (1) Voltage Max. 1 V with chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to right steering clutch ECMV
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of Left steering clutch ECMV: Disconnection failure (Steering controller system) DXHAKA When signal is output to left steering clutch solenoid circuit, current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is limited to medium (half). 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 90600, 90602: Left steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left). Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 clutch solenoid SLC5 (male) Resistance (Internal disconnection) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN3 (female) (25) 2 Max. 1 z tance wiring or defective contact – SLC5 (female) (1) in connector) Wiring harness between STCN3 (female) (23) ResisMax. 1 z – SLC5 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to left steering clutch ECMV
D475A, D475ASD-5E0
27
SEN01830-01
40 Troubleshooting
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Left steering clutch ECMV: Short circuit failure (Steering controller system) DXHAKB When signal was output to left steering clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is limited to medium (half). 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 90601, 90603: Left steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
• • • • • • • • •
Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left steering SLC5 (male) Resistance clutch solenoid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (25) – SLC5 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring Short circuit of wiring harness between harness (with another wirResisSTCN3 (female) (25) – SLC5 (female) (1) with ing harness) Min. 1 Mz tance wiring harness between STCN3 (female) (23) – SLC5 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 – 3 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to left steering clutch ECMV
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXHAKY] Left steering clutch ECMV: Hot short Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of Left steering clutch ECMV: Hot short failure (Steering controller system) DXHAKY Current keeps flowing to left steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, machine cannot travel any more. Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90600, 90602: Left steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left). Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 clutch solenoid SLC5 (male) Resistance (Internal short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) (25) – SLC5 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to left steering clutch ECMV
D475A, D475ASD-5E0
29
SEN01830-01
40 Troubleshooting
Failure code [DXHBKA] Right brake ECMV: Disconnection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • • •
1
Failure code Symptom of Right brake ECMV: Disconnection failure (Steering controller system) DXHBKA 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. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Right brake is kept applied. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Command current, output current of right steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 brake solenoid (Internal SR83 (male) Resistance short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN3 (female) (15) 2 Max. 1 z tance wiring or defective contact – SR83 (female) (1) in connector) Wiring harness between STCN3 (female) (13) ResisMax. 1 z – SR83 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to right steering brake ECMV
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXHBKB] Right brake ECMV: Short circuit Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Right brake ECMV: Short circuit failure (Steering controller system) DXHBKB 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. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Right brake is kept applied. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Command current, output current of right steering brake ECMV) Method of reproducing failure code: Start engine and release parking brake lever.
• • • • • • • • • •
Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right steering SR83 (male) Resistance brake solenoid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (15) – SR83 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between ness (with another wiring STCN3 (female) (15) – SR83 (female) (1) with Resisharness) Min. 1 Mz wiring harness between STCN3 (female) (13) tance – SR83 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 – 3 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to right steering brake ECMV
D475A, D475ASD-5E0
31
SEN01830-01
40 Troubleshooting
Failure code [DXHBKY] Right brake ECMV: Hot short Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • • •
1
Failure code Symptom of Right brake ECMV: Hot short failure (Steering controller system) DXHBKY Current keeps flowing to right steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering brake solenoid circuit. Limits operation of engine, transmission and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Right brake is kept applied. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Command current, output current of right steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 brake solenoid (Internal SR83 (male) Resistance short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24V circuit) STCN3 (female) (15) – SR83 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to right steering brake ECMV
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXHCKA] Left brake ECMV: Disconnection Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • • •
1
Failure code Symptom of Left brake ECMV: Disconnection failure (Steering controller system) DXHCKA 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. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Left brake is kept applied. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Command current, output current of left steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 brake solenoid (Internal SL81 (male) Resistance short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) (5) Resis2 Max. 1 z tance wiring or defective contact – SL81 (female) (1) in connector) Wiring harness between STCN3 (female) (13) ResisMax. 1 z – SL81 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to left steering brake ECMV
D475A, D475ASD-5E0
33
SEN01830-01
40 Troubleshooting
Failure code [DXHCKB] Left brake ECMV: Short circuit Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
1
Failure code Symptom of Left brake ECMV: Short circuit failure (Steering controller system) DXHCKB 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. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Left brake is kept applied. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Command current, output current of left steering brake ECMV) Method of reproducing failure code: Start engine and release parking brake lever.
• • • • • • • • • •
Cause
1
Possible causes and the standard values when normal
2
3
4
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left steering SL81 (male) Resistance brake solenoid (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (5) – SL81 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between ness (with another wiring STCN3 (female) (5) – SL81 (female) (1) with Resisharness) Min. 1 Mz wiring harness between STCN3 (female) (13) tance – SL81 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 – 3 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to left steering brake ECMV
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXHCKY] Left brake ECMV: Hot short Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information
• • • • • • • • •
1
Failure code Symptom of Left brake ECMV: Hot short failure (Steering controller system) DXHCKY Current keeps flowing to left steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering brake solenoid circuit. Limits operation of engine, transmission and brake. Sudden stop prevention valve is applied 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: Command current, output current of left steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever. Cause
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 brake solenoid (Internal SL81 (male) Resistance short circuit) Between (1) – (2) 5 – 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24V circuit) STCN3 (female) (5) – SL81 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 – 2 (Since this is an internal defect, it cannot be ler diagnosed).
Circuit diagram related to left steering brake ECMV
D475A, D475ASD-5E0
35
SEN01830-01
40 Troubleshooting
Failure code [F@BBZL] (or VHMS_LED display "n3" o "38") Engine blow-by pressure sensor: Abnormally high pressure occurrence Action code — Failure content Controller's action Symptoms that appear on machine
1
Failure code Symptom of Engine blow-by pressure sensor: Abnormally high pressure occurfailure rence (VHMS controller system) F@BBZL • Blow-by pressure sensor signal circuit detected pressure higher than 4.71 kPa {480 mmAq}. • None in particular. • If machine is used as it is, engine may be broken.
General information
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "38".
Possible causes and the standard values when normal
Cause Standard values when normal and remarks for troubleshooting Abnormal rise of blow-by 1 pressure (When system is Check engine and repair, if there is abnormality. normal) Defective blow-by presIf failure code [DHE5KB] or [DHE5KY] is displayed, carry out trou2 sure sensor system bleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller Between V2A (female) (18) – V2A (female) 0.3 – Voltage (12) 0.7 V
Circuit diagram related to blow-by pressure sensor
36
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01830-01
37
SEN01830-01
40 Troubleshooting
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine
Failure code
Left front exhaust temperature sensor (1): Exhaust temperature Symptom of abnormal rise failure F@BYNS (VHMS controller system) • Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C in range above rated output speed and 750°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken.
General information
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "61".
Possible causes and the standard values when normal
Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou2 temperature sensor bleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. V2A Exhaust temperature Voltage 3 Defective VHMS controller 20°C Approx. 0.9 – 1.2 V (7) – (13) 500°C Approx. 2.6 – 3.5 V
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0
39
SEN01830-01
40 Troubleshooting
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
40
Failure code Symptom of Left rear exhaust temperature sensor (1): Exhaust temperature failure abnormal rise (VHMS controller system) f@BYNS • Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C in range above rated output speed and 750°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "71". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble2 temperature sensor shooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. V2A Exhaust temperature Voltage 3 Defective VHMS controller 20°C Approx. 0.9 – 1.2 V (6) – (13) 500°C Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0
41
SEN01830-01
40 Troubleshooting
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Right front exhaust temperature sensor (1): Exhaust temperature failure abnormal rise (VHMS controller system) F@BZNS • Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C in range above rated output speed and 750°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on machine monitor (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "38". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right front If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou2 exhaust temperature senbleshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller
42
V2A
Exhaust temperature
Voltage
(5) – (13)
20°C 500°C
Approx. 0.9 – 1.2 V Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0
43
SEN01830-01
40 Troubleshooting
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code
Right rear exhaust temperature sensor (1): Exhaust temperature Symptom of abnormal rise failure f@BZNS (VHMS controller system) • Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C in range above rated output speed and 750°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "39". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right rear If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble2 exhaust temperature senshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller
44
V2A
Exhaust temperature
Voltage
(16) – (13)
20°C 500°C
Approx. 0.9 – 1.2 V Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0
45
SEN01830-01
40 Troubleshooting
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Left front exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) F@BYNR • Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C in range above rated output speed and 800°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "62". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou2 temperature sensor bleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller
46
V2A
Exhaust temperature
Voltage
(7) – (13)
20°C 500°C
Approx. 0.9 – 1.2 V Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (2)
D475A, D475ASD-5E0
47
SEN01830-01
40 Troubleshooting
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Left rear exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) f@BYNR • Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C in range above rated output speed and 800°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "72". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble2 temperature sensor shooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller
48
V2A
Exhaust temperature
Voltage
(6) – (13)
20°C 500°C
Approx. 0.9 – 1.2 V Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (2)
D475A, D475ASD-5E0
49
SEN01830-01
40 Troubleshooting
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Right front exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) F@BZNR • Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C in range above rated output speed and 800°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "82". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right front If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou2 exhaust temperature senbleshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller
50
V2A
Exhaust temperature
Voltage
(5) – (13)
20°C 500°C
Approx. 0.9 – 1.2 V Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (2)
D475A, D475ASD-5E0
51
SEN01830-01
40 Troubleshooting
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise 1 Action code — Failure content Controller's action Symptoms that appear on machine General information
Possible causes and the standard values when normal
Failure code Symptom of Right rear exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) f@BZNR • Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C in range above rated output speed and 800°C in range below maximum torque speed) • None in particular. • If machine is used as it is, engine may be broken. • Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). • "n3" on VHMS controller LED changes to "92". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right rear If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble2 exhaust temperature senshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller
52
V2A
Exhaust temperature
Voltage
(16) – (13)
20°C 500°C
Approx. 0.9 – 1.2 V Approx. 2.6 – 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (2)
D475A, D475ASD-5E0
53
SEN01830-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN01830-01
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
54
SEN01831-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting of electrical system (E-mode) Contents of troubleshooting table ................................................................................................................... 3 E-1 The engine does not start......................................................................................................................... 4 E-2 The preheater does not operate............................................................................................................... 8 E-3 The ripper pin puller cylinder does not operate ...................................................................................... 12 E-4 The monitor panel does not come on at all when the starting switch is turned on ................................. 14 E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out..................................................................................................................................... 16 E-6 When the starting switch is turned on, the basic check items flash ....................................................... 17 E-7 While the engine is operating, any caution item flashes ........................................................................ 18 E-8 An emergency caution item flashes while the engine is running............................................................ 21 E-9 While the preheater is operating, the preheating pilot lamp does not come on ..................................... 24 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine) ................................................................................................................. 26
D475A, D475ASD-5E0
1
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40 Troubleshooting
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on ................................................................................................................................. 26 E-12 The engine coolant temperature gauge does not indicate normally..................................................... 27 E-13 Indication of the power train (torque converter) temperature gauge is abnormal................................. 28 E-14 The hydraulic oil temperature gauge does not indicate normally ......................................................... 30 E-15 Indication of the fuel gauge is abnormal............................................................................................... 31 E-16 Indications of gear speed and engine speed are abnormal.................................................................. 32 E-17 Indication of the shift mode service meter is abnormal ........................................................................ 32 E-18 The switch module cannot be operated................................................................................................ 33 E-19 The warning lamp does not flash or does not go out............................................................................ 34 E-20 The alarm buzzer does not sound or does not stop ............................................................................. 35 E-21 Auto shift down is not possible or is not released................................................................................. 36 E-22 The automatic pitch back system does not operate (only superdozer specification) ........................... 37 E-23 The alarm buzzer cannot be cancelled................................................................................................. 38 E-24 The operator mode cannot be operated ............................................................................................... 39 E-25 The service mode cannot be operated ................................................................................................. 40 E-26 The back-up alarm does not sound ...................................................................................................... 42 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ...... 44 E-28 Troubleshooting for air conditioner system........................................................................................... 50 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ........................................... 65 E-30 Fan does not reverse............................................................................................................................ 67 E-31 Gear cannot be shifted ......................................................................................................................... 69 E-32 Electric priming pump does not operate or does not stop automatically .............................................. 70
2
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40 Troubleshooting
SEN01831-02
Contents of troubleshooting table a
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information
Problem that appears on machine Information related to detected trouble 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
Possible causes and standard value in normal state
• Disconnection in wiring The connector connection is defective or wiring harness is disconnected. • Ground fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. • Hot short circuit A harness not connected to the power (24 V) circuit comes 2 into contact with the power (24 V) circuit. • Short circuit Causes by which a trouble A harness of an independent circuit abnormally comes into is assumed to be defected contact with one of another circuit. (The order number indicates a serial number, not (1) Method of indicating connector numbers and handling of Ta priority sequence.) adapter For troubleshooting, insert or connect T-adapter shown 3 below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the T-adapters in both the male and female. • When “male” or “female” is indicated for a connector number, disconnect connector, and insert the T-adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. 4 • 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 troubleshooting. • Connector No.: Indicates (Model – No. of pins) (Color). • “Connector No. and pin No.” from each branching/merging point: indicate the ends of branch or source of merging within the parts of the same wiring harness • Arrow (io): Roughly indicates mounting place on machine.
D475A, D475ASD-5E0
3
SEN01831-02
40 Troubleshooting
E-1 The engine does not start Symptom of failure
(1) The engine does not start.
General information
• The engine start circuit has the neutral safety function, and the engine does not start unless the parking brake 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. • Before starting the troubleshooting, validate that the related failure code is not displayed. (If the failure code [D130KA], [D130KB], [DD14KA], [DD14KB], [DDQ2KA] or [DDQ2KB] is displayed, conduct troubleshooting for the displayed code first.) Cause 1 Insufficient battery capacity
Standard values when normal and remarks for troubleshooting Battery voltage
Battery specific gravity
Min. 24 V
Min. 1.26
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 2
Defective starting switch (internal disconnection)
KEY (male) Between (5) and (3)
Defective neutral safety 3 relay (internal disconnection)
4
Defective alternator (internal short-circuit)
Possible causes and the standard values when normal
Switch position
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
a Prepare with the starting switch OFF, then start the engine 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. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Alternator
Voltage
Between Terminal R and ground
Max. 1 V
a Prepare with the starting switch OFF, then start the engine and carry out troubleshooting.
5
Detective starting motor (internal defect)
Starting motor A, B
Voltage
Electric power supply : between Terminal B and ground
20 – 30 V
Charge : between Terminal R and ground
Max. 1 V
Starting : between Terminal S and ground
20 – 30 V
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. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (disconnection in wir6 ing or defective contact in connector)
4
Wiring harness between KEY (female) (3) and NFS (female) (3)
Resistance
Max. 1 z
Wiring harness between NSF (female) (5) and ST1 (female) (1)
Resistance
Max. 1 z
Wiring harness between NSF (female) (5) and ST2 (female) (1)
Resistance
Max. 1 z
D475A, D475ASD-5E0
40 Troubleshooting
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Cause
Standard values when normal and remarks for troubleshooting a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
Possible causes and the standard values when normal
Hot short of wiring harness between alternator R terminal and ST1 (female) (2) or ST2 (female) (2) with ground
7
Voltage
Max. 1 V
Hot short in wiring harness (Contact with 24 V circuit) Hot short of wiring harness between STCN1 (female) (23) and pre-lubrication motor signal terminal with ground
Voltage
Max. 1 V
Hot short of wiring harness between S03 (female) (9) and pre-heater relay HTRIC terminal with ground
Voltage
Max. 1 V
D475A, D475ASD-5E0
5
SEN01831-02
40 Troubleshooting
Symptom of failure
(2) Trouble (1) is not detected but the engine does not start (When the machine is equipped with prelubricator).
General information
• "PE" is displayed on the gear speed display unit and "E" on the right side flashes. • After the engine is started, if "Po" is displayed on the gear speed display unit and "o" on the right side flashes, the engine oil pressure is not heightened. (In this case, the pre-lubrication motor and the engine oil pressure switch for pre-lubrication may be defective. Accordingly, carry out the following troubleshooting.) Cause Defective engine oil pressure switch for pre-lubrica1 tion (Internal disconnection or short circuit)
Defective pre-lubrication 2 relay (PLUB)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then keep starting switch OFF or start engine and carry out troubleshooting. STCN2
Starting switch
Resistance
Between (3) and chassis ground
OFF
Max. 1 z
Start engine
Min. 1 Mz
When the relay is replaced with another one with the starting switch OFF, the engine starts or "PE" is displayed on the gear speed display unit and "E" on the right side flashes after the starting switch is turned ON. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
3
Defective pre-lubrication motor
Pre-lubrication motor
Voltage
Between signal terminal and chassis ground
20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 4 wiring harness or defective contact in connector)
Wiring harness between engine oil pressure switch terminal POP and STCN2 (female) (3)
Resistance
Max. 1 z
Wiring harness between KEY (female) (1) and pre-lubrication relay (PLUB) (female) (1)
Resistance
Max. 1 z
Wiring harness between pre-lubrication relay (PLUB) (female) (2) and STCN2 (female) (18)
Resistance
Max. 1 z
Wiring harness between pre-lubrication motor signal terminal and STCN1 (female) (23)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Short circuit with chassis ground in wiring harness 5 (Contact with ground circuit)
6
Between wiring harness between KEY (female) (1) and pre-lubrication relay (PLUB) (female) (1) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between pre-lubrication relay (PLUB) (female) (2) and STCN2 (female) (18) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between pre-lubrication motor signal terminal and STCN1 (female) (23) and chassis ground
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
7
SEN01831-02
40 Troubleshooting
E-2 The preheater does not operate Symptom of failure
• The preheater does not operate.
General information
a This troubleshooting describes the procedures to be followed when the automatic and manual preheating does not function to heat the electrical intake air heater mounting section. (When only the preheating lamp does not light up, carry out the troubleshooting of “E-8 While the preheater is operating, the preheating pilot lamp does not light up”) • For preheating, both the “Automatic preheating function” and “Manual preheating function” are available. When either function is performed, the preheating lamp comes on. • If “the monitor panel does not light up” or “the battery relay does not make operating noise” when turning the starting switch ON, the main electric power supply system can be suspected to be defective. So, check the main electric power supply system. • Before starting the troubleshooting, validate that the related failure code is not displayed. (If the failure code [D182KZ] is displayed, firstly conduct this troubleshooting.) Causes
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF.
1
Defective starting switch (internal disconnection)
Defective fuse 2 (FS22) 3
4
Defective circuit breaker (CB30, CB6)
Defective preheater relay (internal disconnection)
Starting switch
Switch position
Resistance
Between 250 (B) – 255 (R1)
OFF
Min. 1 Mz
HEAT (R1)
Max. 1 z
If the fuse is burnt, it is highly possible that a defective grounding, etc. has occurred in the circuit. If the breaker is cutout, it is highly possible that a defective grounding, etc. has occurred in the circuit. a Prepare with starting switch OFF and diagnose with starting switch ON. If preheating starts normally at the intake air temperature below minus 5°C after the preheater relay PHR is replaced with another one, the preheater relay PHR is defective. a Prepare with the starting switch OFF and diagnose with the starting switch HEAT.
Possible causes and the standard values when normal Defective heater relay 5 (internal defect)
Heater relay
Voltage
Electric power supply: between terminal HTR1A, HTR2A and ground
20 – 30V
Signal: between terminal HTR1C, HTR2C and ground
20 – 30V
When the both voltages of electric power supply and signal are normal and no operating noise is heard, the heater relay is defective.
6
7
8
Defective diode (internal short circuit)
Defective electrical intake air heater (internal defect)
a Prepare with starting switch OFF and diagnose with starting switch still OFF. Diagnose diode HTD1, HTD2 (male) • See the “Inspection procedure of diode” in the “Testing and adjusting” section. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Electrical intake air heater
Continuity
Between terminals
Continue
D475A, D475ASD-5E0
40 Troubleshooting
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Causes
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harnesses between FS22 (2) – PHR (female) (5)
Wiring harness between PHR (female) (3) – terminal HTR1C – terminal HTR2C Disconnection in wiring harness Wiring harness between starting switch 255 8 (disconnection or defective (R1) – terminal HTR1C – terminal HTR2C contact of connectors) Wiring harness between terminal BRC of battery relay – terminal HTR1A and terminal HTR1A Wiring harness between terminal REL1, REL2 of heater relay – electrical intake air heater HT1
Possible causes and the standard values when normal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between FS22 (2) – PHR (female) (5)
Resistance
Min. 1 Mz
Between ground and wiring harness between PHR (female) (3) – terminal HTR1C – terminal HTR2C
Resistance
Min. 1 Mz
Defective harness Between ground and wiring harness 9 grounding (contact with ground circuit) between starting switch 255 (R1) – terminal HTR1C – terminal HTR2C
Resistance
Min. 1 Mz
Between ground and wiring harness between terminal BRC of battery relay – terminal HTR1A and terminal HTR2A
Resistance
Min. 1 Mz
Between ground and wiring harness between terminal REL1, REL2 of heater relay – electrical intake air heater HT1
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
9
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40 Troubleshooting
Circuit diagram related
10
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40 Troubleshooting
D475A, D475ASD-5E0
SEN01831-02
11
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40 Troubleshooting
E-3 The ripper pin puller cylinder does not operate Symptom of failure
• The ripper pin puller cylinder does not operate.
General information Cause 1 Defective fuse (FS22-2)
Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have possibly occurred to the circuit.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective pin puller switch 263 (male) Switch Resistance 2 (Internal disconnection or short circuit) Pull Max. 1 z Between (1) and (2) Press Min. 1 Mz Defective pin puller sole3 noid (Internal disconnection or short circuit)
Possible causes and the standard values when normal
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 224 (male)
Resistance
Between (1) and (2)
10 – 80 z
Between (1) and ground
Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector)
Wiring harness between FS22-2 outlet and 263 (female) (1)
Resistance
Max. 1 z
Wiring harness between 263 (female) (2) and 224 (female) (1)
Resistance
Max. 1 z
Wiring harness between 224 (female) (2) and ground
Resistance
Max. 1 z
a 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 FS22-2 5 ness (Contact with ground (outlet side) and ground circuit) Between wiring harness (between 263 (female) (2) and 224 (female) (1)) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 6
12
Hot short in wiring harness Between wiring harness (between 263 (Contact with 24 V circuit) (female) (2) and 234 (female) (1)) and ground
Voltage
Max. 1 V
Wiring harness between 244 (female) (2) and ground
Voltage
Max. 1 V
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Circuit diagram related
D475A, D475ASD-5E0
13
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40 Troubleshooting
E-4 The monitor panel does not come on at all when the starting switch is turned on Symptom of failure
• The monitor panel does not come on at all when the starting switch is turned ON.
General information
• 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. Cause 1
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. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
Possible causes and the standard values when normal
Wiring harness between S03 (female) (1) (2) and CB2 outlet
Resistance
Max. 1 z
Wiring harness between S03 (female) (3) (4) and ground
Resistance
Max. 1 z
Wiring harness between S03 (female) (5), (6) and CB6 outlet
Resistance
Max. 1 z
Wiring harness between S01 (female) (1) and CB2 outlet
Resistance
Max. 1 z
Wiring harness between S01 (female) (2) and ground
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Between wiring harness CB2 (outlet side) and S03 (female) (2) and S01 (female) (1) and ground
Resistance
Min. 1 Mz
Between wiring harness CB6 (outlet side) and S03 (female) (5) (6) and ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
4
Defective monitor panel (Gauge/lamp module)
S03
Voltage
Between (1), (2) and (3), (4)
20 – 30 V
S01
Voltage
Between (1) and (2)
20 – 30 V
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON and OFF.
5 CAN communication error
14
S03
Voltage
Between (5) (6) and (3) (4)
20 – 30 V
If failure code [DAFRKR] of CAN communication error is displayed, carry out troubleshooting for it.
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40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
15
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40 Troubleshooting
E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out Symptom of failure
• When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out.
General information
• 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.
Possible causes and the standard values when normal
16
Cause 1
Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This internal defect cannot be diagnosed.
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40 Troubleshooting
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E-6 When the starting switch is turned on, the basic check items flash Trouble Related information
• The radiator coolant level caution lamp flashes. • When any basic check items are detected to be abnormal before the engine starts, they will flash.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Radiator coolant level decrease
Because the radiator coolant level decrease is detected, inspect the radiator coolant level (the lamp flashes below the specified level).
The main radiator coolant 2 level sensor is defective. (Internal disconnection)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. WLD (male) Between (1) and (2)
Possible causes and standard value in normal state
Radiator coolant level
Resistance
Normal level
Max. 1 z
Lower level
Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between S03 (female) (11) Resis3 Max. 1 z wiring or defective contact and WLD (female) (1) tance in connector) Wiring harness between WLD (female) (2) ResisMax. 1 z and ground tance a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 4
Defective monitor panel (Gauge/lamp module)
S03
Radiator coolant level
Voltage
Between (11) and ground
Normal level
Max. 1 V
Lower level
20 – 30 V
Circuit diagram related
D475A, D475ASD-5E0
17
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40 Troubleshooting
E-7 While the engine is operating, any caution item flashes Symptom of failure
(1) The battery charge level caution lamp flashes.
General information
• When any abnormality is detected during engine operation, the relevant caution item will flash. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then start the engine and carry out troubleshooting.
1
Possible causes and the standard values when normal
Defective alternator (insufficient power generation)
Alternator
Engine speed
Voltage
Between Terminal R and ground
Min. medium speed (half)
20 – 30 V
a Prepare with the starting switch OFF, then carry out troubleshootDisconnection of wiring ing without turning the starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between S04 (female) (9) and ResisMax. 1 z in connector) alternator R terminal tance Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness between S04 (female) (9), alternator terminal R, starting motor terminal R, STCN1 (female) (15), and TMCN1 (female) (15) and chassis ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 4
18
Defective monitor panel (Gauge/lamp module)
S04
Engine speed
Voltage
Between (9) and ground
Min. medium speed (half)
20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
19
SEN01831-02
40 Troubleshooting
Symptom of failure
(2) The air cleaner clogging caution lamp flashes.
General information
• If abnormality is detected while the engine is running, the caution item lamp flashes. Cause 1 Clogged air cleaner
Standard value in normal state/Remarks on troubleshooting Clean or replace the air cleaner. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)
Wiring harness between S03 (female) (13) and AF1 (female) (1)
Resistance
Max. 1 z
Wiring harness between AF1 (female) (2) and AF2 (female) (1)
Resistance
Max. 1 z
Wiring harness between AF1 (female) (2) – chassis ground
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Between wiring harness between S03 (female) (13) and AF1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between AF1 (female) (2) and AF2 (female) (1) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective monitor panel (gauge, lamp module)
Defective air cleaner clog5 ging sensor (Internal disconnection)
S03
Air cleaner
Voltage
Between (13) and chassis ground
When normal
Max. 1 V
When clogged
20 – 30 V
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. AF1, AF2 (male) Between (1) and (2)
Air cleaner
Resistance
When normal
Max. 1 z
When clogged
Min. 1 Mz
Circuit diagram related
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-8 An emergency caution item flashes while the engine is running Symptom of failure
(1) The engine oil pressure caution lamp flashes.
General information
• If abnormality is detected while the engine is running, the emergency calculation item flashes and the caution buzzer sounds. • The engine controller checks the engine oil pressure for abnormality. • Failure code [B@BAZG] may be displayed, too. Cause
Possible causes and the standard values when normal
1
Standard value in normal state/Remarks on troubleshooting
Check the engine oil pressure, as the drop of engine oil pressure is Reduction of engine oil presdetected. sure • Carry out the troubleshooting of "S-12 Oil pressure drops."
Defective engine hydraulic 2 system
If no problem is found in cause 1, the engine oil pressure sensor circuit can be suspected to be defective. So, carry out the troubleshooting of "Failure codes [CA135] and [CA141] Abnormal engine oil pressure sensor."
3 Defective monitor panel
Since this is an internal defect, it cannot be diagnosed.
Circuit diagram related
D475A, D475ASD-5E0
21
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40 Troubleshooting
Symptom of failure
(2) The engine coolant temperature caution lamp flashes.
General information
• When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. • The engine coolant temperature caution lamp flashes or goes out as it links with indication on the engine coolant temperature gauge. • The engine controller checks the engine coolant temperature for abnormality. • Failure code [B@BCNS] may be displayed, too. Cause
1 Possible causes and the standard values when normal
Overheated engine coolant temperature
Standard value in normal state/Remarks on troubleshooting As overheated engine coolant was detected, check the engine coolant temperature. (When the coolant temperature is over 102°C, the lamp flashes. When the coolant temperature is over 105°C, the lamp flashes and the buzzer sounds.)
The engine coolant temCheck the indication on the engine coolant temperature gauge. If the perature sensor system is 2 indication is abnormal, carry out the troubleshooting of "E-12 Indicadefective. tion on the engine coolant temperature gauge is abnormal". (Engine controller system) 3
Defective monitor panel (Gauge/lamp module)
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.)
Symptom of failure
(3) The power train oil temperature caution lamp flashes.
General information
• 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. • Failure code [B@CENS] may be displayed, too. Cause 1
Possible causes and the standard values when normal
As an overheated power train oil temperature was detected, check the power train oil temperature. (Oil temperature above 120°C: Lamp blinks, above 130°C: Lamp blinks and buzzer sounds)
The power train oil temperCheck the indication on the power train oil temperature gauge. If the ature sensor system is 2 indication is abnormal, carry out the troubleshooting of "E-13 Indicadefective. tion on the power train oil temperature gauge is abnormal". (Machine monitor system) 3
22
Overheated oil temperature of power train
Standard value in normal state/Remarks on troubleshooting
Defective monitor panel (Gauge/lamp module)
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.)
D475A, D475ASD-5E0
40 Troubleshooting
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Symptom of failure
(4) The hydraulic oil temperature caution lamp flashes.
General information
• 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. • Failure code [B@HANS] may be displayed, too. Cause 1
Possible causes and the standard values when normal
Overheated hydraulic oil temperature
Standard value in normal state/Remarks on troubleshooting As an overheated hydraulic oil temperature was detected, check the hydraulic oil temperature. (Above 100°C: Lamp blinks, above 110°C: Lamp blinks and buzzer sounds)
The hydraulic oil temperaCheck the indication on the engine coolant temperature gauge. If the ture sensor system is 2 indication is abnormal, carry out the troubleshooting of "E-14 Indicadefective. tion on the hydraulic oil temperature gauge is abnormal". (Machine monitor system) 3
Defective monitor panel (Gauge/lamp module)
D475A, D475ASD-5E0
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.)
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E-9 While the preheater is operating, the preheating pilot lamp does not come on Symptom of failure
• While the preheater is operating, the preheating pilot lamp does not come on.
General information
a This troubleshooting describes the procedures to be followed when the preheating lamp does 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
Standard value in normal state/Remarks on troubleshooting
a Prepare with the starting switch OFF, then carry out troubleshootDisconnection of wiring ing without turning the starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between S03 (female) (9) and ResisMax. 1 z in connector) heater relay HTR1C terminal tance Possible causes and the standard values when normal
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har2 ness (Contact with ground Between wiring harness between S03 Resiscircuit) (female) (9) and heater relay HTR1C terminal Min. 1 Mz tance and ground a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 3
24
Defective monitor panel (Gauge/lamp module)
S03
Starting switch
Voltage
Between (9) and ground
ON
Max. 1 V
HEAT
20 – 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
25
SEN01831-02
40 Troubleshooting
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine) Symptom of failure
• At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tiltmounted machine)
General information
• 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.)
Possible causes and the standard values when normal
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-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on Symptom of failure
• At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on.
General information
• Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lock-up 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.)
Possible causes and the standard values when normal
26
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, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-12 The engine coolant temperature gauge does not indicate normally Symptom of failure
• The engine coolant temperature gauge does not indicate normally.
General information
• Information of the engine coolant temperature sensor is received from the engine controller by CAN communication. • When any abnormality occurs in the engine coolant temperature sensor system, failure code [CA144] or [CA145] may be displayed. Cause
Standard value in normal state/Remarks on troubleshooting If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it. a Diagnose with starting switch ON or with engine started.
1 Possible causes and the standard values when normal 2
Defective engine coolant temperature sensor system
Engine controller CAN communication error
Caution lamp (d) OFF
Flashing
White range (a) Green range (b)
Red range (c)
If failure code [DB2RKR] or [dB2RKR] is displayed, carry out troubleshooting for it.
3 Defective engine controller Since trouble is in system, troubleshooting cannot be carried out. 4 Defective monitor panel
If causes 1 – 3 are not detected, monitor panel may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Coolant temperature gauge and caution lamp Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
D475A, D475ASD-5E0
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E-13 Indication of the power train (torque converter) temperature gauge is abnormal Symptom of failure
• Indication of the power train (torque converter) temperature gauge is abnormal.
General information
• When any abnormality occurs in the power train oil pressure sensor system, failure code [DGT1KX] or [DGT1KA] may be displayed. Cause
Standard value in normal state/Remarks on troubleshooting If failure code [DGT1KX] or [DGT1KA] is displayed, carry out troubleshooting for it. a Diagnose with starting switch ON or with engine started.
Defective power train oil 1 pressure sensor system Possible causes and the standard values when normal
Caution lamp (d) OFF
Flashing
White range (a) Green range (b)
Red range (c)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 2
Defective monitor panel (Gauge/lamp module)
S04 (female)
Torque converter oil temperature
Resistance
Between (12) and ground
10 – 130°C
About 3.8 kz – about 80 kz
Coolant temperature gauge and caution lamp Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
28
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40 Troubleshooting
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Circuit diagram related
D475A, D475ASD-5E0
29
SEN01831-02
40 Troubleshooting
E-14 The hydraulic oil temperature gauge does not indicate normally Symptom of failure
• The hydraulic oil temperature gauge does not indicate normally.
General information
• 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
Standard value in normal state/Remarks on troubleshooting If failure code [DGS1KX] is displayed, carry out troubleshooting for it. a Diagnose with starting switch ON or with engine started.
1 Possible causes and the standard values when normal
Defective hydraulic oil temperature sensor system
Caution lamp (d) OFF
Flashing
White range (a) Green range (b)
Red range (c)
2
Transmission controller CAN communication error
If failure code [DAQRKR] is displayed, carry out troubleshooting for it.
3
Defective transmission controller
This is an internal defect, which cannot be troubleshot.
4
Defective monitor panel (Gauge/lamp module)
This is an internal defect, which cannot be troubleshot.
Coolant temperature gauge and caution lamp Serial numbers: 30001 – 30070
Serial numbers: 30071 and up
30
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40 Troubleshooting
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E-15 Indication of the fuel gauge is abnormal Symptom of failure
• Indication of the fuel gauge is abnormal.
General information Cause
Defective fuel level sensor. 1 (Internal disconnection or short circuit)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 422 (male)
Remained fuel level
Resistance
Between (1) and (2) (ground)
Full
About 4 z
Empty
About 85 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between S04 (female) (10) and 422 (female) (1)
Resistance
Max. 1 z
Wiring harness between 422 (female) (2) and ground
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between S04 (female) (10) and 422 (female) (1)) and ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
4
Hot short in wiring harness (Contact with 24 V circuit) Between wiring harness (between S04 (female) (10) and 422 (female) (1)) and ground
Voltage
Max. 1 V
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 5
Defective monitor panel (Gauge/lamp module)
S04 (female)
Remained fuel level
Resistance
Between (10) and ground
Full
About 4 z
Empty
About 85 z
Circuit diagram related
D475A, D475ASD-5E0
31
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E-16 Indications of gear speed and engine speed are abnormal Symptom of failure
(1) Indications of gear speed and engine speed are abnormal.
General information
• Signals of gear speed and engine speed are received from the transmission controller and the engine controller through communication. Cause
Possible causes and the standard values when normal
Engine controller or trans1 mission controller CAN communication error 2
Defective monitor panel (Gauge/lamp module)
1
Standard value in normal state/Remarks on troubleshooting If failure code [DB2RKR], [dB2RKR] or [DAQRKR] is displayed, carry out troubleshooting for it. This is an internal defect, which cannot be troubleshot.
E-17 Indication of the shift mode service meter is abnormal Symptom of failure
(1) During engine operation, the service meter does not advance.
General information
• The service meter measures time according to engine drive signals (alternator voltage). Cause
Possible causes and the standard values when normal
When the battery charge level caution lamp flashes during engine 1 Defective alternator system operation, carry out the troubleshooting of "While the engine is operating, caution items flash." 2
Symptom of failure
Standard value in normal state/Remarks on troubleshooting
Defective monitor panel (Gauge/lamp module)
This is an internal defect, which cannot be troubleshot.
(2) Shift mode and service meter are not displayed at all.
General information Possible causes and the standard values when normal
32
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, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-18 The switch module cannot be operated Symptom of failure
(1) Though the switch is used, lamps do not change.
General information Possible causes and the standard values when normal
Cause 1
Defective monitor panel (Switch module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
Symptom of failure
(2) Though the switch is used, the system setting does not change.
General information
• Switch module signals are transmitted to each controller through communication. Cause
Possible causes and the standard values when normal
Standard value in normal state/Remarks on troubleshooting
Disconnection in wiring har- a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ness (Disconnection in wir1 ing or defective contact in Wiring harness between S01 (female) (8) – ResisMax. 1 z connector) STCN2 (female) (21), – TMC2 (female) (21) tance Defective monitor panel 2 (Switch module)
a Prepare with the starting switch OFF, then start the engine and carry out the troubleshooting. S01
Voltage
Between (8) and ground
6–9V
Circuit diagram related
D475A, D475ASD-5E0
33
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40 Troubleshooting
E-19 The warning lamp does not flash or does not go out Symptom of failure
• The warning lamp does not flash or does not go out.
General information Possible causes and the standard values when normal
34
Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective machine monitor This is an internal defect, which cannot be troubleshot. (Gauge/lamp module)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-20 The alarm buzzer does not sound or does not stop Symptom of failure
• The alarm buzzer does not sound or does not stop.
General information
• When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other failure codes are displayed.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective circuit breaker (CB2)
When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit.
Defective alarm buzzer 2 (Internal disconnection or short circuit)
Possible causes and the standard values when normal
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 217 (male)
Resistance
Between (1) and (2)
200 z
Between (2) and ground
Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between S03 (female) (18) Resis3 Max. 1 z ing or defective contact in and 217 (female) (1) tance connector) Wiring harness between 217 (female) (2) and ResisMax. 1 z CB2 outlet tance a Prepare with the starting switch OFF, then carry out troubleshootShort circuit with chassis ing without turning the starting switch ON. 4 ground in wiring harness Resis(Contact with ground circuit) Between wiring harness related to CB2 (outMin. 1 Mz let side) and ground tance a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 5
Defective monitor panel (Gauge/lamp module)
S03 Between (18) and ground
Alarm buzzer
Voltage
At stop
20 – 30 V
At operation (sounding)
Max. 3 V
Circuit diagram related
D475A, D475ASD-5E0
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40 Troubleshooting
E-21 Auto shift down is not possible or is not released Symptom of failure
• Auto shift down is not possible or is not released.
General information Cause
Defective auto shift down switch (Internal 1 disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ASD (male) Between (2) and (3)
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Auto shift down switch
Resistance
OFF (0)
Min. 1 Mz
ON (1)
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between TMC3 (female) (39) and ADS (female) (3)
Resistance
Max. 1 z
Wiring harness between ADS (female) (2) and TMC1 (female) (10)
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between TMC3 (female) (39) and ASD (female) (3)) and ground
Resistance
Min. 1 Mz
4
Defective transmission controller
Since trouble is in system, troubleshooting cannot be carried out.
5
Defective transmission control system
If causes 1 – 4 are not detected, transmission controller may have defects related to this function.
Circuit diagram related
36
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40 Troubleshooting
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E-22 The automatic pitch back system does not operate (only superdozer specification) Symptom of failure
• The machine cannot start or stop a pivot turn.
General information Cause
Defective pivot turn switch 1 (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FTU (male) Between (2) and (3)
Pivot turn switch
Resistance
OFF (0)
Min. 1 Mz
ON (1)
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (9) 2 wiring harness or defective and FTU (female) (3) contact in connector) Wiring harness between FTU (female) (2) and TMC1 (female) (10) Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC3 (female) (9) and FTU (female) (3)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective transmission controller
TMC1, TMC3 Between TMC3 (9) and TMC1 (10)
5
Defective transmission control system
Automatic pitch back switch
Voltage
OFF (0)
20 – 30 V
ON (1)
Max. 3 V
If none of causes 1 – 4 is the cause of the trouble, the transmission control system may be defective (Troubleshooting cannot be carried out since the defect is in the system).
Circuit diagram related
D475A, D475ASD-5E0
37
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E-23 The alarm buzzer cannot be cancelled Symptom of failure
• The alarm buzzer cannot be cancelled.
General information
• The cancel signal is sent from the steering controller to the machine monitor by communication. Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Defective buzzer cancel 1 switch (Internal disconnection or short circuit)
BUZ (male) Between (1) and (2) Between (1) and (3)
Buzzer cancel switch
Resistance
OFF (0)
Min. 1 Mz
OFF (0)
Min. 1 Mz
Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Wiring harness between STCN2 (36) and BUZ (female) (2)
Resistance
Max. 1 z
Wiring harness between STCN2 (26) and BUZ (female) (3)
Resistance
Max. 1 z
Wiring harness between BUZ (female) (1) and STCN1 (female) (10)
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between STCN2 (36) and BUZ (female) (2)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between STCN2 (26) and BUZ (female) (3)) and ground
Resistance
Min. 1 Mz
4
Machine monitor CAN com- If failure code [DAFRKR] is displayed, carry out troubleshooting for munication error it.
5
Defective steering controller
Since trouble is in system, troubleshooting cannot be carried out.
Circuit diagram related
38
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40 Troubleshooting
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E-24 The operator mode cannot be operated Symptom of failure
• The operator mode cannot be operated.
General information
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective buzzer cancel switch system
Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of "The alarm buzzer cannot be cancelled." a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Defective information switch 2 (Internal short circuit or disconnection)
CUR (male) Between (1) and (2) Between (1) and (3)
Possible causes and the standard values when normal
Information switch
Resistance
OFF (0)
Min. 1 Mz Max. 1 z
OFF (0)
Min. 1 Mz Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector)
Wiring harness between STCN2 (16) and CUR (female) (2)
Resistance
Max. 1 z
Wiring harness between STCN2 (6) and CUR (female) (3)
Resistance
Max. 1 z
Wiring harness between CUR (female) (1) and STCN1 (female) (10)
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Short circuit with chassis Between wiring harness (between STCN2 4 ground in wiring harness (16) and CUR (female) (2)) and ground (Contact with ground circuit) Between wiring harness (between STCN2 (6) and CUR (female) (3)) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
5 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
Circuit diagram related
D475A, D475ASD-5E0
39
SEN01831-02
40 Troubleshooting
E-25 The service mode cannot be operated Symptom of failure
• The service mode cannot be operated.
General information Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective buzzer cancel switch system
Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of "E-23 The alarm buzzer cannot be cancelled".
2
Defective information switch system
Since the information switch system is supposed to be out of order, carry out the troubleshooting of "E-24 The operator mode cannot be cancelled".
3
Defective circuit breaker (CB6)
When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Defective service switch S24 4 (Internal short circuit or disconnection) Between (1) and (2), Between (4) and (5)
Service switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Possible causes and the standard values when normal
Wiring harness between CB6 outlet and S24 Disconnection in wiring har- (1) ness (Disconnection in wir- Wiring harness between S24 (4) and STCN1 5 ing or defective contact in (female) (10) connector) Wiring harness between S03 (female) (16)
Resistance
Max. 1 z
Resistance
Max. 1 z
and S24 (2)
Resistance
Max. 1 z
Wiring harness between STCN1 (female) (6) and S24 (5)
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Short circuit with chassis ground in wiring harness 6 (Contact with ground circuit)
Between wiring harness (between CB6 (outlet) and S24 (1)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between S24 (4) and STCN1 (female) (10)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between S03 (female) (16) and S24 (2)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between STCN1 (female) (6) and S24 (5)) and ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 7
Defective monitor panel (Gauge/lamp module)
S03
Service switch
Voltage
Between (16) and ground
OFF
Max. 1 V
ON
20 – 30 V
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 8
40
Defective steering controller
STCN1
Service switch
Voltage
Between (6) and ground
OFF
About 8 V
ON
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
41
SEN01831-02
40 Troubleshooting
E-26 The back-up alarm does not sound Symptom of failure
• The back-up alarm does not sound.
General information
• 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 1 Defective fuse (FS22-1)
Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have probably occurred in the circuit. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
2
Defective back-up relay (Internal disconnection)
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. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Possible causes and the standard values when normal
Wiring harness between FS22-1 outlet and Disconnection in wiring har- BKA (female) (1), (3) ness (Disconnection in wir- Wiring harness between BKA (female) (5) 3 ing or defective contact in and BUA (female) (1) connector) Wiring harness between BUA (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
and ground
Resistance
Max. 1 z
Wiring harness between TMC2 (female) (18) – BKA (female) (2)
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)
5
42
Defective back-up alarm (Internal defect)
Between wiring harness (between FS22-1 (outlet) and BKA (female) (1), (3)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between BKA (female) (5) and BUA (female) (1)) and ground
Resistance
Min. 1 Mz
When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
43
SEN01831-02
40 Troubleshooting
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on 1 Symptom of failure
(1) None of the night light, the headlamp and the working lamp on the panel comes on.
General information
• Headlamp and working lamp are operated with 1 switch. • If headlamp switch is operated, panel lighting is changed for night.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective circuit breaker CB5
If circuit breaker is turned OFF, circuit probably has ground fault etc.
Defective headlamp and 2 working lamp switch (International disconnection)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. FWL (male) Between (2) and (3)
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Possible causes and the standard values when normal
Disconnection of wiring harness (Disconnection in 3 wiring or defective contact in connector)
Wiring harness between FWL (female) (2) and CB5 outlet
Resistance
Max. 1 z
Wiring harness between FWL (female) (3) and LMFL (female) (1) and LMFR (female) (1) and LMW (female) (1) and S01 (female) (10) or S03 (female) (8)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (2) and LMFR (female) (2) or LMW (female) (2) and ground
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault of wiring har4 ness (Contact with ground circuit)
44
Wiring harness between FWL (female) (2) – CB5 outlet and ground
Resistance
Min. 1 Mz
Wiring harness between FWL (female) (3) – LMFL (female) (1), LMFR (female) (1), LMW (female) (1), S01 (female) (10) or S03 (female) (8) and ground
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Symptom of failure
(2) Only the night light on the panel does not comes on. (Whole or part)
General information
• If headlamp switch is operated, panel lighting is changed for night. Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective night lamp (S02) The night lamp is supposed to be defective. Check if the bulb is (Blown) blown. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Disconnection of wiring harness (Disconnection in 2 wiring or defective contact in connector)
Possible causes and the standard values when normal
Wiring harness between S01 (female) (10) and FWL (female) (3)
Resistance
Max. 1 z
Wiring harness between S01 (female) (2) and ground
Resistance
Max. 1 z
Wiring harness between S02 (female) (1) and CB2 (outlet)
Resistance
Max. 1 z
Wiring harness between S02 (female) (2) and ground
Resistance
Max. 1 z
Wiring harness between S03 (female) (8) and FWL (female) (3)
Resistance
Max. 1 z
Wiring harness between S03 (female) (3), (4) and ground
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Ground fault of wiring har3 ness (Contact with ground circuit)
Between wiring harness (between S01 (female) (10) and FWL (female) (3)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between S02 (female) (1) and CB2 (outlet)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between S03 (female) (8) and FWL (female) (3)) and ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 4
Defective monitor panel (Switch module)
Between S01 (10) and (2) Between S02 (1) and (2)
Defective monitor panel 5 (Gauge/lamp module)
D475A, D475ASD-5E0
Light switch ON
20 – 30 V
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Between S03 (8) and (3), (4)
Light switch ON
20 – 30 V
45
SEN01831-02
Symptom of failure
40 Troubleshooting
(3) Only the headlamp does not comes on. (Both right and left, or one side only)
General information Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective headlamp (Blown)
The headlamp is supposed to be defective. Check if the bulb is blown.
2
Defective circuit breaker (CB5)
When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
3
Defective headlamp relay (Internal disconnection)
When the relay is replaced 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 headlamp relay (LMFL, LMFR) are defective. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Possible causes and the standard values when normal
Disconnection of wiring harness (Disconnection in 4 wiring or defective contact in connector)
Wiring harness between CB5 (outlet) and LMFL (female) (3) and LMFR (female) (3)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (5) and 204 (female) (1), 207 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFR (female) (5) and 203 (female) (1), 208 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (2) – ground
Resistance
Max. 1 z
Wiring harness between LMFR (female) (2) – ground
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Ground fault of wiring har5 ness (Contact with ground circuit)
Between wiring harness (between CB5 (outlet) and LMFL (female) (3) and LMFR (female) (3)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between LMFL (female) (5) and 204 (female) (1), 207 (female) (1)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between LMFR (female) (5) and 203 (female) (1), 208 (female) (1)) and ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 6
46
Hot short (Contact with 24V Between wiring harness between LMFL (female) (2) and ground and ground circuit) in wiring harness
Voltage
Max. 1 V
Between wiring harness between LMFR (female) (3) and ground and ground
Voltage
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
Symptom of failure
SEN01831-02
(4) Only the working lamp does not comes on. (Both right and left, or one side only)
General information Cause 1
Defective working lamp (Blown)
2 Defective fuse (FS22-4)
Defective working lamp 3 relay (Internal disconnection)
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. a 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 headlamp comes on after the starting switch is turned ON and the light switch is turned ON, the working lamp relay (LMW) is defective. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
Possible causes and the standard values when normal
Disconnection of wiring harness (Disconnection in 4 wiring or defective contact in connector)
Wiring harness between FS22-4 (outlet) and LMW (female) (3)
Resistance
Max. 1 z
Wiring harness between LMW (female) (5) and 221 (female) (1) or 242 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMW (female) (2) and ground
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har5 ness (Contact with ground circuit)
Between wiring harness (between FS22-4 (outlet) LMW (female) (3)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between LMW (female) (5) and 221 (female) (1) or 242 (female) (1)) and ground
Resistance
Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Hot short (Contact with 24V 6 circuit) in wiring harness Between wiring harness between LMW Voltage Max. 1 V (female) (2) and ground
D475A, D475ASD-5E0
47
SEN01831-02
Symptom of failure
40 Troubleshooting
(5) Only the rear lamp does not comes on. (Both right and left, or one side only)
General information Cause
Standard value in normal state/Remarks on troubleshooting
Defective rear lamp (Blown)
The working lamp is supposed to be defective. Check if the bulb is blown.
2 Defective fuse (FS22-5)
When the fuse is blown, a ground fault may have probably occurred in the circuit.
