D275 Ax-5 PDF

SEBM025508
Machine model Serial number
D275AX-5 20001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• D275AX-5 mount the SDA6D140E-3 engine.

For details of the engine, see the 140-3 Series Engine Shop Manual.
© 2004
All Rights Reserved 00-1
Printed in Japan 06-04 (03) (8)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ....... 10-1
20 TESTING AND ADJUSTING ............................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1
90 OTHERS ............................................................................................ 90-1
00-2 D275AX-5
2
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions must be taken to these pages according to Q Page to be newly added Add
the list below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
q 00- 1 (8) 10- 8 10-54 (5) 10- 99 10-141 (4)

00- 2 (2) 10-10 10-55 (5) 10-100 10-142 (4)
q 00- 2-1 (8) 10-11 (5) 10-56 10-101 10-143 (4)
q 00- 2-2 (8) 10-12 10-57 10-102 10-144 (5)
q 00- 2-3 (8) 10-13 10-58 10-103 10-145 (5)
q 00- 2-4 (8) 10-14 (5) 10-59 10-104 10-146
q 00- 3 10-15 10-60 10-105 10-147
q 00- 4 10-16 10-61 10-106 (2) 10-148
q 00- 5 10-17 10-62 10-107 (2) 10-149
q 00- 6 10-18 10-63 10-108 10-150
q 00- 7 10-19 10-64 10-109 (2) 10-151
q 00- 8 10-20 10-65 10- 110 (2) 10-152
q 00- 9 10-21 (5) 10-66 10- 111 (2) 10-153
q 00-10 10-22 10-67 10- 112 10-154
q 00-11 10-24 10-68 10- 113 10-155 (5)
q 00-12 10-25 (5) 10-69 10- 114 (2) 10-156
q 00-13 10-26 10-70 10- 115 10-157
q 00-14 10-27 10-71 10- 116 (2) 10-158
q 00-15 10-28 10-72 10- 117 (5) 10-159
q 00-16 10-29 10-73 10- 118 (2) 10-160
q 00-17 10-30 10-74 10- 119 (2) 10-161
q 00-18 10-31 10-75 10- 119-1 (5) 10-162
q 00-19 10-32 (5) 10-76 10- 119-2 (2) 10-163
q 00-20 10-33 (5) 10-77 10-120 10-164
q 00-21 10-34 10-78 10-121 10-165
q 00-22 10-35 (5) 10-79 10-122 (2) 10-166
01- 1 10-36 (5) 10-80 10-123 (5) 10-167 (5)
01- 3 10-37 (5) 10-81 10-124 (2) 10-168
01- 4 (5) 10-38 10-82 10-125 (5) 10-169
01- 5 (5) 10-39 10-83 10-126 (5) 10-170
01- 6 (5) 10-40 10-84 10-127 (5) 10-171
01- 7 10-41 10-85 10-128 10-172
01- 8 10-42 10-86 10-129 (5) 10-173
01- 9 10-43 10-88 10-130 10-174
01-10 10-44 10-89 10-132 10-176
01-11 10-45 (5) 10-90 (5) 10-133 (5) 10-177
01-12 (7) 10-46 10-91 (5) 10-134 10-178 (5)
10- 1 (4) 10-47 (5) 10-93 10-135 10-179
10- 2 (2) 10-48 (5) 10-94 10-136 10-181
10- 4 10-49 (2) 10-95 10-137 10-182
10- 5 (5) 10-50 10-96 10-138 10-183
10- 6 10-52 (5) 10-97 (2) 10-139 (2) 10-184
10- 7 (2) 10-53 (5) 10-98 10-140 (4) 10-185
D275AX-5 00-2-1
(8)
10-186 10-250 20-122 (5) 20-176 (5) 20-308 (6)

10-187 10-251 20-123 (5) 20-177 (1) 20-309 (1)
10-188 10-252 20-124 (5) 20-178 (1) 20-310 (1)
10-189 10-253 (2) 20-125 (5) 20-179 (1) 20- 311 (1)
10-190 10-254 (5) 20-126 (5) 20-180 (1) 20-312 (1)
10-191 10-256 20-127 (5) 20-181 (1) 20-313 (1)
10-192 10-257 20-128 (5) 20-182 (5) 20-314 (1)
10-194 10-258 20-129 (5) 20-183 (5) 20-315 (1)
10-195 10-259 (5) 20-130 (5) 20-184 (5) 20-316 (3)
10-196 10-260 20-130-1 (5) 20-185 (5) 20-317 (3)
10-197 10-261 20-131 (1) 20-186 (5) 20-318 (1)
10-198 10-262 20-132 (1) 20-187 (5) 20-319 (3)
10-199 10-263 20-133 (1) 20-188 (5) 20-320 (3)
10-200 10-264 20-134 (5) 20-189 (5) 20-321 (3)
10-201 10-265 20-134-1 (5) 20-190 (5) 20-322 (3)
10-202 10-266 20-135 (1) 20-191 (5) 20-323 (3)
10-203 (5) 10-267 20-136 (1) 20-192 (5) 20-324 (3)
10-206 10-268 20-137 (5) 20-193 (5) 20-325 (3)
10-207 10-269 20-138 (5) 20-194 (3) 20-326 (3)
10-208 10-270 20-138-1 (5) 20-195 (3) 20-327 (3)
10-209 10-271 20-139 (1) 20-196 (1) 20-328 (3)
10-210 10-272 20-140 (5) 20-197 (1) 20-329 (3)
10- 211 10-273 20-141 (3) 20-198 (5) 20-330 (1)
10-212 10-274 20-142 (3) 20-199 (5) 20-331 (1)
10-213 10-275 20-143 (1) 20-200 (5) 20-332 (1)
10-214 (5) 10-276 20-144 (1) 20-201 (5) 20-333 (6)
10-215 (5) 10-277 q 20-145 (8) 20-202 (5) 20-334 (1)
10-216 (5) 10-278 (5) 20-146 (1) 20-203 (5) 20-335 (1)
10-217 (5) 20- 1 (1) 20-147 (1) 20-204 (5) 20-336 (1)
10-218 20- 2 (1) 20-148 (5) 20-205 (5) 20-337 (1)
10-219 (5) 20- 3 (1) q 20-149 (8) 20-206 (5) 20-338 (1)
10-220 (5) 20- 4 (1) q 20-150 (8) 20-207 (1) 20-339 (1)
10-221 (5) 20- 5 (5) 20-151 (1) 20-208 (1) 20-340 (1)
10-222 (5) 20- 6 (1) 20-152 (3) 20-209 (1) 20-341 (1)
10-223 20- 7 (1) 20-153 (5) 20-210 (1) 20-342 (1)
10-224 20- 8 (5) 20-154 (1) 20- 211 (1) 20-343 (1)
10-225 20-101 (5) 20-155 (5) 20-212 (1) 20-344 (1)
10-226 (5) q 20-102 (8) 20-156 (1) 20-213 (1) 20-345 (1)
10-227 (5) 20-102-1 (5) 20-157 (1) 20-214 (1) 20-346 (1)
10-228 (5) 20-102-2 (5) 20-158 (1) 20-215 (5) q 20-347 (8)
10-229 (5) q 20-103 (8) 20-159 (5) 20-216 (5) 20-348 (1)
10-230 (5) 20-104 (1) 20-159-1 (5) 20-216-1 (5) 20-349 (1)
10-231 20-105 (1) 20-160 (5) 20-217 (5) 20-350 (6)
10-232 20-106 (5) 20-161 (1) 20-218 (5) 20-351 (1)
10-233 20-107 (1) 20-162 (1) 20-219 (5) 20-352 (3)
10-234 (5) 20-108 (5) Q 20-162-1 (8) 20-220 (1) 20-353 (3)
10-235 (5) 20-109 (5) 20-163 (5) 20-221 (1) 20-401 (3)
10-236 (5) 20- 110 (5) 20-164 (5) 20-301 (3) 20-402 (5)
10-237 20- 111 (5) 20-165 (5) 20-302 (1) 20-403 (5)
10-238 20- 112 (5) 20-166 (6) 20-303 (1) 20-404 (5)
10-240 20- 113 (1) 20-167 (5) 20-304 (3) 20-405 (1)
10-241 (5) 20- 114 (5) 20-168 (5) 20-305 (1) 20-406 (5)
10-242 20- 115 (1) 20-169 (5) 20-306 (1) 20-407 (1)
10-243 (5) 20- 116 (5) 20-170 (5) 20-307 (1) 20-408 (1)
10-244 20- 117 (1) 20-171 (5) 20-307-1 (3) q 20-409 (8)
10-246 20- 118 (1) 20-172 (1) 20-307-2 (3) q 20-410 (8)
10-247 20- 119 (5) 20-173 (5) 20-307-3 (3) q 20- 411 (8)
10-248 20-120 (1) 20-174 (1) 20-307-4 (3) q 20-412 (8)
10-249 20-121 (5) 20-175 (1) 20-307-5 (3) q 20-413 (8)
00-2-2 D275AX-5
(8)
q 20-414 (8) 20-473 (5) 20-532 (1) 20-591 (6) 20-716 (1)
20-415 (3) 20-474 (5) 20-533 (1) 20-601 (1) 20-717 (1)
20-416 (1) 20-475 (5) 20-534 (1) 20-602 (1) 30- 1 (4)
20-417 (1) 20-476 (1) 20-535 (1) 20-603 (3) 30- 2 (2)
20-418 (3) 20-477 (5) 20-536 (1) 20-604 (1) 30- 3 (4)
20-419 (3) 20-478 (5) 20-537 (1) 20-605 (3) 30- 4 (2)
20-420 (1) 20-479 (5) 20-538 (1) 20-606 (1) 30- 5 (2)
20-421 (1) 20-480 (5) 20-539 (1) 20-607 (1) 30- 6 (2)
20-422 (3) 20-481 (1) 20-540 (1) 20-608 (1) 30- 7 (4)
20-423 (1) 20-482 (5) 20-541 (1) 20-609 (1) 30- 8 (2)
20-424 (3) 20-483 (5) q 20-542 (8) q 20-610 (8) 30- 8-1 (4)
20-425 (3) 20-484 (5) 20-543 (1) 20- 611 (3) 30- 8-2 (4)
20-426 (1) q 20-485 (8) 20-544 (1) 20-612 (1) 30- 8-3 (4)
20-427 (3) 20-486 (5) 20-545 (3) 20-613 (1) 30- 8-4 (4)
q 20-428 (8) 20-487 (1) 20-546 (1) 20-614 (5) 30- 8-5 (4)
20-429 (1) 20-488 (5) 20-547 (3) 20-615 (1) 30- 8-6 (4)
20-430 (3) 20-489 (1) 20-548 (1) q 20-616 (8) 30- 8-7 (4)
20-431 (1) 20-490 (5) 20-549 (1) 20-617 (1) 30- 9 (2)
20-432 (1) 20-491 (1) 20-550 (1) 20-618 (1) 30- 10 (2)
20-433 (1) q 20-492 (8) 20-551 (1) 20-619 (1) 30- 11 (2)
q 20-434 (8) 20-493 (1) 20-552 (1) 20-620 (1) 30- 12 (2)
20-435 (1) 20-494 (5) 20-553 (1) 20-621 (3) 30- 13 (2)
20-436 (1) 20-495 (1) 20-554 (1) 20-622 (1) 30- 14 (2)
20-437 (1) 20-496 (5) 20-555 (1) 20-623 (1) 30- 15 (2)
20-438 (1) 20-497 (1) 20-556 (1) 20-624 (1) 30- 16 (2)
20-439 (3) 20-498 (1) q 20-557 (8) 20-625 (3) 30- 17 (2)
20-440 (1) 20-499 (1) 20-558 (1) 20-626 (1) 30- 18 (2)
20-441 (3) 20-500 (5) q 20-559 (8) 20-627 (3) 30- 19 (2)
20-442 (1) 20-501 (5) 20-560 (1) 20-628 (3) 30- 20 (2)
20-443 (1) 20-502 (5) 20-561 (3) 20-629 (3) 30- 21 (2)
20-444 (1) q 20-503 (8) 20-562 (1) q 20-630 (8) 30- 22 (2)
20-445 (3) 20-504 (1) 20-563 (1) q 20-631 (8) 30- 23 (2)
20-446 (3) q 20-505 (8) 20-564 (1) 20-632 (1) 30- 24 (2)
20-447 (5) 20-506 (1) 20-565 (1) 20-633 (1) 30- 25 (2)
20-448 (1) 20-507 (5) 20-566 (1) 20-634 (1) 30- 26 (3)
20-449 (5) 20-508 (1) 20-567 (1) 20-635 (3) 30- 27 (3)
20-450 (5) 20-509 (5) 20-568 (1) 20-636 (3) 30- 28 (2)
20-451 (1) 20-510 (1) 20-569 (3) 20-637 (1) 30- 29 (2)
20-452 (5) 20- 511 (5) 20-570 (1) 20-638 (1) 30- 30 (2)
20-453 (1) 20-512 (1) 20-571 (3) 20-639 (3) 30- 31 (3)
20-454 (3) 20-513 (5) 20-572 (1) 20-640 (1) 30- 32 (3)
20-455 (1) 20-514 (1) 20-573 (3) 20-641 (1) 30- 33 (2)
20-456 (1) 20-515 (1) 20-574 (1) 20-642 (1) 30- 34 (2)
20-457 (1) 20-516 (1) 20-575 (3) 20-643 (1) 30- 35 (2)
20-458 (5) 20-517 (1) 20-576 (1) 20-701 (1) 30- 36 (2)
20-459 (1) 20-518 (1) 20-577 (3) 20-702 (1) 30- 37 (2)
20-460 (5) 20-519 (5) 20-578 (6) 20-703 (3) 30- 38 (2)
20-461 (5) 20-520 (1) 20-579 (6) 20-704 (1) 30- 39 (2)
20-462 (5) 20-521 (3) 20-580 (6) 20-705 (3) 30- 40 (2)
20-463 (1) 20-522 (1) 20-581 (6) 20-706 (3) 30- 41 (2)
20-464 (5) 20-523 (1) 20-582 (6) 20-707 (3) 30- 42 (2)
20-465 (5) 20-524 (3) 20-583 (6) 20-708 (1) 30- 43 (2)
20-466 (5) 20-525 (1) 20-584 (6) 20-709 (1) 30- 44 (2)
q 20-467 (8) q 20-526 (8) 20-585 (6) 20-710 (1) 30- 45 (2)
20-468 (1) q 20-527 (8) 20-586 (6) 20- 711 (1) 30- 46 (2)
20-469 (5) 20-528 (1) 20-587 (6) 20-712 (3) 30- 47 (2)
20-470 (5) 20-529 (1) 20-588 (6) 20-713 (3) 30- 48 (2)
20-471 (3) 20-530 (1) 20-589 (6) 20-714 (1) 30- 49 (2)
20-472 (1) 20-531 (1) 20-590 (6) 20-715 (1) 30- 50 (3)
D275AX-5 00-2-3
(8)
30- 51 (2) 30- 111 (2) 30-170 (2) 30-229 (3)

30- 52 (2) 30- 112 (2) 30-171 (2) 30-230 (2)
30- 53 (2) 30- 113 (2) 30-172 (2) 30-231 (3)
30- 54 (2) 30- 114 (2) 30-173 (2) 30-232 (2)
30- 55 (2) 30- 115 (2) 30-174 (2) 30-233 (2)
30- 56 (2) 30- 116 (2) 30-175 (2) 30-234 (2)
30- 57 (2) 30- 117 (2) 30-176 (2) 30-235 (2)
30- 58 (2) 30- 118 (2) 30-177 (2) 30-236 (2)
30- 59 (2) 30- 119 (2) 30-178 (2) 30-237 (2)
30- 60 (2) 30-120 (2) 30-179 (2) 30-238 (2)
30- 61 (2) 30-121 (2) 30-180 (2) 30-239 (2)
30- 62 (2) 30-122 (2) 30-181 (2) 30-240 (2)
30- 63 (2) 30-123 (2) 30-182 (2) 30-241 (2)
30- 64 (2) 30-124 (2) 30-183 (2) 30-242 (2)
30- 65 (2) 30-125 (2) 30-184 (2) 30-243 (2)
30- 66 (2) 30-126 (2) 30-185 (2) 30-244 (2)
30- 67 (2) 30-127 (2) 30-186 (2) 30-245 (2)
30- 68 (2) 30-128 (2) 30-187 (2) 30-246 (2)
30- 69 (2) 30-129 (2) 30-188 (2) 30-247 (2)
30- 70 (2) 30-130 (2) 30-189 (2) 30-248 (2)
30- 71 (2) 30-131 (2) 30-190 (2) 30-249 (2)
30- 72 (2) 30-132 (2) 30-191 (2) 30-250 (2)
30- 73 (2) 30-133 (3) 30-192 (2) 30-251 (2)
30- 74 (3) 30-134 (2) 30-193 (2) 30-252 (2)
30- 75 (3) 30-135 (2) 30-194 (2) 30-253 (2)
30- 76 (3) 30-136 (2) 30-195 (2) 30-254 (2)
30- 77 (3) 30-137 (2) 30-196 (2) 30-255 (2)
30- 79 (2) 30-138 (2) 30-197 (2) 30-256 (2)
30- 80 (2) 30-139 (2) 30-198 (2) 30-257 (2)
30- 81 (2) 30-140 (2) 30-199 (2) 30-258 (2)
30- 82 (2) 30-141 (2) 30-200 (2) 30-259 (2)
30- 83 (2) 30-142 (2) 30-201 (2) 30-260 (2)
30- 84 (2) 30-143 (2) 30-202 (2) 30-261 (2)
30- 85 (2) 30-144 (2) 30-203 (2) 30-262 (2)
30- 86 (2) 30-145 (2) 30-204 (2) 30-263 (2)
30- 87 (2) 30-146 (2) 30-205 (2) 30-264 (2)
30- 88 (2) 30-147 (2) 30-206 (2) 30-265 (2)
30- 89 (2) 30-148 (2) 30-207 (5) 30-266 (2)
30- 90 (2) 30-149 (2) 30-208 (5) 30-267 (2)
30- 91 (2) 30-150 (2) 30-209 (2) 30-268 (2)
30- 92 (2) 30-151 (2) 30-210 (2) 30-269 (2)
30- 93 (2) 30-152 (2) 30- 211 (3) 30-270 (2)
30- 94 (2) 30-153 (2) 30-212 (2) 30-271 (4)
30- 95 (2) 30-154 (2) 30-213 (2) 30-272 (4)
30- 96 (2) 30-155 (2) 30-214 (2) 90- 1
30- 97 (2) 30-156 (2) 30-215 (2) 90- 2
30- 98 (2) 30-157 (2) 30-216 (2) 90- 3
30- 99 (2) 30-158 (2) 30-217 (2) 90- 5
30-100 (2) 30-159 (2) 30-218 (2) 90- 7
30-101 (2) 30-160 (2) 30-219 (2) 90- 9
30-102 (2) 30-161 (2) 30-220 (2) 90- 11
30-103 (2) 30-162 (2) 30-221 (2) 90- 13
30-104 (2) 30-163 (2) 30-222 (2) 90- 15
30-105 (2) 30-164 (2) 30-223 (2) 90- 16
30-106 (2) 30-165 (2) 30-224 (3)
30-107 (2) 30-166 (2) 30-225 (2)
30-108 (2) 30-167 (2) 30-226 (5)
30-109 (2) 30-168 (2) 30-227 (5)
30- 110 (2) 30-169 (2) 30-228 (5)
00-2-4 D275AX-5
(8)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing 3) Do not sling a heavy load with one rope alone,
interference with the part to be removed. but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
4 Auxi-
liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
GENERAL
01 GENERAL
SPECIFICATION DRAWING .................................................................................................................. 01- 3

SPECIFICATIONS ................................................................................................................................... 01- 4
WEIGHT TABLE ...................................................................................................................................... 01- 10
TABLE OF FUEL, COOLANT AND LUBRICANT .................................................................................... 01- 12
D275AX-5 01-1
20-242 D155AX-5
GENERAL SPECEFICATION DRAWING
SPECEFICATION DRAWING
Semi U-tilt dozer + U-tilt dozer + Semi U-tilt dozer + U-tilt dozer+
Item Unit
Giant ripper Giant ripper Multi-shank ripper Multi-shank ripper
Overall 9,260 9,595 8,905 9,245

A mm
length
Overall
3,965 3,965 3,965 3,965
B height mm
(3,985) (3,985) (3,985) (3,985)
(with ROPS)
Overall 4,300 4,615 4,300 4,615

C mm
width
D275AX-5 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D275AX-5
Serial number 20001 and up
Machine weight
• Bare tractor 38,430
Weight
kg
• Above with semi U-dozer + variable multi- 50,800
shank ripper + ROPS + cab + air condi-
tioner + side cover
Min. turning radius m 3,9 (Pivot turn)
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st speed 3.8
Forward
Transmission speed ranges
2nd speed km/h 6.7

3rd speed 11.2
1st speed 4.9

Performance
Reverse
2nd speed km/h 8.7

3rd speed 14.9
Bare tractor
With semi U-dozer + variable multi- 88.26 {0.90}
Ground pressure
shank ripper
With ROPS + cab + air conditioner + 117.67 {1.20}
kPa {kg/cm2}
side cover
With U-dozer + variable multi-shank 119.63 {1.22}
ripper + ROPS + cab + air conditioner
+ side cover
Bare tractor (To top of lift cylinder) 5,570
Overall height Overall width Overall length
With Semi U-dozer + variable multi- 8,930

shank ripper mm
With U-dozer + variable multi-shank 9,270
ripper
Bare tractor (To top of lift cylinder) 2,925
Dimensions
With Semi U-dozer + variable multi- 4,300

shank ripper mm
With U-dozer + variable multi-shank 4,620
ripper
To top of exhaust pipe 3,965

To top of air intake duct mm 3,110
(To top of control lever)
01-4 D275AX-5
(5)

Overall height
With cab 3,775

With ROPS canopy mm 3,975
With canopy 3,975
Dimensions
Track gauge 2,260

Length of track on ground 3,480
Track shoe width (Standard) mm 610
Minimum ground clearance 510
(To the bottom of under cover)
Name SDA6D140E-3
Type of engine 4-cycle, water-cooled, in-line vertical type,

direct injection type with turbocharger and aftercooler
Number of cylinders = Bore × Stroke mm 6—140×165

Piston displacement ¬ {cc} 15.24 {15,240}
Flywheel horsepower kw{HP}/rpm 306{410}/2,000

Performance
Engine
Max. torque Nm{kgm}/rpm 1,989{203}/1,400

Max. speed at no load rpm 2,150
Min. speed at no load rpm 700
Min. fuel consumption ratio g/kw•h {g/HP•h} 215 {160}
Starting motor 24V, 11kW

Alternator 24V, 75A
Battery 12V, 170Ah × 2
Radiator core type D-7
Torque converter 3-element, 1-stage, 1-phase

Power train system
Planetary gear type, multiple disc clutch type,

hydraulically actuated type (electric),
Transmission force-feed lubrication gear pump type,
forward 3-speed, reverse 3-speed,
electrically operated type
D275AX-5 01-5
(5)
MPa Variable swash plate type (HPV180)

{kg/cm2} Max. discharge pressure: 41.2 {420}
HSS pump
¬/min/rpm Logical discharge pressure: 411/2,286
MPa Fixed swash plate type (HMF180)

HSS motor
{kg/cm2} Max. allowable working pressure: 41.2 {420}
Power train system
Spiral bevel gear type, force-feed lubrication

Bevel gear shaft
gear pump type
Differential planetary gear type, hydraulic motor actuat-

HSS steering system ed type, electric motorized type, hydraulically actuated
type
HSS
Wet type, multiple disc clutch type, spring-boosted

Master brake
type, hydraulically actuated type, pedal operated type
Spur gear 1-stage, planetary gear 1-stage type,

Final drive
splash type lubrication
Suspension Rigid, balancing beam type

Undercarriage
Carrier roller 2 on each side
Track roller 7 on each side
Assembly type, single grouser, 39 each side Pitch:

Track shoe (610 mm)
260.6 mm
Power train + lubrication pump (tandem) Gear type (BAR(3)100+50)
Scavenging pump Gear type (SAR(3)140)

hydraulic system
Work equipment
MPa Variable swash plate type (HPV95)

Work equipment pump
Variable in-line pump type
MPa Variable swash plate type: (LPV45)

Fan pump
MPa
{kg/cm2} Fixed swash plate type (LMF75)
Fan motor
¬/min/rpm Max. allowable working pressure: 15.7 {160}
01-6 D275AX-5
(5)
Type
Main control
• For blade lift Double + single + single type, spool type,

valve
• For blade tilt hydraulic assisted type Ripper tilt + ripper lift +
• For ripper lift blade lift + blade tilt
• For ripper tilt
Type Double acting piston type

Dimension of riper Dimension of ripper Dimension of blade Dimension of blade Dimension of blade
Cylinder bore mm 120

lift cylinder
Piston rod outside diameter mm 80

Piston stroke (Max.) mm 1,495
Max. distance between pins mm 2,470
Min. distance between pins mm 985

tilt cylinder
Work equipment hydraulic system

Piston stroke (Max.) mm 190
Min. distance between pins mm 1,365
Hydraulic cylinder
tilt + pitch cylinder


lift cylinder


tilt cylinder

Hydraulic tank Box type(Control valve externally installed type)
D275AX-5 01-7
Type Hydraulic semi U-tilt dozer,Hydraulic U-tilt dozer
Blade support method Brace type (Right-side tilt cylinder)
Max. lifting blade height mm 1,450

Performance
(from ground level)

Max. lowering blade depth mm 640
(from ground level)
Semi U-dozer
Max. tilt mm 1,000

Blade cutting angle variation deg. ±6
Blade capacity (SAE) m3 13.7
Dimensions
Blade width mm 4,300

Blade height mm 1,960
Blade cutting angle deg. 52
Work equipment
Max. lifting blade height mm 1,450

Performance
(from ground level)

Max. lowering blade depth mm 640
(from ground level)
Max. tilt mm 1,070
U-dozer
Blade cutting angle variation deg. ±6

Blade capacity (SAE) m3 16.6
Dimensions Performance Dimensions
Blade width mm 4,620

Blade height mm 1,975
Blade cutting angle deg. 52
Semi U-dozer
Max. tilt mm 1,140

Max. pitch angle deg. 6
Max. pitch-back angle deg. 6
U-dozer
Max. tilt mm 1,220

Max. pitch angle deg. 6
Max. pitch-back angle deg. 6
01-8 D275AX-5
Type Variable cutting angle type,parallelogram type

Variable multi-shank ripper
Weight kg 4,490
Beam length mm 2,495
Number of shanks unit 3
Cutting angle (Standard) deg. 51.7 (Stepless adjustment is possible between 38.9
Performance
and 61.2 deg.)

Cutting depth Two Switch-Selectable
Work equipment
Max. digging depth mm 900

Max. lifting height mm 955
Type Variable cutting angle type, parallelogram type
Variable giant ripper
Weight kg 3,640
Beam length mm 1,252
Number of shanks unit 1
Cutting angle (Standard) deg. 52.7 (Stepless adjustment is possible between 38.7
Performance
and 62.2°)
Cutting depth – Three Switch-Selectable
Max. digging depth mm 1,300
Max. lifting height mm 870
D275AX-5 01-9
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is for reference in handling or
transporting components.
Unit: kg
Engine
• Dumper assembly 1,930
• Engine assembly 1,765
• Dumper assembly 135
• Universal joint 25
• Engine mounting parts (Wiring) 5
Main radiator assembly 306

(Including built-in oil cooler)
Sub radiator assembly 73
Hydraulic cooler 78
Fuel tank assembly (When empty) 385
Fuel tank assembly (When full) 1,090
Power train unit assembly (Including HSS pump, motor) 2,615

• Torque converter, PTO assembly 534
• Transmission assembly 645
• HSS assembly 996
• Brake valve assembly 14
• HSS charging filter assembly 25
• HSS cooler bypass valve assembly 5
• Power train filter assembly 23 × 2
• Scavenging pump 19
• Power train, lubricating pump 27
• Work equipment pump + HSS charging pump 78
• HSS motor 64
• HSS pump 103
• Fan pump 45
• Fan motor 25
Final drive assembly 1,720 × 2

Sprocket teeth (25×5) × 2
Hull frame assembly 4,054
Track group assembly (each side) 5,021

• Track frame 1,396
• Idler assembly 333
• Recoil spring assembly 352
• First bogie and track roller assembly 231
• Second-fourth bogies and track roller assembly 527 × 3
• Track roller assembly (Single flange x 1) 149 × 2
• Track roller assembly (Double flange x 1) 161 × 5
• Carrier roller assembly 58 × 2
01-10 D275AX-5
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly (610mm width, wet type) 3,405 × 2

Pivot shaft assembly 142 × 2
Equalizer bar 273
Hydraulic tank assembly 166

Main control valve
(Blade lift + blade tilt + ripper lift + ripper tilt) 99
Engine underguard 250

Transmission underguard 312
Operator seat 41
Semi U-tilt dozer assembly 6,750

• Blade 4,150
• Straight frame 967 × 2
• Tilt brace 153 × 1
• Center brace 141 × 2
• Tilt cylinder assembly 230
Semi U-tilt + pitch dozer assembly 6,827

• Blade 4,150
• Straight frame 967 × 2
• Center brace 141 × 2
• Pitch cylinder assembly 230 × 2
Radiator guard assembly (Including cylinder yoke + lattice mask) 1,336

Blade lift cylinder assembly 235 × 2
Multi-shank ripper assembly 4,462

• Shank 350 × 3
• Lift cylinder assembly 184 × 2
• Tilt cylinder assembly 155 × 2
Giant ripper assembly 3,600

• Shank 500 × 1
• Lift cylinder assembly 184 × 2
• Tilt cylinder assembly 155 × 2
• Pin puller cylinder assembly 7
ROPS assembly 650

Cab assembly 415
ROPS canopy 650
Dash board 83
Floor frame assembly 591
Air conditioner assembly (Including air conditioner unit assembly) 87
Operator seat assembly 64
D275AX-5 01-11
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANT
TABLE OF FUEL, COOLANT AND LUBRICANT
Ambient temperature Specified Refilled

Refilling position Kind of oil oil amount oil amount
–30 –20 –10 0 10 20 30 40°C (¬) (¬)
SAE 30CD
SAE 10WCD
Engine oil pan 55 50
SAE 10W-30CD
SAE 15W-40CD
Power train oil pan

SAE 30CD
including torque convert- 150 90
er, transmission and bev- Engine oil SAE 10WCD
el gear case
Damper case 1.5 1.5
Final drive case (each side) SAE 30CD 40 40
Pivot shaft case (each side) 10 10
153 130
SAE 10WCD (Bare
tractor)
Hydraulic oil SAE 10W-30CD

270 130
(With
SAE 15W-40CD blade and
ripper)
Idler (each) 0.85 0.85
Track roller (each) 0.80 0.80

Gear oil GO 140
Carrier roller (each) 0.65 0.65
Bogie cartridge pin (each) 0.67 0.67
ASTM D975 No. 2

Fuel tank Diesel fuel 840 —
ASTM D975
No. 1
Cooling system Coolant Komatsu genuine super coolant (AF-NAC added) 130 —
01-12 D275AX-5
(7)
STRUCTURE, FUNCTION AND
10 STRUCTURE, FUNCTION AND

POWER TRAIN ................................................................................................................................... 10- 4

OVERALL DRAWING OF POWER TRAIN UNIT ................................................................................ 10- 6
HYDRAULIC PIPING OF POWER TRAIN .......................................................................................... 10- 8
DAMPER, UNIVERSAL JOINT ........................................................................................................... 10- 10
TORQUE CONVERTER, PTO ............................................................................................................ 10- 12
TORQUE CONVERTER ...................................................................................................................... 10- 16
TORQUE CONVERTER VALVE ......................................................................................................... 10- 20
TORQUE CONVERTER VALVE ......................................................................................................... 10- 24
SCAVENGING PUMP ......................................................................................................................... 10- 32
TRANSMISSION CONTROL ............................................................................................................... 10- 33
TRANSMISSION ................................................................................................................................. 10- 34
TRANSMISSION ECMV ...................................................................................................................... 10- 46
MAIN RELIEF VALVE .......................................................................................................................... 10- 52
POWER TRAIN PUMP, STEERING LUBRICATION PUMP ................................................................ 10- 55
LUBRICATION RELIEF VALVE ........................................................................................................... 10- 56
HSS SYSTEM ..................................................................................................................................... 10- 58
HSS PUMP .......................................................................................................................................... 10- 60
HSS MOTOR ....................................................................................................................................... 10- 76
PPC, HSS CHARGE FILTER .............................................................................................................. 10- 85
HSS CHARGE FILTER BYPASS ......................................................................................................... 10- 86
HSS OIL COOLER BYPASS VALVE ................................................................................................... 10- 88
STEERING, BRAKE CONTROL ......................................................................................................... 10- 90
BEVEL GEAR SHAFT, HSS, BRAKE .................................................................................................. 10- 93
BRAKE VALVE .................................................................................................................................... 10- 106
BRAKE ECMV ..................................................................................................................................... 10- 107
PARKING BRAKE VALVE ................................................................................................................... 10- 113
SUDDEN BRAKE PREVENTION VALVE ........................................................................................... 10- 114
FINAL DRIVE ...................................................................................................................................... 10- 115
SPROCKET.......................................................................................................................................... 10- 119-1
TRACK FRAME ................................................................................................................................... 10- 120
RECOIL SPRING ................................................................................................................................ 10- 122
IDLER .................................................................................................................................................. 10- 124
TRACK ROLLER ................................................................................................................................. 10- 126
CARRIER ROLLER ............................................................................................................................. 10- 128
TRACK ROLLER BOGIE ..................................................................................................................... 10- 130
TRACK SHOE ..................................................................................................................................... 10- 132
MAIN FRAME ...................................................................................................................................... 10- 134
SUSPENSION ..................................................................................................................................... 10- 136
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM ...................................................................... 10- 139
PPC CONTROL PIPING DIAGRAM .................................................................................................... 10- 143
WORK EQUIPMENT CONTROL ........................................................................................................ 10- 144
WORK EQUIPMENT PUMP ................................................................................................................ 10- 146
COOLING FAN PUMP ........................................................................................................................ 10- 162
D275AX-5 10-1
4
COOLING FAN MOTOR ..................................................................................................................... 10- 170

HYDRAULIC TANK ............................................................................................................................. 10- 176
ACCUMULATOR ................................................................................................................................. 10- 178
PPC LOCK VALVE .............................................................................................................................. 10- 179
PPC VALVE ......................................................................................................................................... 10- 181
PPC VALVE ......................................................................................................................................... 10- 188
HYDRAULIC CYLINDER .................................................................................................................... 10- 194
PISTON VALVE ................................................................................................................................... 10- 197
QUICK DROP VALVE .......................................................................................................................... 10- 198
PIN PULLER SWITCH ........................................................................................................................ 10- 199
PIN PULLER SOLENOID VALVE ........................................................................................................ 10- 200
BLADE CONTROL KNOB .................................................................................................................. 10- 202
PITCH, DUAL TILT SOLENOID VALVE ............................................................................................... 10- 203
CONTROL VALVE .............................................................................................................................. 10- 206
DUAL TILT SPECIFICATION .............................................................................................................. 10- 210
OPERATION OF CONTROL VALVE ................................................................................................... 10- 214
SELF-REDUCING PRESSURE VALVE .............................................................................................. 10- 231
CYLINDER STAY ................................................................................................................................ 10- 238
BLADE ................................................................................................................................................ 10- 240
RIPPER EQUIPMENT ........................................................................................................................ 10- 246
CAB MOUNT ...................................................................................................................................... 10- 248
CAB ..................................................................................................................................................... 10- 249
AIR CONDITIONER ............................................................................................................................ 10- 251
ENGINE CONTROL ............................................................................................................................ 10- 252
ENGINE CONTROL SYSTEM ............................................................................................................ 10- 253
DECELERATION POTENTIOMETER ................................................................................................ 10- 254
CRI ENGINE CONTROL SYSTEM ..................................................................................................... 10- 256
MONITOR SYSTEM ........................................................................................................................... 10- 258
MONITOR PANEL ............................................................................................................................... 10- 260
SENSORS .......................................................................................................................................... 10- 264
MODE SELECTION SYSTEM ............................................................................................................ 10- 268
SENSORS .......................................................................................................................................... 10- 271
ELECTRICAL EQUIPMENT ................................................................................................................ 10- 274
PALM COMMAND CONTROL SYSTEM ............................................................................................ 10- 277
10-2 D275AX-5
2
20-242 D155AX-5
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
• The power generated by engine (1) has its tor- • Brake (15) of the HSS is used for braking the ma-
sional vibration dampened by damper (2), and chine. Brake (15) is a wet, multiple disc clutch,
then passes through universal joint (3), and is spring boosted type. If brake (15) on only 1 side
transmitted to torque converter (10). is applied, the machine can carry out pivot turns.
• The power from the engine is transmitted The power sent from brake (15) is transmitted to
through the oil by torque converter (10) to the final drive (16).
transmission input shaft (turbine shaft) in accor- • Final drive (16) consists of a single-stage spur
dance with the change in load. gear and a single-stage planetary gear system.
• Transmission (11) uses a combination of a plan- It reduces the speed and rotates sprocket (17) to
etary gear system and hydraulic clutches to re- drive track shoe (18) and move the machine. It
duce the speed and shift the gears (3 forward also rotates fan motor (21) with the oil dis-
gears and 3 reverse gears). It connects 2 sets of charged from fan pump (19) driven with PTO (7).
clutches selected according to the change in
load, and transmits the power to bevel gear (12)
from the bevel pinion at the rear end of the trans-
mission.
• The power transmitted to the bevel gear shaft is
transmitted to HSS (Hydrostatic Steering Sys-
tem) (13). HSS pump (10) is driven by PTO (7),
and output oil of the HSS pump drives HSS mo-
tor (14). The rotation of the pair of the HSS
gears on the right and left is controlled by HSS
motor (14). The steering is carried out by gener-
ating a difference in speed on the right and left.
It is also possible to use the HSS mechanism to
rotate the right and left sides in opposite direc-
tions to carry out pivot turns.
10-4 D275AX-5
MAINTENANCE STANDARD POWER TRAIN
1. Engine (SDA6D140E-3) 8. Power train pump 15. Brake

2. Damper [SAL(3)-100] 16. Final drive
3. Universal joint 9. Steering lubricating oil pump 17. Sprocket
4. Scavenging pump [SAR(3)-50] 18. Track shoe
[BAR(3)-140] 10. Torque converter 19. Fan pump (LPV45)
5. HSS charge pump [SAL(3)-72] 11. Transmission 20. HSS pump (HPV180)
6. Work equipment pump 12. Bevel gear 21. Fan motor (LMF75)
(HPV95) 13. HSS unit
7. PTO 14. HSS motor (HMF180)
D275AX-5 10-5
(5)
MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
10-6 D275AX-5
MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT
1. HSS charge pump [SAL(3)-72] Outline

2. Work equipment pump (HPV95) • The power train unit consists of the main compo-
3. Torque converter, PTO nents of torque converter (3), transmission (6),
4. Power train pump [SAR(3)-100] and HSS unit (14). Accordingly, after the power
5. Steering lubricating oil pump [SAR(3)-50] train unit is removed, it can be divided into the
6. Transmission torque converter, transmission unit, and HSS
7. Parking brake valve unit.
8. Left brake ECMV • The HSS unit consists of the bevel pinion unit,
9. Right brake ECMV bevel gear shaft, HSS motor, planetary gear sys-
10. Sudden brake prevention valve tem, and brake.
11. Fan pump (LPV45)
12. HSS pump (HPV180)
13. HSS motor (HMF180)
14. HSS unit
15. Main relief valve
16. Power train oil strainer
17. Scavenging pump [BAR(3)-140]
D275AX-5 10-7
2
MAINTENANCE STANDARD HYDRAULIC PIPING OF POWER TRAIN
HYDRAULIC PIPING OF POWER TRAIN
1. Scavenging pump [BAR(3)-140] C. Transmission 1st clutch oil pressure pick-up port
2. HSS charge pump [SAL(3)-72] (F1)
3. Power train lubrication oil filter D. Transmission 2nd clutch oil pressure pick-up port
4. Power train oil filter (2ND)
5. Work equipment pump (HPV95) E. Transmission 3rd clutch oil pressure pick-up port
6. Centralized pressure pick-up ports (2RD)
7. Power train pump [SAR(3)-100] F. Transmission R clutch oil pressure pick-up port
8. Steering lubricating oil pump [SAR(3)-50] (R)
9. HSS charge filter G. Transmission F clutch oil pressure pick-up port
10. Brake control valve (FWD)
11. HSS motor (HMF180) H. Transmission main relief pressure pick-up port
12. Main relief valve (TM)
13. HSS pump (HPV180) J. Torque converter stator clutch pressure pick-up
14. Power train oil cooler port (SC)
(built in radiator lower tank) K. Torque converter lock-up clutch pressure pick-up
15. Transmission ECMV port (LU)
L. Torque converter regulator pressure pick-up port
A. Left brake oil pressure pick-up port (LB) (OUT)
B. Right brake oil pressure pick-up port (RB) M. Torque converter relief pressure pick-up port (IN)
10-8 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
10-10 D275AX-5
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
1. Breather Outline
2. Oil level gauge • The damper dampens the torsional vibration
3. Drain plug caused by the change in engine torque and the
4. Output shaft impact torque generated when accelerating sud-
5. Flywheel denly or when carrying out heavy-duty digging.
6. Outer body In this way it acts to protect the torque converter,
7. Coupling transmission, and other parts of the power train.
8. Universal joint • This damper has few component parts: it uses a
9. Cover rubber coupling, so the vibration is absorbed by
10. Rubber coupling the damping effect of the rubber material.
11. Inner body
Operation
• This motive force from the engine passes
through flywheel (5) and it transmitted to outer
body (6).
• The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is trans-
mitted to inner body (11). It passes through uni-
versal joint (8), and is then transmitted to the
torque converter and transmission.
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size clearance limit
12 Clearance between flywheel Shaft Hole
housing and cover
– 0.022 + 0.070 0.022–
511.18 0.2
– 0.092 0 0.162
– 0.020 + 0.063 0.020– Replace

13 Clearance between flywheel and 466.72 0.2
damper – 0.083 0 0.146
Standard size Tolerance Repair limit

14 Outer circumference of coupling
oil seal contact surface 0
90 89.8
– 0.087
D275AX-5 10-11
(5)
MAINTENANCE STANDARD TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
10-12 D275AX-5
D275AX-5 10-13
1. Work equipment pump, HSS charge pump A. From power train pump (to torque converter
mounting port valve, transmission ECMV, and steering brake
2. HSS pump mounting port ECMV)
3. Power train oil strainer B. To oil cooler
4. Scavenging pump mounting port C. Torque converter oil inlet
5. Fan pump mounting port D. To transmission case (From torque converter case)
6. PTO lubrication tube E. To transmission case (To scavenging pump)
7. Power train, Steering lubricating oil pump F. From steering case and transmission case
mounting port (Oil pan pass)
8. Coupling
9. Input shaft [PTO drive gear (56 teeth)]
10. Idler gear (77 teeth)
11. Idler gear shaft
12. Torque converter case
13. Drive case
14. Turbine
15. Stator
16. Stator boss
17. Pump
18. Retainer
19. Shaft
20. Stator clutch rear housing
21. Stator clutch front housing
22. Stator shaft
23. Stator shaft boss (90 teeth)
24. Return spring
25. Stator clutch plate
26. Stator clutch disc
27. Stator clutch piston
28. Transmission input shaft
29. Turbine boss (90 teeth)
30. Lock-up clutch plate
31. Lock-up clutch disc
32. Lock-up clutch piston
33. Lock-up clutch housing
34. Pump drive gear (49 teeth)
(Work equipment, HSS charge pump, power
train, and steering lubricating oil pump)
35. HSS, Fan pump drive gear (49 teeth)
36. Scavenging pump drive gear (57 teeth)
37. Power train oil strainer
10-14 D275AX-5
(5)
Outline Structure
• The torque converter is the 3-element, 1-stage, • Pump (17) is combined with coupling (8), shaft
and 1-phase type, which is combined with the (9), clutch housing (33), and drive case (13) into
transmission into 1 unit. It is equipped with a 1 unit and rotated by the engine power.
torque converter lock-up device of the wet and • Turbine (14) is combined with turbine boss (29)
multiple disc type and a stator clutch to reduce and transmission input shaft (turbine shaft) (28)
the fuel consumption and increase the operabili- into 1 unit and rotated by the engine power.
ty and reduce the horsepower consumption by • Stator (15) is combined with stator boss (16),
the engine. stator shaft (22), and stator shaft boss (23) into
• For higher efficiency of continuous dozing and 1 unit and fixed to front housing (21) and rear
leveling work, the engine power should be trans- housing (20) through the stator clutch unit.
mitted directly to the input shaft of the transmis- • The lock-up clutch unit consists of clutch plate
sion. For this reason, the hydraulic lock-up (30) meshed with drive case (13), clutch disc
clutch is built in the torque converter. When the (31) meshed with turbine boss (29), and clutch
torque converter is locked up (the pump and tur- piston (32) which slides inside housing (33) com-
bine is combined into 1 unit), the oil supplied bined with the drive case into 1 unit.
from the torque converter relief valve does not • The stator clutch unit consists of clutch disc (26)
stop. Accordingly, the oil flowing from the pump meshed with boss (23) coupled with stator shaft
through the turbine is given an unnecessary di- (22) by the spline, clutch plate (25) supported by
rectional property and resists the revolution of the pins on front housing (21) and rear housing
the pump and turbine (agitates the oil). (20) of the clutch, and clutch piston (27) which
To avoid this, a stator clutch similar to the lock-up slides inside the front and rear housings.
clutch is installed so that the stator can rotate The front hosing and rear housing of the stator
freely together with the pump and turbine when clutch are bolted to the front housing of the trans-
the torque converter is locked up. As a result, mission R clutch.
the oil discharged from the pump and turbine is • The PTO unit consists of input shaft (9), idler
returned to the pump against less resistance. gear (10), scavenging pump drive gear (36),
work equipment pump and power train pump
★ The torque converter is set in the lock-up range drive gear (34), and HSS pump and fan pump
and torque converter range under the following drive gear (35).
conditions.
Lock-up range
★ Torque converter output shaft speed:
Above 1,420 rpm
Torque converter range

Torque converter output shaft speed:
Below 1,410 rpm
★ While the transmission gear is being shifted, the

torque converter is set in the torque converter
range.
D275AX-5 10-15
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
10-16 D275AX-5
Unit: mm

1 Outside diameter of coupling oil
seal contact surface 0
120 119.8
– 0.054
Repair hard
chrome plating or
2 Inside diameter of retainer seal + 0.040
150 150.5 replace
ring contact surface 0
3 Inside diameter of sleeve seal ring + 0.035

90 90.5
contact surface 0
Standard clearance Clearance limit

4 Backlash between PTO drive gear
and scavenging pump drive gear
0.204–0.512 –
5 Backlash between PTO drive gear

0.204–0.512 –
and driven gear
Standard size Repair limit

6 Wear of stator shaft seal ring
Width: 4.5 Width: 4.05
Height: 5.5 Height: 4.95
Thickness of disk 5.0 4.5

Lock-up clutch
7 Thickness of plate 5.0 4.5
Thickness of Replace
15.0 13.9
overall assembly
Thickness of disk 5.0 4.5

Stator clutch
8 Thickness of plate 5.0 4.5
Thickness of 15.0 13.9

overall assembly
Installed Installed Installed

Free length Free length
9 Stator clutch spring length load load
83.5N 79.3N
35 27.2 34.0
{8.5kg} {8.1kg}
D275AX-5 10-17
Power train route

1. When lock-up clutch is OFF
and stator clutch is ON
If the lock-up clutch is OFF, drive
case (13) and turbine (14) are
disconnected from each other. If
stator clutch is ON at this time,
rear housing (20) and stator shaft
(22) are connected to each other
to fix stator (15) and the lock-up
torque converter works as an or-
dinary torque converter. The en-
gine power is transmitted through
the damper and universal joint to
coupling (8) and rotates input
shaft (9), clutch housing (33),
drive case (13), and pump (17)
as 1 unit. The power of the pump
rotates turbine (14) through oil
and is transmitted to transmis-
sion input shaft (28) combined
with the turbine into 1 unit.
2. When lock-up clutch is ON and

stator clutch is OFF
If the lock-up clutch is ON, drive
case (13) and turbine (14) are
connected to each other. If stator
clutch is OFF at this time, rear
housing (20) and stator shaft (22)
are disconnected from each oth-
er and stator (15) is dragged and
rotated by pump (17) and turbine
(14). The engine power is trans-
mitted through the damper and
universal joint to coupling (8) and
rotates input shaft (9), clutch
housing (33), drive case (13),
and pump (17) as 1 unit. Since
drive case and turbine (14) are
connected by the clutch, the pow-
er is transmitted directly to trans-
mission input shaft (28) without
using the oil.
10-18 D275AX-5
Flow of oil
• The oil pressure is regulated to below
1.0 MPa {10.2 kg/cm2} by the torque
converter relief valve and the oil flows
through port C and oil hole of stator
clutch front housing (21) into pump
(17). Since the pump is rotated con-
stantly by the engine power, the oil in
the pump is given a centrifugal force
and put in turbine (14), then the turbine
is rotated by the centrifugal force of the
oil. Since the turbine is combined with
transmission input shaft (28), the pow-
er received by the turbine is transmitted
the transmission. The oil discharged
from the turbine is sent to stator (15)
and put in the pump again, but some of
it is sent from the stator through port B
to the oil cooler.
D275AX-5 10-19
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
10-20 D275AX-5
1. Cover A. From pump

2. Valve spring P. Stator clutch pressure pick-up port
3. Load piston P3. Lock-up clutch pressure pick-up port
4. Valve body P8. Main relief pressure pick-up port
5. Stator clutch modulating valve
6. Piston
7. Piston
8. Piston spring (small)
9. Cover
10. Lock-up clutch modulating valve
11. Valve spring (inside)
12. Valve spring (outside)
13. Shaft
14. Stopper
15. Load piston
16. Cover
17. Plug
18. Valve body
19. Valve spring
20. Lock-up changeover valve
21. Piston
22. Valve
23. Ball
24. Valve
25. Coil
26. Base
27. Case
28. Cap
29. Plunger
30. Shaft
D275AX-5 10-21
(5)
Outline
• The torque converter valve is installed to the top 3. Stator clutch modulating valve
of the torque converter case and consists of Modulating valve (5) regulates the clutch pres-
valves of the following 4 types. sure to 2.55 – 2.75 MPa {26 – 28 kg/cm2} to pro-
• The main relief valve and torque converter relief tect the stator clutch from abnormally high
valve are installed to the transmission case. pressure and heightens the pressure of the oil
1. Torque converter lock-up valve from lock-up changeover valve (20) gradually to
Lock-up changeover valve (20) turns ON and the specified level.
OFF the lock-up clutch and stator clutch. 4. Lock-up clutch modulating valve
2. Torque converter lock-up solenoid valve Modulating valve (10) regulates the clutch pres-
The solenoid valve receives electric signals from sure to 1.27 – 1.37 MPa {13 – 14 kg/cm2} similar-
the controller and changes the pilot pressure for ly to stator clutch modulating valve (5).
lock-up changeover valve (20) to turn ON and
OFF the 2 clutches.
10-22 D275AX-5
20-242 D155AX-5
TORQUE CONVERTER VALVE
10-24 D275AX-5
Unit: mm
Tolerance
Clearance between stator size clearance limit
1 clutch modulating valve and Shaft Hole
valve body
– 0.035 + 0.013 0.035–
25 0.08
– 0.045 0 0.058
Clearance between lock-up – 0.035 + 0.013 0.035–

2 clutch modulating valve and 25 0.08
– 0.045 0 0.058
valve body
Clearance between lock-up – 0.035 + 0.013 0.035–

3 25 0.08
valve and valve body – 0.045 0 0.058
Standard size Repair limit Replace
4 Stator clutch modulating Installed Installed Installed

valve spring length load load
197.0N 187.2N
103.5 92.7 100.4
{20.10kg} {19.10kg}
Lock-up clutch modulating 158.6N 150.7N

5 141.4 88.7 137.16
valve spring (outside) {16.18kg} {15.37kg}
6 Lock-up clutch modulating 80.5 80.5 – 78.09 –

valve spring (inside)
55.9N 53.1N
7 Lock-up valve spring 66 54.0 64.0
{5.7kg} {5.42kg}
D275AX-5 10-25
(5)
Operation of torque converter lock-up

valve and solenoid valve
• The torque converter lock-up valve supplies oil
for turning ON and OFF the lock-up clutch and
stator clutch installed in the torque converter.
The lock-up valve is operated by the pilot oil
pressure of the solenoid valve which operates
according to the electric signals from the lock-up
controller.
• If the electricity flows in the solenoid valve, the
drain circuit is closed to raise the pilot pressure
in the lock-up valve and operate the valve to lock
up the torque converter.
• If the lock-up valve operates, the oil in the stator
clutch is drained and the stator clutch becomes
free.
10-26 D275AX-5
Torque converter lock-up control system

System diagram
Operation
• The torque converter lock-up control system
controls the lock-up operation of the torque con-
verter automatically with a sensor signal and the
controller in it according to the load on the ma-
chine. When the torque converter is locked up,
the pilot lamp on the monitor panel lights up.
• The signal of the transmission outlet speed sen-
sor is input to the transmission controller.
• The lock-up mode is set with the mode selection
panel.
• The machine controller receives the gear speed
information from the transmission controller and
the transmission outlet speed sensor signal from
the SSC controller and turns ON and OFF the
lock-up system by connecting and disconnecting
the lock-up solenoid and pilot lamp to and from
the chassis ground.
D275AX-5 10-27
1. When traveling in torque converter range
While the machine is in the "torque converter cured by throttle A and regulated by modulating
range", the solenoid valve is deactivated and valve (5).
plunger (29) is returned up by the oil pressure
and the seats of valve (22) and ball (23) are sep-
arated and ports P and N are opened.
Since the drain circuit of port N is open, oil in port
M is also drained.
Since lock-up changeover valve (20) is pushed
to the right by spring (19), the passages between
ports Q and L and between S and T are closed
and the passages between Q and S and be-
tween L and R are opened. Then, the oil from
the pump flows through port Q into port S and
applies back pressure to the stator clutch piston
and excited the stator clutch when the circuit oil
pressure rises. At the same time, the oil which
has been applying back pressure to the lock-up
clutch piston is drained through port L into R and
the lock-up clutch is deactivated. The oil from
the pump flows in port P, too. It is drained
through throttle A, however, since the solenoid is
deactivated. The oil pressure in port Q is se-
10-28 D275AX-5
2. When traveling in direct range
While the machine is in the "direct range", the

solenoid valve is excited and plunger (29) is
pushed back down and the seats of valve (22) is
closed and ports P and M are opened and the
drain circuit of port N is closed. The oil from M
moves piston (21) and lock-up changeover valve
(20) to the left to close the passages between
ports Q and S and between ports L and R and
open the passages between ports Q and L and
between ports S and T. Then, the oil from the
pump flows through port Q into port L and ap-
plies back pressure to the lock-up clutch piston
and excited the lock-up clutch when the circuit oil
pressure rises. At the same time, the oil which
has been applying back pressure to the stator
clutch piston is drained through port S into T and
the stator clutch is deactivated. The oil pressure
in port L is regulated by modulating valve (10).
D275AX-5 10-29
Operation of modulation valves of stator

clutch and lock-up clutch
• The modulating valves are in the circuits be-
tween the lock-up changeover valve and the inlet
of the 2 clutches. When each clutch is turned
ON, the modulating valve in its circuit heightens
the oil pressure applied to the piston gradually to
the specified level to excited the clutch smoothly
and reduce the impacts given to the torque con-
verter and transmission.
★ The following is the explanation of the modulat-
ing valve for the stator clutch. Although the mod-
ulating valve for the lock-up clutch operates
similarly to that for the stator clutch, the oil flow
into the clutches in the direct range and torque
converter range is reversed, however.
1. When traveling in direct range

While the machine is in the "direct range", the
solenoid valve is excited and the oil in port M of
lock-up changeover valve (24) pushes piston
(21) and valve ( 20) to the left. Lock-up
changeover valve (20) is pushed to the left by the
oil pressure higher than the tension of spring
(19) and the passage between ports Q and S is
closed and the passage between ports S and T
is opened to drain the oil from port S through port
T. If the oil pressure in port S is lost, modulating
valve (5) is returned to the right by the tension of
spring (2) to open part B of port S fully. At this
time, the operating oil of the stator clutch is
drained from port S to port T and the clutch is de-
activated. The oil from the pump flows through
port Q to port L and the lock-up clutch is turned
ON.
10-30 D275AX-5
2. When traveling in torque converter range

While the machine is in the "torque converter
range", the solenoid valve is deactivated and the
oil from the pump and in port M is drained.
Valve (22) is moved to the right by the tension of
spring (19) and the passages between ports Q
and L and between ports S and T are closed and
the passage between port Q and S is opened.
As a result, the circuit is connected from port Q
through modulating valve (5) to the stator clutch.
The oil from the pump flows through port Q to the
stator clutch and the oil pressure in the circuit
starts rising.
If the circuit pressure rises, the oil flowing
through orifice d of modulating valve (5) pushes
piston (7). The reaction force of piston (7) moves
the modulating valve to the left to narrow part B
of port S.
Port S is connected to port U to apply back pres-
sure to load piston (3). Load piston (3) is moved
to the right to compress spring (2) and the ten-
sion of the spring opens part B of port S. This
operation is repeated intermittently to increase
the load on spring (2). During this operation, the
oil pressure rises gradually until part B of port S
is closed. Then, rise of the oil pressure is com-
pleted.
At this time, the stator clutch pressure is 2.65 ±
0.1 MPa {27.0 ± 1 kg/cm2}
+0.1
The lock-up clutch pressure is 1.3 0 MPa
+1 2
{13 0 kg/cm }.
D275AX-5 10-31
MAINTENANCE STANDARD SCAVENGING PUMP
SCAVENGING PUMP
BAR (3) 140
A. Discharge port
B. Suction port
Unit: mm
1 Spline shaft rotation torque –
Standard Permissible
Rotating Discharge
discharge discharge
Delivery Type speed pressure
amount amount –
(rpm) MPa ({kg/cm2})
_ (¬/min) (¬/min)
(Oil: E010-CD
Oil temperature: 45 - 55°C) 2.94
BAR140 2,500 – –
{30}
10-32 D275AX-5
(5)
MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
★ For steering operation concerned to operation of ★ PCCS: Abbreviation for Palm Command Control
PCCS lever, see STEERING AND BRAKE System
CONTROL.
1. Brake pedal Lever positions Outline

2. Safety lever 1 : Neutral • The transmission is controlled with PCCS le-
3. PCCS lever (Forward-Reverse, 2 : Forward ver (3).
Gear shift) 3 : Reverse The PCCS lever is used to select the travel
3A. UP switch 4 : OFF direction and shift the gear.
(Gear is shifted up each 5 : Shift UP • Since the safety mechanism is employed,
time this switch is pressed.) 6 : Shift DOWN transmission neutral safety switch (4) does
3B. DOWN switch 7 : Free not work and the engine does not start un-
(Gear is shifted down each 8 : Lock less safety lever (2) is in the LOCK position.
time this switch is pressed.)
4. Transmission neutral safety
switch
5. Cable
6. Transmission control valve
D275AX-5 10-33
(5)
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
10-34 D275AX-5
A. To forward clutch L. From power train pump

B. To reverse clutch M. To steering valve
C. To 3rd clutch N. To steering case
D. To 2nd clutch P. From steering case
E. To 1st clutch Q. Transmission lubrication oil inlet
F. To torque converter case R. Transmission 1st clutch pressure pick-up port
G. From torque converter case S. Transmission 3rd clutch pressure pick-up port
H. To scavenging pump T. Transmission R clutch pressure pick-up port
J. To torque converter case U. Transmission 2nd clutch pressure pick-up port
K. From scavenging pump V. Transmission F clutch pressure pick-up port
D275AX-5 10-35
(5)
10-36 D275AX-5
(5)
1. Main relief valve Outline

2. Transmission case
• The transmission consists of planetary gear sys-
3. Transmission control valve and valve cover as-
tems and disc clutches and has "3 forward gear
sembly
speeds and 3 reverse gear speeds".
4. Lubricating oil relief valve
• Among the 5 sets of planetary gear system and
5. Input shaft
disc clutch of the transmission, 2 clutches are
6. Reverse clutch sungear (34 teeth)
fixed hydraulically with control valves to select 1
7. Pinion shaft
rotating direction and rotating speed.
8. Ring gear of reverse travel (86 teeth)
• Clutches No. 1, No. 2, No. 3, No. 4, and No. 5 are
9. Planetary pinion for reverse travel (26 teeth)
fixed respectively when the reverse, forward,
10. Disc
3rd, 2nd, and 1st gears are selected.
11. Plate
12. Piston
13. Planetary pinion for forward travel (27 teeth) Number of plates and discs
14. Planetary pinion for 3rd gear speed (36 teeth)
Clutch No. Number of discs Number of plates
15. Ring gear for 3rd gear speed (Number of internal
teeth: 91, Number of external teeth: 109)
No.1 6 6
16. Sun gear for 2nd gear speed (39 teeth) No.2 8 7
17. Planetary pinion for 1st gear speed (21 teeth) No.3 4 5
18. Sun gear for 1st gear speed (49 teeth) No.4 4 5
19. Output shaft (Number of teeth of sun gear for 3rd No.5 3 4
gear speed: 20)
20. Ring gear for 1st gear speed (Number of internal
teeth: 91, Number of external teeth: 105) Gear speeds and operated clutches
21. 1st clutch carrier (90 teeth)
22. Clutch housing for 1st gear speed Gear speed Operated clutches (Turned ON)
23. Clutch housing for 2nd gear speed
Forward 1st No.2·No.5
24. Planetary pinion for 2nd gear speed (26 teeth)
Forward 2nd No.2·No.4
25. Ring gear for 2nd gear speed (Number of inter- Forward 3rd No.2·No.3
nal teeth: 90, Number of external teeth: 105) Neutral ª 1. No.5
26. Clutch housing for 3rd gear speed Reverse 1st No.1·No.5
27. Carrier for 2nd and 3rd gear speeds Reverse 2nd No.1·No.4
28. Clutch housing for forward travel Reverse 3rd No.1·No.3
29. Sun gear for forward travel (37 teeth)
30. Ring gear for forward travel (Number of internal ª1: While the transmission is in neutral, the 1st
teeth: 91, Number of external teeth: 105) clutch is filled with low-pressure oil and en-
31. Carrier for forward travel (86 teeth) gaged so that the machine can start without a
32. Clutch housing for reverse travel time lag.
33. Return spring
34. Ring gear for reverse travel (Number of internal
teeth: 90, Number of external teeth: 105)
35. Pin
36. Carrier for reverse travel (90 teeth)
D275AX-5 10-37
(5)
10-38 D275AX-5
Unit: mm

1 No. 1 clutch spring (12 pcs.) Free length Free length
length load load
174.6N 165.7N
91 71 88.3
{17.8 kg} {16.9 kg}
53.0N 50.0N
2 No. 2 clutch spring (12 pcs.) 84 79.8 81.5
{5.4 kg} {5.1 kg}
95.1N 90.2N
{9.7 kg} {9.2 kg}
93.2N 88.3N
4 No. 4 clutch spring (12 pcs.) 70 51 67.9
{9.5 kg} {9.0 kg}
83.4N 79.4N
{8.5 kg} {8.1 kg}
Thickness of clutch disc Standard size Tolerance Repair limit

6
(No. 1, 2 clutches)
5.4 ± 0.1 4.9
7 Thickness of clutch disc 5.4 ± 0.1 4.6

(No. 3 - 5 clutches)
8 Thickness of clutch plate 3.2 ± 0.1 2.9

(No. 1 - 5 clutches)
9 Total thickness of No. 1 clutch 51.6 ± 0.3 48.8
10 Total thickness of No. 2 clutch 65.6 ± 0.4 58.2 Replace
Backlash between each sun gear Standard clearance Clearance limit

14 and planetary pinion (Forward, re-
verse, 1st - 3rd gear speeds) 0.14–0.35 –
Backlash between each planetary

15 gear and internal teeth of ring 0.15–0.38 –
gear (Forward, reverse, 1st and
2nd gear speeds)
Backlash between planetary pin-

16 ion and internal teeth of ring gear 0.16–0.41 –
(3rd gear speed)
17 Backlash between carrier and in- 0.18–0.54 –

ternal teeth of ring gear (Reverse)
Backlash between each carrier

18 and internal teeth of ring gear 0.18–0.48 –
(Forward, 1st gear speed)
D275AX-5 10-39
Operation
1. Operation of disc clutch
• To lock ring gear (8) a disc clutch is used. The
clutch consists of piston (12), plates (11), discs
(10), pin (35) and piston return springs (33).
The internal teeth of the disc engage with the ex-
ternal teeth of the ring gear.
The teeth on the outside diameter of the plate
engage with pins (35) secured by housing (32).
Clutch engaged (locked)

• Oil from the control valve flows under pressure
through the port in housing (32) to the back of
piston (12).
The piston presses plates (11) and discs (10) to-
gether, and the resulting frictional force stops the
rotation of discs so ring gear (8) meshing with
the internal teeth of the disc is locked.
Clutch disengaged (free)

• When the supply of pressure oil from the control
valve is shut off, piston (12) is returned to its orig-
inal position by the force of piston return spring
(33). This relieves the frictional force between
plates (11) and discs (10), making the ring (8)
free.
10-40 D275AX-5
Oil circuit of 1st clutch

Since the 1st clutch is the farthest from the control
valve and has the longest circuit to the cylinder, it
takes the longest time to fill the circuit.
To solve this problem, the oil is supplied to the 1st
clutch even if the gear shift lever is in the NEUTRAL
position,
Accordingly, when the gear shift lever is shifted from
the NEUTRAL position to the F1 position, the pump
is required to supply oil of only quantity to fill the for-
ward clutch.
When the gear shift switch is changed from the F1 to
F2, the pump is required to supply fill of only quantity
to fill the 2nd clutch since the forward clutch has
been filled with the oil.
The time lag in the gear shifting operation is reduced
by using the oil as explained above.
D275AX-5 10-41
2. Forward 1st
• When the transmission is set to FORWARD 1st, • Carrier (21) is meshed with ring gear (25), and
the No. 2 clutch and No. 5 clutch are engaged. rotates as one unit, so the rotation is transmitted
The motive force from the torque conver ter to planet pinion (17).
transmitted to input shaft (5) is then transmitted • Ring gear (20) is being held in position by No. 5
to output shaft (19). clutch, so the rotation of planet pinion (17) ro-
• No. 2 clutch is actuated by the hydraulic pressure tates sun gear (18), and this rotates output shaft
applied to the clutch piston, and holds ring gear (19).
(30) in position. No. 5 clutch is actuated by the
hydraulic pressure applied to the clutch piston,
and engages ring gear (20).
• The motive force from the torque converter is
transmitted to input shaft (5), and the rotation of
the input shaft passes through sun gear (29) and
is transmitted to planet pinion (13).
• Ring gear (30) is held in position by No. 2 clutch,
so the rotation of planet pinion (13) rotates carri-
er (31), which is on the inside of ring gear (30).
• Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).
10-42 D275AX-5
3. Forward 2nd
• When the transmission is set to FORWARD 2nd • Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 4 clutch are engaged. spline, and rotate as one unit, so the rotation is
The motive force from the torque conver ter transmitted to planet pinion (24).
• No. 2 clutch is actuated by the hydraulic pressure tates sun gear (16), and this rotates output shaft
applied to the clutch piston, and holds ring gear (19).
D275AX-5 10-43
4. Forward 3rd
• When the transmission is set to FORWARD 3rd • Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 3 clutch are engaged. spline, and rotate as one unit, so the rotation is
The motive force from the torque conver ter transmitted to planet pinion (14).
• No. 2 clutch is actuated by the hydraulic pressure tates output shaft (19).
applied to the clutch piston, and holds ring gear
10-44 D275AX-5
5. Reverse 1st
• When the transmission is set to REVERSE 1st, carrier (31) passes through planet pinion (24)
the No. 1 clutch and No. 5 clutch are engaged. and is transmitted to ring gear (25).
The motive force from the torque converter • Carrier (21) is meshed with ring gear (25), and
transmitted to input shaft (5) is then transmitted rotates as one unit, so the rotation is transmitted
to output shaft (19). to planet pinion (17).
• No. 1 clutch is actuated by the hydraulic pres- • Ring gear (20) is being held in position by No. 5
sure applied to the clutch piston, and holds car- clutch, so the rotation of planet pinion (17) ro-
rier (36) in position. No. 5 clutch is actuated by tates sun gear (18), and this rotates output shaft
the hydraulic pressure applied to the clutch pis- (19).
ton, and engages ring gear (20).
• Carrier (36) is held in position by No. 1 clutch, so
the rotation of planet pinion (9) rotates ring gear
(8).
Ring gear (8) rotates in the opposite direction
from the input shaft, and rotates carrier (31).
• Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
D275AX-5 10-45
(5)
MAINTENANCE STANDARD TRANMISSION ECMV
TRANMISSION ECMV
(Electronic Control Modulation Valve)
10-46 D275AX-5
1. Proportional solenoid valve for 3rd clutch ECMV

2. Proportional solenoid valve for 1st clutch ECMV
3. Proportional solenoid valve for R clutch ECMV
4. Proportional solenoid valve for 2nd clutch ECMV
5. Proportional solenoid valve for F clutch ECMV
6. Fill switch for 3rd clutch
7. Fill switch for 2nd clutch
8. Fill switch for 1st clutch
9. Fill switch for R clutch
10. Fill switch for F clutch
11. Connector for 1st proportional solenoid valve
12. Connector for 3rd proportional solenoid valve
13. Connector for R proportional solenoid valve
14. Connector for 2nd proportional solenoid valve
15. Connector for F proportional solenoid valve
16. Connector for 3rd fill switch
17. Connector for 2nd fill switch
18. Connector for 1st fill switch
19. Connector for R fill switch
20. Connector for F fill switch
21. Filter
22. Pressure control valve
23. Oil pressure detection valve
24. Pressure control valve spring
A. 1st clutch operating pressure pick-up port

B. 3rd clutch operating pressure pick-up port
C. R clutch operating pressure pick-up port
D. 2nd clutch operating pressure pick-up port
E. F clutch operating pressure pick-up port
F. To clutch
P. From pump
T. Drain
D275AX-5 10-47
(5)
Outline of ECMV
• The ECMV (Electronic Control Modulation
Valve) consists of the following two units, a pres-
sure control valve and fill switch.
• Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
• Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1) It outputs a signal (fill signal) to the controller
as soon as the clutch is filled with oil to report
the completion of filling.
2) It outputs a signal (fill signal) to the controller
while an oil pressure is applied to the clutch
to report the presence/absence of oil pres-
sure.
A region: Before gear shift (When draining)
B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
ECMV and proportional solenoid

• One proportional solenoid is attached to one EC-
MV. After receiving the command current from
the controller, it produces thrust in the right fig-
ure.
By making the proportional solenoid-produced

thrust act on the pressure control valve spool, it
produces an oil pressure shown in the right fig-
ure. By controlling the amount of command cur-
rent, the thrust is changed to operate the
pressure control valve, controlling the oil flow
and oil pressure.
ECMV and fill switch

• One fill switch is attached to one ECMV. When
the clutch completes filling, the pressure of the
clutch turns "ON" the fill switch. By this signal,
the oil pressure starts build-up.
10-48 D275AX-5
(5)
Operation of ECMV
• The ECMV is controlled by the command current
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relation among the proportional solenoid
command current of the ECMV, the clutch input
pressure, and fill switch output signal is as
shown in the figure to the right.
A region: Before gear shift (When draining)

B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
• The clutch is crimped by the piston when shifting

the gear with the gear shift switch. If a high oil
pressure is applied suddenly, however, the pis-
ton connects to the clutch suddenly, causing the
machine to make a sudden start and give an ex-
cessive shock to the machine.
To prevent them, it is designed so that if you con-
nect the ECMV to shift gears with the gear shift
switch, the oil pressure to the clutch may be
gradually increased up to the specified level. By
this design, the clutch is excited smoothly to
eliminate the shock at the start, improve the du-
rability of the power transfer system, and also
provide operator comfort.
1. Before gear shift (Region A in the diagram)

When a current is not carried to the proportional
solenoid (1), the pressure control valve (2) is
draining the oil at the clutch port A through the
drain port dr.
Since, at that time, no oil pressure acts on the oil
pressure detection valve (3), the fill switch (4) is
OFF.
D275AX-5 10-49
2
2. When filling (When inputting the trigger com-

mand to the pressure control valve)
(B and C regions in the diagram)
If you supply a current to the proportional sole-
noid (1) with no oil in the clutch, an oil pressure
proportional to the solenoid force acts on the
chamber B, pushing the pressure control valve
(2) rightward. This operation opens the pump
port P and clutch port A to start filling the clutch
with oil. When the clutch is filled with oil, the fill
switch (4) is turned ON.
3. Pressure regulation (D region in the diagram)

If you flow a current to the proportional solenoid
(1), the solenoid produces thrust proportional to
the current. Pressure is regulated by striking a
balance among the thrust of the solenoid, the
thrust of the oil pressure of the clutch port, and
reaction force of the pressure control spring (5).
10-50 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Body Outline
2. Torque converter relief valve
3. Valve spring
Main relief valve (6) sets the set pressure of the
4. Piston
oil pressure for the transmission, steering clutch,
5. Piston spring
and brake.
7. Valve spring 2. Torque converter relief valve
8. Piston spring Torque converter relief valve (2) acts to protect
9. Piston the torque converter from abnormally high pres-
sure by relieving the circuit if the torque convert-
A. Drain port (for torque converter relief) er inlet port pressure rises above the set
B. Drain port pressure.
C. From pump Unit: MPa {kg/cm2}
D. Drain port Set pressure
E. To torque converter
P1. Main relief oil pressure detection port Main relief pressure 3.2 ± 0.1{32.7 ± 1.0}
P8. Torque converter relief oil pressure detection
Torque converter relief
port 0.98 ± 0.05{10.2 ± 0.5}
pressure
10-52 D275AX-5
(5)
Unit: mm
Tolerance
Clearance between main relief size clearance limit
10 Shaft Hole
valve and valve body
– 0.035 + 0.013 0.035–
28 0.08
– 0.045 0 0.058
Clearance between main relief – 0.020 + 0.018 0.020–

11 19 0.07
valve and piston – 0.030 0 0.048
Clearance between torque
– 0.035 + 0.013 0.035–
12 converter relief valve and valve 22 0.08
– 0.045 0 0.068
body
Clearance between torque – 0.020 + 0.021 0.020–
13 15 0.07
converter relief valve and piston – 0.030 0 0.051

Replace
Main relief valve spring Free length Free length
14 length load load
(outside)
481N 457N
122 78 118.3
{49kg} {46.6kg}
Main relief valve spring 368N 349N

15 108 78 104.8
(inside) {37.5kg} {35.6kg}
7.32N 6.96N
16 Main relief valve piston spring 30 25 29.1
{0.746kg} {0.71kg}
Torque converter relief valve 182N 174N

17 50 41.5 48.5
spring {18.6kg} {17.7kg}
Torque converter relief valve 4.87N 4.61N

18 26 20 25.2
piston spring {0.497kg} {0.47kg}
D275AX-5 10-53
(5)
Operation of main relief valve

• The oil from power train pump passes through
the filter, enters port A of the main relief valve,
then passes through orifice a and enters port B.
When the oil from the pump fills the circuit, the oil
pressure starts to rise.
• As the oil pressure in the circuit rises, the oil en-
tering port B pushes piston (4). The reaction
compresses spring (7), moves main relief valve
(6) to the left in the arrow direction, and opens
ports A and C.
Then, the oil from the pump is relieved from port
A to port C, then flows from port C to the torque
converter.
The oil pressure at port A at this point is 3.2 ± 0.1
MPa {32.7 ± 1.0 kg/cm2}.
Operation of torque converter relief valve

• The oil relieved by the main relief valve flows
from port C to the torque converter, and at the
same time, passes through orifice b and enters
port D.
When the passage to the torque converter is
filled with oil, the oil pressure starts to rise.
• As the oil pressure to the torque converter rises,
the oil entering port D pushes piston (9). The re-
action compresses spring (3), moves relief valve
(2) to the right in the arrow direction, and opens
ports C and E.
Then, the oil from port C is relieved to port E and
is drained to the oil tank.
The oil pressure at port C at this point is
0.98±0.05MPa {10.2±0.5 kg/cm2}.
10-54 D275AX-5
(5)
MAINTENANCE STANDARD POWER TRAIN PUMP, STEERING LUBRICATION PUMP
POWER TRAIN PUMP, STEERING LUBRICATION PUMP

SAR (3) 100 + 50
Unit: mm
Standard
Type Clearance limit
clearance
1 Side clearance
SAR (3) 100 0.13–0.18 0.22
SAR (3) 50 0.10–0.15 0.19
Clearance between plain SAR (3) 100

2 bearing inner diameter and gear 0.060–0.149 0.20 Replace
shaft outer diameter SAR (3) 50
Type Standard size Tolerance
3 Pin driving depth SAR (3) 100 0

14
SAR (3) 50 – 0.5
4 Spline shaft rotation torque 13.7–73.5Nm{1.4–2.4kgm}
Delivery
Standard Delivery
Speed pressure
Type delivery limit
Delivery (rpm) MPa
(¬/min) (¬/min)
{kg/cm2}
– –
(Oil: EO10-CD
Oil temperature: 45 – 50°C) SAR (3) 100 32.7±1 188 174
2,300rpm
SAR (3) 50 3±0.3 94 86
D275AX-5 10-55
(5)
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
1. Forward clutch housing • The lubrication relief valve is installed to the right
2. Spring side face of the forward clutch housing. And pre-
3. Piston vents any abnormal pressure in the lubrication
oil.
A. From oil cooler
B. Drain Unit: MPa {kg/cm2}
C. Drain
Set pressure
Outline Pressure when normal 0.14 ± 0.05 {1.4 ± 0.5}

• The oil leaving the torque converter passes
through the oil cooler built in the radiator lower Cracking pressure 0.30 ± 0.03 {3.0 ± 0.3}
tank. It then goes through the lubrication relief
valve and lubricates the transmission and PTO.
10-56 D275AX-5
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
Unit: mm

4 Lubrication relief valve spring length load load Replace
12.5N 11.9N
26 23.6 25.2
{1.27kg} {1.21kg}
D275AX-5 10-57
MAINTENANCE STANDARD HSS SYSTEM
HSS SYSTEM
10-58 D275AX-5
MAINTENANCE STANDARD HSS SYSTEM
1. PCCS lever A. Travel REVERSE signal 2

2. HSS controller B. Travel; REVERSE signal 1
3. Servo valve C. Steering signal 1,2
4. HSS pump D. Engine speed signal
5. Engine E. Hydraulic pressure signal
6. Hydraulic pump F. Steering circuit pressure signal A
7. Hydraulic valve G. Steering circuit pressure signal B
8. Sproket
9. Final drive
10. HSS motor
11. HSS closed circuit
12. Motor free solenoid
Outline
• The HSS system is a hydraulic system; HSS
stands for hydraulic Steering System.
• The HSS system consists of a set of piston pump
and piston motor as shown in the diagram. With
this system, it is possible to turn continuously by
generating a difference in speed between the left
and right tracks.
There is no need to reduce speed.
• The HSS controller controls the angle of the
swash plate in the HSS pump according to the
angle of operation of the monolever, and controls
the speed and directional of rotation of the HSS
motor.
The HSS motor uses the planetary gear system
of the bevel gear shaft to create a difference in
the speed of the left and right sprockets, and this
turns the machine.
• The HSS controller detects the speed of the en-
gine and the hydraulic pressure at all parts, and
controls the swash plate angle of the HSS pump
to ptevent the engine from stalling.
D275AX-5 10-59
MAINTENANCE STANDARD HSS PUMP
HSS PUMP
HPV160
1. Servo valve connector 5. Suction safety valve

2. Piston pump 6. Charge safety valve
3. Servo piston 7. Plug for measuring (PA and PB pump pressure)
4. Servo valve
Outline
• The pump is composed of variable displacement
piston pump with swash plate, servo valve, suc-
tion safety valve, and charge safety valve.
10-60 D275AX-5
1. PISTON PUMP
★ A figure shows the state where the Servo valve was removed from the HSS pump.
PSVO : Servo valve source pressure PSVA : Servo valve output

PB : Pump inlet and outlet port PSVB : Servo valve output
PA : Pump inlet and outlet port PSV1 : Servo valve source pressure
PD2 : Pump drain port PC : Charge pressure
PR : Charge safety valve relief pressure
D275AX-5 10-61
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Servo piston 12. Bearing
6. Slider 13. Spline
7. Shoe 14. Bearing
Outline
• The rotation torque transmitted to the pump shaft • Rocker cam (4) has plane A, and shoe (7) is al-
is converted to hydraulic energy and pressurized ways pressed against this surface as it slides in
oil is discharged according to the load. a circle.
• It is possible to charge the delivery amount (nor- • Rocker cam (4) sends high pressure oil to the
mal delivery ↔ 0 ↔ reverse delivery) by chang- space between cylindrical surface B and cradle
ing the swash plate angle. (3) fixed to the case (2), to form a hydrostatic
bearing and carries out a rocking movement.
Structure
• Piston (8) carries out motion relative to the axial
• Cylinder block (9) is supported to shaft (1) by a direction inside each cylinder chamber of cylin-
spline (13), and shaft (1) is supported by front der block (9).
and rear bearings (12) and (14). • Cylinder block (9) carries out rotation relative to
• The end of piston (8) has a concave ball shape, valve plate (10) while sealing the pressurized oil,
and shoe (7) is caulked to it to form one unit. Pis- and this surface ensures that the hydraulic bal-
ton (8) and shoe (7) form a spherical bearing. ance is maintained correctly. The oil inside each
cylinder chamber of cylinder block (9) is sucked
in and discharged through valve plate (10).
10-62 D275AX-5
Operation
1. Operation of pump
• Cylinder block (9) rotates together with shaft (1),
and shoe (7) slides on plane A.
When this happens, angle α of center line X of
rocker cam (4) to the axial direction of cylinder
block (9) changes. This angle α is called the
swash plate angle.
1) With swash plate angle α formed by the an-
gle between center line X of rocker cam (4)
to the axial direction of cylinder block (9),
plane A acts as a cam for shoe (7). In this
way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated
between volumes E and F inside the cylinder
block. The amount of suction and discharge
is equal to difference F - E.
In other words, cylinder block (9) rotates, and
the volume of chamber F becomes smaller,
so oil is discharged during this process. At
the same time, the volume of chamber E be-
comes larger and oil is sucked in as the vol-
ume increases.
2) When center line X of rocker cam (4) is the
same as the axial direction of cylinder block
(9) (swash plate angel = 0), the difference
between volumes E' and F' inside cylinder
block (9) is 0, so no oil flows in or out, and no
pumping is carried out.
3) With swash plate angle α formed by the an-
gle between center line X of rocker cam (4)
to the axial direction of cylinder block (9),
plane A acts as a cam for shoe (7). In this
way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated
between volumes E'' and F'' inside the cylin-
der block. The amount of suction and dis-
charge is equal to difference F'' - E''.
In other words, cylinder block (9) rotates, and
the volume of chamber E'' becomes smaller,
so oil is discharged during this process. At
the same time, the volume of chamber F''
becomes larger and oil is sucked in as the
volume increases. When the swash plate an-
gle changes, the suction/discharge action of
ports PA and PB is reversed.
D275AX-5 10-63
2. Control of discharge amount

1) If swash plate angle α becomes larger, the
difference between volumes E and F be-
comes large, and oil delivery Q is increased.
Swash plate angle α is changed by servo
piston (5).
Servo piston (5) carries out reciprocal move-
ment in a straight line (↔) according to the
command from the valve. This straight-line
movement is transmitted to rocker cam (4)
through slider (6), and rocker cam (4), which
is supported on the cylindrical surface by
cradle (2) slides on the cylindrical surface (
direction).
In the case of the pump, swash plate angle α
is a maximum of ±19°.
10-64 D275AX-5
2. Servo valve
1. Connector PSV1：Servo valve source pressure

2. Solenoid valve B PSVB：Servo valve outlet pressure
3. Connector PSVA：Servo valve outlet pressure
4. Solenoid valve A
5. Shaft
6. Coil
7. Base
8. Lever 1
9. Spring
10. Lever 2
11. Body
12. Screw
13. Arm
14. Spool
D275AX-5 10-65
Operation
1) When pressurized oil (servo source pres-
sure) does not enter from the charge pump
or when is no current flowing to solenoid
valve coil (6), the servo valve and servo pis-
ton (15) are not actuated.
10-66 D275AX-5
2) When the current flows to solenoid valve coil

(6) and coil is excited, solenoid propulsion
force f1 is generated and shaft (5) pushes
spool (14) to the right in the direction of the
arrow. Lever 2 (10), which is interconnected
with spool (14), uses screw (12) as a fulcrum
and rotates clockwise while pulling spring
(9).
3) When spool (14) moves, the passages be-
tween ports A and B and ports D and E
open, and pressurized oil from the charge
pump passes through ports A and B and
flows to port F of servo piston (15).
At the same time, the oil at port G passes
through ports D and E, and is drained.
D275AX-5 10-67
4) Servo piston (15) is moved to the right in the

direction of the arrow by the pressurized oil
entering port F, and the swash plate angle of
the variable pump becomes larger by an
amount equal to stroke a of the servo piston.
At the same time, arm (13), which is con-
nected to servo piston (15) rotates arm (13)
around screw (12) as a fulcrum, and lever 1
(8) is moved to the left. Servo piston (15)
stops in a position where solenoid propulsion
force f1 is balanced with spring force f2.
10-68 D275AX-5
5) The stroke of the servo piston, which chang-

es the delivery amount of the variable pump,
is controlled by the servo valve. The relation-
ship between the stroke of the servo piston
and the current of the solenoid valve is as
shown in the diagram.
D275AX-5 10-69
3. Suction safety valve
1. Charge pump Function

2. HSS pump • There are two suction safety valves installed to
3. Oil cooler the HSS pump, and they have the following func-
4. Charge safety valve tions.
5. Suction safety valve 1) High pressure relief valve
5A. Valve The valve restricts the maximum pressure in-
5B. Piston side the HSS circuit in order to protect the
5C. Sleeve HSS circuit and to restrict the maximum
5D. Poppet steering foree of the machine.
5E. Valve seat 2) Suction safety valve
5F. Spring The valve ensures the flow of charge oil to
5G.Pressure adjustment screw: one turn adjusts the HSS circuit and prevents the charge oil
pressure by approx. 13.7 MPa {140kg/cm2} from flowing into the pump high pressure
side (delivery side).
6. HSS motor
10-70 D275AX-5
Operation when acting as high pressure relief

valve (Valve at piston pump delivery side)
• Port A is connected to the piston pump circuit
and port B is connected to the charge circuit.
The pressurized oil also fills port C through drill
hole a in piston (5B). In addition, poppet (5D) is
in tight contact with valve seat (5E).
• If abnormal pressure is generated in the piston

pump circuit and the oil pressure at port A and C
reaches the pressure set by spring (5F), poppet
(5D) is pushed to the right in the direction of the
arrow, and the oil at port C is relieved from port
D to port B to reduce the oil pressure at port C.
• When the oil pressure at port C goes down, a dif-

ferential pressure is generated between port A
and port C by orifice b in piston (5B). Valve (5A)
is pushed to the right in the direction of the arrow
by the oil pressure at port A, and the oil at port A
is relieved to port B. In this way, the piston pump
circuit is prevented from reaching any higher
pressure.
D275AX-5 10-71
Operation when acting as suction safety valve
1. When HSS pump delivery is 0