1
Defective rear lamp switch 3 (International disconnection)
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. RWL (male) Between (2) and (3)
Possible causes and the standard values when normal
Disconnection of wiring harness (Disconnection in 4 wiring or defective contact in connector)
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between RWL (female) (2) and FS22-5 (outlet)
Resistance
Max. 1 z
Wiring harness between RWL (female) (3) and 226 (female) (1) or 243 (female) (1)
Resistance
Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har5 ness (Contact with ground circuit)
48
Between wiring harness (between FS22-5 (outlet) – RWL (female) (2)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between RWL (female) (3) – 226 (female) (1) and 243 (female) (1)) and ground
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
49
SEN01831-02
40 Troubleshooting
E-28 Troubleshooting for air conditioner system Troubleshooting procedure for air conditioner system a The control panel of the air conditioner constantly monitors the sensors and other devices in the system. When it detects any abnormality, "Self-diagnosis notice" is displayed by operating switches specially. a If you feel any abnormality in the air conditioner system, check the "Self-diagnosis notice" first according to the procedure for "Troubleshooting by self-diagnosis notice", and then; q If the "Self-diagnosis notice" is displayed, continue the "Troubleshooting by self-diagnosis notice". q If the "Self-diagnosis notice" is not displayed, carry out the "Troubleshooting by failure phenomenon". Troubleshooting by self-diagnosis notice a Check the "Self-diagnosis notice" on the control panel according to the following procedure. q
How to display "Self-diagnosis notice" 1) Turn the starting switch ON. 2) Press OFF switch (1) and check that anything is not displayed on display monitor (2). 3) Hold the UP switch ( ) and DOWN switch ( ) of temperature setting switch (3) simultaneously for 3 seconds or more. 4) Check the "Self-diagnosis notice" displayed on display monitor (2).
q
How to select "Self-diagnosis notice" If m u ltip le "Self-di a g n o s i s n o t i c e s " a r e recorded, press the UP switch ( ) or DOWN switch ( ) of temperature setting switch (3) to select another notice.
q
q
How to delete "Self-diagnosis notice" When reproducing the "Self-diagnosis notices" or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the "Self-diagnosis notices" are deleted. Finishing display of "Self-diagnosis notice" To finish display of the "Self-diagnosis notice", press OFF switch (1) or turn the starting switch OFF.
Self-diagnosis notice E-E11 E12 E13 E14 E15 E16 E18 E21 E22 E43 E44 E45 E51
50
Failure mode No failures Disconnection in recirculated air sensor Short circuit in recirculated air sensor Disconnection in fresh air sensor Short circuit in fresh air sensor Disconnection in coolant temperature sensor Short circuit in coolant temperature sensor Short circuit in daylight sensor Disconnection in air blow sensor Short circuit in air blow sensor Abnormality in air outlet damper Abnormality in air mix damper Abnormality in recirculated and fresh air damper Abnormal refrigerant pressure
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E11 Contents of trouble
SEN01831-02
Disconnection in recirculated air sensor
• Disconnection in the recirculated air sensor system is detected.
• Fixes the recirculated air temperature for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause Defective recirculated air 1 sensor (Internal disconnection) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Self-diagnosis notice
Symptom of failure
E12 Contents of trouble
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)
Resistance
Between (1) and (2)
300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (13) and THI (female) (2)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and THI (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
Short circuit in recirculated air sensor
• Disconnection in the recirculated air sensor system is detected.
• Fixes the recirculated air temperature for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause Defective recirculated air 1 sensor (Internal disconnection) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Defective air conditioner system
D475A, D475ASD-5E0
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)
Resistance
Between (1) and (2)
300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (13) and THI (female) (2)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and THI (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
51
SEN01831-02
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E13 Contents of trouble
Disconnection in fresh air sensor
• Disconnection in the fresh air sensor system is detected.
• Assumes that the fresh air sensor is not installed for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause
1
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Self-diagnosis notice
Defective air conditioner system
Symptom of failure
E14 Contents of trouble
Defective fresh air sensor (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACT (male)
Resistance
Between (1) and (2)
100 z – 210 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (10) and ACT (female) (1)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and ACT (female) (2)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
Short circuit in fresh air sensor
• Short circuit in the fresh air sensor system is detected.
• Assumes that the fresh air sensor is not installed for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause
1
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
52
Defective fresh air sensor (Internal disconnection)
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACT (male)
Resistance
Between (1) and (2)
100 z – 210 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (10) and ACT (female) (1)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and ACT (female) (2)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E15 Contents of trouble
SEN01831-02
Disconnection in coolant temperature sensor
• Disconnection in the coolant temperature sensor system is detected.
• Ignores the warm-up control and fixes the engine coolant temperature at 60°C for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause Defective coolant 1 temperature sensor (Internal disconnection) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Self-diagnosis notice
Symptom of failure
E16 Contents of trouble
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male)
Resistance
Between (1) and (2)
95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (11) and THW (female) (2)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and THW (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
Short circuit in coolant temperature sensor
• Short circuit in the coolant temperature sensor system is detected.
• Ignores the warm-up control and fixes the engine coolant temperature at 60°C for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause Defective coolant 1 temperature sensor (Internal short circuit) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Defective air conditioner system
D475A, D475ASD-5E0
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male)
Resistance
Between (1) and (2)
95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (11) and THW (female) (2)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and THW (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
53
SEN01831-02
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E18 Contents of trouble
Short circuit in daylight sensor
• Short circuit in the daylight sensor system is detected.
• Assumes that the daylight sensor is not installed for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause 1
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
54
Defective daylight sensor (Internal short circuit)
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting The daylight sensor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (9) and SLS (female) (2)
Resistance
Max. 1 z
Wiring harness between AP1 (female) (6) and SLS (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E21 Contents of trouble
SEN01831-02
Disconnection in air blow sensor
• Disconnection in the air blow sensor (frost sensor) system is detected.
• Fixes the evaporator temperature at 10°C for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause Defective air blow sensor 1 (frost sensor) (Internal disconnection) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Self-diagnosis notice
Symptom of failure
E22 Contents of trouble
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (male)
Resistance
Between (1) and (2)
100 z – 115 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (12) and THF (female) (2)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and THF (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
Short circuit in air blow sensor
• Short circuit in the air blow sensor (frost sensor) system is detected.
• Fixes the evaporator temperature at 10°C for control. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause Defective air blow sensor 1 (frost sensor) (Internal short circuit) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector)
3
Defective air conditioner system
D475A, D475ASD-5E0
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (male)
Resistance
Between (1) and (2)
100 z – 115 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (12) and THF (female) (2)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (20) and THF (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
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SEN01831-02
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E43 Contents of trouble
Abnormality in air outlet damper
• Abnormality in air outlet servomotor system or front air outlet servomotor system is detected.
• Stops the air outlet servomotor and front air outlet servomotor. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective air outlet The air outlet servomotor may be defective. Check it directly. servomotor (Internal defect)
2
Defective front air outlet The front air outlet servomotor may be defective. Check it directly. servomotor (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in 3 wiring harness or defective contact in connector) Possible causes and the standard values when normal
Resistance
Max. 1 z
Wiring harness between MV1 (female) (3) and AP1 (female) (6)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (5) and AP1 (female) (16)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (6) and AP2 (female) (2)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (7) and AP2 (female) (6)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in 4 wiring harness or defective contact in connector)
5
56
Wiring harness between MV1 (female) (1) and AP2 (female) (20)
Defective air conditioner system
Wiring harness between MV2 (female) (1) and AP1 (female) (6)
Resistance
Max. 1 z
Wiring harness between MV2 (female) (3) and AP2 (female) (20)
Resistance
Max. 1 z
Wiring harness between MV2 (female) (5) and AP1 (female) (15)
Resistance
Max. 1 z
Wiring harness between MV2 (female) (6) and AP2 (female) (1)
Resistance
Max. 1 z
Wiring harness between MV2 (female) (7) and AP2 (female) (11)
Resistance
Max. 1 z
If none of causes 1 – 4 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E44 Contents of trouble
SEN01831-02
Abnormality in air mix damper
• Abnormality in air mix servomotor system is detected.
• Stops the air mix servomotor. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause 1
Standard value in normal state/Remarks on troubleshooting
Defective air mix servomoThe air mix servomotor may be defective. Check it directly. tor (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)
3
Defective air conditioner system
D475A, D475ASD-5E0
Wiring harness between MAM (female) (1) and AP2 (female) (20)
Resistance
Max. 1 z
Wiring harness between MAM (female) (3) and AP1 (female) (6)
Resistance
Max. 1 z
Wiring harness between MAM (female) (5) and AP1 (female) (7)
Resistance
Max. 1 z
Wiring harness between MAM (female) (6) and AP2 (female) (7)
Resistance
Max. 1 z
Wiring harness between MAM (female) (7) and AP2 (female) (6)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
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40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E45 Contents of trouble
Abnormality in recirculated and fresh air damper
• Abnormality in recirculated and fresh air servomotor system is detected.
• Stops the recirculated and fresh air servomotor. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause
Standard value in normal state/Remarks on troubleshooting
Defective recirculated and 1 fresh air servomotor (Internal defect)
The recirculated and fresh air servomotor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)
3
58
Defective air conditioner system
Wiring harness between MRF (female) (1) and AP2 (female) (20)
Resistance
Max. 1 z
Wiring harness between MRF (female) (3) and AP1 (female) (6)
Resistance
Max. 1 z
Wiring harness between MRF (female) (5) and AP1 (female) (8)
Resistance
Max. 1 z
Wiring harness between MRF (female) (6) and AP2 (female) (4)
Resistance
Max. 1 z
Wiring harness between MRF (female) (7) and AP2 (female) (5)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis notice
Symptom of failure
E51 Contents of trouble
SEN01831-02
Abnormality in refrigerant pressure
• Abnormality in refrigerant pressure circuit is detected.
• Turns the compressor clutch OFF. Action of control • When the following condition is satisfied, the operation returns to normalcy. panel + + + General information Cause 1
Possible causes and the standard values when normal
Standard value in normal state/Remarks on troubleshooting
Defective high-low pressure The high-low pressure switch may be defective. Check it directly. switch (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in Wiring harness between AP1 (female) (5) 2 wiring harness or defective and SPHL (female) (2) contact in connector) Wiring harness between SPHL (female) (1) and chassis ground 3
Defective air conditioner system
D475A, D475ASD-5E0
Resistance
Max. 1 z
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
59
SEN01831-02
40 Troubleshooting
Circuit diagram related
60
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Troubleshooting by failure phenomenon Symptom of failure
• The air conditioner does not operate.
(1) The air conditioner does not operate at all.
General information Cause Defective circuit breaker 1 CB4
Standard value in normal state/Remarks on troubleshooting If the circuit breaker is turned OFF, the circuit probably has a grounding fault, etc. (Refer to cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between circuit breaker CB4 outlet and ACU (female) (4), (5)
Disconnection in wiring harness (Disconnection in Wiring harness between AP3 (male) (6) and 2 wiring harness or defective AP1 (female) (3) contact in connector) Wiring harness between AP2 (female) (19) and chassis ground
Wiring harness between AP5 (male) (7) and chassis ground
Possible causes and the standard values when normal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Between wiring harness between circuit breaker CB4 outlet and ACU (female) (4), (5) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between AP3 (male) (6) and AP1 (female) (3) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective air conditioner unit
ACU
Voltage
Between (4) and (8)
20 – 30 V
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective control panel
AP1, AP2
Voltage
Between AP1 (3) and AP2 (19)
20 – 30 V
If the above voltage is normal and the control panel does not operate, the control panel is defective.
D475A, D475ASD-5E0
61
SEN01831-02
Symptom of failure
40 Troubleshooting
• The air conditioner does not operate.
(2) Air does not come out (Air flow is insufficient).
General information Cause 1 Defective fuse (in unit)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blower main relay 2 Resistance (on coil side) RLBM (male) 300 – 440 z
Between (1) and (3)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective blower main relay (on contact side)
RLBM
Fan switch
Voltage
Between (4) and chassis ground
ON (Operated)
20 – 30 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective blower linear controller (Internal defect)
Fan switch Operate in range of Low, Medium, and High
If air flow can be changed with fan switch, blower linear controller is normal.
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
Defective blower motor (Internal defect)
Possible causes and the standard values when normal
Fan switch
Voltage
Between (1) and (2)
ON (Operated)
20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between circuit breaker CB4 outlet, ACU (4), AP3 (female) (6), and RLBM (female) (1)
Resistance
Max. 1 z
Wiring harness between circuit breaker CB4 outlet, ACU (5) and RLBM (female) (3)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (8), AP4 (10) and RLBM (female) (2)
Resistance
Max. 1 z
Disconnection in wiring Wiring harness between AP2 (female) (19) harness (Disconnection in and chassis ground 6 wiring harness or defective Wiring harness between BLC (female) (3) contact in connector) and RLBM (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between MB (female) (1) and RLBM (female) (4)
Resistance
Max. 1 z
Wiring harness between MB (female) (2) and BLC (female) (4)
Resistance
Max. 1 z
Wiring harness between BLC (female) (1), ACU (8), and chassis ground
Resistance
Max. 1 z
Wiring harness between AP1 (female) (1), AP3 (8), and BLC (female) (2)
Resistance
Max. 1 z
7
62
MB
Defective air conditioner system
If none of causes 1 – 6 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
D475A, D475ASD-5E0
40 Troubleshooting
Symptom of failure
SEN01831-02
• The air conditioner does not operate.
(3) Air is not cooled (Cooling capacity is low).
General information Cause 1 Defective fuse (in unit)
2
Defective compressor clutch relay (on coil side)
Defective compressor 3 clutch relay (on contact side)
Possible causes and the standard values when normal
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RLCC (male)
Resistance
Between (1) and (3)
140 – 340 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). RLCC
Fan switch
Voltage
Between (3) and chassis ground
ON (Operated)
20 – 30 V
4
Defective compressor clutch (Internal defect)
The compressor clutch may be defective. Check it directly.
5
Defective compressor (Internal defect)
The compressor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between circuit breaker CB4 outlet, ACU (4), AP3 (6), AP1 (female) (3) and RLCC (female) (1)
Resistance
Max. 1 z
Disconnection in wiring Wiring harness between circuit breaker CB4 harness (Disconnection in outlet, ACU (5) and RLCC (female) (4) 6 wiring harness or defective Wiring harness between AP2 (female) (9), contact in connector) AP4 (7) and RLCC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between AP2 (19) and chassis ground
Resistance
Max. 1 z
Wiring harness between RLCC (female) (3), ACU (10) and A/C (female) (1)
Resistance
Max. 1 z
7
Defective air conditioner system
D475A, D475ASD-5E0
If none of causes 1 – 6 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
63
SEN01831-02
40 Troubleshooting
Circuit diagram related
64
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) Symptom of failure
• The ORBCOMM terminal does not operate normally (Data are not transmitted).
General information
• Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine. Cause
Terminal power supply is 1 abnormal or satellite is not captured
Standard value in normal state/Remarks on troubleshooting At least 3 minutes after starting the VHMS, check the decimal point at the right bottom of the LED of the VHMS controller or the decimal point at the right bottom of the central part of the lower line of the multi-information display unit. * To check the decimal point on the multi-information display unit, turn the starting switch ON and select the "Real-time monitoring mode" or "Dual display monitoring mode" and input the ID = 20300. Lamp is OFF
Power is not applied to ORBCOMM terminal or the communication with VHMS controller is abnormal.
Lamp is ON
Power is applied to ORBCOMM terminal and the communication with VHMS controller is normal. But it does not capture satellite.
Power is applied to ORBCOMM terminal, capturing satelFlashing lite and the communication with VHMS controller is normal. Possible causes and the standard values when normal
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wir2 ing harness or defective contact in connector)
Between KOM1 (female) (36), (39), (40) and VF2 (male) (5)
Resistance
Max. 1 z
Between KOM1 (female) (37), (38) and chassis ground
Resistance
Max. 1 z
Between V4B (female) (3) and KOM1 (female) (11)
Resistance
Max. 1 z
Between V4B (female) (4) and KOM1 (female) (5)
Resistance
Max. 1 z
Between V4B (female) (10) and KOM1 (female) (4)
Resistance
Max. 1 z
Defective ORBCOMM tera Prepare with starting switch OFF, then carry out troubleshooting minal without turning starting switch ON. (When LED is turned OFF) 3 * Constant power supply is used. When disconnecting Between KOM1 (female) (36), (39), (40) and Voltage 20 – 30 V connector and carrying out KOM1 (female) (37), (38) troubleshooting, take care.
Decimal point position of VHMS controller
D475A, D475ASD-5E0
65
SEN01831-02
40 Troubleshooting
Decimal point position of multi-function monitor
Circuit diagram related
66
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-30 Fan does not reverse Symptom of failure
• When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse.
General information
• If any switched is operated during reverse prohibition period, orange lamp blinks. • Orange lamp lights up in cleaning mode and reverse mode. Cause Abnormality in fan reverse 1 solenoid Operation of fan cleaning 2 switch in reverse prohibition period Operation of fan reverse 3 switch (if equipped) in reverse prohibition period
Defective fan cleaning switch (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting If failure code [DW7BKA], [DW7BKB] or [DW7BKY] is displayed, carry out troubleshooting for it first. If switch is operated after engine is started, fan does not reverse and orange lamp blinks. At this time, orange lamp indicated that switch operation is ineffective but does not indicate trouble. Turn key switch OFF to stop engine and turn battery relay OFF, and then set fan in fan cleaning or fan reverse mode again. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAN1 (male) Between (1) and (2)
Switch
Resistance
OFF
Min. 1 Mz
CLN position
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective fan cleaning switch (if equipped) (Internal disconnection)
Possible causes and the standard values when normal
FAN2 (male)
Switch
Resistance
OFF
Min. 1 Mz
Between (1) and (3)
CLN position
Min. 1 Mz
REV position
Max. 1 z
OFF
Min. 1 Mz
Between (3) and (4)
[When standard cleaning switch is employed] Disconnection in wiring harness (Internal disconnection)
CLN position
Max. 1 z
REV position
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FAN1 (female) (1) and STCN1 (female) (10)
Resistance
Max. 1 z
Wiring harness between FAN1 (female) (2) and STCN2 (female) (38)
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 [When optional reverse switch is employed] Disconnection in wiring harness (Internal disconnection)
Wiring harness between FAN2 (female) (3) and STCN1 (female) (10)
Resistance
Max. 1 z
Wiring harness between FAN2 (female) (4) and STCN2 (female) (38)
Resistance
Max. 1 z
Wiring harness between FAN2 (female) (1) and STCN2 (female) (2)
Resistance
Max. 1 z
If causes 1 – 5 are not detected, steering controller may be defec6 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried out.)
D475A, D475ASD-5E0
67
SEN01831-02
40 Troubleshooting
Circuit diagram related
68
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-31 Gear cannot be shifted Symptom of failure
• Gear cannot be shifted (Shift switch does not work).
General information Cause
Possible causes and the standard values when normal
Trouble in shift operation switch • Shift-up switch 1 • Shift-down switch • Shift switch (Optional-type lever)
2 Gear speed limit
3
Defect in transmission clutch
D475A, D475ASD-5E0
Standard value in normal state/Remarks on troubleshooting a When failure code related to shift operation switch is not displayed. Press shift operation switch for more than 10 seconds. If any of following failure code is displayed at this time, carry out troubleshooting for it. [DD12KA], [DD12KB], [DD13KA], [DD13KB], [DD5KA], [DD5KB] a When failure code related to shift operation switch is displayed. Carry out troubleshooting for displayed failure code. If failure code of action code E03 or E04 is displayed, gear speed limit is applied. In this case, carry out troubleshooting for that failure code first. Transmission clutch may have defect in it. Check it directly.
69
SEN01831-02
40 Troubleshooting
E-32 Electric priming pump does not operate or does not stop automatically Symptom of failure
• Electric priming pump does not operate or does not stop automatically.
General information Cause 1 Low battery charge level 2
Defective circuit breaker CB8
Standard value in normal state/Remarks on troubleshooting Battery charge level may be low. Check battery directly. If circuit breaker CB8 is turned OFF, circuit probably has ground fault. (Check cause No. 5)
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it harness and carry out troubleshooting (since power supply is unswitched). (Power supply system) 3 (Disconnection in wiring or defective contact in Between EPP (1) – (2) Voltage 20 – 30 V connector) a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting.
Disconnection in wiring • Lamp blinks but stops in about 5 seconds. harness (Drive power supply system) Between EFPL (1) – (2), EFPR (1) – (2) Voltage 20 – 30 V 4 (Disconnection in wiring or a Prepare with battery ground cable disconnected, then carry out defective contact in troubleshooting without reconnecting (since power supply is connector) unswitched). Resistance
Between EPP (female) (2) – ground
Max. 1 z
a Prepare with battery ground cable disconnected, then carry out troubleshooting without reconnecting (since power supply is unswitched).
Possible causes and the standard values when normal Ground fault in wiring harness 5 (Contact with ground circuit)
Wiring harness between EPP (female) (1) – circuit breaker B8S and ground
Resistance
Min. 1 Mz
Wiring harness between EPP (female) (3) – EFPL (female) (1) and ground
Resistance
Min. 1 Mz
Wiring harness between EPP (female) (4) – EFPL (female) (2) and ground
Resistance
Min. 1 Mz
Wiring harness between EPP (female) (5) – EFPR (female) (1) and ground
Resistance
Min. 1 Mz
Wiring harness between EPP (female) (6) – EFPR (female) (2) and ground
Resistance
Min. 1 Mz
a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting. Defective electric priming pump switch 6 (Malfunction or automatic stop failure)
Between EPP (3) – (4) and (5) – (6)
Voltage
20 – 30 V
• Lamp blinks but output voltage is improper. • Results of troubleshooting steps 1 – 4 are normal and lamp does not blink. a When electric priming pump does not stop automatically, electric priming pump switch may be defective. (Turn toggle switch OFF to stop pump and then replace switch.)
7
70
• Lamp blinks but stops in about 5 seconds. Overload on electric priming a If pump is overloaded, power supply is turned OFF automatically pump to protect circuit (Priming switch is reset automatically).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with battery ground cable disconnected, then carry out troubleshooting without reconnecting (since power supply is unswitched).
Possible causes and the standard values when normal
Trouble in electric priming 8 pump
Between EFPL (male) (1) – (2)
Resistance
1–3z
Between EFPL (male) (1) – pump body
Resistance
Min. 1 Mz
Between EFPL (male) (2) – pump body
Resistance
Min. 1 Mz
Between EFPR (male) (1) – (2)
Resistance
1–3z
Between EFPR (male) (1) – pump body
Resistance
Min. 1 Mz
Between EFPR (male) (2) – pump body
Resistance
Min. 1 Mz
Circuit diagram related
D475A, D475ASD-5E0
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SEN01831-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN01831-02
© 2008 KOMATSU All Rights Reserved Printed in Japan 06-08 (01)
72
SEN01832-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table ................................................................................................................ 3 H-1 No force (no drawbar pull)........................................................................................................................ 4 H-2 No travel (at 2nd or 3rd speed) ................................................................................................................ 6 H-3 No travel at all gear speeds ..................................................................................................................... 7 H-4 Machine travels only in one direction forward or in reverse ..................................................................... 8 H-5 Large time lag at gear speed shifting or forward-reverse shifting ............................................................ 9 H-6 Steering is not possible .......................................................................................................................... 10 H-7 Steering is possible only on one side ......................................................................................................11 H-8 Steering overrun occurs ......................................................................................................................... 12 H-9 Brake does not work .............................................................................................................................. 13 H-10 Torque converter is not lock-up ............................................................................................................ 14 H-11 Power train oil is overheated ................................................................................................................ 15 H-12 All work equipment speeds are slow.................................................................................................... 16 H-13 Work equipment does not move .......................................................................................................... 17
D475A, D475ASD-5E0
1
SEN01832-02
40 Troubleshooting
H-14 Blade lift speed is slow or lacks power ................................................................................................. 18 H-15 Blade tilt speed is slow or lacks power................................................................................................. 19 H-16 Ripper lift speed is slow or lacks power ............................................................................................... 20 H-17 Ripper tilt speed is slow or lacks power ............................................................................................... 21 H-18 Excessive hydraulic drift of blade lift .................................................................................................... 22 H-19 Excessive hydraulic drift of blade tilt .................................................................................................... 23 H-20 Excessive hydraulic drift of ripper lift .................................................................................................... 24 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine)........................................ 24 H-22 Blade pitch does not work (dual tilt attachment machine) .................................................................... 25 H-23 Abnormal sound comes out from around work equipment pump......................................................... 25 H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats) . 26 H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator) 27
2
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
Information in troubleshooting table a
1
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information
Trouble in machine Information related to detected trouble or troubleshooting Cause
Standard value in normal state/Remarks on troubleshooting
1
Possible causes and standard value in normal state
2
3
Possible causes of trouble (Given numbers are refer• Standard value in normal state to judge possible causes ence numbers, which do not • Remarks on judgment indicate priority)
4
D475A, D475ASD-5E0
3
SEN01832-02
40 Troubleshooting
H-1 No force (no drawbar pull) Symptom of failure General information
Possible causes and the standard values when normal
1
• No force (No drawbar pull) • Before troubleshooting, check that the power train oil level is normal. Causes Standard values when normal and remarks for troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). Internal defect of torque Torque converter Torque converter 2 PCCS lever converter inlet pressure outlet pressure 0.8 – 1.0 MPa 0.39 – 0.64 MPa Full neutral {8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high Incorrect pressure set to idle mode for troubleshooting. 3 transmission main relief PCCS lever Transmission main relief pressure valve Full neutral 2.55 – 3.04 MPa {26.0 – 31.0 kg/cm2} a Prepare with starting switch OFF, then carry out troubleshooting Defective operation of without turning starting switch ON. 4 transmission main relief Check it directly that the spring free length (120.3 mm) is normal valve and that the spool moves smoothly. a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 5 transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 1ST
1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Measuring conditions Engine speed Internal defect of transmis6 sion F3 stall Min. 1,590 rpm F3 stall + Work equipment relief Min. 1,450 rpm (pitch back) a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (drag7 Drive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) 3RD
4
D475A, D475ASD-5E0
40 Troubleshooting
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Causes
Possible causes and the standard values when normal
8 Defective steering clutch
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {0 kg/cm2} {Min. 25 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of “Steering is not possible.”
5
SEN01832-02
40 Troubleshooting
H-2 No travel (at 2nd or 3rd speed) Symptom of failure General information
1
• No travel (at 2nd or 3rd speed) • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
1
Internal defect of torque converter
2
Defective operation of transmission valve (ECMV)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Torque converter Torque converter PCCS lever inlet pressure outlet pressure 0.8 – 1.0 MPa 0.39 – 0.64 MPa Full neutral {8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2} a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting. Transmission clutch Clutch pressure 2ND
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supsion clutch posed to be defective. Check it directly. Defective operation (dragDefective operation (dragging) is supposed, check linkage valves. ging) of parking brake a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (dragDrive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end Min. 2.45 MPa 0 MPa Left clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure Defective steering clutch, {Min. 25 kg/cm2} {0 kg/cm2} brake 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {0 kg/cm2} {Min. 25 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of “Steering is not possible.” 3RD
3 Possible causes and the standard values when normal
4
5
6
6
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-3 No travel at all gear speeds Symptom of failure General information
1
• No travel at all gear speeds • Before troubleshooting, check that the power train oil level is normal. Causes Standard values when normal and remarks for troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Incorrect pressure set to Transmission main relief PCCS lever 2 transmission main relief pressure valve 2.55 – 3.04 MPa Full neutral {26.0 – 31.0 kg/cm2} a Prepare with starting switch OFF, then carry out troubleshooting Defective operation of without turning starting switch ON. 3 transmission main relief Check it directly that the spring free length (120.3 mm) is normal valve and that the spool moves smoothly. a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 4 transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 1ST
1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is sup5 sion clutch posed to be defective. Check it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). Defective operation of 6 Brake pedal Brake oil pressure (right and left) brake 3RD
Possible causes and the standard values when normal
Release
Min. 2.45 MPa {Min. 25 kg/cm2}
0 MPa {0 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure 2 } {0 kg/cm2} {Min. 25 kg/cm Defective seal of steering 7 0 MPa Min. 2.45 MPa clutch Right clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right brake pressure {Min. 25 kg/cm2} {0 kg/cm2} Internal defect of steering The inside of the steering clutch is supposed to be defective, check 8 clutch it directly. Perform troubleshooting for failure codes [DDQ2KA], [DDQ2KB], Defective operation of park- [DDQ2L4] and [dDQ2L4]. 9 ing brake lever switch Even if the failure code does not appear, confirm that the switch input is changed properly. Step on
D475A, D475ASD-5E0
7
SEN01832-02
40 Troubleshooting
H-4 Machine travels only in one direction forward or in reverse Symptom of failure General information
Possible causes and the standard values when normal
1
• Machine travels only in one direction Forward or in Reverse. • Before troubleshooting, check that the power train oil level is normal. Causes Standard values when normal and remarks for troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Incorrect pressure set to PCCS lever Transmission main relief pressure 2 transmission main relief Full neutral 2.55 – 3.04 MPa {26.0 – 31.0 kg/cm2} valve When the oil pressure is abnormal, clean the valve and then check the oil pressure again. a Prepare with starting switch OFF, then carry out troubleshooting Defective operation of without turning starting switch ON. 3 transmission main relief Check it directly that the spring free length (120.3 mm) is normal valve and that the spool moves smoothly. a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 4 transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 1ST
1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to sion clutch be defective. Check it directly. Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, sion clutch check it directly. a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (dragDrive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) Defective operation of forward-reverse potentiome- Perform troubleshooting related to forward-reverse potentiometer. ter of travel lever 3RD
5 6
7
8
8
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-5 Large time lag at gear speed shifting or forward-reverse shifting Symptom of failure General information
Possible causes and the standard values when normal
1
• Large time lag at gear speed shifting or forward-reverse shifting • Before troubleshooting, check that the power train oil level is normal. Causes Standard values when normal and remarks for troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective operation of PCCS lever Transmission main relief pressure 2 transmission main relief Full neutral 2.55 – 3.04 MPa {26.0 – 31.0 kg/cm2} valve When the oil pressure is abnormal, clean the valve and then check the oil pressure again. a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). Transmission clutch Clutch pressure Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 3 transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} 1ST
1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2} Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to 4 sion clutch be defective. Check it directly. Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, 5 sion clutch check it directly. a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (drag6 Drive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) 3RD
D475A, D475ASD-5E0
9
SEN01832-02
40 Troubleshooting
H-6 Steering is not possible Symptom of failure General information
• Steering is not possible. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
1
Possible causes and the standard values when normal
Defective operation of brake
Defective operation of 2 steering clutch valve (ECMV)
Defective seal of steering clutch Internal defect of steering 4 clutch Defective operation of 5 steering potentiometer of travel lever
3
10
1
Standard values when normal and remarks for troubleshooting Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting. 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.”) a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure 2 {0 kg/cm } {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {Min. 25 kg/cm2} {0 kg/cm2} When the cause 2 is not applicable, the clutch seal is supposed to be defective. Check it directly. The inside of the steering clutch is supposed to be defective, check it directly. Perform the troubleshooting related to steering potentiometer.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-7 Steering is possible only on one side Symptom of failure General information
• Steering is possible only on one side. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
Possible causes and the standard values when normal
1
Defective operation of 1 steering clutch valve (ECMV)
Defective seal of steering clutch Internal defect of steering 3 clutch Defective operation of 4 steering potentiometer of travel lever
2
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {0 kg/cm2} {Min. 25 kg/cm2} When the cause 1 is not applicable, the clutch seal is supposed to be defective. Check it directly. The inside of the steering clutch is supposed to be defective, check it directly. Perform the troubleshooting related to steering potentiometer.
11
SEN01832-02
40 Troubleshooting
H-8 Steering overrun occurs Symptom of failure General information
• Steering overrun occurs. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
Possible causes and the standard values when normal
12
1
1
Defective operation of brake
2
Defective operation of steering clutch
Standard values when normal and remarks for troubleshooting a Prepare with starting the engine, then drive the engine in low idle mode for troubleshooting. 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.”) When the track shoe does not stop in the troubleshooting of the cause 1, the steering clutch is defective. (Execute the troubleshooting of “Steering is not possible.”)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-9 Brake does not work Symptom of failure General information
• Brake does not work. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes 1 Degradation of brake
2
Possible causes and the standard values when normal
1
Defective operation of brake pedal
Defective operation of 3 steering brake valve (ECMV)
4 Defective brake seal 5 Internal defect of brake
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting a Start the engine for troubleshooting. Step on the brake pedal, shift the gear to F2 and drive the engine in high idle mode. When the machine moves, the brake performance is degraded. The brake pedal and the brake valve are supposed not to work normally. Check them directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end Min. 2.45 MPa 0 MPa Left clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.45 MPa Right clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right brake pressure {Min. 25 kg/cm2} {0 kg/cm2} When the brake seal is not normal in the troubleshooting of the cause 3, the brake seal is supposed to be defective. Check it directly. The inside of the brake is supposed to be defective. Check it directly.
13
SEN01832-02
40 Troubleshooting
H-10 Torque converter is not lock-up Symptom of failure General information
Possible causes and the standard values when normal
14
1
• The torque converter is not lock-up. • Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes Standard values when normal and remarks for troubleshooting 1 Defective power train pump The power train pump is supposed to be defective. Check it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective operation of Torque converter Clutch pressure 2 torque converter lock-up valve Min. 1.13 – 1.42 MPa At lock-up time {Min. 11.5 – 14.5 kg/cm2} Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up 3 clutch clutch seal is supposed to be defective. Check it directly. Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check 4 clutch it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Measuring conditions Engine speed Internal defect of torque 5 converter F3 stall Min. 1,590 rpm F3 stall + Work equipment relief Min. 1,450 rpm (pitch back)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-11 Power train oil is overheated
1
Symptom of failure
• The power train oil is overheated.
General information
• Before troubleshooting, check that the power train oil level is normal. • Before troubleshooting, check that the indication of the power train oil temperature gauge agrees with actual temperature of the power train oil. (When the indication does not agree with actual temperature, execute the troubleshooting of “The indication of power train oil temperature gauge is abnormal.”) • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
1 2
Possible causes and the standard values when normal
3
4
5
6
Standard values when normal and remarks for troubleshooting Engine output is supposed to have increased abnormally. TroubleRise of engine output shoot referring to the shop manual for engine. Defective power train pump The power train pump is supposed to be defective, or air is supor air entry in suction circuit posed to have entered from the suction circuit. Check them directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Torque converter Torque converter Internal defect of torque PCCS lever inlet pressure outlet pressure converter 0.39 – 0.64 MPa 0.8 – 1.0 MPa Full neutral {4.0 – 6.5 kg/cm2} {8.0 – 10.0 kg/cm2} Defective operation (slide) The inside of the transmission clutch is supposed to be defective of transmission clutch (the clutch slides). Check it directly. a Start the engine for troubleshooting. Defective operation (drag- Drive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of “Brake does not work.”) Defective operation (slide) The inside of the steering clutch is supposed to be defective (the of steering clutch clutch slides). Check it directly.
D475A, D475ASD-5E0
15
SEN01832-02
40 Troubleshooting
H-12 All work equipment speeds are slow Symptom of failure General information
• All work equipment speeds are slow. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Causes Defective PTO (pump drive 1 unit of work equipment) Defective work equipment 2 pump
3
Possible causes and the standard values when normal
Defective unload valve function
Defective set pressure or 4 defective function of main relief valve
Defective function of self5 pressure reducing valve (PPC original pressure)
6
16
1
Internally defective PPC valve
Standard values when normal and remarks for troubleshooting The PTO pump drive unit of the work equipment is assumed to be defective; directly check it. The pump of the work equipment is assumed to be defective; directly check it. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Unload pressure 2.94 – 4.9 MPa Full neutral {30 – 50 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Main relief pressure 27.4 ± 1.4 MPa Stroke end (Except blade cylinder) {280 ± 14 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Original pressure of control cirWork equipment lever cuit Min. 3.72 MPa Full neutral {Min. 38 kg/cm2} When the troubleshooting in cause 5 is abnormal, the PPC valve is assumed to be defective internally; directly check it.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-13 Work equipment does not move Symptom of failure General information
• Work equipment does not move. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Causes Defective PTO (Pump drive 1 unit of work equipment) Defective work equipment 2 pump
3
Possible causes and the standard values when normal
1
Defective unload valve function
Defective set pressure or 4 defective function of main relief valve
Defective function of self5 pressure reducing valve (PPC original pressure)
Defective function of work 6 equipment lock lever and PPC lock valve
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting The PTO pump drive unit of the work equipment is assumed to be defective; directly check it. The work equipment pump is assumed to be defective; directly check it. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Unload pressure 2.94 – 4.9 MPa Full neutral {30 – 50 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Main relief pressure 27.4 ± 1.4 MPa Stroke end {280 ± 14 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Original pressure of control cirWork equipment lever cuit Min. 3.72 MPa Full neutral {Min. 38 kg/cm2} Check that the PPC lock valve works properly when the work equipment lock lever is moved up and down.
17
SEN01832-02
40 Troubleshooting
H-14 Blade lift speed is slow or lacks power
1
Symptom of failure
• Blade lift speed is slow or lacks power.
General information
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. • Confirm whether the blade is remodeled. • When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting “High Hydraulic Drift Rate of Blade Lift.” Causes
Possible causes and the standard values when normal
18
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcBlade lever PPC valve output pressure 1 tion Min. 3.72 MPa Lift stroke end {Min. 38 kg/cm2} Defective function of blade The spool function of the blade lift control valve is assumed to be 2 lift control valve (Spool) defective; directly check it. The blade lift cylinder is assumed to be aired; carry out the air bleed 3 Aired blade lift cylinder and observe how the phenomenon changes.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-15 Blade tilt speed is slow or lacks power
1
Symptom of failure
• Blade tilt speed is slow or lacks power.
General information
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. • Confirm whether the blade is remodeled. • When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting “High Hydraulic Drift Rate of Blade Tilt.” Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcBlade lever PPC valve output pressure 1 tion Min. 3.72 MPa Lift stroke end {Min. 38 kg/cm2} Defective function of blade The spool function of the blade tilt control valve is assumed to be 2 tilt control valve (Spool) defective; directly check it. The blade tilt cylinder is assumed to be aired; carry out the air bleed 3 Aired blade tilt cylinder and observe how the phenomenon changes.
D475A, D475ASD-5E0
19
SEN01832-02
40 Troubleshooting
H-16 Ripper lift speed is slow or lacks power
1
Symptom of failure
• Ripper lift speed is slow or lacks power.
General information
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. • Confirm whether the ripper is remodeled. • When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting “High Hydraulic Drift Rate of Ripper Lift.” Causes
1 Possible causes and the standard values when normal
2 3 4
20
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcRipper lever PPC valve output pressure tion Min. 3.72 MPa Lift stroke end {Min. 38 kg/cm2} Defective function of ripper The spool function of the ripper lift control valve is assumed to be lift control valve (Spool) defective; directly check it. Defective function of ripper The function of the suction valve of the ripper lift control valve is lift control valve (suction assumed to be defective, directly check it. valve) The ripper lift cylinder is assumed to be aired; carry out the air bleed Aired ripper lift cylinder and observe how the phenomenon changes.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-17 Ripper tilt speed is slow or lacks power Symptom of failure General information
1
• Ripper tile speed is slow or lacks power. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. • Confirm whether the ripper is remodeled. Causes
Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcRipper lever PPC valve output pressure 1 tion Min. 3.72 MPa Tilt stroke end {Min. 38 kg/cm2} Defective function of ripper The spool function of the ripper tilt control valve is assumed to be 2 tilt control valve (Spool) defective; directly check it. The ripper tilt cylinder is assumed to be aired; carry out the air bleed 3 Aired ripper tilt cylinder and observe how the phenomenon changes.
D475A, D475ASD-5E0
21
SEN01832-02
40 Troubleshooting
H-18 Excessive hydraulic drift of blade lift Symptom of failure General 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. Causes
Possible causes and the standard values when normal
22
1
1
Defective seal of blade lift control valve (Spool)
2
Defective seal of blade lift cylinder
Standard values when normal and remarks for 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 control 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 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, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-19 Excessive hydraulic drift of blade tilt Symptom of failure General 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. Causes
Possible causes and the standard values when normal
1
1
Defective seal of blade tilt control valve (Spool)
2
Defective seal of blade tilt cylinder
D475A, D475ASD-5E0
Standard values when normal and remarks for troubleshooting a 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 control 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 lock lever. 3) Set the blade lever to the right tilt side, and confirm how the phenomenon changes. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Blade tilt cylinder Cylinder leak quantity Right tilt stroke end 20 cc/min
23
SEN01832-02
40 Troubleshooting
H-20 Excessive hydraulic drift of ripper lift Symptom of failure General 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. Causes
Possible causes and the standard values when normal
1
1
Defective seal of ripper lift control valve (Spool)
2
Defective seal of ripper lift cylinder
Standard values when normal and remarks for troubleshooting a 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 control 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 lock lever. 3) Set the blade lever to the lift lowering side, and confirm how the phenomenon changes. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Ripper lift cylinder Cylinder leak quantity Lowering stroke end 20 cc/min
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) 1 Symptom of failure General information
• The ripper pin puller cylinder does not work. • Confirm that the main relief pressure for transmission is normal before troubleshooting. Causes
Possible causes and the standard values when normal
24
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Measurement Pin puller working Defective function of pin Pin puller switch 1 position pressure puller solenoid Push-in Cylinder bottom side Min. 2.55 MPa {Min. 26 kg/cm2} Pull-in Cylinder head side Internally defective pin The pin puller cylinder is assumed to be defective internally; directly 2 puller cylinder check it. Check that the fuse is not melted. Defective fuse FS2-2 (20A) 3 If melted, the short circuit is probably assumed, check the harness for pin puller of the related circuit.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-22 Blade pitch does not work (dual tilt attachment machine) Symptom of failure General information
Possible causes and the standard values when normal
1
• The blade pitch does not work.
Causes Defective function of blade 1 pitch selection solenoid valve Defective function of blade 2 pitch control valve (Spool) Defective function of blade 3 pitch cylinder
Standard values when normal and remarks for troubleshooting The spool of the blade pitch operation valve is assumed to be defective; directly check it.
The function of the blade pitch cylinder is assumed to be defective; directly check it. The function of the blade pitch selection solenoid valve is assumed to be defective; directly check it. Perform the troubleshooting related to the blade pitch. Defective function of blade 4 Even if the failure code does not appear, confirm that the switch pitch switch input is changed properly.
H-23 Abnormal sound comes out from around work equipment pump 1 Symptom of failure General information
Possible causes and the standard values when normal
• Abnormal noise from around work equipment pump. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Causes 1 Inappropriate oil Clogged hydraulic oil tank 2 strainer
Standard values when normal and remarks for 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 3 Air inhaled in suction circuit machine pump; directly check the pipes. Internally defective work The work equipment pump is assumed to be defective internally; 4 equipment pump directly check it.
D475A, D475ASD-5E0
25
SEN01832-02
40 Troubleshooting
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats) Symptom of failure General information
• Fan rotation is normal (Sound/Vibration of fan is abnormally large or engine overheats). • Before carring out troubleshooting, check that oil level in hydraulic tank is normal. Causes
1 Defective engine rotation
2
Defective PTO (fan pump drive)
Possible causes and the standard values when normal
3
Defect in fan pump or fan motor
4 Defective fan
26
1
Standard values when normal and remarks for troubleshooting a Start engine and carry out troubleshooting. Measurement conditions Engine speed Engine low idle 650 rpm Engine high idle 2,150 rpm If engine speed is low, carry out troubleshooting for the engine troubleshooting “S-5 Rotation is irregular”. Fan pump drive of PTO may be defective. Check it directly. a Prepare with starting switch OFF, then run engine at high idle and carry out troubleshooting. Fan pump EPC circuit basic Measurement conditions pressure 3.72 MPa — {38 kg/cm2} a Prepare with starting switch OFF, then run engine at high idle and carry out troubleshooting. Measurement conditions Fan drive circuit pressure 15.2 ± 2.5 MPa Fan 100% mode {155 ± 25 kg/cm2} a Prepare with starting switch OFF, then run engine at high idle and carry out troubleshooting. Measurement conditions Defective fan Fan 100% mode 880 rpm Fan may be broken or installed defectively. Check it directly.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator) Symptom of failure General information
Possible causes and the standard values when normal
1
• Operator's seat isolator quakes abnormally. • When operator's seat isolator quakes largely, it makes shocks. — Causes Standard values when normal and remarks for troubleshooting Breakage of laminated rub- The laminated rubber may be broken. Perform Testing and adjust1 ber ing, "Breakage of rubber". The damper may malfunction. Perform Testing and adjusting, "Oil 2 Malfunction of damper leakage from damper". The stopper rubber may be broken. Perform Testing and adjusting, 3 Breakage of stopper rubber "Breakage of stopper rubber".
D475A, D475ASD-5E0
27
SEN01832-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN01832-02
© 2011 KOMATSU All Rights Reserved Printed in Japan 06-11
28
SEN01833-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
40 Troubleshooting
1
Troubleshooting of engine (S-mode) Method of using troubleshooting chart............................................................................................................ 3 S-1 Starting performance is poor .................................................................................................................... 6 S-2 Engine does not start ............................................................................................................................... 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10 S-4 Engine stops during operations ...............................................................................................................11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power) ..................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16 S-9 Oil becomes contaminated quickly ......................................................................................................... 17 S-10 Fuel consumption is excessive............................................................................................................. 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19 S-12 Oil pressure drops ................................................................................................................................ 20 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22 S-15 Abnormal noise is made....................................................................................................................... 23
D475A, D475ASD-5E0
1
SEN01833-01
40 Troubleshooting
S-16 Vibration is excessive ........................................................................................................................... 24
2
D475A, D475ASD-5E0
40 Troubleshooting
Method of using troubleshooting chart
SEN01833-01
1
The troubleshooting chart consists of “questions”, “check items”, “causes”, and “troubleshooting” blocks. The “questions” and “check items” narrow down the causes to highly probable “causes” by simple inspection or from symptoms without using a diagnostic tool. Then, the final verifications of “causes” are carried out by checking the narrowed down “causes” in the order of their probability with diagnostic tools or by direct inspection following the “troubleshooting” procedure. Questions: Information to be obtained by questioning the user or operator, and which corresponds to the sections A and B in the right chart. Section A includes basic information, and section B contains items which can be obtained depending on the level of the user or operator. Check items: Items checked by the serviceman in order to narrow down the causes, section C of the right chart is corresponding to them. Causes: Items to be narrowed down by the questions and check items. The serviceman narrows down the causes to highly probable causes according to the information from A, B and C. Troubleshooting: Items to be verified at the end in order to check if the narrowed down causes are the true factors causing the failure. The verification is carried out by applying diagnostic tools or implementing direct inspection in the order of probability.
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to their closer relationship with the causes. E : A cause that can be referred to in relation to the question or check item. Q : A cause that is related the question or check item. w : A cause particularly probable among those marked with Q above. a Count the priority level of each marking as w > Q when determining the cause. Don't count E when determining the cause. The item with this marking may be counted, however, if no difference is present than this and the cause cannot be determined.
D475A, D475ASD-5E0
3
SEN01833-01
40 Troubleshooting
Exhaust smoke is black Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].
4
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
If we look for the linkage of these three phenomena to possible causes, we find that they have causal relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
D475A, D475ASD-5E0
5
SEN01833-01
40 Troubleshooting
S-1 Starting performance is poor
1
Q Q
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter element
E E
Q w w
E w
Q Q Q Q w
w w Q Q w w w w
w w w E w Q Q w w w Q
w w
Q Q Q Q Q w
Q Q Q
w
q q q q q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
q Clean
Replace
Correct
Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of the failure code for "No-pressure feed by supply pump (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes engine at low idle? None When specific gravity of electrolyte and voltage of battery are measured, they are low Remedy
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring and cylinder
E
Correct
Confirm recent repair history Degree of Operated for long period machine operation Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) During operation, charge level monitor indicates abnormal charge (if monitor is installed) Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly Fuel does not flow out if air bleeding plug of fuel filter is While engine is removed cranked with startIf spill hose from injector is disconnected, ing motor, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive
Defective contact of valve and valve seat
Clogged air cleaner element
Causes
Clean
Troubleshooting
Check items
Questions
General causes for poor starting performance are q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel (particularly during winter) q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-2 Engine does not start
1
a) Engine does not turn General causes why engine does not turn q Engine seized inside o See "S-4 Engine stops during operations". q Water hammer caused by coolant which entered cylinder q Defective electrical system q Malfunction of hydraulic pump
Defective starting motor (motor section)
Defective steering circuit wiring
Defective starting motor (safety relay section)
Defective starting switch
Defective connection of battery terminal
Defective battery relay
Q
w w w Q Q w
w Q w w Q
Q
q q
When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 - 30 V) between battery relay terminal B and terminal E When terminal B and terminal C of starting switch are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine does not start
q
Replace
Replace
Replace
Replace
q
Correct
Remedy
q
—
w
Replace
Troubleshooting
Defective or deteriorated battery
Q
Inspect flywheel ring gear directly
D475A, D475ASD-5E0
q
E E
Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is Makes grating noise turned to START, starting Soon disengages pinion moves out, but Makes rattling noise and does not turn
Turn starting switch OFF, connect cord, turn the switch ON and carry out troubleshooting
Carry out troubleshooting in E-mode
Confirm recent repair history Degree of machine operaOperated for long period tion Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON
Replace
Check items
Questions
Broken flywheel ring gear
Causes
7
SEN01833-01
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)
Defective injector
Defective operation of flow damper
Defective operation of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Stuck or seized supply pump plunger
Broken supply pump shaft spline
Seized, abnormally worn feed pump
E w Q w w w w E
E
Q Q
Q Q
E E Q
Q w Q w w w w
Q
q
When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" Carry out troubleshooting of failure code for "Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3)" Inspect overflow valve directly Engine can be started in reduced cylinder mode
q q q q q
q q q Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Clean
Replace
Correct
Correct
q q Add
Remedy
Clogged feed pump gauze filter
Clogged fuel filter element
Leaking, clogging and entry of air to fuel piping
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Confirm recent repair history Degree of Operated for long period E E machine operation Exhaust smoke suddenly stopped coming out (when starting again) Non-specified fuel is being used w Replacement of filters not carried out according to Operation and Maintenance w Manual When fuel tank is inspected, it is found to be empty w Air breather hole of fuel tank cap is clogged Q w Rust and water are found when fuel tank is drained Q When fuel filter is removed, there is no fuel in it w Q w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q If air bleeding plug of fuel filter is removed, fuel does not flow While engine is Q Q Q out cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q
Replace
Troubleshooting
Check items
Questions
Use of improper fuel
Causes
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA271], [CB271] and failure code [CA272], [CB272] *3: Failure code [CA273], [CB273] and failure code [CA274], [CB274]
8
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel
Defective intake air heater system
Defective coolant temperature sensor and/or wiring harness
Defective or deteriorated battery
Clogged injector and/or defective spray
Stuck and/or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter and/or strainer
Leaking, clogging of fuel system, and entry of air
Clogged air breather hole of fuel tank cap
Use of improper fuel
Worn piston ring and/or cylinder liner
Worn dynamic valve system (Valve, rocker lever, etc.)