• The HSS circuit is closed, and the charge pres-
sure oil does not flow into the HSS circuit. There-
fore, the charge pressure oil from the charge
pump all passes through charge safety valve
(with coin filter) (4) and is drained through oil
cooler (3) to the tank.
2. When HSS pump delivery is discharged from

port PA
1) Valve at piston pump delivery side
• When pressure oil is discharged from
port PA of HSS pump (2), port PA be-
comes the high pressure side. This pres-
sure oil at port PA passes through drill
hole a in piston (5B) and flows to port A.
When this happens, valve (5A) is pushed
to the left in the direction of the arrow
against sleeve (5C) because of the differ-
ence in area (A1>A2). Therefore, the
pressure oil from charge pump (1) is pre-
vented from flowing into the HSS closed
circuit.
10-72 D275AX-5
2) Valve at piston pump suction side

• Port PB becomes the suction side, so it
becomes the low pressure side. Be-
cause of the difference in area (A1>A2),
valve (5A) is pushed to the right in the di-
rection of the arrow by the charge pres-
sure oil and the seat of sleeve (5C)
opens. As a result, the charge pressure
oil at port B passes through the gap and
flows to port PB to carry out the charge
function for the HSS circuit.
D275AX-5 10-73
4. Charge safety valve
1. Charge pump 4C. Valve seat

2. HSS pump 4D. Poppet
3. Oil cooler 4E. Spring
4. Charge safety valve 4F. Pressure adjustment screw
4A. Valve 5. Suction safety valve
4B. Spring 6. HSS motor
Function
• The charge safety valve is installed to the HSS
pump between the suction safety valve and the
oil cooler. It acts to restrict the maximum pres-
sure in the charge circuit.
★ Set pressure:
3.7 MPa {38kg/cm2} at 204 ¬/min
10-74 D275AX-5
Operation
• Port A is connected to the charge circuit, and
port B is connected to the tank drain circuit. The
pressure oil passes through orifice a in valve
(4A) and fills C. Poppet (4D) is in tight contact
with valve seat (4C).
• If abnormal pressure is generated in the circuit or

the shuttle valve of the HSS motor is at neutral,
and the pressure oil at ports A and C reaches
the pressure set by spring (4E), poppet (4D) is
pushed to the right in the direction of the arrow,
and the oil at C is relieved to port D to reduce the
pressure of the oil at C.
• When the pressure of the oil at port C goes

down, a differential pressure is created between
ports A and C because of orifice a in valve (4A).
Valve (4A) is pushed to the right in the direction
of the arrow by the oil pressure at port A, and the
oil at port A is relieved to port B. In this way, the
pressure in the charge circuit is prevented from
going any higher.
• Drain port D at the poppet portion is drained to

the HSS pump case, so the back pressure of
drain port B is not added to the charge relief
pressure, and the valve always displays the set
relief characteristics.
D275AX-5 10-75
MAINTENANCE STANDARD HSS MOTOR
1. Output shaft 10. Flashing shuttle valve

2. Motor case 11. Plug
3. Swash plate 12. Spool return spring
4. Piston 13. Bypass valve
5. Cylinder block 14. Charge relief valve
6. Valve plate 15. Bearing (rear)
7. End cover 16. Spline
8. Cover 17. Shoe
9. Return spring 18. Bearing (front)
Unit: mm

Free length Installed Installed Installed
Free length
× OD length load load
19 Spool return spring
Replace spring
530N 498N if damaged or
43.5 × 28.7 36.0 –
{54kg} {50.8kg} deformed
294N 297N
20 Spool return spring 48.5 × 21 41.0 –
{30kg} {38.2kg}
D275AX-5 10-77
Outline
• Pressurized oil sent from pump is converted to
rotation energy and is transmitted to output
shaft.
Structure
• Cylinder block (5) is supported to shaft (1) by a
spline (14), and shaft (1) is supported by front
and rear bearings (16) and (13).
• The end of piston (4) has a concave ball shape,
and shoe (15) is caulked to it to form one unit.
• Piston (4) and shoe (15) form a spherical bear-
ing.
• Piston (4) carries out motion relative to the axial
direction inside each cylinder chamber of cylin-
der block (5).
• Cylinder block (5) carries out rotation relative to
valve plate (6) while sealing the pressurized oil,
and this surface ensures that the hydraulic bal-
ance is maintained correctly. The oil inside each
cylinder chamber of cylinder block (5) is sucked
in and discharged through valve plate (6).
10-78 D275AX-5
3. Bypass valve
Function
• When the machine carries out a pivot turn, the
HSS motor receives a reverse force from the
steering brake and is rotated at high speed. At
this time, the bypass valve is changed according
to the signals from the pivot turn solenoid to add
a passage so that the oil will circulate inside the
motor and the load on the HSS motor rotating at
high speed will be reduced.
Operation
(1) When the pivot turn solenoid is deactivated
• Bypass valve spool (1) is in neutral. The quantity
of the oil circulating in the HSS circuit is equiva-
lent to discharge Q of the motor.
(2) When the pivot turn solenoid is turned ON

• Bypass valve spool (1) is pushed to the right as
indicated by the arrow and MA and MB are con-
nected to each other and the oil circulates inside
the motor. Quantity Q1 of the oil circulating in
the HSS circuit is the difference between dis-
charge Q of the motor and flow rate Q2 of the oil
circulating inside the motor.
Q1 = Q – Q2
10-82 D275AX-5
4. Charge relief valve
1. Charge pump 8. Charge relief valve

2. HSS pump 8A. Valve
3. Oil cooler 8B. Spring
4. Charge safety valve 8C. Valve seat
5. Suction safety valve 8D. Puppet
6. HSS motor 8E. Spring
7. Shuttle valve 8F. Pressure adjustment screw
8G. Filter
Function
• The charge relief valve is installed to the HSS
motor. It maintains the minimum pressure on the
low pressure side of the circuit to secure the suc-
tion performance of the HSS pump.
★ Set pressure:
2.3 MPa {23kg/cm2} (at 120¬/min)
D275AX-5 10-83
Operation
• While the HSS pump is discharging oil through
port PA or PB, the oil on the low pressure side of
the HSS circuit flows through port MA or MB and
shuttle valve (7) to inlet port A of charge relief
valve (8).
• The oil in port A also fills port C through orifice a

of valve (8A). At this time, puppet (8D) is fitted to
valve seat (8C).
• If the oil pressure in port C rises to the level set

with spring (8E), puppet (8D) is pushed to the
right as indicated by the arrow and the oil in port
C is relieved to port D, thus the oil pressure in
port C lowers.
• If the oil pressure in port C lowers, differential

pressure is generated between ports A and C
because of orifice a. As a result, valve (8A) is
pushed to the right as indicated by the arrow and
the oil in port A is relieved to port B.
By this operation, the oil pressure in the charge
circuit is kept at the set pressure of charge relief
valve (8). This charge pressure keeps supplying
the oil to the closed HSS circuit.
• Since drain port D of the puppet is joined to the

drain part of the HSS motor, the back pressure
on drain port B is not added to the charge relief
pressure and the specified relief characteristics
are maintained.
10-84 D275AX-5
MAINTENANCE STANDARD PPC, HSS CHARGE FILTER
PPC, HSS CHARGE FILTER
1. Plug A. To HSS motor

Performance
2. Cover B. To filter bypass valve
3. Spring C. From charge pump Mesh size (µm) 30/8
4. Plate
5. Element Filtering area (cm2) 5,400
6. Case
Oil flow (¬/min) 138
D275AX-5 10-85
MAINTENANCE STANDARD HSS CHARGE FILTER BYPASS
HSS CHARGE FILTER BYPASS
C1. To HSS motor Outline

C2. To HSS pump When the difference between the charge inlet pres-
P. Charge filter outlet sure and charge outlet pressure is increased, the
P1. Charge filter inlet HSS charge filter bypass valve drains the oil into the
T. To hydraulic tank tank without sending it to the HSS charge circuit.
(Cracking differential pressure:
490 ± 98 kPa {5 ± 1 kg/cm2})
Unit: mm
Standard Tolerance Standard Clearance

Clearance between filter bypass size Shaft Hole clearance limit
1
valve and valve body
– 0.035 + 0.013 0.035–
28 0.08
– 0.045 0 0.058
Clearance between filter bypass – 0.020 + 0.018 0.020–
2 15 0.06
valve and piston – 0.030 0 0.048 Replace
3 Filter bypass valve spring Free length Free length
length load load
71.15N
70.3 64.3 – –
{7.26kg}
10-86 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD HSS OIL COOLER BYPASS VALVE
HSS OIL COOLER BYPASS VALVE
1. Plug A. From charge relief valve

2. Valve B. To hydraulic tank
3. Shim C. From oil cooler
4. Plug D. To oil cooler
5. Spring E. From charge safety valve
6. Body
Outline
• This valve is installed in the circuit between the
HSS pump and HSS motor charge relief valve oil
return circuit and the oil cooler. If any abnormal
pressure is generated in the oil flowing to the oil
cooler, this valve acts to return the oil directly to
the hydraulic tank.
Set pressure
Cracking pressure
0.487 {4.97}
MPa{kg/cm2})
10-88 D275AX-5
MAINTENANCE STANDARD HSS OIL COOLER BYPASS VALVE
Unit: mm
Tolerance
Clearance between oil cooler by- size Shaft Hole clearance limit
1
pass valve and valve body
– 0.035 + 0.013 0.035–
22 0 0.08
– 0.045 0.058
Replace
2 Spring length load load
156.9N 149.1N
52 46 50
{16kg} {15.2kg}
D275AX-5 10-89
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

• Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
TRANSMISSION CONTROL.
• PCCS: Palm Command Control System
10-90 D275AX-5
(5)
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
1. Brake pedal Positions of levers and pedals

2. Safety lever 1 : Neutral
3. PCCS lever (Steering) 2 : Forward straight
4. Steering controller 3 : Reverse straight
5. Limit switch 4 : Left clutch OFF
6. Steering ECMV 5 : Left clutch OFF
7. Brake valve Left brake ON
8. Parking brake lever (From safety lever) 6 : Right clutch OFF
9. Cable 7 : Right clutch OFF
10. Rod (From brake pedal) Right brake ON
11. Potentiometer 8 : Brake OFF
9 : Brake ON
0 : Free
A : Lock
Outline
• PCCS lever (3) sends electric signals to steering • Safety lever (2) is connected to parking brake le-
controller (4). Upon receiving those signals, ver (8) and used as the parking brake lever, too.
steering controller (4) sends signals to HSS
Pump servo to changes the discharge of the
pump to operate the starting motor.
• Brake pedal (1) sends electric signals through
potentiometer (11) to steering controller (4).
Upon receiving this signal, steering controller (4)
sends proportional current to ECMV (6) to oper-
ate the brake. Rod (10), as a redundant device,
operates the brake through brake valve (7) (only
in the complete braking mode).
D275AX-5 10-91
(5)
20-242 D155AX-5
MAINTENANCE STANDARD BEVEL GEAR SHAFT, HSS, BRAKE
BEVEL GEAR SHAFT, HSS, BRAKE
D275AX-5 10-93
10-94 D275AX-5
1. Cover A. To transmission case (power train pump)

2. Output shaft B. From transmission case (scavenging pump)
3. Bearing cage C. To pin puller solenoid valve
4. Spring D. From pin puller solenoid valve
5. Brake piston (140 teeth) E. Drain plug
6. Return spring F. Left brake oil pressure pick-up port
7. Brake plate (6 pcs. on each side) G. Right brake oil pressure pick-up port
8. Brake disc (7 pcs. on each side)
9. Brake outer drum (140 teeth)
10. Brake inner drum
11. Bearing cage
12. Shim (For adjustment of bevel gear)
13. Bearing A
14. Bevel gear shaft
15. Bevel gear (40 teeth)
16. Bearing B
17. Carrier
18. Ring gear (111 teeth)
19. Planetary pinion gear (35 teeth)
20. Hub (111 teeth)
21. Sun gear (41 teeth)
22. Shim (For adjustment of bevel pinion)
23. Bearing cage
24. Bearing
25. Nut (For adjustment of preload on bearing)
26. Bevel pinion (21 teeth)
27. Gear E (For driving right sun gear) (50 teeth)
28. Gear D (16 teeth)
29. Shaft
30. HSS motor
31. Pinion (20 teeth)
32. Gear A (34 teeth)
33. Gear C (16 teeth)
34. Gear B (For driving left sun gear) (50 teeth)
D275AX-5 10-95
10-96 D275AX-5
Unit: mm

Thickness of brake plate Replace
2.9 2.6
35
Tolerance Repair limit
Strain of brake plate Repair or replace
Max. 0.3 0.4

Thickness of brake disc Replace
4.5 4.0
36
Tolerance Repair limit
Strain of brake disc Repair or replace
Max. 0.3 0.4

Total thickness of brake plates
37
and discs
48.9 45.3

Backlash between brake disc and
38
brake inner drum
0.42–0.72 1.0
Backlash between sun gear and
39 0.14–0.39 0.60 Replace
planetary pinion
Backlash between planetary pin-
40 0.16–0.40 0.70
ion and ring gear
Tolerance
Sealing fitting face of small end of size Shaft Hole clearance limit
41 brake piston
– 0.100 + 0.072 0.100–
220 –
– 0.172 0 0.244
Backlash between gear A and
42
pinion
0.20–0.48 0.70
43 0.08–0.72 0.70 Replace
gear C
Backlash between gear D and
44 0.19–0.46 0.80
gear E
45 0.10–0.58 0.80
gear B
Backlash between bevel gear and
46 0.25–0.33 0.50 Adjust or replace
pinion
D275AX-5 10-97
2
Outline
Bevel gear shaft Brake
• The bevel gear shaft device changes the output • The brake is installed specially to stop the ma-
power of the transmission by a right angle to the chine and connected to brake inner drum (10).
lateral directions and reduce the output speed by • The brake is the wet, multiple disc clutch, and
using a bevel pinion and a bevel gear. spring boosted type, which is operated hydrauli-
• The bevel gear shaft device has a spiral bevel cally with the oil from the brake valve connected
pinion and spiral bevel gear and is lubricated to the brake pedal.
forcibly with pressurized oil. • The brake is lubricated forcibly with oil sent from
• The bevel gear shaft device consists of bevel pin- the steering lubricating oil pump through the
ion (26) meshed with bevel gear (15), bevel gear housing, cage, discs, and plates.
shaft (14), and bearings (13) and (16) to support • The brake consists of inner drum (10) [connect-
the bevel gear shaft. ed to brake outer drum (9) and carrier (17)],
discs (8), plates (7), brake outer drum (9), piston
(5), spring (4), bearing cage (3) to support those
HSS
parts, brake cover (1), and output shaft (2).
• The HSS (Hydrostatic Steering System) consists
Brake outer drum (9) and brake cover (1) are
of the transfer unit which reverses the rotating di-
fixed to the HSS case.
rection of HSS motor (30) and transmits it to sun
Output shaft (2) is connected to brake inner
gear (21) and the planetary unit which adjusts
drum (10) by spline.
and outputs the input. It changes the turning di-
• If the engine is stopped, the back pressure on
rection of the machine by stopping or reversing
the brake piston lowers and the brake is turned
the rotation of the HSS motor.
ON automatically. If the engine is started again,
• The transfer unit has a spur gear speed reducing
the oil pressure in the circuit rises and the brake
mechanism.
is deactivated. Since this is dangerous, be sure
• The transfer unit is lubricated forcibly with the oil
to set the parking brake to the LOCK position.
sent from the steering lubricating oil pump.
• The planetary unit is lubricated forcibly with the
oil sent from the steering lubricating oil pump.
• The transfer unit consists of HSS motor pinion
(31), gear A (32), gear C (33), shaft (29), gear D
(28), gear E (27), gear B (34), and cover (1) to
support those parts.
• The planetary unit consists of sun gear (21),
planetary pinion (19), and hub (20), carrier (17)
[connected to brake inner drum (10)].
10-98 D275AX-5
Mechanical power
Hydraulic power
Flow of power for HSS Conbined power
• The power from the transmission passes • The braking force is applied by braking the rota-
through bevel pinion gear (26) and bevel gear tion of inner drum (10) (which is interconnected
(15), and is transmitted to bevel gear shaft (14). with carrier (17)) at brake outer drum (9), which
It then goes from bevel gear shaft (14) through is fixed to the HSS case.
hub (20), ring gear (18), carrier (17), and brake
inner drum (10), and is transmitted to left and
right output shafts (2).
• When the steering is operated, HSS motor (30)
rotates and the power is transmitted from pinion
gear (31) to gear A (32), where it is divided to the
left and right. The power sent to the left is trans-
mitted from gear A (32) to gear B (34), sun gear
(21), and planet pinion gear (19). It is combined
with the power from the transmission at the plan-
etary gear portion, and is transmitted from carri-
er (17) to output shaft (2). The power sent to the
right is transmitted from gear A (32) through gear
C (33), gear D (28), and gear E (27) to right sun
gear (21) in order to reverse the rotation of the
power from the HHS motor. (The flow of power
beyond this point is the same as on the left side.)
D275AX-5 10-99
OPERATION OF HSS
1. When PCCS lever is at NEUTRAL (Traveling straight forward)
★ The direction of rotation of the HSS motor and gears is as seen from the left side of the machine.
Traveling straight forward 1 Transmission output speed

When the PCCS lever is at the NEUTRAL position, 2 Left bevel gear shaft output speed
HST motor (30), and transfer gear (33) and left and 3 Transmission output speed
right sun gears (21) of the planetary gear portion, 4 Right bevel gear shaft output speed
which are interconnected with the HSS motor, are : Transmission power
stopped. • Direction of rotation of HSS motor¸
In this condition, the power from bevel gear shaft Turn Left turn Right turn Neutral
(14) is input to hub (20), passes through ring gear PCCS lever
position Travel
(18) and planet pinion (19), and is transmitted to car- direction
Forward Reverse Forward Reverse All
rier (17). It then passes through brake inner drum
(10), which forms one unit with the carrier, and is Direction of rotation
Left Right Right Left Stopped
of HSS motor
transmitted to output shaft (2).
Therefore, the left and right output speeds are the ★ Counterrotation turn is not equipped
same and the machine travels in a straight line.
10-100 D275AX-5
2. PCCS lever operated to RIGHT TURN
1 Transmission output speed 4 Transmission output speed : Transmission power

2 Acceleration from HSS motor 5 Deceleration from HSS speed : HSS motor power
3 Left bevel gear shaft output 6 Right bevel gear shaft output : Combined power
speed (q + w) speed (r - t)
Forward
When the machine is traveling forward, bevel gear This rotation acts on the left and right planetary gear
shaft (14) and hub (20), which is connected to it, ro- mechanisms. The speed of carrier (17) on the left is
tate clockwise. accelerated from the speed when traveling in a
If the PCCS lever is operated to the RIGHT TURN straight line by the amount of the power from the
position when the machine is traveling forward, HSS HSS motor.
motor (30) rotates clockwise, the rotation passes On the other hand, the speed of carrier (17) on the
through gear A (32), and gear B (34) on the left side right is decelerated from the speed when traveling in
of the machine rotates clockwise, while gear E (27) a straight line, so a difference in rotation is generated
in the right side of the machine is rotated counter- in the output on the left and right. The output speed
clockwise by gear C (33). in the right is lower, so as a result, the machine trav-
In other words, the rotation of the HSS motor is els forward and turns to the right.
transmitted to sun gears (21) as rotation in opposite
directions on the left and right by the transfer portion.
D275AX-5 10-101

2 Acceleration from HSS motor 5 Deceleration from HSS speed : HSS motor power
speed (q + w) speed (r - t)
Reverse
When the machine is traveling in reverse, bevel gear straight line by the amount of the power from the
shaft (14) and hub (20), which is connected to it, ro- HSS motor. On the other hand, the speed of carrier
tate counterclockwise. (17) on the right is decelerated from the speed when
If the PCCS lever is operated to the RIGHT TURN traveling in a straight line, so a difference in rotation
position when the machine is traveling in reverse, is generated in the output on the left and right. The
HSS motor (30) is rotated counterclockwise in the output speed in the right is lower, so as a result, the
opposite direction from when traveling forward by the machine travels in reverse and turns to the right.
function of the HSS controller.
The rotation passes through gear A (32), and gear B
(34) on the left side of the machine rotates counter-
clockwise, while gear E (27) on the right side of the
machine is rotated clockwise by gear C (33).
In other words, the rotation of the HSS motor is
This rotation acts on the left and right planetary gear
mechanisms. The speed of carrier (17) on the left is
accelerated from the speed when traveling in a
10-102 D275AX-5
3. PCCS lever operated to LEFT TURN

2 Deceleration from HSS motor 5 Acceleration from HSS speed : HSS motor power
speed (q – w) speed (r + t)
Forward
When the machine is traveling forward, bevel gear The speed of carrier (17) on the right is accelerated
shaft (14) and hub (20), which is connected to it, ro- from the speed when traveling in a straight line by the
tate clockwise. amount of the power from the HSS motor. On the
If the PCCS lever is operated to the LEFT TURN po- other hand, the speed of carrier (17) on the left is de-
sition when the machine is traveling forward, HSS celerated from the speed when traveling in a straight
motor (30) rotates counterclockwise, the rotation line, so a difference in rotation is generated in the
passes through gear A (32), and gear B (34) on the output on the left and right. The output speed in the
left side of the machine rotates counterclock-wise, left is lower, so as a result, the machine travels for-
while gear E (27) on the right side of the machine is ward and turns to the left.
rotated clockwise by gear C (33).
mechanisms.
D275AX-5 10-103

2 Deceleration from HSS motor 5 Acceleration from HSS speed : HSS motor power
speed (q – w) speed (r + t)
Reverse
When the machine is traveling in reverse, bevel gear The speed of carrier (17) on the right is accelerated
shaft (14) and hub (20), which is connected to it, ro- from the speed when traveling in a straight line by the
tate counterclockwise. amount of the power from the HSS motor. On the
If the PCCS lever is operated to the TURN LEFT po- other hand, the speed of carrier (17) on the left is de-
sition when the machine is traveling in reverse, HSS celerated from the speed when traveling in a straight
motor (30) is rotates clockwise in the opposite direc- line, so a difference in rotation is generated in the
tion from when traveling forward by the function of output on the left and right. The output speed in the
the HSS controller. The rotation passes through gear left is lower, so as a result, the machine travels in re-
A (32), and gear B (34) on the left side of the ma- verse and turns to the left.
chine rotates clockwise, while gear E (27) on the
right side of the machine is rotated counterclockwise
by gear C (33).
mechanisms.
10-104 D275AX-5
Operation of brake
1. Brake released
When the brake pedal is at the RELEASED po-
sition, the brake valve is also at the NEUTRAL
position, so oil flows to back pressure port A of
brake piston (5).
When the oil pressure rises, the piston is pushed
to the left in the direction of the arrow, compress-
es spring 84), and releases the pressure push-
ing disc (8) and plate (7) into tight contact. When
this happens, the power transmitted from bevel
gear shaft (14) through the HSS to brake inner
drum (10) is transmitted to output shaft (2), and
is then transmitted to the final drive.
2. Brake applied (brake pedal depressed)

When the brake pedal is depressed, the brake
valve is switched, and the oil at port A, which
was applying back pressure to piston (5), is con-
nected to the drain circuit.
In this condition, piston (5) is pushed to the right
in the direction of the arrow by the tension of
spring (4), so disc (8) and plate (7) are brought
into tight contact with the stopper of brake outer
drum (9). The brake outer drum is joined to the
HSS case and is locked in position.
Therefore, the rotation of brake inner drum (10)
(in other words, output shaft (2)) is braked when
the disc and plate are brought into tight contact.
By adjusting the amount the brake pedal is de-
pressed, it is possible to adjust the hydraulic
pressure applied to piston (5), thereby adjusting
the braking force.
D275AX-5 10-105
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
1. Parking brake valve A. Left brake operating pressure F. To right brake

2. Right brake ECMV pick-up port G. From steering lubricating oil
3. Left brake ECMV B. Right brake operating pressure pump
4. Filter pick-up port H. To transmission lubrication
5. Sudden brake prevention valve C. To right brake J. From power train pump
6. Valve seat D. To left lubrication K. To pin puller solenoid valve
E. To right lubrication
Outline
• The brake valve is installed through the main re- • When the parking brake lever is set to the LOCK
lief valve between the power train pump and the position, the port of the parking brake valve is
brake piston in the HSS unit. It consists of 2 sets changed to drain the oil between the ECMV for
of brake ECMV (Right and left), parking brake both brakes and the brakes and excited the
valve, and sudden brake prevention valve. brakes. The parking brake valve is connected to
Each valve is installed as an assembly on the the brake pedal by the linkage.
valve seat. • The steering ECMV operates to excited the
• If the brake pedal is pressed, the oil pressure ap- brake so that the machine can make a pivot turn
plied to the brake piston is shut off and the brake when the turning operation stroke of the PCCS
piston fits the discs and plates with the spring lever is 80 - 100%.
force to excited the brake. Since the brake is
used to only stop the machine in the HSS, both
brakes are applied simultaneously.
• The sudden brake prevention valve is installed to
prevent the brake from stopping the machine
suddenly because of a trouble in the electric sys-
tem.
10-106 D275AX-5
2
MAINTENANCE STANDARD BRAKE ECMV
BRAKE ECMV
(Electronic control modulation valve)
A: To brake 1. Connector for fill switch

B: From pump 2. Connector for proportional solenoid
T: Drain 3. Oil pressure detection valve
Dr: Drain 4. Fill switch
P1: Brake oil pressure pick-up port 5. Proportional solenoid
P2. Pilot oil pressure pick-up port 6. Pressure control valve
D275AX-5 10-107
2
Outline of ECMV Operation of ECMV

• The ECMV (Electronic Control Modulating valve) • The ECMV is controlled using the command cur-
consists of a pressure control valve and a fill rent from the controller to the proportional sole-
switch. noid and a fill switch output signal.
• Pressure control valve Outline
This valve allows a proportional solenoid to re-
• This valve sets the steering clutch oil pressure or
ceive a current sent from a steering controller
the steering brake oil pressure to a set pressure
and converts it to oil pressure.
and switches a circuit to the clutch chamber and
• Fill switch
the brake chamber.
This component detects that a clutch is filled with
oil and has the following functions.
1) When the clutch is filled with the oil, at the
same time, a signal (fill signal) is output to
the controller and transmits filling termina-
tion.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the control-
ler and transmits the presence of oil pres-
sure.
ECMV and Proportional Solenoid

• One proportional solenoid is mounted for each
ECMV. A thrust is generated according to the
command current of the controller.
The thrust generated by the proportional sole-
noid is actuated on a pressure control valve
spool and generates oil pressure. Accordingly,
by controlling an amount of the command cur-
rent, the thrust changes and the pressure control
valve is actuated, then a flow of oil and the oil
pressure is controlled.
10-108 D275AX-5
Operation
1. When PCCS lever is in NEUTRAL and brake pedal is RELEASED (During straight travel and when
PCCS lever is moved from NEUTRAL to 80% of stroke)
When brake pedal is RELEASED (During gradual turn: Both brakes are OFF and parking brake is
OFF)
• If the PCCS lever is in NEUTRAL and the brake

pedal is OFF, proportional solenoid valve (1) of
the brake ECMV is excited and pushes ball (2) to
the left to close the seal. The oil in pump port Pb
flows in port A and pushes valve (3) to the left to
open the passage between ports Pb and B and
close the passage between ports B and Dr.
The oil in port Pb flows through port B to the
back pressure port of the brake piston. If the cir-
cuit pressure rises, the brake piston moves to the
left to compress the brake spring and RELEASE
the brake.
• If the parking brake is deactivated, the parking
brake valve is closed and the oil in the brake cir-
cuit is not drained.
D275AX-5 10-109
2
2. When PCCS lever is moved to left more than 80% of stroke (Pivot turn: Left brake is turned ON, right
brake is deactivated, and parking brake is deactivated)
• If the PCCS lever is moved to the left more than • If the parking brake is turned OFF, the parking
80% of the stroke in the state in 1 above, the pro- brake valve is closed and the oil in the brake cir-
portional solenoid valve (1) of the left brake cuit is not drained.
ECMV is deactivated and ball (2) becomes free
and the seal is opened. Since oil in port A is
drained through the seal, valve (3) is moved to
the right by the tension of spring (4).
At this time, the passage between ports Pb and
B is closed and the passage between ports B
and drain port Dr is opened.
• The oil from the power train pump is drained
through port Pb, throttle a, and the seal of ball
(2).
The oil which has been flowing in the brake pis-
ton por t to apply back pressure is drained
through port B to Dr.
• The left brake is turned ON by the tension of the

brake spring.
10-110 D275AX-5
2
3. When brake pedal is PRESSED

(Brake is ON and parking brake is OFF)
• If the brake pedal is pressed, proportional sole- • If the brake pedal is pressed, the parking brake
noid valves (1) of both brake ECMV's are deacti- valve connected by the linkage operates and
vated. drains the oil from the brake circuit.
• The controller outputs a command current to
proportional solenoid valves (1) according to the
pressing stroke of the brake pedal. If a current
flows in proportional solenoid valves (1), the so-
lenoid generates trust in proportion to the cur-
rent. The oil pressure, or the braking force, is
regulated by this trust of the solenoids, oil pres-
sure in the brake port, and reaction force of pres-
sure control valve spring (4).
D275AX-5 10-111
2
4. When parking brake is turned ON

(Brake is ON, PCCS lever is in NEUTRAL, brake pedal is RELEASED)
• If the safety lever for the PCCS lever is set to the

LOCK position, parking brake valve (1) moves to
the left and the ports A and B are connected to
port C. The oil which has been flowing in the
brake piston port to apply back pressure is
drained through ports A, B, and C. As a result,
the back pressure in the brake piston port keeps
lowering and the brake is turned ON completely
and kept as it is.
• When the engine is started again, ports A and B
are kept connected to drain port C. Accordingly,
the brake is kept turned ON.
• If the parking brake is turned OFF, parking brake
valve (1) moves to the right. Ports A and B are
disconnected from drain port C and the brake is
turned OFF by the oil pressure.
10-112 D275AX-5
MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm
Tolerance
Clearance between parking brake size Shaft Hole clearance limit
1 Replace
valve spool and valve body
– 0.020 + 0.011 0.020–
14 0.05
– 0.030 0 0.041
Outside diameter of sliding parts Tolerance Clearance limit Repair by hard

2 fitting to dust seal and V-packing 14 chromium plating
– 0.020
(Spool) 13.9 or replace
– 0.030

Using
3 Parking brake valve spool spring Free length Using load Free length Using load Replace
length
38.2N 36.3N
65 47.7 63.1
{3.9kg} {3.71kg}
D275AX-5 10-113
MAINTENANCE STANDARD SUDDEN BRAKE PREVENTION VALVE
SUDDEN BRAKE PREVENTION VALVE
Outline
• The sudden brake prevention valve is installed to
prevent the brake from stopping the machine
suddenly because of a trouble in the electric sys-
tem.
• Sudden brake prevention valve (1) is installed in
the brake ECMV drain circuit. If brake ECMV so-
lenoid valve (2) is deactivated, the oil is drained
from the brake circuit and the brake is applied
suddenly. To prevent this, if solenoid valve (3) of
sudden brake prevention valve (1) is deactivated,
the circuit of throttle a is formed. As a result, pilot
pressure drain circuit D is choked and the brake
is SEMI-RELEASED.
10-114 D275AX-5
2
10 STRUCTURE, FUNCTION AND MAINTENANCE
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Outline
• The final drive is a single stage spur gear, single
stage planetary gear reduction type. The lubrica-
tion is of splash type using the rotation of the
gears. The final drive can be removed and in-
stalled as a single unit.
• Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
D275AX-5 10-115
10-116 D275AX-5
2
1. Floating seal 12. Cover

2. Sun gear 13. No.1 pinion
3. Carrier 14. Final drive case
4. Hub 15. Bearing cage
5. Cover 16. No.1 gear
6. Sprocket boss 17. No.1 gear hub
7. Sprocket teeth 18. Boss
8. Floating seal guard 19. Shaft
9. Cover 20. Wear guard
10. Planetary gear 21. Pivot shaft
11. Ring gear
Unit: mm

22 Backlash between No.1 pinion
and No.1 gear
0.28–0.93 0.93
Backlash between sun gear and Replace

23 0.22–0.81 0.81
planet pinion
Backlash between planet pinion
24 0.25–0.90 0.90
and ring gear

Repair or
25 Outside diameter of No.1 pinion
oil seal contact surface 0 replace
95 94.913
– 0.087
Thickness of thrust collar of roller

26 30 29.95
bearing
Tolerance
Clearance between outer diame-
size clearance limit
27 ter of planet gear shaft and inner Shaft Hole
diameter of carrier hole. Replace
(Small diameter) – 0.036 – 0.024 – 0.023-
85 0.034
– 0.058 – 0.059 0.034
Clearance between outer diame-
ter of planet gear shaft and inner – 0.036 – 0.072 – 0.071-
28 105 – 0.014
diameter of carrier hole. – 0.058 – 0.107 – 0.014
(Large diameter)
Standard shim thickness for No.1
29 2 Adjust
pinion bearing cage

Repair or
30 Wear of wear guard
replace
72 18
D275AX-5 10-117
(5)
2
Path of power transmission
10-118 D275AX-5
2
• The power from the bevel gear shaft and steer-

ing clutch is transmitted to 1st pinion (13) to ro-
tate 1st gear (16) meshed with the 1st pinion and
sun gear (2) meshed with the 1st gear.
The rotation of sun gear (2) is transmitted to
planetary pinion (10). Since ring gear (11)
meshed with the planetary pinion is fixed to cov-
er (9), the planetary pinion rotates along the ring
gear and revolves around the sun gear.
Then, the rotating force of sun gear (2) forms the
rotating force of carrier (3), which supports the
planet pinion via hub (4), and is transmitted to
sprocket hub (6).
The rotating direction of carrier (3) is the same
with sun gear (2).
The rotational force transmitted to sprocket hub
(6) is further transmitted to sprocket teeth (7).
D275AX-5 10-119
2
10 STRUCTURE, FUNCTION AND MAINTENANCE
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard clearance Repair limit

1 Wear of tooth tip
Repair or
402.4 386
replace
2 Thickness of tooth root 23.2 17
10-119-1 D275AX-5
2(5)
MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
★ The above drawing is reduced to 35%. Enlarge it to 280% to return it to the full scale and make a copy on
an OHP sheet.
D275AX-5 10-119-2

MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
1. Idler Outline
2. Recoil spring assembly • The track roller uses an K-shape bogie mount to increase the
3. Carrier roller ground contact area between the track shoe and ground surface
4. Track frame on rough surfaces, thereby increasing the drawbar pull.
5. Sprocket • The K-shape bogie is fitted with rubber pads to absorb the shock
6. Sprocket cover guard from the ground surface.
7. Track roller bogie
8. Track roller
9. Track roller support guard Track roller, bogie
10. Pivot shaft
11. Cylinder
12. Guide Track roller flange type and bogie arrangement
1st 2nd 3rd 4th 5th 6th 7th
S D D D D D S
10-120 D275AX-5
MAINTENANCE STANDARD TRACK FRAME
Unit: mm
Item Repair limit
Deformation of track frame outer Curvature 7 (for length of 3,000)

4 Repair or replace
pipe Twisting 3 (for level length of 300)
Dents (pipe portion) 12

Clearance between inner pipe size clearance limit
11 and adjustment cylinder protru- Shaft Hole Replace
sion – 0.15 + 0.1
50 0.15–0.45 2.0
– 0.35 0
Clearance between idler bogie Standard clearance Clearance limit

12 Adjust
and guide 0–0.5 3.0
13 Press-fitting force for cartridge 2.75–530 kN {28–54 ton} –
D275AX-5 10-121
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
Outline
1. Yoke • Recoil spring (4) is used to adjust the track ten-
2. Nut sion by pumping in or releasing grease from lu-
3. Retainer br icator (10) to move rod (5) forward or
4. Recoil spring backward. The recoil spring (4) also acts to
5. Rod dampen any sudden shock brought to bear on
6. Spring cylinder the idler.
7. Retainer
8. Holder
9. Piston
10. Lubricator (for pumping in and releasing grease)
11. Grease chamber cylinder
10-122 D275AX-5
2
MAINTENANCE STANDARD RECOIL SPRING
Unit: mm

12 Recoil spring length load load
372.7 kN 345.1 kN
1,231 1,045 1.415
{38,000 kg} {35,185 kg}
Standard Tolerance Standard Clearance Replace

Clearance between inner cylinder size clearance limit
Shaft Hole
13 and outer cylinder of outer cylin-
der bushing – 0.055 + 0.317 0.115–
340 0.8
– 0.228 + 0.060 0.545
Clearance between adjustment – 0.100 + 0.054 0.100–

14 110 –
cylinder and bushing – 1.350 0 0.404
Press-fitting force for outer cylin-

15 42.1–96.1 kN{4.3–9.8ton}
der bushing (outer cylinder side)
Press-fitting force for outer cylin-

16 44.1–228.6 kN{4.5–23.3ton} Adjust
der bushing (inner cylinder side)
Clearance between recoil spring

17 0–1.0
mount nut and lock plate
D275AX-5 10-123
(5)
2
MAINTENANCE STANDARD IDLER
IDLER
10-124 D275AX-5
2
MAINTENANCE STANDARD IDLER
Unit: mm

Outside diameter of protruding
1
part
822 –
2 Outside diameter of tread surface 780 755
3 Width of protruding part 121 –

Rebuild or
4 replace
Width of tread 77 85.5
5 Overall tread 275 –
6 Thickness of tread 25.5 13
7 Width of shaft flange 242 –

Clearance between shaft and size Shaft Hole clearance limit
8 Replace bushing
bushing
– 0.350 + 0.170 0.340–
147 –
– 0.413 – 0.010 0.583
Tolerance Standard
Standard Interfer-
interfer-
Interference between shaft and size Shaft Hole ence limit
9 ence
seal guard
+ 0.046 – 0.150 0.150–
84 – Replace
0 – 0.200 0.246
10 Play in axial direction of shaft
0.5–1.0 –
D275AX-5 10-125
(5)
2
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
10-126 D275AX-5
(5)
2
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

Outside diameter of flange
1
(outside of single flange)
291 –
Outside diameter of flange
2 277 –
(inside of double flange)
single flange 255 185

Outside diame-
3
ter
double flange 255 195
single flange 65 30
Thickness of Rebuild or
4
tread replace
double flange 65 35
5 Overall width 336 –
6 Width of tread (single flange) 80 –
7 Width of tread (double flange) 80 –

Width of flange (double flange of
8 27.5 12.5
outside)
Width of flange (double flange of
9 24 9
inside)
10 Width of shaft flange 28.5 – Replace

11 Replace bushing
bushing
– 0.350 + 0.225 0.343–
115 –
– 0.413 + 0.007 0.038
Tolerance Standard
Standard Interfer-
interfer-
12 ence
seal guard
+ 0.046 – 0.150 0.150–
65 – Replace
0 – 0.200 0.246
0.44–0.91 –
D275AX-5 10-127
(5)
2
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
10-128 D275AX-5
MAINTENANCE STANDARD CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
232 –
Outside diameter of carrier roller
2 200 175
tread Rebuild or
3 Thickness of tread replace
40 27.5
4 Width of carrier roller tread 76.5 –
5 Width of flange 23 12

6 Replace bushing
support
0 + 0.35 0–
76 –
– 0.2 0 0.550
Tolerance Standard
Standard Interfer-
interfer-
7 ence
seal guard
+ 0.210 + 0.030 0.120–
77 – Replace
+ 0.150 0 0.210

0–0.22 –
D275AX-5 10-129
(5)
2
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Guide 6. Small bogie Outline

2. Cap 7. Track roller assembly • The track roller are installed to
3. Track roller assembly (double) 8. Cover small bogie (6). The track rollers
4. Large bogie 9. Cartridge pin and track shoes are always in
5. Rubber mount contact.
• The vibration of the machine
from the ground surface is ab-
sorbed by rubber mount (5).
10-130 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
★ Portion P shows the link on the side where the

bushing is pressed fitted.
10-132 D275AX-5
MAINTENANCE STANDARD TRACK SHOE
Unit: mm

Reverse or
1 Link pitch
replace
260.6 263.6
2 Height of grouser 88 30 Lug welding

rebuild or replace
3 Thickness of plate 20 –
4 Link height 166 148 Rebuild or

replace
5 Thickness of link metal 51.7 33.7
6 Bushing outside diameter 82 (Standard ground)

90.5
84.5 (Heavy duty ground)
7 8.6 (Standard ground)

Thickness of bushing metal 17.1
11.1 (Heavy duty ground)
Tolerance Standard
Standard Interfer- Reverse or
interfer-
Interference between bushing size Shaft Hole ence limit replace
8 ence
and link
+ 0.602 + 0.087 0.285–
90 0.10
+ 0.372 0 0.602
Interference between pin and link + 0.296 – 0.206 0.442–
55.5 –
(without wedge ring) + 0.236 – 0.280 0.576
9
Interference between pin and link + 0.296 – 0.034 0.270–
55.5 –
(with wedge ring) + 0.236 – 0.096 0.392
10 Clearance between link and link Each side Both sides Both sides
1.4 2.8 –
Replace
Tightening torque Additional tightening
11 Tightening torque for regular bolt
784±78 Nm {80 ± 8kgm} 120° ± 10°
12 Tightening torque for master bolt 490±49 Nm {50 ± 5kgm} 180° ± 10°
D275AX-5 10-133
(5)
2
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
10-134 D275AX-5
MAINTENANCE STANDARD MAIN FRAME
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Clamp
7. Cap
8. Plate
Unit: mm

Clearance between radiator size Shaft Hole clearance limit
9
guard mounting pin and bushing
– 0.030 + 0.257 0.410–
80 0 more than
– 0.076 + 0.170 0.555
Clearance between radiator – 0.030 + 0.257 0.343–
10 80 1.0
guard mounting pin and bushing – 0.076 + 0.170 0.405 Replace
Clearance between ripper beam – 0.036 + 0.267 0.098–
11 110 1.5
mount pin and bushing – 0.090 + 0.180 0.254
Clearance between ripper cylin- – 0.036 + 0.257 0.064–
12 90 1.5
der mounting pin and bushing – 0.090 + 0.170 0.256
Clearance between equalizer bar – 0.036 – 0.109–
13 120 1.5
shaft and bushing – 0.090 – 0.260
Press-fitting force for radiator
14 6.08–138.3kN {6.2–14.1ton}
guard mount bushing
Press-fitting force for radiator
15 68.7–155.0kN {7.0–15.8ton}
guard mount bushing
Press-fitting force for ripper beam
16 69.7–37.3kN {7.1–14.0ton} Adjust
mount bushing
Press-fitting force for ripper cylin-
17 57.9–114.8kN {5.9–11.7ton}
der mount bushing
Press-fitting force for equalizer
18 31.4–105.9kN {2–13ton}
bar shaft bushing
D275AX-5 10-135
MAINTENANCE STANDARD SUSPENSION
SUSPENSION
1. Equalizer bar 8. Seal Outline

2. Pivot shaft assembly 9. Bushing • The front of the track frame rocks up and down us-
3. Cover 10. Side pin ing the rear pivot shafts (6) as a fulcrum.
4. Thrust plate 11. Center pin Equalizer bar (1) rocks using center pin (11) as a
5. Thrust plate 12. Bushing fulcrum. The left and right track frames are con-
6. Pivot shaft nected by side pin (10).
7. Seal cage
10-136 D275AX-5
Unit: mm

Clearance between center pin size Shaft Hole clearance limit
13
and bushing
– 0.030 + 0.247 0.196–
105 1.0
– 0.060 – 0.166 0.307
Clearance between side pin and – 0.030 + 0.046 0.030–

14 75 1.0 Replace bushing
bushing – 0.060 0 0.106
Tolerance Standard Interfer-

Standard
interference
Interference between side pin size Shaft Hole
15 ence limit
boss and bushing
0 – 0.088 0.098–
140 –
– 0.018 – 0.098 0.106
Press-fitting force for center pin
16 32.4–225.6kN {3.3–23ton}
bushing
–
Press-fitting force for side pin
17 34.3–68.7kN {3.5–7.0ton}
bushing
D275AX-5 10-137
q1. Indicates the left of the blade single tilt specifications.

q2. Indicates the right of the blade single tilt specifications.
Unit: mm
Standard Tolerance Standard Interference

Interference between size Shaft Hole interference limit
18
thrust washer and seal
+ 0.213 – 0.180 0.278–
210 –
+ 0.098 – 0.226 0.439 Replace
Interference between thrust + 0.140 – 0.061 0.161–
19 140 –
washer and seal + 0.100 – 0.124 0.264
Interference between pivot + 0.096 – 0.075 0.125–
20 194 –
shaft and seal + 0.050 – 0.147 0.243

Clearance between pivot size Shaft Hole clearance limit
21
shaft and bushing Replacing
– 0.145 + 0.132 0.204– bushing
155 1.0
– 0.208 + 0.059 0.340
Clearance between pivot – 0.170 + 0.144 0.229–
22 190 1.0
shaft and bushing – 0.242 + 0.059 0.386
10-138 D275AX-5
MAINTENANCE STANDARD WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

SEMI U-DOZER
1. Blade tilt cylinder

2. R.H. blade lift cylinder
3. HSS charge filter bypass valve
4. HSS charge filter
5. Main control valve
6. Accumulator
7. Hydraulic tank
8. Work equipment pump
9. HSS charge pump
10. L.H. blade lift cylinder
11. Oil cooler
D275AX-5 10-139
2
U-DOZER + DUAL TILT
1. Blade tilt cylinder 8. Hydraulic tank

2. R.H. blade lift cylinder 9. Work equipment pump
3. HSS charge filter bypass valve 10. HSS charge pump
4. HSS charge filter 11. L.H. blade lift cylinder
5. Main control valve 12. Blade pitch cylinder
6. Accumulator 13. Oil cooler
7. Dual tilt solenoid valve
10-140 D275AX-5
4
2
MULTI-SHANK RIPPER
1. Main control valve

2. Divider block
3. Ripper tilt cylinder
4. Ripper lift cylinder
D275AX-5 10-141
4
2
GIANT RIPPER
• The diagram shows a machine equipped with a
pin puller cylinder
1. Main control valve 6. Ripper lift cylinder (left)

2. Divider block 7. Ripper tilt cylinder (left)
3. Ripper tilt cylinder (right) 8. Pin puller solenoid valve
4. Ripper lift cylinder (right) 9. Brake valve
5. Pin puller cylinder a. To steering case
10-142 D275AX-5
4
2
MAINTENANCE STANDARD PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

PPC CONTROL PIPING DIAGRAM
1. HSS charge filter bypass valve 6. Ripper control PPC valve

2. HSS charge filter 7. PPC lock valve
3. Blade control PPC valve 8. Work equipment safety lever
4. Main control valve 9. Work equipment pump
5. Accumulator 10. HSS charge pump
D275AX-5 10-143
4
2
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL

• The diagram shows a machine equipped with
pitch dozer and pin puller cylinder.
10-144 D275AX-5
(5)
2
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
1. Work equipment safety lever

2. Blade control valve
3. Pitch button
4. Tilt switch
5. Ripper control lever
6. Pin puller switch
7. PPC lock valve
Lever and switch positions

1 : Blade HOLD
2 : Blade LOWER
3 : Blade FLOAT
4 : Blade RAISE
5 : Blade LEFT TILT/PITCH
6 : Blade RIGHT TILT/PITCH
7 : Ripper HOLD
8 : Ripper RAISE
9 : Ripper LOWER
0 : Ripper TILT IN
A : Ripper TILT BACK
B : FREE
C : LOCK
D : Single tilt
E : Dual tilt
F : Pitch OFF
G : Pitch ON
H : Pin puller switch PUSH IN
I : Pin puller switch PUSH OUT
Outline
• The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
• Work equipment safety lever (1) is interconnect-
ed with PPC lock valve (7), and at the LOCK po-
sition, the oil in the PPC circuit is stopped.
D275AX-5 10-145
(5)
2
MAINTENANCE STANDARD WORK EQUIPMENT PUMP
WORK EQUIPMENT PUMP

HPV95 (112-cm3/rev specification)
Outline
This pump consists of a swash plate-type variable-capacity piston pump and an LS valve.
10-146 D275AX-5
1. Piston pump
2. Control assembly
3. Gear pump
PA : Pump discharge
PA1 : Pump pressure signal
PA2 : Gear pump discharge
PD1 : Pump drain
PD2 : Pump drain
PP2 : 2nd pump pressure signal
PS1 : Pump suction
PS2 : Gear pump suction
PLS1 : Load pressure input
PLS2 : Load pressure pick-up
PNC1 : Control pressure
PNC2 : Control pressure pick-up
Specifications
Model: HPV95 (112 cm3/rev)
Theoretical displacement: 112 ±1 cm3/rev
Rated speed: 2,302 rpm
Max. cut-off pressure: 31.9 MPa {325 kg/cm2}
D275AX-5 10-147
PA : Pump discharge PD2 : Pump drain

PA1 : Pump pressure signal PS1 : Pump suction
PD1 : Pump drain PNC1 : Control pressure
10-148 D275AX-5
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Shoe 12. Impeller
6. Servo piston 13. Spline
7. Lod
D275AX-5 10-149
Outline
• The engine rotation and torque transmitted to the • Piston (8) carries out motion relative to the axial
pump shaft is converted to hydraulic energy and direction inside each cylinder chamber of cylin-
pressurized oil is discharged according to the der block (9).
load. • The cylinder block (9) carries out rotation relative
• It is possible to change the discharge amount by to valve plate (10) while sealing the pressurized
changing the swash plate angle. oil, and this surface ensures that the hydraulic
balance is maintained correctly.
Structure
• The oil inside each cylinder chamber of cylinder
• Cylinder block (9) is supported to shaft (1) by a block (9) is sucked in and discharged through
spline (13), and shaft (1) is supported by the valve plate (10).
front and rear bearings. • Impeller (12) is fixed to shaft (1), and rotates to-
• The end of piston (8) has a concave ball shape gether with the shaft, it makes it easier for the oil
and shoe (5) is caulked to it to form one unit. Pis- sucked in from the suction port to be sucked in
ton (8) and shoe (5) form a spherical bearing. and sends it into the cylinder chamber by centrif-
• Rocker cam (4) holds plane A, and shoe (5) is al- ugal force.
ways pressed against this surface as it slides in
a circle.
• Rocker cam (4) forms a static bearing sending
high pressure oil at cylindrical surface B of cra-
dle (3), which is fixed to the case, and carries out
a sliding movement.
10-150 D275AX-5
OPERATION
• Cylinder block (9) rotates together with shaft (1),
and shoe (5) slides on plane A. When this hap-
pens, rocker cam (4) moves along cylindrical
surface B, so angle α of center line X of rocker
cam (4) to the axial direction of cylinder block (9)
changes. This angle α is called the swash plate
angle.
• With swash plate angle α formed by the angle

between center line X of rocker cam (4) to the ax-
ial direction of cylinder block (9), plane A acts as
a cam for shoe (5).
In this way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated be-
tween volumes E and F inside the cylinder block.
The amount of suction and discharge is equal to
difference F - E.
• In other words, cylinder block (9) rotates, and the
volume pf chamber E becomes smaller, so oil is
discharged during this process. At the same
time, the volume of chamber F becomes larger
and oil is sucked in this process.
• When center line X of rocker cam (4) is the same

as the axial direction of cylinder block (9) (swash
plate angle = 0), the difference between volumes
E' and F' inside cylinder block (9) is 0, so pump
does not suction and discharge, and no pump-
ing's carried out. Actually swash plate angle
does not become 0.)
• The swash plate angle α is proportional to pump
discharge volume.
D275AX-5 10-151
2. Control of discharge amount

• If swash plate angle α becomes larger, the differ-
ence between volumes E and F becomes larger,
and oil discharge Q is increased. Swash plate
angle α is changed by servo piston (6).
• Servo Piston (6) carries out reciprocal move-
ment in a straight line according to the command
from the LS valve single pressure. This straight
line movement is transmitted to rocker cam (4)
through rod (7), and rocker cam (4), which is
supported on the cylindrical surface by cradle (3)
rotates on the cylindrical surface.
• The area receiving the pressure is different at
the left and right sides of servo piston (6), and
the receiving pressure at the small diameter pis-
ton end is always connected with main pump dis-
charge pressure (self pressure) PP.
• Output pressure PNC of the LS valve is applied
to the chamber receiving the pressure at the
large diameter piston end (which receives pres-
sure of the pump).
• The movement of servo piston (6) is controlled
by the relationship of the size of pump pressure
PP and the pressure at the large diameter piston
end, and the comparative size of the ratio of area
receiving the pressure at the large diameter pis-
ton end and small diameter piston end.
• The movement of the servo piston is controlled
by a valve called the LS valve. Main pump pres-
sure PP and pressure PLS (the LS pressure)
from the control valve outlet port enter this valve.
• The relationship between discharge volume Q
and the difference in pressure (∆ P = PP - PLS)
(called the LS differential pressure) between
main pump pressure PP and LS pressure PLS
and is as shown in the diagram on the right.
10-152 D275AX-5
Control assembly
PP: Pump pressure signal

PT: Drain
PLS1: Load pressure signal
PLS2: Load pressure pick-up
PNV1: Control pressure
PNV2: Control pressure pick-up
D275AX-5 10-153
1. Valve body 8. Locknut

2. LS valve 9. Locknut
3. Variable throttle valve 10. Plug
4. Plug 11. Spring
5. Spool 12. Spool
6. Spring 13. Plug
7. Plug
10-154 D275AX-5
1. Operation of LS valve
1) When the control valve is at HOLD position
Operation
• The LS valve is a 3-way selector valve, and main
pump pressure PP and pressure PLS (LS pres-
sure) from the outlet port of the control valve are
applied to d port and a port.
• Spool (4) of this LS valve is pushed by the force
of spring (3) from the end receiving the LS pres-
sure, and the position of the spool (4) is deter-
mined by the LS pressure PLS + spring force F
and the size of main pump pressure PP.
• Main pump pressure PP always effects to ports
d and e. LS pressure PLS enters chamber g
from port a.
• Before the engine is started, servo piston (1) is
pushed to the right by spring (5) of rod (2). (See
the diagram on the right)
• After the engine is started, lf the control lever is
at HOLD position, the LS pressure PLS is 0 MPa
{0kg/cm2}. (The circuit is connected to the drain
circuit through the passage inside the control
valve spool.)
• When this happens, spool (4) is pushed to the
left, and port d and port c are connected. Pump
pressure PP enters the large diameter piston
end from port f, and the difference in area of pis-
ton (1) to the left so that the swash plate angle
becomes minimum.
D275AX-5 10-155
(5)
2
2) Movement in direction to increase pump discharge ( to the right)
Operation
• When LS differential pressure ∆ PLS, which is • Circuits c - f, which are the pressure of f port at
the difference in pressure between main pump the large diameter piston end of servo piston (1),
pressure PP and LS pressure PLS, becomes become the drain pressure, so servo piston (1) is
smaller (for example, the area of opening of the pushed from the small diameter piston end to the
control valve becomes larger and pump pres- large diameter piston end.
sure PP is reduced), spool (4) is pushed to the Rod (2) also moves to the right because of this
right under the combined force of the LS pres- movement, and changes the swash plate angle.
sure PLS and the force of spring (3). Main pump
pressure PP enters chamber h. The combined
force of spring (3) and the force of LS pressure
PLS is greater than the force of main pump pres-
sure PP, so spool (4) is pushed to the right.
• Because of the movement of spool (4), port c
and port b are connected, and circuit c - f be-
come drain pressure PT.
10-156 D275AX-5
3) Movement in direction to reduce pump dis-

charge (to the left)
Operation
• The following explains the situation when servo • Main pump pressure PP also enters the small di-
piston (1) moves to the left (the direction to make ameter piston end, but servo piston (1) is pushed
the discharge amount smaller). If LS differential from the large diameter piston end to the small
pressure ∆ PLS becomes larger (for example, diameter piston end because of the difference in
the area of opening of the control valve becomes area between the large diameter piston end and
smaller and pump pressure PP increases), spool the small diameter piston end.
(4) is pushed to the left by pump pressure PP. • As a result, rod (2) moves in the direction to
• Because of the movement of spool (4), main make the swash plate angle smaller (to the left).
pump pressure PP flows into port c, and main
pump pressure PP enters the large diameter pis-
ton end from port f.
D275AX-5 10-157
4) When servo piston is balanced
Operation
• In the LS valve, lf main pump pressure PP is bal- • When this happens, the force pushing the small
anced with the combined force of LS pressure diameter piston and the force pushing the large
PLS at chamber g and force F of spring (3), ser- diameter piston are balanced, so servo piston
vo piston (1) stops at the intermediate position (1) stops. In other words, the following condition
for the swash plate angle. (Force F of spring (3) is reached.
converted to the hydraulic power: Approx. 1.96 • Pump pressure PP x area receiving pressure at
MPa {20kg/cm2}. small diameter piston end = hydraulic pressure
• If an LS pressure (main pump pressure - force of PNC at the large diameter piston end x area re-
spring) that fulfills the above conditions for bal- ceiving pressure at large diameter piston end.
ancing enters ports a, main pump pressure PP The difference I area between the large diameter
entering from port d and combined force F of piston and small diameter piston is normally ap-
spring (3) and the force from LS pressure PLS prox. 2:1, so the pressure at the large diameter
are balanced, and pressure of a certain size en- piston end is approx. 1/2 of pump pressure PP.
ters port f from port c.
10-158 D275AX-5
2. Operation of variable throttle valve

1) Properties of variable throttle valve
• Because the main pump controls its own pres-
sure, there is a tendency for the response speed
of the swash plate to be quick at high pressure
and slow at low pressure.
The variable throttle valve has been installed be-
tween the LS valve and the port at the large di-
ameter end of the servo piston for the following
reasons.
1 To reduce the swash plate speed between
MIN and MAX at high pressure; to reduce
the impact force on the rod and other parts of
the main pump; and to prevent excessive re-
sponse.
2 To prevent cavitation at the suction port
caused by the sudden increase in the suc-
tion volume when changing from MIN to
MAX.
• The characteristics of the variable throttle valve

are as shown in the diagram below.
It has the function and property of maintaining
the response during operations at low pressure
by making the area of the opening smaller at
high pressure and the area of the opening larger
at low pressure, and by preventing the above
problems 1 and 2 at high pressure.
D275AX-5 10-159
2) Pump discharge pressure at high pressure
Operation
• In the variable throttle valve (6), main pump pres-
sure PP from LS valve (5) passes through port b
and enters port f.
• When main pump pressure PP is high, if it is
greater than the force of spring (3) because of
the difference in area of the land portion diame-
ters at both ends of chamber f, spool (4) is
moved to the left.
• If spool (4) moves to the left, the area of the
opening from port a to port c is throttled, so the
flow of oil entering the large diameter end of ser-
vo piston (1) from port d is reduced and the
speed of movement of servo piston (1) becomes
slower.
10-160 D275AX-5
3) Pump discharge pressure at low pressure
Operation
• When main pressure PP is low, even if it enters
chamber f from port b, the pressure is low, so it
does not become greater than the force of spring
(3), and spool (4) remains pushed to the right.
• The area of the opening from port a to port c be-
comes larger, so output pressure PNC from the
LS valve (5) is transmitted as it is.
D275AX-5 10-161
MAINTENANCE STANDARD COOLING FAN PUMP
COOLING FAN PUMP

LPV45
P: EPC valve main pressure TO: Drain

PE: Pump charge pressure PHO: Pump discharge pressure
10-162 D275AX-5
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D275AX-5 10-163
Function
• The rotation and torque of the engine are trans- • Piston (6) in each cylinder of cylinder block (7)
mitted to the shaft of this pump and converted moves relatively in the axial direction.
into hydraulic energy in this pump. This pump • Cylinder block (7) rotates relatively against valve
discharges the pressurized oil according to the plate (8), sealing the pressurized oil, and the hy-
load. draulic balance is maintained properly.
• The discharge of this pump can be changed by • The oil in each cylinder of cylinder block (7) can
changing the swash plate angle in it. be sucked and discharged through valve plate
(8).
Structure
• Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported by the
front and rear bearings.
• The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6) and
shoe (5) form a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) slides around ball (11).
10-164 D275AX-5
Operation
• Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane A. At this time,
rocker cam (4) tilts around ball (11). As a result,
angle α between center line X of rocker cam (4)
and the axis of cylinder block (7) changes. Angle
α is called the swash plate angle.
• If angle α is made between center line X of rock-
er cam (7) 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 vol-
umes 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.)
• 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 oil is not sucked
or discharged. (The swash plate angle is not set
to 0 actually, however.)
• In short, swash plate angle α is in proportion to
the pump discharge.
D275AX-5 10-165
2. Control of discharge
• If swash plate angle α is increased, the differ-
ence between volumes E and F is increased, or
discharge Q is increased. Swash plate angle α
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)
slides around ball (11).
10-166 D275AX-5
Servo valve
P: EPC valve main pressure

T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D275AX-5 10-167
(5)
2
Function
• The servo valve controls the current input to the • The servo piston is raised by the rocker cam.
EPC valve and the swash plate angle of the The position feedback is applied and the lever
pump so that they will be related as shown in the moves to compress the spring.
figure. • 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.
• These processes are repeated until the swash
plate is fixed to a position where the EPC output
is balanced with the spring force.
• 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.
• The output pressure of the EPC valve is applied

to the piston chamber to push the piston. Piston
(6) pushes spool (5) until it is balanced with the
spring.
• Then, the land of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
10-168 D275AX-5
Safety valve
Function
• The fan pump discharge pressure is heightened
when the engine is started or the fan is stopped
and rotated in reverse.
• The safety valve is installed to protect the fan
system circuit.
• If the discharge pressure exceeds the cracking
pressure of the safety valve, the seat of the safe-
ty valve opens to relieve the oil into the drain pas-
sage and prevent generation of abnormally high
pressure in the discharge port.
D275AX-5 10-169
MAINTENANCE STANDARD COOING FAN MOTOR
COOLING FAN MOTOR

LMF75
P : From fan pump

T : From oil cooler to tank
TC : To tank
Specifications
Model: LMF75
Capacity: 75 cc/rev
Rated speed: 1,050 rpm
Rated flow rate: 78.8 ¬/min
Cracking pressure of check valve:
76.5 kPa {0.78 kg/cm2}
10-170 D275AX-5
1. Output shaft 11. Check valve

2. Case 12. Changeover screw
3. Thrust plate 13. Changeover spool
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Check valve spring
Unit: mm

Free length
Installed Installed Installed If damaged or
x Outside Free length
10 Check valve spring length load load deformed,
diameter
replace spring
13.72N 10.29N
16.4 × 8.9 11.5 –
{1.4kg} {1.05kg}
D275AX-5 10-171
1. Hydraulic motor unit

Function
• This hydraulic motor is called a swash plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
• The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only 1 side of the Y-Y line
connecting the top dead center and bottom dead
center of the stroke of piston (4).
• The oil sent to 1 side of cylinder block (5) press-
es pistons (4) (4 or 5 pieces) and generates force
F1 (F1 kg = P kg/cm2 x π/4D2 cm2).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of α degrees
to the output shaft (1), the force is divided into
components F2 and F3.
• The radial component F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = Σ(F3 x ri)] ro-
tates the cylinder block (5) through the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
revolves to transmit the torque.
10-172 D275AX-5
2. Suction valve
Function
• If the fan pump stops, the hydraulic oil does not
flow into the motor. Since the motor continues
revolution because of the force of inertia, howev-
er, the pressure on the outlet side of the motor
rises.
• When the oil stops flowing in from inlet port P, the
suction valve sucks in the oil on the outlet side
and supplies it to the port MA where there is not
sufficient oil to prevent cavitation.
Operation
(1) When pump is started
• If the hydraulic oil from the pump is supplied to
port P and the pressure on the MA side rises and
starting torque is generated in the motor, the mo-
tor starts revolution. The oil on the outlet MB
side of the motor returns through port T to the
tank.
(2) When pump is stopped

• If the engine is stopped and the input revolution
of the fan pump lowers to 0 rpm, the hydraulic oil
from the pump is not supplied to port P any
more. As the hydraulic oil is not supplied to the
MA side of the motor, the motor speed lowers
gradually to stop.
• If the motor shaft is revolved by the force of iner-
tia while the oil flow in the port P is reducing, the
oil in port T on the outlet side is sent by the suc-
tion valve to the MA side to prevent cavitation.
D275AX-5 10-173
3. Operation of revolution direction changeover valve

(1) Forward rotation of motor (Clockwise rota- (2) Reverse rotation of motor (Counterclockwise
tion) rotation)
• To rotate the motor forward (clockwise), adjust • To rotate the motor in reverse (counterclock-
changeover screw (12) to position A (until the wise), adjust changeover screw (12) to position
screw stops). B (until the screw stops).
• Then, changeover spool (13) moves to the right Then, changeover spool (13) moves to the left to
to set the motor in the forward rotation mode. set the motor in the reverse rotation mode.
10-174 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filler cap 7. Hydraulic tank

2. Hydraulic filter element 8. Strainer
3. Spring 9. Sight gauge
4. Suction valve 10. Pressure valve
5. Cover 11. Drain valve
6. Cover 12. Drain plug
10-176 D275AX-5
MAINTENANCE STANDARD HYDRAULIC TANK
Specified value Specified value
Tank capacity (¬) 200 Cracking pressure 102.9 ± 19.6

(KPa {kg/cm2}) {1.05 ± 0.2}
Hydraulic Hi (¬) 149
Level inside Hydraulic Mesh size (µm) 30/8
tank Center (¬) 135
tank filter
Filtering area (cm2) 13,600
Low (¬) 117
Filtering oil flow (¬/min) 245
Cracking pressure 16.7 ± 6.9
(KPa {kg/cm2}) {0.17 ± 0.07} Mesh size (µm) 105
Breather Strainer
cap Vacuum valve actuating Filtering area (cm2) 1,850
0– 0.49
pressure
{0– 0.005 }
(KPa {kg/cm2})
D275AX-5 10-177
MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
For PPC valve
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1MPa {32kg/cm2}
Max. actuation pressure: 1.2MPa {12kg/cm2}
Function
• The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the en-
gine is stopped with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
• After the engine is stopped, when the PPC valve
is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure 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 actu-
ates the main control valve.
10-178 D275AX-5
(5)
2
MAINTENANCE STANDARD PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The PPC lock valve is installed in the PPC circuit
between the PPC, HSS charge valve and PPC
valve. If the work equipment safety lever is
placed at the LOCK position, the PPC lock valve
is actuated together with the work equipment
safety lever. This stops the oil in the PPC circuit
and makes it impossible to operate the work
equipment.
D275AX-5 10-179
20-242 D155AX-5
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
For blade lift, blade tilt
P. From PPC charge valve port P P1. To blade tilt valve port PA2
T. To hydraulic tank P2. To blade tilt valve port PB2
P3. To blade lift valve port PB3
P4. To blade lift valve port PA3
D275AX-5 10-181
1. Spool 6. Nut (for lever joint)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
10-182 D275AX-5
Unit: mm

11 Centering spring (for P1) length load load
108.8N 87.0N
34.0 × 15.5 31.6 –
{11.09kg} {8.87kg}
16.7N 13.7N
12 Metering spring (for P3, P4) 27.23 × 8.14 24.9 –
{1.7kg} {1.4kg}
99.0N 79.2N Replace spring

13 Centering spring (for P2) 43.2 × 15.5 31.6 –
{10.09kg} {8.07kg} if damaged or
deformed
113.2N 90.5N
14 Centering spring (for P3, P4) 48.57 × 15.5 31.6 –
{11.54kg} {9.23kg}
16.7N 13.7N
15 Metering spring (for P1, P2) 26.53 × 8.15 24.9 –
{1.7kg} {1.4kg}
159.36N 127.5N
16 Detent spring (for P4) 20.39 × 19.5 13.1 –
{16.25kg} {13kg}
38.44N 30.79N
17 Detent spring (for P3) 45.36 × 7.5 26 –
{3.92kg} {3.14kg}
D275AX-5 10-183
Operation
1. At neutral
1) PPC valve for blade lift
Ports PA3 and PB3 of the blade lift control valve,
and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1).
2) PPC valve for blade tilt

Ports PA2 and PB2 of the blade tilt control valve,
and ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1).
10-184 D275AX-5
2. During fine control (neutral-fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P4 to port PA3.
When the pressure at port P4 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P4.
When this happens, spool (1) moves up or down
so that force of metering spring (2) is balanced
with pressure at port P4.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control level, so the pressure at port P4 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber PA3 (the
same as the pressure at port P4) and the force
of the control valve spool return spring are bal-
anced.
D275AX-5 10-185
3. During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up to the force of centering spring (3)
and the pressure at port P4.
When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P4 is released.
If the pressure at port P4 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P4 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P3 and enters cham-
ber PB3 to fill the chamber with oil.
4. At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber PA3 from port P4, and pushes
the control valve spool.
The oil returning from chamber PB3 from port
P3 through fine control hole f' and flows to drain
chamber D.
10-186 D275AX-5
5. Blade operated to FLOAT

When piston (4) at port P4 (LOWER side) is
pushed by disc (5) and moves down, protrusion
a of the piston contacts ball (11) during the
downward stroke. (The detent starts to be actu-
ated.)
If piston (4) is pushed further, ball (11) pushes up
collar (12), which is being held by detent spring
(13), and moves to the outside, so the ball pass-
es over protrusion a of the piston. At this point,
piston (4') at the opposite side is pushed up by
the spring (14).
As a result, the oil inside chamber F flows
through b and c and enters chamber E, and pis-
ton (4') follows disc (5). Passage d is intercon-
nected with port P4, so it is under more or less
the same pressure as port P4.
Chamber E is normally interconnected with drain
chamber D, but when ball (11) passes over pro-
trusion a of the piston, passage d and chamber
E (which were shut off) are interconnected and
pressurized oil flows. At the same time, the con-
trol valve also moves to the FLOAT position, so
the blade circuit is set to the FLOAT condition.
The pressurized oil inside chamber E pushes up
piston (4'), so even of the lever is released, it is
held at the FLOAT position.
6. Blade released from FLOAT

When disc (5) is returned from the FLOAT posi-
tion, it is pushed down by a force greater than the
pressure of the oil in chamber E.
For this reason, chamber E is shut off from pas-
sage d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOAT, position is released.
D275AX-5 10-187
PPC VALVE
For ripper
P. From charge pump

T. To hydraulic tank
P1. To ripper tilt (BACK)
P2. To ripper tilt (IN)
P3. To ripper lift (LOWER)
P4. To ripper lift (RAISE)
10-188 D275AX-5
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever joint)
Unit: mm

12 Centering spring (for P3, P4) Free length Free length
length load load
71.39N 56.9 Replace spring

50.05×15.5 34 – if damaged or
{7.28kg} {5.8kg}
deformed
55.9N 45.1N
13 Centering spring (for P1, P2) 50.35×15.5 34 –
{5.7kg} {4.6kg}
16.7N 17.7N
14 Metering spring 26.53×8.15 24.9 –
{1.7kg} {1.4kg}
D275AX-5 10-189
Operation
1. At neutral
Ports A and B of the control valve and ports P1,
P2, P3 and P4 of the PPC valve are connected
to drain chamber D through fine control hole f of
spool (1).
10-190 D275AX-5
2. During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
pressure through fine control hole f and goes
from port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1. The relation-
ship in the position of the spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber A (the
same as the pressure at port P1) and the force
of the control valve spool return spring are bal-
anced.
D275AX-5 10-191
3. During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters cham-
ber B to fill the chamber with oil.
4. At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes form
port P2 through fine control hole f' and flows to
drain chamber D.
10-192 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Blade lift cylinder
Blade tilt cylinder
Ripper lift cylinder
10-194 D275AX-5
Ripper tilt cylinder
Unit: mm

size Shaft Hole clearance limit
– 0.030 + 0.258 0.078–

Blade lift 80 0.745
– 0.076 + 0.048 0.334
Clearance between
1 piston rod and bush- – 0.036 + 0.257 0.084–
Blade tilt 100 0.693
ing – 0.090 + 0.047 0.347
– 0.036 + 0.257 0.084–

Ripper lift 100 0.693
– 0.090 + 0.047 0.347
– 0.036 + 0.257 0.084–

Ripper tilt 90 0.693
– 0.090 + 0.047 0.347
Clearance between
piston rod spherical 100 + 0.300
2 Blade lift – – 1.0
surface and blade (Ball) 0
ball portion
+ 0.207 Replace
Blade lift 90 – – 1.0
+ 0.120
Clearance between
+ 0.200
3 piston rod spherical Blade tilt 70 – – 1.0
0
shaft and bushing
+ 0.207
Ripper lift 90 – – 1.0
+ 0.120
Clearance between
cylinder support – 0.120 + 0.035 0.120–
4 Blade lift 95 1.0
shaft bushing and – 0.207 0 0.242
yoke
+ 0.174
Blade tilt 70 – – 2.0
+ 0.100
Clearance between
cylinder bottom sup- + 0.207
5 90 – – 1.0
port shaft and bush- Ripper lift + 0.120
ing
+ 0.207
Ripper tilt 90 – – 1.0
+ 0.120
Thickness of stan-
dard shim between
6 Blade lift 4.0 Adjust
tip of piston rod and
cap
D275AX-5 10-195
Dual tilt cylinder (Opt)
Pin puller cylinder (Opt)
Unit: mm

Clearance between
1 piston rod and bush- Dual tilt – 0.036 + 0.257 0.084–
100 0.693
ing – 0.090 + 0.047 0.347
Pin puller – 0.065 + 0.133 0.072–

30 0.55
– 0.117 + 0.007 0.250
Clearance between piston rod + 0.200 Replace

2 70 – – 1.0
support shaft and bushing 0
Clearance between piston rod – 0.100

3 29 – – –
spherical surface and bushing – 0.200
Clearance between cylinder bot- + 0.174

4 70 – – 2.0
tom support shaft and bushing + 0.100
Clearance between cylinder bot- + 0.100

5 26 – – –
tom support shaft and bushing – 0.100
10-196 D275AX-5
MAINTENANCE STANDARD PISTON VALVE
PISTON VALVE
For blade lift cylinder
Outline
• The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the hy-
draulic pump to reduce the oil pressure being ex-
erted on the piston.
When the blade is tilted, the blade is subject to a
tortional force owing to the uneven position of the
pistons in the two cylinders; that is the piston one
side is still moving while the piston on the other
side has reached its stroke end.
The piston valves are installed to prevent the tor-
tional force from occurring. When one of the pis-
tons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to redure the subsequent surge pressure in the
cylinder by letting the oil escape from the cylin-
der before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED

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

Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder
bottom, so valve (6) and piston valve (3) stop at
that position and do not move further. Only pis-
ton (2) moves further.
When this happens, the oil at the cylinder head,
which was sealed by piston valve (3), escapes
from piston valve seats (4) and (5), and the pres-
sure inside the cylinder stops rising.
D275AX-5 10-197
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

For blade lift cylinder
Unit: mm

Clearance between spool and size Shaft Hole clearance limit
1
valve body
– 0.011 + 0.010 0.011–
38.0 0.03
– 0.016 0 0.026
Replace

2 Valve spring Free length Free length
length load load
136.3N 122.6N
75.2 55.9 67.7
{13.9kg} {12.5kg}
10-198 D275AX-5
MAINTENANCE STANDARD PIN PULLER SWITCH
PIN PULLER SWITCH
1. Connector
2. Wire
3. Switch
4. Knob
Function
• The pin puller solenoid valve is controlled by
turning the pin puller switch ON/OFF. This
changes the oil circuit to the pin puller cylinder
and sets the shank mounting pin to the PUSH IN
or PULL OUT position.
D275AX-5 10-199
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To HSS case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
10-200 D275AX-5
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
Operation
1. Pin puller switch at PUSH IN position

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

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9) and
it is excited. Then, the solenoid pushes out push
pin (8) and spool (5) moves to the left in the ar-
row direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump flows
from port P to port B and enters the head end of
pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder re-
tracts and pulls shank mounting pin (11) out of
shank (12).
D275AX-5 10-201
MAINTENANCE STANDARD BLADE CONTROL KNOB
BLADE CONTROL KNOB
1. Switch (dual-single selector switch) • If switch (1) is set to the DUAL position and the
2. Switch (pitch) lever is operated, blade carries out dual tilt oper-
3. Cover ation. If the lever is tilted to the left, the blade
4. Connector (male) carries out left dual tilt operation. If the lever is
5. Connector (female) tilted to the right, the blade carries out right dual
tilt operation.
Outline
• If switch (1) is set in either DUAL or SINGLE po-
• If the blade control knob is tilted forward, back- sition and the lever is tilted to the right or left
ward, to the right, or to the left, the blade is while switch (2) is pressed and held, the blade is
raised, lowered, tilted to the right, or tilted to the pitched.
left. If switch (1) is set to the DUAL position and
the lever is tilted to the right or left, dual tilt oper-
ation is carried out. If the lever is tilted to the
right or left while (2) is pressed and held, pitching
operation is carried out.
• 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 tilt-
ed to the right, the latter is pitched forward.
10-202 D275AX-5
MAINTENANCE STANDARD PITCH, DUAL TILT SOLENOID VALVE
PITCH, DUAL TILT SOLENOID VALVE
1. Connector OUTLINE
2. Solenoid (b) • The pitch switch solenoid valve is located be-
3. Valve tween the PPC valve and the blade valve, and at
4. Solenoid (a) the downstream of the pitch tilt switch solenoid
5. Manual push pin valve, and its function is to switch the PPC pilot
pressure.
A. A port • By operating the pitch back switch or the pitch
B. B port dump switch of the blade control lever, the pilot
P. P port pressure can be delivered to the left pitch cylin-
T. T port der and the right pitch cylinder, and it enables to
switch from the tilt to the pitch.
• In addition, the pitch solenoid valve is operated
by the controller.
D275AX-5 10-203
(5)
2
PITCH, DUAL TILT SOLENOID VALVE MAINTENANCE STANDARD
PAGE INTENTIONALLY LEFT BLANK
D275AX-5 10-205
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Standard specification
Cautions for tightening bolts marked with ª
Tighten the 3 bolts in the following 3 steps so
that they will be tightened equally.
1st time: 58.8 ±9.8 Nm {6 ± 1 kgm}
2nd time: 137.3 ± 9.8 Nm {14 ± 1 kgm}
3rd time: 186.3 ± 9.8 Nm {19 ±1 kgm}
A: Pump pressure pick-up port LS: To HSS pump LS valve

B: LS pressure pick-up port P1: From pump
C: PPC main pressure PR: PPC output
T: Drain TS: Seal drain
A1: To blade tilt right cylinder head PA1: From blade PPC valve port P3
A2: To blade lift cylinder head PA2: From blade PPC valve port P1
A3: To ripper lift cylinder head PA3: From ripper PPC valve port P3
A4: To ripper tilt cylinder bottom PA4: From ripper PPC valve port P1
B1: To blade tilt right cylinder bottom PB1: From blade PPC valve port P4
B2: To blade lift cylinder bottom PB2: From blade PPC valve port P2
B3: To ripper lift cylinder bottom PB3: From ripper PPC valve port P4
B4: To ripper tilt cylinder head PB4: From ripper PPC valve port P2
10-206 D275AX-5
1. Valve block 5. Blade tilt spool

2. Ripper tilt spool 6. Valve body
3. Ripper lift spool 7. Load check valve
4. Blade lift spool 8. Pressure compensation valve
Unit: mm

Free length
Spool return spring x Outside Free length
9 length load load
(only for blade lift) diameter
223.4N 178.4N
76.3 × 30 68.5 –
{22.8kg} {18.2kg}
140.1N 111.7N
10 Spool return spring 51.7 × 31.3 50 –
{14.3kg} {11.4kg}
If damaged or
Spool return spring 216.6N 173.5N deformed,
11 54.7 × 36.5 32.5 –
(for blade lift FLOAT) {22.1kg} {17.7kg} replace spring
12.7N 9.8N
12 Load check valve spring 20.8 × 10.2 13.5 –
{1.3kg} {1.0kg}
Pressure compensation valve 562N 449N
13 108.3 × 29.5 81 –
192.4N 154N
14 Unload spring 86.7 × 30 66 –
{19.63kg} {15.7kg}
D275AX-5 10-207
1. LS check valve 5. Unload valve

2. Main relief valve 6. Suction valve
3. LS relief valve 7. Check valve (built in spool)
4. Self-pressure reducing valve
Unit: mm

Free length
x Outside Free length
8 Suction valve spring length load load
diameter
6.37N 5.1N
64.9 × 12.5 56 – If damaged or
{0.65kg} {0.52kg}
deformed,
14.7N 11.8N replace spring
9 Check valve spring in spool 27.9 × 6.5 22.5 –
{1.5kg} {1.2kg}
0.29N 0.20N
{0.03kg} {0.02kg}
10-208 D275AX-5
1. Suction valve 3. LS bypass valve

2. Preset check valve
Unit: mm
Free length
× Outside Free length
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.4N
46.8 × 7.5 40.6 –
{0.56kg} {0.45kg}
D275AX-5 10-209
MAINTENANCE STANDARD DUAL TILT SPECIFICATION
DUAL TILT SPECIFICATION

Cautions for tightening bolts marked with ª
Tighten the 3 bolts in the following 3 steps
so that they will be tightened equally.
1st time: 58.8 ±9.8 Nm {6 ± 1 kgm}
2nd time: 137.3 ± 9.8 Nm {14 ± 1 kgm}
3rd time: 186.3 ± 9.8 Nm {19 ±1 kgm}
A: Pump pressure pick-up port LS: To HSS pump LS valve

B: LS pressure pick-up port P1: From pump
C: PPC main pressure PR: PPC output
T: Drain TS: Seal drain
A1: To blade tilt right cylinder head PA1: From dual tilt and pitch changeover valve
A2: To blade lift cylinder head PA2: From blade PPC valve port P1
A3: To blade tilt left cylinder head PA3: From dual tilt and pitch changeover valve
A4: To ripper lift cylinder head PA4: From ripper PPC valve port P3
A5: To ripper tilt cylinder bottom PA5: From ripper PPC valve port P1
B1: To blade tilt right cylinder bottom PB1: From dual tilt and pitch changeover valve
B2: To blade lift cylinder bottom PB2: From blade PPC valve port P2
B3: To blade tilt left cylinder bottom PB3: From dual tilt and pitch changeover valve
B4: To ripper lift cylinder bottom PB4: From ripper PPC valve port P4
B5: To ripper tilt cylinder head PB5: From ripper PPC valve port P2
10-210 D275AX-5
1. Valve block 6. Blade tilt right spool

2. Ripper tilt spool 7. Valve body
3. Ripper lift spool 8. Load check valve
4. Blade tilt left spool 9. Pressure compensation valve
5. Blade lift spool
Unit: mm

Free length
Spool return spring Installed Installed Installed
10 × Outside Free length
(only for blade lift) length load load
diameter
223.4N 178.4N
76.3 × 30 68.5 –
{22.8kg} {18.2kg}
140.1N 111.7N
11 Spool return spring 51.7 × 31.3 50 –
{14.3kg} {11.4kg} If damaged or
Spool return spring 216.6N 173.5N deformed,
12 54.7 × 36.5 33.5 –
(for blade lift FLOAT) {22.1kg} {17.7kg} replace spring
12.7N 9.8N
13 Load check valve spring 20.8 × 10.2 13.5 –
{1.3kg} {1.0kg}
Pressure compensation valve 562N 449N
14 108.3 × 29.5 81 –
192.4N 154N
15 Unload spring 86.7 × 30 66 –
{19.63kg} {15.7kg}
D275AX-5 10-211
1. LS check valve 5. Unload valve

2. Main relief valve 6. Suction valve
3. LS relief valve 7. Check valve (built in spool)
4. Self-pressure reducing valve
Unit: mm

Free length
8 Suction valve spring × Outside Free length
length load load
diameter
6.37N 5.1N If damaged or
64.9 × 12.5 56 –
{0.65kg} {0.52kg} deformed,
14.7N 11.8N replace spring
{1.5kg} {1.2kg}
0.29N 0.20N
{0.03kg} {0.02kg}
10-212 D275AX-5
1. Suction valve 3. LS bypass valve

2. Preset check valve
Unit: mm

Free length
× Outside Free length
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.4N
46.8 × 7.5 40.6 –
{0.56kg} {0.45kg}
D275AX-5 10-213
MAINTENANCE STANDARD OPERATION OF CONTROL VALVE
OPERATION OF CONTROL VALVE
FUNCTION
• When the main spool is at the HOLD position, it
drains the excess oil discharged by the pump,
and prevents the pressure from being formed in
the circuit from rising.
OPERATION
1.AT HOLD (OPERATION OF UNLOAD VALVE)

(1) When the main spool is at the HOLD posi- (3) When FO becomes larger than set load FS of
tion, the pump pressure passes from cham- spring (2), the spool moves to the right and con-
ber A through oriffice (4) to chamber D. nects the passage between chamber A and
Chambers C and C' are connected to the chamber B, so the oil from the pump is drained.
drain circuit. Therefore, spool (1) is balanced at a position that
(2) When oil is supplied from the pump, the matches the supply of oil from the pump.
pressure in chamber D rises, and spool (1) is Actually, the amount of oil supplied from the
pushed to the right by pressure FO which is pump is small, so the pressure in the circuit is al-
determined by the cross-sectional area of most the same as the set load of spring (2).
piston (3) receiving the pressure.
10-214 D275AX-5
(5)
2
2 Control of oil flow