Confirm recent repair history Degree of machine Operated for long period E E E E operation Suddenly failed to start w w Q Non-specified fuel is being used Q Q Q Q Replacement of filters not carried out according to Operation and Maintenance w w w Manual Engine oil replenished more frequently w When engine is preheated or when temperature is low, preheating monitor does not w indicate normally (if monitor is installed) Dust indicator is red (if indicator is installed) w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w w When fuel filter is removed, there is no fuel in it w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q Starting motor cranks engine slowly w When engine is cranked, abnormal sound is generated around cylinder head w Fuel does not flow out if air bleeding plug of fuel filter is While engine is Q Q w w removed cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q Q w When exhaust manifold is touched immediately after starting engine, temperature of w some cylinders is low
q q q q q q q
Replace
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
q Replace
Replace
Remedy
Replace
Inspect air cleaner directly q Inspect dynamic valve system directly q When compression pressure is measured, it is found to be low q When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Clean
Troubleshooting
Check items
Questions
Clogged air cleaner element
Causes
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
D475A, D475ASD-5E0
9
SEN01833-01
40 Troubleshooting
S-3 Engine does not pick up smoothly
1
General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
E w
Clogged injector and/or defective spray
Defective operation of flow damper (Maximum leakage from injector)
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter and/or strainer
E E Q Q
Q w
w w w w w
w w w w
w w w w Q Q Q
w
w w Q
w
w
w w Q Q
w w Q w
Q
w
q q q
Correct
Replace
Replace
Clean
Clean
q q Clean
Replace
Replace
Adjusting
Replace
Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Remedy
Leaking, clogging of or entry of air to fuel piping
Clogged air breather hole of fuel tank cap
Worn piston ring and/or cylinder liner
Seized turbocharger or interference of turbocharger
Improper valve clearance
Defective contact of valve and valve seat
E E
Correct
Confirm recent repair history Degree of machine operation Operated for long period Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blue under light load Color of exhaust gas is Black When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, interference sound is emitted from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive
Clean
Troubleshooting
Check items
Questions
Clogged air cleaner element
Causes
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-4 Engine stops during operations
1
General causes why engine stops during operations q Seized parts inside engine q Insufficient supply of fuel q There is overheating q Malfunction of hydraulic pump
Malfunction of hydraulic pump
Broken auxiliary equipment (pump, compressor, etc.)
Stuck or seized supply pump plunger
Broken supply pump shaft spline
Broken or seized feed pump
Clogged feed pump gauze filter
Clogged fuel filter and/or strainer
Leaking and/or clogged fuel piping
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
Broken or seized gear train
Broken or seized crankshaft bearing
Broken or seized piston and/or connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes
Confirm recent repair history
EE
Operated for long period
Q w Q w w
w Q
Condition when engine Engine overheated and stopped stopped Engine stopped slowly
Q w w Q
Non-specified fuel is being used
Q Q Q Q Q Q Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual
w w
Engine stopped after hunting
w w
Fuel level monitor indicates low level (if monitor is installed) When fuel tank is inspected, it is found to be empty
w
Air breather hole of fuel tank cap is clogged
w w Q Q w w Q Q
Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy
Check items
Rust and water are found when fuel tank is drained
w w w w
Metal particles are found when oil pan is drained Does not turn at all When engine is cranked by hand
Q
w
Turns in opposite direction
w
Moves by amount of gear backlash
w w
Supply pump shaft does not turn
w
q q q q q q q q
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
q Replace
Remedy
q
Replace
Inspect dynamic valve system directly Inspect piston and connecting rod directly Inspect crankshaft bearing directly Inspect gear train directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
Replace
Troubleshooting
Engine turns, but stops when load is applied to machine
—
Questions
Abnormal noise was heard and engine stopped sudw w w w denly
Carry out troubleshooting in H-mode
Degree of machine operation
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
D475A, D475ASD-5E0
11
SEN01833-01
40 Troubleshooting
S-5 Engine does not rotate smoothly
1
General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)
Q w
When priming pump is operated, it makes no reaction or it is heavy
Defective G (Bkup) speed sensor or wiring harness
Defective Ne speed sensor and/or wiring harness
Clogged injector and/or defective spray (dirt in injector)
Defective operation of flow damper (Maximum leakage from injector)
Clogged fuel filter or strainer
Clogged feed pump gauze filter
Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q
Q Q Q Q
q
When air is bled from fuel system, air comes out Inspect feed pump gauze filter directly Inspect fuel filter and strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Carry out troubleshooting of failure code for "Abnormality in engine Ne speed sensor (*1)" Carry out troubleshooting of failure code for "Abnormality in engine Bkup speed sensor (*2)"
q q q q q Correct
Correct
Correct
Replace
Replace
Replace
Clean
q Add
Remedy
Leaking or clogging or entry of air to fuel piping
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank
E E
Replace
Confirm recent repair history Degree of machine Operated for long period operation Occurs at a certain speed range Occurs at low idle Condition of hunting Occurs even when speed is raised Occurs on slopes Replacement of filters not carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping
Correct
Troubleshooting
Check items
Questions
Low setting of low idle speed
Causes
*1: Failure code [CA689] and failure [CB689] *2: Failure code [CA778] and failure [CB778]
1
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-6 Engine lacks output (or lacks power) General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See "S-14 Coolant temperature becomes too high (Overheating)" q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
1 Defective fuel temperature sensor and/or wiring harness
Defective boost pressure sensor and/or wiring harness
Defective drive of injector (signal and/or solenoid)
Defective installation of boost pressure sensor (air leakage)
Clogged injector or defective spray (dirt in injector)
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter and/or strainer
Leaking or clogged fuel piping
Clogged air breather hole of fuel tank cap
Worn piston ring and/or cylinder liner
Improper valve clearance
Defective contact of valve and valve seat
Seized turbocharger or interference of turbocharger
Air leakage from air intake piping
Clogged air cleaner element
Causes
Q
Q Q Q Q
Confirm recent repair history
E
E
E
E E
Q
Q
Q Q Q Q
Q Q w
Q Q Q Q
w w w w w w w w w
When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head
w Q
High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive
w w Q w
Q Q Q Q Q Q
D475A, D475ASD-5E0
q q q q q q q
Replace
Replace
Correct
Replace
Replace
Replace
Correct
q Clean
Replace
Adjusting
Replace
Replace
Correct
Inspect air cleaner directly q Inspect air intake piping directly q When boost pressure is measured, it is found to be low q q q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Inspect boost pressure sensor mount directly Carry out troubleshooting of failure code for "Abnormality in charge pressure sensor (*2)" Carry out troubleshooting of failure code for "Abnormality in fuel temperature sensor (*3)" Remedy
w Q
w
Clean
w
Replace
Suddenly Power was lost Gradually Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Color of exhaust Black gas Blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Clean
Troubleshooting
Check items
Questions
Degree of machine Operated for long period operation
13
SEN01833-01
40 Troubleshooting
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA122] and failure code[CA123] *3: Failure code [CA263], [CB263] and failure code [CA265], [CB265]
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-7 Exhaust smoke is black (incomplete combustion)
E w w
Defective coolant temperature sensor or wiring harness
Improper fuel injection pressure
Improper injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged or seized injector
Stuck or seized supply pump plunger
Worn piston ring and/or cylinder liner
E
E Q Q Q Q
Q w
Q Q w w Q w
Q Q
Q
Q Q Q
w w Q Q Q Q w w w Q Q Q Q
w Q Q Q
Q Q w w w
q q q
q q
Replace
Adjusting
q
Adjusting
Correct
Replace
Replace
Replace
Replace
q
Correct
Adjusting
Replace
Replace
Inspect air cleaner directly q When turbocharger is rotated by hand, it is fount to be heavy q When compression pressure is measured, it is found to be low q Inspect valve clearance directly q When muffler is removed, exhaust sound improves Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinder Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor error (*2)" Remedy
Crushed or clogged muffler
Leakage of air between turbocharger and cylinder head
Improper valve clearance
Defective contact of valve and valve seat
E
Replace
Confirm recent repair history Degree of Operated for long period machine operation Suddenly became black Color of exhaust Gradually became black gas Blue under light load Non-specified fuel is being used Oil replenished more frequently Suddenly Power was lost Gradually Dust indicator is red (if indicator is installed) Muffler is crushed Air leaks between turbocharger and cylinder head, and clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills
Seized turbocharger or interference of turbocharger
Clogged air cleaner element
Causes
Clean
Troubleshooting
Check items
Questions
General causes why exhaust smoke is black q Insufficient intake of air q Excessive injection of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See "S-14 Coolant temperature becomes too high (Overheating)" q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
1
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA144] and failure code[CA145] D475A, D475ASD-5E0
15
SEN01833-01
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)
Confirm recent repair history Degree of machine oper- Operated for long period ation Oil consumption suddenly increased Oil replenished more frequently Oil becomes contaminated quickly Outside of engine is contaminated with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is contaminated with oil Inside of turbocharger exhaust outlet pipe is contaminated with oil There is oil in coolant Oil level in damper chamber is increasing Exhaust smoke is blue under light load Excessive Amount of blow-by gas None
Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn or damaged rear oil seal
Worn piston ring and/or cylinder liner
Broken piston ring
Clogged breather or breather hose
Turbocharger Worn seal at blower end
Worn seal at turbocharger end
E E E
E w
Q Q
w Q Q w
w w w w w w w Q w w w Q
w w w w
Q w
q q q q q q q q q q Correct
Correct
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Clean
Replace
Replace
q q q q Correct
When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found contaminated abnormally Excessive play of turbocharger shaft Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine Remedy
16
Worn or damaged valve (stem, guide, seal)
Dust sucked in from intake system
Causes
Correct
Troubleshooting
Check items
Questions
General causes why oil consumption is excessive q Abnormal combustion of oil q Long-time operation of engine at low idle or high idle (Do not run engine continuously at idle without load for more than 20 minutes) q External leakage of oil q Wear of parts in lubrication system
1
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-9 Oil becomes contaminated quickly
1
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
Clogged oil filter
Clogged oil cooler
Clogged breather and/or breather hose
Worn piston ring and/or cylinder liner
Worn valve and/or valve guide
Defective seal at turbocharger turbine end
Causes
Confirm recent repair history Degree of machine operation Operated for long period E E E Non-specified fuel is being used Q Engine oil replenished more frequently w Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is w Q installed) Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is contaminated with oil w Engine oil temperature rises quickly w Blue under light load w Color of exhaust gas Black w Excessive Q Q w Q Amount of blow-by gas None w
q
Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly
q q q q q
—
Clean
Replace
Replace
Clean
Clean
Replace
Replace
q Remedy
D475A, D475ASD-5E0
See S-7
q
Replace
Troubleshooting
Check items
Questions
General causes why oil becomes contaminated q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load
17
SEN01833-01
40 Troubleshooting
S-10 Fuel consumption is excessive
1
General causes why fuel consumption is excessive q Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel
Defective coolant temperature sensor or wiring harness
Improper injection timing
Defective operation of injector
Defective spray by injector
Defective common rail fuel pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Q
Q Q Q Q
Q Q w w w
w w Q Q Q Q
Q Q
Q q q q q q q Correct
Correct
Replace
q Replace
Correct
q Replace
Remedy
E
Q
Replace
Remove and inspect head cover directly Inspect feed pump oil seal directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change change on some cylinders If spill hose from injector is disconnected and measured, much fuel spills Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor (*2)" Confirm with monitoring function of machine monitor
E E
Correct
Confirm recent repair history Degree of Operated for long period machine operation More than other machines of same model Condition of fuel Gradually increased consumption Suddenly increased There is external leakage of fuel from engine Combustion is irregular Engine oil level rises and oil smells of diesel fuel When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high Torque converter stall speed or hydraulic pump relief speed is high Color of exhaust Black gas White
Correct
Troubleshooting
Check items
Questions
Fuel leakage inside head cover
Causes
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA144] and failure code[CA145]
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 General causes why oil is mixed in coolant q Internal leakage in lubrication system q Internal leakage in cooling system
Broken oil cooler core and/or O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring and/or hole caused by pitting
Cracks inside cylinder block
Broken cylinder head and/or head gasket
Causes
Degree of machine operation Oil level
E
Operated for long period
Q
Suddenly increased
Q Q Q
Gradually increased
Q
Q
Q Q
w
Hard water is being used as coolant
Check items
Oil level has risen and oil is milky
Troubleshooting
E
There are excessive air bubbles in radiator, coolant spurts back
w
Pressure-tightness test of cylinder head shows there is leakage
q
w
q q
Inspect cylinder block and liner directly
q
Inspect cylinder liner directly
q
D475A, D475ASD-5E0
Replace
Replace
Replace
Remedy
Replace
Pressure-tightness test of oil cooler shows there is leakage
Replace
Questions
Confirm recent repair history
19
SEN01833-01
1
General causes why oil pressure drops q Leakage, clogging, and/or wear of lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness
Defective oil pressure sensor and/or defective wiring harness
Leaking, crushed, clogged hydraulic piping
Clogged oil filter
Defective oil pump relief valve
Defective oil pump
Clogged and/or broken pipe in oil pan
Clogged strainer in oil pan
Coolant and fuel mixing in oil
Lack of oil in oil pan
w Q w
w
Q Q w
w w w w w w
Q
q q q q q q q Replace
Replace
Correct
Clean
Adjusting
Replace
q Clean
Remedy
E
Q w Q w Q w w w Q
Q
See S-13
Metal particles are found in oil filter Inspect oil pan strainer and pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued and damaged Inspect oil filter directly Carry out troubleshooting of failure code for "Abnormality in oil pressure sensor (*1)" If oil level sensor is replaced, oil level monitor indicates normally
E
—
Metal particles are found when oil filter is drained
E
Add
Confirm recent repair history Degree of machine operation Operated for long period Oil pressure monitor indicates low oil pressure (if monitor is installed) Non-specified oil is being used Replacement of filters not carried according to Operation and Maintenance Manual Indicates pressure drop at low idling time Oil pressure Indicates pressure drop at low and high idling times monitor Indicates pressure drop on slopes (if installed) Indicates pressure drop occasionally Oil level monitor indicates oil level drop (if monitor is installed) Oil level in oil pan is low External hydraulic piping is leaking or crushed Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained
Clean
Troubleshooting
Check items
Questions
Worn journal of bearing
Causes
Clean
S-12 Oil pressure drops
40 Troubleshooting
*1: Failure code [CA135] and failure code[CA141]
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-13 Oil level rises (Entry of coolant or fuel)
1
General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant".
Confirm recent repair history Degree of Operated for long period machine operation Fuel consumption increasing Coolant replenished more frequently There is oil mixed in coolant Oil smells of diesel fuel Oil is milky When engine is started, drops of water come from muffler When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, or coolant spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level in damper chamber of machine is low Oil level in hydraulic tank is low
Defective seal of auxiliary equipment (pump, compressor)
E
w Q Q
Defects in supply pump
Defective thermostat seat
Clogged water pump drain hole (breather hole) and/or defective seal
Worn or damaged rear oil seal
Damaged cylinder liner O-ring and/or hole caused by pitting
Cracks inside cylinder block
Fuel leakage inside head cover
Broken oil cooler core and/or O-ring
E w w
Q Q
w
w
w
Q Q
w
w
Q Q
Q w w w w
q
When compression pressure is measured, it is found to be low Remove and inspect head cover directly Inspect cylinder block and/or liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect water pump directly Remove and inspect thermostat cover directly Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly
q q q q q q q q Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
q Remedy
D475A, D475ASD-5E0
E E
Replace
Troubleshooting
Check items
Questions
Broken cylinder head and/or head gasket
Causes
21
SEN01833-01
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, and/or damages of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Oil temperature of power train is rising
Rise in power train oil temperature on applicable machine side
Defective coolant temperature gauge
Slipping fan belt and/or worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged or crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Damaged cylinder liner O-ring and/or hole caused by pitting
Clogged or broken oil cooler
E E Q w
Q Q
Q w w w
Q
w w w Q w w w w w
w
w w w w
q
q q q q q q Replace
Correct
Replace
Correct
Correct
Replace
Replace
Add
q
—
q
Carry out troubleshooting in H-mode
q
Replace
When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is tested, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt and pulley directly When coolant temperature is measured, it is found to be normal
E E
Replace
Confirm recent repair history Degree of Operated for long period machine operation Sudden overheated Condition for Persistent overheating Coolant tempera- Rises quickly ture gauge Does not go down from red range (if installed) Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Engine oil level has risen and oil is milky Fan belt tension is low Milky oil is floating on coolant There are excessive air bubbles in radiator and coolant spurts back When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose Fan belt whines under sudden acceleration Power train oil temperature gauge enters red range faster than engine coolant temperature gauge (if oil temperature gauge and coolant temperature gauge are installed) on the installed machine side
Replace
Troubleshooting
Check items
Questions
Broken cylinder head and/or head gasket
Causes
Remedy
22
1
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-15 Abnormal noise is made
1
D475A, D475ASD-5E0
Improper fuel injection timing (abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged or seized injector
Deformed cooling fan and/or looseness or interference of fan belt
Removed or seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring and/or cylinder liner
Improper valve clearance
Defective inside of muffler (dividing board out of position)
Q
Q
Q Q
Q Q w w
w
w w w
w w w Q w
Q w
Q Q
w Q Q
Q w
q
When turbocharger is rotated by hand, it is fount to be heavy Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Abnormal noise is heard only when engine is started Confirm with monitoring function of machine monitor
q q q q q q q q q q Correct
Correct
Replace
Correct
Replace
Replace
Replace
Replace
Replace
q Correct
Remedy
Broken dynamic valve system (valve and/or rocker lever)
E
Replace
Confirm recent repair history Degree of Operated for long period machine operation Gradually increased Condition of abnormal noise Suddenly increased Non-specified fuel is being used Oil replenished more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is emitted around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust Blue under light load gas Black Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive
Interference or seizure of turbocharger
Leakage of air between turbocharger and cylinder head
Causes
Replace
Troubleshooting
Check items
Questions
General causes why abnormal noise is emitted q Abnormality due to defective parts q Abnormal combustion q Air leakage from air intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a While the engine is not sufficiently warmed up, it is operated in the low-temperature mode. Accordingly, the engine sound rises slightly higher. This is no abnormality, however. a When the engine is accelerated, the engine sound rises slightly for approx. 3 seconds maximum. This is no abnormality, however.
23
SEN01833-01
40 Troubleshooting
S-16 Vibration is excessive
1
Confirm recent repair history Degree of Operated for long period machine operation Condition of vibra- Suddenly increased tion Gradually increased Non-specified oil is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed
E
E
Q Q w w Q
Q Q w w Q
Q
E Q
Q Q Q Q Q Q
Q
Exhaust smoke is black
w
Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with monitoring function of machine monitor Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect front support spigot joint portion directly Inspect output shaft or inside of damper directly
q
Broken output shaft and/or parts in damper on installed machine side
Worn front support spigot joint portion
Misalignment between engine and devices on installed machine side
Loose engine mounting bolts and/or broken cushions
Improper injection timing
Worn camshaft bushing
Improper gear train backlash
E Q
Q
q q q q q q q Replace
Replace
Adjusting
Replace
Adjusting
Replace
Replace
Replace
q Remedy
24
Worn main bearing and/or connecting rod bearing
Stuck dynamic valve system (valve, rocker lever, etc.)
Causes
Replace
Troubleshooting
Check items
Questions
General causes why vibration occurs q Defective parts (abnormal wear, breakage, etc.) q Misalignment between installed machine q Abnormal combustion a If abnormal noise vibration occur, carry out troubleshooting for "S-15 Abnormal noise is emitted", too.
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01833-01
25
SEN01833-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN01833-01
© 2008 KOMATSU All Rights Reserved Printed in Japan 06-08 (01)
26
SEN02013-06
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tools list .............................................................................................................................................. 7 Sketches of special tools .............................................................................................................................. 14
D475A, D475ASD-5E0
1
SEN02013-06
50 Disassembly and assembly
How to read this manual 1.
(Rev. 2009.01) 1
Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Removal q In “Removal” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : Amount of oil or coolant to be drained 4:
Weight of part or component
Installation q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
2
D475A, D475ASD-5E0
50 Disassembly and assembly
2.
SEN02013-06
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Disassembly q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 6 : Amount of oil or coolant drained
a
Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools Various special tools are illustrated for the local manufacture.
q
D475A, D475ASD-5E0
3
SEN02013-06
50 Disassembly and assembly
Coating materials list a a
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 manual.
Category
Komatsu code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloPolyethylene ride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Can
• Used to stick and seal metal, glass, and plastics.
Polyethylene • Used to seal plugs. container Tube
• Heat-resistant seal used to repair engines.
50 g
• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods. • Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.
Aron-alpha 201
790-129-9130
2g
Loctite 648-50
79A-129-9110
50 cc
• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.
1 kg
• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
Gasket sealant
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)
LT-4
ThreeBond 1735
790-129-9080
LG-6
790-129-9160
200 g
Tube
• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.
LG-8 ThreeBond 1207B
4
(Rev. 2009.02) 1
419-15-18131
100 g
D475A, D475ASD-5E0
50 Disassembly and assembly
Gasket sealant
CateKomatsu code gory
Molybdenum disulfide lubricant
Container
Main features and applications
790-129-9310
200 g
Tube
• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.
LG-10 ThreeBond 1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.
LG-11 ThreeBond 1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.
ThreeBond 1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.
Can
• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the propeller shaft splines, needle bearings, pins and bolts of various links, etc.
—
Can
• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.
—
LC-G NEVER-SEEZ
09940-00040
09995-00250
—
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Grease
Q'ty
LG-9 ThreeBond 1206D
LM-P
Seizure prevention compound
Part number
SEN02013-06
Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)
Hyper White Grease G2-T, G0-T (*)
SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*)
D475A, D475ASD-5E0
200 g
190 g
• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg
400 g 16 kg
• Bellows-type container Can •
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.
5
SEN02013-06
G2-U-S ENS grease
—
427-12-11871
SUNSTAR PAINT PRIMER 580 SUPER
Caulking material
Adhesive
Primer
SUNSTAR GLASS PRIMER 580 SUPER
6
SUNSTAR PAINT PRIMER 435-95
Q'ty
Container
Main features and applications
Tube
• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.
2 kg
Can
• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.
20 ml
Glass container
• Used as primer for cab side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
• Used as primer for glass side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S ThreeBond 1855
Part number
• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)
SUNSTAR GLASS PRIMER 435-41
22M-54-27240
150 ml
Can
SUNSTAR SASH PRIMER GP-402
22M-54-27250
20 ml
Glass container
• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
417-926-3910
320 ml
Polyethylene container
• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210
320 ml
Ecocart (Special container)
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Used to seal front window. (Using limit: 6 months after date of manufacture)
Cartridge
• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
GE TOSHIBA SILICONES TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code gory
50 Disassembly and assembly
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02013-06
Special tools list
Component
Removal and installation of radiator guard assembly
Removal, installation of cylinder head assembly
790-431-1120
Adapter
t
1
791-520-4140
Screw
t
1
791-181-1020
Sleeve
t
1
791-765-1150
Plate
t
1
791-112-1180
Nut
t
1
790-101-2540
Washer
t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
2
790-331-1110
Wrench
q
1
Tightening of cylinder head bolt
3
795-931-1100
Seal puller assembly
t
1
Extraction of oil seal
795T-621-1430 Plate
t
1
N
Q
795T-621-1441 Push tool
t
1
N
Q
01050-32280
Bolt
t
3
01582-02218
Nut
t
3
01640-22232
Washer
t
3
795-931-1100
Seal puller assembly
t
1
795T-621-1531 Push tool
t
1
01050-32050
Bolt
t
5
Symbol
1
A
Removal, installation of engine front seal
4
3 Removal, installation of engine rear seal
5
Disassembly and assembly of torque converter
Disassembly and assembly of PTO assembly
Part No.
1
C
D475A, D475ASD-5E0
2
Part Name
01640-02032
Washer
t
5
790-413-1010
Bracket
t
1
790-501-5000
Repair stand
t
1
791T-813-1110
Push tool
Sketch
a
New/ remodel
a
* *** ****
Q'ty
a
Tools with part number 79 Tmeans that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Necessity: t ............ Special tools that cannot be substituted and should always be used q ............ Special tools that will be useful if available and are substitutable with tools available on the market New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively. R ............ Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank ..... Tools already available for other models. They can be used without any modification. Tools marked with Q in the sketch column are presented in the sketches of the special tools (See “Sketches of special tools”). Necessity
a
1
Nature of work, remarks
Pulling out pin or radiator guard
Press fitting of oil seal
Extraction of oil seal N
Q Press fitting of oil seal
Disassembly, assembly of torque converter
t
1
N
Q
791T-813-1120 Plate
t
1
N
Q
04020-01228
• Pin
t
1
01017-52030
Bolt
t
1
01643-32000
Washer
t
1
Disassembly, assembly of PTO assembly
7
Disassembly and assembly of transmission
D
1 Disassembly and assembly of steering
E 2 3
1
2
Disassembly and assembly of final drive assembly
3
5
6
7
8
790-413-1010
Bracket
t
1
Repair stand
t
1
799-301-1600
Oil leak tester
t
1
Sketch
Part Name
790-501-5000
Nature of work, remarks Disassembly, assembly of transmission Checking actuation of piston
791-622-1110
Bracket
t
1
01016-51690
Bolt
t
1
01011-81600
Bolt
t
1
791T-822-1810 Push tool
t
1
Q
791T-822-1820 Push tool
t
1
Q
791-822-1830
Wrench
t
1
790-337-1032
Lifting tool
t
1
791-827-1910
Plate
t
1
01011-83015
Bolt
t
3
790-431-1081
Guide
t
1
790-431-1031
Block
t
1
790-101-2350
Leg
t
2
790-101-2430
Adapter
t
2
790-101-2360
Plate
t
4
02215-11622
Nut
t
2
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
790-431-1101
Installer assembly
t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
791-585-1510
Installer
t
1
790-431-1220
Remover assembly t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
790-431-1210
Installer assembly
t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
790-431-1230
Remover & installer t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
790-431-1240
Guide
t
1
J 4
8
Part No.
New/ remodel
Symbol
Q'ty
Component
50 Disassembly and assembly
Necessity
SEN02013-06
Removal, installation of clutch, brake assembly
Press fitting of bearing Removal, installation of bearing round nut Removal, installation of final drive assembly
Pulling out sprocket bearing
Press fitting of sprocket bearing Installation of floating seal
Pulling out center hub
Press fitting of center hub
Pulling out, press fitting of carrier pin Assembly of No. 1 pinion
D475A, D475ASD-5E0
1 Assembly of Idler
Disassembly and assembly of carrier roller
Assembly of track roller
t
1
N
Rod
t
2
790-101-2510
Block
t
1
790-101-2570
Plate
t
2
01580-01613
Nut
t
2
01643-31645
Washer
t
2
790-101-2102
Puller (294 kN {30 ton})
t
2
Pump
t
1
t
1
Installation of floating seal
3
791-830-1480
Push tool
t
1
Press fitting of seal guide
4
791-601-1000
Oil pump
t
1
Filling with oil
5
791-515-1520
Installer
t
1
Installation of floating seal Press fitting of floating seal collar
Push tool
t
1
7
791-630-1270
Wrench
t
1
8
791-830-1740
Plate
t
1
9
791-515-1520
Installer
t
1
10
791-830-1730
Push tool
t
1
11
791-601-1000
Oil pump
t
1
790-401-1700
Lifting tool
t
1
790-401-1761
Adapter
t
1
790-401-1540
Shackle
t
2
790-401-1770 13
15
Press fitting of idler bushing
Installer
791-830-1770
Disassembly and assembly of bogie
Nature of work, remarks
790-101-1102
6
14
Sketch
Plate
Part Name
791-560-1520
12
D475A, D475ASD-5E0
791-830-1760 791-830-1320
Part No.
2
L
Disassembly and assembly of bogie and track roller
New/ remodel
Symbol
Q'ty
Component
SEN02013-06
Necessity
50 Disassembly and assembly
T-bolt
t
2
791T-830-1780 Plate
t
3
01011-62700
Bolt
t
6
01673-32780
Washer
t
6
N
Removal, installation of round nut N
Press fitting of bushing Installation of floating seal
N
Press fitting of seal ring Filling with oil
Removal, installation of track roller assembly
N
Q Fixture of bogie
1 791-830-1620
Plate
t
1
N
2 791-830-1630
Spacer
t
1
N
3 791-830-1640
Screw
t
3
N
4 01580-12722
Nut
t
3
5 01630-32780
Washer
t
3
6 790-101-4000
Puller (490 kN {50 ton})
t
1
7 790-101-1102
Pump
t
1
Pulling out ring and shaft
1 791-830-1650
Plate
t
1
N
2 791-830-1660
Spacer
t
1
N
3 796-670-1120
Plate
t
1
4 790-434-1070
Screw
t
1
5 01580-13629
Nut
t
2
6 01643-33690
Washer
t
1
7 790-101-4000
Puller (490 kN {50 ton})
t
1
N
Pulling out ring
9
t
1
1 791-830-1620
Plate
t
1
N
2 791-830-1640
Screw
t
3
N
Part No.
15 8 790-101-1102
Nut
t
3
Washer
t
3
5 790-101-4000
Puller (490 kN {50 ton})
t
1
6 790-101-1102
3 01580-12722 16 4 01643-32780
Disassembly and assembly of bogie
Part Name
t
1
t
2
18
791-530-1510
Installer
t
1
Installation of floating seal
19
791-601-1000
Oil pump
t
1
Filling with oil
21
1
2
3
10
N
Press fitting of pin assembly
Pump
1
N
Q
791-630-1860
Bracket
t
1
791-630-1870
Bracket
t
1
791T-830-1510 Spacer
t
2
19M-09-12850
Bolt
t
2
01643-33380
Washer
t
2
t
1
N
Q
791T-830-1710 • Bar
1
N
Q
791T-830-1720 • Plate
1
N
Q
07283-31079
• Grip
1
01582-01210
• Nut
2
01643-31232
• Washer
2
04530-11628
• Eye bolt
1
790-434-1401
Remover assembly t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
791T-830-1700 Lifting tool
Disassembly and assembly of equalizer bar
Pulling out ring
791T-830-1670 Guide
L
M
Nature of work, remarks
17
20
Disassembly and assembly of recoil spring
Sketch
Pump
Symbol
New/ remodel
Q'ty
Component
50 Disassembly and assembly
Necessity
SEN02013-06
791-685-8502
Compressor
t
1
791-635-3160
Extension
t
1
790-201-2790
Spacer
t
1
790-101-1300
Cylinder (980 kN {100 ton})
t
1
790-101-1102
Pump
t
1
791-730-1120
Bolt
t
6
01580-13326
Nut
t
6
01643-33380
Washer
t
6
792-900-1610
Adapter
t
1
792-900-1530
Screw
t
1
791-775-1110
Sleeve
t
1
791T-850-1150 Plate
t
1
01582-53024
Nut
t
1
01643-33080
Washer
t
1
Q
Removal of No. 1 bogie assembly
Removal of No. 1 bogie track roller
Pulling out idler cushion guide pin
Disassembly, assembly of recoil spring
Removal of recoil spring assembly
Q
Pulling out center pin
D475A, D475ASD-5E0
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
791T-850-1160 Bracket
t
1
Q
791T-850-1170 Bracket
t
1
Q
790-438-1110
Screw
t
1
790-101-2540
Washer
t
2
791-112-1180
Nut
t
2
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
791T-850-1180 Sleeve
t
1
Q
791T-850-1190 Plate
t
1
Q
791-730-1130
Bolt
t
2
791-101-3310
Plate
t
1
01643-32060
Washer
t
2
01580-02016
Nut
t
2
790-105-2300
Jack assembly
t
1
790-101-1102
Pump
t
1
1
791-646-7531
Plug remover
t
1
2
791-660-7460
Pin brush
t
1
Cleaning of pin
3
791-646-7900
Push tool
t
1
Knocking in large plug
4
791-932-1110
Push tool
t
1
Knocking in all plugs
790-701-3000 and 791-601-1000
Seal checker
5
t
1
Filling with oil and checking air tightness
791-632-1010
Installer
t
1
Replacing of link seal
1 791-832-1610
Plate
t
1
1
Disassembly and assembly of equalizer bar
N 2
Disassembly and assembly of pivot shaft
P
6
Disassembly and assembly of track shoe
R
8
D475A, D475ASD-5E0
Part No.
Part Name
2 791-832-1270
Bracket
t
1
Bolt
t
1
4 791-832-1250
Bracket
t
1
5 01010-62050
Bolt
t
2
6 791-832-1220
Plate
t
1
7 791-832-1230
Shaft
t
2
8 791-832-1210
Frame
t
1
9 791-832-1240
Nut
t
2
10 04530-11628
Eye bolt
t
2
11 791-832-1310
Adapter
t
1
12 791-832-1280
Adapter
t
1
13 791-832-1320
Guide
t
1
14 01310-21032
Screw
t
5
15 791-832-1640
Pusher
t
1
16 791-832-1340
Extension
t
2
17 791-832-1650
Adapter
t
1
Nature of work, remarks
Pulling out center pin
Pulling out side pin bushing
Press fitting of seal
Knocking out small plug
Oil pump
3 01010-81495
Sketch
790-101-2102
Symbol
New/ remodel
Q'ty
Component
SEN02013-06
Necessity
50 Disassembly and assembly
Pulling out and press fitting of pin and bush
N
11
18 791-832-1480
Adapter
t
1
19 791-832-1670
Guide
t
1
20 791-832-1330
Guide
t
1
21 791-832-1660
Adapter
t
1
22 791-832-1630
Guide
t
1
23 791-832-1470
Guide
t
1
24 791-832-1410
Extension
t
1
Pusher
t
1
8 25 791-832-1350 26 791-832-1620
Disassembly and assembly of track shoe
R
Guide
t
1
27 04530-11018
Eye bolt
t
1
28 790-101-4500
Cylinder t (1960 kN {200 ton})
1
29 790-101-1102
Pump
t
1
30 790-101-4200
Puller (294 kN {30 ton})
t
1
31 791-685-9230
Spacer
t
1
9
Push tool assembly t
1
N
• Adapter
1
N
3 791-685-5660
• Ring
1
N
4 791-685-5670
• Plate
1
N
5 791-685-5680
• Ring
1
N
6 791-685-5690
• Push tool
1
N
7 791-685-5710
• Adapter
1
N
8 791-685-5720
• Spring
1
N N
• Bar
1
• Bolt
1
11 01580-01210
• Nut
1
12
791-685-5740
Push tool
t
1
N
1 791-832-1490
Push tool
t
1
N
2 791-832-1510
Push tool
t
1
N
1 791-685-5700
Push tool assembly
1
N
2 791-685-5650
• Adapter
1
N
3 791-685-5660
• Ring
1
N
4 791-685-5670
• Plate
1
N
5 791-685-5680
• Ring
1
N
6 791-685-5690
• Push tool
1
N
7 791-685-5710
• Adapter
1
N
8 791-685-5720
• Spring
1
N
9 791-685-5730
• Bar
1
N
10 01252-30655
• Bolt
1
11 01580-01210
• Nut
1
13
791-685-5750
Push tool
t
1
Nature of work, remarks
Pulling out and press fitting of pin and bush
Pulling out and press fitting of pin and bush
1 791-685-5600
9 791-685-5730
11
N
2 791-685-5640
10 01252-30655 10
12
Part Name
Sketch
Part No.
New/ remodel
Symbol
Q'ty
Component
50 Disassembly and assembly
Necessity
SEN02013-06
Press fitting ring (For large plug)
Press fitting ring Press fitting ring
Press fitting ring (For small plug)
Press fitting ring (For small plug)
Press fitting ring (For small plug) N
Press fitting ring
D475A, D475ASD-5E0
1
790-502-1003
Cylinder repair stand
q
1
Disassembly, assembly of cylinder
790-201-1702
Push tool kit
t
1
Press fitting of coil bushing
3
790-201-1881
• Push tool
1
790-201-1871
• Push tool
1
• Ripper lift • Ripper puller
790-201-1721
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1500
Push tool kit
790-201-1670 790-201-1680
t
1
Press fitting of dust seal
• Plate
1
• Blade lift
• Plate
1
• Ripper lift
790-201-1690
• Plate
1
• Blade tilt (standard specification) • Blade pitch (superdozer specification) • Ripper tilt
790-201-1530
• Plate
1
• Pin puller
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-720-1000
Expander
t
1
796-720-1690
Ring
t
1
07281-01919
Clamp
t
1
796-720-1690
Ring
t
1
07281-02169
Clamp
t
1
796-720-1710
Ring
t
1
07281-02709
Clamp
t
1
796-720-1630
Ring
t
1
07281-00709
Clamp
t
1
790-102-2304
Wrench
t
1
U
4
5
6
D475A, D475ASD-5E0
Nature of work, remarks
• Blade tilt (standard specification) • Blade pitch (superdozer specification) • Ripper tilt
2
Disassembly, assembly of hydraulic cylinder
Sketch
Part Name
Part No.
New/ remodel
Symbol
Q'ty
Component
SEN02013-06
Necessity
50 Disassembly and assembly
Installation of all cylinder piston rings Blade lift (standard specification) Blade lift (superdozer specification) Ripper tilt, lift Blade tilt (standard specification) Blade pitch (superdozer specification) Pin puller Removal and installation of pin puller cylinder head
13
SEN02013-06
Sketches of special tools
50 Disassembly and assembly
1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A4 Plate
A4 Push tool
14
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02013-06
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A5 Push tool
C2 Push tool
D475A, D475ASD-5E0
15
SEN02013-06
50 Disassembly and assembly
C2 Plate
E2 Push tool
16
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02013-06
E2 Push tool
L13 Plate
D475A, D475ASD-5E0
17
SEN02013-06
50 Disassembly and assembly
L17 Guide
L20 Spacer
18
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02013-06
L21 Lifting tool
L21 Bar
D475A, D475ASD-5E0
19
SEN02013-06
50 Disassembly and assembly
L-21 Plate
N1 Plate
20
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02013-06
N2 Bracket
N2 Bracket
D475A, D475ASD-5E0
21
SEN02013-06
50 Disassembly and assembly
P Sleeve
P Plate
22
D475A, D475ASD-5E0
50 Disassembly and assembly
D475A, D475ASD-5E0
SEN02013-06
23
SEN02013-06
D475A, D475ASD-5E0 Bulldozer Form No. SEN02013-06
© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13(02)
24
SEN02014-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly Engine and cooling system (SAA12V140E-3) Engine and cooling system (SAA12V140E-3) ................................................................................................ 2 Removal and installation of engine assembly ...................................................................................... 2 Removal and installation of radiator assembly..................................................................................... 6 Removal and installation of aftercooler assembly ................................................................................ 8 Removal and installation of radiator guard assembly ........................................................................ 10 Removal and installation of fuel tank assembly ................................................................................. 12 Removal and installation of engine hood assembly ........................................................................... 13 Removal and installation of fan drive assembly ................................................................................. 15 Removal and installation of fan motor assembly................................................................................ 16
D475A, D475ASD-5E0
1
SEN02014-01
50 Disassembly and assembly
Engine and cooling system (SAA12V140E-3) Removal and installation of engine assembly
4.
Lift off radiator upper cover (2). 4
1
1
Radiator upper cover assembly: 85 kg
Removal k k k
1.
2.
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. [*1] a Ask professional traders for collecting and filling operation of refrigerant. a Never release the refrigerant to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. Accordingly, put on protective goggles, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person.
2
Remove engine hood assembly (3). For details, see "Removal and installation of engine hood assembly".
6.
Remove right and left engine side covers (4) and right and left covers (5).
Drain the coolant. 6
3.
5.
Coolant: 210 l
Remove right and left potentiometer wiring grommets (1) from the cover.
D475A, D475ASD-5E0
50 Disassembly and assembly
7.
Remove undercovers (1st, 2nd and 3rd ones from the front) (33).
SEN02014-01
10. Disconnect radiator outlet tube (11). 11. Disconnect torque converter oil cooler tubes (12) and (13). 12. Disconnect heater hose (14).
8.
Disconnect radiator inlet hoses (6) and aeration hoses (7).
13. Lift off the right and left aftercooler outlet piping assemblies. a Loosen hose clamp (15). a Remove pipe mounting bolt (16). a Remove piping fixing bracket (17).
9.
Lift off the right and left aftercooler inlet piping assemblies. a Loosen hose clamps (8). a Remove pipe mounting bolt (9). a Remove piping fixing bracket (10).
D475A, D475ASD-5E0
3
SEN02014-01
14. Disconnect air conditioner hose (15) and remove the compressor assembly. a Cover the hoses so that dirt, water, etc. will not enter them. a Disconnect all the clamps of hose (11).
50 Disassembly and assembly
17. Disconnect engine rear-side air conditioner hoses (23) and wiring connectors (24).
18. Disconnect fuel filter hose (25), 4 hoses (26) and heater hose (27) between the valve and engine. 15. Remove engine lubricating oil pump hose (18), pump mounting bracket mounting bolts (19), and pump and bracket assembly (20). a Remove cables (21).
19. Remove damper rubber shield (28).
16. Remove cables (22) from the starting motor.
4
D475A, D475ASD-5E0
50 Disassembly and assembly
20. Sling universal joint (29), remove the mounting bolts, and lift off the universal joint. 4
SEN02014-01
Installation q
Carry out installation in the reverse order to removal.
q
Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
Universal joint: 65 kg
5
Coolant: 210 l
21. Remove front mounting bolt (30) and rear mounting bolt (31).
22. Remove engine assembly (32). 4
a
Engine assembly: 3,900 kg
When removing the engine assembly, check that all the wirings and pipings are disconnected and the engine assembly does not interfere with other parts.
D475A, D475ASD-5E0
5
SEN02014-01
Removal and installation of radiator assembly
50 Disassembly and assembly
4.
Disconnect radiator inlet hoses (3) (right and left) and aeration hoses (4) (right and left).
5.
Disconnect sub-tank hose (5).
6.
Disconnect power line cooler aeration hose (6).
1
Removal 1.
Drain the coolant. 6
2.
Coolant: 210 l
Remove right and left potentiometer wiring grommets (1) from the cover.
a
3.
Lift off radiator upper cover (2). 4
6
Remove the fan motor assembly. For details, see "Removal and installation of fan motor assembly".
7.
Remove isolator bolts (7) (2 each on the right and left sides).
8.
Remove wind breaker panels (8) (upper, lower, right and left).
9.
Disconnect headlamp connectors (9).
Radiator upper cover assembly: 85 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02014-01
10. Disconnect radiator upper wiring harness (10) and radiator coolant level sensor connector (11).
13. Remove tube (15).
11. Sling radiator assembly (12) and remove upper mounting bolts (13) (2 each on the right and left sides).
15. Lift off radiator assembly (12). a When removing the radiator assembly, take care not to damage its core.
14. Lift off lower mounting bolts (16) (right and left).
4
Radiator assembly: 485 kg
12. Remove undercover (14).
Installation q
Carry out installation in the reverse order to removal.
q
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5
D475A, D475ASD-5E0
Coolant: 210 l
7
SEN02014-01
Removal and installation of aftercooler assembly
50 Disassembly and assembly
3.
Disconnect radiator upper clamp (3) and aftercooler upper clamp (4).
4.
Remove mounting bolt (6) of aftercooler upper pipe (5).
5.
Remove lower cover bolts (7) and open lower cover (8).
6.
Remove mounting bolt (10) of aftercooler lower pipe (9) and aftercooler lower mounting bolt (13).
1
Removal 1.
2.
Remove right and left potentiometer wiring grommets (1) from the cover.
Lift off radiator upper cover (2). 4
8
Radiator upper cover assembly: 85 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
7.
Sling aftercooler (11) and remove upper mounting bolts (12).
8.
Move aftercooler upper pipe (5) and lower pipe (9) toward the engine and lift off aftercooler (11), taking care that the aftercooler will not interfere with the pipes.
SEN02014-01
Installation q
Carry out installation in the reverse order to removal.
D475A, D475ASD-5E0
9
SEN02014-01
50 Disassembly and assembly
Removal and installation of radiator guard assembly
Adapter
t 1
791-520-4140
Screw
t 1
791-181-1020
Sleeve
t 1
791-765-1150
Plate
t 1
Nut
t 1
790-101-2540
Washer
t 1
790-101-2102
Puller t 1 (294 kN {30 ton})
790-101-1102
Pump
A 1 791-112-1180
4.
Drain coolant. 6
t 1
5.
Disconnect radiator inlet and outlet hoses, aeration hose, and wiring harness clip. For details, see "Removal and installation of radiator assembly".
6.
Disconnect hydraulic cooler hose (5). Disconnect fan motor hose (6). k Release the remaining pressure from the hydraulic circuit. For details, see Testing and adjusting, Releasing residual pressure from work equipment circuit. a Fit a cover to prevent dirt from entering the piping.
Removal 1.
2.
10
Coolant: 210 l
Sketch
Q'ty
790-431-1120
New/remodel
Necessity
Symbol
Part Name
Sling blade lift cylinder assembly (4), then fit cylinder holder tool and secure to radiator guard.
1
Special tools
Part No.
3.
Remove lock plate (1) of the lift cylinder rod pin, then remove pin (2). [*1] a Start the engine and retract the piston rod fully, then tie the piston rod with wire to prevent it from coming out. a Tie the piston rod on the opposite side in the same way.
Remove hood assembly. For details, see "Removal and installation of hood assembly". Remove engine side covers (left and right).
D475A, D475ASD-5E0
50 Disassembly and assembly
7.
Disconnect work equipment hoses (7) and (8).
SEN02014-01
Installation q
Carry out installation in the reverse order to removal.
[*1] a Standard shim thickness: 4 mm q
Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again. 5
8.
Sling radiator guard assembly and remove lock bolt, then using tool A1, push rear pin (11) to inside of radiator guard and remove.
9.
Remove lock plate, then using tool A1, pull front pin (12) to outside of radiator guard and remove.
Coolant: 210 l
10. Lift off radiator guard assembly (13). a Be extremely careful not to damage the wiring and piping when removing. 4
Radiator guard assembly: 4,700 kg
D475A, D475ASD-5E0
11
SEN02014-01
Removal and installation of fuel tank assembly 1
50 Disassembly and assembly
6.
Remove fuel tank mounting bolt (9).
7.
Lift off fuel tank assembly (10).
Removal 1.
Disconnect hose (1). a Before disconnecting the hose, close the fuel valve.
2.
Remove case (2).
4
3.
Remove joint (3) and hose clamp (4).
4.
Disconnect fuel return hoses (5) and (6), and remove hose clamp (7).
5.
Disconnect fuel gauge wiring connector (8).
Fuel tank assembly (when full): 2,335kg
Installation q
12
Carry out installation in the reverse order to removal.
D475A, D475ASD-5E0
50 Disassembly and assembly
Removal and installation of engine hood assembly
SEN02014-01
3.
Disconnect wiring connectors (3) (201 and 209) and remove clamp (4).
4.
Disconnect hose (5) to the sub-tank and remove hose clamp (4).
5.
Open right and left covers (6) and (7).
6.
Remove right and left side covers (8).
1
Removal k
1.
2.
Disconnect the cable from the negative (–) terminal of the battery. Remove right and left potentiometer wiring grommets (1) from the cover.
Lift off radiator upper cover (2). 4
Radiator upper cover assembly: 85 kg
D475A, D475ASD-5E0
13
SEN02014-01
7.
Loosen clamps (9) and disconnect air cleaner hoses (10). [*1]
8.
Remove sub-tank drain hose clamp (11).
9.
Disconnect wiring connectors (12) (HR1 and HR2 at the right rear of the hood).
50 Disassembly and assembly
11. Remove hood mounting bolts (16) and (17).
12. Lift off hood assembly (18). 4
Hood assembly: 600 kg
10. Loosen the mounting bolts of cover (13) and remove covers (14) and (15).
Installation q
Carry out installation in the reverse order to removal.
[*1] Hose inserted length: Min. 40 mm 3 Hose clamp: 8.83 ± 0.5 Nm {0.9 ± 0.05 kgm}
14
D475A, D475ASD-5E0
50 Disassembly and assembly
Removal and installation of fan drive assembly 1
SEN02014-01
5.
Remove wiring harness clamp (5) and disconnect connector (6).
6.
Bracket (7).
7.
Disconnect fan motor hoses (8), (9) and (10).
8.
Sling fan drive assembly (11) and remove bracket mounting bolts (12).
9.
Lift off fan drive assembly (11).
Removal 1.
Drain the hydraulic oil. 6
2.
Hydraulic tank: Approx. 340 l
Remove 8 mounting bolts (2) of radiator mask (1) and open the radiator mask.
3.
Remove net (3).
4.
Remove fan blade (4).
4
a a
Fan drive assembly: 250 kg
Loosen mounting bolts (13) of the lower right and left shrouds. Move the fan to the position shown in the photo.
Installation
D475A, D475ASD-5E0
q
Carry out installation in the reverse order to removal.
q
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
15
SEN02014-01
50 Disassembly and assembly
Removal and installation of fan motor assembly
1
Removal 1.
2.
Remove the fan drive assembly. For details, see "Removal and installation of fan drive assembly".
3.
Remove nut (2).
4.
Remove fan (3).
Remove the mounting bolt and lock plate (1). [*1]
5.
Remove the 4 mounting bolts and fan motor assembly (4). [*3] 4
16
[*2]
Fan motor assembly: 65 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02014-01
Installation q
Carry out installation in the reverse order to removal.
[*1] Be sure to adjust the hole of lock plate (1) by turning nut (2) in the tightening direction. [*2]
3
a
[*3]
a
Mounting nut (2): 1,080 – 1,275 Nm {110 – 130 kgm} After tightening the nut, check dimension (d) shown below. q MIN: 2.0 mm q MAX: 4.0 mm
When fitting the fan motor and fan, clean and degrease them thoroughly.
D475A, D475ASD-5E0
17
SEN02014-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN02014-01
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
18
SEN02338-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Engine (SAA12V140E-3) Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of cylinder head assembly ...................................................................................... 8 Removal and installation of fuel injector assembly ....................................................................................... 19 Removal and installation of engine front seal ............................................................................................... 25 Removal and installation of engine rear seal ................................................................................................ 27
D475A, D475ASD-5E0
1
SEN02338-03
Removal and installation of fuel supply pump assembly
50 Disassembly and assembly
1
Removal of fuel supply pump on left bank side k
a
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery. Do not remove the undercover.
1.
Close the fuel valve under the fuel tank.
2.
Remove left side cover (1) and left cover (2).
3.
Remove 2 main fuel filters (3). a Use a filter wrench etc. to remove the filters.
k k
2
4.
Remove fuel hose clamp (4) and bracket (5).
5.
Remove high-pressure pipe clamp (6) and high-pressure pipe (7).
6.
Remove clamp (8) and fuel tube (9).
7.
Remove lubrication tube (10).
8.
Remove common rail cover (11).