(1) Work equipment valve (Following explanation is
for blade right tilt cylinder circuit)
• Use of the CLSS circuit (Closed Center Load
Sensing System) makes it possible to control the
oil flow by adjusting the area of opening of the
spool driven by the PPC valve, regardless of the
load.
1) At HOLD
When the spool is at the HOLD position, the spool (3) of the pressure compensation valve, so
pump pressure is sent from chamber A through it pushes against the load of spring (4) and
the notch in spool (3) of the pressure compensa- moves to the right to the maximum stroke posi-
tion valve, and passes through chamber B to tion. In this condition, the area of the opening to
chamber C. Chamber G is drained through spool (1) of the blade tilt valve is at its minimum.
chamber H to chamber F. When this happens,
the pump pressure is acting on the left end of
D275AX-5 10-215
(5)
2
2) At blade right tilt
1 When the tilt lever is operated to right tilt, pilot • ∆PLS = differential pressure between ports
pressure PB1 acts on the right end of spool (1) K and J = 1.96 MPa {20kg/cm2}
through the PPC valve, and when the pressure • ∆PLS' = differential pressure between ports
becomes greater than the set load of spring (2), I and D
the spool starts to move to the left. It is balanced • ∆PLS ≈ ∆PLS'
at a position corresponding to PPC output pres-
sure PB1.
10-216 D275AX-5
(5)
2
2 Chamber C and chamber D are connected, and

the oil from the pump flows through ports A, B,
C, and D to tilt cylinder (6). At the same time, the
load pressure in chamber D passes through LS
orifice (5) and chamber H, and is sent to cham-
ber G. It is also sent from the LS circuit O to
pump servo valve (7).
3 The condition of the pressure of spool (3) is
chamber B pressure ≈ chamber C pressure, and
chamber G pressure ≈ chamber D pressure, so
spool (3) is controlled by the differential pressure
of spool (1) (chamber C pressure - Chamber D
pressure), and balances with spring (4).
In other words, if the oil flow is too large, the dif-
ferential pressure of spool (1) becomes larger,
so spool (3) moves in the direction to throttle the
oil flow; on the other hand, if the oil flow is too
small, spool (3) moves in the direction to in-
crease the oil flow.
4 In addition, pump servo valve (7) is controlled so

that the differential pressure between pump
pressure P and LS pressure LS (LS differential
pressure: ∆PLS) remains constant, so a suitable
amount of oil flows to ensure that the loss of
pressure at the control valve (∆PLS') is equal to
∆PLS. The loss of pressure in the control valve
is determined by the area of the opening of the
main spool, so the oil flow matches the opening
of the spool.
5 The return oil flow from the tilt cylinder passes
through chamber E and chamber F, and is
drained.
D275AX-5 10-217
(5)
2
3) Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)
10-218 D275AX-5
• In the case where the blade falls owing to the

weight of the blade, the return flow from a cylin-
der is controlled according to the opening area of
main spool (1).
• Oil flows from the suction valve (2) to a cylinder

so that it prevents the circuit from being evacuat-
ed.
1) When a spool port opens with PPC output

pressure at PA2, oil on the cylinder head
side passes through ports A, B and D and
then drains into the tank owing to the weight
of the blade. At this time, the opening area
between ports A and B squeezes the return
flow from a lift cylinder in order to control the
drop speed.
2) In the case where the blade falls owing to the
weight of the blade, oil on the cylinder head
side passes through a drain circuit and the
suction valve (2) and then it is supplied to the
cylinder bottom side. At the same time, the
output flow from the pump passes through
ports A1, B1, C1, D1 and E1 and then it is
supplied to the cylinder bottom side.
D275AX-5 10-219
(5)
2
4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
10-220 D275AX-5
(5)
2
• When the lift valve is at FLOAT, the cylinder port

and drain port are connected to put the circuit in
a no-load condition.
• When the lift valve is in the FLOAT condition, the
pump passage and cylinder ports A3 and B3 are
separated so that the other control valves can be
operated.
1) When the work equipment control lever is at
the FLOAT position, if pressure PA3 be-
comes 3.4 MPa (35 kg/cm 2 ) or more, lift
spool (1) is moved to the maximum stroke
position.
2) In this condition, ports A3 and B3 and the LS
passage O are all connected to the drain cir-
cuit, so there is no load on the lift cylinder.
3) If the cylinder is driven by the weight of the
blade, the oil entering from A3 flows to ports
A, B, B1 and A1, while the rest of the oil
flows through port D, and is drained. The oil
from suction valve (9) flows to port B3. When
this happens, the oil flow is throttled by the
area of opening between ports A and B of
spool (1), and the cylinder speed is con-
trolled.
4) The pump circuit chamber E and ports A3
and B3 are separated, and pump pressure P
is formed, so it is possible to carry out com-
pound operations with other control valves.
D275AX-5 10-221
(5)
2
3. At relief
(1) Blade lift, blade tilt, ripper lift, ripper tilt
★ The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke end.
• ∆P1 = ∆P3 + ∆P4 = Differential pressure be- • ∆P4 = Differential pressure between ports B and
tween ports M and P P
• ∆P2 = Differential pressure between ports P and • ∆LS = ∆P1 + ∆P2 = Differential pressure
N between ports M and N = 1.96 MPa (20 kg/cm2)
• ∆P3 = Differential pressure between ports M and
B
10-222 D275AX-5
(5)
2
1) If blade tilt valve (1) is moved, and the pres-

sure of tilt cylinder (8) becomes higher, work
equipment LS relief valve (5) will crack and
oil will be drained from LS circuit O. (Ports P,
F, G, J, and K). As a result, there will be a
drop in pressure in LS passage O starting
from LS sensing hole F, and ∆P2 will become
larger.
2) For the same reason, if the pressure in
chamber I and H drops, spool (2) will push
against spring (3) and move to the right, and
will make the opening between chambers B
and C smaller, so the flow between cham-
bers B and C will be throttled and ∆P4 will
become larger.
3) Because of the pump swash plate control,
the system circuit is balanced at a circuit
pressure which makes the pressure loss
generated by the flow at work equipment LS
relief valve (5) ∆P1 + ∆P2 equal to LS differ-
ential pressure (∆LS). When this happens,
pump LS valve (6) detects the differential
pressure generated by LS relief valve (5),
and moves the pump swash plate from the
maximum to the minimum position where the
LS differential pressure is 1.96 MPa (20 kg/
cm2).
4) When the pump is at the minimum swash
plate angle (minimum oil flow), if the mini-
mum oil flow is greater than the LS relief oil
flow + leakage at any part, the pressure is
confined in the pump circuit (between the
pump and chambers A and chamber B
through pressure compensation valve (7)),
so the LS differential pressure rises. If this
differential pressure goes above the set
pressure for unload valve (4), the unload
valve is actuated to relieve the excess oil flow
and balance the circuit.
D275AX-5 10-223
(2) Compound operation of work equipment valve

★ The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
10-224 D275AX-5
• It consists of a parallel circuit, so when com-

pound operations are carried out, the oil flow is
divided according to the size of each spool open-
ing.
1) Tilt spool (1) and lift spool (2) are actuated by

PPC valve output pressure PA1 and PB2,
and each is balanced at a position that
matches its own pilot pressure.
2) When pressure P2≤ ≤ P3

Lift valve load pressure P3 is sent to pump
LS valve (4) through LS passage O.
1 When pump swash plate does not reach

maximum angle
When the maximum flow of oil from the pump
is greater than the total of the oil flow de-
manded by the tilt valve and lift valve, an oil
flow that matches the opening of the spool
flows to both the tilt valve and lift valve.
2 When pump swash plate is at maximum an-

gle
When the maximum flow of oil from the pump
is smaller than the total of the oil flow de-
manded by the tilt valve and lift valve, the
flow of oil to the tilt valve and lift valve is di-
vided according to differential pressure PO -
P2 and differential pressure PO - P3. In other
words, more oil flows to P2 where the load is
small.
★ In cases where the blade is raised in the air

and the tilt valve and lift valve (for raise) are
operated at the same time, the tilt valve load
pressure is smaller than the lift valve load
pressure, so the flow of oil to the tilt valve is
given priority. In addition, the oil flow de-
manded by the tilt valve is smaller, so the
condition is just as if priority was given to the
oil flow for the tilt valve.
3) When pressure P2 = pressure P3

P - P2 ≈ P - P3, so an oil flow proportional to
the size of the spool opening is distributed to
each spool.
D275AX-5 10-225
(3) Unload valve preset system

★ The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is op-
erated.
10-226 D275AX-5
(5)
2
• This improves the response of the system in-

cluding the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of PPC valve) to the LS cir-
cuit, and compensating the rise of the LS circuit
pressure.
(1) When lift spool (1) is at the HOLD position, pilot

pressure P1 (basic pressure of PPC valve) is
sent through preset check valve (3) to the cham-
ber F of the pressure compensation valve. This
pressure is called preset pressure P2. At the
same time, unload pressure P is being sent to
chamber B, but P1 + FO > P (FO: load of spring
(4)), so pressure compensation spool (2) moves
to the left and the size of the opening between A
and B becomes the maximum.
(2) When spool (1) is switched, unload pressure P

flows immediately through chamber A, B, C, D,
and E to lift cylinder (8), so the pressure at the
port starts to rise and the time lag becomes
smaller.
(3) At the same time, preset pressure P2 is supplied

to LS circuit O by the timing of the spool, and the
pressure in the LS circuit rises. Because of this,
unload valve (7) closes, and oil is sent further to
pump LS valve (6) to improve the response of
the pump swash plate angle. This makes it pos-
sible to reduce the response time for giving the
necessary oil flow. Check valve (5) is built in the
spool to prevent preset pressure P2 from venting
in force from the cylinder port.
(4) When cylinder port pressure P3 rises and be-

comes greater than preset pressure P2, it
pushed up check valve (5), and oil is sent to
chamber F of the pressure compensation valve
and pump LS valve (6) to give the basic ∆PLS
control.
When this happens, pressure P3 at the cylinder
port is prevented from entering the PPC pump
circuit by preset check valve (3).
D275AX-5 10-227
(5)
2
(4) Dual tilt and pitch system

★ A machine with the dual tilt specification has the dual tilt and pitch system circuit.
1) When single tilt operation is carried out
• In the single tilt mode, solenoid valve (1) is in the

neutral position and connected to PA3 and PB3
of the control valve as shown in the figure. PPC
circuits (2) and (3) are separated from output cir-
cuits (4) and (5) of the PPC valve.
Accordingly, the right tilt cylinder does not move
and only the left tilt cylinder moves to carry out
the single tilt operation.
10-228 D275AX-5
(5)
2
2) When dual tilt operation is carried out
• In the dual tilt mode, solenoid valve (1) is changed

as shown in the figure.
At this time, PPC circuit (2) connected to PB1 of
the control valve is connected to output circuit (4)
of the PPC valve.
PPC circuit (3) connected to PA1 of the control
valve is connected to output circuit (5) of the
PPC valve.
Accordingly, both tilt cylinders move in the oppo-
site directions to carry out the dual tilt operation.
D275AX-5 10-229
(5)
2
3) When pitch operation is carried out
• In the pitch mode, solenoid valve (1) is changed

as shown in the figure.
At this time, PPC circuit (2) connected to PB1 of
the control valve is connected to output circuit (5)
of the PPC valve.
PPC circuit (3) connected to PA1 of the control
valve is connected to output circuit (4) of the
PPC valve.
Accordingly, both tilt cylinders move in the same
direction to carry out the pitch operation.
10-230 D275AX-5
(5)
2
MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
P1 : From pump
P2 : To control valve
PC : To front pump LS valve
PR : Supply to PPC valve etc.
TS : To hydraulic tank
D275AX-5 10-231
1. Valve (sequence valve) 6. Spring (reducing valve main)

2. Spring 7. Valve (reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (reducing valve pilot)
10-232 D275AX-5
Unit: mm

Free length
Spring × Outside Free length
10 length load load
(reducing pressure valve, main) diameter
19.6N 17.7N
19.2 × 7.2 16.1 –
{2kg} {1.8kg} Replace spring if
Spring 28.0N 22.4N any damages or
11 17.8 × 7.2 12.7 – deformations are
(reducing pressure valve, pilot) {2.86kg} {2.29kg}
found.
199.8N 186.2
12 Spring 71 × 18 59 –
{20.4kg} {19kg}
61.7N 58.8N
13 Spring (safety valve) 16.1 × 7.8 13.4 –
{6.3kg} {6kg}
D275AX-5 10-233
Function
• The self-pressure reducing valve lowers the dis-
charge pressure of the main pump and supplies
control pressure to the solenoid valves, PPC
valves, etc.
Operation
1. When engine is stopped

• Poppet (5) is pressed against the seat by
spring (6) and the passage between ports
PR and T is closed.
• Valve (8) is pressed downward by spring (7)

and the passage between ports P1 and PR
is opened.
• Valve (2) is pressed to the left by spring (3)
and the passage between ports P1 and P2 is
closed. (See Fig. 1.)
10-234 D275AX-5
(5)
2
2. When in neutral or load pressure P2 is low

(When blade is moving under its own weight)
Note:When load pressure P2 is lower than output • If the PR pressure rises above the set level, pop-
pressure PR of the self-pressure reducing pet (5) opens and the hydraulic oil flows from the
valve. PR port through hole a in spool (8) and opening
• Valve (2) receives the force of spring (3) and PR of poppet (5) to tank port T.
pressure (which is 0 MPa {0 kg/cm2} when the Accordingly, differential pressure is generated
engine is stopped) in the direction to close the between before and after hole a in spool (8) and
circuit between ports P1 and P2. If the hydraulic then spool (8) moves to close the passage be-
oil flows in from port P1, the P1 pressure between port P1 and PR. The P2 pressure is con-
comes almost equal to the total of the force of trolled constant (at the set pressure) by the area
spring (7) and the value of area of φd x PR pres- of the oil passage at this time and supplied as
sure, then the area of the passage between the PR pressure. (See Fig. 2.)
ports P1 and P2 is so adjusted that the P1 pres-
sure will be kept constant above the PR pres-
sure.
D275AX-5 10-235
(5)
2
3. When load pressure P2 is high
• If load pressure P2 rises and the pump dis- • If the PR pressure rises above the set pressure,
charge increases because of digging operation poppet (5) opens and the hydraulic oil flows from
of the work equipment, etc., the P1 pressure ris- the PR port through hole a in spool (8) and open-
es higher than the total of the force of spring (7) ing of poppet (5) to tank port T.
and the value of φ d x PR pressure, and then Accordingly, differential pressure is generated
valve (2) moves to the right stroke end. between before and after hole a in spool (8) and
As a result, the area of the passage between then spool (8) moves to close the passage be-
ports P1 and P2 increases and the passage re- tween port P1 and PR. The P1 pressure is low-
sistance lowers and the loss of the engine power ered and controlled constant (at the set
is reduced. pressure) by the area of the oil passage at this
time and supplied as the PR pressure. (See Fig.
3.)
10-236 D275AX-5
(5)
2
4. When abnormally high pressure is generated
• If the PR pressure on the self-pressure reducing

valve rises high abnormally, ball (10) separates
from the seat against the force of spring (9) and
the hydraulic oil flows from output port PR to T.
Accordingly, the PR pressure lowers. By this op-
eration, the hydraulic devices (PPC valves, sole-
noid valves, etc.) are protected from abnormally
high pressure. (See Fig. 4.)
D275AX-5 10-237
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
1. Yoke 4. Bushing
2. Oil seal 5. Air Breather plug
3. Bushing
Unit: mm

Clearance between cylinder yoke
6 and bushing
– 0.172 + 0.088 0.218–
140 –
– 0.235 + 0.046 0.323
Replace
Clearance between cylinder yoke – 0.160 + 0.075 0.199–
7 and bushing 105 –
– 0.214 + 0.039 0.289
Clearance between lift cylinder – 0.120 + 0.035 0.120–

8 support shaft and bushing 95 0.5
– 0.207 0 `0.242
10-238 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD BLADE
BLADE
Semi U-dozer
10-240 D275AX-5
Unit: mm

Clearance between brace and size Shaft Hole clearance limit
1 brace
– 0.3 + 0.5 Replace
70 0.6–1.0 2
– 0.5 + 0.3
Clearance between brace pin and – 0.3 + 0.5

2 70 0.6–1.0 2
bracket – 0.5 + 0.3
Clearance between brace spheri- – 0.2 + 0.3

3 115 0.2–0.6 1
cal surface and cap – 0.3 0 Adjust shim or
Clearance between center brace – 0.2 + 0.3 replace
4 130 0.2–0.6 1
spherical surface and cap – 0.3 0
Clearance between joint and – 0.2 + 0.5

5 120 0.5–1.2 2
blade bracket – 0.7 + 0.3

6 120 0.5–1.2 2
frame – 0.7 + 0.3
Clearance between frame pin and – 0.3 + 0.3

7 60 0.3–0.8 3
joint – 0.5 0
Replace
8 60 0.3–0.8 3
frame – 0.5 0
Clearance between blade bracket – 0.3 + 0.3

9 60 0.3–0.8 3
pin and joint – 0.5 0

10 pin and blade bracket 60 0.3–0.8 3
– 0.5 0
Clearance between center brace – 0.2 + 0.3 Adjust shim or

11 spherical surface and cap 130 0.2–0.6 1
– 0.3 0 replace
Clearance between center link – 0.04 + 0.3

12 pin and center link 115 0.14–0.40 2
– 0.10 + 1.0

– 0.10 + 1.0
Replace
14 and blade bracket 400 0.2–0.9 2
– 0.4 0
Clearance between trunnion and – 0.5 + 1.0

15 cap spherical surface 195 0.5–2.0 8
– 1.0 0
D275AX-5 10-241
(5)
U-dozer
10-242 D275AX-5
Unit: mm

Clearance between brace and size Shaft Hole clearance limit
1 brace
– 0.3 + 0.5 Replace
70 0.6–1.0 2
– 0.5 + 0.3
Clearance between brace pin and – 0.3 + 0.5

2 70 0.6–1.0 2
bracket – 0.5 + 0.3
Clearance between brace spheri- – 0.2 + 0.3

3 115 0.2–0.6 1
cal surface and cap – 0.3 0 Adjust shim or
Clearance between center brace – 0.2 + 0.3 replace
4 130 0.2–0.6 1
spherical surface and cap – 0.3 0

5 120 0.5–1.2 2
blade bracket – 0.7 + 0.3

6 120 0.5–1.2 2
frame – 0.7 + 0.3

7 60 0.3–0.8 3
joint – 0.5 0
Replace
8 60 0.3–0.8 3
frame – 0.5 0

9 60 0.3–0.8 3
pin and joint – 0.5 0

– 0.5 0
Clearance between center brace – 0.2 + 0.3 Adjust shim or

11 spherical surface and cap 130 0.2–0.6 1
– 0.3 0 replace

12 pin and center link 115 0.14–0.40 2
– 0.10 + 1.0

– 0.10 + 0.1
Replace
14 and blade bracket 400 0.2–0.9 2
– 0.4 0
Clearance between trunnion and – 0.5 + 1.0

15 cap spherical surface 195 0.5–2.0 8
– 1.0 0
D275AX-5 10-243
(5)
Cutting edge, end bit
Unit: mm

1 Height of outside of end bit
415 300
Replace
2 Width of end bit 662 500
3 Height of inside of end bit 330 260
4 Height of cutting edge 330 260 (215 to turning) Turn or replace
10-244 D275AX-5
20-242 D155AX-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
Variable multiple shank ripper
10-246 D275AX-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
Giant ripper
Unit: mm

Clearance between bushing and
1 bracket and arm mount pin
– 0.036 + 0.207 0.156–
110 1.5
– 0.090 + 0.120 0.297
Clearance between bushing and – 0.036 + 0.207 0.156–

2 beam and arm mount pin 120 1.5
– 0.090 + 0.120 0.297
Clearance between cylinder – 0.036 + 0.207 0.156–

3 mount pin and bushing 90 1.5 Replace
– 0.090 + 0.120 0.297
Clearance between shank and Standard size Tolerance Repair limit

4 mount pin
82 ± 0.3 –

5 Wear of point
420 255
6 Wear of protector 155 115
D275AX-5 10-247
MAINTENANCE STANDARD CAB MOUNT
CAB MOUNT
1. Support Outline
2. Damper mount (front) • Viscous mounts are installed at two places at the
3. Damper mount (rear) front and two places at the rear to secure the
floor frame and cab.
• An oil-filled damper mount is used to absorb the
vibration.
10-248 D275AX-5
MAINTENANCE STANDARD CAB
CAB
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D275AX-5 10-249
MAINTENANCE STANDARD CAB
ROPS guard
1. ROPS guard
10-250 D275AX-5
MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
Air conditioner piping
1. Air conditioner compressor 9. Valve (hot water outlet)

2. Condenser 10. Receiver tank
3. Window defroster 11. Hot water return piping
4. Side defroster 12. Valve (hot water inlet)
5. Air conditioner unit 13. Refrigerant piping
6. Vent A. Fresh air
7. Blower motor B. Recirculated air
8. Hot water pick-up piping C. Hot air/cold air
D275AX-5 10-251
MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Decelerator pedal Outline

2. Starter switch • The throttle signal and throttle dial are input to
3. Decelerator potentiometer the steering controller and transmission control-
4. Steering controller ler and processed together with the other infor-
5. Transmission controller mation, then the result is sent as the throttle
6. Fuel throttle dial command to the engine controller. The engine
7. Engine controller controller controls the fuel supply pump accord-
8. Battery ing to the command.
9. Battery relay
10. Starter
11. Fuel supply pump
10-252 D275AX-5
MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
• The engine controller receives the manual sig- • The information of the engine controller is used
nals of the 2nd throttle and the 3rd throttle sig- commonly by the all controllers through the net-
nals which is the control signals from the work for the optimum control of the engine and
machine body, then selects the lower engine machine body.
speed and controls the fuel supply pump. • The automatic deceleration function sets the en-
The 3rd throttle control signals contain the fol- gine speed to 1,000 rpm temporarily when the
lowing. travel direction is changed from F3, R3, or R2 (to
1 1st throttle signal protect the transmission clutch).
2 SSC (Shoe Slip Control) control
3 Automatic deceleration (F3, R3, R2)
• The steering controller selects the lowest engine

speed from information 1, 2, and 3 and trans-
mits it as the 3rd throttle to the engine controller.
D275AX-5 10-253
2
MAINTENANCE STANDARD DECELERATION POTENTIOMETER
DECELERATION POTENTIOMETER
1. Connector Outline
2. Lever • The deceleration potentiometer is installed to the
3. Body front lower part of the operator's cab and con-
4. Potentiometer nected to the decelerator pedal by linkage.
5. Coupling
6. Shaft • If the decelerator pedal is pressed, the throttle
7. Stopper 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 steering controller ac-
cording to the position of the decelerator pedal.
10-254 D275AX-5
(5)
20-242 D155AX-5
MAINTENANCE STANDARD CRI ENGINE CONTROL SYSTEM
CRI ENGINE CONTROL SYSTEM

★ "CRI" is an abbreviation for Common Rail Injection.
System diagram
Outline
• The signals detected by various sensors are in-
put to the engine controller.
• The input signals are processed by the controller
and output to each actuator to control the fuel in-
jection rate and fuel injection timing.
10-256 D275AX-5
MAINTENANCE STANDARD CRI ENGINE CONTROL SYSTEM
1. Fuel tank System configuration

2. Fuel supply pump assembly • The CRI system consists of fuel supply pump
2A. PCV (2), common rail (5), injector (8), ECU (10) to
2B. High pressure pump control them, and sensors.
2C. Priming pump • The fuel supply pump generates fuel pressure in
2D. Feed pump the common rail. The fuel pressure is controlled
2E. Bypass valve by the fuel discharge rate of the supply pump.
2F. G speed sensor The discharge rate is controlled by turning on
3. Fuel filter and off PCV (discharge control valve) (2A) of the
4. Overflow valve fuel supply pump according to the electric sig-
5. Common rail nals from the ECU.
6. Pressure limiter The common rail receives the pressurized fuel
7. Flow damper from the fuel supply pump and distributes it to
8. Injector assembly the cylinders.
8A. Orifice The fuel pressure is sensed by the common rail
8B. Control chamber fuel pressure sensor installed to the common rail
8C. Hydraulic piston and controlled by the feedback method so that
8D. Injector the actual fuel pressure will match to the com-
8E. Nozzle mand pressure set according to the engine
9. Fuel cooler speed and the load on the engine.
10. ECU (Engine Control Unit) The fuel pressure in the common rail is applied
11. NE speed sensor to the nozzle (8E) side of the injector and control
chamber (8B) through the fuel injection pipe of
each cylinder.
• 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 (8A). The needle valve is
raised to start fuel injection by the nozzle crack-
ing pressure applied as the high-pressure fuel on
the nozzle side. If the TWV is turned off, the fuel
circuit is so change that the high-pressure 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 con-
trolled respectively by the timing to turn on the
TWV and the length of the turn-on time of the
TWV.
D275AX-5 10-257
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
• The monitor system monitors the machine con- • The monitor panel has functions of displaying
dition with the sensors installed to various parts data and selecting the SSC mode.
of the machine and processes and displays the The CPU (Central Processing Unit) in it process-
obtained information on the panel quickly to no- es, displays, and outputs the information. The
tify the operator of the machine condition. display unit is LCD (Liquid Crystal Display) and
The main display sections and functions of the the switches are seat switches.
panel are as follows.
1) Monitor unit which turns on the alarm when
the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel level,
etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and volt-
age of the sensors and solenoids.
• In the monitor panel, there are various mode se-

lector switches of the SSC (Shoe Slip Control),
which are used to operate the machine control
system.
10-258 D275AX-5
MAINTENANCE STANDARD MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)

Display of monitor panel
1 Contents and conditions of processing 2 Method 3 Flow of signals
1) Display of travel direction and gear speed.
F1, R3, etc. are notified by CAN according to information Transmission controller–Steering
of transmission controller. controller–Monitor panel
2) Display of engine speed in gauge number. CAN Engine speed sensor–Engine

The number of pulses the engine rotation is converted (Controller Area Network) controller– Steering controller–
into a gauge number and notified to the monitor panel by Monitor panel
CAN.
3) Display of troubleshooting CAN

When the machine has a trouble, the corresponding fail- Each sensor/solenoid–Control-
ure code is notified to the monitor panel by CAN. ler–Monitor panel
Which one should be turned on, the buzzer or the cau-
tion lamp, is notified, too.
1 In normal state
User code
2 In trouble history display mode
The service code (6-digit code) and the following
items are displayed
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrences
The monitor panel displays the code on the hour meter
section.
Display of monitoring condition

1) The communication conditions of each sensor, each so- CAN
lenoid, and CAN are displayed.
The item Nos. and device conditions are notified to the Each sensor–Controller–Monitor
monitor panel by CAN. panel
The monitor panel displays the items and each value on
its multi-information section.
2) Each items is selected by using the cursor switches, se- Monitor panel–Controller–Monitor
lector switches, buzzer cancel switch, and shift UP/ panel
DOWN switches.
Other items
1) Function selection mode (Displayed each time cancel
switch is turned to left)
1 Replacement periods of oil filter and oil are dis-
played.
2 Engine speed, oil pressure in work equipment cir-
cuit, etc. are displayed.
3 Failure codes related to electronic control are dis-
played. — —
4 Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of maintenance
mode
3) Mode to display failure codes related to machine body
such as overheating, abnormal water temperature, etc.
4) Mode to display service meter and information related to
load on machine
D275AX-5 10-259
(5)
MAINTENANCE STANDARD MONITOR PANEL
MONITOR PANEL
Monitor portion
1. Display plate (Speed range display) 9. Power train oil temperature caution lamp
2. Charge lamp 10. Engine water temperature caution lamp
3. Power train oil temperature gauge 11. Dual tilt display lamp
4. Engine water temperature gauge 12. Engine oil pressure caution lamp
5. Fuel gauge 13. Maintenance caution lamp
6. Hydraulic oil temperature gauge 14. Preheat pilot lamp
7. Hydraulic oil temperature caution lamp 15. Radiator water level check lamp
8. HSS charge pressure caution lamp 16. Display plate (Multi information)
Outline 3. Cautions
• The monitor portion consists of a monitor that is- Caution items are checked until the engine stops
sues an alarm when an error occurred in a vehi- after the engine starts.
cle, a gauge that always displays the state of the If an error occurs, the error is displayed by flash-
vehicle, and the service meter. ing and the alarm lamp synchronously flashes.
The monitor portion installs a microcomputer Further, if an emergency item flashes, the alarm
and processes and displays signals from each buzzer also sounds synchronously.
sensor. ★ Flashing of the monitor and alarm lamp is re-
Besides, the items displayed on the monitor por- peated. They come on and off for about 0.8 sec-
tion and gauge portion are listed in the table on ond.
the next page. ★ The flashing period of the monitor slightly chang-
es when atmospheric temperature is low (below
Operation
about - 10°C), but this case in not abnormal.
1. When the power turns on (When the starter
switch is ON)
1) All items of the gauge and monitor portions
come on for three seconds.
2) The alarm lamp comes on for two seconds.
2. Star-up inspection
1) After all lighting of Section 1 is terminated, if
there is an error in a start-up inspection item,
the item flashes.
2) If the engine is started, the check items be-
fore starting go off. (If the engine is running
is judged by the signal (CAN) from the en-
gine controller.)
10-260 D275AX-5
Monitor panel display

Display
Symbol Display item Display range Display method
category
Displays when engine is stopped and

starting switch is ON
Radiator water level Below low level
Display when normal: OFF
Display when abnormal: Flashes
Check
When sensor is abnormal

Display when normal: OFF
Engine oil pressure or when wiring harness is
Display when abnormal: ON
disconnected
Displays when starting switch is ON and

Caution 1
engine is running
Battery charge When charge is defective Display when normal: OFF
SAP00522 Display when abnormal: Flashes
CAUTION lamp flashes
Below 49.0kPa
Engine oil pressure
{0.5kg/cm2}
Radiator water level Below low level
When at highest level

(108°C or above) on
Engine water temperature
engine water
temperature gauge
Displays when starting switch is ON and
When at highest level engine is running
Caution 2
Torque converter oil tem- (130°C or above) on Display when normal: OFF
perature engine water Display when abnormal: Flashes
temperature gauge CAUTION lamp flashes
Alarm buzzer sounds
Hydraulic oil temperature 105±3°C or above
When HSS charge

HSS charge pressure
pressure is reduced
When replacement time

Maintenance of filter or oil has been
passed
Lights according to required time

determined by engine controller based.
Preheating When preheating It also lights at the time of manual pre-
heat by setting starting switch at preheat
position (turning it counterclockwise).
Pilot
Display lights at the time of operation.

Dual tilt At the time of operation
It goes off at the time of non-operation.
D275AX-5 10-261
Display
Symbol Display item Display range Display method
category
Engine water temperature
Torque converter oil One place lights up to show

temperature applicable level
Gauges
Hydraulic oil temperature
All lamps light up below ap-

Fuel level
plicable level
Multi information
Service meter Actuated when the engine is

From 0 to 99999
(Hours meter) rotating
10-262 D275AX-5
Switch Portion
1. Switch functions
a) ON-OFF switching in lock-up mode
b) Economy mode setting - OFF, mode 1, mode 2
c) ON-OFF switching in reverse slow mode
d) ON-OFF switching in SSC mode
e) SSC mode level setting - Mode 1 to 5
a, b, and c are mounted for all specifications and d and e are mounted for the SSC specifications.
• SSC specifications
• Without SSC specifications
Economy Mode Function

In a field, such as a rock-bed place where many shoe 2. Initial Setup at key ON
slips are generated, the following power is output in The function the operator desires according to
each mode so that the frequency of decelerator oper- the situation of an operating place is selected and
ation can decrease. all functions shall be set to the OFF state.
• Economy mode 1 → Set to about 90% of the full
power.
• Economy mode 2 → Set to about 70% of the full
power.
• Reverse slow mode → Set to about 80% of the
full travel speed at reverse time.
D275AX-5 10-263
MAINTENANCE STANDARD SENSORS
SENSORS
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine water temperature Resistance – –

Torque converter
Resistance – –
oil temperature
Hydraulic oil temperature Resistance – –
Radiator water level Contact ON OFF
Fuel level Resistance – –
HSS charge pressure Contact ON OFF
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
10-264 D275AX-5
Engine cooling water temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Radiator water level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
D275AX-5 10-265
Fuel level sensor
1. Connector Function
2. Float • The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Body ing go to the fuel level. This movement of the
5. Spring float is transmitted by the arm and actuates a
6. Contact variable resistance. This sends a signal to the
7. Spacer monitor panel to indicate the remaining fuel level.
When the display on the monitor panel reaches
a certain level, a warning lamp flashes.
10-266 D275AX-5
HSS charging pressure sensor
1. Switch
2. Case
3. Wire
4. Connector
D275AX-5 10-267
MAINTENANCE STANDARD MODE SELECTION SYSTEM
MODE SELECTION SYSTEM

(SSC (Shoe Slip Control) System)
System diagram
Outline
• The mode selection system automatically car- • The lock-up control mode is the same as the
ries out engine control to match the operating conventional lock-up function. It cannot be se-
mode selected by the operator, and acts to re- lected in combination with the above modes.
duce fuel consumption, extend the life of the
track shoes, and reduce the frequency of opera-
tion of the deceleration.
• The engine control modes consist of the econo-
my mode control used when dozing, the SSC
(shoe ship control) used when ripping, and the
reverse slow mode control, which can be used
for either operation.
10-268 D275AX-5
Function of model selection system Function of engine controller

• This system consists of the mode selection pan- 1. The engine controller controls the fuel supply
el (containing a microcomputer) to select work- pump according to the lowest engine speed
ing condition, steering controller (containing a (highest voltage) in the 3 signals of the manual
microcomputer) to control the engine, engine command input from the deceleration potentiom-
controller to receive the commands from the eter, manual signal of the throttle dial, and the
steering controller and controls the fuel supply SSC command signal.
pump, transmission controller to turn on and off
the lock-up system of the torque converter ac-
cording to the signals from the transmission out-
put speed sensor, and various sensors.
The function of each controller is explained be-
low.
Functions of steering controller and

transmission controller
1. The steering controller calculates the travel
speed to the ground from the signals of the ac-
celeration sensor and inputs the transmission
output speed sensor signal to it to calculate the
shoe speed, then obtains the shoe slip rate.
2. If the engine speed sensor signal and transmis-
sion output speed sensor signal are input, the
steering controller calculates the traction force.
3. The steering controller calculates the optimum
engine speed from the results of 1 and 2 above,
mode set signal of the monitor panel, and speed
information from the transmission controller,
then sends it as the SSC command to the engine
controller.
4. The transmission controller sends the lock-up
signal to the lock-up solenoid valve, judging from
the input gear speed information of the transmis-
sion controller.
★ See "OPERATION OF TORQUE CON-
VERTER LOCK-UP CONTROL SYSTEM".
D275AX-5 10-269
Operation of mode selection system

• Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in
accordance with the contents of work
Simulta-
Mode Single
Work neous Mode work condition Mode operation, characteristic
switch selection selection
• ON/OFF switching is automatically per- 1. When the torque converter approaches to the
formed in accordance with a load. stall area or performs gear shaft operation,
lock-up is set to OFF. When the torque convert-
Speed number F2, F3, er reaches a light lode, lock-up is set to ON.
of gear ratios F1 R1, R2, R3 2. Can be used in all number of gear ratios.
Lock-up
1,230 rpm 1,260 rpm 3. Simultaneous selection disabled with another

speed side speed side
ON
or more or more
! mode
Low
shaft speed
1,200 rpm 1,230 rpm 4. Suitable for dozing work of comparatively a few
T/C output
OFF
or more or more load fluctuations
_ 2,140 rpm
ON
or more
High
2,200 rpm
Dozing
OFF
or more
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC
mode switch 1 or 2 ON are set simultaneously, the F1 shift economy
control is performed. When the ripper lever is
actuated and the switch is turned on, the slip
Economy
control is performed.
2. The engine output can be suppressed in two
! ! stages without performing the decelerator op-
eration of the engine.
Mode 1: 90% (at 1.5 km/h)
Mode 2: 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be sup-
pressed partially
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
Reverse slow
performing the decelerator operation of the en-

gine.
! ! 2. Target travel speed at reverse time
R1
R2 70% at full operation
R3
The following conditions are satisfied: 1. At start, to prevent rashing out, the modulating
1 When F1 is shifted. valve is actuated. At this time, the steering con-
2 After the ripper down, ripper tilt levers troller performs index characteristic down of
are actuated and the switch is set to ON about 40% and performs the engine outpuut
control if a ripper down signal is input.
2. The seering controller performs the engine
SSC (Shoe Slip Control)
output control in accordance with the index

force characteristic (refer to the rock-bed se-
Ripping
lection shown below) selected by the operator

among the index force characteristics set in
five stages and suppresses the generation of a
slip.
3. The steering controller regards the index force
! ! immediately before the slip (exceeding the
shoe ripping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller per-
forms index characteristic down of about 30 to
80% and performs the engine outpuut control
if a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is sup-
pressed partially.
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection
Rock-bed
selection
mode 3 comes on.

2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the
state and load of the rock-bed
★ When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the en-
gine output control is performed in accordance with the command having the smallest value among the con-
trol command, throttle command, and decelerator command.
10-270 D275AX-5
SENSORS
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
D275AX-5 10-271
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
• 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 con-
troller.
• The input and output characteristics of the sensor
are shown in the diagram on the right.
10-272 D275AX-5
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
D275AX-5 10-273
MAINTENANCE STANDARD ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT
Relay box
10-274 D275AX-5
Operation of lamp system
Lamp system circuit diagram
D275AX-5 10-275
Preheat (Electrical intake air heater) control
Preheat circuit
10-276 D275AX-5
MAINTENANCE STANDARD PALM COMMAND CONTROL SYSTEM
PALM COMMAND CONTROL SYSTEM
1. Monitor panel (Multi-information) 6. Steering control valve

2. Auto shift-down switch 7. Transmission output speed sensor
3. Engine controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
D275AX-5 10-277
MAINTENANCE STANDARD PALM COMMAND CONTROL SYSTEM
• Shift Mode Function

1. Function
If you shift the lever to the forward or reverse, the
gear speed selected from the shift mode is
turned on.
• Shift mode 1
• Shift mode 2
2. Type of Modes
1 F1-R2
2 F2-R2
3 F1-R1 (Manual mode)
3. Selecting method
Shift the steering or forward-reverse lever to “N”.
Shift up switch ON Shit up switch ON
Manual mode Shift mode 1 Shift mode 2
Shift down switch ON Shift down switch ON
4. Displaying method
Monitor panel
• Auto Shift-down Function

1. Operating condition
This function automatically shifts the gear speed
down if load is increased while the machine is
travelling at 2nd or 3rd speed or while the ma-
chine is in operation.
2. Selecting method
Turn the auto shift-down switch (1) “ON”.
3. Operation and features of the mode
1) This function turns on the shift-down auto-
matically by calculating the drawbar pull
(load to the machine body) based the engine
speed, transmission speed and throttle infor-
mation from the steering controller.
2) Once the machine is automatically shifted
down, shit-up won’t be turned on automati-
cally (shift up from the manual switch is
available, though).
3) This function is available for both the forward
and reverse travel.
10-278 D275AX-5
(5)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

Standard value table for engine ............................................................................................................... 20- 2
Standard value table for chassis .............................................................................................................. 20- 3
TESTING AND ADJUSTING ................................................................................................................... 20-101
TROUBLESHOOTING ............................................................................................................................. 20-301
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the ma-
chine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the re-
sults of various tests. It is used for reference together with the state of repair and the history of operation to
judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
D275AX-5 20-1
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Engine SDA6D140E-3
Item Measurement conditions Unit Standard value for Service limit value
new machine
High idling 2,150 ± 50 2,150 ± 50
Speed Low idling rpm 700 ± 50 700 ± 50
Rated speed 2,000 2,000
Intake air pressure
At rated output kPa {mmHg} Min. 116.0 {870} Min. 97.3 {730}
(Boost pressure)
Whole speed range
Exhaust temperature °C Max. 650 Max. 700
(Outside air temperature: 20°C)
At sudden acceleration Max. 6.0 Max. 8.0
Exhaust gas color Bosch index
At high idling Max. 1.0 Max. 2.0
Valve clearance Air intake valve 0.35 —
mm
(At normal temperature) Exhaust valve 0.57 —
2
Oil temperature: 40 – 60°C MPa {kg/cm } Min. 2.4 {24.6} Min. 2.84 {29}
Compression pressure
(Engine speed: 200 – 250rpm) (rpm) (200 – 250) (200 – 250)
Cooling water temperature:
Blow-by pressure Within operating range kPa {mmH2O} Max. 1.96 {200} Max. 3.92 {400}
At rated output
Cooling water temperature:
Within operating range
At high idling
SAE30 or SAE15W-40 oil 0.34 – 0.54 {3.5 – 5.5} Min. 0.21 {2.1}
Oil pressure
SAE10W oil MPa {kg/cm2} 0.29 – 0.49 {3.0 – 5.0} Min. 0.18 {1.8}
(SAE15W-40 oil)
At low idling
SAE30 or SAE15W-40 oil 0.12 {1.2} Min. 0.08 {0.8}
SAE10W oil 0.10 {1.0} Min. 0.07 {0.7}
Oil temperature Whole speed range (In oil pan) °C 90 – 110 Max. 120
Deflection under finger pressure
Tension of alternator belt mm 13 – 16 13 – 16
of 98N {10kg}
Tension of air conditioner Deflection under finger pressure
mm 10 10
compressor belt of 58.8N {6kg}
20-2 D275AX-5
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Category Item Measurement conditions Unit Standard value for Service
new machine limit value
Decelerator pedal • Engine water temperature:
900 ± 50 900 ± 50
speed Within operating range
Auto deceleration • Torque converter oil temperature:
Within operating range 2,000 ± 25 2,000 ± 25
speed
Engine speed
Torque converter stall • Hydraulic oil temperature:

Within operating range 1,620 ± 50 1,510
speed rpm
• Decelerator pedal speed: Press pedal.
• Auto deceleration speed:
Torque converter stall Set all equipment in neutral.
+ Work equipment re- • Torque converter stall speed: F3 1,580 ± 50 1,450
lief speed • Torque converter stall + Work equip-
ment relief speed: F3 + Ripper RAISE
Neutral → 30 ± 10 30 ± 10
Forward and Forward
Neutral →
PCCS lever
reverse
Reverse 30 ± 10 30 ± 10
• Stop engine.
mm 40 ± 10 40 ± 10
• Set lever knob to center. Neutral →
Left (Play: Max. 3) (Play: Max. 3)
Steering
Neutral → 40 ± 10 40 ± 10
Stroke of control lever/pedal
Right (Play: Max. 3) (Play: Max. 3)

• Stop engine.
Decelerator pedal mm 47 ± 5 47 ± 5
• Set pedal to center.
All stroke 75 ± 8 75 ± 8
• Engine: Low idling
Brake pedal Stroke to 0 of mm
• Set pedal to center. 61 ± 10 61 ± 10
oil pressure
• Engine: Low idling Neutral –
72 ± 10 72 ± 10
• Hydraulic oil temperature: Raise/Float
Blade lever mm
Within operating range Neutral –
• Set lever knob to center. 53 ± 10 53 ± 10
Right/Left tilt
Neutral –
• Engine: Low idling 85 ± 10 85 ± 10
• Hydraulic oil temperature: Raise/Lower
Ripper lever Neutral – mm
Forward/ 85 ± 10 85 ± 10
• Set lever knob to center. Reverse tilt
Neutral → 46.1 ± 4.9 46.1 ± 4.9
Forward and Forward {4.7 ± 0.5} {4.7 ± 0.5}
PCCS lever
reverse Neutral → 46.1 ± 4.9 46.1 ± 4.9

• Stop engine. Reverse {4.7 ± 0.5} {4.7 ± 0.5}
N {kg}
• Set lever knob to center. Neutral → 26.5 ± 4.9 26.5 ± 4.9
{2.7 ± 0.5} {2.7 ± 0.5}
Operating effort of control lever/pedal
Left
Steering
Neutral → 26.5 ± 4.9 26.5 ± 4.9
Right {2.7 ± 0.5} {2.7 ± 0.5}
• Stop engine. 49.0 ± 9.8 49.0 ± 9.8
Decelerator pedal N {kg} {5.0 ± 1.0} {5.0 ± 1.0}
• Engine: Low idling 490.0 ± 49.0 490.0 ± 49.0
Brake pedal N {kg} {50.0 ± 5.0} {50.0 ± 5.0}
Neutral → 27.4 ± 9.8 27.4 ± 9.8
• Engine: Low idling Raise {8.4 ± 1.0} {8.4 ± 1.0}
• Hydraulic oil temperature: Neutral → 82.3 ± 9.8 82.3 ± 9.8
Blade lever N {kg} {8.4 ± 1.0} {8.4 ± 1.0}
Within operating range Float
• Set lever knob to center. Neutral – 27.4 ± 9.8 27.4 ± 9.8
Right/Left tilt {2.8 ± 1.0} {2.8 ± 1.0}
• Engine: Low idling Neutral – 24.5 ± 9.8 24.5 ± 9.8
• Hydraulic oil temperature: Raise/Lower {2.5 ± 1.0} {2.5 ± 1.0}
Ripper lever N {kg}
Within operating range Neutral – 24.5 ± 9.8 24.5 ± 9.8
• Set lever knob to center. Tilt in/out {2.5 ± 1.0} {2.5 ± 1.0}
D275AX-5 20-3
1

Engine: Max. 0.2 Max. 0.2
Torque converter in- Low idling {Max. 2} {Max. 2}
let pressure Engine: 0.49 – 1.0 0.49 – 1.0
High idling {5 – 10} {5 – 10}
Engine: Max. 0.2 Max. 0.2
Torque converter Low idling {Max. 2} {Max. 2}
outlet pressure Engine: 0.49 ± 0.1 0.49 ± 0.1
• Torque converter oil
High idling MPa {5 ± 1} {5 ± 1}
temperature:
Within operating range Engine:
{kg/cm2} 1.27 ± 0.2 1.27 ± 0.2
Torque converter
Low idling {13 ± 2} {13 ± 2}
lock-up clutch pres-
sure Engine: 1.27 ± 0.2 1.27 ± 0.2
High idling {13 ± 2} {13 ± 2}
Engine: 2.65 ± 0.2 2.65 ± 0.2
Torque converter
Low idling {27 ± 2} {27 ± 2}
stator clutch pres-
Engine: 2.65 ± 0.2 2.65 ± 0.2
sure
High idling {27 ± 2} {27 ± 2}
Engine: 2.84 – 3.14 Min. 2.65
Transmission main Low idling {29 – 32} {Min. 27}
relief pressure Engine: 3.14 – 3.43 Min. 2.94
High idling {32 – 35} {Min. 30}
Engine: 2.84 – 3.14 Min. 2.65
Transmission F Low idling {29 – 32} {Min. 27}
Power train oil pressure
clutch pressure Engine: 3.14 – 3.43 Min. 2.94

Engine: 2.84 – 3.14 Min. 2.65
Transmission R Low idling {29 – 32} {Min. 27}
Engine: 2.84 – 3.14 Min. 2.65
Transmission 1st Low idling {29 – 32} {Min. 27}
• Torque converter oil Engine: 2.84 – 3.14 Min. 2.65
MPa
Transmission 2nd temperature: Low idling {kg/cm2} {29 – 32} {Min. 27}
clutch pressure Within operating range Engine: 3.14 – 3.43 Min. 2.94
Engine: 2.84 – 3.14 Min. 2.65
Transmission 3rd Low idling {29 – 32} {Min. 27}
Transmission lubri- Engine: 0.05 – 0.29 0.05 – 0.29
cating oil pressure
(For reference) High idling {0.5 – 3.0} {0.5 – 3.0}
Engine: 2.84 – 3.14 Min. 2.26
Steering left brake Low idling {29 – 32} {Min. 23}
pressure Engine: 3.14 – 3.43 Min. 2.45
Engine: 2.84 – 3.14 Min. 2.26
Steering right brake Low idling {29 – 32} {Min. 23}
pressure Engine: 3.14 – 3.43 Min. 2.45
20-4 D275AX-5
1

• Torque converter oil
Ripper pin puller op- Engine: MPa 3.14 – 3.43 Min. 2.45
temperature:
erating pressure High idling {kg/cm2} {32 – 35} {Min. 25}
HSS main relief 38.2 – 41.7 38.2 – 41.7
• Hydraulic oil temperature:
pressure MPa {390 – 425} {390 – 425}
HSS charge relief {kg/cm2} 2.6 – 3.4 2.6 – 3.4
• Engine: High idling
pressure {27 – 35} {27 – 35}
F1 3.7 ± 0.2 3.7 ± 0.2
• Flat road F2 6.6 ± 0.3 6.6 ± 0.3
• Engine water Lock-up
F3 10.6 ± 0.6 10.6 ± 0.6
temperature: switch: km/h
OFF R1 4.8 ± 0.2 4.8 ± 0.2
• Torque converter oil R2 8.5 ± 0.4 8.5 ± 0.4
temperature: R3 14.3 ± 0.7 14.3 ± 0.7
Travel speed
Within operating range F1 3.8 ± 0.2 3.8 ± 0.2
• Engine: High idling F2 6.7 ± 0.3 6.7 ± 0.3
• Run up distance: Lock-up
F3 11.2 ± 0.6 11.2 ± 0.6
10 – 30m switch: km/h
• Measuring distance: R1 4.9 ± 0.2 4.9 ± 0.2
ON
20m R2 8.7 ± 0.4 8.7 ± 0.4
R3 14.9 ± 0.7 14.9 ± 0.7
Engine:
— —
Low idling
Unload pressure + 1.37 + 1.37
Engine: 2.45 0 2.45 0
High idling + 14 + 14
{25 0 } {25 0 }
Engine: 27.44 ± 1.37 27.44 ± 1.37
Blade lift relief pres- Low idling {280 ± 14} {280 ± 14}
sure • Hydraulic oil Engine: 27.44 ± 1.37 27.44 ± 1.37
temperature: High idling {280 ± 14} {280 ± 14}
Within operating range Engine: 27.44 ± 1.37 27.44 ± 1.37
Blade tilt relief pres- • Unload pressure: Low idling {280 ± 14} {280 ± 14}
sure Set all equipment in
Engine: 27.44 ± 1.37 27.44 ± 1.37
neutral. MPa
High idling {280 ± 14} {280 ± 14}
• Relief pressure: {kg/cm2}
Set cylinder to stroke Engine: 27.44 ± 1.37 27.44 ± 1.37
Ripper lift relief pres- end. Low idling {280 ± 14} {280 ± 14}
sure • LS pressure: Engine: 27.44 ± 1.37 27.44 ± 1.37
Set cylinder to stroke High idling {280 ± 14} {280 ± 14}
end. Engine: 27.44 ± 1.37 27.44 ± 1.37
Ripper tilt relief pres- Low idling {280 ± 14} {280 ± 14}
sure Engine: 27.44 ± 1.37 27.44 ± 1.37
High idling {280 ± 14} {280 ± 14}
Engine: 25.48 ± 1.27 25.48 ± 1.27
LS pressure Low idling {260 ± 13} {260 ± 13}
(Load sensing pres-
sure) Engine: 25.48 ± 1.27 25.48 ± 1.27
High idling {260 ± 13} {260 ± 13}
Control circuit main 3.43
+ 0.49
3.43
+ 0.49
0 – 0.20
pressure • Hydraulic oil temperature:
MPa +5 +5
(HSS, PPC, fan) Within operating range {35 0 } {35 – 2 }
{kg/cm2}
PPC valve output • Engine: High idling 3.14 – 3.92 3.14 – 3.92
pressure {32 – 40} {32 – 40}
D275AX-5 20-5
1
(5)

Low idling 8 – 15 20
Raise
High idling 3–5 6
Blade lift sec
Low idling 1 – 1.5 2
Lower
45 – 55°C
• Apply no load to blade.
• Between ground level and ris- High idling 1 – 1.5 2
ing end of blade
Low idling 3–5 7

Left tilt
High idling 2.8 ± 0.5 3.5

Blade tilt sec
• Hydraulic oil temperature: Low idling 3–5 7

Right tilt
45 – 55°C
• Between left tilt end and right High idling 2.8 ± 0.5 3.5
tilt end
Work equipment speed
Low idling 5–8 10

Work equipment
Left tilt

Blade
sec
dual tilt
• Hydraulic oil temperature: Low idling 5–8 10
Right tilt
45 – 55°C
• Between left tilt end and right High idling 2.8 ± 0.5 3.5
tilt end
Low idling 6–9 12

Forward

Blade
sec
pitch • Hydraulic oil temperature:
Backward
45 – 55°C Low idling 5–8 10

• Between forward end and
backward end High idling 2.8 ± 0.5 3.5
Raise

Ripper lift sec
45 – 55°C Low idling 3.3 – 4.3 6
Lower
• Apply no load to ripper.

• Between ground level and ris-
ing end of blade High idling 3.5 ± 0.5 4.5
20-6 D275AX-5
1

Tilt in
Ripper tilt sec
• Hydraulic oil temperature: Low idling 8 – 14 17
Tilt out
45 – 55°C
• Apply no load to ripper.
• Between tilt-in end and tilt-out High idling 3.5 ± 0.5 4.5
end
45 – 55°C Low idling Max. 8 11
• Move lever to stroke end.
Blade • Lower blade from max. rising posi-
tion and measure time after blade
comes in contact with ground until High idling Max. 1.8 2.5
Time lag
idler is lifted.
sec
45 – 55°C Low idling Max. 6 8
• Move lever to stroke end.
Ripper • Lower ripper from max. rising posi-
tion and measure time after ripper
comes in contact with ground until High idling Max. 1.5 2.5
sprocket is lifted.
Work equipment
Hydraulic
drift of lift- Max. 200/15 minutes 300/15 minutes
ed blade
• Hydraulic oil temperature: 45 – 55°C
• Engine: Stopped
• Measure reduction of blade bottom height h
(for 15 minutes).
Hydraulic
Hydraulic drift
drift of
machine Max. 50/5 minutes 100/15 minutes
lifted by mm
blade
• Engine: Stopped
• Measure reduction of idler center height h
(for 5 minutes).
Hydraulic
drift of
tilted by
blade
• Engine: Stopped
• Measure reduction of idler center height h
(for 5 minutes).
D275AX-5 20-7
1

Hydraulic
drift of lift- Max. 80/15 minutes 160/15 minutes
ed ripper
• Hydraulic oil temperature: 45 – 55ºC
• Engine: Stopped
• Measure reduction of shank bottom height h
(for 15 minutes).
mm
Hydraulic
drift of
lifted by
ripper • Hydraulic oil temperature: 45 – 55ºC
• Engine: Stopped
• Measure reduction of sprocket center height h
(for 5 minutes).
Blade tilt
4 16
cylinder
Ripper lift • Hydraulic oil temperature: 45 – 55ºC
cc/min 4 16
cylinder • Relieve cylinder and measure leakage for 1
minute.
Ripper tilt
4 16
cylinder
• Fan: 100% speed mode
Min. speed 450 ± 30 400
• Engine: Low idling
Fan speed rpm
• Fan: 100% speed mode
Max. speed 1,050 ± 50 950
Fan pump oil • Fan: 100% speed mode MPa 16.17 – 19.11 16.17 – 19.11
pressure • Engine: High idling {kg/cm2} {165 – 195} {165 – 195}
20-8 D275AX-5
1
(5)
TESTING AND ADJUSTING 20
Tools for testing, adjusting, and troubleshooting .................................................................................. 20- 102-1

Measuring engine speed ......................................................................................................................... 20-103
Measuring intake air pressure (Boost pressure) ...................................................................................... 20-106
Measuring exhaust temperature .............................................................................................................. 20-108
Measuring exhaust gas color ................................................................................................................... 20-110
Adjusting valve clearance ........................................................................................................................ 20-111
Measuring compression pressure ........................................................................................................... 20-112
Measuring blow-by pressure .................................................................................................................... 20-113
Measuring engine oil pressure ................................................................................................................ 20-114
Handling of fuel system devices .............................................................................................................. 20-115
Releasing residual pressure from fuel system ......................................................................................... 20-115
Measuring fuel pressure .......................................................................................................................... 20-116
Bleeding air from fuel circuit .................................................................................................................... 20-117
Inspection of fuel circuit for leakage ........................................................................................................ 20-119
Testing and adjusting alternator belt tension ........................................................................................... 20-120
Testing and adjusting air conditioner compressor belt tension ................................................................ 20-120
Adjusting fuel control dial and decelerator pedal ..................................................................................... 20-121
Measuring power train oil pressure ......................................................................................................... 20-123
Testing and adjusting HSS oil pressure ................................................................................................... 20-131
Adjusting transmission speed sensor ...................................................................................................... 20-135
Bleeding air from HSS pump ................................................................................................................... 20-136
Simple method of testing brake performance .......................................................................................... 20-136
Adjusting brake pedal and parking brake lever ........................................................................................ 20-137
Adjusting PCCS lever console position ................................................................................................... 20-139
Emergency escape method when power train has trouble ...................................................................... 20-140
Adjusting clearance of idler ..................................................................................................................... 20-143
Inspecting wear of sprocket ..................................................................................................................... 20-143
Testing and adjusting track shoe tension ................................................................................................. 20-144
Testing and adjusting work equipment oil pressure ................................................................................. 20-145
Testing and adjusting control circuit main pressure ................................................................................. 20-149
Measuring PPC valve output pressure .................................................................................................... 20-150
Adjusting play of PPC valve ..................................................................................................................... 20-152
Measuring outlet pressure of ripper pin puller solenoid valve ................................................................. 20-153
Testing parts which cause hydraulic drift of blade and ripper .................................................................. 20-154
Measuring internal leakage of work equipment cylinder ......................................................................... 20-155
Releasing residual pressure from work equipment cylinder .................................................................... 20-156
Bleeding air from work equipment cylinder .............................................................................................. 20-156
Adjusting ripper lever position .................................................................................................................. 20-157
Adjusting safety lock lever ....................................................................................................................... 20-158
Measuring fan motor speed ..................................................................................................................... 20-159
D275AX-5 20-101
1
(5)
Measuring fan circuit oil pressure ........................................................................................................ 20- 159-1

Changing rotation direction of fan motor .................................................................................................. 20-160
Bleeding air from fan pump ...................................................................................................................... 20-160
Adjusting blade ........................................................................................................................................ 20-161
Testing and adjusting operator’s cab .................................................................................................... 20- 162-1
Special functions of monitor panel (EMMS) ............................................................................................. 20-163
Handling of high-voltage circuit of engine controller ................................................................................ 20-209
Adjustment method of replaced controller ............................................................................................... 20-209
Preparation work for troubleshooting for electric system ......................................................................... 20- 211
Handling of optional devices .................................................................................................................... 20-213
Pm clinic service ...................................................................................................................................... 20-214
Undercarriage troubleshooting report ...................................................................................................... 20-220
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safe-
ty pins and blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-102 D275AX-5
(8)
1
TOOLS FOR TESTING, ADJUSTING, AND
TESTING AND ADJUSTING TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Testing and adjusting item Symbol Part No. Part name Q’ty Remarks
Measuring intake air

A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
pressure (boost pressure)
Measuring exhaust B 799-101-1502 Digital thermometer 1 –99.9 – 1,299ºC

temperature — 799-201-1150 Adapter connector 1 For Pm clinic specification
1 799-201-9000 Handy smoke checker 1 Pollution level: 0 – 70%
Measuring exhaust gas
C (With standard color)
color 2 Purchased Smoke meter 1 (Pollution level x 1/10 C Bosch index)
Air intake side: 0.35 mm,
Adjusting valve clearance D Purchased Filler gauge 1
Exhaust side: 0.57 mm
0 – 6.9 MPa {0 – 70 kg/cm2}
795-502-1590 Compression gauge 1
KIT No.: 795-502-1205
Measuring compression
—
pressure 795-471-1310 Adapter 1
6217-71-6110 Gasket 1
Measuring blow-by
E 799-201-1504 Blow-by checker 1
pressure
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
F
pressure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Measuring fuel pressure F — — — aSame as above F
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Measuring power train oil
N
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting HSS 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
G
oil pressure
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
19M-06-32820 Switch assembly 1
Emergency escape when 1 7824-66-6430 Resistor 1

H
power train has trouble 17M-06-41530 Wiring harness 1
2 790-190-1600 Pump assembly 1
Testing and adjusting
work equipment oil G — — — aSame as above G
pressure
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting
control circuit basic J 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
pressure
Oil pressure pickup
2 799-401-3200 1 Size: 03
adapter
D275AX-5 20-102-1
(5)
TOOLS FOR TESTING, ADJUSTING, AND
TESTING AND ADJUSTING TROUBLESHOOTING
Testing and adjusting item Symbol Part No. Part name Q’ty Remarks

1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve
K Oil pressure pickup
output pressure 2 799-401-3100 1 Size: 02
adapter
Oil pressure pickup
3 799-401-3200 1 Size: 03
adapter
1 {25, 60, 400, 600 kg/cm2}
Measuring ripper pin
puller solenoid valve outlet P 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
pressure
Oil pressure pickup
2 799-401-3200 1 Size: 03
adapter
Measuring leakage in
L Purchased Measuring cylinder 1
work equipment cylinder
Measuring fan motor Digital indication L: 60 – 2,000 rpm
M 799-203-8001 Multitachometer 1
speed H: 60 – 19,999 rpm
1 {25, 60, 400, 600 kg/cm2}
Measuring fan circuit oil
Q Oil pressure pickup
pressure 2 799-401-3400 1 Size: 05
adapter
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
Measuring water
temperature and oil — — — — aSame as above B
temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

—
effort and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and
— Purchased Scale 1
hydraulic drift
Measuring work
— Purchased Stopwatch 1
equipment speed
Measuring voltage and
— Purchased Tester 1
resistance
799-601-7400 T-adapter assembly
799-601-7360 Adapter For relay (5-pin)
799-601-9000 T-adapter assembly For heavy-duty wire connector
Troubleshooting for
For heavy-duty wire connector
sensors and wiring — 799-601-9300 T-adapter assembly
(For 24-pin and 40-pin types)
harnesses
799-601-9410 Socket For NE sensor and G sensor
799-601-9420 Adapter For boost pressure sensor and fuel sensor
799-601-9430 Socket For PCV solenoid
20-102-2 D275AX-5
(5)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
a Measure the engine speed under the following 3. Measuring high idling speed
condition. 1) Start the engine and set the fuel control dial
• Engine water temperature: in the high idling position.
Within operating range 2) Set the PCCS lever and work equipment
• Hydraulic oil temperature: control lever in neutral and measure the en-
Within operating range gine speed.
• Power train oil temperature: a The high idling speed measured in the “Mon-
Within operating range itoring mode” or in the “Pm Clinic auxiliary
mode” is the auto-deceleration speed.
1. Preparation work a When measuring the high idling speed of the
Turn the starting switch ON and set the monitor engine, use the “Adjustment mode”.
panel in the “Monitoring mode” to prepare for Adjustment code:
measurement of the engine speed. 0007 (Engine decelerator cut mode)
a For the operating method, see “SPECIAL
FUNCTIONS OF MONITOR PANEL
(EMMS)”.
• Monitoring code: 01000 (Engine speed)
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control dial
in the high idling position.
2) Set the PCCS lever and work equipment
2. Measuring low idling speed control lever in neutral and press the decel-
1) Start the engine and set the fuel control dial erator pedal and measure the engine speed.
in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the en-
gine speed.
D275AX-5 20-103
(8)
1
5. Measuring torque converter stall speed 6. Torque converter stall + Work equipment re-
1) Start the engine and set the fuel control dial lief speed (Full stall speed)
in the low idling position. 1) Start the engine and set the fuel control dial
2) Press the brake pedal securely and set the in the low idling position and raise the ripper
parking brake lever in the FREE position and to the stroke end.
set the PCCS lever in the FORWARD and 2) Keep pressing the brake pedal securely and
3rd gear speed position. set the parking brake lever in the FREE posi-
★ Before going to the next step, check that tion and set the PCCS lever in the FOR-
the upper display unit of the monitor pan- WARD and 3rd gear speed position.
el is set in the normal display state and it ★ Before going to the next step, check that
displays [F3]. the upper display unit of the monitor pan-
★ Keep the steering unit in neutral. el is set in the normal display state and it
3) Press the decelerator pedal and set the fuel displays [F3].
control dial in the high idling position. ★ Set the steering unit in neutral.
4) Return the decelerator pedal slowly to stall 3) Press the decelerator pedal and set the fuel
the torque converter with the engine at high control dial in the high idling position.
idling. 4) Return the decelerator pedal slowly to stall
¤ Keep pressing the brake pedal securely the torque converter with the engine at high
and keep your right foot on the decelera- idling.
tor pedal for safety until the work is fin- ¤ Keep pressing the brake pedal securely
ished. and keep your right foot on the decelera-
5) Just after the power train oil temperature tor pedal for safety until the work is fin-
gauge reads the top line of the green range, ished.
return the direction of the PCCS lever into 5) Just after the torque converter oil tempera-
neutral. ture gauge reads the top line of the green
range, return the direction of the PCCS lever
into neutral.
6) Repeat above steps 2) – 5) 3 times.

7) Perform steps 2) – 4) again and measure the
engine speed about 5 seconds after the 6) Repeat above steps 2) – 5) 3 times.
power train oil temperature gauge reads the
top line of the green range.
★ After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the power train oil temperature
with the engine at high idling.
20-104 D275AX-5
1
7) Perform steps 2) – 4) again and relieve the ★ The engine speed can be measured in the “Pm
ripper in the raising direction and measure Clinic auxiliary mode” of the monitor panel (Mea-
the engine speed about 5 seconds after the sure the high idling speed of the engine in the
power train oil temperature gauge reads the “Adjustment mode”, however).
top line of the green range.
★ After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the power train oil temperature
with the engine at high idling.
D275AX-5 20-105
1
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
a Measuring instruments for intake air pressure a Insert the joint of the gauge and hose half-
(boost pressure) way and open the self-seal on the hose side
repeatedly, and the oil is drained.
Symbol Part No. Name a If Pm kit (A) is available, the air bleeding cou-
A 799-201-2202 Boost gauge kit pling (790-261-1130) in it may be used.
a If any oil is left in the hose, the gauge does
a A nipple (quick coupler) is installed to the intake not move. Accordingly, be sure to drain the
air pressure (boost pressure) pickup port of the oil.
Pm clinic specification machine.
k When installing and removing the measuring in- 5. Run the engine at high idling and stall the torque
strument, take care not to touch a hot part. converter and measure the intake air pressure
(boost pressure) at this time.
a Measure the intake air pressure (boost pressure)
a For the procedure for stalling the torque con-
under the following condition.
verter, see MEASURING ENGINE SPEED.
• Engine water temperature:
a Normally, the intake air pressure (boost
pressure) should be measured while the en-
• Torque converter oil temperature:
gine is operated at the rated output. In the
field, however, an approximate value can be
obtained by stalling the torque converter.
1. Open the right side cover of the engine.
2. Remove boost pressure pick-up plug (1).
6. After finishing measurement, remove the mea-

suring instrument and return the removed parts.
3. Install nipple [1] of boost gauge kit A and con-

nect gauge 2.
4. Run the engine at medium or higher speed and

drain the oil from the hose.
20-106 D275AX-5
1
(5)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
★ The boost pressure can be measured in the “Pm

Clinic auxiliary mode” of the monitor panel.
D275AX-5 20-107
1
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE
a Measuring instrument for exhaust temperature 3. Install sensor 1 of digital thermometer B and
connect them to meter 2.
Symbol Part No. Name a Clamp the wiring harness of the digital ther-
B 799-101-1502 Digital thermometer mometer so that it will not touch a hot part
during measurement.
a Measuring instruments for exhaust temperature
(Pm clinic specification)
An exhaust temperature sensor is installed to the
Pm clinic specification machine. Accordingly,
prepare an adapter connector to connect the ex-
haust temperature sensor to a digital thermome-
ter.
Symbol Part No. Name

B 799-101-1502 Digital thermometer
— 799-201-1150 Adapter connector
k Install and remove the measuring instrument af-

ter the exhaust manifold is cooled. 4. Procedure for measuring maximum exhaust
a Measure the exhaust temperature under the fol- temperature for troubleshooting
lowing condition. Operate the machine actually and measure the
• Engine water temperature: maximum exhaust temperature.
Within operating range a Use the PEAK mode of the digital thermom-
• Torque converter oil temperature: eter.
Within operating range a The exhaust temperature largely depends
• Hydraulic oil temperature: on the outside air temperature (intake air
Within operating range temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by
1. Open the right side cover of the engine and re- the following calculation.
move turbocharger heat insulation cover (1). • Corrected value [ºC] = Measured value +
2 x (20 – Outside air temperature)
2. Remove exhaust temperature pick-up plug (2).
20-108 D275AX-5
1
(5)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
5. Procedure for measuring exhaust temperature k Just after the torque converter oil tempera-
periodically for preventive maintenance ture gauge reads the red range, return the di-
a If the torque converter is stalled simply, the rection of the PCCS lever into neutral and
torque converter oil temperature is overheat- lower the torque converter oil temperature.
ed before the exhaust temperature is stabi-
lized. Accordingly, measure according to the
following procedure.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650ºC accord-
ing to the following procedure (Condition a in
the figure).
i) Start the engine and set the fuel control
dial to the low idling position. Raise the
ripper lift cylinder to the stroke end with
the ripper lever.
ii) Press the brake pedal securely 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 idling posi-
tion.
iv) Return the decelerator pedal slowly to
stall the torque converter and relieve the
ripper in raising direction with the engine
at high idling.
k Press the brake pedal securely and keep
your right foot on the decelerator pedal
for safety until the work is finished.
2) Stop only relieving the ripper and lower the
exhaust temperature by only stalling the
torque converter (Condition b in the figure).
a If the temperature does not lower but ris-
es, set the temperature in step 1).
3) After the temperature lowers and is stabi-
lized, measure it (Condition c in the figure).
D275AX-5 20-109
1
(5)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR
a Measuring instrument for exhaust gas color 2. Measuring with smoke meter C2
1) Insert probe 1 of smoke meter C2 in the out-
Symbol Part No. Name let of the exhaust pipe and fix it to the ex-
1 799-201-9000 Handy smoke checker haust pipe with a clip.
C
2 Purchased Smoke meter
k When installing and removing the measuring in-

strument, take care not to touch a hot part.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
a Measure the exhaust gas color under the follow-
ing condition.
1. Measuring with handy smoke checker C1 2) Connect the probe hose, receptacle of the
1) Stock a sheet of filter paper to C1. accelerator switch, and air hose to smoke
2) Insert the exhaust gas intake pipe in the ex- meter C2.
haust pipe. a Limit the supplied air pressure to 1.5MPa
3) Start the engine. {15kg/cm2}.
4) Accelerate the engine suddenly or run it at 3) Connect the power cable to a receptacle of
high idling and operate the handle of smoke AC power supply.
checker C1 so that the filter paper will absorb a Before connecting the cable, check that
the exhaust gas. the power switch of the smoke meter is
turned off.
4) Before connecting the cable, check that the
power switch of the smoke meter is turned
off.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter C2.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing measurement, remove the
measuring instrument and return the re-
moved parts.
20-110 D275AX-5
1
(5)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEAR-

ANCE
6) Start the engine. a Adjusting instrument for valve clearance

7) Accelerate the engine suddenly or run it at
high idling and press the accelerator pedal of Symbol Part No. Name
smoke meter C2 and collect the exhaust gas D Purchased Filler gauge
into the filter paper.
8) Place the contaminated filter paper on the 1. Open the inspection cover under the universal
clean filter paper (at least 10 sheets) in the joint (1) and disconnect universal joint (1) from
filter paper holder and read the indicated val- the engine.
ue.
moved parts.
2. Open the right side cover of the engine and re-

move all cylinder head covers (2).
3. Rotate the crankshaft forward and set line a of

“1.6TOP” of the damper to pointer (3) to set the
No. 1 cylinder piston to the compression top
dead center.
a Rotate the hexagonal part of the water pump
drive shaft end to crank the engine.
a When the No. 1 cylinder piston is at the com-
pression top dead center, the No. 1 cylinder
rocker arm can be moved with the hand by
the valve clearance. If the rocker arm does
not move, the piston is not at the compres-
sion top dead center. In this case, revolve the
crankshaft 1 more turn.
D275AX-5 20-111
1
(5)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
a For the method of measuring compression pres-

sure, see the Engine Shop Manual for “140-3 Se-
ries”.
4. Insert filler gauge D in clearance b between

rocker arm (4) and cross head (5) and adjust the
valve clearance with adjustment screw (6).
a Adjust the adjustment screw with the filler
gauge inserted so that the filler gauge can
be moved lightly.
3 Locknut:
5. Fix adjustment screw (6) and tighten locknut (7).
53.0 – 64.7Nm {5.4 – 6.6kgm}

a After tightening the locknut, check the valve
clearance again.
6. Rotate the crankshaft forward by 120 degrees

and repeat steps 3 – 5 for each cylinder in the fir-
ing order.
• Firing order: 1 – 5 – 3 – 6 – 2 – 4
7. After finishing adjustment, return the removed
3 Cylinder head cover mounting bolt:

parts.
3 Universal joint mounting bolt:

29.4 – 34.3Nm {3.0 – 3.5kgm}
98.0 – 122.5Nm {10.0 – 12.5kgm}
20-112 D275AX-5
1
(5)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE
★ Measuring instrument for blow-by pressure ★ The blow-by pressure may vary largely with
the engine condition. If the measured value
Symbol Part No. Name is judged abnormal, check for increase of oil
E 799-201-1504 Blow-by kit consumption, bad exhaust gas color, deteri-
oration of oil, high deterioration speed of oil,
★ Measure the blow-by pressure under the follow- etc. which are related to the abnormal blow-
ing condition. by pressure.
1. Open the left side cover of the engine and pull

out blow-by hose (1).
2. Install nozzle 1 of blow-by checker E to blow-by

hose (1) and connect them to gauge 2.

3. Run the engine at high idling, stall the torque

converter, and measure the blow-by pressure.
★ For the procedure for stalling the torque con-
verter, see MEASURING ENGINE SPEED.
★ Normally, the blow-by pressure should be
measured while the engine is operated at the
rated output. In the field, however, an ap-
proximate value can be obtained by stalling
the torque converter.
★ If it is impossible to run the engine at the rat-
ed output or stall the torque converter, mea-
sure while the engine is running at high
idling.
The value obtained in this case is about 80%
of the blow-by pressure at the rated output.
D275AX-5 20-113
1
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure 3. Run the engine at low idling and high idling and
measure the engine oil pressure in each speed.
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
F
Hydraulic tester
2 799-401-2320
(0.98MPa {10kg/cm2})
a A nipple (quick coupler) is installed to the engine

oil pressure switch mounting part of the Pm clinic
specification machine.
a Measure the engine oil pressure under the fol-
lowing condition.
1. Open the left side cover of the engine and re- suring instruments and return the removed
move low engine oil pressure switch (1). parts.
2. Install nipple 1 of hydraulic tester F1 and con-

nect them to hydraulic tester F2.
20-114 D275AX-5
1
(5)
HANDLING OF FUEL SYSTEM DEVICES
TESTING AND ADJUSTING RELEASING RESIDUAL
HANDLING
PRESSURE
OF FUEL
FROM
SYSTEM
FUEL DEVICES
SYSTEM
HANDLING OF FUEL SYS- RELEASING RESIDUAL

TEM DEVICES PRESSURE FROM FUEL SYS-
TEM
★ Precautions for testing and adjusting fuel system ★ Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) con- and high-pressure circuit of the fuel system while
sists of more precise parts than the conventional the engine is running.
fuel injection pump and nozzle. If foreign matter Low-pressure circuit:
enters this system, it can cause a trouble. Feed pump – Fuel filter – Fuel supply pump
When testing and adjusting the fuel system, take High-pressure circuit:
care more than the past. If dust, etc. sticks to any Fuel supply pump – Common rail – Fuel in-
part, wash that part thoroughly with clean fuel. jector
★ Precautions for replacing fuel filter capacitor ★ The pressure in both low-pressure circuit and
Be sure to use Komatsu genuine fuel filter car- high-pressure circuit lowers to a safety level au-
tridge. tomatically 30 seconds after the engine is
Since the common rail fuel injection system stopped.
(CRI) consists of more precise parts than the ★ Before the fuel circuit is tested and its parts are
conventional fuel injection pump and nozzle, it removed, the residual pressure in the fuel circuit
employs a high-efficiency special filter to prevent must be released completely. Accordingly, ob-
foreign matter from entering it. serve the following.
If a filter other than the genuine one is used, the ¤ Before testing the fuel system or removing its
fuel system may have a trouble. Accordingly, parts, wait at least 30 seconds after stopping the
never use such a filter. engine until the residual pressure in the fuel cir-
cuit is released. (Do not start the work just after
stopping the engine since there is residual pres-
sure.)
D275AX-5 20-115
1
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE
a Measuring instrument for fuel pressure 3. Run the engine at high idling and measure the
fuel pressure.
Symbol Part No. Name a If the fuel pressure is in the following range,
799-101-5002 Hydraulic tester it is normal.
1
790-261-1203 Digital hydraulic tester 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
F
Hydraulic tester
2 799-401-2320
(0.98MPa {10kg/cm2})
a Measure only the fuel pressure in the low-pres-

sure circuit from the feed pump to the fuel filter
and fuel supply pump.
k Since the pressure in the high-pressure circuit
from the fuel supply pump to the common rail
and fuel injector is very high, it cannot be mea-
sured.
1. Open the left side cover of the engine and re-

move fuel pressure pick-up plug (1).
suring instruments and return the removed
parts.
2. Install nipple 1 of hydraulic tester F1 and con-

nect them to hydraulic tester F2.
20-116 D275AX-5
1
(5)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
★ If fuel is used up or if a fuel circuit device is re-

moved and installed, bleed air from the fuel cir-
cuit according to the following procedure.
1. Remove fuel filter (1) and fill it with fuel and in-
stall it again.
★ Fill the fuel filter with clean fuel and take care
that dirt will not enter it.
★ Add fuel through inlet ports a (8 places) of
the filter. Since hole b is the outlet port (clean
side), do not add fuel through it.
★ If clean fuel is not available, do not remove
the filter but fill it with the fuel from the fuel
tank by operating the priming pump. 2. Remove air bleed plug (2a) of the fuel filter and
operate priming pump (3).
★ Operate the priming pump until the fuel flows
out of the plug hole and install the plug.
3 Air bleed plug:
7.8 – 9.8kgm {0.8 – 1.0Nm}
D275AX-5 20-117
1
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Remove plug (2b) of the fuel filter and operate

priming pump (3).
out of the plug hole, then install the plug.
3 Plug: 3.9 – 6.9kgm {0.4 – 0.7Nm}
4. Loosen air bleeder (4) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.
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 – 6.9kgm {0.5 – 0.7Nm}
5. Start the engine with the starting motor.

★ The air in the high-pressure circuit is bled au-
tomatically if the engine is cranked.
★ If the engine does not start, there may be still
air in the low-pressure circuit. In this case,
repeat the above steps from 2.
20-118 D275AX-5
1
TESTING AND ADJUSTING INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
k Very high pressure is generated in the high-pres- 8. Run the engine at high idling and apply a load to
sure circuit of the fuel system. If fuel leaks while it.
the engine is running, it is dangerous since it can a Relief the oil by blade raising operation.
catch fire.
After testing the fuel system or removing its 9. Inspect the fuel piping and devices for fuel leak-
parts, inspect it for fuel leakage according to the age.
following procedure. a Inspect around the high-pressure circuit
a Clean and degrease the engine and the parts parts coated with the color checker for fuel
around it in advance so that you can inspect it leakage.
easily for fuel leakage. a If any fuel leakage is detected, repair it and
inspect again from step 2.
1. Spray color checker (developer) over the fuel a If any fuel leakage is not detected, inspection
supply pump, common rail, fuel injector, and is completed.
joints of the high-pressure piping.
2. Run the engine at speed below 1,000rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leak-

age.
a Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
a If any fuel leakage is detected, repair it and
4. Run the engine at low idling.

age.
leakage.
6. Run the engine at high idling.

age.
leakage.
D275AX-5 20-119
1
(5)
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING

ALTERNATOR BELT TEN- AIR CONDITIONER COM-
SION PRESSOR BELT TENSION
Testing Testing
• Press the intermediate point between alternator • Press the intermediate point between air condi-
pulley and drive pulley with a finger and measure tioner compressor pulley and drive pulley with a
deflection “a” of the belt. finger and measure deflection “a” of the belt.
★ Pressing force: Approx. 98N {Approx. 10kg} ★ Pressing force: Approx. 58.8N {Approx. 6kg}
Adjusting Adjusting
★ If the deflection is abnormal, adjust it according ★ If the deflection is abnormal, adjust it according
to the following procedure. to the following procedure.
1. Loosen the 2 alternator mounting bolts and the 1 1. Loosen the 2 compressor bracket mounting
adjustment rod set bolt. bolts.
2. Loosen locknut (1) and turn adjustment nut (2) to 2. Loosen locknut (1) and turn adjustment nut (2) to
move alternator (3) and adjust the belt tension. move compressor (3) and adjust the belt tension.
3. Tighten the 2 alternator mounting bolts and the 1 3. Tighten the 2 compressor bracket mounting
adjustment rod set bolt. bolts.
20-120 D275AX-5
1
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

• The following 3 signals are input as speed
signals to the engine controller.
1) Fuel control dial potentiometer signal
2) Decelerator pedal potentiometer signal
3) 3rd throttle signal
• The engine controller controls the fuel con-
trol device (CRI system) of the engine ac-
cording to the lowest one of these speed
signals.
• Adjust the decelerator pedal speed with the
decelerator pedal linkage.
D275AX-5 20-121
1
(5)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
2. Preparation work 3. Adjusting decelerator pedal speed

1) Start the engine and set the monitor panel in Set the fuel control dial in the high idling position
the “Adjustment mode” to prepare for mea- and press decelerator pedal (2) to the stopper
surement of the engine speed. and check that the decelerator pedal speed is
a For the operating method, see “SPE- normal.
CIAL FUNCTIONS OF MONITOR PAN- • Decelerator pedal speed: 900 ± 50rpm
EL (EMMS)”. a If the decelerator pedal speed is abnormal,
• Adjustment code: adjust dimension a of rod (1).
0007 (Engine decelerator cut mode) • Standard dimension a of rod:
a The unit of displayed engine speed is 124mm (For reference)
1rpm.
4. High idling speed
Set the fuel control dial in the high idling position
and check that the high idling speed is normal.
• High idling speed: 2,150 ± 50rpm
a If the high idling speed is abnormal, adjust it
according to the following procedure.
• When engine speed is above 1,950rpm:
Lower the engine speed below 1,900rpm
temporarily with stopper bolt (3) to eliminate
the play of the decelerator pedal, then
heighten it to the high idling speed.
• When engine speed is below 1,950rpm:
Heighten the engine speed to the high idling
speed with stopper bolt (3).
2) Set the fuel control dial in the high idling po-

sition and check that the engine speed is
above 1,000rpm.
a If the engine speed is below 1,000rpm,
heighten it above 1,000rpm by increas-
ing dimension a of rod (1).
20-122 D275AX-5
1
(5)
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE
a Measuring instruments for power train oil pres-

sure

1
Hydraulic tester
N 2 799-401-2320
(0.98 MPa {10 kg/cm2})
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
a A nipple (quick coupler) is installed to the trans-

mission lubricating oil pressure pickup port of the
Pm clinic specification machine.
k Stop the machine on level ground and lower the
work equipment to the ground, then set the park-
ing brake lever and safety lock lever in the lock
position.
a Measure the power train oil pressure under the
following condition.
a Centralized pressure pickup ports (1) – (12) are
installed inside the inspection cover on the right
outside of the operator’s cab and transmission
lubricating oil pressure pickup port (13) is in-
stalled to the top of the power train filter.
a Table of locations of centralized pressure pickup

points for measuring oil pressure and gauges to
use
Gauge
No. Stamp Oil pressure to be measured
(MPa {kg/cm2})
1 IN Torque converter inlet oil pressure 2.5 {25}
2 OUT Torque converter outlet oil pressure 0.98 {10}
Torque converter lockup clutch
3 LU 2.5 {25}
pressure
Torque converter stator clutch
4 SC 5.9 {60}
pressure
5 TM Transmission main relief pressure 5.9 {60}
Transmission forward clutch oil
6 FWD 5.9 {60}
pressure
Transmission reverse clutch oil
7 R 5.9 {60}
pressure
8 1ST Transmission 1st clutch oil pressure 5.9 {60}
Transmission 2nd clutch oil
9 2ND 5.9 {60}
pressure
10 3RD Transmission 3rd clutch oil pressure 5.9 {60}
11 LB Steering right clutch oil pressure 5.9 {60}
12 RB Steering right brake oil pressure 5.9 {60}
Transmission lubricating oil
13 — 0.98 {10}
pressure
D275AX-5 20-123
1
(5)
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge 1 of hydraulic 1) Connect hydraulic tester N2 to oil pressure
tester N1 to oil pressure pick-up nipple (1). pick-up nipple (2).
a Use an oil pressure gauge of 2.5MPa a Use an oil pressure gauge of 0.98MPa
{25kg/cm2}. {10kg/cm2}.
2) Start the engine and set the PCCS lever in 2) Start the engine and set the PCCS lever in
the full neutral position. the full neutral position.
3) Measure the oil pressure while the engine is 3) Measure the oil pressure while the engine is
running at low idling and high idling. running at low idling and high idling.
4) After finishing measurement, remove the 4) After finishing measurement, remove the
measuring instrument and return the re- measuring instrument and return the re-
moved parts. moved parts.
20-124 D275AX-5
1
(5)
3. Measuring torque converter lock-up clutch

pressure (LU)
1) Connect oil pressure gauge 1 of hydraulic
tester N1 to oil pressure pick-up nipple (3).
a Use an oil pressure gauge of 2.5MPa
{25kg/cm2}.

moved parts.
2) Run the engine and lift up the machine body

with the blade and ripper so that the track
shoes can run idle.
k After lifting up the machine body, set the
safety lock lever in the LOCK position.
3) Turn on the lock-up mode switch.

4) Set the PCCS lever in the FORWARD and
1st gear speed position and make the shoes
run idle.
k Take care not to be caught in the track
shoes during measurement.
5) Raise the engine speed gradually and mea-
sure the oil pressure when the lock-up pilot
lamp lights up.
D275AX-5 20-125
1
(5)
4. Measuring torque converter stator clutch 5. Measuring transmission main relief pressure
pressure (SC) (TM)
1) Connect oil pressure gauge 1 of hydraulic 1) Connect oil pressure gauge 1 of hydraulic
tester N1 to oil pressure pick-up nipple (4). tester N1 to oil pressure pick-up nipple (5).
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Run the engine and set the PCCS lever in
the full neutral position. the full neutral position.
running at low idling and high idling. running at low idling and high idling.
20-126 D275AX-5
1
(5)
6. Measuring transmission forward clutch pres- 7. Measuring transmission reverse clutch pres-
sure (FWD) sure (R)
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the parking brake le- 2) Run the engine and set the parking brake le-
ver in the FREE position. ver in the FREE position.
3) Press the brake pedal and set the PCCS le- 3) Press the brake pedal and set the PCCS le-
ver in the FORWARD and 3rd gear speed ver in the REVERSE 3rd gear speed posi-
position. tion.
running at low idling. running at low idling.
k Since the torque converter will be k Since the torque converter will be
stalled, press the brake pedal securely stalled, press the brake pedal securely
and keep your right foot on the decelera- and keep your right foot on the decelera-
tor pedal for safety until the work is fin- tor pedal for safety until the work is fin-
ished. ished.
D275AX-5 20-127
1
(5)
8. Measuring transmission 1st clutch pressure 9. Measuring transmission 2nd clutch pressure
(1ST) (2ND)
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the parking brake le- 2) Run the engine and set the parking brake le-
ver in the FREE position. ver in the FREE position.
3) Press the brake pedal and set the PCCS le- 3) Press the brake pedal and set the PCCS le-
ver in the FORWARD and 1st gear speed po- ver in the FORWARD and 2nd gear speed
sition. position.
running at low idling. running at low idling.
k Since the torque converter will be k Since the torque converter will be
stalled, keep pressing the brake pedal stalled, keep pressing the brake pedal
securely. securely.
k Do not raise the engine speed to high k Do not raise the engine speed to high
idling during measurement. idling during measurement.
20-128 D275AX-5
1
(5)
10. Measuring transmission 3rd clutch pressure 11. Measuring steering left brake pressure (LB)
(3RD) 1) Connect oil pressure gauge 1 of hydraulic
1) Connect oil pressure gauge 1 of hydraulic tester N1 to oil pressure pick-up nipple (11).
tester N1 to oil pressure pick-up nipple (10). a Use an oil pressure gauge of 5.9MPa
a Use an oil pressure gauge of 5.9MPa {60kg/cm2}.
{60kg/cm2}.
2) Run the engine and set the parking brake le-

2) Run the engine and set the parking brake lever in the FREE position.
ver in the FREE position. 3) Measure the oil pressure while the engine is
3) Press the brake pedal and set the PCCS le- running at low idling and high idling.
ver in the FORWARD and 3rd gear speed a Turn the pivot turn mode switch ON and
position. drive the machine in FORWARD and 1st
4) Measure the oil pressure while the engine is (F1) actually and check that the oil pres-
running at low idling. sure lowers to 0 when the PCCS lever is
k Since the torque converter will be moved to the left steering stroke end.
stalled, keep pressing the brake pedal a Check that the oil pressure lowers to 0
securely. when the brake pedal is pressed or the
k Do not raise the engine speed to high
parking brake lever is set in the LOCK
idling during measurement. position.

moved parts.
moved parts.
D275AX-5 20-129
1
(5)
12. Measuring steering right brake pressure (RB) 13. Measuring transmission lubricating oil pres-
1) Connect oil pressure gauge 1 of hydraulic sure
tester N1 to oil pressure pick-up nipple (12). 1) Remove oil pressure pickup plug (13).
{60kg/cm2}.
2) Install nipple N3 and connect hydraulic tester

N2.
2) Run the engine and set the parking brake le- a Use an oil pressure gauge of 0.98 MPa
ver in the FREE position. {10 kg/cm2}.
3) Measure the oil pressure while the engine is
running at low idling and high idling.
a Turn the pivot turn mode switch ON and
drive the machine in FORWARD and 1st
(F1) actually and check that the oil pres-
sure lowers to 0 when the PCCS lever is
moved to the right steering stroke end.
a Check that the oil pressure lowers to 0
when the brake pedal is pressed or the
parking brake lever is set in the LOCK
position.
3) Run the engine at high idling and measure

the oil pressure.

moved parts.

measuring instruments and return the re-
moved parts.
20-130 D275AX-5
1
(5)
MEASURING POWER TRAIN OIL PRESSURE
14. Measuring output pressure of sudden stop 4) Measure the oil pressure while the engine is
prevention valve running at low idling.
1) Connect oil pressure gauge 1 of hydraulic a If the output pressure of the sudden stop
tester N1 to oil pressure pickup nipples (11) prevention valve is in the following range,
and (12). it is normal.
a Use an oil pressure gauge of 5.9 MPa • 1.13 – 1.57 MPa {11.5 – 16.0 kg/cm2}
{60 kg/cm2}.
• (11): For steering left brake oil pressure

measuring instruments and return the re-
• (12): For steering right brake oil pressure moved parts.
2) Run the engine and set the monitor panel in

the adjustment mode.
a For the method of operating the adjust-
ment mode, see SPECIAL FUNCTIONS
OF MONITOR PANEL (EMMS).
a Adjustment code:
9995 (Electric brake constant ON mode)
3) Set the parking brake lever in the FREE po-
sition and set the all PCCS levers in the
NEUTRAL position.
D275AX-5 20-130-1
(5)
TESTING AND ADJUSTING TESTING AND ADJUSTING HSS OIL PRESSURE
TESTING AND ADJUSTING HSS OIL PRESSURE
★ Testing and adjusting instrument for HSS oil 3) Install nipple G2 and connect oil pressure
pressure gauge 1 of hydraulic tester G1.
★ Use an oil pressure gauge of 58.8MPa
Symbol Part No. Name {600kg/cm2}.
1
G
799-101-5220 Nipple (10 × 1.25mm)
2
07002-11023 O-ring
Measuring
¤ Stop the machine on a level place, lower the
work equipment to the ground, and set the park-
ing brake lever and safety lock lever in the LOCK
position.
★ Measure the HSS oil pressure under the follow-
ing condition.
• Hydraulic oil temperature: 4) Run the engine and set the parking brake le-
Within operating range ver in the FREE position and press the brake
pedal.
1. Measuring HSS main relief pressure
¤ Since the steering circuit will be stalled,
1) Remove the floor inspection cover.
keep pressing the brake pedal securely
2) Remove oil pressure pick-up plug (1) or (2).
and keep your right foot on the decelera-
• (1): For left steering (Port PA)
tor pedal for safety until the work is fin-
• (2): For right steering (Port PB)
ished.
5) Run the engine at high idling and steer to the
right or left with the PCCS lever. When the
steering circuit is relieved, measure the oil
pressure.
★ Since a pivot turn will be made with only
the steering system, set the direction of
the PCCS lever into neutral.

moved parts.
D275AX-5 20-131
1
★ HSS main relief pressure (A) can be measured ★ HSS main relief pressure (B) can be measured
in the “Pm Clinic auxiliary mode” of the monitor in the “Pm Clinic auxiliary mode” of the monitor
panel. panel.
20-132 D275AX-5
1
2. Measuring HSS charge relief pressure 5) Measure the oil pressure while the engine is
1) Open the right fender inspection cover. running at high idling.
2) Remove oil pressure pick-up plug (3).