[*1]
D475A, D475ASD-5E0
50 Disassembly and assembly
9.
Disconnect wiring connectors (12). a Connectors: PCV1, PCV2 and G
SEN02338-03
Removal of fuel supply pump on right bank side k
a
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery. Do not remove the undercover.
1.
Close the fuel valve under the fuel tank.
2.
Remove right side cover (1) and right cover (2).
3.
Remove 4 engine oil filters (3). a Use a filter wrench etc. to remove the filters.
4.
Remove heat insulation plate (4).
k k
10. Remove the mounting bolts of fuel supply pump assembly (13) and pull out the fuel supply pump assembly and mounting bracket (14) together. a Wind a rope around the fuel supply pump and sling it. a Remove the high-pressure pipe clamp just under the fuel supply pump without fail. 4 Left fuel supply pump assembly: 17 kg
a
After the fuel supply pump is removed, the coupling on the drive case moves out of position. Accordingly, rotate the crankshaft to set the drive case in position when installing the fuel supply pump.
11. If necessaty, remove nut (15), coupling (16) and key (17) from supply pump assembly (13).
D475A, D475ASD-5E0
3
SEN02338-03
5.
Disconnect wiring clamp (5) and fuel hose clamps (6).
6.
Remove hose clamp (7) of the fuel air bleeding valve.
7.
4
Remove the common rail according to the following procedure. 1) Remove clamp (8). 2) Remove the common rail cover mounting bolts to drop cover (9). 3) Remove clamp (10). 4) Remove high-pressure pipe (11). 5) Remove bracket (12). 6) Remove common rail cover (9).
50 Disassembly and assembly
7)
Disconnect 6 upper high-pressure pipes (13) of the common rail and high-pressure pipes (14) on this side.
8)
Disconnect common rail wiring connector (15).
9)
Remove right and left mounting bolts (16) to remove common rail (17).
D475A, D475ASD-5E0
50 Disassembly and assembly
8.
Remove brackets (18) and (19).
9.
Remove clamp (20) and fuel tube (21).
SEN02338-03
13. If necessary, remove nut (25), coupling (26) and key (27) from supply pump assembly (24).
10. Remove lubrication tube (22). 11. Disconnect wiring connectors (23). a Connectors: PCV1, PCV2 and G 12. Remove the mounting bolts of fuel supply pump assembly (24) and pull out the fuel supply pump assembly and mounting bracket together. a Wind a rope around the fuel supply pump and sling it. a Remove the high-pressure pipe clamp just under the fuel supply pump without fail. 4
a
Right fuel supply pump assembly: 17 kg
After the fuel supply pump is removed, the coupling on the drive case moves out of position. Accordingly, rotate the crankshaft to set the drive case in position when installing the fuel supply pump.
D475A, D475ASD-5E0
5
SEN02338-03
Installation a
The following is the installation procedure for the left bank fuel supply pump assembly. The basic installation procedure for the right fuel supply pump assembly is the same.
1.
Install key (17), coupling (16) to supply pump assembly (13), then tighten with nut (15). a Be careful not to forget the key (17) when installing the coupling (16). 3 Nut: 176 – 196 Nm {18 – 20 kgm}
50 Disassembly and assembly
High-pressure pipe k
k
2.
Install supply pump assembly (13) temporarily. 2 Supply pump assembly mounting bolt: Adhesive (LT-2) a Before tightening the mounting bolt on the pump side and mounting bolt (14) on the engine mounting bracket side to the specified torque, tighten the sleeve nuts of the high-pressure pipe (between the supply pump and common rail).
5.
3.
Connect the wiring connector (12).
4.
Remove common rail cover (11).
6
When handling the high-pressure pipe and clamp, observe the following. q Never bend the high-pressure pipe to correct before installing or use it for another section. q Install the specified clamp to the specified position securely and tighten it to the specified torque. q Do not apply lubricant to the high-pressure pipe sleeve nut and the threads of the mating part. a If lubricant is applied, the axial tension is increased too much and the highpressure pipe may be broken when the sleeve nut is tightened. Before installing the high-pressure pipe, check it. If it has any defect, replace it since fuel may leak. q Check the taper seal of the connecting part (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and dent "c". q Check part "d" (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
Install the high-pressure pipe according to the following procedure. 1) Install high-pressure pipe assembly (7) and then tighten the sleeve nuts to the specified torque. a Using a spanner-type torque wrench (commercially available), control the tightening torque. 3 High-pressure pipe sleeve nut (Supply pump side): 39.2 – 49 Nm {4 – 5 kgm} High-pressure pipe sleeve nut (Common rail side): 39.2 – 58.8 Nm {4 – 6 kgm} 2) Tighten the supply pump assembly mounting bolts. 3) Tighten supply pump assembly bracket (14) mounting bolts. D475A, D475ASD-5E0
50 Disassembly and assembly 3
4)
5)
6)
Bracket mounting bolt (14): 19.6 – 29.4 Nm {2.0 – 3.0 kgm} Install lubrication tube (10). 3 Lubrication tube joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Install high-pressure pipe clamp (6) according to the following procedure. 1] Finger tighten all the mounting bolts of high-pressure pipe clamp (6) and bracket (16). 2] Tighten the high-pressure pipe clamp (6) mounting bolts permanently. a When tightening the high-pressure pipe clamp mounting bolts, ta ke care ex tremely that an excessive force will not be applied to the mounting area on the supply pump side. 3 Clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm} 3] Tighten bracket (16) mounting bolts permanently. Install 4 rubber covers (15) to the highpressure pipe sleeve nuts. a Install the rubber covers so that their slits will be directed as follows. q Supply pump side: Down q Common rail side: Inward (Facing each other)
D475A, D475ASD-5E0
SEN02338-03
q
Carry out the following installation in the reverse order to removal.
[*1]
3 3
k
Joint bolt on main fuel filter (upper) side: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Joint bolt on fuel supply pump side: 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
Check that each high-pressure pipe is at least 10 mm apart from the wiring harness around it.
7
SEN02338-03
50 Disassembly and assembly
Removal and installation of cylinder head assembly
4. 1
4
A 2 790-331-1110
Wrench
Muffler assembly: 60 kg (1 piece)
Sketch
New/remodel
Q'ty
Part Name
Necessity
Symbol
Special tools
Part No.
Remove mounting bands (3) and connector nuts and then wind a rope around muffler assembly (4) and lift it off.
q 1
Removal k k k
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery.
1.
Close the fuel valve under the fuel tank.
2.
Remove the engine hood. For details, see "Removal and installation of engine hood".
3.
Remove right and left engine side covers (1) and right and left covers (2).
5.
Remove the piping and then remove the corrosion resistor, air bleeding valve and mounting bracket (5) together. 4
6.
Remove muffler mounting bracket (6). 4
8
Corrosion resistor, air bleeding valve and mounting bracket: Approx. 35 kg
Muffler mounting bracket: 38 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
7.
SEN02338-03
Remove aftercooler inlet pipe (7) and aftercooler outlet pipe (8). [*1]
8.
Remove bracket (9) and turbocharger intake connector (10) together. [*2]
9.
Remove turbocharger exhaust connector (11).
14. Remove the common rail cover. For details, see "Removal and installation of fuel supply pump assembly". 15. Remove right and left rubber covers (17) and (18). 16. Remove right and left high-pressure pipes (19).
10. Disconnect right and left main wirings (12). 11. Remove engine oil filter assembly (13). 17. Remove right and left air intake manifolds (20). 4
12. Disconnect fuel hose and piping (14).
Air intake manifold: 35 kg
[*3]
13. Remove main fuel filter assembly (15) and fuel prefilter assembly (16).
D475A, D475ASD-5E0
9
SEN02338-03
18. Remove each tube of the turbocharger. q Lubrication tube (21) q Lubricating oil drain tube (22) q Coolant tube (23) q Coolant drain tube (24)
50 Disassembly and assembly
19. Remove heat insulation cover (25).
[*4] [*4]
20. Sling turbocharger and exhaust manifold assembly (26), remove the mounting bolts, and lift off the turbocharger and exhaust manifold assembly. [*5] 4
10
Turbocharger and exhaust manifold assembly: 60 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02338-03
21. Removal of injector external wiring 1) Remove cover plate (27). 2) Disconnect connector (28) from each cylinder head and disconnect wiring harness (29). 22. Remove air vent tubes (30) and (31). 23. Remove spill tube (32).
[*6]
25. Removal of rocker arm assembly 1) Loosen locknuts (34) and then loosen adjustment screws (35) fully. a Check that the rocker arm is not affected by the valve tension but it is free. 2) Remove rocker arm assembly (36). a Put a location tag to each rocker arm assembly before storing.
24. Remove head cover (33).
26. Remove push rods (37). 27. Remove crossheads (38). 28. Removal of fuel injector 1) Remove injector terminal mounting nuts (39). 2) Remove clamp mounting bolt (40). 3) Push connector (41) into the cylinder head and remove injector wiring harness (42). 4) Remove holder mounting bolt (43).
D475A, D475ASD-5E0
11
SEN02338-03
5)
Insert small L-bar [B] under the fuel connector and pry out fuel injector (44) slowly. a Do not grip the solenoid valve at the top of the injector with pliers to pull out the injector.
50 Disassembly and assembly
Installation Cylinder head assembly 1.
Install the cylinder head gasket.
2.
Sling and install cylinder head assembly (45). 4
Cylinder head assembly: 30 kg
29. Lift off cylinder head assembly (45). 4
a
Cylinder head assembly: 30 kg
If the cylinder head assembly is removed without removing the fuel injector, the injector tip projects from the bottom of the cylinder head. Accordingly, use a block, etc. to prevent the injector from interfering with the floor.
a a 2 3
3
If there are 5 punch marks on the head of a bolt, do not reuse that bolt but replace it. Tighten the mounting bolts in the order shown in the figure. Cylinder head assembly mounting bolt: Molybdenum disulfide grease (LM-P) Cylinder head assembly mounting bolts (1) – (6): 1st time: 137 – 157 Nm {14 – 16 kgm} 2nd time: 284 – 294 Nm {29 – 30 kgm} 3rd time: Retighten by 90 – 120° Cylinder head assembly mounting bolt (7): 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30. Remove the cylinder head gasket.
12
D475A, D475ASD-5E0
50 Disassembly and assembly a
SEN02338-03
Use tool A2 (See the tool table) to retighten the mounting bolts. When not using tool A2, make marks on the bolts and cylinder head, and then retighten each bolt by 90 – 120°
6.
a
After tightening the bolts, make punch mark "a" on the main bolt head (Do not make it when new bolts are used, however).
Fuel injector a Check that there is no dirt in the injector sleeve. 2 O-ring: Engine oil (EO30) 3.
Fit O-rings (46) and (47) to fuel injector (44). a Take care not to fit O-ring (47) to center groove (A).
4.
Install gasket (48) to fuel injector (44).
5.
Insert fuel injector (44) and injector holder (49) together in the cylinder head.
D475A, D475ASD-5E0
Install spherical washer (50) to injector holder mounting bolt (43) and tighten injector holder (49) temporarily. 2 Spherical washer: Engine oil (EO30) a Tighten injector holder (49) permanently after tightening the high-pressure pipe temporarily.
Crosshead 7. Install crossheads (38). 2 Sliding parts of crosshead: Engine oil (EO30)
13
SEN02338-03
8.
9.
14
Adjust the crosshead according to the following procedure. 1) Loosen locknut (102) and then loosen adjustment screw (103) to a position where it will not touch valve stem (104). 2) Hold the contact face to the rocker arm with the finger to keep crosshead in contact with valve stem (105) on the push rod side. 3) Tighten adjustment screw (103) slowly and check the point at which adjustment screw (103) touches valve stem (104). 4) Tighten adjustment screw (103) further by 20 – 30° from the above point. 5) While holding adjustment screw (103), tighten locknut (102). 3 Locknut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
Injector wiring harness 1) Push out connector (41) from inside of the cylinder head and install injector wiring harness (42) in the cylinder head. 2) Tighten injector terminal mounting nuts (39) and clamp mounting bolt (40). a Tighten injector terminal mounting nuts (39) alternately. 3 Injector terminal mounting nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} a After tightening the injector terminal mounting nuts, press the wiring harness against the injector body to take up the slack.
50 Disassembly and assembly
10. Install push rods (37). a Check that each push rod end is fitted in the receiving area of the cam follower. 2 Both ends of push rod: Engine oil (EO30)
11. Install rocker arm assembly (36). 2 Rocker shaft: Engine oil (EO30) 2 Threaded part and seat of rocker arm assembly mounting bolt: Engine oil (EO30) a Check that the ball of adjustment screw (35) is fitted in the push rod socket. a When tightening the mounting bolt, check that adjustment screw (35) does not press the push rod. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Tighten locknut (34) after adjusting the valve clearance. a Adjust the valve clearance. For details, see Testing and adjusting, "Testing and adjusting valve clearance".
D475A, D475ASD-5E0
50 Disassembly and assembly 3
a
Tightening torque for locknut: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} After tightening the locknut, check the valve clearance again.
12. Install spill tube (32). 3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} 13. Place cylinder head cover (33). (Place it to prevent dirt from entering. It will need to be removed again.)
D475A, D475ASD-5E0
SEN02338-03
14. Fuel injector and high-pressure pipe (between common rail and fuel injector) k When handling the high-pressure pipe and clamp, observe the following. q Never bend the high-pressure pipe to correct before installing or use it for another section. q Install the specified clamp to the specified position securely and tighten it to the specified torque. q Do not apply lubricant to the highpressure pipe sleeve nut and the threads of the mating part. a If lubricant is applied, the axial tension is increased too much and the high-pressure pipe may be broken when the sleeve nut is tightened. k Before installing the high-pressure pipe, check it. If it has any defect, replace it since fuel may leak. q Check the taper seal of the connecting part (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and dent "c". q Check part "d" (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
15
SEN02338-03
1)
2)
3) 4)
5)
16
Fit O-ring (52) to the high-pressure pipe sleeve nut (51). 2 O-ring: Engine oil (EO30) Tighten sleeve nut (51) temporarily into fuel injector (44). a If sleeve nut (51) does not catch the threads, press its end with a small rod, etc. toward the injector and turn the spanner. Tighten sleeve nut (53) on the common rail side temporarily, too. Tighten injector holder (49) permanently. 3 Injector holder mounting bolt (43): 58.9 – 73.5 Nm {6.0 – 7.5 kgm} Tighten the sleeve nut to the specified torque. a Using a spanner-type torque wrench (commercially available), control the tightening torque. 3 High-pressure pipe (19) sleeve nut (Injector side): 39.2 – 49 Nm {4 – 5 kgm} 3 High-pressure pipe (19) sleeve nut (Common rail side): 39.2 – 49 Nm {4 – 5 kgm} a After tightening each sleeve nut (51), check that O-rings (46) and (52) are not projected from the sleeve nut.
50 Disassembly and assembly
6)
7)
Install the cylinder head cover. 3 Cylinder head cover mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm} Install rubber covers (17) and (18) to the sleeve nuts of high-pressure pipes (19). a Install the rubber covers so that their slits will be directed as follows. q Injector side (17): Down q Common rail side (18): Cylinder block side
15. Air intake manifold assembly 1) Install the gasket. a Direct the side having the mark of "UP" up and direct it toward the air intake manifold. 2 Threaded part and seat of mounting bolt: Molybdenum disulfide grease (LM-P) a Tighten the mounting bolts according to the following procedure. 3 Air intake manifold mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
D475A, D475ASD-5E0
50 Disassembly and assembly
16. Install the high-pressure pipe clamps (between the common rail and fuel injector). For details, see "Removal and installation of fuel supply pump assembly".
SEN02338-03
[*2]
3
Air intake connector mounting bolt: 49 – 68.6 Nm {5.0 – 7.0 kgm}
[*3] 17. Install the high-pressure pipes (between the common rail and fuel supply pump). For details, see "Removal and installation of fuel supply pump assembly". a For precautions, see the section of the high-pressure pipe (between the common rail and fuel injector). a Using a spanner-type torque wrench (commercially available), control the tightening torque.
3 3 3
Fuel tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Fuel hose joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Spill tube joint bolt Cylinder head side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Air intake manifold side: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*4] q
Carry out the following installation in the reverse order to removal.
[*1] Air hose Use a new MIKALOR clamp. 1) Set the hose to the original position (marked position). (Insertion depth of air hose: Min. 80 mm) 2) Set the bridge (BR) under the clamp bolt and lap it over the band at least 3 mm (b). Dimension (b): Min. 3 mm 2 Threaded part (BC) of clamp bolt: Lubricating oil (Threebond PANDO 18B)
q
a
a
Do not use an impact wrench.
When reusing used hose 3) Set the clamp to the trace of the clamp on the hose. 3 Clamp bolt: Min. 6 Nm {0.6 kgm}
q
q
3 3 3
Turbocharger coolant tube joint bolt (upper side): 24.5 – 34.3 Nm {2.3 – 3.5 kgm} Turbocharger coolant tube sleeve nut (lower side): 24.5 – 59 Nm {2.3 – 6 kgm} Turbocharger coolant hose: 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
[*5] Exhaust manifold assembly 1) Install the gasket. a Direct the side having the mark of "OUT" toward the exhaust manifold. a Tighten the mounting bolts in the numeric order shown in the figure. a After tightening the mounting bolts, tighten them again to the same torque. 2 Threaded part and seat of mounting bolt: Molybdenum disulfide grease (LM-P) 3 Exhaust manifold mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
When using new hose 4) Tighten until dimension BDG becomes as follows. BDG: 17 – 20 mm
D475A, D475ASD-5E0
17
SEN02338-03
50 Disassembly and assembly
Reference Turbocharger assembly 2 Turbocharger assembly mounting bolt and nut: Molybdenum disulfide grease (LM-P) 3 Turbocharger assembly mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 kgm} [*6]
3
q
k
18
Air vent tube mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.
Check that each high-pressure pipe is at least 10 mm apart from the wiring harness around it.
D475A, D475ASD-5E0
50 Disassembly and assembly
Removal and installation of fuel injector assembly
SEN02338-03 4
1
Corrosion resistor, air bleeding valve and mounting bracket: Approx. 35 kg
Removal k k k
1.
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery. Close the fuel valve under the fuel tank.
2.
Remove the engine hood. For details, see "Removal and installation of engine hood".
3.
Remove right and left engine side covers (1) and right and left covers (2).
6.
Remove muffler mounting bracket (6). 4
4.
Remove mounting bands (3) and connector nuts and then wind a rope around muffler assembly (4) and lift it off. 4
5.
Muffler mounting bracket: 38 kg
7.
Remove aftercooler inlet pipe (7) and aftercooler outlet pipe (8). [*1]
8.
Remove bracket (9) and turbocharger intake connector (10) together. [*2]
9.
Remove turbocharger exhaust connector (11).
Muffler assembly: 60 kg (1 piece)
Remove the piping and then remove the corrosion resistor, air bleeding valve and mounting bracket (5) together.
D475A, D475ASD-5E0
19
SEN02338-03
50 Disassembly and assembly
10. Disconnect right and left main wirings (12). 11. Remove engine oil filter assembly (13).
17. Remove right and left air intake manifolds (20). 4
12. Disconnect fuel hose and piping (14).
Air intake manifold: 35 kg
[*3]
13. Remove main fuel filter assembly (15) and fuel prefilter assembly (16).
14. Remove the common rail cover. For details, see "Removal and installation of fuel supply pump assembly".
18. Removal of injector external wiring 1) Remove cover plate (27). 2) Disconnect connector (28) from each cylinder head and disconnect wiring harness (29). 19. Remove head cover (30).
15. Remove right and left rubber covers (17) and (18). 16. Remove right and left high-pressure pipes (19).
20
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02338-03
20. Removal of rocker arm assembly 1) Loosen locknuts (34) and then loosen adjustment screws (35) fully. a Check that the rocker arm is not affected by the valve tension but it is free. 2) Remove rocker arm assembly (36). a Put a location tag to each rocker arm assembly before storing.
5)
Insert small L-bar [B] under the fuel connector and pry out fuel injector (44) slowly. a Do not grip the solenoid valve at the top of the injector with pliers to pull out the injector.
Installation
21. Removal of fuel injector 1) Remove injector terminal mounting nuts (39). 2) Remove clamp mounting bolt (40). 3) Push connector (41) into the cylinder head and remove injector wiring harness (42). 4) Remove holder mounting bolt (43).
D475A, D475ASD-5E0
Fuel injector a Check that there is no dirt in the injector sleeve. 2 O-ring: Engine oil (EO30) 1.
Fit O-rings (46) and (47) to fuel injector (44). a Take care not to fit O-ring (47) to center groove (A).
2.
Install gasket (48) to fuel injector (44).
3.
Insert fuel injector (44) and injector holder (49) together in the cylinder head.
21
SEN02338-03
4.
Install spherical washer (50) to injector holder mounting bolt (43) and tighten injector holder (49) temporarily. 2 Spherical washer: Engine oil (EO30) a Tighten injector holder (49) permanently after tightening the high-pressure pipe temporarily.
5.
Injector wiring harness 1) Push out connector (41) from inside of the cylinder head and install injector wiring harness (42) in the cylinder head. 2) Tighten injector terminal mounting nuts (39) and clamp mounting bolt (40). a Tighten injector terminal mounting nuts (39) alternately. 3 Injector terminal mounting nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm} a After tightening the injector terminal mounting nuts, press the wiring harness against the injector body to take up the slack.
22
50 Disassembly and assembly
6.
Install rocker arm assembly (36). 2 Rocker shaft: Engine oil (EO30) 2 Threaded part and seat of rocker arm assembly mounting bolt: Engine oil (EO30) a Check that the ball of adjustment screw (35) is fitted in the push rod socket. a When tightening the mounting bolt, check that adjustment screw (35) does not press the push rod. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a Tighten locknut (34) after adjusting the valve clearance. a Adjust the valve clearance. For details, see Testing and adjusting, "Testing and adjusting valve clearance".
3
a
Tightening torque for locknut: 52.9 – 64.7 Nm {5.4 – 6.6 kgm} After tightening the locknut, check the valve clearance again.
D475A, D475ASD-5E0
50 Disassembly and assembly
7.
Place the cylinder head cover. (Place it to prevent dirt from entering. It will need to be removed again.)
8.
Fuel injector and high-pressure pipe (between common rail and fuel injector) k When handling the high-pressure pipe and clamp, observe the following. q Never bend the high-pressure pipe to correct before installing or use it for another section. q Install the specified clamp to the specified position securely and tighten it to the specified torque. q Do not apply lubricant to the highpressure pipe sleeve nut and the threads of the mating part. a If lubricant is applied, the axial tension is increased too much and the high-pressure pipe may be broken when the sleeve nut is tightened. k Before installing the high-pressure pipe, check it. If it has any defect, replace it since fuel may leak. q Check the taper seal of the connecting part (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and dent "c". q Check part "d" (End of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
SEN02338-03
1)
2)
D475A, D475ASD-5E0
3) 4)
5)
Fit O-ring (52) to the high-pressure pipe sleeve nut (51). 2 O-ring: Engine oil (EO30) Tighten sleeve nut (51) temporarily into fuel injector (44). a If sleeve nut (51) does not catch the threads, press its end with a small rod, etc. toward the injector and turn the spanner. Tighten sleeve nut (53) on the common rail side temporarily, too. Tighten injector holder (49) permanently. 3 Injector holder mounting bolt (43): 58.9 – 73.5 Nm {6.0 – 7.5 kgm} Tighten the sleeve nut to the specified torque. a Using a spanner-type torque wrench (commercially available), control the tightening torque. 3 High-pressure pipe (19) sleeve nut (Injector side): 39.2 – 49 Nm {4 – 5 kgm} 3 High-pressure pipe (19) sleeve nut (Common rail side): 39.2 – 49 Nm {4 – 5 kgm} a After tightening each sleeve nut (51), check that O-rings (46) and (52) are not projected from the sleeve nut.
23
SEN02338-03
6)
7)
9.
Install the cylinder head cover. 3 Cylinder head cover mounting bolt: 14.7 – 34.3 Nm {1.5 – 3.5 kgm} Install rubber covers (17) and (18) to the sleeve nuts of high-pressure pipes (19). a Install the rubber covers so that their slits will be directed as follows. q Injector side (17): Down q Common rail side (18): Cylinder block side
50 Disassembly and assembly
Removal q
Carry out the following installation in the reverse order to removal.
[*1] q
a
Air hose Use a new MIKALOR clamp. 1) Set the hose to the original position (marked position). (Insertion depth of air hose: Min. 80 mm) 2) Set the bridge (BR) under the clamp bolt and lap it over the band at least 3 mm (b). Dimension (b): Min. 3 mm 2 Threaded part (BC) of clamp bolt: Lubricating oil (Threebond PANDO 18B)
a
Do not use an impact wrench.
q
When reusing used hose 3) Set the clamp to the trace of the clamp on the hose. 3 Clamp bolt: Min. 6 Nm {0.6 kgm}
q
When using new hose 4) Tighten until dimension BDG becomes as follows. BDG: 17 – 20 mm
Install the high-pressure pipe clamps (between the common rail and fuel injector). For details, see "Removal and installation of fuel supply pump assembly".
10. Install the high-pressure pipes (between the common rail and fuel supply pump). For details, see "Removal and installation of fuel supply pump assembly". a For precautions, see the section of the high-pressure pipe (between the common rail and fuel injector). a Using a spanner-type torque wrench (commercially available), control the tightening torque.
[*2]
3
Air intake connector mounting bolt: 49 – 68.6 Nm {5.0 – 7.0 kgm}
[*3]
3
3
k
24
Fuel tube joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Fuel hose joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Check that each high-pressure pipe is at least 10 mm apart from the wiring harness around it.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02338-03 a
Removal and installation of engine front seal
1
3 795-931-1100
A
Seal puller
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Remove front seal (2) in the following procedure. 1) Replace the tip of tool A3 with the hook type one. 2) Hitch the hook to the hoop of front seal (2). 3) Remove front seal with impact of slide hammer (SH). q
Tool A3
a
CS: Crankshaft
t 1
795T-621-1430 Plate
t 1 N Q
795T-621-1441 Push tool
t 1 N Q
4 01050-32280
• Bolt
t 3
01582-02218
• Nut
t 3
01640-22232
• Washer
t 3
Removal 1.
Remove radiator guard assembly. For details, see "Removal and installation of radiator guard assembly".
2.
Remove crankshaft pulley (1).
3.
Remove front seal (2).
D475A, D475ASD-5E0
[*1]
25
SEN02338-03
50 Disassembly and assembly
Installation 1.
Clean, degrease and then dry the contact surface between the front cover and front seal.
2.
Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts.
3.
When installing front oil seal (2), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 2
1)
3)
Using the A4 (push tool), press oil seal (2) in the front case until it becomes the dimension (a) as shown in the figure. a Oil seal press fit dimensions (a): 17 mm (from shaft end surface) (b): 25.1 mm (from front cover end surface)
Inner circumference of front oil seal: Gasket sealant (LG-7 or equivalent)
The surface having the parts number (PN) marking must face to the outside of engine.
q
Carry out the following installation in the reverse order of removal.
[*1] a Align the dowel pin when installing the crankshaft pulley. a Tighten the mounting bolts in the order shown in the diagram below. 2 Threaded part and seat of bolt: Engine oil (EO30) 3 Crankshaft pulley mounting bolt: 1st time: 73.5 ± 19.6 Nm {7.5 ± 2.0 kgm} 2nd time: 245 ± 19.6 Nm {25 ± 2.0 kgm} 3rd time: 744.8 ± 19.6 Nm {76 ± 2.0 kgm} 2)
26
Tighten bolts using the tool A4 (plate), and press oil seal (2) to the shaft end.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02338-03 a
Removal and installation of engine rear seal
Seal puller
795T-621-1531 Plate
01640-02032
CS: Crankshaft
Sketch
New/remodel
Part Name
Q'ty
Part No.
5 01050-32050
a
a Necessity
Symbol A
q
1
Special tools
3 795-931-1100
Take care in the removal not to damage the seal installation position on the flywheel housing and the seal contact face on the crankshaft. Before removing, slightly drive the seal in once to free it from fixation. 1) Replace the tip of tool A3 with the hook type one. 2) Hitch the hook to the hoop of rear seal (3). 3) Remove rear seal with impact of slide hammer (SH). Tool A3
t 1 t 1 N Q
Bolt
t 5
Washer
t 5
Removal 1.
Remove damper assembly. For details, see "Removal and installation of damper assembly".
2.
Sling with eyebolts [1] (M16, P=2), remove mounting bolts (1), screw in forcing screws [2] (M12, P=1.75), then remove flywheel (2). 4
3.
Flywheel: 140 kg
Remove rear seal (3).
D475A, D475ASD-5E0
27
SEN02338-03
Installation 1.
Clean, degrease and then dry the contact surface between the flywheel housing and rear seal.
2.
Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts.
3.
When installing rear oil seal (3), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. 2
1)
2)
28
50 Disassembly and assembly
4.
Using guide bolt, and install flywheel (2).
5.
Secure flywheel (2) and housing with plate [3].
a
Tighten the mounting bolts in the order shown in the diagram below. 2 Threaded part and seat of bolt: Engine oil (EO30) 3 Flywheel mounting bolt: 1st step: 98 ± 19.6 Nm {10 ± 2 kgm} 2nd step: 294 ± 19.6 Nm {30 ± 2 kgm} 3rd step: 539 ± 19.6 Nm {55 ± 2 kgm}
Inner circumference of rear oil seal: Gasket sealant (LG-7 or equivalent)
The surface having the parts number (PN) marking must face to the outside of engine.
Using the A5 (push tool), press oil seal (3) in the flywheel housing until it becomes the dimension (a) as shown in the figure. a Oil seal press fit dimensions (a): 5 mm (from flywheel housing end surface)
D475A, D475ASD-5E0
50 Disassembly and assembly
6.
SEN02338-03
After installing flywheel, use dial gauge [4] to measure radial and face runout of flywheel. q Face runout: Max. 0.25 mm q Radial runout: Max. 0.25 mm
D475A, D475ASD-5E0
29
SEN02338-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN02338-03
© 2011 KOMATSU All Rights Reserved Printed in Japan 02-11
30
SEN02015-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Power train, Part 1 Power train, Part 1 .......................................................................................................................................... 2 Removal and installation of damper assembly..................................................................................... 2 Disassembly and assembly of damper assembly ................................................................................ 4 Removal and installation of power train unit assembly ........................................................................ 7 Removal and installation of PTO, torque converter assembly ........................................................... 10 Disconnection and connection of PTO, torque converter assembly .................................................. 12 Disassembly and assembly of torque converter assembly ................................................................ 14 Disassembly and assembly of PTO assembly ................................................................................... 24 Removal and installation of TORQFLOW transmission assembly ..................................................... 31 Disassembly and assembly of TORQFLOW transmission assembly................................................. 32
D475A, D475ASD-5E0
1
SEN02015-01
50 Disassembly and assembly
Power train, Part 1
1
Removal and installation of damper assembly
6.
Remove holder (4) and coupling (5).
7.
Remove retainer (6).
Removal
8.
Sling damper cover (7), then use forcing screw [1] (12mm, P=1.75) to remove damper cover. k Install guide bolts (12 mm, P = 1.75, l = 100) in 2 mounting bolt holes in the top of the damper cover so that the damper cover does not come out suddenly.
1.
Remove hood assembly. For details, see Removal and installation of hood assembly.
2.
Open underguard (3rd from front of machine).
3.
Remove drain plug (1) and drain damper oil. 6
4.
4
Remove dipstick and dipstick guide (2).
Sling universal joint (3), then remove mounting bolts, and lift off. [*1] 4
2
Damper cover: 50 kg
Damper case: Approx. 2.2 l
9.
5.
[*2]
Sling damper assembly (8), then using guide bolt [2] (16 mm, P = 2.0) and nut [3], loosen nut slowly so that damper assembly does not come out suddenly, then remove. 4
Damper assembly: 85 kg
Universal joint: 65 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02015-01
Installation q
[*1]
[*2]
Carry out installation in the reverse order to removal. 3
2 3
q
Universal joint mounting bolt: 156.8 – 196 Nm {16 – 20 kgm}
Holder mounting bolt thread: Thread tightener (LT-2) Holder mounting bolt: 490 – 607.6 Nm {50 – 62 kgm}
Refilling with oil (damper case) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
D475A, D475ASD-5E0
3
SEN02015-01
Disassembly and assembly of damper assembly
50 Disassembly and assembly
Assembly 1.
Using push tool, press fit bearing (9). 2 Flywheel pilot portion: Grease (G2-U) a Fill 50% (approx. 55 g) of clearance (a).
2.
Install seal (8) to flange (6), and seal (3) to flange (2). a Install the seal with the lip facing the inside as shown in the diagram.
3.
Align the bolt holes with body (7), then install flange (6). 2 Flange mating surface: Gasket sealant (LG-4) a Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both the flange and body surfaces with gasket sealant. a Coat with a thickness of about 0.1 – 0.2 mm, leave to dry for 2 – 3 minutes, then tighten.
Disassembly 1.
Remove bolt (1), then remove flange (2).
2.
Remove seal (3).
3.
Remove shaft (4).
4.
Remove rubber (5).
5.
Remove flange (6) from body (7).
6.
Remove seal (8).
7.
Remove bearing (9).
Disassembly of damper cover assembly 8. Remove bearing (10) and seal (11) from cover (12). 9.
4
Remove oil seal (13) from retainer (14).
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02015-01
7.
4.
5.
Set shaft (4) to flange and body assembly in position. Assemble rubber (5). a When assembling the rubber, coat the whole surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI). a After assembling the rubber, fill approx. 50% (approx. 400 g) of the space ((b) portion: 16 places) between the shaft and body with grease (G2-LI).
Assembly of damper cover assembly 8. Using push tool [1], press fit oil seal (13) to retainer (14). 2 Oil seal press-fitting surface: Gasket sealant (LG-1) a Coat the inside surface of the retainer thinly with gasket sealant and wipe off any sealant that is forced out. 2 Lip of oil seal: Grease (G2-LI)
9.
6.
Tighten bolt (1).
Using push tool [2], press fit bearing (10) to cover (12).
Install flange (2). 2 Flange mating surface: Gasket sealant (LG-4) a Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both the flange and body surfaces with gasket sealant. a Coat with a thickness of about 0.1 – 0.2 mm, leave to dry for 2 – 3 minutes, then tighten.
D475A, D475ASD-5E0
5
SEN02015-01
50 Disassembly and assembly
10. Using push tool [1], press fit oil seal (11) to cover (12). 2 Oil seal press-fitting surface: Gasket sealant (LG-1) a Coat the inside surface of the cover thinly with gasket sealant and wipe off any sealant that is forced out. 2 Lip of oil seal: Grease (G2-LI)
6
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02015-01
Removal and installation of power train unit assembly
8.
Remove hydraulic pump inlet tube coupling (5) and hydraulic tank side coupling (6), and remove tube (7).
Removal
9.
Disconnect fan motor hose (8).
1.
Drain oil from hydraulic tank and power train case. 6 6
10. Disconnect hoses (9) and (10).
Hydraulic tank: Approx. 120 l Power train case: Approx. 150 l
2.
Remove floor frame assembly. For details, see "Removal and installation of floor frame assembly".
3.
Remove fuel tank assembly. For details, see "Removal and installation of fuel tank assembly".
4.
Remove brake rod (1).
5.
Disconnect cable (2).
11. Disconnect steering hose (11). 12. Disconnect hoses (12) and (13).
6.
Disconnect lubrication hose (3).
7.
Disconnect fan motor pump tube coupling (4).
13. Remove hydraulic pump inlet tube (14). 14. Disconnect hydraulic pump PPC hoses (15) and (16).
D475A, D475ASD-5E0
7
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15. Disconnect hydraulic pump outlet hoses (17) and (18).
50 Disassembly and assembly
19. Remove universal joint (23). 4
[*1]
Universal joint: 65 kg
16. Disconnect hydraulic PPC hoses (19) and (20).
20. Remove front mount bolt (24). 17. Disconnect wiring connector (21) (PL1, PL2, PL3).
[*2]
21. Remove rear mount bolt (25), then remove mount cap (26). [*3] 4
Mount cap: 30 kg
18. Disconnect hose (22), then disconnect clamp (1 place) on top of steering case. 22. Remove housing clip (27), and move flange (28) towards final drive end. [*4] 23. Using forcing screws [1], remove cover (29).
8
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02015-01
24. Remove shaft (30). a Pull out the shaft with forcing screws [2]. a 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.
Installation q
[*1]
[*2]
[*3]
[*4]
Carry out installation in the reverse order to removal. 3
3
3
Universal joint mounting bolt: 156.8 – 196 Nm {16 – 20 kgm}
Front mount bolt: 1,519 – 1,911 Nm {155 – 195 kgm}
Rear mount bolt: 823.2 – 1,029 Nm {84 – 105 kgm}
a
Check that the housing clip is fitted securely in the flange. 3 Housing clip: 4.9 – 8.8 Nm {0.5 – 0.9 kgm}
25. Lift off power train unit assembly (31). 4
Power train unit assembly: 5,500 kg
[*5] [*5]
q
a
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 5
D475A, D475ASD-5E0
Power train case: Approx. 210 l Hydraulic tank: Approx. 140 l
9
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50 Disassembly and assembly
Removal and installation of PTO, torque converter assembly
6.
Sling filter assembly (6), then remove. 4 4
Removal 1.
Remove power train unit assembly. For details, see "Removal and installation of power train unit assembly".
2.
Raise power train unit assembly (1) and set on block. a Set blocks under the front of the oil pan, transmission rear case, and steering case.
7.
Remove brake rod (2).
[*1]
8.
Disconnect central pressure detection hose (3), then remove together with central pressure detection bracket (4). a 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).
10
[*2]
Mount bracket: 70 kg
Remove tube (10) and scavenging pump (11). k Sling the scavenging pump, then remove the mounting bolts. 4
4.
Power train pump, strainer assembly: 100 kg
Lift off mount bracket (9). 4
9.
Torque converter, transmission lubrication filter assembly: Approx. 80 kg
Remove power train pump (7) and strainer assembly (8). k Sling the power train pump, then remove together with the strainer. 4
3.
Transmission filter assembly: 40 kg
Scavenging pump: 24 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
10. Remove hose (12). 11. Remove gauge guide (13).
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14. Remove PTO and torque converter assembly (19). [*3] k Sling the PTO and torque converter assembly, then remove the mounting bolts. a Using a lever block, lift off the PTO and torque converter assembly horizontally. 4
PTO, torque converter assembly: 830 kg
12. Removal of fan pump 1) Remove tube (14). 2) Remove wire (15). 3) Remove connector (16). 4) Lift off pump assembly (17). 4
Fan pump assembly: 72 kg
Installation q
[*1]
[*2]
[*3] 13. Remove oil pan (18). a Remove the block under the oil pan, sling the oil pan, then remove the mounting bolts and disconnect the oil pan. 4
Carry out installation in the reverse order to removal. k
Bend the cotter pin securely.
2
a
PTO boss rotating portion: Grease (G2-LI)
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.
Oil pan: 120 kg
D475A, D475ASD-5E0
11
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50 Disassembly and assembly
Disconnection and connection of PTO, torque converter assembly
5.
Remove oil seal (6).
6.
Remove spacer (7). a Remove snap ring (8), then remove the spacer.
7.
Remove PTO assembly (9) and torque converter assembly (10). a Using eyebolts [1], raise the PTO assembly, then disconnect it from the torque converter assembly.
C
1
790-413-1010 Bracket
t 1
790-501-5000 Repair stand
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disconnection 1.
Set PTO and torque converter assembly (1) to tool C1.
4
2.
Remove coupling assembly (2).
3.
Remove cap (3). a Remove snap ring (4), then remove the cap.
4.
Remove retainer assembly (5). [*1] a Using forcing screws, remove the cover, retainer assembly, and shims. a Check the number and thickness of the shims, and keep in a safe place.
12
PTO, torque converter assembly: 830 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
Connection q
SEN02015-01
3)
Carry out connection in the reverse order to disconnection. 4)
[*1] Adjust the clearance of the taper roller bearing as follows. 1) Assemble the oil seal to the retainer assembly, then install the cover, and tighten to 9.8 Nm {1 kgm}. a Apply liquid gasket (LG-5) to the oil seal press-fitting face. a Apply liquid gasket (LG-5) thinly to the inside of the retainer hole and wipe off any part forced out. a Install the oil seal without slanting it. a Apply grease (G2-LI) to the oil seal lip part 2) Using a clearance gauge, measure clearance (a) between the retainer and the housing. a Measure clearance (a) at four points (A, B, C, D) around the circumference, and take the average as clearance (a).
D475A, D475ASD-5E0
Measure shim thickness. (a) – (0 – 0.05 mm) a Shim thickness: 0.15 mm, 0.20 mm, 0.50 mm Assemble the selected thickness of shim, and tighten the retainer assembly to the specified torque. 2 Mounting bolt: Thread tightener (LT-2) 3 Retainer mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} Assemble the shim as shown in the diagram below so that it does not come at position (b) of the retainer removal tap. q
a
13
SEN02015-01
50 Disassembly and assembly
Disassembly and assembly of torque converter assembly
2)
C
1
790-413-1010 Bracket
t 1
790-501-5000 Repair stand
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Using eyebolts [1], remove lockup clutch and drive case assembly (4). a Disassemble the lockup clutch and drive case assembly as follows. 1] Remove seal ring (5), and using forcing screws [2], remove input shaft (6).
Disassembly q
Set the torque converter assembly to tool C1.
2] 3]
1.
Torque converter valve assembly Remove torque converter valve assembly (1).
2.
Draining oil Remove 2 drain plugs (2), and drain oil from pump case. a After draining the oil, tighten the plugs.
3.
Lockup clutch, drive case assembly 1) Leaving 2 mounting bolts (3) in position, remove mounting bolts, then place input shaft side on top and remove remaining mounting bolts.
14
Remove snap ring (7), then remove plate (8). Set clutch housing side at bottom, and using forcing screws [3], remove turbine (9).
D475A, D475ASD-5E0
50 Disassembly and assembly
4]
5]
SEN02015-01
Set clutch housing at top, then using eyebolts [4], remove housing and piston assembly (10). a When the assembly is removed, the piston will fall out, so support it by hand when removing. Remove piston (11) from housing (12).
9]
4. 6] 7]
Remove seal ring (13) from piston. Remove seal ring (14) from housing.
8]
Using push tool [5], remove bearing (15) from housing.
Stator assembly 1) Remove snap ring (19), then remove stator assembly (20). 2) Disassemble stator assembly as follows. 1] Remove snap ring (21), then remove race (22) from stator (23).
2]
D475A, D475ASD-5E0
Remove 3 discs (16) and 2 plates (17) from drive case (18). a After removing the discs and plates, keep them in a flat place to prevent them from becoming distorted.
Remove snap ring (24) from stator (23).
15
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5.
Pump assembly 1) Remove snap ring (25). 2) Remove pump assembly (26). 3) Disassemble pump assembly as follows. 1] Remove retainer (27). 2] Remove bearing and guide assembly (28) from pump (29).
50 Disassembly and assembly
9.
Pin Remove pin (37).
10. Inner gear Remove snap ring (38), then remove inner gear (39).
3]
6.
Remove bearing outer race (30) from guide (31).
11. Piston 1) Remove piston (40) from case (41).
Stator clutch housing Set stator clutch housing at top and remove stator clutch housing (32).
2) 3)
7.
Spring Remove spring (33).
8.
Springs, discs, plate Remove springs (34), 2 discs (35), and 1 plate (36). a After removing the discs and plates, keep them in a flat place to prevent them from becoming distorted.
16
Remove seal ring (42) from piston. Remove seal ring (43) from case.
D475A, D475ASD-5E0
50 Disassembly and assembly
12. Stator shaft assembly 1) Tap stator shaft assembly (44) with a plastic hammer, and remove from case (45). 2) Disassemble stator shaft assembly as follows. 1] Using push tool [6], remove shaft assem bly (4 6) from stator sha ft assembly.
2]
3] 4]
SEN02015-01
5]
Using push tool [7], remove bearing (55), then remove plate (56).
Remove snap ring (47), then remove bearing inner race (48), bushing (49), and seal ring (50) from shaft. Remove seal ring (51) from stator shaft (52). Remove snap ring (53), then remove plate (54).
D475A, D475ASD-5E0
17
SEN02015-01
Assembly a
q
1.
7)
Wash all parts in clean flushing oil (in particular, oil holes, etc.), then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Set case (41) to tool C1.
Stator shaft assembly 1) Assemble plate (56) to stator shaft (52), and using push tool, press fit bearing (55). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns. 2) Install plate (54), and secure with snap ring (53). 3) Install seal ring (51) to stator shaft (52). a After installing the seal ring, coat it with grease (G2-LI) to fix it to the shaft securely.
4)
5)
6)
18
50 Disassembly and assembly
Install seal ring (50) to shaft. a After installing the seal ring, coat it with grease (G2-LI) to fix it to the shaft securely. Using push tool [9], press fit bushing (49) to shaft. a Be careful not to deform the bushing when press fitting. Using push tool [10], press fit inner race (48) to shaft.
Install snap ring (47), and secure inner race.
8)
Tap stator shaft (52) with a plastic hammer and press fit bearing portion to case. 9) Set shaft (46) to stator shaft, then using push tool, press fit bearing portion. 10) Turn over case and tighten mounting bolts of shaft from case end.
2 3
Mounting bolt: Thread tightener (LT-2) Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
D475A, D475ASD-5E0
50 Disassembly and assembly
2.
Piston 1) Install seal ring (43) to case. 2 Outer circumference of seal ring: Grease (G2-LI) a Be careful to assemble the seal ring facing in the direction shown in the diagram below. 2) Install seal ring (42) to piston. 2 Outer circumference of seal ring: Grease (G2-LI) a Install the seal rings in the correct directions with their grooves (a) in the directions shown in the figure.
D475A, D475ASD-5E0
SEN02015-01
3)
Install piston (40) to case (41). 2 Contact surface of seal ring: Grease (G2-LI)
3.
Inner gear Install inner gear (39) and secure with snap ring (38).
4.
Pin Install pin (37).
5.
Plate, discs, springs Install 1 plate (36), 2 discs (35), and springs (34).
6.
Dowel pins Install dowel pins (34A).
7.
Spring Install spring (33).
19
SEN02015-01
8.
Stator clutch housing Install stator clutch housing (32). a Check that the springs are fitted securely in the holes in the housing and piston. 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}
9.
Pump assembly 1) Assemble pump assembly as follows. 1] Using push tool, press fit bearing outer race (30) to guide (31). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns.
20
50 Disassembly and assembly
2]
2)
3) 4)
Set bearing and guide assembly (28) to pump (29), then tap with a plastic hammer and press fit bearing portion. 3] Install retainer (27). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 58.8 – 74.5 Nm {6 – 7.5 kgm} Install pump assembly (26). a When installing the pump, be careful not to damage the seal ring assembled to the shaft. Install snap ring (25). Install drain plug. 3 Drain plug: 9.8 – 12.7 Nm {1 – 1.3 kgm}
D475A, D475ASD-5E0
50 Disassembly and assembly
10. Stator assembly 1) Assemble stator assembly as follows. 1] Install snap ring (21) to stator (23). When assembling, take care of the direction of the stator vanes (See view Y below).
SEN02015-01
11. Lock-up clutch, drive case assembly 1) Assemble lock-up clutch and drive case assembly as follows. 1] Set turbine (9) to block [11], and set drive case (18) to turbine.
2] 2]
2)
Assemble race (22) to stator (23), and secure with snap ring (24). Install stator assembly (20) to stator shaft, and secure with snap ring (19).
D475A, D475ASD-5E0
Install discs (16) (3 pieces) and plates (17) (2 pieces). At this time, place block (12) to adjust the height so that the disc and plate are not caught in.
21
SEN02015-01
3]
4]
Install seal ring (14) to housing. Be careful to assemble the seal ring facing in the direction shown in the diagram below. 2 Outer circumference of seal ring: Grease (G2-LI) Install seal ring (13) to piston. Install the seal rings in the correct directions with their grooves (b) in the directions shown in the figure. 2 Outer circumference of seal ring: Grease (G2-LI)
50 Disassembly and assembly
5]
6]
Install piston (11) to housing (12). 2 Contact surface of seal ring: Grease (G2-LI) a When installing, be careful not to damage the seal ring. Using eyebolts [4], install housing and piston assembly (10). a Support the piston assembly by hand to prevent it from falling out when installing. 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}
7]
Using push tool, press fit bearing (15). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns. 8] Install plate (8), and secure with snap ring (7). 9] Install input shaft (6). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 156.8 – 196 Nm {16 – 20 kgm} 10] Install 2 seal rings (5).
22
D475A, D475ASD-5E0
50 Disassembly and assembly
2)
Using eyebolt [1], install lock-up clutch and drive case assembly (4). a Align the positions of the turbine oil groove ( mark) and drain plug (2) when installing.
3)
Tighten mounting bolts (3). 3 Mounting bolt: 49 – 58.8 Nm {5 – 6 kgm}
D475A, D475ASD-5E0
SEN02015-01
12. Torque converter valve assembly Install torque converter valve assembly (1). a Tighten the mounting bolts uniformly in turn and be careful not to tighten them unevenly. 3 Mounting bolt: 43.1 – 53.9 Nm {4.4 – 5.5 kgm}
23
SEN02015-01
50 Disassembly and assembly
Disassembly and assembly of PTO assembly
3)
Using puller [2], remove bearings (5) and (6) from gear (7).
C
2
791T-813-1110 Push tool
t 1
791T-813-1120 Plate
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disassembly 1.
2.
24
PTO lubrication tube Sling PTO assembly and remove lubrication tube (1). a Remove the 3 lubrication tubes on the opposite side also, set the torque converter end at the bottom, then lower.
Hydraulic pump gear assembly 1) Using forcing screws [1], pull out cover assembly (2) and lift off. 2) Using puller [2], remove gear assembly (3) from cover (4).
3.
Power train and PPC pump gear assembly 1) Using forcing screw [1], pull out cover assembly (8) and lift off. 2) Using puller [2], remove bearing (9). 3) Remove gear (10).
4) 5)
Using push tool [3], remove boss (11) and bearing (12) from cover. Using forcing screw [4], remove bearing (12) from boss (11).
D475A, D475ASD-5E0
50 Disassembly and assembly
4.
Scavenging drive gear Remove snap ring (13) from bottom of PTO case, then remove gear (14).
5.
Shaft assembly 1) Remove plate (15) of idler gear.
2)
3)
Turn over PTO case, then using forcing screw [1], remove shaft assembly (16). a The bearing outer race and key assembly will come out from the bottom of the PTO case, so place a wooden block in position and be careful not to damage the assembly. Remove plug (17), then using forcing screw, push out bearing (18). a After removing the bearing, assemble the plug again in the correct position.
SEN02015-01
6.
Idler gear assembly 1) Remove idler gear assembly (19) and bearing (20) from bottom of PTO case. 2) Remove outer race (21).
7.
PTO case 1) Remove race assembly (24) together with bearing outer race (25).
2)
D475A, D475ASD-5E0
Remove bearing inner races (26) and (27) from race (28).
25
SEN02015-01
3) 4)
8.
26
50 Disassembly and assembly
Remove bearing outer race (29). Remove sleeve (30).
Bearing 1) Remove snap ring (22). 2) Remove bearing (23).
D475A, D475ASD-5E0
50 Disassembly and assembly
Assembly a a
Clean all parts, and check for dirt or damage. Check that the snap ring is fitted securely in the groove.
1.
Idler gear 1) Using push tool [5], press fit bearing outer race (21) to gear (19). 2) Position idler gear to PTO case.
2.
Shaft assembly 1) Using push tool [6], press fit bearing inner race (18) to shaft. 2) Fit O-ring, align shaft assembly (16) with idler gear, then insert. 3) Tighten shaft assembly (16) mounting bolts lightly (to prevent the shaft assembly from moving when the PTO case is turned over).
D475A, D475ASD-5E0
SEN02015-01
3.
Bearing 1) Turn over PTO case, and press fit bearing spacer (31) and bearing inner race (20) to shaft, then tighten mounting bolts of shaft assembly. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns.
2)
4.
Install plate (15). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
Scavenging drive gear 1) Press-fit bearing (23) to the case up to 1/2 of the width. 2) Turn over the PTO case and put in gear (14). 3) By using push tool C2 press-fit the gear to the inner race of bearing (23). 4) Press-fit bearing (23) to the case up to the full width. 5) Install snap ring (23A) and snap ring (23B). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns 2 Spline portion: Grease (G2-LI)
27
SEN02015-01
50 Disassembly and assembly
5.
Power train, PPC pump gear assembly 1) Using push tool [7], press fit bearing (12) to boss (11). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns.
2)
3)
28
Using push tool [8], press fit boss (11) and bearing (12) to cover. a Expand fit the bearing. 2 Boss spline portion: Grease (G2-LI) Install gear (10). 2 Gear spline portion: Grease (G2-LI) 2 Gear mounting bolt: Thread tightener (LT-2) 3 Gear mounting bolt: 98 – 122.6 Nm {10 – 12.5 kgm}
D475A, D475ASD-5E0
50 Disassembly and assembly
4)
5)
6.
SEN02015-01
Using push tool [7], press fit bearing (9) to gear (10). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns. Raise cover assembly (8) and install. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} a If the cover assembly is stiff and does not enter the case, use a plastic hammer and tap evenly on the side face to install.
Hydraulic pump gear assembly 1) Using push tool [7], press fit bearings (5) and (6) to gear (7). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns.
D475A, D475ASD-5E0
2)
3)
7.
Using push tool [8], press fit gear assembly (3) to cover (4). a Expand fit the bearing. a Set the end where the bearing end face and gear end face are level so that it faces the cover. 2 Gear spline portion: Grease (G2-LI) Fit O-ring, then raise cover assembly (2) and install to case. 3 Mounting bolt: 98– 123 Nm {10 – 12.5 kgm} a If the cover assembly is stiff and does not enter the case, use a plastic hammer and tap evenly on the side face to install.
Lubrication tube Sling PTO assembly, then install lubrication tube (1). a Install 3 lubrication tubes also on the opposite side. 3 Mounting bolt: 19.6 – 29.4 Nm {2 – 3 kgm}
29
SEN02015-01
8.
Install sleeve (30) to the PTO case. a Install the sleeve with the chamfered inside circumference facing down. a Expand-fit the sleeve.
9.
Install the PTO case to the T/C case.
50 Disassembly and assembly
2)
Using push tool, press fit bearing inner races (27) and (26) to race (28).
3)
Install race assembly (24). 2 Internal surface of race: Anti-friction compound (LM-P) Using push tool, press fit bearing outer race (25). a Drop power train oil TO30 or TO10 to the bearing by at least 6 cc and rotate it 10 turns.
10. Install the input shaft parts. 1) Using push tool, press fit bearing outer race (29).
4)
30
D475A, D475ASD-5E0
50 Disassembly and assembly
Removal and installation of TORQFLOW transmission assembly
SEN02015-01
4.
Removal 1. 2. 3.
Remove gauge assembly (2) at the rear face of steering assembly (3). Remove shaft (3). Remove snap ring (4) then remove shaft (5)
Remove TORQFLOW transmission assembly (1). [*1] k Sling the transmission assembly, then remove the mounting bolts. a Using a lever block, raise the transmission horizontally, then remove from the steering. 4
TORQFLOW transmission assembly: 1,330 kg
Installation q
[*1]
D475A, D475ASD-5E0
Carry out installation in the reverse order to removal. a
Using a lever block, sling transmission assembly (1) horizontally, align with spline of shaft at steering case end, then install.
31
SEN02015-01
50 Disassembly and assembly
Disassembly and assembly of TORQFLOW transmission assembly
3.
Transmission case Using eyebolts, remove transmission case (11).
4.
Housing 1) Remove 17 tie bolts (12). 2) Using eyebolts, remove housing (13). 3) Remove seal ring (14) from housing.
D
790-413-1010 Bracket
t 1
790-501-5000 Repair stand
t 1
799-301-1600 Oil leak tester
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disassembly q
Set the transmission assembly on the block.
1.
Control valve assembly 1) Remove cover (1). 2) Remove control valve together with seat.
2.
32
assembly
(2)
Sleeve 1) Remove plug (8). 2) Using eyebolts [1], pull out sleeve (9).
D475A, D475ASD-5E0
50 Disassembly and assembly
5.
Spring Remove spring (15).
6.
Discs, plates, springs Remove discs (16), plates (17), and springs (18) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
7.
No. 1 ring gear Remove ring gear (19).
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11. Sleeve, guide pin 1) Remove sleeve (27). 2) Remove guide pin (28).
12. Shaft, No. 1, 2, 3 carrier assembly Using eyebolts, remove No. 1, 2, and 3 carrier assembly (29). 4
1) 8.
No. 1 housing, piston 1) Using eyebolts, remove No. 1 housing and piston assembly (20). 2) Remove piston (22) from housing (21).
Shaft, No. 1, 2, 3 carrier assembly: 200 kg Disassemble the shaft and carrier assembly as follows. 1] Remove snap ring (130), then remove sun gear (30).
2] 9.
Spring Remove spring (23).
Using eyebolts, remove shaft and No. 1 carrier assembly (31) from No. 2 and 3 carrier assembly (32).
10. Discs, plates, springs Remove discs (24), plates (25), and springs (26) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
D475A, D475ASD-5E0
33
SEN02015-01
2)
Disassemble the shaft and No. 1 carrier assembly as follows. 1] Raise the assembly, then using forcing screw [2], remove shaft and cage assembly (33). 2] Using plastic hammer, remove cage assembly (34), spacer (35), and bearing (36). 3] Remove seal ring (37) from cage assembly. 4] Remove seal ring (38) from cage. 5] Remove seal ring (40) from shaft (39).
50 Disassembly and assembly
3)
Disassemble the No. 2, No.3 carrier assembly as follows. 1] Remove sun gear (48). 2] Using eyebolts, remove plate and gear assembly (49).
3] 4] 5]
6]
7]
Remove shaft (42), ball (43), thrust washer (44), gear (45), and bearing (46) from No. 1 carrier assembly (41). Remove seal rings (47) and (131).
6]
34
Remove ring (50), and disassemble plate (51) and gear (52). Remove plate (54) from No. 2, 3 carrier assembly (53). Remove seal ring (55) from plate.
Remove shaft (56), ball (57), thrust washer (58), gear (59), and bearing (60).
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50 Disassembly and assembly
7] 8]
Using push tool, remove collar and bearing assembly (61) from carrier. Using push tool, remove bearing (62).
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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. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
9]
Using puller and push tool, remove bearing (63) and spacer (64) from collar (65). 10] Remove seal ring (66).
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). 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). 2)
4 No. 2 housing, piston: 80 kg Remove piston (70) from housing (69).
21. Spring Remove spring (79). 22. Discs, plates, springs Remove discs (80), plates (81), and springs (82) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
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23. Guide pin Remove guide pin (83).
50 Disassembly and assembly
26. No. 3 ring gear 1) Remove ring gear (91). 2) Remove ring (92) from ring gear.
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).
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. 1] Remove 2 mounting bolts, then install guide bolts. 2] Remove remaining mounting bolts, then loosen guide bolts [5] slowly, and remove No. 4 carrier assembly (96) from No. 5 clutch assembly (97). 4
36
No. 4 carrier assembly, No. 5 clutch assembly: 160 kg
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50 Disassembly and assembly
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9]
Remove piston (112) from No. 5 housing (111). 10] Remove spacer (113) and seal ring (114) from No. 5 housing. 29. Shaft Remove shaft (115).
3]
Remove shaft (98), ball (99), thrust washer (100), gear (101), and bearing (102).
30. Shaft assembly Set case so that shaft is at bottom, then using eyebolts, remove shaft assembly (117) from case (116). 4
1)
4] 5]
6] 7] 8]
Remove spring (103) and pin (104). Remove discs (105), plates (106), and springs (107). a Keep the discs and plates in a flat place to prevent them from becoming deformed. Remove guide pin (108). Remove inner gear (109). Remove seal ring (110) from inner gear.
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Shaft assembly: 80 kg Disassemble the shaft assembly as follows. 1] Remove the snap ring. By using eyebolts, sling shaft assembly (117) and drive out the bearing to remove cage assembly (118).
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2] 3]
Remove cage (119). Using stand [6], remove bearing (120).
4]
Remove snap ring (134), then remove bearing (121) from cage (133). Remove seal ring (122). Remove cover (123).
5] 6]
50 Disassembly and assembly
9]
Remove snap ring (135), then remove boss and bearing (127). 10] Remove snap ring (136), then using push tool, remove bearing (129) from boss (128).
Assembly a
a a
7] 8]
38
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. Align the notches of the oil groove when installing the discs. After installing the bearing, drop power train oil TO30 or TO10 to it by at least 6 cc and rotate it 10 turns.
Remove bearing (124). Remove seal ring (126).
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50 Disassembly and assembly
1.
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Shaft and cage assembly 1) Install seal ring (126). 2) By using the push tool, install bearing (124).
3)
4)
5)
Install cover(123). 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm} Install seal ring (122) to cage (133). 2 Periphery of seal ring: Grease (G2-LI) Install the outer race of bearing (121) to cage (133) and fix it with snap ring (134).
8)
6)
7) a
By using the push tool, press-fit bearing (120) to cage(133). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} Install the seal ring to cage (119). Install the seal rings in the correct directions with their grooves (c) in the directions shown in the figure. 2 Periphery of seal ring: Grease (G2-LI)
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Install cage (133) to cage (119). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
9)
Install cage assembly (118) to case (116). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 10) Install shaft assembly (117) to cage assembly(118). 11) Install the snap ring. 12) Turn over the assembly and press-fit the inner race of bearing (121) to shaft assembly (117).
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2.
No. 4 carrier and No. 5 clutch assembly 1) Install the dowel pin (1piece) for spacer(113) to No. 5 housing (111). 2) By using the push tool, install spacer (113) to No. 5 housing (111). 3) Install seal ring (114). 2 Periphery of seal ring: Grease (G2-LI) 4) Install the seal rings to piston (112)and housing (111). 2 Periphery of seal ring: Grease (G2-LI) a Install the seal rings in the correct directions with their grooves (d) in the directions shown in the figure.
50 Disassembly and assembly
5)
6) 7) 8)
9)
Install seal ring (110)to inner gear (109). 2 Periphery of seal ring: Grease (G2-LI) Install inner gear (109). Install guide pin (108). Install springs (107) (6 pieces), plates (106) (5 pieces), and discs (105) (6 pieces) alternately. Install pins (104) and springs (103). a Free length of spring: 103.5 mm
10) Install bearing (102) to gear (101), fit thrust washers (100) to both sides, and set them to the carrier. 11) Install ball (99) to shaft (98) and push the shaft into the carrier.
40
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50 Disassembly and assembly
12) Install dowel pins (2 pieces) to No. 5 clutch assembly (97), set No.4 carrier assembly (96) and compress the springs by using guide bolts [5] (2 pieces), and then tighten the mounting bolts. a Check that the springs are fitted securely into the holes of the housing, and then tighten the mounting bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 157 – 196 Nm {16 – 20 kgm}
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4.
No.3 ring gear 1) Install snap ring (92) to the ring gear. 2) Install No. 3 ring gear (91).
5.
Cover, bearing, and collar assembly 1) By using the push tool, press-fit bearing (90) to collar (89). 2) By using the push tool, press-fit bearing (88).
13) By using eyebolts, insert No. 4 carrier and No. 5 clutch assembly (95) into shaft assembly (117). 3.
Plate and ring gear 1) By using eyebolts, install plate (93), matching it to the dowel pins. a Since the plate must be installed in the correct direction, check the bolt holes and drive in the dowel pin portions with a plastic hammer until play between the mating faces is eliminated. 2) Install No. 4 ring gear (94). 3) Install No. 4 sun gear.
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3)
4)
50 Disassembly and assembly
By using the push tool, press-fit bearing and cover assembly (87) to cover (86). a When installing the collar to the cover, direct its large protrusion end up. By using eyebolts, install "cover, bearing, and collar assembly"(85). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
10. No. 4 piston and No. 3 housing 1) Install the seal rings to piston (78) and housing (77). a Install the seal rings in the correct directions with their grooves (g) in the directions shown in the figure. 2 Periphery of seal ring: Grease (G2-LI) 2) Install No. 4 piston (78) to No. 3 housing (77).
6.
No. 3 sun gear Install No. 3 sun gear (84) and secure it with snap ring (132).
7.
Guide pin Install guide pin (83). a Guide pin length: 207 mm
8.
Discs, plates, and springs Install springs (82) (4 pieces each), plates (81) (3 pieces), and discs (80) (4 pieces) alternately.
9.
Springs Install springs (79). a Free length of spring: 81.7 mm
42
3) 4)
By using eyebolts, install No. 3 housing (77). Install seats (76).
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50 Disassembly and assembly
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11. Discs, plates, and springs Install springs (75) (5pieces each), plates (74) (4 pieces), and discs (73) (5 pieces) alternately. 12. Springs Install springs (72). a Free length of spring: 84 mm
3)
By using eyebolts, install No.2 housing and piston assembly (68). a Check that the springs are fitted securely into the holes of the housing.
13. No. 3 piston and No. 2 housing 1) Install the seal rings to No. 3 piston (71) and No. 2 housing (69). a Install the seal rings in the correct directions with their grooves (e) in the directions shown in the figure. 2 Periphery of seal ring: Grease (G2-LI) 2) Install No. 3 piston (71) to No. 2 housing (69). 15. No. 2 and No. 3 carriers 1) Install plate (54) to the carrier. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 2) Install seal ring (66) to the carrier and install seal ring (55) to plate (54 . 2 After centering the seal ring, fix it by applying grease (G2-LI).
14. No. 2 housing and No. 2 piston 1) Install the seal rings to No. 2 piston (70) and No. 2 housing (69). a Install the seal rings in the correct directions with their grooves (f) in the directions shown in the figure. 2 Periphery of seal ring: Grease (G2-LI) 2) Install No. 2 piston (71) to No. 2 housing (69).
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3)
4) 5)
Install bearing (60) to gear (59), fit thrust washers (58) to both sides, and set them to the carrier. Install ball (57) to shaft (56) and push the shaft into the carrier. By using eyebolts, install carrier assembly (53).
50 Disassembly and assembly
20. Ring gear 1) Install cover and snap ring (50) to ring gear (52). 2) Engage the internal teeth of the ring gear assembly with the external teeth of carrier assembly (53). 3) Install the cover to carrier assembly (53) and fix the ring gear assembly. 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
16. No. 2 ring gear Install No. 2 ring gear. 17. Guide pin and sleeve 1) Install guide pin (28). a Guide pin length: 270 mm 2) Install sleeve (27). 18. Discs, plates, and springs Install springs (26) (7 pieces each), plate (25) (6 pieces), discs (24) (7 pieces) alternately. 19. Springs Install springs (23). a Free length of spring: 100 mm
44
21. No. 1 housing and No. 1piston 1) Install the seal rings to No. 1 piston (22) and No. 1 housing (21). a Install the seal rings in the correct directions with their grooves (h) in the directions shown in the figure. 2 Periphery of seal ring: Grease (G2-LI) 2) Install No. 1 piston (22) to No. 1 housing (21).
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50 Disassembly and assembly
3) a
By using eyebolts, install No. 1 housing and piston (20). Check that the springs are fitted securely into the holes of the housing.
22. No. 1 carrier assembly 1) Install bearing (46) to gear (45), fit thrust washer (44) to both sides, and set carrier (41). 2) Install ball (43) to shaft (42) and push the shaft into carrier (41). 3) Install seal rings (47) and (131) to carrier (41). 2 After centering the seal ring, fix it by applying grease (G2-LI). 4) Install snap ring (41) to the carrier. 5) Install ring gear (19) to the carrier.
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23. Input shaft assembly 1) By using the push tool, press-fit bearing (36) to shaft (39). 2) By using the push tool, press-fit bearing (37) to the cage.
3) 4)
5)
Set spacer (35) to bearing and cage assembly (34) and press-fit shaft (39). Install seal ring (40) to shaft (39). 2 Periphery of seal ring: Grease (G2-LI) Install seal ring (38) to bearing and cage assembly (34). 2 Periphery of seal ring: Grease (G2-LI)
45
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24. Shaft and carrier assembly 1) Install No. 1 carrier assembly to bearing and cage assembly (34). 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 2) Turn over the shaft and insert No. 1 sun gear into shaft (39). 3) By using the push tool, press-fit the bearings (2 pieces) to the collar. 4) Press-fit the spacer to the collar according to the following procedure. 1] As shown below, press-fit the spacer so that the lubrication groove A of the spacer matches with lubrication groove B of collar. 2] Apply adhesive (LT-2) to the inside wall of the spacer and wipe off the part of it forced out after press-fitting the spacer. Take care that (LT-2) does not stick to the bearing.
5) 6) 7) 8) 9)
46
50 Disassembly and assembly
25. Discs, plates, and springs Install springs (18) (7 pieces each), plates (17) (6 pieces), and discs (16) (7 pieces) alternately. 26. Springs Install springs (15). a Free length of spring: 100 mm
Insert the bearing and collar assembly into shaft (39). Insert No. 2 sun gear (30) into shaft (39). Install snap ring (130). Install bushing (39A). By using eyebolts, install shaft and carrier assembly (29).
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50 Disassembly and assembly
27. Housing 1) Install seal ring (14) to the housing. 2 After centering the seal ring, fix it by applying grease (G2-LI). 2) By using eyebolts, set housing (13). 3) Tighten tie bolts (12) (17 pieces) alternately. 3 Tie bolt: 353 – 392 Nm {36 – 40 kgm}
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29. Transmission case Fit the O- ring to the mating face of transmission case (11), and then install the transmission case by using eyebolts. 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
28. Discs, plates, springs Check of stroke of each piston By using tool D, check the stroke of each piston. a 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
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30. Rotation detection shaft 1) Set case so that valve mounting surface is at top, then insert rotation detection shaft (115) from output end. a Check that the tip of the shaft is mated with the lock portion of its mating boss.
2)
3)
4)
48
Using push tool, install bearing (129) to boss (128), and secure with snap ring (136). Install boss and bearing assembly (127) to output shaft, and secure with snap ring (135). a Install the bearing slowly and be careful that shaft (115) is mated with the lock portion of boss (128). Install boss (129A).
50 Disassembly and assembly
31. Sleeve 1) Install sleeve (9). 2) Install plug (8).
32. Control valve assembly 1) Install control valve assembly (2) together with seat. 3 Mounting bolt: 44 – 54 Nm {4.5 – 5.5 kgm} 2 Mounting bolt: Gasket sealant (LG-5) 2) Install cover (1).
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50 Disassembly and assembly
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D475A, D475ASD-5E0 Bulldozer Form No. SEN02015-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (02)
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BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Power train, Part 2 Disassembly and assembly of steering case assembly.................................................................................. 2 Disassembly and assembly of steering clutch, brake assembly ................................................................... 15 Disassembly and assembly of transfer gear housing assembly ................................................................... 23 Removal and installation of power train pump assembly .............................................................................. 27 Removal and installation of scavenging pump assembly ............................................................................. 27 Removal and installation of torque converter oil cooler ................................................................................ 28 Removal and installation of torque converter valve assembly ...................................................................... 29 Disassembly and assembly of torque converter valve assembly.................................................................. 30 Removal and installation of transmission control valve assembly ................................................................ 34 Disassembly and assembly of transmission control valve assembly (ECMV assembly) .............................. 35 Removal and installation of steering control valve assembly........................................................................ 38 Disassembly and assembly of steering control valve assembly ................................................................... 39 Removal and installation of final drive assembly .......................................................................................... 41 Disassembly and assembly of final drive assembly...................................................................................... 43
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50 Disassembly and assembly
Disassembly and assembly of steering case assembly
2.
Clutch, brake assembly Using tool E1, sling clutch and brake assembly, then remove mounting bolts, and remove clutch and brake assembly (3). a Remove the clutch and brake assembly on the opposite side in the same way. When pulling out the clutch and brake assembly, be careful not to damage the discs and plates.
3.
Shafts Remove left and right shafts (4).
4.
Lubrication tube Remove lubrication tubes (5).
Bracket
t 1
1 01016-51690
Bolt
t 1
01011-81600
Bolt
t 1
791-622-1110
E 2
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
791T-822-1810 Push tool
t 1
Q
791T-822-1820 Push tool
t 1
Q
Disassembly 1.
Steering rod bracket 1) Remove cover (1). 2) Remove tube (2). 3) Remove brake rod bracket (20).
4)
2
Remove transmission output shaft speed sensor (75) and flange (76) together.
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50 Disassembly and assembly
5.
Pipes, steering valve 1) Remove left and right pipes (6). 2) Remove pipe (7).
3)
Remove steering valve assembly (21) with seat.
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6.
Transfer and gear housing assembly 1) Install a guide bolt and tighten forcing screws [1] to remove housing assembly (10).
2)
Disassemble the transfer and gear housing assembly according to the following procedure. 1] Set the transfer and gear housing assembly on the block. 2] Take out lubrication tube (51).
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3]
4]
5]
6]
4
Reverse the transfer and gear housing assembly and remove lubrication tube (56). Using eyebolts [11], remove pinion housing assembly (57). a Check the quantity and thickness of the inserted shims and then keep them.
Using forcing screws, remove cover (58). a Check the quantity and thickness of the inserted shims and then keep them. Remove holder (59).
50 Disassembly and assembly
7] 8]
9]
Push pinion shaft (60) out of pinion housing assembly (57) with a press. Remove the holder. Using puller [12], remove bearing inner race (61) from pinion shaft (60). Remove cage and bearing assembly (62).
10] Remove collar (63) from gear (64). 11] Using push tool [13], remove bearing outer races (65) and (69), bearing inner races (66) and (67), and collar (68).
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50 Disassembly and assembly
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12] Remove the bolts and remove housing (76) from case (78). 13] Remove drive gear and bearing assembly (77).
14] Remove bearing outer race (79) from case (78).
16] Remove bearing outer race (70) from housing (76). 17] Remove snap ring (83), and then remove bearing outer race (71) from housing (76).
7.
Cage 1) Turn over so that right cage is at top, then remove bearing cage (11). a Check the number and thickness of the shims, and keep in a safe place.
15] Remove bearing inner races (81) and (82) from the drive gear.
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2) 8.
Using eyebolts [2], remove cage (12).
50 Disassembly and assembly
9.
Bevel gear, shaft assembly 1) Using eyebolts, remove bevel gear and shaft assembly (13).
2)
Disassemble the bevel gear and shaft assembly as follows. 1] Pull out reamer bolt, and remove bevel gear (14) from shaft (15). 2] Using puller [3], remove bearings (16) and (17) from shaft.
Assembly a a
1.
6
Cage 1) Turn over steering case, and remove bearing cage (18). a Check the number and thickness of the shims, and keep in a safe place. 2) Remove outer race (19) from bearing cage.
Wash all parts, then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. After installing the bearing, drip power train oil TO30 or TO10 to it by at least 6 cc and rotate it 10 turns. Cage 1) Using push tool, press fit outer race (19). 2) Assemble shim, and install bearing cage (18). q Standard shim thickness: 2 mm 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
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50 Disassembly and assembly
2.
Bevel gear, shaft assembly 1) Assemble bevel gear and shaft as follows. 1] Using tool E2, press fit bearings (17) and (16). 2] Set bevel gear (14) to shaft (15), and tighten reamer bolt. 3 Reamer bolt: 490 – 607.6 Nm {50 – 62 kgm}
2)
3.
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2)
Assemble shim, and install bearing cage (11). q Standard shim thickness: 2 mm 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
4.
Adjusting preload Rotate bevel gear 10 – 20 turns, and fit pushpull scale [4] to tip of teeth, then measure rotating torque of bevel gear shaft. a Measure while the bevel pinion is not engaged. a Standard rotating torque: 9.8 – 11.8 Nm {1.0 – 1.2 kgm} q Rotating force at outside of bevel gear: 51.0 – 61.8 Nm {5.2 – 6.3 kgm}
5.
Transfer and gear housing assembly 1) Assemble the transfer and gear housing assembly according to the following procedure. 1] Press fit bearing outer race (70) on the pinion side to housing (76). 2] Using the push tool, press fit bearing outer race (71) on the drive gear side and install snap ring (83).
Using eyebolts, install bevel gear and shaft assembly (13).
Cage 1) Using eyebolts [2], install cage (12). 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
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3]
Using the push tool, press fit bearing inner races (81) and (82).
50 Disassembly and assembly
7] 8]
9]
4]
Using push tool [18], press fit inner race (61) to pinion shaft (60). Install the holder. 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm} Install pinion gear (64) and collar (63) to the pinion shaft.
Using the push tool, press fit bearing outer race (79) to case (78).
10] Using push tool [19], press fit cage and bearing assembly (62). 11] Install holder (59). 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm} 5] 6]
8
Install drive gear and bearing assembly (77) to the case. Install housing (76), matching it to the dowel pin, and tighten the bolts. 3 Mounting bolt: 277 ± 32 Nm {28.3 ± 3.2 kgm}
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50 Disassembly and assembly
12] Tighten the mounting bolts of cover (58) temporarily in the following order. 3 Mounting bolt: 49 Nm {5 kgm}
13] Loosen the mounting bolts and tighten them again temporarily in the above order. 3 Mounting bolt: 49 Nm {5 kgm} 14] Check clearance (A) between the cover and cage and adjust it to the following range with the shims. 15] Clearance (A): 0.05 – 0.15 mm 16] Check that the dispersion of the clearance is 0.05 mm or less through the periphery and the bearing is press fitted perfectly and is not leaning.
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17] Tighten the mounting bolts of cover (58) permanently in the following order. 3 Mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
18] Install the shim to pinion housing assembly (57). Using eyebolts [11], install pinion housing assembly (57). q Standard shim thickness: 2 mm 19] Install lubrication tube (56).
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20] Install lubrication tube (51) and block as a unit.
2)
10
50 Disassembly and assembly
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. a Standard value for backlash: 0.3 – 0.4 mm a Measure at a minimum of 3 points on diagonally opposite sides.
Install guide bolt [5] to the steering case and install housing assembly (10). 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
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50 Disassembly and assembly
Adjusting If correct backlash pattern is not obtained from the result of inspection, adjust as follows. 1] If backlash is too small: Adjust the shim thickness at the bevel pinion end to move the bevel pinion in direction (A), or adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction (B).
2]
a
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2)
Adjusting tooth contact Testing 1] Coat the tooth face of the bevel pinion lightly with red lead (minimum). Rotate the bevel gear in both the forward and reverse directions, and inspect the pattern left on the teeth. 2] The standard tooth contact should be as follows: (from small end of pinion) a) Width of tooth contact: 30 – 50% b) Center of tooth contact:20 – 40% a 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. a 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.
If backlash is too large: Adjust the shim thickness at the bevel pinion end to move the bevel pinion in direction (A) (the opposite direction from (A) above), or adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction (B) (the opposite direction from (B) above). When adjusting the shim thickness at the bearing cage of the bevel gear shaft, do not change the preload of the bearing. Adjust by moving shims between the bearing cage and the bevel pinion. Always keep the same total thickness of shims.
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Adjusting If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows. 1] 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. 2] 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. a 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.
12
50 Disassembly and assembly
7.
Transmission output shaft and input shaft 1) Install the speed sensor and flange according to the following procedure. 1] Install flange (76). a Remove the speed sensor. 2] Looking at transfer gear (85) through the hole of the flange, check that a tooth of the gear is at the center of the hole. a If a tooth is not seen, turn the transfer gear to bring a tooth to the center of the hole. 3] Remove locknut (84) from speed sensor (75). Apply gasket sealant to the threaded portion of speed sensor (75) and install speed sensor (75) to flange (76). a Tighten the speed sensor until its tip touches the transfer gear, and then return it by 1/2 – 1 turn. 2 Threaded portion of speed sensor: Gasket sealant (LG-6)
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50 Disassembly and assembly
4]
5]
6]
2)
Remove the speed sensor and flange as a unit and tighten locknut (84). a Take care that the speed sensor will not turn when the locknut is tightened. 2 Threaded portion of locknut and its contact surface against flange: Gasket sealant (LG-6) 3 Locknut: 49 – 68.6 Nm {5 – 7 kgm} Install speed sensor (75) and flange (76) as a unit. 2 Flange mounting bolt hole and flange mounting surface: Gasket sealant (LG-6) After installing the speed sensor, rotate the transfer gear slowly and check that the speed sensor does not interfere with the gear.
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8.
Steering valve and pipe 1) Install steering valve assembly (21) and seat as unit.
2) 3) a
Install pipe (7). Install left and right pipes (6). Coat the O-rings thinly with grease (G2LI), and be careful not to damage them when installing.
Install input shaft (9) to the case and fix it with the snap ring. 9.
Lubrication tube Install lubrication tubes (5).
10. Clutch, brake assembly Using tool E1, install clutch and brake assembly (3). 3 Mounting bolt: 279 ± 30 Nm {28.5 ± 3 kgm}
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50 Disassembly and assembly
11. Shafts Install left and right shafts (4). a If it is difficult to insert the shafts with the bevel locked, release the steering brake before inserting. 1) When removing plugs (20) and using bolts (21), set 5 washers under each bolt head to shorten the bolt stem length to 64 mm. If these washers are not used, the bolts break the plate when they are tightened. Remove bolts (21) and tighten them into the plug holes to compress the clutch springs and set the brake free.
12. Steering rod, bracket 1) Install brake rod bracket (20). 2) Install tube (2). 3) Install cover (1).
14
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50 Disassembly and assembly
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Disassembly and assembly of steering clutch, brake assembly
3.
Clutch, brake assembly Turn over clutch and brake assemblies, and using eyebolts [3], disconnect clutch assembly (6) and brake assembly (7).
E 3 791-822-1830
Wrench
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
t 1
Disassembly Disconnection of clutch, brake assembly 1. Collar Remove plate (1), then remove collar (2). 2.
Sleeve 1) Remove plate (3).
Disassembly of clutch assembly 1. Stopper Remove stopper (8). 2.
2) 3)
Discs, plates, springs Remove discs (9), springs (10), and plates (11) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
Using forcing screws [1], remove sleeve (4). Using puller [2], pull out bearing (5) from sleeve.
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50 Disassembly and assembly
3.
Torque pin Remove torque pin (12).
7.
Spacer Remove spacer (22).
4.
Clutch hub Using eyebolts, remove clutch hub (13).
8.
Clutch cage, piston 1) Using eyebolts, remove clutch cage (23). 2) Remove piston (24).
5.
Plate 1) Using forcing screws [4], remove flange (14).
3) 9. 2) 6.
Belleville springs Remove Belleville springs (26).
Bearing cage 1) Remove bearing cage assembly (16).
2)
16
Remove outer race (15) from flange.
Remove outer race (25) from clutch cage.
Remove plate (18) and nut (19), then remove bearings (20) and (21) from cage (17).
10. Brake hub 1) Using eyebolts [5], remove brake hub (27). 2) Remove bearing (28) from brake hub.
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50 Disassembly and assembly
Disassembly of brake assembly 1. Stopper Remove stopper (29). 2.
3.
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4.
Torque pin Remove torque pin (36).
5.
Piston Remove piston (37) and seal ring (38).
6.
Belleville springs Remove Belleville springs (39).
Discs, plates, springs Remove discs (30), springs (31), and plates (32) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
Brake cage 1) Using eyebolts [6], remove brake cage (33). 2) Remove outer race (34) and seal ring (35) from brake cage.
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Assembly Assembly of brake assembly a a
Clean each part, and check for dirt or damage. After installing the bearing, drip power train oil TO30 or TO10 to it by at least 6 cc and rotate it 10 turns.
1.
Disc springs Install disc springs (39). a Install the disc springs back to back by the set (of the same number).
q
q
18
Install the seal rings to the piston and brake cage. Install the seal rings in the correct directions with their grooves (j) in the directions shown in the figure. 2 Periphery of seal ring: Grease(G2-LI) Install and fit the piston to the housing (Remove after fitting).
50 Disassembly and assembly
2.
Piston Install piston (37).
3.
Torque pin Install torque pin (36).
4.
Brake cage 1) Using push tool, install outer race (34) to brake cage. 2) Install seal ring (35). 3) Using eyebolts [6], install brake cage (33). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
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50 Disassembly and assembly
5.
Discs, plates, springs q Set the brake hub. (Use it as a jig temporarily to mesh the internal teeth of the brake disc.) q Install plates (32), springs (31), and discs (30) in turn. a Check the mating surfaces of the discs and plates for dirt or damage, and coat them thinly with engine oil before assembling.
6.
Stopper Install stopper (29). q Remove brake hub. 3 Mounting bolt: 245 – 308.7 Nm {35 – 31.5 kgm} q After Installing the stopper, remove the brake hub.
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Assembly of clutch assembly 1. Brake hub 1) Using push tool, press fit bearing (28) in brake hub. 2) Using eyebolts [5], install brake hub (27) to clutch housing. 3) Install snap ring (27A).
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2.
3.
Belleville springs Install Belleville springs (26). a Fit the Belleville springs back to back when installing. q Install the seal rings to the piston and brake cage. Install the seal rings in the correct directions with their grooves (k) in the directions shown in the figure. 2 Periphery of seal ring: Grease(G2-LI) q Install and fit the piston to the housing.
50 Disassembly and assembly
2) 3) 4.
Spacer Install spacer (22).
5.
Bearing cage 1) Using push tool, press fit bearings (21) and (20) to cage (17), then tighten nut (19), and install plate (18). a Hold the cage with press, and using a hook wrench (tool E3), tighten the nut. 3 Nut: 490 – 607.6 Nm {50 – 62 kgm}
Clutch cage, piston 1) Install outer race (25) to clutch cage.
2) 6.
20
Install piston (24). Using eyebolts, fit seal ring and install clutch cage (23) to housing.
Install bearing cage (16).
Plate 1) Using push tool, press fit outer race (15) to flange.
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50 Disassembly and assembly
2)
7.
8.
Install flange (14). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
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10. Stopper Install stopper (8). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
Clutch hub Set guide bolts to housing, and using eyebolts, install clutch hub (13). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} Torque pin Install torque pin (12).
Connection of clutch, brake assembly 1. Clutch, brake assembly Using eyebolts [3], install brake assembly (7) to clutch assembly (6). 2.
9.
Sleeve 1) Install O-ring (6A)and seal ring (6B)to the sleeve. Apply grease (G2-LI) to each part.
Discs, plates, springs Install plates (11), springs (10), and discs (9) in turn. a Assemble the discs and plates in the order shown in the figure. (A plate must be inserted between the piton and each disc.)
2)
a
Using push tool [7], press fit bearing (5) in sleeve.
Check the mating surfaces of the discs and plates for dirt or damage, and coat them thinly with engine oil before assembling.
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3.
22
3)
Set sleeve (4) to clutch and brake assemblies.
4)
Install plate (3). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 112 ± 9.8 Nm {11.5 ± 1.0 kgm}
50 Disassembly and assembly
Collar Fit collar (2) and install plate (1).
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50 Disassembly and assembly
Disassembly and assembly of transfer gear housing assembly
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4.
Pinion housing 1) Remove lubrication tube (7). 2) Using eyebolts [2], remove pinion housing assembly (8). a Check the number and thickness of the slims, and keep in a safe place.
5.
Pinion assembly 1) Using forcing screws, remove cover (9). 2) Remove holder (10). 3) Push pinion shaft with press, then pull out pinion gear (11). 4) Remove holder, and using puller [3], remove inner race (12) from pinion gear (11).
Disassembly a
Set the transfer gear housing assembly on a block.
1.
Lubrication tube Remove lubrication tube (1) together with block.
2.
Bearing cage 1) Remove bearing cage (2). 2) Using push tool, remove bearing (3). 3) Remove snap ring, and using push tool, remove bearing (4)
3.
Transfer gear 1) Remove transfer gear (5). 2) Using puller [1], remove inner races (6) on both sides.
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5) 6)
Remove cage, bearing assembly (13). Remove collar (14) from transfer gear (15).
7)
Using push tool [4], remove outer race (16), bearings (17) and (18), collar (19), and outer race (20).
50 Disassembly and assembly
Assembly 1.
Pinion assembly 1) Using push tool, press fit outer race (20) in bearing cage. 2) Assemble collar (19), bearing inner races (17) and (18). 3) Using push tool, press fit bearing outer race (16).
4)
5)
24
Using push tool [5], press fit inner race (12) in pinion gear (11), and install holder. 3 Holder mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm} Install transfer gear (15) and collar (14) to pinion gear.
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50 Disassembly and assembly
6) 7)
8)
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Using push tool [6], press fit cage, bearing assembly (13). Install holder (10). 3 Holder mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
2.
Pinion housing 1) Assemble shim, and using eyebolts [2], install pinion housing assembly (8). a Standard shim thickness: 2 mm 2) Install lubrication tube (7).
Install cover (9) as follows. q Tighten cover mounting bolts temporarily in the order shown in diagram below. (Approx. 49 Nm {5 kgm}) q Check clearance (A) between cover and cage, and check that it is as follows. Clearance (A): 0.53 ± 0.47 mm a Check that the variation around the whole circumference is less than 0.05 mm. Check also that the bearing is completely press fitted and is not at an angle. q After checking the above, tighten the mounting bolts of cover (9) in the order shown in the diagram below. 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
3.
Transfer gear 1) Using push tool [7], press fit inner races (6) on both sides. 2) Set transfer gear (5) in case.
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4.
Bearing cage 1) Using push tool, press fit bearing (4), and secure with snap ring. 2) Using push tool, press fit bearing (3). 3) Install bearing cage assembly (2) to case. 3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
5.
Lubrication tube Install lubrication tube (1) together with block.
26
50 Disassembly and assembly
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50 Disassembly and assembly
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Removal and installation of power train pump assembly
Removal and installation of scavenging pump assembly
Removal
Removal
1.
Remove oil strainer inspection cover at front left of operator’s platform.
1.
Open undercover. (3rd from front of machine).
2. 2.
Open undercover. (3rd from front of machine).
Disconnect inlet tube (1). a Oil will leak out from inside the piping, so prepare a container to catch the oil.
3.
Remove oil strainer (1). a Disconnect coupling (2) and remove strainer mounting bolts.
3.
Disconnect outlet tube (2).
4.
Remove scavenging pump assembly (3).
4.
Disconnect hose (3).
5.
Lift off power train pump assembly (4). 4
4
Scavenging pump assembly: 25 kg
Power train pump assembly: 64 kg
Installation q
Carry out installation in the reverse order to removal.
q
Refilling with oil (power train case) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
Installation q
Carry out installation in the reverse order to removal.
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Removal and installation of torque converter oil cooler
50 Disassembly and assembly
7.
4
Removal 1.
Remove engine undercover.
2.
Drain coolant.
3.
Open engine left side cover (1) and remove side cover (2).
Sling torque converter oil cooler assembly (8), then lower assembly to remove. Torque converter oil cooler assembly: 170 kg
Installation
4.
Remove water tubes (3) and (4).
5.
Remove oil inlet tube (5) and outlet tube (6).
6.
Disconnect aeration hose (7).
28
q
Carry out installation in the reverse order to removal.
q
Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
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50 Disassembly and assembly
Removal and installation of torque converter valve assembly
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7.
Remove hose clamp (6).
8.
Remove torque converter valve assembly (7). [*2] 4
Removal 1.
Remove operator’s cab assembly. For details, see "Removal and installation of operator’s cab assembly".
2.
Remove operator’s seat and floor frame cover. a Use turnbuckle (1) when disconnecting the brake rod. Check the mounting dimensions of the rod before disconnecting. [*1]
Torque converter valve assembly: 33 kg
Installation q
[*1] 3.
Disconnect connector of solenoid valve (2).
4.
Disconnect hose clamp (3).
5.
Disconnect central pressure detection hose (4). a Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing.
6.
[*2]
Carry out installation in the reverse order to removal. a
Adjust the brake pedal linkage. 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} 3
Torque converter valve assembly mounting bolt: 43.1 – 53.9 Nm {4.4 – 5.5 kgm}
Disconnect hose (5).
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50 Disassembly and assembly
Disassembly and assembly of torque converter valve assembly
Disassembly of lock-up valve
Assembly of lock-up valve
1.
Remove solenoid valve (14), then remove ball (16), valve (15) and plug (19).
1.
Assemble spool (6).
2. 2.
Remove plug (3), then remove spring (5).
Assemble piston (10) to cover (7), then fit Oring and install cover.
3.
Remove cover (7), then remove piston (10).
3.
Assemble spring (5), then fit O-ring and install plug (3).
4.
Pull out spool (6). 4.
Fit O-ring (17) to plug (19), then assemble.
5.
Assemble valve (15), then fit O-ring (18) to solenoid valve (14) and install.
30
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50 Disassembly and assembly
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50 Disassembly and assembly
Disassembly of torque converter relief valve, main relief valve, stator clutch modulating valve, and lock-up clutch modulating valve 1.
Disassembly of torque converter relief valve 1) Remove cover (10), then remove spring (9). 2) Remove cover (2), then remove valve (5), spring (6), and valve (7). 3) Pull out spool (8).
2.
Disassembly of main relief valve 1) Remove cover (14), then remove spring (18). 2) Remove cover (24), then remove valve (21), spring (22), and valve (23). 3) Pull out spool (20).
3.
Disassembly of stator clutch modulating valve 1) Remove cover (27), then remove piston (34) and spring (35). 2) Remove ring (30) from body. 3) Remove cover (41), then remove valve (40), spring (39), and valve (38). 4) Pull out spool (37), then remove shim (36) from spool.
4.
Disassembly of lock-up clutch modulating valve 1) Remove cover (45), then remove piston (52), springs (53) and (55). 2) Remove ring (47) from body. 3) Remove cover (61), then remove valve (60), spring (59), and valve (58). 4) Pull out spool (57). 5) Remove shaft (56) and shim (54) from spool (57).
32
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50 Disassembly and assembly
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Assembly of lock-up modulating valve, stator clutch modulating valve, main relief valve and torque converter relief valve a a
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. When assembling valves (32) and (34), (12) and (14), (23) and (21), and (7) and (5), assemble as shown in the diagram so that the end with the hole in the center of the valve is on the inside of the spool.
1.
Assembly of lock-up clutch modulating valve 1) Set shim to shaft (56) and assemble to spool (57). a Standard shim thickness: 2.0 mm 2) Assemble spool (57). 3) Assemble valve (58), spring (59), and valve (60) to spool, then fit O-ring and install cover (61). 4) Assemble ring (47) to body. 5) Assemble springs (53) and (55). 6) Assemble piston (52) to cover (45), then fit O-ring and install cover.
2.
Assembly of stator clutch modulating valve 1) Assemble spool (37). 2) Assemble valve (38), spring (39), and valve (40) to spool (37), then fit O-ring and install cover (41). 3) Set shim (36) to spool (37) and assemble ring (30) to body. a Standard shim thickness: 0.5 mm 4) Assemble spring (35). 5) Assemble piston (34) to cover (27), then fit O-ring and install cover.
3.
Assembly of main relief valve 1) Assemble spool (20). 2) Assemble valve (23), spring (22), and valve (21) to spool, then fit O-ring and install cover (24). 3) Assemble spring (18), then fit O-ring and install cover (14).
4.
Assembly of torque converter relief valve 1) Assemble spool (8). 2) Assemble valve (7), spring (6), and valve (5) to spool, then fit O-ring and install cover (2). 3) Assemble spring (9), then fit O-ring and install cover (10).
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Removal and installation of transmission control valve assembly
50 Disassembly and assembly
5.
Disconnect wiring harness connector (4). (8 places)
6.
Disconnect central pressure detection hose (5). (4 places) a Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing.
7.
Remove transmission control valve assembly (6). (4 places)
Removal 1.
Remove operator’s cab assembly. For details, see "Removal of operator’s cab assembly".
2.
Remove operator’s seat and floor frame cover. a Use turnbuckle (1) when disconnecting the brake rod. Check the mounting dimensions of the rod before disconnecting. [*1]
3.
Disconnect hose clamp (2).
4.
Remove valve cover (3).
Installation q
[*1]
34
Carry out installation in the reverse order to removal. a
Adjust the brake pedal linkage. 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}
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50 Disassembly and assembly
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Disassembly and assembly of transmission control valve assembly (ECMV assembly)
Disassembly of ECMV assembly q
q
1.
Before removing the ECMV assembly from the transmission assembly, clean around it so that dirt will not enter it and transmission assembly. Keep the removed parts so that they will not be damaged. Flow control valve 1) Remove bracket (20) and switch assembly (12) from valve body (1). 2) Remove spring (13), shim (14), and spring seat (15). 3) Remove sleeve (18), spring (17), and pin (16).
D475A, D475ASD-5E0
2.
Pressure control valve 1) Remove solenoid (2) from valve body (1). a Mask the solenoid to prevent dirt from entering it. 2) Remove valve (3) and ball (4). a Keep the ball so that it will not be lost. 3) Remove spool (7). a When removing the spool, check that it moves smoothly. 4) Remove spring (8) and shims (9) and (10) from spool (7). a Check the quantity of shims (9) and (10).
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50 Disassembly and assembly
Assembly of ECMV assembly a a
If the pressure control valve was disassembled or any part of it was replaced, be sure to check the oil pressure. Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
1.
Pressure control valve 1) Install shims (9) and (10) and spring (8) to spool (7), and then install the spool to body (1). q Standard number of shims: 3 q Standard shim thickness: 1.5 mm (Thickness of 1 shim: 0.2 mm, 0.5 mm) a Check that the spool moves smoothly. 2) Put ball (4) in valve (3), fit O-ring (5), and install them. 3) Fit O-ring (6) to the solenoid and install them to body (1). a When reusing all of valve body (1), spring (8), spool (7), solenoid (2), and valve (3), install the standard number of the shims. a When replacing solenoid valve (2), check that spring (8) is installed securely.
2.
Flow control valve 1) Install sleeve (18), spring (17), and pin (16) to body (1). 2) Install shim (14) and spring (13) to spring seat (15), fit O-ring (21) to body (1), and install switch assembly (12) and bracket (20) with bolts (19).
3.
Testing ECMV oil pressure Check the ECMV oil pressure. For details, see Testing and adjusting, Testing ECMV oil pressure.
4.
Adjusting ECMV oil pressure As a result of testing, if the oil pressure is out of the standard range, adjust it with shims (9) and (10). Quantity of adjustment per shim (0.5 mm thick) 714-23-15580
0.06 MPa {Approx. 0.65 kg/cm2}
Quantity of adjustment per shim (0.2 mm thick) 714-28-15590
0.025 MPa {Approx. 0.26 kg/cm2}
a
36
a a
Install the shim securely and do not drop it in the valve. After adjusting the shim, test the oil pressure again.
If the shim is increased, the oil pressure is heightened. If the former is decreased, the latter is lowered.
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50 Disassembly and assembly
Disassembly of priority valve q
q
Remove the priority valve assembly from the transmission assembly. a Before removing the priority valve assembly, clean around it so that dirt will not enter the transmission assembly. Keep the removed parts so that they will not be damaged.
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Assembly of priority valve 1.
Install valve (6), spring (7), and sleeve (5) to valve body (1).
2.
Fit the O-ring to plug (10) and install them to body (1). 3 Plug: 58.8 – 78.4 Nm {6 – 8 kgm}
3.
Install spool (2). a Check that the spool moves smoothly.
4.
Install spring (7) and shim (4). Fit O-ring (9) to plug (8) and install them to body (1). 3 Plug: 58.8 – 78.4 Nm {6 – 8 kgm}
1.
Remove plug (8) from valve body (1).
2.
Remove shim (4) and spring (3). a Check the quantity of shim (4).
3.
Remove spool (2). a When removing the spool, check that it moves smoothly.
Quantity of adjustment per shim (0.5 mm thick)
4.
Remove plug (10) from valve body (1).
a
5.
Remove sleeve (5), spring (7), and valve (6).
D475A, D475ASD-5E0
a
52 kPa {0.53 kg/cm2}
If the shim is increased, the oil pressure is heightened. If the former is decreased, the latter is lowered. After adjusting the shim, test the oil pressure again.
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50 Disassembly and assembly
Removal and installation of steering control valve assembly Removal 1.
Remove fuel tank assembly. For details, see Removal and installation of fuel tank assembly.
2.
Disconnect 3 wiring clamps (1).
3.
Remove valve cover (2).
4.
Disconnect harness connector (3).
5.
Remove steering control valve assembly (4).
Installation q
38
Carry out installation in the reverse order to removal.
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50 Disassembly and assembly
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Disassembly and assembly of steering control valve assembly
Disassembly of ECMV assembly q
q
1.
Before removing the ECMV assembly from the steering assembly, clean around it so that dirt will not enter it and steering assembly. Keep the removed parts so that they will not be damaged. Flow control valve 1) Remove bracket (25), switch assembly (17), and cover (28) from valve body (1). 2) Remove springs (18) and (19) and spring seat (20). 3) Remove sleeve (23), spring (22), and pin (21).
D475A, D475ASD-5E0
2.
Pressure control valve 1) Remove solenoid (2) from valve body (1). a Mask the solenoid to prevent dirt from entering it. 2) Remove valve (3) and ball (4). a Keep the ball so that it will not be lost. 3) Remove spool (7). a When removing the spool, check that it moves smoothly. 4) Remove spring (13) and shims (14) and (15) from spool (7). Then, remove ring (12), sleeve (10), spring (9), and poppet (8). a Check the quantity of shims (14) and (15).
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50 Disassembly and assembly
Assembly of ECMV assembly a a
If the pressure control valve was disassembled or any part of it was replaced, be sure to check the oil pressure. Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
1.