3) Install nipple G2 and connect oil pressure measuring instrument and return the re-
gauge 1 of hydraulic tester G1. moved parts.
{60kg/cm2}. 3. Measuring HSS servo charge pressure
★ The control circuit main pressure from the
self-pressure reducing valve of the control
valve is used as the HSS servo charge pres-
sure commonly for work equipment PPC and
fan pump control.
★ For the measuring method, see TESTING
AND ADJUSTING CONTROL MAIN PRES-
SURE.
4) Run the engine and set the PCCS lever in

the full neutral position.
D275AX-5 20-133
1
Adjusting 2. Adjusting HSS charge relief pressure (when

1. Adjusting HSS main relief pressure pressure is low)
a If the HSS main relief pressure is abnormal, a If the HSS charge relief pressure is low, ad-
adjust it with main relief valve (4) or (5) of the just the charge relief valve (8) of the HSS
HSS pump according to the following proce- motor to heighten the HSS charge relief
dure. pressure.
• (4): For left steering (Port PA) 1) Remove the fuel tank.
• (5): For right steering (Port PB)
1) Open the inspection cover under the univer-
sal joint.
2) Fixing adjustment nut (9), loosen locknut

(10).
3) Turn the adjustment nut (9) to adjust the
2) Fixing adjustment nut (6), loosen locknut (7). pressure.
3) Turn the adjustment nut (6) to adjust the a If the adjustment nut is
pressure. • turned to the right, the pressure rises.
a If the adjustment nut is • turned to the left, the pressure lowers.
• turned to the right, the pressure rises. a Quantity of adjustment per turn of adjust-
• turned to the left, the pressure lowers. ment nut: 1 MPa {10.4 kg/cm2}
a Quantity of adjustment per turn of adjust- 4) Fixing adjustment nut (9), tighten locknut
3 Locknut:
ment nut: (10).
Approx. 13.7 MPa {Approx. 140 kg/cm2}
3 Locknut: 29 – 39 Nm {3 – 4 kgm}
4) Fixing adjustment nut (6), tighten locknut (7). 58.8 – 78.5 Nm {6 – 8 kgm}
5) After finishing adjustment, check the oil pres-

5) After finishing measurement, check the oil sure again according to the procedure for
pressure according to the above measuring measurement described above.
method.
20-134 D275AX-5
1
(5)
TESTING AND ADJUSTING HSS OIL PRESSURE
3. Adjusting HSS charge relief pressure (when 5) After finishing adjustment, check the oil pres-
pressure is high) sure again according to the procedure for
a If the HSS charge relief pressure is high, ad- measurement described above.
just the charge safety valve (11) of the HSS
pump to lower the HSS charge relief pres-
sure.
1) Remove the inspection cover under the uni-
versal joint.
2) Fixing adjustment nut (14), loosen locknut

(13).
pressure.
a If the adjustment nut is
• turned to the right, the pressure rises.
• turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment nut: 1.55 MPa {15.88 kg/cm2}
4) Fixing adjustment nut (14), tighten locknut
3 Locknut:
(13).
58.8 – 78.5 Nm {6 – 8 kgm}
D275AX-5 20-134-1
(5)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
1. Remove the undercover of the fuel tank and then 6. Remove sensor (1) and flange (2) together and
remove transmission speed sensor (1) and secure them with nut (3).
flange together. ★ Take care not to change the adjustment an-
★ Before adjusting transmission speed sensor gle of the sensor.
(1), remove it and check that its tip is free 3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
from steel chips and flaws, then install it
again.
7. Install flange (2) and sensor to the HSS case
★ Before installing, separate sensor (1), flange
with the mark of “HSS UP” directed to the upper
(2), and nut (3).
side of the HSS case.
2. Install flange (2) to the HSS case temporarily

8. After finishing adjustment, set the monitor panel
with the mark of “HSS UP” directed to the upper
in the “Monitoring display mode” and check that
side of the HSS case.
it displays the transmission speed normally.
★ For the operating method, see “SPECIAL
3. Look at bevel gear (4) through the hole of flange
FUNCTIONS OF MONITOR PANEL
(2) and check that a tooth tip is at the center of
(EMMS)”.
the hole.
★ Monitoring code: 31400 (Transmission speed)
★ If the tooth tip is not at the center of the hole,
run the engine and move the machine for-
ward or in reverse to adjust the position of
the tooth tip.
4. Tighten sensor (1) until its tip comes in contact

with the tooth tip of gear (4).
2 Threads of sensor:
Gasket sealant (LG-5)
5. Return sensor (1) by the specified angle.

★ Returning angle of sensor: 1/2 – 1 turn
★ Adjust clearance b between the sensor tip
and gear tooth tip to 0.75 – 1.50mm.
D275AX-5 20-135
1
BLEEDING AIR FROM HSS PUMP
TESTING AND ADJUSTING SIMPLE METHOD OF TESTING BRAKE
BLEEDING PERFORMANCE
AIR FROM HSS PUMP
BLEEDING AIR FROM HSS SIMPLE METHOD OF TEST-

PUMP ING BRAKE PERFORMANCE
★ If the HSS pump is removed and installed or its ★ Carry out the simple test of brake performance
piping is disconnected and connected, bleed air under the following condition.
from the pump case according to the following • Torque converter oil temperature:
procedure. Within operating range
★ Before bleeding air, check that the hydraulic oil
level is proper. 1. Set the blade and ripper in the travel position on
a level place.
1. Remove the floor inspection cover.
2. Loosen air bleeder (1) and leave it for 15 min-

utes.
2. Run the engine and set the parking brake lever

in the FREE position.
3. Run the engine at low idling and press the brake

3. After 15 minutes, run the engine at low idling. pedal and set the PCCS lever in the FORWARD
★ After starting the engine, do not move the and 2nd gear speed position.
PCCS lever from the full neutral position. ¤ If this test is carried out in the 1st gear posi-
tion, the brake will be overloaded. According-
4. After oil flows out of air bleeder (1), tighten air ly, be sure to carry out in the 2nd gear speed.
bleeder (1). ★ Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel con-

trol dial in the high idling position.
5. Return the decelerator pedal slowly and check

that the machine does not start when the engine
speed reaches the high idling level.
¤ Since the torque converter will be stalled,
press the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
20-136 D275AX-5
1
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Brake pedal
Parking lever
D275AX-5 20-137
1
(5)
Adjusting brake pedal side 5. Setting brake potentiometer to initial posi-

1. Adjusting brake pedal stroke tion
Adjust stroke a of brake pedal (1) by adjusting in- Turn the starting switch ON and set the monitor
stalled dimension b of stopper bolt (2). panel in the adjustment mode and set the brake
a Adjust the brake pedal stroke with the brake potentiometer to the initial position.
rod disconnected from the pedal. a For the method of operating the adjustment
• Pedal stroke a: 74 mm mode, see SPECIAL FUNCTIONS OF
• Installed dimension b of stopper bolt: 42 mm MONITOR PANEL (EMMS).
a Adjustment code:
2. Adjusting installed length of brake rod 0005 (Brake potentiometer initial setting)
1) Install brake rod (3) and leave brake pedal
(1) free [Do not press brake pedal (1)]. Adjusting parking brake lever side
2) Adjust installed dimensions c and d of brake 6. Assembly and installation of lever assembly
rod (3) with turnbuckle (5) so that the spool 1) Assemble lever assembly (7) and adjust the
of brake valve (4) will be at the OFF position. operation of limit switch (8).
a The locknut screw of the turnbuckle on a Assemble the lever assembly with the
the brake pedal side is left-handed. parking cable disconnected from the le-
• Installed dimension c: 32 mm ver.
3 Locknut:
• Installed dimension d: 14 mm • When lever is at upper position: OFF, at
lower position: ON
34.3 – 58.8 Nm {3.5 – 6.0 kgm} • Operating stroke of limit switch: 3 mm
2) Install lever assembly (7).
3. Checking brake pedal stroke 7. Adjusting installed length of parking cable
1) Press brake pedal (1) and check that its 1) Connect parking cable (9) to the lever side
stroke is as adjusted in step 1 above. and valve side, and then adjust installed di-
2) Press brake pedal (1) and check that it is mensions f and g.
stopped at stopper (6). • Installed dimension f of cable: 112.8 mm
3) Press brake pedal (1) and check that spool • Installed dimension g of cable: 114.0 mm
stroke e of brake valve (4) is in the normal 2) Operate parking lever (10) between the
range at this time. FREE position and LOCK position and ad-
• Spool stroke e: 19 – 23 mm just the position of rod end (11) so that spool
stroke h of brake valve (4) will be normal.
4. Checking brake oil pressure • Spool stroke h: 23.0 mm
1) Run the engine and set the monitor panel in
the adjustment mode. 8. Checking brake oil pressure
a For the method of operating the adjust- Run the engine and set the parking brake lever
ment mode, see SPECIAL FUNCTIONS in the FREE position and LOCK position and
OF MONITOR PANEL (EMMS). check that the brake oil pressure will be as fol-
a Adjustment code: lows.
9996 (Electric brake OFF mode) a For the measuring point of the brake oil pres-
2) Set the parking brake lever in the FREE po- sure, see MEASURING POWER TRAIN OIL
sition and press the brake pedal and check PRESSURE.
that brake oil pressures on both sides be- • LOCK position: 0, FREE position: Specified
come 0 at this time.
pressure
a For the point to measure the brake oil
pressure, see MEASURING POWER
TRAIN OIL PRESSURE.
20-138 D275AX-5
1
(5)
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

9. Checking limit switch
1) Turn the starting switch ON and set the mon-
itor panel in the display mode.
a For the method of operating the display
mode, see SPECIAL FUNCTIONS OF
MONITOR PANEL (EMMS).
• Monitoring code:
40910 (Steering controller input signal 1)
sition and LOCK position and check that the
limit switch signals are input normally.
D275AX-5 20-138-1
(5)
TESTING AND ADJUSTING ADJUSTING PCCS LEVER CONSOLE POSITION
ADJUSTING PCCS LEVER CONSOLE POSITION
1. Set operator’s seat (1) in the forward (dozing) po-

sition.
2. Under this condition, check that console (2) is in

parallel with operator’s seat (1).
★ If the console is not parallel with the opera-
tor’s seat, adjust dimension a of rod (3).
• Standard dimensions a: 179mm
★ The locknut on the rear side of the turnbuckle
is a left-handed (reversing) screw.
D275AX-5 20-139
1
TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS

TROUBLE
a Devices used for emergency escape a Since the female side of connector PL2
is kept disconnected, mask it with a vinyl
Symbol Part No. Part name sheet, etc.
19M-06-32820 Switch assembly a Put switch assembly 1 in the cab
1 7824-66-6430 Register through the cab window.
H
17M-06-41530 Wiring harness
2 790-190-1600 Pump assembly
1. Escape with switch box (Use H1)

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
a The engine must be startable for the follow-
ing procedure. If the engine cannot be start-
ed, see EMERGENCY ESCAPE WITH
BRAKE RELEASING DEVICE.
1) Connect switch assembly 1 and register 2 3) Disconnect neutral safety relay (NSF) in the
to wiring harness 3 of emergency escape fuse room and connect pins 3 and 5 of the
device H1. connector on the wiring harness side.
k Since register 2 controls the drive volt-
a Perform this operation only when the en-
gine does not start electrically because
age of the solenoid, connect it to the wir-
of a trouble in the transmission controller.
k If the engine is started by this method,
ing harness before connecting to the
machine.
k Set the all gear speed switches of switch
the neutral safety function does not work.
Accordingly, before starting the engine,
assembly 1 in the OFF position and the
set the parking brake lever in the LOCK
direction switch in the P position to pre-
position and set the PCCS lever in the
vent the machine from starting suddenly.
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.
2) Open the left fender inspection cover and

connect wiring harness 3 to connectors
PL1 (1) and PL2 (2).
• Connector PL1 (1):
Connect to male side and female side.
• Connector PL2 (2):
Connect to male side.
20-140 D275AX-5
1
(5)
4) Start the engine and set the parking brake le- 2. Escape with brake releasing device (Use H2)
ver in the FREE position. ★ If the engine cannot be started and the park-
5) Operate switch assembly 1 and move the ing brake cannot be released, escape ac-
machine to a safe place. cording to the following procedure.
★ The gear speed switch is so made that 1) Assemble pump assembly H2.
the switch on the lower gear speed will
be operated first.
2) Install volume pump 4 of pump assembly

H2 to the outside of the operator’s cab.
3) Remove the fuel tank undercover and dis-

connect supply hose (3) of the pin puller so-
lenoid valve.
D275AX-5 20-141
3
1
4) Connect end hose 5 of pump assembly H2

to the supply hose.
★ Block the solenoid valve side with plug
6.
5) Turn the starting switch ON and set the park-

ing brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure.
• Initial pressure:
Approx. 2.74MPa {28kg/cm2}
★ Since an accumulator is installed in the
circuit, the handle must be operated 30 –
50 times to raise the oil pressure.
★ If the oil pressure does not rise above a
certain level, the relief valve may be set
to low pressure. In this case, adjust the
set pressure of the relief valve.
7) Tow the machine to a safe place.
★ The brake releasing oil pressure lowers
gradually because of internal leakage
and the brake is applied again about 1
minutes after. Accordingly, work quickly.
★ If the brake releasing pressure lowers to
about 1.5MPa {16kg/cm2}, the brake is
applied. In this case, operate the volume
pump again to raise the brake releasing
pressure to the initial pressure.
20-142 D275AX-5
3
1
ADJUSTING CLEARANCE OF IDLER
TESTING AND ADJUSTING ADJUSTING
INSPECTINGCLEARANCE
WEAR OF SPROCKET
OF IDLER
ADJUSTING CLEARANCE OF INSPECTING WEAR OF

IDLER SPROCKET
★ If the idler runs out or tilts because of wear of the ★ Make a copy of the “Full-scale drawing of sprock-
side guide, upper and lower guides, and guide et tooth profile” on a transparent sheet and apply
plate, adjust according to the following proce- it to the sprocket directly to see if the sprocket is
dure. serviceable.
1. Drive the machine for 1 – 2m on a level place,

then measure clearance a (on the inside and
outside).
2. If clearance a is more than 3mm, remove bolt (1)

and reduce shims (2).
• Standard clearance a on each side:
0 – 0.5mm
• Thicknesses of shim:
0.5mm, 1.0mm
★ When the machine is new, the total thickness
of the shims on each side is 7mm.
★ Reduce the shims on the inside and outside
equally.
3 Mounting bolt:
490 – 608Nm {50 – 62kgm}
D275AX-5 20-143
1
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION
Testing
1. Drive the machine slowly on a level place, then
stop it.
★ Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler and

front carrier roller and measure clearance a be-
tween the bottom of the steel bar and shoe
grouser.
• Standard clearance a: 20 – 30mm
Adjusting
★ If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.
1. Remove cover (2).
2. When the tension is too high

Loosen plug (3) to discharge the grease.
¤ Since the high-pressure grease may spout
out, do not loosen the plug more than 1 turn.
3 Plug: 59 – 88Nm {6 – 9kgm}
3. When tension is low

Add grease through grease fitting (1).
★ If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
20-144 D275AX-5
1
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
a Testing and adjusting instruments for work

equipment oil pressure

1
G
799-101-5220 Nipple (10 x 1.25mm)
2
07002-11023 O-ring
Measuring
k Stop the machine on a level place, lower the
ing brake lever and safety lock lever in the LOCK 4) Run the engine at high idling and set the
position. blade lever and ripper lever in neutral and
a Measure the work equipment oil pressure under measure the oil pressure.
the following condition.
1. Measuring unload pressure

1) Open the right fender inspection cover.
2) Remove work equipment oil pressure sensor
(1).

moved parts.
3) Install nipple G2 and connect oil pressure

gauge 1 of hydraulic tester G1.
{60kg/cm2}.
D275AX-5 20-145
(8)
1
2. Measuring main relief pressure ★ The unload pressure and main relief pressure
★ Measure the main relief pressure at the can be measured in the “Pm Clinic auxiliary
same point with the unload pressure. mode” of the monitor panel.
{400kg/cm2}.
1) Start the engine and set the safety lock lever

2) Run the engine at high idling and operate the
blade lever and ripper lever to relieve each
cylinder at a stroke end and measure the oil
pressure.

moved parts.
20-146 D275AX-5
1
3. Measuring LS pressure (Load Sensing pres-

sure)
1) Open the right fender inspection cover.
2) Remove oil pressure pick-up port (2).

moved parts.
3) Install nipple G2 and connect oil pressure

gauge 1 of hydraulic tester G1.
{400kg/cm2}.
4) Start the engine and set the safety lock lever

5) Run the engine at high idling and operate the
blade lever and ripper lever to relieve each
cylinder at a stroke end and measure the oil
pressure.
D275AX-5 20-147
1
Adjusting 4) After finishing adjustment, check both main

a The unload pressure cannot be adjusted. relief pressure and LS pressure (load sens-
ing pressure) again according to the proce-
1. Adjusting main relief pressure dure for measurement described above.
a If the main relief pressure is abnormal, ad-
just LS relief valve (3) of the control valve ac- 2. Adjusting LS pressure (load sensing pres-
cording to the following procedure. sure)
a If the LS relief valve is adjusted, the LS pres- a If the LS pressure (load sensing pressure) is
sure (load sensing pressure) is changed, abnormal, adjust LS relief valve (3) of the
too. control valve.
a If the LS relief valve is adjusted, the main re-
lief pressure is changed, too.
a Adjust the LS pressure similarly to the main
relief pressure.
a After finishing adjustment, check both LS
pressure (load sensing pressure) and main
relief pressure again according to the proce-
dure for measurement described above.
1) Fixing adjustment nut (4), loosen locknut (5).

pressure.
k Do not remove the adjustment nut. If it is
removed, the internal parts may come
off.
a If the adjustment nut is
• turned to the right, the pressure rises.
• turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment nut:
Approx. 19.6 MPa {Approx. 200 kg/cm2}
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
3) Fixing adjustment nut (4), tighten locknut (5).
20-148 D275AX-5
1
(5)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
a Testing and adjusting instruments for control cir- 4. Install nipple 1 of hydraulic tester J1 and con-
cuit main pressure nect oil pressure gauge 2.
a Use an oil pressure gauge of 5.9MPa {60kg/
Symbol Part No. Name cm2}.
1
J 790-261-1203 Digital hydraulic tester
2 799-401-3100 Oil pressure pickup adapter (Size 02)
a A nipple (quick coupler) is installed to the control

valve outlet hose of the Pm clinic specification
machine.
a The control circuit main pressure is the pressure
lowered by the self-pressure reducing valve of
the control valve. It is used commonly for HSS
servo charge, work equipment PPC, and fan
pump control.
Measuring 5. Run the engine at high idling and set the blade
lever and ripper lever in neutral and measure the
work equipment to the ground, and set the park- oil pressure.
position.
a Measure the control circuit main pressure under
1. Open the right fender inspection cover.
2. Disconnect hose (1).

Adjusting
a The self-pressure reducing valve cannot be ad-
justed.
3. Install oil pressure pickup adapter J2 and con-

nect the disconnected hose again.
D275AX-5 20-149
(8)
1
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
a Measuring instruments for PPC valve output 3. Install nipple 1 of hydraulic tester K1 and con-
pressure nect oil pressure gauge 2.
Symbol Part No. Name cm2}.
1
K

position.
a Before measuring the PPC valve output pres-
sure, check that the control circuit main pressure
is normal.
a Measure the PPC valve output pressure under
4. Start the engine and set the safety lock lever in
the FREE position.
5. Run the engine at high idling and operate the
control lever of the circuit to be measured and
1. Open the right side cover.
measure the oil pressure.
a Measure the oil pressure with the lever at a
2. Remove the pressure switch or pressure pick-up
stroke end.
plug (1) of the circuit to be measured.
a When measuring the blade circuit, operate
a For the circuit to be measured, see the draw-
the lever until the blade floats.
ing on the next page.
a If a circuit does not have a pressure switch or
a pressure pick-up plug, install pick-up
adapter K2 or K3.

20-150 D275AX-5
(8)
1
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
D275AX-5 20-151
1
TESTING AND ADJUSTING ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE
★ If the end play of the blade lever and ripper lever

is excessive, adjust it with their PPC valves ac-
★ This figure shows the PPC valve for the ripper.
• Standard play a:
0.5 – 3.0mm at 200mm from revolution cen-
ter of lever (in both longitudinal and lateral di-
rections)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust the

play.
★ Do not move the piston at this time.
3. Fix disc (3) and tighten locknut (2).

3 Locknut: 98 – 127Nm {10 – 13kgm}
4. Install boot (1).
20-152 D275AX-5
3
1
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID
TESTING AND ADJUSTING VALVE
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER

SOLENOID VALVE
a Measuring instruments for outlet pressure of rip-

per pin puller solenoid valve

1
P 790-261-1203 Digital hydraulic tester

position.
a Measure the outlet pressure of the ripper pin
4. Run the engine at high idling and operate the rip-
puller solenoid valve under the following condi-
per pin puller switch and measure the oil pres-
tion.
sure.
1. Disconnect pin puller cylinder hose (1) or (2).

2. Install oil pressure pickup adapter P2 and con-

3. Install nipple 1 of hydraulic tester P1 and con-

nect oil pressure gauge 2.
cm2}.
D275AX-5 20-153
1
(5)
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND
TESTING AND ADJUSTING RIPPER
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE

AND RIPPER
★ If the blade or ripper drifts hydraulically, check to

see if the cause is on the cylinder packing side or
control valve side according to the following pro-
cedure.
1. Set the cylinders to be tested in the following po-

sitions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of the
machine body.
★ Since the blade lift cylinder is equipped
with a piston valve, do not extend it to the
stroke end.
2. Extend the cylinder to be tested with the corre-
sponding lever and check its movement.
• If the lowering speed is increased, the cylin-
der packing is defective.
• If the lowering speed does not change, the
control valve is defective.
★ If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
[Reference]
Reason why the lowering speed is increased
when the cylinder packing is the cause of the
2) Blade tilt cylinder hydraulic drift:
Extract the tilt cylinder to the stroke end and 1) If the machine is set in the above position
brace the blade to push up the right side of (where the holding pressure is applied to the
the machine body. bottom side), the oil leaks from the bottom
side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod, the pressure in
the head side is increased by the oil flowing
in from the bottom side.
2) As the pressure in the head side is in-
creased, it is balanced at a certain level
(which depends on the leakage), then the
lowering speed is lowered.
3) If the circuit on the head side is opened to the
drain circuit by the above operation of the le-
ver (the bottom side is closed by the check
valve at this time), the oil on the head side
flows in the drain circuit. As a result, the
3) Ripper lift cylinder pressure is unbalanced and the lowering
Brace the ripper to push up the rear side of speed is increased.
the machine body.
20-154 D275AX-5
1
TESTING AND ADJUSTING MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYL-

INDER
a Measuring instruments for internal leakage of 3. Run the engine at high idling and apply the relief
work equipment cylinder pressure to the cylinder bottom side.
• Blade tilt cylinder:
Symbol Part No. Name Operate to extend the cylinder
L Purchased Measuring cylinder to be measured.
• Ripper lift cylinder:
a Measure the internal leakage of work equipment Operate to lower ripper.
cylinder under the following condition. • Ripper Tilt cylinder:
• Hydraulic oil temperature: 45 – 55ºC Operate to tilt ripper forward.
a Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be mea- 4. After 30 second, measure leakage in 1 minute.
sured.
5. After finishing measurement, return the removed
1. Extend the cylinder to be measured to the stroke parts.
end and set the machine in the measuring posi-
tion.
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 cylin-
der.
k Take care not to disconnect the hose on the
bottom side.
D275AX-5 20-155
1
(5)
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER
BLEEDING
TESTING AND ADJUSTING RELEASING RESIDUAL AIR FROM
PRESSURE FROM WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL BLEEDING AIR FROM WORK

PRESSURE FROM WORK EQUIPMENT CYLINDER
EQUIPMENT CYLINDER
★ When disconnecting the piping between the con- ★ If the work equipment cylinder is removed and in-
trol valve and work equipment cylinder, release stalled or its piping is disconnected and connect-
the residual pressure from the circuit according ed, bleed air from its circuit according to the
to the following procedure. following procedure.
1. Loosen the oil filler cap of the hydraulic tank 1. Run the engine at low idling for about 5 minutes.
gradually to release the residual pressure from
the tank. 2. Running the engine at low idling, extend and re-
tract the cylinder to be bled 4 – 5 times.
2. Set the safety lock lever in the FREE position ★ Move the piston rod to about 100mm before
and operate the work equipment control lever to the stroke end and never relieve the oil.
each direction.
★ If the work equipment control lever is operat- 3. Running the engine at high idling and carry out
ed 2 – 3 times, the residual pressure in the the operation in 2.
accumulator is released.
4. Running the engine at low idling, move the cylin-
3. Run the engine at low idling for about 5 seconds, der to the stroke end to relieve the oil.
then stop it.
4. Repeat steps 2 – 3 above 2 – 3 times.
20-156 D275AX-5
1
TESTING AND ADJUSTING ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
★ Adjust the ripper lever to the best position ac- 5) Loosen nut (3).
cording to the following procedure. 6) Reverse knob (4).
★ The ripper lever can be adjusted forward and in 7) Tighten nut (3) to secure knob (4).
reverse within the range of ±40mm from the cen-
ter 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).
D275AX-5 20-157
1
TESTING AND ADJUSTING ADJUSTING SAFETY LOCK LEVER
ADJUSTING SAFETY LOCK LEVER
1. Adjust dimension a between pins of rod (1).

• Dimension a between pins: 444mm
2. Connect rod (1) to safety lock lever (2) and PPC

lock valve (3).
★ Install connecting pin (4) on the safety lock
lever side with the cotter pin on the outside of
the machine.
20-158 D275AX-5
1
TESTING AND ADJUSTING MEASURING FAN MOTOR SPEED
MEASURING FAN MOTOR SPEED
a Measuring instruments for fan motor speed 5. Measure the fan motor speed while the engine is
running at high idling and low idling.
M 799-203-8001 Multitachometer
1. Open the radiator mask and stick 1 sheet of re-

flecting tape 1 to the fan.
2. Set stand 3 of probe 2 of multitachometer M,

matching it to reflecting tape 1, then connect it
to multitachometer M.
k Take care that the probe will not interfere
with the fan.

3. Close the radiator mask.

k Be sure to close the radiator mask before
starting the engine. Do not start the engine
with the radiator mask open.
4. Run the engine and set the monitor panel in the

adjustment mode.
a For the method of operating the adjustment
mode, see SPECIAL FUNCTIONS OF
MONITOR PANEL (EMMS).
a Adjustment code:
1005 (Fan 100% speed mode)
D275AX-5 20-159
1
(5)
TESTING AND ADJUSTING MEASURING FAN CIRCUIT OIL PRESSURE
MEASURING FAN CIRCUIT OIL PRESSURE
a Measuring instruments for fan circuit oil pressure 3. Install nipple Q3 and connect oil pressure gauge
1 of hydraulic tester Q1.
Symbol Part No. Name a Use an oil pressure gauge of 39.2 MPa {400
799-101-5002 Hydraulic tester kg/cm2}.
1
Oil pressure pickup adapter
Q 2 799-401-3400
(Size: 05)
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
a A nipple (quick coupler) is installed to the fan

pump outlet hose of the Pm clinic specification
machine.
k Stop the machine on level ground and lower the
work equipment to the ground, then set the park-
ing brake lever and safety lock lever in the lock
position. 4. Run the engine and set the monitor panel in the
a Measure the fan circuit oil pressure under the fol- adjustment mode.
lowing condition. a For the method of operating the adjustment
• Hydraulic oil temperature: mode, see SPECIAL FUNCTIONS OF
Within operating range MONITOR PANEL (EMMS).
a Adjustment code:
1. Remove the floor inspection cover and discon- 1005 (Fan 100% speed mode)
nect hose (1).
5. Measure the fan circuit oil pressure while the en-
gine is running at high idling and low idling.
2. Install oil pressure pickup adapter Q2 and con-

suring instruments and return the removed
parts.
20-159-1 D275AX-5
(5)
TESTING AND ADJUSTING MEASURING FAN CIRCUIT OIL PRESSURE
D275AX-5 20-159-2
(5)
CHANGING ROTATION DIRECTION OF FAN MOTOR
TESTING AND ADJUSTING BLEEDING
CHANGING ROTATION AIR FROM
DIRECTION FAN
OF FAN PUMP
MOTOR
CHANGING ROTATION BLEEDING AIR FROM FAN

DIRECTION OF FAN MOTOR PUMP
a When reversing the current of the cooling air in a If the fan pump is removed and installed or its
the cold season or reversing it for cleaning the piping is disconnected and connected, bleed air
radiator fins, change the rotation direction of the from the pump case according to the following
fan motor according to the following procedure. procedure.
k When changing the rotation direction of the fan a Before bleeding air, check that the hydraulic oil
motor, be sure to stop the engine. level is proper.
1. Open the radiator mask and loosen locknut (1). 1. Remove the floor inspection cover.
2. Turn screw (2) to change the position of spool 2. Loosen air bleeder (1) and leave it for 15 min-
(3). utes.
a Turn or return the screw until the spool end is
stopped by the motor case.
• NORMAL: Normal direction (to pull air)
• REVERSE: Reverse direction (to push air)
3. Secure screw (2) with locknut (1) and close the
3 Locknut: 59 – 74Nm {6.0 – 7.5kgm}

radiator mask.
3. After 15 minutes, run the engine at low idling.
4. After oil flows out of air bleeder (1), tighten air

bleeder (1).
20-160 D275AX-5
1
(5)
TESTING AND ADJUSTING ADJUSTING BLADE
ADJUSTING BLADE
★ If the blade is removed and installed or disas- 2) Adjust the shim of lift (2).
sembled and reassemble, adjust it according to
the following procedure. Adjusted Adjusted Standard Standard
shim
point clearance clearance thickness
1. Adjusting shims for assembly
2 b Max. 1mm 4.0mm
1) Adjust the shim of center (1).
Adjusted Adjusted Standard Standard

shim
1 a See note. 4.5mm
Note: Adjust the shim so that the play of the

ball in the axial direction will be less
than 1mm and the ball can rotate
smoothly.
D275AX-5 20-161
1
TESTING AND ADJUSTING ADJUSTING BLADE
3) Adjust the shim of trunnion (3).
Adjusted Adjusted Standard Standard

shim
1.56 ± 0.65mm
3 c (Total 12mm
thickness)
2. Adjusting blade tilt distance

1) Adjust dimension d of brace (4) with the han-
dle.
• Dimension d of brace: 1,460mm
2) Measure right and left tilt distances e1 and
e2.
• Right tilt distance e1: Approx. 700mm
• Left tilt distance e2: Approx. 700mm
3) If both tilt distances are not the same, adjust
dimension d of brace (4) according to the fol-
lowing procedure.
• e1 > e2: Increase dimension d finely.
• e1 < e2: Decrease dimension d finely.
20-162 D275AX-5
1
TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR’S CAB
TESTING AND ADJUSTING a [a] side: Inside of cab (Pressurized)

[b] side: Out of cab
OPERATOR’S CAB (Atmospheric pressure)
Check after installing cab assembly
1. Measuring pressure in cab

• Criterion:
Measured value X 58.9 Pa {6 mmH2O}
• Engine speed: High idling
• Fan speed: 100% mode
(Refer to user adjustment mode on monitor
panel)
• Air conditioner fan switch: High
• Air conditioner Fresh/Recirculation switch:
Fresh air position
a If the measured value is lower than the stan-
2. Check of searing performance
dard value, check the seals of the holes for
1) Close the all openings of the cab.
wiring harnesses and optional parts in the
2) Splash water around the hatched part of the
cab.
cab at the rate of about 19 l/min for 10 min-
utes.
1) A simple method of measuring the internal
• At this time, it is not necessary to splash
pressure is as follows.
pressurized water.
i) Prepare a transparent vinyl hose.
3) Splash water horizontally from a hose over
• Inside diameter: 6 mm,
sealing surface (4).
Length: 3,000 mm
4) Check around the dashboard carefully.
ii) Secure the inside end of the hose to the
a If water leaks, caulk the leaking part and
top of the back seat with a tape.
check again.
iii) Remove bolt (1) under the left console
box. Pass the other end of the hose
through the bolt hole and take it out of in-
spection cover (2) on the left side of the
cab.
iv) Seal the hole of bolt (1) with tape (3).

v) Pour water in the hose up to about half,
then bent the hose to U - shape.
vi) Set the water level in the vinyl hose out
of the cab to that in the cab.
vii) Run the engine at high idling and mea-
sure water level difference c.
(Value c: Pa {mmH2O})
D275AX-5 20-162-1
(8)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special func- Operation section 1 of special Operation section 2 of special
tions functions functions
(Basic operation) (Changeover operation)
1. Gear speed display section 3. Service switch 4. Buzzer cancel switch
2. Multi-information section 5. Information switch
6. Shift-up switch
7. Shift-down switch
a EMMS: Equipment Management Monitoring System
D275AX-5 20-163
1
(5)
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items with special switches for test-
ing, adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
Normal display (Default) 1 Maintenance mode Maintenance item: 12 items

[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 6 items
Travel direction/Gear speed [>] [<]
[ ]
+
(q) 3 Error code display mode
Shift mode/Service meter
[>] [<]
[T] 4 Adjustment mode Adjustment menu: 4 items
[>] [<]
(Automatic) 1 Maintenance mode
Action code display function
[ON] & [ ](q) [ T]
Service mode
Maintenance interval change

5 Maintenance item: 12 items
mode
[>] [<]
Electric system error code
6
display mode
[>] [<]
Mechanical system error code
7
display mode
[>] [<]
8 Adjustment mode Adjustment menu: 21 items
[>] [<]
9 Load memory display mode Display menu: 3 items
[>] [<]
10 Real-time monitoring mode
[>] [<]
11 Dual display monitoring mode [ON]: Service switch
[>] [<] [ ]: Buzzer cancel switch (Left)
[T]: Buzzer cancel switch (Right)
Maintenance interval change [ > ]: Information switch (Right)
5
mode [ < ]: Information switch (Left)
(q): Min. 2.5 sec
20-164 D275AX-5
1
(5)
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 con-
tents and operation method of each function and
mode, see Operation Manual.
Normal display mode (Default)

The monitor panel displays the following information
normally.
Gear speed display section (1):
• Left side: Travel direction (P ·N·F·R)
• Right side: Gear speed (1·2·3)
• Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 charac-
ters each.
• Left side:
Gear shift mode (F1-R1·F1-R2·F2-R2)
• Right side:
Service meter (Unit: 0.1h)
a To change the normal display mode to the oper-
ator mode, hold buzzer cancel switch (4) in the
[ ] position for 2.5 seconds.
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-infor-
mation section (2) and reset after the replace-
ment.
a Gear speed display section (1) keeps dis-
playing normally.
Order Display Item

1 01:ENG OIL Engine oil
2 02:ENG FLT Engine oil filter
3 03:BYPS FLT Bypass filter
4 04:FUEL FLT Fuel filter
5 05:CORR FLT Corrosion resistor
6 06:P/L OIL Power train oil
7 07:P/L FLT Power train oil filter
8 08:HYD OIL Hydraulic oil
9 09:HYD FLT Hydraulic oil filter
10 10:CHG FLT HSS charge filter
11 11:DAMP OIL Damper oil
12 12:F/D OIL Final drive oil
D275AX-5 20-165
1
(5)
2. Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is dis-
played on multi-information section (2) as an
auxiliary function of the periodic diagnoses such
as the Pm clinic, even if any measuring instru-
ment is not connected.
playing normally.
Order Display Item

1 01-ENG. SPEED Engine speed
2 02-BOOST PRESSURE Boost pressure
Work equipment oil
3 03-HYD. PUMP PRES
pressure
4 04-BATTERY VOLT Battery voltage
5 05-HSS PUMP-A HSS oil pressure A
6 06-HSS PUMP-B HSS oil pressure B
3. Error code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the ma-
chine are displayed by a 6-character error code
on the multi-information section (2).
When the user or the operator needs to be noti-
fied of the error code of each fault, this mode is
applied.
playing normally.
a When a serviceman needs to check the error
codes for troubleshooting, the Electric sys-
tem error code display mode and the Me-
chanical system error code display mode
should be used for more detailed informa-
tion.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [ ] po-
sition on the screen shown at right, and the
all error codes detected currently are dis-
played at the interval of about 2 seconds. (To
finish displaying, turn the buzzer cancel
switch to the [ T ] position.)
20-166 D275AX-5
(6)
1
Error codes table
Error Action Caution Caution

Fault part Fault Controller
code code lamp buzzer
1500L0 Transmission clutch q See separate table (L0) Transmission CALL E03 q q
15SAL1 Forward clutch q See separate table (L1) Transmission CALL E03 q q
15SALH Forward clutch q See separate table (LH) Transmission CALL E03 q q
15SBL1 Reverse clutch q See separate table (L1) Transmission CALL E03 q q
15SBLH Reverse clutch q See separate table (LH) Transmission CALL E03 q q
15SEL1 1st clutch q See separate table (L1) Transmission CALL E03 q q
15SELH 1st clutch q See separate table (LH) Transmission CALL E03 q q
15SFL1 2nd clutch q See separate table (L1) Transmission CALL E03 q q
15SFLH 2nd clutch q See separate table (LH) Transmission CALL E03 q q
15SGL1 3rd clutch q See separate table (L1) Transmission CALL E03 q q
15SGLH 3rd clutch q See separate table (LH) Transmission CALL E03 q q
1800MW P/L clutch Slip (MW) Transmission E02 q q
2301L1 Right brake q See separate table (L1) Steering CALL E04 q q
2301LH Right brake q See separate table (LH) Steering CALL E04 q q
2302L1 Left brake q See separate table (L1) Steering CALL E04 q q
2302LH Left brake q See separate table (LH) Steering CALL E04 q q
AB00MA Alternator Malfunction (MA) Machine
AD00L2 Common rail q See separate table (L2) Engine E02 q q
AD00MA Common rail Malfunction (MA) Engine E02 q q
AD10L3 Fuel supply pump q See separate table (L3) Engine CALL E03 q q
AD10MA Fuel supply pump Malfunction (MA) Engine CALL E03 q q
AD10MB Fuel supply pump Defective function (MB) Engine E02 q q
AD11KA Fuel supply pump solenoid 1 Disconnection (KA) Engine CALL E03 q q
AD11KB Fuel supply pump solenoid 1 Short circuit (KB) Engine CALL E03 q q
AD51KA Fuel supply pump solenoid 2 Disconnection (KA) Engine CALL E03 q q
AD51KB Fuel supply pump solenoid 2 Short circuit (KB) Engine CALL E03 q q
ADA1KA No. 1 injector solenoid Disconnection (KA) Engine E02 q q
ADAZKB No. 1, 2, 3 injector solenoid Short circuit (KB) Engine CALL E03 q q
ADB1KA No. 2 injector solenoid Disconnection (KA) Engine E02 q q
ADC1KA No. 3 injector solenoid Disconnection (KA) Engine E02 q q
ADD1KA No. 4 injector solenoid Disconnection (KA) Engine E02 q q
ADDZKB No. 4, 5, 6 injector solenoid Short circuit (KB) Engine CALL E03 q q
ADE1KA No. 5 injector solenoid Disconnection (KA) Engine E02 q q
ADF1KA No. 6 injector solenoid Disconnection (KA) Engine E02 q q
B@BAZG Engine oil Oil pressure reduction (ZG) Machine
B@BCNS Radiator coolant Overheat (NS) Machine
B@BCZK Radiator coolant Level reduction (ZK) Machine
B@CENS Power train oil Overheat (NS) Machine
B@CHZG HSS charge oil Oil pressure reduction (ZG) Machine
B@HANS Hydraulic oil Overheat (NS) Machine q
D110KA Battery relay Disconnection (KA) Steering
D110KB Battery relay Short circuit (KB) Steering
D130KA Neutral safety relay Disconnection (KA) Transmission E02 q q
D130KB Neutral safety relay Short circuit (KB) Transmission E02 q q
D161KA Back-up alarm relay Disconnection (KA) Transmission E01
D161KB Back-up alarm relay Short circuit (KB) Transmission E01
D275AX-5 20-167
1
(5)