Pressure control valve 1) Install poppet (8), spring (9), O-ring (11), sleeve (10), and ring (12) to spool (7). 2) Install shims (14) and (15) and spring (13) to spool (7), and then install the spool to body (1). q Standard number of shims: 3 q Standard shim thickness: 1.5 mm (Thickness of 1 shim: 0.2 mm, 0.5 mm) a Check that the spool moves smoothly. 3) Fit the O-ring to valve (3), install the ball, fit the O-ring to the solenoid (2), and install them to body (1). a When reusing all of valve body (1), spring (13), spool (7), solenoid (2), and valve (3), install the standard number of the shims. a When replacing solenoid valve (2), check that spring (13) is installed securely.
2.
Flow control valve 1) Install sleeve (23), spring (22), and pin (21) to body (1). 2) Install springs (19) and (18) to spring seat (20) and put them in cover (28). Fit Orings (26) and (27) and install switch assembly (17) and bracket (25) with bolts (24).
3.
Testing ECMV oil pressure Check the ECMV oil pressure. For details, see Testing and adjusting, Testing ECMV oil pressure.
4.
Adjusting ECMV oil pressure As a result of testing, if the oil pressure is out of the standard range, adjust it with shims (14) and (15).
40
Quantity of adjustment per shim (0.5 mm thick) 714-23-15580
0.06 MPa {Approx. 0.65 kg/cm2}
Quantity of adjustment per shim (0.2 mm thick) 714-23-15590
0.025 MPa {Approx. 0.26 kg/cm2}
a a a
If the shim is increased, the oil pressure is heightened. If the former is decreased, the latter is lowered. Install the shim securely and do not drop it in the valve. After adjusting the shim, test the oil pressure again.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02016-03
Removal and installation of final drive assembly
4.
Remove cover (3), then using forcing screw, pull out drive shaft (4). [*1] a If the shaft will not come out, set a jack on the ground and push the shoe grouser up, then move the sprocket to the front or rear to a position where the shaft will come out, and remove the shaft. a Pull the shaft out to a position where it contacts the sprocket.
5.
Remove 3 bolts of final drive and install tool J1.
6.
Sling final drive assembly (5), then remove mounting bolts, and lift off. [*2]
790-337-1032 J
1 791-827-1910 01011-83015
Lifting tool
t 1
Plate
t 1
Bolt
t 3
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Removal 1.
Remove track shoe assembly. For details, see "Expansion and installation of track shoe assembly".
2.
Raise chassis with jack or ripper and set stand [1] under frame.
3.
Remove covers (1) and (2).
4
D475A, D475ASD-5E0
Final drive assembly: 3,600 kg
41
SEN02016-03
50 Disassembly and assembly
Installation q
Carry out installation in the reverse order to removal.
[*1] q
a
[*2]
Installed position of gear hole cover button (6): 72 ± 0.8 mm If the installed position is higher than the specified position, the button may be driven defectively. In this case, pull out the button, check for foreign matter and scuffing, and then driving it again. .
2 3
42
Final drive assembly mounting bolt: Thread tightener (LT-2) Final drive assembly mounting bolt: 1,960 – 2,450 Nm (200 – 250 kgm)
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02016-03
Disassembly and assembly of final drive assembly
Disassembly 1.
790-431-1081 Guide
t 1
790-431-1031 Block
t 1
790-101-2350 Leg
t 2
790-101-2430 Adapter 2 790-101-2360 Plate
t 2
02215-11622 Nut 790-101-2102
Puller (294 kN {30 ton})
Sprocket 1) Set final drive assembly to block (height: approx. 50 mm). 2) Remove sprocket (1).
3.
Cover Using eyebolts [1], remove cover (2).
4.
Hub 1) Remove plate (3). 2) Using eyebolts [2], lift off hub (4).
t 1
790-431-1101 Installer assembly
t 1
790-101-1102 Pump
2.
t 2
t 1
Puller (294 kN {30 ton})
t 1 t 1
t 1 J 4 791-585-1510 Installer 790-431-1220 Remover assembly t 1 5 790-101-2102
Puller (294 kN {30 ton})
t 1
790-431-1210 Installer assembly
t 1
Puller (294 kN {30 ton})
790-101-1102 Pump
7
t 1
790-101-1102 Pump
6 790-101-2102
t 1 t 1
790-431-1230
Remover & installer
t 1
790-101-2102
Puller (294 kN {30 ton})
t 1
790-101-1102 Pump
t 1
8 790-431-1240 Guide
t 1
D475A, D475ASD-5E0
Final drive case: Approx. 71 l
t 4
790-101-1102 Pump
3 790-101-2102
6
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
Draining oil Remove drain plug and drain oil from final drive case.
43
SEN02016-03
5.
Sprocket hub assembly 1) Remove holder (5). a Check the number and thickness of the shims, and keep in a safe place.
2) 3)
44
50 Disassembly and assembly
Using tool J2, disconnect sprocket hub assembly (6) and bearing (7) portion. Using eyebolts [3], remove sprocket hub assembly (6).
4)
Remove bearing inner race (8) from sprocket hub assembly.
5)
Turn over sprocket hub assembly, then remove floating seal cover (9) and bearing outer races (10) and (11). Remove floating seal (12) from floating seal cover. a Keep the floating seal in a safe place to protect it from damage.
6)
6.
Wear guard Lift off wear guard (13).
7.
Cover assembly 1) Using eyebolts, lift off cover assembly (14).
D475A, D475ASD-5E0
50 Disassembly and assembly
2)
8.
Disassemble cover assembly as follows. 1] Remove floating seal cover (15). 2] Remove floating seal (16) from floating seal cover. a Keep the floating seal in a safe place to protect it from damage.
3]
Remove spacer (17) and bearing inner race (18).
4]
Remove plate, then remove ring gear (19).
SEN02016-03
2)
Disassemble carrier assembly as follows. 1] Set carrier assembly on block (height: approx. 100mm). 2] Remove holder (21). 3] Using tool J7, remove planetary gear shaft (22).
4]
Remove planet gear (23), bearing inner races (24A) and (24B), and spacer (24C).
5]
Remove bearing outer race (24D).
Carrier assembly 1) Using eyebolts [5], remove carrier assembly (20).
D475A, D475ASD-5E0
45
SEN02016-03
9.
Sun gear 1) Remove plate (25). 2) Remove holder (26). 3) Pull out sun gear shaft assembly (27).
4)
50 Disassembly and assembly
2)
Using tool J5, pull out hub assembly (29) and bearing inner race (30) from shaft assembly (31).
3)
Disassemble hub assembly (29) as follows. 1] Remove gear (32) from hub (33). 2] Remove bearing outer races (34A) and (34B).
4)
Using eyebolts [6], pull out shaft assembly (31) from case. Disassemble shaft assembly as follows. 1] Remove collar (36). 2] Remove bearing inner race (37) and collar (38).
Remove holder (51) from sun gear shaft assembly, and pull out sun gear (52)
10. Hub, shaft assembly 1) Remove plate (28).
5)
46
D475A, D475ASD-5E0
50 Disassembly and assembly
11. Cage assembly 1) Using eyebolts [7], remove cage assembly (39). 2) Remove shims (40). a Check the number and thickness of the shims, and keep in a safe place.
3)
Disassemble cage assembly as follows. 1] Using puller [8], remove bearing outer race (41). 2] Remove oil seals (42) and (43).
SEN02016-03
13. Outer race, oil seals 1) Using puller [10], remove bearing outer race (48). 2) Remove oil seals (49) and (50) from cover.
Assembly a
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Hub, shaft assembly 1) Assemble shaft assembly as follows. 1] Install collar (38). 2] Using push tool [17], press fit bearing inner race (37). 3] Install collar (36).
12. Gear assembly 1) Remove gear assembly (44). 2) Using puller [9], remove bearing inner races (45) and (46) from gear (47).
D475A, D475ASD-5E0
47
SEN02016-03
2) 3)
50 Disassembly and assembly
Using eyebolts [6], install shaft assembly (31) to case. Assemble hub assembly as follows. 1] Using push tool, press fit bearing outer races (34A) and (34B) to hub (33).
5)
2. 2]
4)
Set gear (32) to hub (33). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 823 – 1,029 Nm {84 – 105 kgm} Set shaft assembly (31) and hub assembly (29) in position, then using tool J6, press fit bearing (30) portion.
Install plate (28). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 490 – 608 Nm{50 – 62 kgm}
Carrier assembly 1) Assemble carrier assembly as follows. a The planetary gear bearing forms a set, so align the mating marks on the inner race, outer race, and spacer when assembling.
1]
48
Install ring and spacer to planet gear, then using push tool [18], press fit top and bottom bearing outer races (24D).
D475A, D475ASD-5E0
50 Disassembly and assembly
2]
Assemble spacer (24C) and bearing inner races (24B) and (24A) to planet gear (23), then set to carrier. a Set so that the protruding part at the end face of the planet gear faces the outside of the machine.
3]
Using tool J7, press fit planetary gear shaft (22). a Align the shaft with the position of the bearing and spacer hole, and press fit gradually. Install holder (21). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm} a After tightening the bolts, check that the gear rotates smoothly.
4]
D475A, D475ASD-5E0
SEN02016-03
3.
Sun gear 1) Press fit sun gear (52) to sun gear shaft, and install holder (51). 2 Holder mounting bolt: Thread tightener (LT-2) 2) Assemble sun gear shaft assembly (27) to carrier (53), then install holder (26) and spacer (25). 2 Holder mounting bolt: Thread tightener (LT-2)
4.
Carrier, sun gear assembly Using eyebolts [5], install carrier and sun gear assembly (20).
49
SEN02016-03
5.
Cover assembly 1) Assemble cover assembly as follows. 1] Using push tools [11] and [12], install oil seals (50) and (49). a Install the bottom oil seal with the part receiving the pressure at the bottom; install the top oil seal with the part receiving the pressure at the top. 2 Lip of oil seal: Grease (G2-LI) 2 Oil seal press-fitting surface: Gasket sealant (LG-5) a Coat the inside surface of the case thinly with gasket sealant and wipe off any sealant that is forced out.
2]
3]
4] 5]
50
50 Disassembly and assembly
6]
Using tool J4, press fit floating seal (16) to floating seal cover. a Remove all oil and grease from the O-ring and O-ring contact surface, and dry before installing. a After installing the floating seal, check that the angle of the seal is less than 1 mm.
7]
Install floating seal cover (15). a Fit a cork plug in the forcing tap.
Using push tool [13], press fit bearing outer race (48) to cover.
Fit ring gear (19) and install plate. a Fit so that the notched part of the end face of the gear faces the inside of the machine. Install spacer (54), then using tool J3, press fit bearing inner race (18). Install spacer (17).
D475A, D475ASD-5E0
50 Disassembly and assembly a
2)
6.
Install so that the cut-out portion of the floating seal cover is facing the bottom as shown in the diagram below.
Using eyebolts, raise cover assembly (14) and install. 2 Case mating surface: Gasket sealant (Three Bond 1216) a Check that there are no dents, rust, oil, grease, or water on the mating surface of the case and cover. a Coat the whole circumference of the mating surface of the case (one side) with gasket sealant without any break. a Install the cover assembly within 20 minutes after coating with gasket sealant. 3 Mounting bolt: 1,715 – 1,911 Nm {175 – 195 kgm}
SEN02016-03
7.
Sprocket hub assembly 1) Using tool J4, install floating seal (12) to floating seal cover. a Remove all oil and grease from the O-ring and O-ring contact surface, and dry before installing. a After installing the floating seal, check that the angle of the seal is less than 1 mm.
2) 3)
Using push tool, press fit bearing outer races (11) and (10). Install floating seal cover (9).
4)
Set bearing (8) to sprocket hub assembly.
Wear guard 1) Raise wear guard (13) and install. 2) Install wear guard plate (13a). 3 Mounting bolt: 823 – 1,029 Nm {84 – 105 kgm}
D475A, D475ASD-5E0
51
SEN02016-03
5)
52
50 Disassembly and assembly
Using eyebolts [3], sling sprocket hub assembly (6) and set to cover. a Check that there is no dirt on the sliding surface of the floating seal, then coat thinly with engine oil.
6)
Using tool J3, press fit bearing (7) portion. a Rotate the sprocket hub assembly when press fitting.
7)
Install holder (5). a Tighten 6 mounting bolts temporarily at equal distances around the circumference, then adjust with shims so that clearance (X) between cover (14) and holder (5) is within the standard value. Clearance (X): 0.1 – 0.3 mm 3 Mounting bolt (temporary tightening): Approx. 74 Nm {7.5 kgm} 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
8.
Hub 1) Using eyebolts [2], raise hub (4) and install. 2) Install plate (3). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
9.
Cover Using eyebolts [1], install cover (2).
D475A, D475ASD-5E0
50 Disassembly and assembly
10. Sprocket Install sprocket (1). 3 Mounting bolt: 2,500 – 2,794 Nm {255 – 285 kgm}
SEN02016-03
12. Cage assembly 1) Assemble cage assembly as follows. 1] Using push tools [11] and [12], install oil seals (43) and (42). a Install the bottom oil seal with the part receiving the pressure at the bottom; install the top oil seal with the part receiving the pressure at the top. 2 Lip of oil seal: Grease (G2-LI) 2 Oil seal press-fitting surface: Gasket sealant (LG-5) a Coat the inside surface of the case thinly with gasket sealant and wipe off any sealant that is forced out.
11. Gear assembly 1) Using push tool [14], press fit bearing inner races (46) and (45) to gear. 2) Set tool J8 to cover (14), and install gear assembly (44). a Leave tool J8 in position until the cage is installed.
2]
D475A, D475ASD-5E0
Using push tool [15], press fit bearing outer race (41).
53
SEN02016-03
2)
Using eyebolt [7], set cage assembly (39) to case, and remove tool J8.
3)
Tighten mounting bolts (C), (D), (E), and (F) of cage (A) uniformly to a tightening torque of 69 Nm {7 kgm}, then loosen bolts. Tighten mounting bolts (C) and (D) of cage (A) uniformly to a tightening torque of 20 Nm {2 kgm}. In this condition, use feeler gauge [16] to measure clearances (a) and (b) between cage (A) and cage (B). Determine thickness (c) of shims to insert according to Table 1 on next page. Assemble shim set on the previous stage, then tighten mounting bolts of cage (A) uniformly. 3 Mounting bolts: 319 – 608 Nm {32.5 – 62 kgm}
4)
5)
6) 7)
54
50 Disassembly and assembly
13. Refilling with oil Tighten drain plug and add engine oil through the oil filler to the specified level. 5
Final drive case: Approx. 71 l (GO85W140)
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02016-03
Table 1 a + b (mm) More than
Number of shim to use
Less than
t = 0.15
t = 0.5
t = 1.0
Total shim thickness c (mm)
3.05
3.15
9
1
—
1.85
3.15
3.25
6
—
1
1.90
3.25
3.35
3
1
1
1.95
3.35
3.45
—
—
2
2.00
3.45
3.55
7
—
1
2.05
3.55
3.65
4
1
1
2.10
3.65
3.75
1
—
2
2.15
3.75
3.85
8
—
1
2.20
3.85
3.95
5
1
1
2.25
3.95
4.05
2
—
2
2.30
4.05
4.15
9
—
1
2.35
4.15
4.25
6
1
1
2.40
4.25
4.35
3
—
2
2.45
4.35
4.45
—
1
2
2.50
4.45
4.55
7
1
1
2.55
4.55
4.65
4
—
2
2.60
4.65
4.75
1
1
2
2.65
4.75
4.85
8
1
1
2.70
4.85
4.95
5
—
2
2.75
4.95
5.05
2
1
2
2.80
5.05
5.15
9
1
1
2.85
5.15
5.25
6
—
2
2.90
5.25
5.35
3
1
2
2.95
5.35
5.45
—
—
3
3.00
5.45
5.55
7
—
2
3.05
5.55
5.65
4
1
2
3.10
5.65
5.75
1
—
3
3.15
5.75
5.85
8
—
2
3.20
5.85
5.95
5
1
2
3.25
5.95
6.05
2
—
3
3.30
6.05
6.15
9
—
3
3.35
6.15
6.25
6
1
2
3.40
6.25
6.35
3
—
3
3.45
6.35
6.45
—
1
3
3.50
6.45
6.55
7
1
2
3.55
6.55
6.65
4
—
3
3.60
6.65
6.75
1
1
3
3.65
6.75
6.85
8
1
2
3.70
6.85
6.95
5
—
3
3.75
6.95
7.05
2
1
3
3.80
7.05
7.15
9
1
2
3.85
7.15
7.25
6
—
3
3.90
7.25
7.35
3
1
3
3.95
D475A, D475ASD-5E0
55
SEN02016-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN02016-03
© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (02)
56
SEN02017-04
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Undercarriage and frame, Part 1 Removal and installation of track frame assembly.......................................................................................... 2 Disassembly and assembly of idler assembly ................................................................................................ 4 Removal and installation of recoil spring assembly ........................................................................................ 7 Disassembly and assembly of recoil spring assembly ...................................................................................11 Removal and installation of track roller assembly ......................................................................................... 13 Disassembly and assembly of track roller assembly .................................................................................... 15 Removal and installation of carrier roller assembly ...................................................................................... 17 Disassembly and assembly of carrier roller assembly .................................................................................. 18 Removal and installation of bogie assembly ................................................................................................. 21 Disassembly and assembly of bogie assembly ............................................................................................ 25 Removal and installation of No.1 bogie assembly ........................................................................................ 27 Removal and installation of operator's seat isolator...................................................................................... 32 Disassembly and assembly of operator's seat isolator ................................................................................. 33
D475A, D475ASD-5E0
1
SEN02017-04
Removal and installation of track frame assembly 1
50 Disassembly and assembly
7.
Using eyebolts [3], pull out pin (3). [*1] a It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so adjust the height of the track frame before removing.
8.
Remove mounting bolts, and disconnect cover (4) from track frame.
9.
Remove cover (5). a With the right track frame, disconnect 4 blade tilt cylinder hoses from the cover.
Removal 1.
Remove track shoe assembly. For details, see "Expansion and installation of track shoe assembly".
2.
Raise chassis with jack or ripper, then set support [1] under frame to keep rear of chassis off ground.
3.
Set hydraulic jack [2] to center of equalizer bar, and raise front of chassis.
4.
Sling track frame assembly.
5.
Remove cover (1).
6.
Remove cover (2).
10. Remove seal (6) together with washer (7). [*2] 11. Remove washer (8), then remove spacer (9).
2
D475A, D475ASD-5E0
50 Disassembly and assembly
12. Lift off track frame assembly (10). [*3] a Oil will flow out from the pivot case, so catch it in an oil container. 6
Pivot case: 26 l
4
Track frame assembly: 13,500 kg
SEN02017-04
Installation q
[*1]
Carry out installation in the reverse order to removal. 2
a
a [*2]
a a
[*3]
q
a
Inside surface of bushing: Grease (G2-LI) Before installing the pin, adjust the height of the track frame and align the center of the equalizer bar hole and track frame hole. Set the pin with the grease hole facing the outside of the machine. After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). Be careful not to install with the seal displaced in the direction of twisting. Be careful not to install the track frame with seal (11) displaced in the direction of twisting.
Refilling with oil (pivot case) Add oil through oil filler to the specified level. 5
D475A, D475ASD-5E0
Pivot case: 26 l (SAE30)
3
SEN02017-04
50 Disassembly and assembly
Disassembly and assembly of idler assembly
6.
Using puller [4], remove seal guide (6) and retainer (7) and plate (8).
7.
Remove seal guides (2) and (6) from retainers (3) and (7).
8.
Remove floating seal (9) from seal guides (2) and (6). a Keep the floating seal in a safe place to protect it from damage.
9.
Remove floating seal (10) from seal guides (3) and (7). a Keep the floating seal in a safe place to protect it from damage.
791-830-1760
Plate
t 1
791-830-1320
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
Plate
t 2
Nut
t 2
01643-31645
Washer
t 2
790-101-2102
Puller t 2 (294 kN {30 ton})
790-101-1102
Pump
t 1
2 791-560-1520
Installer
t 1
3 791-830-1480
Push tool
t 1
4 791-601-1000
Oil pump
t 1
1 01580-01613 L
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
N
Disassembly 1.
Remove oil filler plug and drain oil. 6
Idler: 1.4 – 1.5 l (GO140)
2.
Set idler assembly (1) on block [1].
3.
Remove mounting bolts, then using forcing screws [2], remove seal guide (2) together with retainer (3) and plate (4).
4.
Turn over idler assembly.
5.
Remove mounting bolts, then using eyebolts [3], remove shaft (5) together with retainer.
4
D475A, D475ASD-5E0
50 Disassembly and assembly
10. Remove bushings (11) from idler (12).
SEN02017-04
2.
Using tool L2, install floating seal (10) to retainers (3) and (7).
3.
Fit O-ring and install retainer (3) and plate (4) to idler. a Check that the plate can be turned smoothly with the hand.
4.
Using eyebolts [3], set idler (12) to shaft (5). a Set block (height: approx. 200 mm) under the idler.
5.
Turn over idler assembly. a Tie with wire to prevent the shaft from falling out.
6.
Fit O-ring and install retainer (7) and plate (8) to idler.
Assembly a 1.
Clean all parts, and check for dirt or damage. Set bushing (11) and tool L1 to idler (12), and press fit bushing (11). a First, center the bushing with a plastic hammer, then press fit with a puller. a Press fit so that press-fitting dimension (a) from the end face of the idler to the top surface of the bushing is the dimension given below. q Press-fitting dimension (a): 17 ± 0.5 mm
D475A, D475ASD-5E0
5
SEN02017-04
7.
Using tool L2, install floating seal (9) to seal guides (2) and (6).
50 Disassembly and assembly
9.
Using tool L4, fill with oil to specified level, then tighten oil filler plug. 5
3
8.
Set seal guide (2) to shaft, then using tools L1 and L3, press fit seal guide (2). a Seal guide press-fitting force: 83.3 – 137.2 kN {8.5 – 14 ton}
a
a
6
Idler: 1.4 – 1.5 l (GO140) Oil filler plug: 156.8 – 254.8 Nm {16 – 26 kgm}
Press fit the seal guide so that press-fitting dimension (a) from the end face of the shaft to the top surface of the seal guide is the dimension given below. q Press-fitting dimension (a): 124.5 ± 0.2 mm Turn over the idler assembly and repeat the same procedure to press fit the seal guide (6) on the opposite side.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Removal and installation of recoil spring assembly
5.
Lift off trunnion (3). 4
Trunnion: 140 kg
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
790-434-1401 Remover assembly t 1 M 1 790-101-2102
Puller (294 kN {30 ton})
790-101-1102 Pump
t 1 t 1
Removal 1.
Remove track shoe assembly. For details, see "Expansion and installation of track shoe assembly". k To prevent danger, never stand in front of the idler yoke assembly.
2.
Drain oil from recoil cylinder chamber using oil pump. 6
3.
4.
6.
Remove covers (4). a Remove both the inside and outside covers.
7.
Using tool M1, remove pins (5). [*1] a Remove both the inside and outside pins.
Recoil cylinder chamber: Approx. 75 l
Using eyebolt [1], remove cover (1). 4
Cover: 70 kg
Remove cover (2).
D475A, D475ASD-5E0
7
SEN02017-04
8.
Lift off idler and recoil spring assembly (6). [*2] a Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at the track frame end. 4
50 Disassembly and assembly
2)
Idler, recoil spring assembly: 3,500 kg
k
9.
Disconnect recoil cylinder assembly (7) from idler yoke assembly (8) as follows. [*3] 1) Put idler yoke assembly (8) in contact with ground, then raise recoil cylinder assembly (7). a When doing this, check that there is no damage to the weld of recoil cylinder assembly (7). a Wrap cloth around the chrome plated bushing to protect it.
k
3)
8
Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides. [*4]
To prevent danger, never stand in front of the idler yoke assembly or behind the recoil cylinder assembly. The recoil spring inside the recoil cylinder is applying a pushing force of approx. 788 kN {approx. 81 tons} on the idler yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance (a) between the flange of the recoil cylinder and idler yoke is 8 – 12 mm.
When the bolts are loosened, the torque will suddenly drop. Check that the installed load of the recoil spring is not applying any pushing force on the mounting bolts, then remove all bolts. a If the torque increases (the installed load of the recoil spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows.
D475A, D475ASD-5E0
50 Disassembly and assembly k
k
SEN02017-04
If the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (10), or nut (11) at the tip of the shaft has fallen off, so there is danger that the idler yoke assembly may fly off to the front. For this reason, disassemble as follows.
When disconnecting the idler yoke assembly and recoil cylinder assembly, do not stand in front of the idler yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed. 1] Prepare the following parts. q Bolt [1] (x 6): 791-730-1120 q Nut [2] (x 6): 01580-13326 q Washer [3] (x 6): 01643-33380 (use again) 2] Remove 6 bolts marked , then install bolts [1], nuts [2], and washers [3]. a Check that dimension L is less than 450 mm. a Screw in bolts [1] until they contact the bottom of the yoke (Y) thread. 3] Remove remaining 12 bolts (those not marked ). 4] Hold bolts [1] with a wrench to prevent them from turning, and loosen 2 nuts [2] simultaneously on diagonally opposite sides. a Be careful not to let the load bear on only one bolt. 5] When recoil spring is fully extended and torque has completely dropped in loosening direction of nut [2], remove bolt [1]. a When clearance (b) is approx. 280 mm, the spring is fully extended.
D475A, D475ASD-5E0
10. Remove ring (12).
9
SEN02017-04
50 Disassembly and assembly
11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15). [*5]
14. Remove holder (20) from recoil spring assembly.
12. Disassemble piston assembly (15) as follows. 1) Remove wear ring (16) from piston. 2) Remove snap ring (17), then remove packing (18).
Installation q
[*1]
[*2]
Carry out installation in the reverse order to removal. a
Before installing the pin, align the center of the hole in the track frame and the dowel pin at the recoil cylinder end with a bar.
a
Using a lever block, keep horizontal and be careful not to damage the oil seal at the track frame end when installing. Adjust the clearance. For details, see Testing and adjusting, Adjusting clearance of idler.
a
13. Remove recoil spring assembly (19). 4
[*3]
Recoil spring assembly: 780 kg
[*4]
a
If the recoil spring set bolt is broken or the nut at the tip of the shaft has fallen off, see Assembly of recoil spring assembly when assembling.
2 3
[*5]
10
a
Idler yoke assembly mounting bolt: Thread tightener (LT-2) Idler yoke assembly mounting bolt: 2,205 – 2,695 Nm {225 – 275 kgm}
To prevent air from accumulating inside the cylinder, fill with grease as follows. 1] Fill the inside of the cylinder with approx. 2.0 l of grease. 2] Set with the cylinder drain hole facing up, then loosen the lubricator. 3] Push the piston until it contacts the stopper. This will push out the air and any extra grease.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Release hydraulic pressure gradually and relieve tension of spring.
4.
Remove rear pilot (5), spacer (6), bolt (7), and front pilot (8) from spring (4).
Part No.
M 2
Part Name
791-685-8502
Compressor
t 1
791-635-3160
Extension
t 1
790-201-2790
Spacer
t 1
790-101-1300
Cylinder (980 kN t 1 {100 ton})
790-101-1102
Pump
Sketch
3. New/Remodel
Special tools
Q’ty
Apply hydraulic pressure slowly to compress spring, then remove lock plate (2) and remove nut (3).
Necessity
2.
Symbol
Disassembly and assembly of recoil spring assembly
t 1
Disassembly 1.
Remove recoil spring assembly (1) with tool M2. k The spring is under high installed load, so be careful to set it correctly. a Installed load of spring: Approx. 788 kN {approx. 81 ton}
D475A, D475ASD-5E0
11
SEN02017-04
50 Disassembly and assembly
Assembly 1.
Assemble front pilot (8), bolt (7), spacer (6), and rear pilot (5) to spring (4), then set in tool M2. k The spring is under high installed load, so be careful to set all parts correctly.
2.
Apply hydraulic pressure slowly to compress spring, and set so that installed length of spring is specified value. a Installed length (a) of spring: 1,441 mm a Installed load of spring: Approx. 788 kN {approx. 81 ton}
3.
Fit nut (3), then install lock plate (2). a When securing the recoil spring mounting nut, make a clearance (b) of 0 – 1 mm between lock plate (2) and nut (3), then bring lock plate (2) and bolt (7) into tight contact, and secure in position. 2 Lock plate mounting bolt: Thread tightener (LT-2)
4.
Gradually release hydraulic pressure to completely release tension of spring, then remove recoil spring assembly (1) from tool M2.
12
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Removal and installation of track roller assembly
12 L
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
790-401-1540
Shackle
t 2
790-401-1770
T-bolt
t 2
791T-830-1780 Plate
t 3
13 01011-62700 01673-32780
Bolt
t 6
Washer
t 6
Sketch
New/Remodel
Part Name
Q’ty
Part No.
Necessity
Symbol
Special tools
5.
Remove the mounting bolts and place track roller assembly (2) on steel plate [1]. [*2]
6.
Operate the blade and ripper to lift the machine body until track roller assembly (2) separates from the bogie.
7.
Pull track roller assembly (2) out of the machine body from the top of the steel plate with a bar, etc. [*3]
N Q
Removal 1.
Loosen the track shoe. For details, see "Expansion and installation of track shoe assembly".
2.
Install tool L13 and secure bogie assembly (1). [*1]
4
3.
Operate the blade and ripper to lift the machine body until track roller assembly (2) separates from the track shoe.
4.
Place steel plate [1] on the track shoe and operate the blade and ripper to lower the machine body until the track roller assembly comes in contact with the steel plate. a Operate the blade and ripper slowly, running the engine at the low idling speed.
D475A, D475ASD-5E0
Track roller assembly: 240 kg
13
SEN02017-04
50 Disassembly and assembly a
Installation q
Install the track roller assembly with the oil filler plug out. a After installing the track roller assembly, set the position of dowel pin (4). 2 Track roller assembly mounting bolt: Adhesive (LT-2) 3 Track roller assembly mounting bolt: 2,205 – 2,695 Nm {222 – 275 kgm}
Carry out installation in the reverse order to removal.
[*1] After removing tool L13, replace the mounting bolts of cover (3) with the regular parts. 3 Cover mounting bolt: 883 – 1,470 Nm {90 – 150 kgm}
[*3] [*2] Install S to the first and last track rollers and install D to the other track rollers. S: Single flange D: Double flange
14
When using the assembling tool Set tool L12 under the track roller assembly (2) and lift up and set track roller assembly (2) to the track frame.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Disassembly and assembly of track roller assembly
t 1
N
t 1
L
10 791-830-1730
Push tool
t 1
11 791-601-1000
Oil pump
t 1
Part Name
Using press, remove seal guide (6) together with retainer (7) and plate (8) from shaft.
7.
Remove seal guides (2) and (6) from retainers (3) and (7).
8.
Remove floating seal (9) from seal guides (2) and (6). a Keep the floating seal in a safe place to protect it from damage.
9.
Remove floating seal (10) from retainers (3) and (7). a Keep the floating seal in a safe place to protect it from damage.
Sketch
New/Remodel
Plate Installer
Part No.
Necessity
8 791-830-1740 9 791-515-1520
Symbol
Q’ty
Special tools
6.
N
Disassembly 1.
Remove oil filler plug and drain oil. 6
Track roller: 1.4 – 1.5 l
2.
Set track roller assembly (1) on block [1].
3.
Remove mounting bolts, then using forcing screws [2], remove seal guide (2) together with retainer (3) and plate (4).
4.
Turn over track roller assembly.
5.
Remove mounting bolts, then using eyebolts [3], remove shaft (5) together with retainer.
10. Remove bushing (11) from roller (12).
D475A, D475ASD-5E0
15
SEN02017-04
50 Disassembly and assembly
Assembly a 1.
Clean all parts, and check for dirt or damage. Set roller (12) to press, then using tool L8, press fit bushing (11). a First, center the bushing with a plastic hammer, then press fit with a press. a Press fit so that press-fitting dimension (a) from the end face of the roller to the top surface of the bushing is the dimension given below. q Press-fitting dimension (a): 17 ± 0.5 mm
2.
Set shaft (5) to roller.
a
a
3.
Using tool L9, install floating seal (10) to retainers (3) and (7).
4.
Fit O-ring and install retainers (3), (7) and plate (8) to roller. a Check that the plate can be turned smoothly with the hand. 7.
Press fit the seal guide so that press-fitting dimension (b) from the end face of the shaft to the top surface of the seal guide is the dimension given below. q Press-fitting dimension (b): 141.5 ± 0.2 mm Turn over the track roller assembly and press fit seal guide (6) on the opposite side according to the above procedure.
Using tool L11, fill with oil to specified level, then tighten oil filler plug. 5
3
5.
Using tool L9, install floating seal (9) to seal guides (2) and (6).
6.
Using tool L10, press fit seal guide (2) to shaft. a Seal guide press-fitting force: 49 – 83 kN {5 – 8.5 ton}
16
Track roller: 1.4 – 1.5 l (GO140) Oil filler plug: 156.8 – 254.8 Nm {16 – 26 kgm}
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Removal and installation of carrier roller assembly Removal 1.
Loosen the track shoe. For details, see Expanding track shoe assembly.
2.
Lift up the track shoe with hydraulic jack [1].
3.
Lift off carrier roller assembly (1). 4
[*1]
Carrier roller assembly: 105 kg
Installation q
[*1]
Carry out installation in the reverse order to removal. a
Make a clearance (a) of 5 mm between the carrier roller and support as shown below. 2 Carrier roller assembly mounting bolt: Adhesive (LT-2) 3 Carrier roller assembly mounting bolt: 744.8 ± 83.3 Nm {76 ± 8.5 kgm}
D475A, D475ASD-5E0
17
SEN02017-04
50 Disassembly and assembly
Disassembly and assembly of carrier roller assembly
5.
Using tool L7, remove nut (4).
6.
Remove the fitted part of the seal guide with puller [2] and remove bearing (5) and roller (6) as one unit by using eyebolts.
7.
Remove bearing outer race (7) from the roller.
8.
Remove seal guide (8) and bearing inner race (9) as one unit with puller [3].
9.
Remove floating seal (10) from seal guide (8).
L
4 791-601-1000
Oil pump
t 1
5 791-515-1520
Installer
t 1
6 790-830-1770
Push tool
t 1
7 791-631-1270
Wrench
t 1
Sketch
Q’ty
Part Name
New/Remodel
Part No.
Necessity
Symbol
Special tools
N
Disassembly 1.
Remove the oil filler plug and drain the oil. a Drain the oil, turning the shaft. 6
Carrier roller: Approx. 13 l
2.
Set carrier roller assembly (1) to block [1].
3.
Remove the mounting bolts and cover (2).
4.
Remove ring (3).
18
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04 a
10. Remove seal guide (11) with push tool [4]. 11. Remove floating seal (12) from seal guide (11).
5.
Tighten nut (4) with tool L7. 3 Nut: 98 Nm {10 kgm} a After the nut is tightened, if its hole is not matched to the hole of the shaft, match its hole by loosening the nut.
6.
Install ring (3).
7.
Fit the O-ring to cover (2) and install them.
Assembly a
Clean the all parts and check them for dirt.
1.
Press fit bearing inner race (9) with push tool [5].
2.
Press fit the bearing inner race, turning the roller, until the roller becomes a little hard to turn.
Press fit bearing outer race (7) with push tool [6].
3.
Set roller (6) and bearing inner race (5) to the shaft.
4.
Press fit bearing inner race (5) to the shaft with push tool [7].
D475A, D475ASD-5E0
19
SEN02017-04
8.
Install floating seal (10) to seal guide (8) with tool L5.
9.
Fit the O-ring to seal guide (8) and install them, matching them to the dowel pin.
50 Disassembly and assembly
12. Supply specified quantity of oil by using tool L4 and tighten the oil filler plug. 5
3
Carrier roller: 1.25 – 1.35 l (GO140) Oil filler plug: 157 – 255 Nm {16 – 26 kgm}
10. Install floating seal (12) to seal guide (11) with tool L5. 11. Press fit seal guide (11) with tool L6. a Press fit the seal guide so that dimension (a) between the shaft end and seal guide top will be 181.25 ± 0.2 mm.
20
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Removal and installation of bogie assembly
Part No.
13
14
Part Name
1.
Loosen the track shoe. For details, see Expansion and installation of track shoe assembly.
2.
Install tool L13 and secure the bogie assembly.
3.
Operate the blade and ripper to lift the machine body until the track roller assembly separates from the track link. k Set a block between the track roller and track link so that the machine body will not lower.
4.
Set block [1] out of the track shoe, matching it to the height of the track link.
5.
Set steel plate [2] on the track shoe and block [1].
6.
Operate the blade and ripper to lower the machine body until the track roller of bogie assembly (1) comes in contact with steel plate [2]. a Operate the blade and ripper slowly, running the engine at the low idling speed.
Necessity Q’ty New/Remodel Sketch
Symbol
Special tools
Removal
791T-8301780
Plate
t 3 N Q
01011-62700
Bolt
t 6
01673-32780
Washer
t 6
1 791-830-1620 Plate
t 1 N
2 791-830-1630 Spacer
t 1 N
3 791-830-1640 Screw
t 3 N
4 01580-12722
Nut
t 3
5 01630-32780
Washer
t 3
Puller 6 790-101-4000 t 1 (490 kN {50 ton}) 7 790-101-1102 Pump
L
t 1
1 791-830-1650 Plate
t 1 N
2 791-830-1660 Spacer
t 1 N
3 796-670-1120 Plate
t 1
4 790-434-1070 Screw
t 1 N
15 5 01580-13629
Nut
t 2
6 01643-33690
Washer
t 1
7 790-101-4000
Puller t 1 (490 kN {50 ton})
8 790-101-1102 Pump
t 1
1 791-830-1620 Plate
t 1 N
2 791-830-1640 Screw
t 3 N
3 01580-12722 16 4 01643-32780 5 790-101-4000
Nut
t 3
Washer
t 3
Puller t 1 (490 kN {50 ton})
6 790-101-1102 Pump
t 1
17
791T-8301670
18
791-530-1510 Installer
t 1
19
791-601-1000 Oil pump
t 1
D475A, D475ASD-5E0
Guide
t 2 N Q
21
SEN02017-04
7.
Remove cover (2).
8.
Pulling out shaft and ring 1) Set tool L14. 2) Push out shaft (3) and ring (4) to the opposite side simultaneously. a Pushing out force: 225.5 – 460.9 kN {13 – 47 tons}
50 Disassembly and assembly
4) 5)
Set tool L15. Pull out spacer (6) and rings (7) and (8). a Pulling out force: 225.5 – 460.9 kN {23 – 47 tons}
6) 7)
Remove spacer (6). Remove spacer (9) and floating seals (10) between rings (7) and (8). a Store the floating seals so that they will not be damaged. Pull out the shaft and rings on the opposite side according to above steps 1) – 7).
8)
3)
Remove floating seals (5) from the end faces of rings (4) and (7). a Store the floating seals so that they will not be damaged. 9.
Remove tool L13.
10. Place bogie assembly (1) on steel plate [2]. 11. Operate the blade and ripper to raise the machine body until the bogie assembly can be pulled out. k Set a block between the track roller and track link so that the machine body will not lower.
22
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
12. Sling bogie assembly (1) and pull it out, sliding it on steel plate [2]. 4
2) 3) 4) 5) 6)
Bogie assembly: 1,200 kg
Press fit shaft (3) to ring (8). Install spacer (9). Press fit ring (7) to shaft (3). Install spacer (6). Press fit ring (4) to shaft (3). 2 Apply lubricant (LM-P) to parts (a) (about 10 mm) of rings (8) and (4).
Installation 1.
Assembly of pin assembly 1) Using tool L18, install floating seals (5) to rings (4) and (7) and install floating seals (10) to the opposite side of ring (7) and ring (8). a When installing the floating seals, completely degrease the O-rings and O-ring contacting surfaces. a Check that each floating seal is not inclined more than 1 mm.
D475A, D475ASD-5E0
2.
Apply lever block [3] between the guard of bogie assembly (1) and the bogie assembly on the opposite side. Slide bogie assembly (1) on the steel plate to set it to the mounting position.
3.
Match the pin hole of the track frame to that of the bogie and set guide tool L17.
23
SEN02017-04
4.
Press fitting of pin assembly 1) Set tool L16 and cover (2).
50 Disassembly and assembly
5.
Refilling with oil Supply the specified quantity of oil by using tool L19. a Oil supplying pressure: 0.49 MPa {5 kg/cm2} 5
2)
24
Press fit pin assembly (11). a Direct arrow (a) on the end face of the pin assembly up (when the pin assembly is installed to the machine). a Push in the pin assembly with cover (2). a Push in the pin assembly to machined face (b) of the bogie. 2 Apply lubricant (LM-P) all over the side of the pin assembly. a Total press fitting force of pin assembly: 294.2 – 490.5 kN {30 – 50 tons}
Pin assembly: 180 – 200 cc (GO-140)
6.
Press fit the pin assembly on the opposite side of the bogie according to above steps 3 and 4.
7.
Tighten the mounting bolts of pin assembly cover (2) (2 places on inside and outside). 3 Cover mounting bolt: 883 – 1,470 Nm {90 – 150 kgm}
8.
Adjust the tension of the track shoe. For detail, see Testing and adjusting, "Testing and adjusting track shoe tension".
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Disassemble the pin assembly according to Removal and installation of bogie assembly (Step 8).
Special tools
4.
Disconnection of bogie Disconnect inner bogie (4) and outer bogie (5).
L
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
3.
Symbol
Disassembly and assembly of bogie assembly
1 791-830-1620 Plate
t 1 N
2 791-830-1640 Screw
t 3 N
3 01580-12722 Nut 16 4 01643-32780 Washer 5 790-101-4000
t 3
Puller t 1 (490 kN {50 ton})
6 790-101-1102 Pump 19
t 3
791-601-1000 Oil pump
t 1 t 1
Disassembly 1.
2.
Track roller assembly Turn over bogie assembly (1) and lift off 2 track roller assemblies (2).
Assembly 1.
Assembly of pin assembly Assemble the pin assembly according to Removal and installation of bogie assembly (Steps 3 – 5 of Installation).
2.
Set inner bogie (4) to outer bogie (5).
3.
Press fitting of pin assembly 1) Set tool L16 and cover (3).
Remove cover (3).
D475A, D475ASD-5E0
25
SEN02017-04
2)
4.
Press fit the pin assembly. a Direct arrow (a) on the end face of the pin assembly up (when the pin assembly is installed to the machine). a Push in the pin assembly with cover (3). a Push in the pin assembly to the machined face (b) of the bogie and secure the level difference of 5 mm between the bogie and pin assembly. 2 Apply lubricant (LM-P) all over the side of the pin assembly. a Total press fitting force of pin assembly: 294.2 – 490.5 kN {30 – 50 tons}
5.
Press fit the pin assembly on the opposite side of the bogie according to above steps 3 and 4. a After press fitting the pin assembly, rock the small bogie so that it can be moved with light force.
6.
Tighten the mounting bolts of pin assembly cover (3) (2 places on inside and outside). 3 Cover mounting bolt: 883 – 1,470 Nm {90 – 150 kgm}
7.
Track roller assembly Sling and install 2 track roller assemblies (2) to bogie assembly (1). 2 Track roller mounting bolt: Adhesive (LT-2) 3 Track roller mounting bolt: 2,205 – 2,695 Nm {225 – 275 kgm}
Refilling with oil Supply the specified quantity of oil by using tool L19. a Oil supplying pressure: 0.49 MPa {5 kg/ cm2} 5
26
50 Disassembly and assembly
Pin assembly: 180 – 200 cc (GO140)
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
Removal and installation of No.1 bogie assembly
Removal 1.
Loosen track shoe tension. For details, see Expansion and installation of track shoe assembly.
2.
Operate blade and ripper, and raise chassis to a position where track roller of No. 2 bogie assembly is separated from track link. k Set a block between the track roller and the track link to prevent the chassis from coming down.
3.
Fit eyebolts to holes of pad mounting bolt (M12 x 2) portion at rear of No. 1 bogie assembly, and raise No. 1 bogie assembly (1).
4.
Put steel plate between track shoe and roller, then loosen roller cap bolts (2) approx. 20 mm. (Both inside and outside)
5.
Tap end face of shaft (3) with hammer and remove track roller assembly (4). q There is a dowel pin on the near side of the track roller assembly, so be careful not to break it. (Dowel pin insertion tolerance: 5 – 6 mm)
6.
Remove roller cap bolt (2), then put track roller assembly (4) on steel plate, and pull out.
Part No.
Part Name
1 791-830-1620 Plate
14
t 1 N
2 791-830-1630 Spacer
t 1 N
3 791-830-1640 Screw
t 3 N
4 01580-12722
Nut
t 3
5 01630-32780
Washer
t 3
6 790-101-4000
Puller t 1 (490 kN {50 ton})
7 790-101-1102 Pump
t 1
1 791-830-1650 Plate
t 1 N
2 791-830-1660 Spacer
t 1 N
3 796-670-1120 Plate
t 1
4 790-434-1070 Screw
t 1 N
15 5 01580-13629
L
Necessity Q’ty New/Remodel Sketch
Symbol
Special tools
Nut
t 2
6 01643-33960
Washer
t 1
7 790-101-4000
Puller t 1 (490 kN {50 ton})
8 790-101-1102 Pump
t 1
1 791-830-1620 Plate
t 1 N
2 791-830-1640 Screw
t 3 N
3 01580-12722
Nut
t 3
Washer
t 3
16 4 01643-32780
Puller 5 790-101-4000 t 1 (490 kN {50 ton}) 6 790-101-1102 Pump
t 1
791T-830-1670 Guide
t 2 N Q
18
791-530-1510 Installer
t 1
19
791-601-1000 Oil pump
t 1
791-630-1860 Bracket
t 1
791-630-1870 Bracket
t 1
791T-830-1510 Spacer
t 2
19M-09-12850 Bolt
t 2
01643-33380
t 2
17
20
Washer
791T-830-1700 Lifting tool
21
Q
Track roller assembly: 240 kg
t 1 N Q
791T-830-1710 • Bar
1 N Q
791T-830-1720 • Plate
1 N Q
07283-31079
• Grip
1
01582-01210
• Nut
2
01643-31232
• Washer
2
04530-11628
• Eye bolt
1
D475A, D475ASD-5E0
4
27
SEN02017-04
7.
Raise No. 1 bogie (5) with tool L20 and hold in position.
8.
Remove cover (6).
9.
Pulling out shaft and ring 1) Set tool L14. 2) Push out shaft (7) and ring (8) to the opposite side simultaneously. a Pushing out force: 225.5 – 460.9 kN {13 – 47 tons} a When the ring is pushed out, it interferes with the idler. Accordingly, supply grease to the track tension adjustment parts in advance and move the idler cushion assembly to the front side of the machine body.
50 Disassembly and assembly
3)
Remove floating seals (9) from the end faces of rings (8) and (12). a Store the floating seals so that they will not be damaged.
4)
Set tool L15.
5)
Pull out spacer (11) and rings (12) and (13). a Pulling out force: 225.5 – 460.9 kN {23 – 47 tons} Remove spacer (11). Remove spacer (14) and floating seals (10) between rings (12) and (13). a Store the floating seals so that they will not be damaged.
6) 7)
28
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02017-04
10. Lower bogie (5) on the steel plate and pull it out. 4
2) 3) 4) 5) 6)
Bogie assembly: 180 kg
Press fit shaft (7) to ring (13). Install spacer (14). Press fit ring (12) to shaft (7). Install spacer (11). Press fit ring (8) to shaft (7). 2 Apply lubricant (LM-P) to parts (a) (about 10 mm) of rings (13) and (8).
Installation 1.
Assembly of pin assembly 1) Using tool L18, install floating seals (9) to rings (8) and (12) and install floating seals (10) to the opposite side of ring (12) and ring (13). a When installing the floating seals, completely degrease the O-rings and O-ring contacting surfaces. a Check that each floating seal is not inclined more than 1 mm.
D475A, D475ASD-5E0
2.
Slide bogie (5) on steel plate [1] to the center.
3.
Set bogie (5) to the mounting position with tool L20.
4.
Match the pin hole of the track frame to that of the bogie and insert guide tool L17.
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5.
Press fitting of pin assembly 1) Set tool L16 and cover (6).
50 Disassembly and assembly
6.
Refilling with oil Supply the specified quantity of oil by using tool L19. a Oil supplying pressure: 0.49 MPa {5 kg/ cm2} 5
2)
30
Press fit the pin assembly (11). a Direct arrow (a) on the end face of the pin assembly up in the mounting state on the machine body. a Push in the pin assembly with cover (6). a Push in the pin assembly to machined face (b) of the bogie and secure the level difference of 5 mm between the bogie and pin assembly. 2 Apply lubricant (LM-P) all over the side of the pin assembly. a Total press fitting force of pin assembly: 294.2 – 490.5 kN {30 – 50 tons}
Pin assembly: 180 – 200 cc
7.
Press fit the pin assembly on the opposite side of the bogie according to above steps 5 and 6.
8.
Install covers (6) (2 places on inside and outside).
9.
Install eyebolts instead of the pad mounting bolts (M12 x 2 pieces) of bogie (5) and lift and hold the bogie.
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50 Disassembly and assembly
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10. Insert tool L21 in the shaft of track roller assembly (4), then lift and balance the track roller assembly and set it on the track shoe. 4
Track roller assembly: 220 kg
11. Lower the machine body slowly. When the clearance between bogie (5) and shaft (3) becomes about 20 mm, install cap (15) and secure it with bolts (2) temporarily. 12. Matching the dowel pin holes, tighten bolts (2). 2 Cap mounting bolt: Adhesive (LT-2) 3 Cap mounting bolt: 2,205 – 2,695 Nm {225 – 275 kgm}
13. Adjust the tension of the track shoe. For detail, see Testing and adjusting, Testing and adjusting track shoe tension.
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Removal and installation of operator's seat isolator a
50 Disassembly and assembly
3. 1
Remove operator's seat (1). 4
Operator's seat: 50 kg
Machine with operator's seat isolator
Removal 1.
Disconnect power connector (2) of operator's seat (1).
2.
Remove four M8 nuts (4) securing operator's seat (1) and bracket (3).
4.
Remove four M12 nuts (6) securing operator's seat isolator (5) and turntable.
Installation q
32
Perform installation in the reverse order to removal.
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50 Disassembly and assembly
Disassembly and assembly of operator's seat isolator a
SEN02017-04
1
Machine with operator's seat isolator
Disassembly q
Perform disassembly in the reverse order to assembly.
Assembly 1.
Install stopper rubbers (3) to two stopper bosses (2) of base plate (1). a Hitch one side of stopper rubber (3) to the groove of the boss and press it with a round bar to install it to the boss.
D475A, D475ASD-5E0
2.
Install four laminated rubbers (4) to base plate (1) with eight M10 bolts (5). 3 Laminated rubber mounting bolt: 40 Nm {4.08 kgm}
3.
Install collar (7) to damper mounting pin (6) of the base plate with the tapered side down.
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4.
Install protection tube (9) side of damper (8) to the mounting pin of the base plate.
5.
Install slotted head nut (10) and pass cotter pin (11) and bend it to secure. (2 places)
6.
50 Disassembly and assembly
7.
Insert the top plate mounting pin into free side (15) of the damper installed to the top plate and remove the tape.
8.
Match the holes of the top plate with the mounting screws of the laminated rubbers and secure them with eight M10 bolts (5). 3 Laminated rubber mounting bolt: 40 Nm {4.08 kgm}
9.
Place plate (16) on the stopper pin and secure it with two M10 bolts (17).
Put collar (13) to the damper mounting pin of top plate (12) with the tapered side down and secure it with tape (14) to prevent it from falling.
10. Turn over the top plate, install slotted head nut (10) to the mounting pin, and pass cotter pin (11) and bend it to secure. (Two places)
34
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50 Disassembly and assembly
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D475A, D475ASD-5E0 Bulldozer Form No. SEN02017-04
© 2016 KOMATSU All Rights Reserved Printed in Japan 02-16 (01)
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BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Undercarriage and frame, Part 2 Expansion and installation of track shoe assembly......................................................................................... 2 Overall disassembly and overall assembly of track shoe ............................................................................... 5 Press-fitting jig dimension table for link press ............................................................................................... 21 Field disassembly and assembly of one link................................................................................................. 22 Disassembly and assembly of master link .................................................................................................... 27 Removal and installation of pivot shaft assembly ......................................................................................... 31 Removal and installation of equalizer bar ..................................................................................................... 32 Disassembly and assembly of equalizer bar bushing ................................................................................... 35
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Expansion and installation of track shoe assembly
50 Disassembly and assembly
Expansion of track shoe assembly (Normal) 1
a
If Checking before expansion of track shoe assembly shows that there is no abnormality, do as follows.
1.
Set master link in position. a Bring the master link above the idler (just behind the center). a Set blocks [1] and [2] at the front end of the idler and between the carrier rollers so that the mating faces of the master link will not open until the master bolt is removed.
2.
Relieve track shoe tension. [*1] k Never loosen lubricator (1) more than one turn. a If the track is not relieved by loosening the lubricator, move the machine backwards and forwards.
Expansion Checking before expansion of track shoe assembly k
k q
a
q
a
2
In some cases, it may be extremely dangerous to expand the track shoe assembly. To prevent danger, carry out the following checks before expansion of the track shoe assembly. Never loosen the lubricator more than one turn. Loosen lubricator (1) at the adjustment cylinder, release the grease, then move the machine backwards and forwards a short distance, and check that the track tension is relieved. If the shoe tension is relieved, go to "Expansion of track shoe assembly (Normal)".
If the above procedure does not relieve the track tension and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring case is broken, the recoil spring set bolt is broken, or the nut at the end of shaft has fallen off). If the shoe tension is not relieved, go to "Expansion of track shoe assembly (when there is abnormality inside track frame)".
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50 Disassembly and assembly
3.
4.
Remove track shoe (2). [*2] a Loosen each of the 4 bolts by 1 – 2 turns. Check that the 4 bolts can be turned lightly, then pull them out. Do not pull out only 1 bolt without loosening the other three. a If a bolt is turned forcibly while it cannot be turned lightly, the threads of it and master link (3) may be damaged.
Raise tip of master link, move machine towards rear slowly, and lay out track shoe assembly (4). a Length of track: Approx. 12.5 m k To prevent danger, never stand in front of the idler yoke assembly.
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1.
Remove work equipment assembly. For details, see "Removal and installation of work equipment assembly".
2.
Loosen lubricator (1), then move machine backwards and forwards to remove grease. k Never loosen lubricator (1) more than one turn. a Check that all the grease has been removed.
3.
Drive slowly forward to put track shoe at idler end in contact with large block [3] or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and slack is formed in track shoe assembly, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link.
4.
Remove shoe (2), then disconnect master link (3).
5.
Move machine towards rear slowly and lay out track shoe assembly.
Expansion of track shoe assembly (when there is abnormality inside track frame) a k
When "Checking before expansion of track shoe assembly" shows any abnormality, do as follows. If there is any abnormality inside the track frame, there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so expand the track shoe assembly as follows.
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50 Disassembly and assembly
Installation q
[*1]
Carry out installation in the reverse order to expansion (normal). a a a
[*2]
4
a
For details of the track shoe tension, see Testing and adjusting, Testing and adjusting of track shoe tension. Tighten all of the 4 bolts with the fingers until the master link contacting faces are fitted to each other. If a bolt is tightened forcibly before the master link contacting faces are fitted to each other, the threads of that bolt and the master link may be damaged.
Tighten the master link shoe mounting bolts in the order shown in the diagram below. 2 Shoe mounting bolt: Seizure prevention compound (Maruzen Molymax No. 2 or equivalent) 3 Shoe mounting bolt: 1st step: 980 ± 98 Nm {100 ± 10 kgm} 2nd step: Tighten a further 180 ± 10°
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50 Disassembly and assembly
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a
Part No.
Part Name
1
791-646-7531 Plug remover
t 1
2
791-660-7460 Pin brush
t 1
3
791-646-7900 Push tool
t 1
4
791-932-1110 Push tool
t 1
5
790-701-3000 Seal checker and 791-601-1000 Oil pump
t 1
6
791-632-1010 Installer
t 1
Push tool assembly
t 1
N
2 791-685-5640 • Adapter
1
N
3 791-685-5660 • Ring
1
N
4 791-685-5670 • Plate
1
N
5 791-685-5680 • Ring
1
N
6 791-685-5690 • Push tool
1
N
7 791-685-5710 • Adapter
1
N
8 791-685-5720 • Spring
1
N
9 791-685-5730 • Bar
1
N
10 01252-30655 • Bolt
1
11 01580-01210 • Nut
1
1 791-685-5600
9
R
Push tool assembly
1
N
2 791-685-5650 • Adapter
1
N
3 791-685-5660 • Ring
1
N
4 791-685-5670 • Plate
1
N
5 791-685-5680 • Ring
1
N
6 791-685-5690 • Push tool
1
N
7 791-685-5710 • Adapter
1
N
8 791-685-5720 • Spring
1
N
9 791-685-5730 • Bar
1
N
10 01252-30655 • Bolt
1
11 01580-01210 • Nut
1
1 791-685-5700
12
13
791-685-5750 Push tool
D475A, D475ASD-5E0
t 1
a
When disassembling the track shoe, see shop manual – Guidance for reusable parts – Lubricated tracks (III) (Form No.: SEBG4092). Check that the track press has protective cover (1).
Sketch
Symbol
New/remodel
Special tools Q'ty
Overall disassembly
Necessity
Overall disassembly and overall assembly of track shoe
a
When removing the pin, totally cover pin end push tool (2) and link wedge with thick cloth (3) so that the broken pieces of wedge ring (4) will not be scattered.
N
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50 Disassembly and assembly
2.
a
The track press operator and other workers must put on helmets, safety glasses and earplugs.
1.
Removal of shoe Sling the shoe assembly and set it on a floor with the shoe up. Remove the shoe with a shoe bolt impact wrench. a If a shoe bolt is still hard (If its torque is not lowered to 0) after it is unscrewed by 1 turn, loosen the other bolts, and it can be removed easily. a If a bolt is unscrewed forcibly while its torque is not 0, it will stick to the link and will need to be repaired. a When moving the shoe assembly, take care not to damage the master link. a If it is obliged to cut a shoe nut with gas, keep the temperature of the sealing parts below 80°C and prevent the spatters from entering the clearance of the link so that the sealing parts will not be deteriorated by the heat.
6
Disassembly of link 1) Set the link assembly on the link press and hit it with a hammer so that the bushing will be fitted to the jaw. a If the link tread, outside of the bushing, etc. are worn, adjust the height of the jaw or guide plate to align the disassembly jig with the pin and bushing so that the link hole will not be damaged during disassembly. a If the above parts are not aligned perfectly, the link hole may be damaged and the pin and bushing may be broken during disassembly. a Drive the small plug of the pin inward with tool R1 after disassembly to avoid making the workshop dirty.
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50 Disassembly and assembly
2)
Operate the left cylinder to pull out the fitted parts of the left link, pin, and bushing simultaneously. a Check the pulling out force of the pin and bushing to see if the necessary fitting force of the pin and bushing is obtained when they are turned over and assembled. a When the wedge link is cut, it bangs. This phenomenon is normal.
3)
Return the left cylinder and operate the right cylinder to pull out the right link, pin, and bushing simultaneously.
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4)
Return the right cylinder and take out the links, pins, bushings, and spacers on both sides, then send the next link assembly to the jaw. a If the end faces of the bushings and sealing surfaces are damaged, oil will leak. Accordingly, handle them with care. a Take care not to scratch your hands with the sharp edges of a cut wedge link.
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3.
Inspection Inspect the following items to see if the parts can be reused for an oil lubricated track or a grease lubricated track, then generally examine whether the link assembly should be recycled as an oil lubricated track or as an grease lubricated track. a For judgment of recycling of the parts, see shop manual – Guidance for reusable parts – Lubricated tracks (III) (Form No.: SEBG4092). 1) Check the parts visually for damage, then apply a dye penetrant test or a magnetic flaw test to the parts which seem to be damaged. Discard a cracked part since it cannot be reused. 2) Measure the outside diameters of the fitting parts of the pin and bushing and those of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the allowable interference is obtained. When reusing the parts for an oil lubricated track, the pin and link must have the standard interference. a If the allowable interference is not obtained, replace the parts with new ones. a For the criteria, see “Maintenance standard”.
50 Disassembly and assembly a 3)
4)
5)
Precautions for storage Store the seal without removing it from the link to prevent rusting of the counterbore of the link, taking care not to damage the seal lip. Apply rust-preventive oil to the pin and bushing fitting parts and shoe and master link mating faces of the link. Apply rust-preventive oil all over the pin, bushing, and spacer. In particular, take care not to damage the end faces of the bushing.
Overall assembly a
When assembling the track shoe, see shop manual – Guidance for reusable parts – Lubricated tracks (III) (Form No.: SEBG4092).
When recycling for oil lubricated track 1. Preparation work 1) Cleaning of seal assembly Take the seal assembly out of the link and divide it into the seal ring and load ring, then clean them. a Since the seal ring and load ring are deteriorated easily by cleaning liquid (trichloroethylene, etc.), clean them quickly. After cleaning them, wipe off the cleaning liquid.
8
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50 Disassembly and assembly
2)
3)
4)
SEN02018-02
When reusing the pin, chamfer the corners of its end smoothly with a grinder. Remove the projections of the fitting parts with the grinder. a If the corners of the pin end are worn and sharpened, they may scuff the fitting parts to cause oil leakage.
Clean the link, pin, bushing, and spacer, if they are dirty. Remove the projections of the link and bushing with the grinder. a Since the parts are rusted easily, clean them just before assembling them. a Do not repair the end faces of the bushing with a grinder, etc. since that can cause oil leakage. If the large plug has been driven out, drive it with tool R3. Clean the pin hole with tool R2 in advance.
D475A, D475ASD-5E0
1] 2] 3] 4]
5)
Insert the plug in the hole of the guide through the plug inserting hole. Push the bar with the hand and insert the plug until it stops. Push the plug with the bar to press the guide against the pin. Drive the bar with a hammer. a Driving distance (a) from pin end: 10 ± 1 mm a If the edge of the pin hole is worn and sharpened, chamfer it with a small grinder (wheel tip angle: 45 – 60°) so that the plug will not be damaged. a Coat the plug with GO90 and drive it with the smaller end ahead.
Installation of seal assembly Clean the counterbore of the link carefully and push in the seal to the bottom with tool R6. a If any oil sticks to the counterbore of the link and seal assembly, the seal turns and its sealing performance is lowered. Accordingly, do not apply any oil. Take care that oil will not stick to the seal when the seal is inserted in the counterbore.
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6)
7)
10
Adjust the dimensions of the fitting jig of the link press to keep the projection distance of the pin and bushing constant and keep the fitting dimensions of the seal within the limits when those parts are assembled. a For the standard dimensions, see “Press-fitting jig dimension table for link press”. a If the pin end (Part P) and link sides (Parts Q and R) are worn, count in the quantity of the wear when adjusting the dimensions of the fitting jig so that the pin and bushing will be projected by the same distance on both sides.
Adjust the relief pressure of the link press so that the pressing force will not exceed the specified value. a If the pressing force is too large, the spacer is pressed against the bushing with an excessive force. As a result, the spacer may be broken or it and bushing end may be worn abnormally. a Press cutting force of pin and bushing: 1,274 kN {130 tons} Press cutting force C 1.8 x Average press fitting force (Set the press cutting force by adjusting the relief pressure of the link press.)
50 Disassembly and assembly
2.
Assembly of link 1) Apply oil (GO90) between the pin and bushing with a clean brush, then set them on this side of the link press jaw. a When reusing (turning) the bushing, set its worn side to the shoe fitting face of the link (which is directed up on the link press).
2)
Press fit both bushing-side master links to the bushings with the shoe fitting faces up. a At this time, use the pin-side master links as supports. a Fitting force of bushing: 245 – 382 kN {25 – 39 tons}
3)
Measure the distance between the shoe bolt holes of both links with a shoe bolt hole pitch gauge. Press fit the master link until the specified shoe bolt hole pitch is obtained. a Remove the all chips made when the bushing is press fitted by blowing air against them.
D475A, D475ASD-5E0
50 Disassembly and assembly
4)
Turn over the master links and check that they are press fitted in parallel.
5)
Measure the projections of the bushing on both sides with a depth gauge. a Adjust the fitting jig of the link press so that the bushing will be projected by the same distance on both sides.
6)
SEN02018-02
7)
Apply gasket sealant (198-32-19890) to the pin fitting hole of the link to prevent oil from oozing through the scuffs of the pin fitting parts.
8)
Set the right link and install the spacer to the pin. a Check that the sealing surface and bush ends are free from dirt and apply oil (GO90) to them with a clean cloth or brush. a Clean the spacer with a clean cloth before installing it.
Send out the master link and set the next pin and bushing. a When reusing the pin, install it with its side hole on the link tread side similarly to a new one. If it is not installed in this direction, its strength may lower. Accordingly, make a mark of the side hole on the end face of the pin.
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9)
Set the right jig on the receiving side and the left jig on the pushing side and press fit the pin and bushing simultaneously. a If the jigs shake while the pin and bushing are press fitted, the seal may come off the link. Accordingly, press fit smoothly. If the seal comes off the link, stop press fitting and install the seal to the link correctly, then start press fitting again. a Press fitting force of pin and bushing: 578 – 833 kN {59 – 85 tons}
50 Disassembly and assembly
11) Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.
12) Set the left jig on the receiving side and the right jig on the pushing side and press fit the left link. a When press fitting, take care that the seals and spacers on both sides will not come off. Press fitting force of link: 578 – 833 kN {59 – 85 tons} 10) Using the spacer for fine adjustment, press fit the pin until it is fitted to the lower part of the pin end receiving jig. a Adjust the depth of the receiving jig so that the pin will be projected by the same distance on both sides.
12
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50 Disassembly and assembly
13) Press fit until the link, spacer, and bushing are fitted to each other. a Actually, you cannot see from outside if the above parts are fitted. Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the hydraulic pressure to that level. For setting of the relief pressure, see Preparation work. a Check that adjacent 2 links can turn around each other.
SEN02018-02
15) Install the ring to jig R12.
16) Match the jig to the pin hole and push it in until the ring is inserted in the pin hole. a A sound is made when the ring is inserted in the pin hole.
14) Measure the distance between the shoe bolt holes with a shoe bolt hole pitch gauge and check that the result is within the limits. a If the distance between the shoe bolt holes is longer than the limit, disassemble and check for abnormality, then press fit again. a If the distance between the shoe bolt holes is shorter than the limit and the shoe cannot be installed, the spacer or bushing end may be worn more than the allowable limit. In this case, disassemble and replace the parts.
D475A, D475ASD-5E0
17) Similarly, insert the ring in the pin groove on the opposite side with jig R9.
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18) Push in the ring with jig R13. Pushing force of ring: 392 – 490 kN {40 – 50 tons}
19) After each link is assembled, bleed air from the pin with tool R5 and check the sealing performance. a Keep the degree of vacuum inside the pin at 91 – 95 kPa {680 – 710 mmHg} for 5 seconds and check that the pressure does not change. If the pressure changes, disassemble and check the seal. If the seal is free from abnormality, assemble again.
14
50 Disassembly and assembly
20) Supply oil (GO90) with tool R5 until the oil supply pressure rises to 196 – 294 kPa {2 – 3 kg/cm2}. a In a cold or very cold district, supply Komatsu genuine oil (150-09-19270 or 195-32-61990) having better lowtemperature characteristics instead of GO90. a If the oil pressure is heightened too much, it has bad effects on the seal. Take care.
a
Supply oil so that the depth L of the hollow of the pin hole will be in the following range when the link is left with the small plug side up (when the link assembly is placed on its side) for 30 minutes. Dimension L: 40 – 70 mm
D475A, D475ASD-5E0
50 Disassembly and assembly
21) After supplying oil, drive in the small plug to the specified position with tool R4. a Apply GO90 around the small plug. a Drive in the plug to the following depth. Driving depth from end: 7.5 ± 1 mm 22) Assemble the master link on the pin side at last. a Check that the master links on both sides are press fitted in parallel.
3.
Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Regular link) Initial torque: 784 ± 78 Nm {80 ± 8 kgm} Retightening angle: 180 ± 10°
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2)
When installing a double track, place the assembled double shoes on a level place in 1 line with the shoe side up. Pull pinside master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) on the links and check that master bolts (4) can be tightened easily by hands until the mating faces of the links are fitted together, and then connect the master links.
2
Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 ± 98 Nm {100 ± 10 kgm} Retightening angle: 180 ± 10° a Tighten the bolts in the order of [1] – [4].
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When recycling for grease lubricated track 1. Preparation work 1) Cleaning of seal assembly Take the seal assembly out of the link and divide it into the seal ring and load ring, then clean them. a Since the seal ring and load ring are deteriorated easily by cleaning liquid, clean them quickly. After cleaning them, wipe off the cleaning liquid.
50 Disassembly and assembly
4)
5)
6)
16
2)
When reusing the pin, chamfer the corners of its end carefully with a grinder so that it will be press fitted smoothly.
3)
Drive the large plug and small plug with tools R3 and R4. 1] Insert each plug in the hole of the guide through the plug inserting hole. (Apply oil to the plug.) 2] Push the bar with the hand and insert the plug until it stops. 3] Push the plug with the bar to press the guide against the pin. 4] Drive the bar with a hammer. a Driving distance (a) from pin end: Small plug: 7.5 ± 1 mm Large plug: 10 ± 1 mm a If the plugs were not pull out of the pin when disassembled, use them as they are.
Clean the outside of the pin, surfaces of the spacer, and end faces and inside of the bushing, if they are dirty. Apply grease to the outside of the pin and surfaces of the spacer.
Installation of seal assembly Clean the counterbore of the link carefully and push in the seal to the bottom with tool R6. a If any grease sticks to the counterbore of the link and seal assembly, the seal turns and its sealing performance is lowered. Accordingly, do not apply any grease.
D475A, D475ASD-5E0
50 Disassembly and assembly
7)
Adjust the dimensions of the fitting jig of the link press to keep the projection distance of the pin and bushing constant and keep the fitting dimensions of the seal within the limits when those parts are assembled. a For the standard dimensions, see “Press-fitting jig dimension table for link press”. a If the pin end (Part P) and link sides (Parts Q and R) are worn, count in the quantity of the wear when adjusting the dimensions of the fitting jig so that the pin and bushing will be projected by the same distance on both sides.
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2)
Press fit both bushing-side master links to the bushings with the shoe fitting faces up. a At this time, use the pin-side master links as supports. a Fitting force of bushing: 245 – 382 kN {25 – 39 tons}
3)
Measure the distance between the shoe bolt holes of both links with a shoe bolt hole pitch gauge. Press fit the master link until the specified shoe bolt hole pitch is obtained. a Remove the all chips made when the bushing is press fitted by blowing air against them. Turn over the master links and check that they are press fitted in parallel.
4) 2.
Assembly of link 1) Apply lithium grease (G2-LI) between the pin and bushing, then set them on this side of the link press jaw. a When reusing (turning) the bushing, set its worn side to the shoe fitting face of the link (which is directed up on the link press).
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5)
50 Disassembly and assembly
Measure the projections of the bushing on both sides with a depth gauge. a Adjust the fitting jig of the link press so that the bushing will be projected by the same distance on both sides.
7)
6)
18
Send out the master link and set the next pin and bushing. a When reusing the pin, install it with its side hole on the link tread side similarly to a new one. If it is not installed in this direction, its strength may lower. Accordingly, make a mark of the side hole on the end face of the pin. a If the outside of the pin is worn, set it with the un-worn part on the traction side. In this case, install it with its side hole on the link tread side, too.
8)
Set both links and operate both pushing jigs to press fit the pin and bushing simultaneously. a If the jigs shake while the pin and bushing are press fitted, the seal may come off the link. Accordingly, press fit smoothly. If the seal comes off the link, stop press fitting and install the seal to the link correctly, then start press fitting again. a Press cutting force of pin and bushing: 1,274 kN {130 tons} Press cutting force C 1.8 x Average press fitting force (Set the press cutting force by adjusting the relief pressure of the link press.) Measure the distance between the shoe bolt holes with a shoe bolt hole pitch gauge. If the result is within the limits, stop press fitting.
D475A, D475ASD-5E0
50 Disassembly and assembly
9)
SEN02018-02
12) Assemble the master link on the pin side at last. a Check that the master links on both sides are press fitted in parallel.
Install the ring to jig R12.
3.
10) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove. Similarly, insert the ring on the opposite side with jig R9. a A sound is made when the ring is inserted in the pin.
Shoe (Regular link) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Regular link) Initial torque: 784 ± 78 Nm {80 ± 8 kgm} Retightening angle: 180 ± 10°
11) Push in the ring with jig R13. Pushing force of ring: 392 – 490 kN {40 – 50 tons}
D475A, D475ASD-5E0
19
SEN02018-02
4.
20
50 Disassembly and assembly
Assembly of 1/2 track Place the assembled 2 shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2) together and set them to each other by the mating faces. Place shoe (3) on the links and check that master bolts (4) can be tightened easily by hands until the mating faces of the links are fitted together, and then connect the master links. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 ± 98 Nm {100 ± 10 kgm} Retightening angle: 180 ± 10° a Tighten the bolts in the order of [1] – [4].
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02018-02
Press-fitting jig dimension table for link press
Jig dimension (mm) a
4.6
b
2.0
c
59.1
D475A, D475ASD-5E0
21
SEN02018-02
50 Disassembly and assembly
Field disassembly and assembly of one link
1 791-832-1610 Plate
t 1
2 791-832-1270 Bracket
t 1
3 01010-81495
t 1
Bolt
t 1 N
2 791-832-1510 Push tool
t 1 N 1 N
t 1
5 01010-62050
t 2
2 791-685-5650 • Adapter
1 N
6 791-832-1220 Plate
t 1
3 791-685-5660 • Ring
1 N
7 791-832-1230 Shaft
t 2
8 791-832-1210 Frame
t 1
9 791-832-1240 Nut
t 2
Bolt
R
12
4 791-685-5670 • Plate
1 N
5 791-685-5680 • Ring
1 N
6 791-685-5690 • Push tool
1 N 1 N
Eye bolt
t 2
7 791-685-5710 • Adapter
11 791-832-1310 Adapter
t 1
8 791-685-5720 • Spring
1 N
12 791-832-1280 Adapter
t 1
9 791-685-5730 • Bar
1 N
13 791-832-1320 Guide
t 1
10 01252-30655
• Bolt
1
t 5
11 01580-01210
• Nut
1
Screw
8 15 791-832-1640 Pusher
22
1 791-832-1490 Push tool
4 791-832-1250 Bracket
14 01310-21032
9
Part Name
Push tool 1 791-685-5700 assembly
10 04530-11628
R
11
Part No.
Necessity Q’ty New/Remodel Sketch
Part Name
Symbol
Part No.
Necessity Q’ty New/Remodel Sketch
Symbol
Special tools
13
t 1
16 791-832-1340 Extension
t 2
17 791-832-1650 Adapter
t 1
18 791-832-1480 Adapter
t 1 N
19 791-832-1670 Guide
t 1
20 791-832-1330 Guide
t 1
21 791-832-1660 Adapter
t 1
22 791-832-1630 Guide
t 1
23 791-832-1470 Guide
t 1 N
24 791-832-1410 Extension
t 1
25 791-832-1350 Pusher
t 1
29 790-101-1102 Pump
t 1
Puller (294 kN 30 790-101-4200 {30 ton})
t 1
31 791-685-9230 Spacer
t 1
Push tool 1 791-685-5600 assembly
1 N
2 791-685-5640 • Adapter
1 N
3 791-685-5660 • Ring
1 N
4 791-685-5670 • Plate
1 N
5 791-685-5680 • Ring
1 N
6 791-685-5690 • Push tool
1 N
7 791-685-5710 • Adapter
1 N
8 791-685-5720 • Spring
1 N
9 791-685-5730 • Bar
1 N
10 01252-30655
• Bolt
1
11 01580-01210
• Nut
1
791-685-5750 Push tool
t 1 N
Disassembly 1.
Install tools R8-4, R8-1, and R8-5 to link (1) with 2 bolts (2). a Use 2 track bolts as 2 bolts (2).
D475A, D475ASD-5E0
50 Disassembly and assembly
2.
Install tool R8-12 to tool R8-4. a Check that the hole of R8-12 is aligned. If it is not aligned, retighten R8-5 and adjust the position of R8-12. Install tool R8-10 to tool R8-8. Install a rope to R8-10, then sling and install R8-10 to R8-12. Install tools R8-2 and R8-3 to tool R8-1. a Hitch and install R8-2 to the rib of R8-8 so that R8-8 will not lean.
3.
Install tools R8-6, R8-10, R8-7, and R8-11 to tool R8-28. Install ropes to the eyebolt of R8-28 and R810, then sling them so that R8-7 will be horizontal.
4.
Insert R8-7 in the hole of R8-8 installed to the track, then clamp it with R8-9.
D475A, D475ASD-5E0
SEN02018-02
5.
Pulling out of pin 1) Set tools R8-13, R8-14, and R8-15 to R811, then apply hydraulic pressure to push pin (3). 2) After the cylinder reaches the stroke end, connect tools R8-16 and R8-14 and repeat the work. 3) Repeat step 5.2). 4) After the cylinder reaches the stroke end again, remove tools R8-13 and R8-14 and add R8-25 and R8-14 to pull out pin (3).
6.
Set tools R8-30 and R8-31 to the roller tread side of the link to be disassembled, then connect tool R8-29 and apply hydraulic pressure to open the link by 5 – 6 mm and disconnect the link.
23
SEN02018-02
7.
8.
Repeat steps 1 – 5 to remove pin (4) on the opposite side.
50 Disassembly and assembly
Assembly 1.
Assemble the link sub-assembly according to the following procedure. 1) Set tool R8-17 to the bushing-side end of link (6) and press fit bushing (7). a Press fitting force of bushing: 245 – 382 kN {25 – 39 tons}
Repeat step 6 to remove link (5).
2)
2.
24
Set tool R8-18 to the pin-side end of the link and press fit pin (8). a Set the pin with its side hole on the link tread side. a Press fitting force of pin: 333 – 451 kN {34 – 46 tons}
Set link sub-assembly (9) to the link to be connected.
D475A, D475ASD-5E0
50 Disassembly and assembly
3.
Set link (10) on the opposite side and support it with tool R8-19.
4.
Similarly to the disassembly procedure, set tools R8-29, R8-6 – R8-11, and R8-24 to the link.
5.
SEN02018-02
6.
Similarly to the disassembly procedure, push open link (11) to be connected by using tools R8-30 and R8-31.
7.
Set link (12) to be connected to link (11) and connect them with tool R8-22, then remove tools R8-30 and R8-31.
Use R8-18 and R8-23 to press fit the pin. Use tools R8-21, R8-17, R8-20, and R8-14 to press fit the bushing. Press fit the pin and bushing alternately. a Press fit the pin first. After the bushing is engaged with the link, remove tool R8-19 installed in step 3, then press fit the bushing. a Press fitting force of pin: 333 – 451 kN {34 – 46 tons} a Press fitting force of bushing: 245 – 382 kN {25 – 39 tons}
D475A, D475ASD-5E0
25
SEN02018-02
8.
Press fitting of pin 1) Set tools R8-28, R8-6 – R8-12, R8-26, R8-27, R8-14, and R8-22 and apply hydraulic pressure to press fit pin (13). 2) After the cylinder reaches the stroke end, remove tools R8-26, R8-27, and R8-14 and repeat the work with tools R8-16, R814, R8-25, and R8-14. 3) After the cylinder reaches the stroke end again, remove tools R8-12, R8-16, R8-25, R8-14, and R8-22 and press fit the pin with tools R8-18, R8-23, and R8-24. 2 Pin fitting hole of link: Gasket sealant (198-32-19890) a Set the pin with its side hole on the link tread side. a Press fitting force of pin: 666 – 902 kN {68 – 92 tons}
9.
Install the ring with tools R9, R11, R12, and R13. a For the method of using the tools, see "Overall assembly of track shoe".
26
50 Disassembly and assembly
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02018-02
Disassembly and assembly of master link
t 1
2 791-832-1270 Bracket
t 1
3 01010-81495 Bolt
t 1
4 791-832-1250 Bracket
t 1
11 01580-01210 • Nut
5 01010-62050 Bolt
t 2
1 791-832-1490 Push tool
t 1 N
6 791-832-1220 Plate
t 1
2 791-832-1510 Push tool
t 1 N
7 791-832-1230 Shaft
t 2 t 1
1 N
8 791-832-1210 Frame
Push tool 1 791-685-5700 assembly
9 791-832-1240 Nut
t 2
2 791-685-5650 • Adapter
1 N
10 04530-11628 Eye bolt
t 2
3 791-685-5660 • Ring
1 N
11 791-832-1310 Adapter
t 1
4 791-685-5670 • Plate
1 N
12 791-832-1280 Adapter
t 1
5 791-685-5680 • Ring
1 N
13 791-832-1320 Guide
t 1
6 791-685-5690 • Push tool
1 N 1 N
9
11
R
12
8 791-685-5720 • Spring
1 N
9 791-685-5730 • Bar
1 N
10 01252-30655 • Bolt
1 1
14 01320-41030 Screw
t 5
7 791-685-5710 • Adapter
15 791-832-1640 Pusher
t 1
8 791-685-5720 • Spring
1 N
t 2
9 791-685-5730 • Bar
1 N
t 1
10 01252-30655 • Bolt
1
18 791-832-1480 Adapter
t 1 N
11 01580-01210 • Nut
1
19 791-832-1670 Guide
t 1
20 791-832-1330 Guide
t 1
21 791-832-1660 Adapter
t 1
22 791-832-1630 Guide
t 1
23 791-832-1470 Guide
t 1 N
24 791-832-1410 Extension
t 1
25 791-832-1350 Pusher
t 1
26 791-832-1620 Guide
t 1
27 04530-11018 Eye bolt
t 1
8 17 791-832-1650 Adapter
28 791-101-4500
30 790-101-4200
Puller (294 kN {30 ton})
31 790-685-9230 Spacer
t 1 t 1
791-685-5750 Push tool
t 1 N
Disassembly a
For the method of using tool R8, see Field disassembly of one link.
1.
Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see Expanding track shoe assembly.
2.
Disassembly of shoe Disconnect the all master links and divide the shoes into 4 parts.
t 1
Push tool 1 791-685-5600 assembly
1 N
2 791-685-5640 • Adapter
1 N
3 791-685-5660 • Ring
1 N
4 791-685-5670 • Plate
1 N
5 791-685-5680 • Ring
1 N
6 791-685-5690 • Push tool
1 N
7 791-685-5710 • Adapter
1 N
D475A, D475ASD-5E0
13
Cylinder t 1 (1960 kN {200 ton}
29 790-101-1102 Pump
9
Part Name
1 791-832-1610 Plate
16 791-832-1340 Extension
R
Part No.
Necessity Q’ty New/Remodel Sketch
Part Name
Symbol
Part No.
Necessity Q’ty New/Remodel Sketch
Symbol
Special tools
27
SEN02018-02
3.
Removal of master link q Master pin type 1) Cutting of regular link with gas Cut the parts marked with gas and remove the parts marked . q Necessary special tool: Gas cutting machine
2)
50 Disassembly and assembly
q
1)
Removal of regular link Push pin (1) in the direction of with a press to remove it from link (2), then pull pin (1) and link (3) together out of bushing (4). 2)
28
Master link type Cutting and removal of master link on bushing side with gas Cut the parts marked with gas and remove the parts marked . Move master links (5) and (6) in the direction of and to pull them out. Then, push pins (8) and (9) out of regular link (7) in the directions of and with a press. q Necessary special tools: 1. Gas cutting machine 2. Tool R8
Removal of master link on pin side Cut the parts marked with gas and remove the parts marked . Push pin (10) out of link (11) in the direction of with a press. Then, pull pin (10) and link (12) together out of bushing (13). q Necessary special tools: 1. Gas cutting machine 2. Tool R8
D475A, D475ASD-5E0
50 Disassembly and assembly
Assembly a
For the method of using tool R8, see "Field disassembly of one link".
1.
Assembly of bushing-side link 1) Press fit bushing-side master link (1) to bushing (2) with a press. a When press fitting both master links, take care that they will be in parallel with each other. a Do not damage the mating surfaces of the master links and end faces of the bushing. Unit: mm
2.
L1
226 ± 0.7
L2
276 ± 0.7
D1
36 drill hole
D2
33 x 2.0
Installation of bushing-side link 1) Expand the center of the link tread with tool R8 as shown in the figure. (Expand the link end by 10 mm.)
D475A, D475ASD-5E0
SEN02018-02
2)
Set spacer (3) and seal assembly (4) to the counterbore of the link of the connecting part.
3)
Match the pin hole and bushing hole to each other and connect the pin and bushing with guide pin [2].
4)
Press fit pin (5) with tool R8 and install bushing-side master link (1). 2 Apply gasket sealant (198-3219890) to the pin hole of the link. a Set the pin with its side hole on the link tread side.
29
SEN02018-02
5) 6) 7)
50 Disassembly and assembly
Install ring (6) with tools R8, R9, R11, R12, and R13. Install the shoe to the link of the connecting part. Drive large plug (7) with tool R3 and supply oil with tool R5, then drive small plug (8) with tool R4. a When press fitting both master links, take care that they will be in parallel with each other (Bushing side and pin side). a Do not damage the mating surfaces of the master links and end faces of the bushing. a Take care that dirt and sand will not stick to the seal, spacer, end of bushing, and tap-hole mating face of the master link.
2)
3) 4)
4.
3.
30
Assembly of link on pin side 1) Set spacer (3) and seal assembly (4) to the counterbore of the master link.
Pass pin (10) through bushing (9) and set and press fit pin-side master links (11) from both sides with tool R8. Install the ring with tools R8, R9, R11, R12, and R13. Drive large plug (13) with tool R3 and supply oil with tool R5, then drive small plug (14) with tool R4.
Connection of master links Place the assembled 2 shoes on a level place in 1 line with the shoe side up. Pull pin-side master link (15) and bushing-side master link (16) together and set them to each other by the mating faces. Place the shoe on the links and check that master bolts can be tightened easily by hands until the mating faces of the links are fitted together, and then connect the master links. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 ± 98 Nm {100 ± 10 kgm} Retightening angle: 180 ± 10°
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02018-02
Removal and installation of pivot shaft assembly
3.
Remove seal (2), then remove cover (3).
[*2]
P
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
791T-850-1180 Sleeve
t 1
Q
791T-850-1190 Plate
t 1
Q
791-730-1130
Bolt
t 2
791-101-3310
Plate
t 1
01643-32060
Washer
t 2
01580-02016
Nut
t 2
790-105-2300
Jack assembly
t 1
790-101-1102
Pump
t 1
Installation q
[*1]
Removal 1.
2.
4
2 2
Remove track frame assembly. For details, see "Removal of track frame assembly". Sling pivot shaft assembly (1) and remove mounting bolts, then using forcing screw [1], pull out pivot shaft assembly. [*1]
Carry out installation in the reverse order to removal.
3
[*2]
a
Pivot shaft assembly: 390 kg a
q q
D475A, D475ASD-5E0
Pivot shaft press-fitting surface: Anti-friction compound (LM-P) Pivot shaft mounting bolt: Adhesive (LT-2) Pivot shaft mounting bolt: 1,519 – 1,911 Nm {155 – 195 kgm2}
Using tool P, press fit seal (2) to the pivot shaft. 2 Seal press-fitting surface: Gasket sealant (LG-6) Check that press-fitting dimension (a) of the seal from the end face of the shaft is the specified dimension. Press-fitting dimension (a): 665 ± 1.0 mm Press-fitting surface: 20.6 – 32.4 kN {2.1 – 3.3 ton}
31
SEN02018-02
50 Disassembly and assembly
Removal and installation of equalizer bar
5.
Set stand and hydraulic jack [1] (294 kN {30 ton}) under radiator guard.
6.
Remove cover (6).
792-900-1610
Adapter
t 1
792-900-1530
Screw
t 1
791-775-1110
Sleeve
t 1
791T-850-1150 Plate N 1 01582-53024 Nut
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Q
t 1 t 1
01643-33080
Washer
790-101-2102
Puller t 1 (294 kN {30t on})
7.
Remove cover (7).
790-101-1102
Pump
t 1
8.
Remove main bolt (8) of side pin.
9.
Using eyebolt [2], remove side pin (9). [*3] a It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so use hydraulic jack [1] to adjust the height at the equalizer bar end before removing. a Repeat Steps 6 to 9 to remove the side pin on the opposite side.
Removal 1.
Remove engine underguard and power train underguard (front). 4 4
2.
Engine underguard: 330 kg Power train underguard (front): 340 kg
Remove cover (1). a At the right track frame, disconnect 4 blade tilt cylinder hoses from the cover. a The front of the machine is raised using the blade, so install a blind plug securely in the hose at the tilt cylinder end.
3.
Remove seal (2) together with washer (3). [*1]
4.
Remove washer (4), then remove spacer (5). a Oil will flow out from the pivot case, so catch it in an oil container. 6
32
Pivot case: 26 l
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02018-02
10. Operate hydraulic jack [1] slowly and lower chassis to point where equalizer bar contacts left and right track frames. 11. Disconnect lubrication tube (10). 12. Remove lock plate (11).
[*4]
13. Using tool N1, remove center pin (12). [*5] a It is difficult to remove the pin if the centers of the equalizer bar hole and main frame hole are not aligned, so use hydraulic jack [1] to adjust the height at the main frame end before removing.
14. Operate blade and raise front of chassis, and set hydraulic jack under radiator guard. 15. Raise equalizer bar (13), move it past main frame and track frame, and remove. k After removing the equalizer bar, do not lower the chassis. 4
Installation q
[*1]
Carry out installation in the reverse order to removal. a a
[*2]
After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). Be careful not to install with the seal displaced in the direction of twisting.
3
a a
D475A, D475ASD-5E0
Equalizer bar assembly: 600 kg
Main mounting bolt of side pin: 2,450 – 2,695 Nm {250 – 275 kgm} After tightening main mounting bolts (8) of the side pin, tighten the mounting bolts of covers (6) and (7). Take care of the tightening order of main mounting bolts (8) of the side pin and the mounting bolts of covers (6) and (7).
33
SEN02018-02
[*3]
2
a
a
[*4]
Inside surface of bushing: Grease (G2-LI) Before installing the pin, operate hydraulic jack [1] to adjust the height of the main frame and align the center of the equalizer bar hole and track frame hole. Set the pin with the grease hole facing the outside of the machine.
2 3
[*5]
Equalizer bar bushing and main frame bushing: Grease (G2-LI) Before installing the pin, operate the crane to align the center of the main frame hole and the equalizer bar hole.
Refilling with oil (pivot case) Add oil through oil filler to the specified level. 5
34
Lock plate mounting bolt: Tread tightener (LT-2) Lock plate mounting bolt: 1,519 – 1,911 Nm {155 – 195 kgm}
2
a
q
50 Disassembly and assembly
Pivot case: 26 l (SAE30)
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02018-02
Disassembly and assembly of equalizer bar bushing
3)
Set tool N2 in position and remove side bushing (4) from equalizer bar (5).
N 2
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
791T-850-1160 Bracket
t 1
Q
791T-850-1170 Bracket
t 1
Q
790-438-1110
Screw
t 1
790-101-2540
Washer
t 2
791-112-1180
Nut
t 2
790-101-2102
Puller t 1 (294 kN {30 ton})
790-101-1102
Pump
Disassembly 1.
Center bushing Remove center bushings (1).
2.
Side bushing 1) Remove seals (2). 2) Remove snap ring (3).
D475A, D475ASD-5E0
t 1
Assembly 1.
Side bushing 1) Set side bushing (4) and tool N2 in position, then press fit side bushing (4) to equalizer bar (5). 2 Outer circumference of bushing: Anti-friction compound (LM-P)
35
SEN02018-02 a
a
2)
3)
36
Align the direction of installation of the side bushing as shown in the diagram below. 1] Make split surface (mating surface) (a) of outer bushing horizontal. 2] Set inner bushing and outer bushing grease hole (b) at an angle. Side bushing press-fitting force: 47 – 96 kN {4.8 – 9.8 ton}
50 Disassembly and assembly
2.
Center bushing Using press, press fit bushing (1). 2 Outer circumference of center bushing: Anti-friction compound (LM-P) a Center bushing press-fitting force: 68.6 – 233.2 kN {7 – 23.8 ton}
Install snap ring (3). a After installing the snap ring, fill front and rear portion C of side bushing with grease (G2-LI). 2 Amount of grease to fill side bushing: 0.45 l Using press, press fit seal (2). a Seal press-fitting force: 9.8 – 29.4 kN {1 – 3 ton} a Press fit so that the mouthpiece of the seal does not extend from the end face of the equalizer bar. 2 Lip of oil seal: Grease (G2-LI)
D475A, D475ASD-5E0
50 Disassembly and assembly
D475A, D475ASD-5E0
SEN02018-02
37
SEN02018-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN02018-02
© 2010 KOMATSU All Rights Reserved Printed in Japan 04-10
38
SEN02019-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Hydraulic system Removal and installation of hydraulic pump assembly ................................................................................... 2 Removal and installation of hydraulic valve assembly .................................................................................... 4 Disassembly and assembly of control valve ................................................................................................... 5 Disassembly and assembly of merge divider valve and self pressure reducing valve assembly ................... 9 Removal and installation of PPC relief valve assembly .................................................................................11 Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 12 Disassembly and assembly of ripper pin puller cylinder assembly ............................................................... 17
D475A, D475ASD-5E0
1
SEN02019-01
Removal and installation of hydraulic pump assembly
50 Disassembly and assembly
5.
Disconnect hoses (5).
6.
Remove tube coupling (6).
7.
Remove pump inlet tube (7).
8.
Disconnect PPC hoses (8) and (9).
9.
Disconnect wiring clamp at the top of pump (10) and wiring harness connector (11).
1
Removal k
k
1.
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see Testing and adjusting, " R e l e a s i n g r e m a i n i n g p re s s u re f r o m hydraulic circuit". Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery. Drain oil from hydraulic tank. 6
Hydraulic tank: 170 l
2.
Remove floor frame assembly. For details, see "Removal of floor frame assembly".
3.
Disconnect pump outlet hoses (1) and (2).
4.
Disconnect PPC hoses (3) and (4).
10. Sling hydraulic assembly (12), then remove mounting bolts, and remove.
2
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02019-01
Installation q
Carry out installation in the reverse order to removal.
q
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
D475A, D475ASD-5E0
3
SEN02019-01
50 Disassembly and assembly
Removal and installation of hydraulic valve assembly
6.
Disconnect 5 PPC hoses (5) from bottom side. a PPC hoses are distinguished by color bands.
Removal
7.
Disconnect ripper hoses (6) and (7).
8.
Disconnect tubes (8) and (9). Disconnect hose (10).
k
k
1.
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see Testing and adjusting, " R e l e a s i n g r e m a i n i n g p re s s u re f r o m hydraulic circuit". Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery. Drain oil from hydraulic tank. 6
Hydraulic tank: 170 l
2.
Remove right cover of operator cab.
9.
3.
Remove hose (1).
10. Disconnect wiring connectors (11) and (12), and clamp (13).
4.
Disconnect 5 PPC hoses (2) from upper side. 11. Sling control valve assembly (14), and then remove. 4
5.
Main control valve assembly: 195 kg
Disconnect blade lift hoses (3) and blade tilt hoses (4).
Installation
4
q
Carry out installation in the reverse order to removal.
q
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
q
Bleeding air in the hydraulic piping For detail, see Testing and adjusting, Air bleeding from hydraulic cylinder.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02019-01
Disassembly and assembly of control valve
D475A, D475ASD-5E0
5
SEN02019-01
6
50 Disassembly and assembly
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02019-01
Disassembly
Assembly
1.
q
Coat the sliding surface of each part with engine oil before installing.
1.
Ripper tilt valve 1) Install spool (2) to the valve body. 2) Install lower retainer (9) and spring (12). Fit the O-ring to case (1) and install them. 3) Install retainer (9) and spring (12). Fit the O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
2.
Blade left tilt valve 1) Install spool (3) to the valve body. 2) Install lower retainer (9) and spring (15). Fit the O-ring to case (1) and install them. 3) Install retainer (9) and spring (15). Fit the O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
3.
Blade lift valve 1) Install spool (4) to the valve body. 2) Install lower retainer (11), spring (14), and plate (2). Fit the O-ring to case (1) and install them. 3) Install retainer (10), spring (13), and plate (2). 4) Install spring (6) and retainer (7) to case (3) and secure them with bolt (8). Fit the O-ring to case (3) and install them. 3 Retainer mounting bolt: 11.8 – 14.6 Nm {1.2 – 1.5 kgm} 3 Case mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
4.
Blade lift valve 1) Install spool (4) to the valve body. 2) Install lower retainer (11), spring (14), and plate (2). Fit the O-ring to case (1) and install them. 3) Install retainer (10), spring (13), and plate (2). 4) Install spring (6) and retainer (7) to case (3) and secure them with bolt (8). Fit the O-ring to case (3) and install them. 3 Retainer mounting bolt: 11.8 – 14.6 Nm {1.2 – 1.5 kgm} 3 Case mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
2.
3.
4.
Ripper lift valve 1) Remove case (1), spring (12), and retainer (9). 2) Remove lower case (1), spring (12), and retainer (9). 3) Remove spool (2). a Do not disassemble spool assembly (2). Blade right tilt valve 1) Remove case (1), spring (15), and retainer (9). 2) Remove lower case (1), spring (15), and retainer (9). 3) Remove spool (3). a Do not disassemble spool assembly (3). Blade lift valve 1) Remove case (3), loosen bolt (8), and remove retainer (7) and spring (6). 2) Remove plate (2), spring (13), and retainer (10). 3) Remove lower case (1), plate (2), spring (14), and retainer (11). 4) Remove spool (4). a Do not disassemble spool assembly (4). Blade lift valve 1) Remove case (3), loosen bolt (8), and remove retainer (7) and spring (6). 2) Remove plate (2), spring (13), and retainer (10). 3) Remove lower case (1), plate (2), spring (14), and retainer (11). 4) Remove spool (4). a Do not disassemble spool assembly (4).
5.
Blade left tilt valve 1) Remove case (1), spring (15), and retainer (9). 2) Remove lower case (1), spring (15), and retainer (9). 3) Remove spool (3). a Do not disassemble spool assembly (3).
6.
Ripper tilt valve 1) Remove case (1), spring (12), and retainer (9). 2) Remove lower case (1), spring (12), and retainer (9). 3) Remove spool (2). a Do not disassemble spool assembly (2).
D475A, D475ASD-5E0
7
SEN02019-01
5.
Blade right tilt valve 1) Install spool (3) to the valve body. 2) Install lower retainer (9) and spring (15). Fit the O-ring to case (1) and install them. 3) Install retainer (9) and spring (15). Fit the O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
6.
Ripper lift valve 1) Install spool (2) to the valve body. 2) Install lower retainer (9) and spring (12). Fit the O-ring to case (1) and install them. 3) Install retainer (9) and spring (12). Fit the O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
8
50 Disassembly and assembly
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02019-01
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly
D475A, D475ASD-5E0
9
SEN02019-01
50 Disassembly and assembly
Disassembly
Assembly
1.
Remove case (7) from valve body (1). Loosen bolt (6) and remove retainer (8), spring (5), retainer (4), plug (3), and spool (2).
q
Coat the sliding surface of each part with engine oil before installing.
1. 2.
Remove plug (14), spring (12), and spool (11).
Fit the O-ring and install ball (37), spring (36), and seat (35) to block (30). 3 Seat: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3.
Remove plug (18), spring (17), and spool (16). 2.
4.
Remove plug (33), spring (32), and spool (31) from block (30).
Fit the O-ring and install valve assembly (20) to block (30). 3 Valve assembly: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5.
Remove valve assembly (20) from block (30). 3.
6.
Remove seat (35), spring (36), and ball (37) from block (30). a After disassembling, if any of body (1) and spools (2), (11), and (16) is defective, replace the whole merge divider valve assembly.
Install spool (31) and spring (32). Fit the O-ring and install plug (33). 3 Plug assembly: 19.6 – 24.5 Nm {2 – 2.5 kgm}
4.
Install spool (16) and spring (17). Fit the O-ring to plug (18) and install them to valve body (1). 3 Plug assembly: 147.1 – 186.3 Nm {15 – 19 kgm}
5.
Install spring (12) to spool (11). Fit the O-ring to plug (14) and install them. 3 Plug assembly: 147.1 – 186.3 Nm {15 – 19 kgm}
6.
Install retainer (4), spring (5), retainer (8), and plug (3) to spool (2) and install them to body (1). Fit the O-ring and install case (7). 3 Mounting bolt of case (7): 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
10
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02019-01
Removal and installation of PPC relief valve assembly Removal k
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see Testing and adjusting, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Remove operator’s cab right cover.
2.
Remove hoses (1), (2), and (3).
3.
Disconnect connector (4).
4.
Remove PPC relief valve assembly (5).
Installation q
Carry out installation in the reverse order to removal.
D475A, D475ASD-5E0
11
SEN02019-01
50 Disassembly and assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly
1 790-502-1003
2
Cylinder repair stand
t 1
790-201-1881 • Push tool
1
790-201-1871 • Push tool
1
790-201-1721 • Push tool
1
790-101-5021 • Grid
1
01010-50816
1
790-201-1500 Push tool kit
1
790-201-1680 • Plate
1
3 790-201-1690 • Plate
1
790-201-1530 • Plate
1
790-101-5021 • Grip
1
01010-50816
1
• Bolt
4 790-720-1000 Expander
5
t 1
07281-01919
t 1
796-720-1690 Ring
t 1
07281-02169
t 1
Clamp
796-720-1710 Ring
t 1
07281-02709
t 1
Clamp
796-720-1630 Ring
t 1
07281-00709
t 1
Clamp
6 790-102-2304 Wrench
12
Sketch
Quick drop valve assembly a Blade lift cylinder only. 1) Remove quick drop valve assembly (1).
2)
Disassemble quick drop valve assembly as follows. 1] Remove elbow (2). 2] Remove spring (3), washer (4), and valves (5) and (6), and pull out collar (7).
t 1
796-720-1690 Ring Clamp
2.
t 1
790-201-1670 • Plate
U
Cylinder tube Remove cylinder tube.
q 1
790-201-1702 Push tool kit
• Bolt
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
1.
t 1
D475A, D475ASD-5E0
50 Disassembly and assembly
3.
SEN02019-01
Piston rod assembly 1) Set cylinder assembly (8) to tool U1. 2) Remove head assembly (9). 3) Pull out piston rod assembly (10). a Put an oil container under the cylinder to catch the oil.
6)
5.
4.
Disassemble piston assembly as follows. 1] Remove wear ring (17). 2] Remove piston ring (18).
Head assembly 1) Remove head assembly (19) from piston rod.
Piston assembly 1) Set piston rod assembly (10) to tool U1.
2) 2) 3) 4) 5)
Remove spacer (11). Remove piston assembly (12). Remove backup rings (13) and (14), and O-ring (15). Remove retainer (16).
D475A, D475ASD-5E0
Disassemble head assembly as follows. 1] Remove O-ring (20) and backup ring (21).
13
SEN02019-01
2] 3]
50 Disassembly and assembly
Remove snap ring (22), then remove seal (23). Remove packing (24), then remove bushing (25).
5]
Install backup ring (21) and O-ring (20).
Assembly a
Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the packings, dust seals, and O-rings when installing.
1.
Head assembly 1) Assemble head assembly as follows. 1] Using tool U2, press fit bushing (25) to head. 2] Install packing (24). 3] Using tool U3, press fit seal (23). 4] Install snap ring (22).
14
2)
Install head assembly (19) to piston rod.
D475A, D475ASD-5E0
50 Disassembly and assembly
2.
SEN02019-01
Piston assembly 1) Assemble piston assembly as follows. 1] Using tool U4, expand piston ring (18). a Set the piston ring on the expander and turn the handle 8 – 10 times to expand the ring. 2] Remove piston ring (18) from tool U4, then install to piston. 3] Set tool U5 in position and compress piston ring (18). 4] Install wear ring (17) to piston.
2) 3)
4) 5)
3.
D475A, D475ASD-5E0
Install retainer (16). Install O-ring (15) and backup rings (14) and (13). a Coat the O-ring and backup ring portion with grease, and secure the backup ring to prevent it from opening. Install piston assembly (12). Assemble spacer (11) and tighten mounting bolts. 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: Blade lift: 98 – 123 Nm {10 – 12.5 kgm} Blade lift, ripper lift, ripper tilt: 157 – 196 Nm {16 – 20 kgm}
Piston rod assembly 1) Set cylinder (8) to tool U1.
15
SEN02019-01
2)
3)
50 Disassembly and assembly
Assemble piston rod (10) to cylinder (8). a Coat the seal portion of the piston with grease. a Push in the piston rod fully. Push head assembly to cylinder and tighten mounting bolts. a Coat the backup ring with grease. 3 Mounting bolt: Blade lift: 490 ± 49 Nm {50 ± 5 kgm} Blade tilt, ripper lift, ripper tilt: 1,320 ± 140 Nm {135 ± 15 kgm}
2)
5.
4.
16
Install quick drop valve assembly (1).
Cylinder tube Install cylinder tube.
Quick drop valve assembly a Blade lift cylinder only. 1) Assemble quick drop valve assembly as follows. 1] Assemble collar (7), and install valves (6) and (5), washer (4), and spring (3). 2] Install elbow (2).
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02019-01 a
Disassembly and assembly of ripper pin puller cylinder assembly
Put an oil container under the cylinder to catch the oil.
Cylinder repair stand
q 1
790-201-1702
Push tool kit
t 1
790-201-1881
• Push tool
1
790-201-1871
• Push tool
1
790-201-1721
• Push tool
1
790-101-5021
• Grid
1
01010-50816
• Bolt
1
790-201-1500
Push tool kit
790-201-1670
• Plate
1
790-201-1680
• Plate
1
3 790-201-1690
• Plate
1
790-201-1530
• Plate
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
1 790-502-1003
2
U
5
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1690
Ring
t 1
07281-02169
Clamp
t 1
796-720-1710
Ring
t 1
07281-02709
Clamp
t 1
796-720-1630
Ring
t 1
07281-00709
Clamp
t 1
Wrench
t 1
6 790-102-2304
2.
Cylinder head assembly 1) Remove cylinder head assembly (2) from piston rod (3).
t 1
Expander
4 790-720-1000
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
2) 3) 4) 5)
Remove O-ring (5) and backup ring (6). Remove O-ring (7). Remove snap ring (8), then remove dust seal (9). Remove rod packing (10), then remove bushing (11).
Disassembly 1.
Cylinder assembly 1) Set pin puller cylinder assembly (1) to tool U1. 2) Using tool U6, loosen cylinder head assembly (2). 3) Remove piston rod (3) together with cylinder head assembly (2).
D475A, D475ASD-5E0
17
SEN02019-01
3.
50 Disassembly and assembly
Piston rod assembly Remove piston ring (12) from piston rod (3).
2.
Cylinder head assembly 1) Using tool U2, press fit bushing (11) to cylinder head (4).
Assembly a
Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the packings, dust seals, and O-rings when installing.
1.
Piston rod assembly 1) Using tool U4, expand piston ring (12). a Set the piston ring on the expander and turn the handle 8 – 10 time to expand the ring. 2) Remove piston ring (12) from tool, then install to piston rod (3). 3) Using tool U5, compress piston ring (12). 2)
18
Using tool U3, press fit dust seal (9) to cylinder head (4).
D475A, D475ASD-5E0
50 Disassembly and assembly
3) 4) 5)
Install snap ring (8) and rod packing (10). Install O-ring (7). Install backup ring (6) and O-ring (4).
6)
Install cylinder head assembly (2) to piston rod (3).
D475A, D475ASD-5E0
SEN02019-01
3.
Cylinder assembly 1) Set cylinder to tool U1 and support with block [1]. 2) Install piston rod (3) together with cylinder head assembly (2). a Coat the seal portion of the piston with grease. a Coat the backup ring with grease. a Push in the piston fully. 3) Using tool U6, tighten cylinder head assembly (2). 3 Cylinder head assembly: 441 ± 44.1 Nm {45 ± 4.5 kgm}
19
SEN02019-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN02019-01
© 2008 KOMATSU All Rights Reserved Printed in Japan 06-08 (01)
20
SEN02020-00
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Work equipment Work equipment .............................................................................................................................................. 2 Removal and installation of blade assembly ........................................................................................ 2 Disassembly and assembly of giant ripper assembly .......................................................................... 4
D475A, D475ASD-5E0
1
SEN02020-00
50 Disassembly and assembly
Work equipment Removal and installation of blade 1 assembly
1 k
Removal k
Lower the work equipment to the ground in a horizontal place, and set blocks [1] securely under the left and right straight frames.
1.
Remove lock plate (1) of lift cylinder rod pin and extract pin (2). [*1]
2.
Sling lift cylinder assembly (3), then start engine and retract piston rod fully, fit cylinder lock tool and secure to radiator guard. a Tie the piston rod with wire to prevent it from coming out. q Repeat the same procedure to disconnect the cylinder from the blade on the opposite side.
2
Release the remaining pressure from the hydraulic circuit. For details, see Testing and adjusting, " R e l e a s i n g re m a i ni n g pr e s s ur e f ro m hydraulic circuit". Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
3.
Remove left and right covers (4).
4.
Disconnect hoses (5). a Mark the hoses before disconnecting. a Fit blind plugs to prevent dirt or dust from entering the piping.
5.
Remove left and right trunnion caps (6).
6.
Remove blade assembly (7). a Start the engine, drive the machine slowly in reverse, and disconnect the blade assembly from the trunnions.
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02020-00
Installation q
Carry out installation in the reverse order to removal.
[*1] a Adjust with block [1] so that height (b) and width (c) of the left and right straight frames are the dimensions given below. q Height (b) of trunnion portion: Approx. 981 mm q Brace width (c): Approx. 3,840 mm
q
Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
D475A, D475ASD-5E0
3
SEN02020-00
Disassembly and assembly of giant ripper assembly
50 Disassembly and assembly
7.
Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder hoses (5), and 2 pin-puller cylinder hoses (6).
8.
Sling tilt cylinder assembly (7), then remove pin (8) and lift off tilt cylinder assembly (7).
Disassembly 1.
Mount machine on block [1] and lower blade to ground. k Lock the brake securely.
2.
Sling shank, then operate pin-puller switch and pull out shank pin.
3.
Raise ripper fully, and lower shank (1) to remove. 4
4.
Shank: 1,050 kg
Set stand [2] under arm and beam. 4
5.
6.
4
Sling lift cylinder assembly and remove pin (2). a Start the engine, retract the piston rod fully, and lower on top of the arm. Sling lift cylinder assembly and remove pin (3). a Start the engine, retract the piston rod fully, and lower on top of the lift cylinder. k Release the remaining pressure from the hydraulic circuit. For details, see Testing and adjusting, "Releasing remaining pressure from hydraulic circuit".
9.
Tilt cylinder assembly: 410 kg
Sling lift cylinder assembly (9), then remove pin (10) and lift off lift cylinder assembly (9). 4
Lift cylinder assembly: 400 kg
D475A, D475ASD-5E0
50 Disassembly and assembly
10. Sling beam (11), then remove left and right pins (12) and lift off beam (11). 4
SEN02020-00
2.
Beam: 2,450 kg
Sling beam (11) and set in mounting position, then fit left and right pins (12) and secure with lock plate. 4
a
Arm: 2,450 kg Set a stand under the beam.
11. Sling arm (13), then remove left and right pins (14) and lift off arm (13). 4
Arm: 1,800 kg
3.
Sling lift cylinder assembly (9) and set in mounting position, then fit pin (10) and secure with lock plate. 4
Lift cylinder assembly: 400 kg
Assembly 1.
Sling arm (13) and set in mounting position, then fit left and right pins (14) and secure with lock plate. 4
a
Arm: 1,800 kg Set a stand under the arm.
D475A, D475ASD-5E0
4.
Sling tilt cylinder assembly (7) and set in mounting position, then fit pin (8) and secure with lock plate. 4
Tilt cylinder assembly: 410 kg
5
SEN02020-00
5.
Connect 2 pin-puller cylinder hoses (6), 4 tilt cylinder hoses (5), and 4 lift cylinder hoses (4).
50 Disassembly and assembly
8.
Mount machine on block [1] and lower blade to ground. k Lock the brake securely.
9.
Operate ripper and raise slightly to remove stand [2].
10. Raise ripper fully, pass wire through shank holder, then raise shank (1) slowly, align with pin hole, and operate pin-puller switch to insert shank pin. 11. Raise blade and lower machine from block [1].
6.
Sling tilt cylinder assembly, start engine, extend piston rod and align with pin hole, then install pin (3) and secure with lock plate.
7.
Sling lift cylinder assembly, start engine, extend piston rod and align with pin hole, then install pin (2) and secure with lock plate.
12. Bleed air from cylinder. For details, see Testing and adjusting, "Bleed air from hydraulic cylinder".
6
D475A, D475ASD-5E0
50 Disassembly and assembly
D475A, D475ASD-5E0
SEN02020-00
7
SEN02020-00
D475A, D475ASD-5E0 Bulldozer Form No. SEN02020-00
© 2007 KOMATSU All Rights Reserved Printed in Japan 02-07 (01)
8
SEN02021-01
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Cab and its attachments Cab and its attachments ................................................................................................................................. 2 Removal and installation of ROPS guard............................................................................................. 2 Removal and installation of operator’s cab assembly .......................................................................... 3 Removal and installation of floor frame assembly................................................................................ 4
D475A, D475ASD-5E0
1
SEN02021-01
Cab and its attachments
50 Disassembly and assembly
1
Removal and installation of ROPS 1 guard Removal 1.
Sling ROPS guard (1) and remove 16 mounting bolts (2). [*1]
2.
Lift off ROPS guard (1). 4
ROPS guard: 918 kg
Installation q
[*1]
2
Carry out installation in the reverse order to removal. 3
ROPS guard mounting bolt: 1,960 – 2,450 Nm {200 – 250 kgm}
D475A, D475ASD-5E0
50 Disassembly and assembly
Removal and installation of operator’s cab assembly
SEN02021-01
6.
Remove front covers (8), (9) and (10).
7.
Remove 3 mounting bolts (11), 6 bolts (12) and 15 bolts (13).
8.
Sling operator’s cab assembly (14), then remove.
Removal k
Disconnect the cable from the negative (–) terminal of the battery.
1.
Remove ROPS guard. For details, see Removal of ROPS guard.
2.
Remove left cover (1) of operator’s cab.
3.
Disconnect wiring connectors (12V, 21 and 20) (2).
4.
Disconnect 4 washer hoses (3) and 19 washer wires (4). Washer hose Red : Right door Black : Rear window Blue : Left door – : Front window
5.
4
Operator’s assembly: 500 kg
Remove garnishes (5), (6) and (7).
Installation q
D475A, D475ASD-5E0
Carry out installation in the reverse order to removal.
3
SEN02021-01
Removal and installation of floor frame assembly
50 Disassembly and assembly
3.
4
Removal k
a a k
k
Operator’s seat: 64 kg
Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person. In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then disconnect the heater hose.
1.
Remove operator’s cab assembly. For details, see "Removal of operator’s cab assembly".
2.
Remove covers (1), (2) and (3).
4
Lift off operator's seat (4). a Remove the seat together with the undercover.
4.
Remove sidecover (5).
5.
Disconnect brake pedal linkage (6). [*4] a Check the mounting dimensions of brake rod before disconnection.
D475A, D475ASD-5E0
50 Disassembly and assembly
6.
Disconnect wiring harness connectors (7) (VF1-CA1-VF2), (8) (PL1-PL2-PL3), (9) (FD5BWR1-PWR2-USB-12V-20-21), and (10) (TCIV12-BSW), and then disconnect the wiring clamp. Disconnect washer hose (11) and the clamp.
SEN02021-01
11. Remove brake rod (17). 12. Disconnect parking brake cable (18).
[*3]
13. Disconnect air conditioner hose (19). [*1] a Collect the refrigerant (R134a) from the air conditioner circuit. 14. Disconnect heater hose (20).
7.
Remove wiring connector (12) (CN2-SSA-PT1) and the clamp.
8.
Disconnect wiring connector (13) (995-111VFD) and remove the connector bracket.
15. Disconnect wiring connector (21) and clamp (22). 16. Remove floor frame bracket bolt (23) on right side. 17. Disconnect ground wiring (24). 18. Remove floor frame bracket bolt (25) on left side.
9.
Disconnect blade PPC hose (14A), hose (14B) and ripper PPC hose (15). [*2]
10. Disconnect wiring connector and clamp (16).
D475A, D475ASD-5E0
5
SEN02021-01
19. Remove 8 floor frame rear mounting bolts (26).
50 Disassembly and assembly
Installation q
[*1]
Carry out installation in the reverse order to removal. a a a
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G).
20. Lift off floor frame assembly (27). a
4 Floor frame assembly: 500 kg Use a chain block to adjust the balance in all directions (front, rear, left, and right), and lift off slowly.
3
Tighten the air conditioner gas piping to the following tightening torques.
Thread size 16 x 1.5
13.23± 1.47 {1.35 ± 0.15}
22 x 1.5
22.05 ± 2.45 {2.25 ± 0.25}
24 x 1.5
31.85 ± 2.45 {3.25 ± 0.25}
M6 bolt (receiver portion)
5.39 ± 1.47 {0.55 ± 0.15}
M6 bolt (compressor portion)
6
Tightening torque (Nm {kgm})
9.8 ± 1.96 {1.0 ± 0.2}
D475A, D475ASD-5E0
50 Disassembly and assembly
[*2]
[*3]
[*4]
a
The connecting positions of the PPC hoses are indicated by the band colors on their quick couplers. When connecting them, confirm them by the band colors.
a
Adjust installed length of parking brake cable. For details, see Testing and adjusting, Adjusting brake pedal and parking brake lever.
a
Adjust installed length of brake rod. For details, see Testing and adjusting, "Adjusting brake pedal and parking brake lever". 3 Brake pedal linkage turnbuckle: 34.3 – 58.8 Nm {3.5 – 6 kgm}
q
Charging with air conditioner gas Charge the air conditioner circuit with air conditioner gas (R134a).
q
Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
D475A, D475ASD-5E0
SEN02021-01
7
SEN02021-01
D475A, D475ASD-5E0 Bulldozer Form No. SEN02021-01
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
8
SEN02339-02
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
Serial number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
50 Disassembly and assembly
1
Electrical system Removal and installation of controller assembly ............................................................................................. 2 Removal and installation of engine controller assembly (left) ......................................................................... 3 Removal and installation of air conditioner condenser assembly ................................................................... 4 Removal and installation of air conditioner compressor assembly ................................................................. 5 Removal and installation of air conditioner unit .............................................................................................. 7
D475A, D475ASD-5E0
1
SEN02339-02
Removal and installation of controller assembly
50 Disassembly and assembly
5.
Disconnect wiring connectors of engine controller (6). (CN-LE1, CN-LE32, CN-LE31, CN-LE4, CNLE2, CN-LE52, CN-LE51)
6.
Remove engine controller (6).
7.
Remove engine controller mounting bracket (7).
8.
Disconnect wiring connectors of transmission controller (8). (CN-TMCN1, CN-TMCN2, CN-TMCN3)
9.
Remove transmission controller (8).
1
Removal k
1.
Disconnect the cable from the negative (–) terminal of the battery. Remove cover (1).
10. Disconnect wiring connectors of steering controller (9). (CN-STCN1, CN-STCN2, CNSTCN3) 11. Remove steering controller (9).
2.
Remove services switch (2) and connector bracket (3).
3.
Remove 2 clips for wiring harness (5).
4.
Remove 3 brackets (4).
Installation q
2
Carry out installation in the reverse order to removal.
D475A, D475ASD-5E0
50 Disassembly and assembly
Removal and installation of engine controller assembly (left)
SEN02339-02
3.
Disconnect wirings (3), (4) and (5).
4.
Remove ground cable fixing bolt (6) and controller (7).
5.
Remove the right controller similarly to the left one.
1
Removal k
1.
2.
Disconnect the cable from the negative (–) terminal of the battery. Remove undercover (1).
Remove the 4 controller cover mounting bolts and remove cover (2). a Remove the fan motor piping clamps to make a space for work. a The cover mounting bolts are used to fix the controller, too.
Installation q
D475A, D475ASD-5E0
Carry out installation in the reverse order to removal.
3
SEN02339-02
50 Disassembly and assembly
Removal and installation of air conditioner condenser assembly
3.
Remove air conditioner condenser assembly (5) from right side of chassis.
Removal 1.
Open engine right side cover (1) and remove side covers (2) and (3).
Installation q
2.
Disconnect hoses (4).
[*1]
[*1]
Carry out installation in the reverse order to removal. a a a a
k
a a k
4
Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
q
Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Check that there is no defect or deterioration on the O-ring. When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: NDO I L 8 , Va l e o t h e r m a l s y s t e m s : ZXL100PG (PAG 46 or equivalent)). 3 Air conditioner hose sleeve nut: Outside: 22.05 ± 2.45 Nm {2.25 ± 0.25 kgm} Inside: 13.25 ± 1.47 Nm {1.35 ± 0.15 kgm}
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 1,100 g
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02339-02
Removal and installation of air conditioner compressor assembly
4.
Loosen 4 mount bolts (6).
5.
Loosen locknut, and remove adjustment bolt (7), then remove belt from pulley. [*2]
Removal
6.
Remove 4 mount bolts (6), then remove air conditioner compressor assembly (8).
k
Disconnect the cable from the negative (–) terminal of the battery
1.
Open engine right side cover (1) and remove side covers (2) and (3).
2.
Disconnect air conditioner compressor clutch connector (CN-351) (4).
3.
Disconnect 2 compressor hoses (5). [*1] Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere.
k
a a k
If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
D475A, D475ASD-5E0
5
SEN02339-02
50 Disassembly and assembly
Installation q
[*1]
Carry out installation in the reverse order to removal. a a a a
[*2]
q
6
a
Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Check that there is no defect or deterioration on the O-ring. When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: NDO I L 8 , Va l e o t h e r m a l s y s t e m s : ZXL100PG (PAG 46 or equivalent)). 3 Air conditioner hose mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm}
Adjust the belt tension. For details, see Testing and adjusting, "Testing and adjusting tension of air conditioner compressor belt".
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 1,100 g
D475A, D475ASD-5E0
50 Disassembly and assembly
SEN02339-02
Removal and installation of air conditioner unit
3.
Remove fresh air filter (2).
4.
Remove cover (3).
Removal
5.
Remove duct (4).
6.
Remove garnishes (5) and (6).
7.
Disconnect air hose (7).
8.
Remove fresh air filter bracket (8).
9.
Disconnect 2 air conditioner hoses (9).
k
1.
2.
Disconnect the cable from the negative (–) terminal of the battery. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. [*1] a Ask professional traders for collecting and filling operation of refrigerant. a Never release the refrigerant to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. Accordingly, put on protective goggles, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person. Remove operator's seat (1).
10. Disconnect heater hose (10). 11. Disconnect wire and wiring connector (11). 12. Remove air conditioner unit (12).
D475A, D475ASD-5E0
7
SEN02339-02
50 Disassembly and assembly
Installation q
[*1]
Carry out installation in the reverse order to removal. a a a a a
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Check that there is no defect or deterioration on the O-ring. When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: NDO I L 8 , Va l e o t h e r m a l s y s t e m s : ZXL100PG (PAG 46 or equivalent)).
3
Tighten the air conditioner gas piping to the following tightening torques.
Thread size
Tightening torque (Nm {kgm})
16 x 1.5
13.23±1.47 {1.35±0.15}
22 x 1.5
22.05±2.45 {2.25±0.25}
24 x 1.5
31.85±2.45 {3.25±0.25}
M6 bolt (receiver portion)
5.39±1.47 {0.55±0.15}
M6 bolt (compressor portion)
9.8±1.96 {1.0±0.2}
q
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 1,100 g
q
Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
8
D475A, D475ASD-5E0
50 Disassembly and assembly
D475A, D475ASD-5E0
SEN02339-02
9
SEN02339-02
D475A, D475ASD-5E0 Bulldozer Form No. SEN02339-02
© 2009 KOMATSU All Rights Reserved Printed in Japan 05-09 (01)
10
SEN00225-00
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine Model
Serial Number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
90 Diagrams and drawings
1
Hydraulic diagrams and drawings Hydraulic diagrams and drawings................................................................................................................... 3 Power train hydraulic circuit diagram ................................................................................................... 3 Hydraulic circuit diagram (1/3) ............................................................................................................. 5 Hydraulic circuit diagram (2/3) ............................................................................................................. 7 Hydraulic circuit diagram (3/3) ............................................................................................................. 9
D475A, D475ASD-5E0
1
90 Diagrams and drawings
Hydraulic diagrams and drawings
SEN00225-00
Power train hydraulic circuit diagram D475A, D475ASD-5E0
Power train hydraulic circuit diagram
D475A, D475ASD-5E0
3
Hydraulic circuit diagram (1/3)
Hydraulic circuit diagram (1/3) D475A, D475ASD-5E0
SEN00225-00 D475A, D475ASD-5E0
5
Hydraulic circuit diagram (2/3)
Hydraulic circuit diagram (2/3) D475A, D475ASD-5E0
SEN00225-00 D475A, D475ASD-5E0
7
Hydraulic circuit diagram (3/3)
Hydraulic circuit diagram (3/3) D475A, D475ASD-5E0
SEN00225-00 D475A, D475ASD-5E0
9
SEN00225-00
D475A, D475ASD-5E0 Bulldozer Form No. SEN00225-00
© 2006 KOMATSU All Rights Reserved Printed in Japan 01-06 (01)
12
SEN00226-03
BULLDOZER 1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine Model
Serial Number
D475A-5E0 D475ASD-5E0
30001 and up 30001 and up
90 Diagrams and drawings
1
Electrical diagrams and drawings Electrical circuit diagram (1/13)....................................................................................................................... 3 Electrical circuit diagram (2/13)....................................................................................................................... 5 Electrical circuit diagram (3/13)....................................................................................................................... 7 Electrical circuit diagram (4/13)....................................................................................................................... 9 Electrical circuit diagram (5/13)......................................................................................................................11 Electrical circuit diagram (6/13)..................................................................................................................... 13 Electrical circuit diagram (7/13)..................................................................................................................... 15 Electrical circuit diagram (8/13)..................................................................................................................... 17 Electrical circuit diagram (9/13)..................................................................................................................... 19 Electrical circuit diagram (10/13)................................................................................................................... 21 Electrical circuit diagram (11/13) ................................................................................................................... 23 Electrical circuit diagram (12/13)................................................................................................................... 25 Electrical circuit diagram (13/13)................................................................................................................... 27 Electrical circuit diagram of inside cab.......................................................................................................... 29 Connector arrangement diagram .................................................................................................................. 31
D475A, D475ASD-5E0
1
SEN00226-03
2
90 Diagrams and drawings
D475A, D475ASD-5E0
Electrical circuit diagram (1/13)
Electrical circuit diagram (1/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
3
Electrical circuit diagram (2/13)
Electrical circuit diagram (2/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
5
Electrical circuit diagram (3/13)
Electrical circuit diagram (3/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
7
Electrical circuit diagram (4/13)
Electrical circuit diagram (4/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
9
Electrical circuit diagram (5/13)
Electrical circuit diagram (5/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
11
Electrical circuit diagram (6/13)
Electrical circuit diagram (6/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
13
Electrical circuit diagram (7/13)
Electrical circuit diagram (7/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
15
Electrical circuit diagram (8/13)
Electrical circuit diagram (8/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
17
Electrical circuit diagram (9/13)
Electrical circuit diagram (9/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
19
Electrical circuit diagram (10/13)
Electrical circuit diagram (10/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
21
Electrical circuit diagram (11/13)
Electrical circuit diagram (11/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
23
Electrical circuit diagram (12/13)
Electrical circuit diagram (12/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
25
Electrical circuit diagram (13/13)
Electrical circuit diagram (13/13) D475A, D475ASD-5E0
SEN00226-03 D475A, D475ASD-5E0
27
90 Diagrams and drawings
Electrical circuit diagram of inside cab
D475A, D475ASD-5E0
SEN00226-03
Electrical circuit diagram of inside cab D475A, D475ASD-5E0
29
Connector arrangement diagram
Connector arrangement diagram D475A, D475ASD-5E0
D475A, D475ASD-5E0 Address of stereogram
Connector No.
Model
Number of pins
Battery relay (Right) (Terminal E)
E-8
GND4
Terninal
1
1
Battery relay (Left) (Terminal E)
I-2
H01
Giboshi
DT
3
Brake potentiometer
U-2
H02
BSW
HD-18
14
Intermediate connector (BULGA specification)
X-2
I-9
BUA
DT
2
Backup alarm
Rear right speaker (Cab)
I-9
BUZ
KES-1
3
6
Front wiper motor (Cab)
G-9
CB1
Terninal
9
Radio (Cab)
K-9
CB2
Address of stereogram
Connector No.
Model
Number of pins
Ground (Engine)
AT-3
SFTU
—
3
PCCS lever shift-up switch
1
Additional heater switch (If equipped)
Y-2
SL81
DT
2
Left brake ECMV (Solenoid)
BB-6
Giboshi
1
Additional heater switch (If equipped)
Y-2
SLC5
DT
2
Left clutch ECMV (Solenoid)
BA-6
HLS
DT
2
Hydraulic oil level switch (If equipped)
H-9
SLS
—
2
Daylight sensor
AF-8
I-9
HP1
DT
3
Work equipment pump oil pressure (F)
F-9
SR83
DT
2
Right brake ECMV (Solenoid)
BB-6
Buzzer switch
AH-7
HP2
DT
3
Work equipment pump oil pressure (R)
F-9
SRC7
DT
2
Right clutch ECMV (Solenoid)
BA-7
1
Circuit breaker (20 A) (Steering controller)
AK-4
HR1
DT-B
12
Intermediate connector (Hood)
P-4
SRT1
DT
2
Reverse clutch ECMV (Solenoid)
AX-5
Terninal
1
Circuit breaker (20 A) (Monitor panel)
AK-4
HR2
DT-A
12
Intermediate connector (Hood)
P-4
SRV
DT-A
12
Service connector
AH-2
Terninal
1
Circuit breaker (20 A) (Transmission controller)
AK-4
HRN1
Terninal
1
Horn (415 Hz)
D-1
SSA
DT
4
Acceleration sensor (SSC model)
R-1
Address of stereogram
Connector No.
Model
Number of pins
Lamp outlet connector (Cab)
J-9
BRE
Terninal
1
1
Rear left speaker (Cab)
J-9
BRE
Terninal
Terninal
1
Rear left speaker (Cab)
J-9
BRK
4
—
4
Rear wiper motor (Cab)
I-9
5
Terninal
1
Rear right speaker (Cab)
6
Terninal
1
9
—
10
—
Connector No.
Model
Number of pins
1
Giboshi
1
2
Terninal
3
Component name
Component name
Component name
Component name
Address of stereogram V-9
11
KES1
6
Left wiper switch (Cab)
J-1
CB3
12
KES1
6
Front wiper switch (Cab)
J-2
CB4
Terninal
1
Circuit breaker (20 A) (Air conditioner)
AK-3
HRN2
Terninal
1
Horn (350 Hz)
C-7
ST/B2
Terninal
1
Safety relay (Terminal B)
AV-4
13
KES1
6
Right wiper switch (Cab)
K-2
CB5
Terninal
1
Circuit breaker (20 A) (Headlamp)
AK-3
HT1
Terninal
1
Electrical intake air heater (Left bank)
AV-6
ST1
DT
3
Intermediate connector (Starting motor A)
AV-5
14
KES1
6
Rear wiper switch (Cab)
K-2
CB6
Terninal
1
Circuit breaker (20 A) (Starting switch terminal B)
AK-3
HT2
Terninal
1
Electrical intake air heater (Right bank)
AR-8
ST2
DT
2
Intermediate connector (Starting motor B)
AV-5
15
M
2
Lamp switch (Cab)
K-2
CM29
AMP070
10
ORBCOMM terminal
AK-9
HTR1A
Terninal
1
Preheater relay (Left)
AR-1
ST8
DT
2
Emergency stop valve
BB-6
17
YAZAKI
4
Right door wiper motor (Cab)
G-9
CM30
AMP070
14
ORBCOMM terminal
AJ-8
HTR1C
Terninal
1
Preheater relay (Left)
AR-1
STB
Terninal
1
Safety relay (Terminal B)
AV-5
18
YAZAKI
4
Left door wiper motor (Cab)
L-4
CN1
DT
2
Injector #1 (Left bank)
AS-9
HTR2A
Terninal
1
Preheater relay (Right)
AQ-1
STCN1
DRC26
24
Steering controller
AD-2
19
DT
4
Intermediate connector (Window washer)
K-3
CN1
DT
2
Injector #1 (Right bank)
AQ-7
HTR2C
Terninal
1
Preheater relay (Right)
AQ-2
STCN2
DRC26
40
Steering controller
AE-2
DT
2
Injector #2 (Left bank)
AV-4
J1939
DT-A
8
Intermediate connector
AU-2
STCN3
DRC26
40
Steering controller
AE-1
20
DTHD#8
1
Cab power supply
Z-4
CN2
21
DTHD#12
1
Cab unswitched power supply
Z-3
CN2
DT
2
Injector #2 (Right bank)
AR-8
KEY
DT
6
Starting switch
AH-8
STF
X
4
Steering controller write connector
AD-4
22
Terninal
1
Cigarette lighter (Cab)
L-9
CN3
DT
2
Injector #3 (Left bank)
AV-5
L.P.
HD-18
14
Intermediate connector (Injector left bank)
AS-2
SW
Terninal
1
Battery relay (Right) (Terminal BR)
F-9
25
Giboshi
1
Rotary lamp outlet connector (Cab)
K-9
CN3
DT
2
Injector #3 (Right bank)
AR-8
L.S.
HD-18
14
Intermediate connector (Injector left bank)
AS-2
SW
Terninal
1
Battery relay (Left) (Terminal BR)
I-1
26
M
2
Rotary lamp switch (Cab)
K-2
CN4
DT
2
Injector #4 (Left bank)
AV-5
LMFL
Relay
5
Front lamp relay (Left)
AK-1
SX8
Terninal
1
Ground
L-4
81
—
2
Room lamp (Cab)
H-9
CN4
DT
2
Injector #4 (Right bank)
AS-8
LMFR
Relay
5
Front lamp relay (Right)
AL-1
TAM1
PACKARD
2
Intake air temperature sensor
AV-8
101
DT-B
12
Intermediate connector (Bulkhead wiring harness)
P-3
CN5
DT
2
Injector #5 (Left bank)
AV-6
LMRP
Relay
5
Ripper point lamp relay
AL-1
TC1
DT
2
Torque converter outlet speed sensor
BB-5
102
DT-A
12
Intermediate connector (Bulkhead wiring harness)
P-3
CN5
DT
2
Injector #5 (Right bank)
AS-9
LMW
Relay
5
Working lamp relay
AL-1
TFUEL
PACKARD
2
Fuel temperature sensor (Left bank)
AU-4
DT
2
Injector #6 (Left bank)
AV-6
LSV
DT
2
Pump LS selector solenoid
AW-5
TFUEL
PACKARD
2
Fuel temperature sensor (Right bank)
AQ-6
AU-9
MFD
DT
2
Merge-divider solenoid valve
R-7
TIM
PACKARD
2
Intake air temperature sensor
AQ-4
201
DT-B
12
Intermediate connector (Yoke angle sensor)
D-7
CN6
203
DT
2
Right headlamp
C-7
CN6
DT
2
Injector #6 (Right bank)
204
DT
2
Left headlamp
C-7
CONV
DT
6
Converter
X-8
MMS
DT-C
12
Intermediate connector
AO-6
TL1
HD-24
23
Intermediate connector (PCCS lever)
Y-2
207
DT
2
Left headlamp
D-7
CSL
DT
3
Left yoke angle sensor
E-1
NE
SUMITOMO
3
Ne sensor
AV-8
TL2
DT-B
8
PCCS lever potentiometer
W-8
208
DT
2
Right headlamp
C-7
CSR
DT
3
Right yoke angle sensor
B-3
NSF
Relay
5
Neutral safety relay
AM-1
TL3
DT
6
Intermediate connector (Console)
W-9
209
DT-A
12
Intermediate connector (Small hood)
E-1
CT1
DT
3
CAN terminal resistor
AF-8
NSW
DT
3
Parking brake switch
AM-4
TLL
DT
2
Left tilt limit solenoid valve
Q-7
217
DT
2
Caution buzzer
AE-6
CTV
DT
3
CAN terminal resistor
AN-6
OEM
HD-24
21
Intermediate connector
AR-3
TLR
DT
2
Right tilt limit solenoid valve
Q-7
221
DT
2
Left working lamp
H-1
CUR
KES-1
3
Cursor switch
AI-7
OEM L
DRC-50
50
Engine controller (Left bank)
AV-1
TLS
DT
2
Blade tilt left oil pressure switch
Q-8
DT
3
Decelerator pedal
T-2
OEM R
DRC-50
50
Engine controller (Right bank)
AU-2
TM1
DT
2
Transmission outlet speed sensor
BB-5
223
DT
2
Ripper point lamp (If equipped)
L-6
DEC
226
DT
2
Left rear working lamp
L-7
DIAL
M
3
Fuel control dial
W-9
OLLV
DT
2
Engine oil level switch
AR-3
TMC1
DRC26
24
Transmission controller
AI-5
241
DT-A
12
Intermediate connector (Right fender)
G-9, P-6
DL1
BENDIX
5
Download connector (ORBCOM specification)
M-3
OLV1
DT
2
Intermediate connector (Engine oil level)
AU-9
TMC2
DRC26
40
Transmission controller
AI-5
242
DT
2
Right working lamp
D-8
DLT
DT
2
Download right (ORBCOM specification)
L-2
OLV2
—
2
Intermediate connector (Engine oil level)
AS-8
TMC3
DRC26
40
Transmission controller
AI-4
243
DT
2
Right rear working lamp
H-9
DPNL
DT
2
Diode
AX-8
P03
DT
6
Intermediate connector (Work equipment knob switch)
Q-9
TMF
X
4
Transmission write connector
AD-4
244
DT
2
Pin puller solenoid
L-5
DUL
DT
2
Dual tilt selector solenoid valve
R-8
PAMB
AMP
3
Ambient pressure sensor
AV-6
TMMD
DT
3
Transmission main oil pressure
AW-5
250
Terninal
1
Starting switch (Terminal B)
AI-9
EG1
DTP
4
Intermediate connector (Engine)
AQ-1
PCV1
SUMITOMO
2
Supply pump #1 (Left bank)
AU-3
TOIL
PACKARD
2
Engine oil temperature sensor
AV-4
255
Terninal
1
Starting switch (Terminal R1)
AI-8
EG2
HD-24
23
Intermediate connector (Engine)
AV-7
PCV1
SUMITOMO
2
Supply pump #1 (Right bank)
AQ-5
TRS
DT
2
Blade tilt right oil pressure switch
P-8
Relay
5
Engine hold relay
AK-1
PCV2
SUMITOMO
2
Supply pump #2 (Left bank)
AU-4
TS1
DT-C
12
Intermediate connector (Monitor panel)
AI-3
256
Terninal
1
Starting switch (Terminal R2)
AI-8
EHL
260
Terninal
1
Starting switch (Terminal BR)
AH-8
ENBP
DT
3
Blow-by pressure
AQ-3
PCV2
SUMITOMO
2
Supply pump #2 (Right bank)
AQ-5
TS1F
DT-C
12
Intermediate connector (Steering controller)
AI-3
262
X
2
Intermediate connector (Horn switch)
S-9
ENG
DRC-60
60
Engine controller (Left bank)
AV-1
PFUEL
AMP
3
Common rail pressure sensor (Left bank)
AU-4
TS2
DT-D
12
Intermediate connector (Monitor panel)
AD-3
263
X
2
Pin puller switch
U-9
ENG
DRC-60
60
Engine controller (Right bank)
AU-2
PFUEL
AMP
3
Common rail pressure sensor (Right bank)
AU-9
TS2F
DT-D
12
Intermediate connector (Steering controller)
AD-3
265
Terninal
1
Horn switch
T-9
ENGL
HD-18
21
Intermediate connector (Engine sensor)
AS-2
PHR
Relay
5
Preheater relay
AM-1
TTM
DT-B
12
Intermediate connector (Monitor panel)
AD-5
266
Terninal
1
Horn switch
T-9
ESD
DT
3
Intermediate connector (Fuse box)
AN-1
PIM
SUMITOMO
3
Boost pressure sensor
AR-3
TTMF
DT-B
12
Intermediate connector (Transmission controller)
AD-5
270
Terninal
1
Starting switch (Terminal ACC)
AH-9
EXA1
DT
3
Exhaust temperature sensor amplifier (Left 1)
AN-6
PL1
HD-24
23
Intermediate connector (Power train)
BB-4
TWTR
PACKARD
2
Coolant temperature sensor
AR-3
280
Terninal
1
Starting switch (Terminal C)
AI-9
EXA2
DT
3
Exhaust temperature sensor amplifier (Left 2)
AL-5
PL1F
HD-24
23
Intermediate connector (Emergency escape device) (If equipped)
AY-8
USB
DTHD#8
1
Intermediate connector (Fuse)
DT
3
Exhaust temperature sensor amplifier (Right 1)
AN-8
PL1M
HD-24
23
Intermediate connector (Emergency escape device) (If equipped)
AY-8
V1
AMP070
20
VHMS controller
AK-6
Z-4
360
DT
6
Washing tank motor
K-3
EXA3
369
DT
6
Washing tank motor
L-3
EXA4
DT
3
Exhaust temperature sensor amplifier (Right 2)
AJ-7
PL2
HD-24
31
Intermediate connector (Power train)
AY-8, BB-4
V2A
AMP070
18
VHMS controller
AL-9
422
DT
2
Fuel level gauge
L-5
EXTLF
DT
2
Exhaust temperature sensor (Left front)
AU-9
PL3
HD-18
14
Intermediate connector (Power train)
BB-4
V2B
AMP070
12
VHMS controller
AM-9
453
DT
2
Torque converter oil temperature sensor
AZ-2
EXTLR
DT
2
Exhaust temperature sensor (Left rear)
AT-9
PLUB
Relay
5
Pre-lubricator relay
AK-3
V3A
AMP070
18
VHMS controller
AM-5
599
DT-A
12
Intermediate connector (Left fender)
Z-4
EXTRF
DT
2
Exhaust temperature sensor (Right front)
AT-9
PM1
Terninal
1
Pre-lubricator motor (If equipped)
F-1
V3B
AMP070
12
VHMS controller
AL-5
653
DT
2
Lockup solenoid
AX-5
EXTRR
DT
2
Exhaust temperature sensor (Right rear)
AT-9
PNL
HD-24
31
Intermediate connector (Emergency escape device) (If equipped)
AW-9
V4A
AMP070
14
VHMS controller
AO-8
800
Giboshi
1
Intermediate connector (Spare power supply 1)
AN-2
EXT1
DT
2
Exhaust temperature sensor amplifier (Left 1)
AM-5
POIL
FRAMATOME
3
Engine oil pressure sensor
AV-4
V4B
AMP070
10
VHMS controller
AO-7
801
Giboshi
1
Intermediate connector (Spare power supply 2)
AN-2
EXT2
DT
2
Exhaust temperature sensor amplifier (Left 2)
AN-9
POP
Terninal
1
Pre-lubricator pressure switch (If equipped)
AV-5
VDA
HD-18
14
Intermediate connector (Download)
M-3
DT
2
Exhaust temperature sensor amplifier (Right 1)
AJ-7
PPB
DT
2
Pitch back solenoid valve
R-8
VDB
DT-A
8
Intermediate connector (Left fender)
Z-4 Y-8
810
Giboshi
1
Spare power supply 1
Z-5
EXT3
811
Giboshi
1
Spare power supply 2
Z-5
EXT4
DT
2
Exhaust temperature sensor amplifier (Right 2)
AN-9
PPD
DT
2
Pitch dump solenoid valve
R-8
VDW
BENDIX
5
VHMS download (ORBCOM specification)
12S1
YAZAKI
2
Accessory socket
X-8
F1T8
DT
2
1st clutch ECMV (Fill switch)
AY-6
PPV
DT
2
Pitch priority solenoid valve
S-8
VEG
HD-24
21
Intermediate connector (Engine)
AV-7
12S2
YAZAKI
2
Accessory socket
X-8
F2T6
DT
2
2nd clutch ECMV (Fill switch)
AY-6
PR1
Terninal
1
Pre-lubricator relay (If equipped)
E-8
VF1
HD-24
21
Intermediate connector (Floor)
AJ-6
12V
DT
3
Intermediate connector (Cab)
Z-3
F3T4
DT
2
3rd clutch ECMV (Fill switch)
AZ-6
PR2
Terninal
1
Pre-lubricator relay (If equipped)
E-8
VF2
HD-24
23
Intermediate connector (Floor)
AK-5
AC
DT
2
Air conditioner compressor
AQ-7
F30
—
1
Circuit breaker (30 A)
B-9
PR3
Terninal
1
Pre-lubricator relay (If equipped)
F-1
WLD
DT
2
Coolant level sensor
C-2
AC1
DT-A
12
Intermediate connector (Air conditioner)
W-8
F96
—
1
Circuit breaker (105 A)
B-9
PR4
Terninal
1
Pre-lubricator relay (If equipped)
G-1
AC2
HD-24
31
Intermediate connector (Air conditioner)
Z-6
FA1
DT
2
Fun pump solenoid
AZ-2
PRE
DT
2
Pre-lubricator
AN-3
ACT
DT
2
Air conditioner external air sensor
E-8
FA2
DT
2
Fun pump solenoid
BA-3
PRS
DT
2
Pre-lubricator
AN-4
ACT
Relay
5
ACC cut relay
AK-2
FAN1
KES1
3
Fan clean mode switch
AI-7
PT1
DT
3
Pitch angle sensor
R-1
ACU
S
12
Air conditioner unit
Z-7
FAN2
KES1
4
Fan reverse mode switch
AI-6
PTH
DT
2
Pitch selector solenoid valve
R-8
ADH
KES1
4
Additional heater switch
AI-6
FAR
DT
2
Fan reverse solenoid
D-2
PW L
DTP
4
Engine controller (Left bank)
AV-1
AF1
DT
2
Air cleaner clogging sensor
G-1
FD5
DT-B
12
Fuse wiring harness
W-1
PW R
DTP
4
Engine controller (Right bank)
AT-2
AF2
DT
2
Air cleaner clogging sensor
H-1
FFT2
DT
2
Forward clutch ECMV (Fill switch)
AZ-6
PWR1
DTHD#4
1
Intermediate connector (fuse)
Z-5
ANB
Terninal
1
Alternator (Terminal B)
AQ-7
FL82
DT
2
Left brake ECMV (Fill switch)
BB-6
PWR2
DTHD#4
1
Intermediate connector (fuse)
Z-5
ANR
Terninal
1
Alternator (Terminal R)
AQ-7
FLC6
DT
2
Left clutch ECMV (Fill switch)
BA-7
R.P.
HD-18
14
Intermediate connector
AQ-5
HD-18
14
Intermediate connector (Injector right bank)
AQ-5
AP1
AMP040
16
Air conditioner control panel
U-2
FR84
DT
2
Right brake ECMV (Fill switch)
BA-6
R.S.
DT
2
Right clutch ECMV (Fill switch)
BA-7
REL1
Terninal
1
Preheater relay (Left)
AR-2
AP2
AMP040
20
Air conditioner control panel
U-2
FRC8
AP3
SWP
12
Air conditioner unit
Y-7
FRT2
DT
2
Reverse clutch ECMV (Fill switch)
AY-6
REL2
Terninal
1
Preheater relay (Right)
AQ-2
AP4
SWP
16
Air conditioner unit
Z-7
FS11
—
—
Fuse box
AL-4
RES
DT
2
Left bank resistor (Pull-up)
AT-3
AP5
SWP
8
Air conditioner unit
Y-7
FS12
—
—
Fuse box
AL-4
RES
DT
2
Right bank resistor (Pull-up)
AQ-4
ASD
KES1
4
Auto shift-down switch
AH-8
FS21
—
—
Fuse box
AL-4
RES L
DT
3
CAN terminal resistor (Left bank)
AU-1
ASUS
DT
2
Intermediate connector (Air suspension seat)
U-9
FS22
—
—
Fuse box
AL-4
RES R
DT
3
CAN terminal resistor (Right bank)
AQ-3
B7L
—
1
Circuit breaker (30 A)
C-9
FS31
—
—
Fuse box
AM-4
RPD
DT
2
Ripper lower oil pressure switch
P-9
—
—
Fuse box
AM-4
RPNL
X
2
Resistor
AY-9
B7S
—
1
Circuit breaker (30 A)
C-8
FS32
B8L
—
1
Circuit breaker (30 A)
C-8
FSB
HD-24
31
Intermediate connector (Fuse box)
W-1
RPU
DT
2
Ripper raise oil pressure switch
Q-9
B8S
—
1
Circuit breaker (30 A)
C-8
FTU
KES-1
4
Auto pitch back switch
AH-8
RSD
DT
2
Diode
P-6
B30S
—
1
Circuit breaker (30 A)
B-9
FWL
KES-1
4
Front working lamp switch
AI-6
RTB
DT
2
Ripper tilt back oil pressure switch
Q-8
B105H1L
—
1
Circuit breaker (105 A)
C-9
G
SUMITOMO
3
G sensor (Left bank)
AU-3
RTI
DT
2
Ripper tilt in oil pressure switch
P-9
B105H1S
—
1
Circuit breaker (105 A)
C-9
G
SUMITOMO
3
G sensor (Right bank)
AQ-5
RWL
KES-1
4
Rear working lamp switch
AI-7
B105H2L
—
1
Circuit breaker (105 A)
B-9
GND
Terninal
1
Ground (Engine)
AT-3
S01
AMP040
12
Monitor panel
AG-8
B105H2S
—
1
Circuit breaker (105 A)
B-9
GND01
Terninal
1
Ground (Floor)
X-1
S02
M
2
Monitor panel
AF-8
B-9
GND02
Terninal
1
Ground (Floor)
X-1
S03
AMP070
20
Monitor panel
AG-8
B105S
—
1
Circuit breaker (105 A)
BKA
Relay
5
Backup alarm relay
AK-2
GND03
Terninal
1
Ground (Left fender)
J-2
S04
AMP070
12
Monitor panel
AG-8
BLD
DT
2
Blade lower oil pressure switch
Q-8
GND04
Terninal
1
Ground (Right fender)
E-8
S1T7
DT
2
1st clutch ECMV (Solenoid)
AY-6
BLMT
YAZAKI
2
Air conditioner additional blower
X-8
GND05
Terninal
1
Ground (Bulkhead)
P-3
S21
DT
3
Intermediate connector (Monitor)
AG-8
BLSW
KES1
4
Additional blower motor switch
AI-6
GND06
Terninal
1
Ground (Heater relay)
AQ-2
S24
—
—
Service switch
AD-6
BLU
DT
2
Blade raise oil pressure switch
Q-8
GND07
Terninal
1
Ground (Floor)
AG-1
S2T5
DT
2
2nd clutch ECMV (Solenoid)
AY-6
BRB
Terninal
1
Battery relay (Right) (Terminal B)
F-9
GND09
Terninal
1
Ground (Left fender)
J-2
S3T3
DT
2
3rd clutch ECMV (Solenoid)
AZ-6
BRB
Terninal
1
Battery relay (Left) (Terminal B)
J-2
GND1
Terninal
1
Ground (Engine)
AS-2
SDS
DT
2
Hydraulic oil temperature sensor
AZ-2
DT
2
Forward clutch ECMV (Solenoid)
AZ-6
—
3
PCCS lever shift-down switch
BRC BRC
Terninal Terninal
1 1
Battery relay (Right) (Terminal M) Battery relay (Left) (Terminal M)
F-8
GND2
Terninal
1
Ground (Engine)
AS-2
SFT1
H-1
GND3
Terninal
1
Ground (Engine)
AT-3
SFTD
a
The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows. DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
V-9 SEN00226-03
D475A, D475ASD-5E0
31
90 Diagrams and drawings
D475A, D475ASD-5E0
SEN00226-03
33
SEN00226-03
D475A, D475ASD-5E0 Bulldozer Form No. SEN00226-03
© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (01)
34