D1D0KB Engine controller load power relay Short circuit (KB) Engine CALL E04 q q
DAFRKR Monitor panel CAN communication Defective communication (KR) Monitor CALL E03 q q
DAQ0KK Transmission controller Lowering of source voltage (input) (KK) Transmission CALL E04 q q
DAQ0KT Transmission controller Fault in controller (KT) Transmission E02 q q
DAQ5KK Transmission controller potentiometer power Lowering of source voltage (input) (KK) Transmission CALL E03 q q
DAQ6KK Transmission controller sensor power Lowering of source voltage (input) (KK) Transmission E01
DAQ9KQ Transmission controller model checking Nonconformance of model selection signal (KQ) Transmission CALL E04 q q
Defective communication
DAQRKR Transmission controller CAN communication Transmission CALL E03 q q
(Abnormality in objective component) (KR)
DAQSKR Transmission controller SNET communication Transmission E01
DB20KT Engine controller Fault in controller (KT) Engine CALL E03 q q
DB22KK Engine controller load power Lowering of source voltage (input) (KK) Engine CALL E04 q q
DB29KQ Engine controller model selection Nonconformance of model selection signal (KQ) Engine CALL E03 q q
DB2AMA Fuel injection amount adjustment switch signal Malfunction (MA) Engine CALL E03 q q
DB2RKR Engine controller CAN communication Engine CALL E03 q q
DB30KK Steering controller Lowering of source voltage (input) (KK) Steering CALL E04 q q
DB30KT Steering controller Fault in controller (KT) Steering E01
DB35KK Steering controller potentiometer power Lowering of source voltage (input) (KK) Steering CALL E03 q q
DB36KK Steering controller sensor power Lowering of source voltage (input) (KK) Steering CALL E03 q q
DB39KQ Steering controller model checking Nonconformance of model selection signal (KQ) Steering CALL E04 q q
DB3RKR Steering controller CAN communication Steering CALL E03 q q
DB3SKR Steering controller SNET communication Steering E01
DD11KB Starting switch Short circuit (KB) Engine CALL E04 q q
DD12KA Shift-up switch Disconnection (KA) Transmission E02 q q
DD12KB Shift-up switch Short circuit (KB) Transmission E02 q q
DD13KA Shift-down switch Disconnection (KA) Transmission E02 q q
DD13KB Shift-down switch Short circuit (KB) Transmission E02 q q
DD14KA Parking brake lever switch Disconnection (KA) Transmission CALL E03 q q
DD14KB Parking brake lever switch Short circuit (KB) Transmission CALL E03 q q
DDE2L6 Engine oil pressure switch q See separate table (L6) Engine CALL E03 q q
DDN4LD Ripper lift raise oil pressure switch q See separate table (LD) Steering
DDN5LD Ripper lift lower oil pressure switch q See separate table (LD) Steering
DDN6LD Ripper tilt oil pressure switch q See separate table (LD) Steering
DDN7KA Blade pitch switch Disconnection (KA) Transmission E02 q q
DDN7KB Blade pitch switch Short circuit (KB) Transmission E02 q q
DDN9KA Blade tilt switch Disconnection (KA) Transmission E01
DDN9KB Blade tilt switch Short circuit (KB) Transmission E01
DDQ2KA Parking brake lever switch Disconnection (KA) Steering CALL E03 q q
DDQ2KB Parking brake lever switch Short circuit (KB) Steering CALL E03 q q
DDQ2L4 Parking brake lever switch q See separate table (L4) Steering CALL E03 q q
Engine water temperature sensor
DGE2KX Out of input signal range (KX) Engine CALL E03 q q
(for high temperature)
q See separate table (L6)

Engine water temperature sensor
DGE3L6 Engine E02 q q
(for low temperature)
20-168 D275AX-5
1
(5)

DGE4KX Fuel temperature sensor Out of input signal range (KX) Engine E01
DGS1KX Hydraulic oil temperature sensor Out of input signal range (KX) Transmission
DH21KA Work equipment pump oil pressure sensor Disconnection (KA) Transmission E01
DH21KB Work equipment pump oil pressure sensor Short circuit (KB) Transmission E01
DH30KX Boost pressure sensor Out of input signal range (KX) Engine E02 q q
DH40KX Common rail pressure sensor Out of input signal range (KX) Engine CALL E03 q q
DHH3KA HSS pump oil pressure sensor A Disconnection (KA) Steering CALL E03 q q
DHH3KB HSS pump oil pressure sensor A Short circuit (KB) Steering CALL E03 q q
DHH4KA HSS pump oil pressure sensor B Disconnection (KA) Steering CALL E03 q q
DHH4KB HSS pump oil pressure sensor B Short circuit (KB) Steering CALL E03 q q
DK10KX Fuel control dial Out of input signal range (KX) Engine CALL E03 q q
DK12KX Deceleration potentiometer Out of input signal range (KX) Engine CALL E03 q q
DK30KA Steering potentiometer 1 Disconnection (KA) Steering CALL E03 q q
DK30KB Steering potentiometer 1 Short circuit (KB) Steering CALL E03 q q
DK30KX Steering potentiometer 1 Out of input signal range (KX) Steering CALL E04 q q
DK30KZ Steering potentiometer 1 Disconnection or short circuit (KZ) Steering CALL E04 q q
DK30L8 Steering potentiometer 1 q See separate table (L8) Steering CALL E03 q q
DK31KA Steering potentiometer 2 Disconnection (KA) Steering CALL E03 q q
DK31KB Steering potentiometer 2 Short circuit (KB) Steering CALL E03 q q
DK40KA Brake potentiometer Disconnection (KA) Steering CALL E03 q q
DK40KB Brake potentiometer Short circuit (KB) Steering CALL E03 q q
DK55KX Forward/Reverse potentiometer Out of input signal range (KX) Transmission CALL E04 q q
DK55KZ Forward/Reverse potentiometer Disconnection or short circuit (KZ) Transmission CALL E04 q q
DK55L8 Forward/Reverse potentiometer q See separate table (L8) Transmission CALL E03 q q
DK56KA Forward/Reverse potentiometer 1 Disconnection (KA) Transmission CALL E03 q q
DK56KB Forward/Reverse potentiometer 1 Short circuit (KB) Transmission CALL E03 q q
DK57KA Forward/Reverse potentiometer 2 Disconnection (KA) Transmission CALL E03 q q
DK57KB Forward/Reverse potentiometer 2 Short circuit (KB) Transmission CALL E03 q q
DK60KA Acceleration sensor Disconnection (KA) Steering E01
DK60KB Acceleration sensor Short circuit (KB) Steering E01
DKH1KA Pitch angle sensor Disconnection (KA) Steering CALL E03 q q
DKH1KB Pitch angle sensor Short circuit (KB) Steering CALL E03 q q
DLE3LC Engine Ne speed sensor q See separate table (LC) Engine CALL E03 q q
DLF1KA Transmission output speed sensor Disconnection (KA) Transmission E01 q q
DLH1LC Engine G speed sensor q See separate table (LC) Engine CALL E03 q q
DV00KB Caution buzzer Short circuit (KB) Monitor E02 q
DW59KA Blade dual selection solenoid Disconnection (KA) Transmission E01
DW59KB Blade dual selection solenoid Short circuit (KB) Transmission E01
DW5AKA Blade pitch selection solenoid Disconnection (KA) Transmission E02 q q
DW5AKB Blade pitch selection solenoid Short circuit (KB) Transmission E02 q q
DWN1KA HSS pump solenoid LEFT Disconnection (KA) Steering CALL E03 q q
DWN1KB HSS pump solenoid LEFT Short circuit (KB) Steering CALL E03 q q
DWN2KA HSS pump solenoid RIGHT Disconnection (KA) Steering CALL E03 q q
DWN2KB HSS pump solenoid RIGHT Short circuit (KB) Steering CALL E03 q q
D275AX-5 20-169
1
(5)

DWN3KA Emergency stop prevention solenoid Disconnection (KA) Steering CALL E04 q q
DWN3KB Emergency stop prevention solenoid Short circuit (KB) Steering CALL E04 q q
DWN4KA HSS free solenoid Disconnection (KA) Steering E01
DWN4KB HSS free solenoid Short circuit (KB) Steering E01
DWN5KA Fan pump solenoid Disconnection (KA) Transmission E01
DWN5KB Fan pump solenoid Short circuit (KB) Transmission E01
DXH1KA Lock-up solenoid Disconnection (KA) Transmission E01
DXH1KB Lock-up solenoid Short circuit (KB) Transmission E01
DXH4KA 1st clutch ECMV Disconnection (KA) Transmission CALL E03 q q
DXH4KB 1st clutch ECMV Short circuit (KB) Transmission CALL E03 q q
DXH5KA 2nd clutch ECMV Disconnection (KA) Transmission CALL E03 q q
DXH5KB 2nd clutch ECMV Short circuit (KB) Transmission CALL E03 q q
DXH6KA 3rd clutch ECMV Disconnection (KA) Transmission CALL E03 q q
DXH6KB 3rd clutch ECMV Short circuit (KB) Transmission CALL E03 q q
DXH7KA Reverse clutch ECMV Disconnection (KA) Transmission CALL E03 q q
DXH7KB Reverse clutch ECMV Short circuit (KB) Transmission CALL E03 q q
DXH8KA Forward clutch ECMV Disconnection (KA) Transmission CALL E03 q q
DXH8KB Forward clutch ECMV Short circuit (KB) Transmission CALL E03 q q
DXHBKA Right brake ECMV Disconnection (KA) Steering CALL E04 q q
DXHBKB Right brake ECMV Short circuit (KB) Steering CALL E04 q q
DXHCKA Left brake ECMV Disconnection (KA) Steering CALL E04 q q
DXHCKB Left brake ECMV Short circuit (KB) Steering CALL E04 q q
a C & B: Clutch and brake.
Separate table: Trouble codes list
Trouble Trouble
Detail of trouble Detail of trouble
code code
KA Disconnection L4 ON/OFF signals do not agree with each other
KB Short circuit L6 Operation state and stop state do not agree with signals
KK Lowering of source voltage (Input) L8 Analog signals do not agree with each other
KQ Disagreement of model selection signals LC Speed signals do not agree with each other
Communication defective (Abnormality
KR LD Switch is pressed for long time
in objective component)
KT Internal defect of controller LH When command current is turned ON, fill signal is turned OFF
KX Out of input signal range MA Malfunction
KZ Disconnection or short circuit MB Lowering of function
L0 Double engagement MW Slip
When command current is turned OFF,
L1 NS Overheating
fill signal is turned ON
L2 Fuel pressure is too high ZG Lowering of oil pressure
L3 Objective part cannot be controlled ZK Lowering of level
a “Controller” in the table indicates classification of the controller in charge of system check, monitor panel,
and code.
MON: Fault code of electric system checked by monitor panel
ENG: Fault code of electric system checked by engine controller
T/M: Fault code of electric system checked by transmission controller
S/T: Fault code of electric system checked by steering controller
Machine: Fault code of mechanical system
20-170 D275AX-5
1
(5)
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).
playing normally.
Order Display Item

Adjustment of LCD
1 01:LCD BRIGHTNES
brightness
Adjustment of display
2 02:DSP BRIGHTNES
brightness
Adjustment of display
3 03:DSP CONTRAST
contrast
Fan 100% speed
4 04:FAN 100% SPEED mode (For cleaning ra-
diator)
D275AX-5 20-171
1
(5)
Action code display function

If a fault to be notified to the operator occurs during
work, an action code and a phone No. are displayed
on the multi-information section (2).
★ Gear speed display section (1) keeps displaying
normally.
★ The phone No. is displayed for only important ac-
tion codes. The display shown at right is an ex-
ample. (The form of the displayed phone No.
depends on the form of the input No.)
★ If an important action code is displayed, the cau-
tion lamp flashes and the caution buzzer sounds.
<Reference>
An action code is displayed only when a serious fault
occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure to
check for a error code in the “Electric system error
code display mode” and “Mechanical system error
code display mode” of the service mode.
Action codes table
Action
Indication method of fault Contents of fault Remedy
code
• Automatic function stops or nor-
• Torque converter is not locked up. mal function stops partially but
E01 • Only action code is displayed. • Blade dual tilt mechanism does machine can work.
not work. • Call your Komatsu distributor for
repair.
• Stop engine and start it again,
• Gear is not shifted up or down. and you can operate machine
• Action code is displayed.
• Blade tilt is not limited. without limiting function. You
E02 • Caution lamp flashes.
• Blade pitch mechanism does not must take care, however.
• Caution buzzer sounds.
work. • Call your Komatsu distributor for
repair.
• Engine water temperature is de-
fective.
• Usable gear speeds are limited.
• Action code is displayed. • Move machine to safe place.
• Engine speed does not rise fully.
CALL E03 • Caution lamp flashes. • Call your Komatsu distributor for
• Gear shifting shocks become
• Caution buzzer sounds. repair.
large.
• Steering performance lowers.
• Brake shocks become large.
• Action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
CALL E04 • Caution lamp flashes. • Machine cannot travel. • Call your Komatsu distributor for
• Caution buzzer sounds. • Machine stops. repair.
20-172 D275AX-5
1
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 op-
erating service switch (3) and buzzer cancel
switch (4).
a Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the [ ]
position for 2.5 seconds.
a If the monitor panel is set in the service
mode, [1C] is displayed on the gear speed
display section (1).
a Each time the monitor panel is set in the ser-
vice mode, the “Maintenance inter val
change mode” is displayed first.
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
• [ > ]: Next mode No.
• [ < ]: Previous mode No.
• [ ]: Execute mode.
a For the details of operation in each mode,
see the following pages.
Gear
3) Finishing mode and function Order speed Display and item
display
The current mode and function can be finished
by either of the following method, regardless of 5-EXCHG, INTVAL. SET MODE
1 1C
the current mode and hierarchy. Maintenance interval change mode
1 When continuing the operation in another 6-ELEC. FAULT CODE MODE
mode or function or in the operator mode: 2 EE
Electric system fault code display mode
Return to the mode screen or function
7-MACHINE FAULT CODE MODE
screen to be used next by operating buzzer 3 bE
cancel switch (4). Mechanical system fault code display mode
• [ T ]: Screen returns. 8-SERVICE ADJUST MODE
4 Cb
2 When finishing the all operation: Adjustment mode
Turn off the starting switch. 9-LOAD MEMORY DISPLEY MODE
5 Ld
Load memory display mode
10-REAL TIME MONITORING MODE
6 5R
Real time monitoring mode
11-DUAL DISPLAY MONITORING MODE
7 dR
Dual display monitoring mode
D275AX-5 20-173
1
(5)
5. Maintenance interval change mode

(5-EXCHG. INTVAL. SET MODE)
In this mode, you can check and set the mainte-
nance interval times of various filters and oils
which are the bases of the maintenance display
function in the operator mode.
1) Selecting and executing mode

i) Select “Maintenance interval change
mode” on the mode selection screen.
★ If the mode is selected, code (1C) is
displayed on gear speed display sec-
tion (1) and the title is displayed on
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (4).
2) Selecting and displaying maintenance item

i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
• [ > ]: Next code
• [ < ]: Previous code
ii) Display the maintenance item selection
switch (4).
• [ ]: Execute item.
3) Contents of information section

The following items are displayed on the in-
formation section.
1: Code
2: Maintenance item
3: Replacement interval time (Set time)
★ The items shown at right are examples.
★ If the replacement interval does not need
to be changed, finish the operation on
this screen.
★ If the replacement interval needs to be
changed, go to step 4).
20-174 D275AX-5
1
4) Changing replacement interval time

i) Change the set time by operating infor-
mation switch (5), shift-up switch (6), and
shift-down switch (7).
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
★ If you do not use the maintenance

function, set the all times to 0.
ii) If the input time is correct, enter the

change of setting by operating buzzer
cancel switch (4).
• [ ]: Enter change.
★ If the change is finished normally, the
information display screen appears
after the screen shown at right.
★ If the change is not finished normally,

the information display screen before
the change appears after the screen
shown at right. In this case, execute
the above operation again.
D275AX-5 20-175
1
Maintenance items table
Replacement interval time

Order Display Item 1st time 2nd time and after
(Cannot be changed) (Can be changed)
1 01:ENG OIL Engine oil 0500h 0500h
2 02:ENG FLT Engine oil filter 0500h 0500h
3 03:BYPS FLT Bypass filter — —
4 04:FUEL FLT Fuel filter 0250h 0500h
5 05:CORR FLT Corrosion resistor 1000h 1000h
6 06:P/L OIL Power train oil 0250h 1000h
7 07:P/L FLT Power train oil filter 0250h 0500h
8 08:HYD OIL Hydraulic oil 0250h 2000h
9 09:HYD FLT Hydraulic oil filter 0250h 2000h
10 10:CHG FLT HSS charge filter 1000h 1000h
11 11:DAMP OIL Damper oil 2000h 2000h
12 12:F/D OIL Final drive oil 0250h 000h
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.
20-176 D275AX-5
1
(5)
6. Electric system error code display mode

(6-ELEC. ERROR CODE MODE)
In this mode, you can check the past electric sys-
tem error codes.

i) Select “Electric system error code display
mode” on the mode selection screen.
★ If the mode is selected, code (EE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
2) Display in the case where no codes are re-

corded
If no error codes have been output up to now,
the information section displays as shown at
right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to now, the
information section displays as shown at right.
1: Record No. (Up to 20)
2: Error code (Code being output currently
is flashing)
3: Number of past occurrences
4: Time measured by service meter after
first occurrence
last occurrence
★ For the details of displayed error codes,
see the “ERROR CODES TABLE” in the
operator mode.
D275AX-5 20-177
1
★ Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output currently.
★ Condition for detecting and keeping error
code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is de-
tected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating infor-
mation switch (5).
★ The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

While a error code to be deleted, operate
shift-up switch (6) or shift-down switch (7).
• [UP] or [DOWN]: Delete error code.
★ A error code which is being output cur-
rently (which is flashing) cannot be delet-
ed.
20-178 D275AX-5
1
7. Mechanical system error code display mode

(7-MACHINE ERROR CODE MODE)
In this mode, you can check the past mechanical
system error codes.

i) Select “Mechanical system error code
display mode” on the mode selection
screen.
★ If the mode is selected, code (bE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
2) Display in the case where no codes are re-

corded
If no error codes have been output up to now,
the information section displays as shown at
right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to now, the
information section displays as shown at right.
1: Record No. (Up to 20)
2: Error code (Code being output currently
is flashing)
3: Number of past occurrences
first occurrence
last occurrence
★ For the details of displayed error codes,
see the “ERROR CODES TABLE” in the
operator mode.
D275AX-5 20-179
1
★ Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output currently.
★ Condition for detecting and keeping error
code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is de-
tected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating infor-
mation switch (5).
★ The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

The mechanical system error codes cannot
be deleted.
20-180 D275AX-5
1
8. Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.

i) Select “Adjustment mode” on the mode
selection screen.
★ If the mode is selected, code (Cb) is
ii) Display the adjustment code input
switch (4).
2) Selecting adjustment items

On the adjustment code input screen, input
the 4-digit code of the item to be adjusted by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
★ If the 4-digit code is input, the informa-
tion of that code is displayed automati-
cally.
3) Contents of display on adjustment screen

1: Code
2: Adjustment item
3: Related information
★ For the detailed information and adjust-
ment procedure, see “ADJUSTMENT
MODE TABLE AND ADJUSTMENT
PROCEDURE”.
D275AX-5 20-181
1
a If an incorrect code is input, the adjust-

ment code input screen appears again
after the screen shown at right. In this
case, execute the above operation
again.
4) When operating machine in adjustment

mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) dis-
plays normally and the machine can be op-
erated normally.
a To select another screen, return the
parking brake lever to the LOCK position
and perform the necessary procedure.
5) Automatic selection of adjustment item (Lim-

ited function)
After one of some adjustment items is select-
ed, if the information switch is operated, the
next adjustment item is selected automati-
cally, even if the code of the next adjustment
item is not input.
• [ > ]: Code is increased
• [ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Adjustment mode ta-
ble. 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.
20-182 D275AX-5
1
(5)
Adjustment mode table and adjustment procedure
Related Disassembly/ Automatic

No. Code Adjustment item
information Assembly selection
1 0001 INP TEL NO. Phone No. input mode Figure/Symbol
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 initial set (Zero-point adjustment) Voltage q 4
6 0006 PUMP N.AJST HSS pump neutral adjustment Pressure 6
7 0007 ENG.FULL CH Engine deceleration-cut mode Speed 5
8 0008 INJ->123456 Common rail reduced cylinder mode Speed
9 0009 PITCH SENS. Pitch angle sensor initial set Voltage 7
@ 0010 FAN 70%MODE Fan 70% speed mode Speed 8
A 0523 SMR SET Service meter adjustment Time
B 1005 FAN100%MODE Fan 100% speed mode Speed 9
C 1012 S/T N-SET Steering lever neutral set Voltage
D 1013 S/T M.L-SET Steering lever left set Voltage
E 1014 S/T M.R-SET Steering lever right set Voltage
F 2222 HSS ADJUST HSS lever initial current set Current
G 2233 R SLOW CUT Reverse slow stop set Letter
H 9995 LOCK BRAKE Electric brake normally ON mode Voltage
I 9996 MECHA BRAKE Electric brake release mode Voltage
J 9997 HI LIMIT High idling limit mode Speed
K 9998 SFT LIMITER Gear speed limit mode Permit
k Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the
machine is assembled or any controller is replaced. (For the adjustment procedure, see “ADJUSTMENT AF-
TER REPLACEMENT OF CONTROLLER”.)
D275AX-5 20-183
1
(5)
1 0001: Phone number input mode

• This code inputs or changes a phone number to
be displayed simultaneously with when the user
code is displayed.
• The lower part displays a phone number and
symbols.
• Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
• Instructions for use:
By operating the information switch (5), shift up
switch (6), and shift down switch (7), input a
phone number and symbols.
• [ > ]: Moves the cursor rightward.
• [ < ]: Moves the cursor leftward.
• [UP]: Advance the numeric character or
character (in the order of available
characters).
• [DOMN]: Reverse the numeric character or
character (in the reverse order of
available characters).
a Sixteen digits of numeric characters are pro-
vided. To avoid confusion, input symbols oth-
er 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.
2 0002: Steering controller specification set

• This code is used to initialize the specification
codes recognized by the steering controller and
the set values of the memory in the controller.
• The specification code is displayed on the lower
line.
• Adjustment method (HSS specification):
1) Set buzzer cancel switch (4) in the [ ] posi-
tion and check that the caution buzzer
sounds.
2) Check that the displayed specification code
has changed from [6*6] to [666].
a If specification code [666] 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.
20-184 D275AX-5
1
(5)
3 0003: Transmission controller specification set

• This code is used to initialize the specification
codes recognized by the transmission controller
and the set values of the memory in the control-
ler.
• The specification code is displayed on the lower
line.
• Adjustment method (HSS specification):
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.
effective.
4 0004: Machine specification set

• This code is used to have the machine specifica-
tion recognized by the controllers which com-
pose the system.
• The machine specification code is displayed on
the lower line.
• Adjustment method:
a Since this code is reset when “Transmission
controller specification set” is executed, ad-
just it after that.
1) Select the code of the machine specification
by setting information switch (5) in the [ > ]
position.
a Be sure to select “SSC power setting 1”
No. Work equipment type SSC type
as the SSC type.
2) Set buzzer cancel switch (4) in the [ ] posi- 00 Single tilt SSC function OFF
tion and check that the caution buzzer 01 Single tilt SSC power setting 1
sounds.
k If the machine specification is different from
02 Single tilt SSC power setting 2
10 Dual tilt SSC function OFF
the setting in the controller, the machine may
11 Dual tilt SSC power setting 1
move abnormally or an error may be made.
Accordingly, be sure to match the setting to 12 Dual tilt SSC power setting 2
the machine specification.
effective.
D275AX-5 20-185
1
(5)
5 0005: Brake potentiometer zero-point adjustment

• This code is used to adjust the zero point of the
brake pedal potentiometer.
• The deviation from the standard value is indicat-
ed by voltage on the lower line (Indication range:
0 – 5000).
1) Check that the brake pedal is in neutral (it is
not pressed).
tion 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 in-
dication on the lower line does not change.
effective.
6 0006: HSS pump neutral adjustment

(HSS specification)
• This code is used to solve a problem in the
straight travel performance of the HSS steering.
• The HSS oil pressure is indicated on the lower line.
• Adjustment method 1 (Check of HSS differential
pressure and deviation direction):
a Before performing this adjustment, check the
differential pressure of the HSS pump to see
if the straight travel performance needs to be
adjusted.
1) Run the engine at high idling with the parking
brake lever in the LOCK position.
2) Set the monitor panel in the real-time monitor-
ing mode (5R) and set it to the following code.
50500 (HSS differential oil pressure)
3) Check the indicated differential pressure to
see if the straight travel performance needs
to be adjusted.
a If the differential pressure is 2 MPa or
lower, the straight travel performance
does not need to be adjusted. In this
case, finish the work.
a If the differential pressure is higher than
2 MPa, perform the following adjustment
step.
4) Run the engine at high idling and tilt the PCCS
lever “to the right end and return it and measure
the differential pressure” and tilt it “to the left end
and return it and measure the differential pres-
sure”, and then judge the deviation direction
from the measured differential pressure.
a The machine deviates during travel in
the lever operation direction in which the
differential pressure is higher.
20-186 D275AX-5
1
(5)
• Adjustment method 2 (Adjustment of neutral po-

sition of HSS):
k Since the steering circuit will be relieved,
take care of safety around the machine and
keep pressing the brake pedal securely dur-
ing adjustment.
1) Set the monitor panel in the adjustment
mode.
sition and keep pressing the brake pedal se-
curely and run the engine at high idling.
3) Turn the PCCS lever fully in the opposite di-
rection to the deviating direction and keep it
that position.
4) Set the buzzer cancel switch (4) in the [ ]
position and return the PCCS lever to the
neutral position.
a It takes about 1 minutes to complete the
adjustment (The progress of the adjust-
ment is displayed graphically on the en-
gine speed display section of the monitor
panel).
5) When the adjustment is completed, the all
segments of the engine speed display sec-
tion of the monitor panel light up and start
flashing.
• Adjustment procedure 3 (Check of adjustment):

Check that the differential pressure in the HSS
pump is in the normal range according to Adjust-
ment method 1 above.
50500 (HSS differential pressure)
• Normal range: Max. 2MPa
effective.
7 0007: Engine deceleration-cut mode

• This code is used to stop the auto-deceleration
function of the engine and check the high idling
speed of the engine singly.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
While this code is displayed, its function is turned
on and the auto-deceleration function is turned
off.
a If this code is turned off, its function is turned
off.
D275AX-5 20-187
1
(5)
8 0008: Common rail reduced cylinder mode

a When the engine common rail system seems to
be faulty, 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 faulty cylinder from the change of
the engine speed.
a Since a fault is detected by the difference of the
engine speed in the reduced cylinder mode op-
eration from that in the normal mode operation,
use this function while the engine is running.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
Select the cylinders to be turned off for the re-
duced cylinder mode operation by operating in-
formation switch (5) and buzzer cancel switch
(4).
Use this method to turn on the selected cylinders
again, too.
• [ ]: Execute or stop reduced cylinder mode
operation.
a The figure at right is an example that No. 2
cylinder is turned off for reduced cylinder
mode operation and turned on again (The
cylinder No. lamp is turned off in the reduced
cylinder mode operation and on in the nor-
mal mode operation).
a Only one or more cylinders can be turned off
for the reduced cylinder mode operation.
off.
9 0009: Pitch angle sensor initial set

• This code is used to adjust the zero point and in-
stallation error of the pitch angle sensor.
• The deviation from the standard neutral position
is displayed by voltage on the lower line (Display
range: 0 – 5000).
Set buzzer cancel switch (4) in the [ ] position
and check that the caution buzzer sounds.
effective.
20-188 D275AX-5
1
(5)
0 0010: Fan 70% speed mode

• This code forcedly sets the rpm of cooling fan at
70%.
• The lower part displays data for factory adjust-
ment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
70%.
a Ending this code disables the function.
A 0523: Service meter adjustment

• This code is used to match the value of a new
service meter to the value of the machine.
k Since this code can only put the service meter
forward and cannot put it back, operate carefully.
• The service meter reading is displayed on the
lower line (Display range: 00000 – 99999).
• Using method:
a If you input a wrong value, do not enter the
setting but cancel this code, then execute the
setting again.
1) Set the service meter reading by operating
information switch (5) and shift-up switch (6).
a The actual service meter displays by the
unit of 0.1h, but this code displays by the
unit of 1h.
sounds.
a Even if the adjustment mode is turned off,
the setting is effective.
D275AX-5 20-189
1
(5)
B 1005: Fan 100% speed mode

• This code forcedly sets the rpm of cooling fan at
approximately 100%.
• The lower part displays data for factory adjust-
ment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
100%.
a Ending this code disables the function.
C 1012: Steering lever neutral set

• This code is used to adjust the steering neutral
position of the PCCS lever.
• The deviation of the steering potentiometer from
the standard neutral position is displayed by volt-
age on the lower line (Display range: 0 – 5000).
Set buzzer cancel switch (4) in the [ ] position
and check that the caution buzzer sounds.
effective.
D 1013: Steering lever left set

• This code is used to adjust the maximum left
steering position of the PCCS lever.
the standard maximum left position is displayed
by voltage on the lower line (Display range: 0 –
5000).
1) Set the PCCS lever to the left steering stroke
end.
sounds.
effective.
20-190 D275AX-5
1
(5)
E 1014: Steering lever right set

• This code is used to adjust the maximum right
steering position of the PCCS lever.
the standard maximum right position is displayed
by voltage on the lower line (Display range: 0 –
5000).
1) Set the PCCS lever to the right steering
stroke end.
sounds.
effective.
F 2222: HSS lever initial current set

• When the steering start feeling is different by the
steering direction, this code is used to adjust the
turning radius at the start of steering.
• The current to drive the HSS pump solenoid is
displayed on the lower line [Display range: –350
(Left end) – 0 – 350 (Right end)].
1) Turning the PCCS lever to the left or right,
display and keep the current to be set.
• If the lever is turned to the left, the cur-
rent becomes negative.
• If the lever is turned to the right, the cur-
rent becomes positive.
sounds.
a As the set current is increased in the positive
or negative direction, the turning radius at
the start of steering is decreased (the ma-
chine turns more quickly).
a The figure at right is an example that the set
current for steering to the left is reduced to
increase the turning radius.
effective.
D275AX-5 20-191
1
(5)
G 2233: Reverse slow stop set

• This code is used to stop the reverse slow func-
tion forcibly, regardless of operation of the
switches on the monitor panel.
• Whether the reverse slow function is turned on is
displayed by letters on the lower line.
Change the setting by operating information
switch (5).
• [ < ], [ > ]: Change setting.
• [DEACTIVE]: Turn off reverse slow function.
• [ACTIVE]: Turn on reverse slow function.
a If the reverse slow function is turned off, the
reverse travel speed is not lowered even if
the reverse slow mode switch on the monitor
panel is turned on.
effective.
H 9995: Electric brake normally ON mode

• This code is used to check that the sudden stop
prevention valve works normally.
• The voltage of the brake potentiometer is dis-
played on the lower line.
• Using method:
on and the electric brake is normally turned on.
off.
I 9996: Electric brake release mode

• This code is used to check the operation of the
mechanical brake.
• The voltage of the brake potentiometer is dis-
played on the lower line.
• Using method:
on and the electric brake is normally released.
off.
20-192 D275AX-5
1
(5)
J 9997: High idling limit mode

• This code is used to limit the use high idling
speed.
• The engine speed (set value) is displayed on the
lower line.
• Limit range: High idling speed – –400rpm
• Using method:
1) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] position.
sounds.
a If the high idling speed is limited, the engine
speed is not raised to the normal high idling
level even if the fuel control dial is controlled
so.
effective.
K 9998: Gear speed limit mode

• This code is used to limit the use of the 3 gear
speeds.
• The usable gear speeds are displayed by bits on
the lower line (in the order of the 3rd, 2nd, and
1st from the left).
• Using method:
Limit or allow the use of the maximum gear
speed by operating information switch (5) and
buzzer cancel switch (4).
• [ ]: Change setting.
• Display on lower line [o]:
Gear speed is effective.
• Display on lower line [ ]:
Gear speed is not effective.
a If the use of a gear speed is limited, the
transmission is not shifted to that gear speed
even if the gear shift-up switch is operated.
effective.
D275AX-5 20-193
1
(5)
9. Load memory display mode

(9-LOAD MEMORY DISPLAY MODE)
In this mode, you can check the load on the ma-
chine, forward odometer, and reverse odometer.

i) Select “Load memory display mode” on
the mode selection screen.
★ If the mode is selected, code (Ld) is
ii) Display the adjustment code input
switch (4).
2) Changing information screen No. Displayed information

Change the information screen by operating
01 1,000rpm service meter
information switch (5).
• [ > ]: Next screen. 02 Forward odometer
• [ < ]: Previous screen. 03 Reverse odometer
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.
★ The data cannot be reset.
20-194 D275AX-5
3
1
4) Display of forward odometer (02)

On this screen, the integrated forward travel
distance is displayed.
5) Display of reverse odometer (02)

On this screen, the integrated reverse travel
distance is displayed.
6) When operating machine in load memory

display mode
position, gear speed display section displays
normally and the machine can be operated
normally.
★ To select another screen, return the
parking brake lever to the LOCK position
D275AX-5 20-195
1
10. Real-time monitoring mode

(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, oil tem-
peratures, currents, voltages, etc. can be moni-
tored by using the signals from sensors,
switches, and solenoids installed various parts of
the machine.
★ This mode is used to monitor 1 item. When
monitoring 2 items simultaneously, use the
“Dual display monitoring mode”.

i) Select “Real-time monitoring mode” on
the mode selection screen.
★ If the mode is selected, code (5R) is
ii) Display the monitoring code input screen
by operating buzzer cancel switch (4).
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit code of the item to be monitored by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
ii) After inputting the code, display the mon-

itoring screen by operating buzzer can-
cel switch (4).
• [ ]: Enter input code.
★ If the input code is normal, the mon-
itoring screen shown at right ap-
pears.
20-196 D275AX-5
1
★ If the input code is abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
1: Code
2: Monitoring item
3: Information
4: Unit (Not displayed for some items)
★ For the details, see the “MONITORING
MODE TABLE”.
4) Function of holding monitoring information

If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be held
and released by operating buzzer cancel
switch (4).
• [ ]: Hold and release.
★ While the monitored item is held, the let-
ter “H” is displayed at the left end of the
lower line.
5) When operating machine in monitoring mode

position, gear speed display section displays
normally and the machine can be operated
normally.
parking brake lever to the FREE position
D275AX-5 20-197
1
6) Automatic selection of monitoring item (Lim-

ited function)
After one of some monitoring items is select-
ed, if the information switch is operated, the
next monitoring item is selected automatical-
ly, even if the code of the next monitoring
item is not input.
• [ > ]: Code is increased
• [ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Monitoring mode ta-
ble. 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.
20-198 D275AX-5
1
(5)
Monitoring mode table

Automatic
No. Code Monitored item Unit Display range selection
1 01000 ENG. SPEED Engine speed rpm 0 – 3000 1

2 03000 FUEL DIAL Voltage of fuel control dial mV 0 – 5000 —
3 03001 FUEL DIAL Acceleration ratio % 0 – 100 2
4 03200 BATTERY Battery voltage mV 0 – 30000 35
5 04102 WATER HIGH Engine water temperature (High temperature side) ºC 0 – 150 24
6 04104 WATER LOW Engine water temperature (Low temperature side) ºC –30 – 100 25
7 04200 FUEL LEVEL Fuel level sensor voltage mV 0 – 5000 27
8 04204 FUEL TEMP. Fuel temperature ºC 0 – 150 —
9 04401 HYD. TEMP. Hydraulic oil temperature ºC 0 – 150 —
10 10000 FAN rpm Command speed of cooling fan rpm 0 – 1500 —
11 20000 ENG-MACHIN Engine controller program No. Character — —
12 20200 MON. PROGRM Monitor panel (Tachometer module) program No. Character — —
13 20201 T/M. PROGRM Transmission controller program No. Character — —
14 20202 S/T. PROGRM Steering controller program No. Character — —
15 20203 ENG-PROGRM Engine controller program No. Character — —
16 30100 T/C TEMP. Torque converter oil temperature ºC 0 – 150 26
17 31400 T/M OUT Transmission speed rpm 0 – 5000 28
18 31520 T/M-FILL Input state of transmission fill switch Bit (See detailed information) —
19 31521 S/T FILL Input state of steering fill switch Bit (See detailed information) —
20 31602 1st CLUTCH Output command current of 1st clutch ECMV mA 0 – 1000 —
21 31603 2nd CLUTCH Output command current of 2nd clutch ECMV mA 0 – 1000 —
22 31604 3RD CLUTCH Output command current of 3rd clutch ECMV mA 0 – 1000 —
23 31606 Rev CLUTCH Output command current of reverse clutch ECMV mA 0 – 1000 —
24 31608 Frd CLUTCH Output command current of forward clutch ECMV mA 0 – 1000 —
25 31612 1 CLUTCH F Output FB current of 1st clutch ECMV mA 0 – 1000 21
26 31613 2 CLUTCH F Output FB current of 2nd clutch ECMV mA 0 – 1000 22
27 31614 3 CLUTCH F Output FB current of 3rd clutch ECMV mA 0 – 1000 23
28 31616 R CLUTCH F Output FB current of reverse clutch ECMV mA 0 – 1000 20
29 31618 BRAKE R.H. Output FB current of right brake ECMV mA 0 – 1000 16
30 31619 BRAKE L.H. Output FB current of left brake ECMV mA 0 – 1000 15
31 31620 BRAKE R.H. Output command current of right brake ECMV mA 0 – 1000 —
32 31621 BRAKE L.H. Output command current of left brake ECMV mA 0 – 1000 —
33 31622 F CLUTCH F Output FB current of forward clutch ECMV mA 0 – 1000 19
34 31623 FAN PUMP.O Output command current of cooling fan pump solenoid mA 0 – 1000 —
35 31624 FAN PUMP.F Output FB current of cooling fan pump solenoid mA 0 – 1000 —
36 31625 PITCH SOL. Drive current of blade pitch solenoid mA 0 – 1000 —
37 31626 HSS M. FREE Drive voltage of HSS free solenoid mV 0 – 30000 —
38 31627 L/U SOL. Drive current of torque converter lock-up solenoid mA 0 – 1000 30
39 31628 E. BRAKE SL Drive current of sudden stop prevention valve mA 0 – 1000 29
40 32900 BODY ANGLE Machine pitch angle º –30 – 30 34
41 36100 Q-INJECTOR Command value of fuel injection rate mm3/st –30 – 600 —
42 36200 CRI. PRESS Command pressure of common rail MPa 0 – 150 —
43 36300 CRI-TIMING Fuel injection timing CA –30.0 – 30.0 —
D275AX-5 20-199
1
(5)
Automatic
44 36400 CRI. PRESS Common rail pressure MPa 0 – 200 5

45 36500 BOOST. PRES Boost pressure KPa 0 – 300 6
46 36600 CRI. CONTRL Engine control mode Character — —
47 36700 CRI-TORQUE Converted torque of engine % 0 – 100 —
48 36800 CRI-Q-MOD1 Fuel injection amount adjustment command value 1 Character 0123456789abcdef —
49 36801 CRI-Q-MOD2 Fuel injection amount adjustment command value 2 Character 0123456789abcdef —
50 40001 VEHICLE SP Travel speed (Theoretical value) km/h 0 – 100 32
51 40900 ENG-SW 1 Engine controller input signal 1 Bit (See detailed information) —
52 40901 ENG-SW 2 Engine controller input signal 2 Bit (See detailed information) —
53 40905 T/M-SW1 Transmission controller input signal 1 Bit (See detailed information) —
54 40906 T/M-SW2 Transmission controller input signal 2 Bit (See detailed information) —
55 40907 T/M TGL. SW Input signal of blade lever knob switch Bit (See detailed information) —
56 40908 T/M SW2 Input signal of blade lever oil pressure switch Bit (See detailed information) —
57 40909 T/M SOL.2 Transmission controller output signal Bit (See detailed information) —
58 40910 S/T-SW1 Steering controller input signal 1 Bit (See detailed information) —
62 40914 S/T SOL.1 Output signal of steering controller Bit (See detailed information) —
63 50000 DESEL PEDAL Deceleration ratio % 0 – 100 3
64 50100 SSC SSC ratio % 0 – 100 4
65 50101 DECEL PEDAL Voltage of deceleration potentiometer mV 0 – 5000 —
66 50200 T/M LEVER 1 Voltage of forward-reverse potentiometer 1 mV 0 – 5000 7
67 50201 T/M LEVER 2 Voltage of forward-reverse potentiometer 2 mV 0 – 5000 8
68 50300 S/T LEVER 1 Voltage of steering potentiometer 1 mV 0 – 5000 9
69 50301 S/T LEVER 2 Voltage of steering potentiometer 2 mV 0 – 5000 10
70 50400 BRAKE PEDL Voltage of brake potentiometer mV 0 – 5000 11
71 50500 HSS PUMP D HSS differential pressure MPa –50 – 50 12
72 50501 HSS PUMP A HSS pressure A MPa 0 – 50 13
73 50502 HSS PUMP B HSS pressure B MPa 0 – 50 14
74 50503 HSS PUMP A Sensor voltage of HSS oil pressure A mV 0 – 5000 —
75 50504 HSS PUMP B Sensor voltage of HSS oil pressure B mV 0 – 5000 —
76 50600 HSS L.H.F Output FB current of left HSS solenoid mA 0 – 1000 17
77 50601 HSS R.H.F Output FB current of right HSS solenoid mA 0 – 1000 18
78 50602 HSS L.H.O Output command current of left HSS solenoid mA 0 – 1000 —
79 50603 HSS R.H.O Output command current of right HSS solenoid mA 0 – 1000 —
80 50900 N-SAFETY Drive current of neutral safety relay mV 0 – 30000 31
81 60000 TRACTION Traction force (Theoretical value) W 0–0 33
82 60100 BODY ANGLE Machine pitch angle sensor voltage mV 0 – 5000 —
83 60200 ACCELERATN Acceleration sensor voltage mV 0 – 5000 —
84 60300 SSC ORDER SSC command speed rpm 0 – 5000 —
86 60500 ENG. CON. PLT Drive voltage of engine controller relay mV 0 – 30000 —
87 60600 BR HOLD Drive voltage of battery relay mV 0 – 30000 —
20-200 D275AX-5
1
(5)
Automatic
88 60700 S/T MODE Steering state code Character — —

89 60800 FILL MODE Variable for setting fill condition Character — —
90 60909 MOD. MODE Setting of modulation condition Character — —
91 70000 CHG. P. MODE Variable for setting condition of gear shift point Character — —
92 70100 SLIP FLAG SSC slip flag Bit (See detailed information) —
93 70300 B. KNOB SW Input signal of blade lever knob switch Bit (See detailed information) —
94 70304 T/M SOL.1 Transmission controller output signal Bit (See detailed information) —
95 70305 T/M RIPPER Input signal of ripper lever oil pressure switch Bit (See detailed information) —
96 70400 BACK ALARM Drive voltage of back-up alarm relay mV 0 – 30000 —
97 70500 regulation Command speed of engine controller 3rd throttle rpm 0 – 2200 —
98 70600 DUAL SOL. Drive current of blade dual solenoid mA 0 – 1000 —
99 70700 HYD. PUMP 1 Work equipment oil pressure MPa 0 – 50 —
100 70701 HYD. PUMP 1 Voltage of work equipment oil pressure sensor mV 0 – 5000 —
D275AX-5 20-201
1
(5)
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 con-
dition for turning on the bit.
31520: Input state of transmission 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)
31521: Input state of steering fill switch

1: Left brake fill switch: ON
2: Left clutch fill switch [C & B specification]: ON
3: (Unused)
4: (Unused)
5: Right clutch fill switch [C & B specification]: ON
6: Left brake fill switch: ON
7: (Unused)
8: (Unused)
40900: Engine controller input signal 1

1: Starting switch signal C: Input
2: (Unused)
3: (Unused)
4: Low engine oil pressure switch: ON
5: High engine oil pressure switch: ON
6: (Unused)
7: (Unused)
8: Model selection signal 1: ON
20-202 D275AX-5
1
(5)
40901: Engine controller input signal 2

3: (Unused)
4: (Unused)
5: N-signal 1: ON
6: N-signal 2: ON
7: (Unused)
8: (Unused)
40905: Transmission controller input signal 1

1: Gear shift-up switch: OFF
2: Gear shift-up switch: ON
3: Gear shift-down switch: OFF
4: Gear shift-down switch: ON
5: Parking brake switch: FREE
6: Parking brake switch: LOCK
7: (Unused)
8: (Unused)
40906: Transmission controller input signal 2

1: Automatic gear shift-down switch: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40907: Input signal of blade lever knob switch

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: Parking brake lever: FREE
6: Parking brake lever: LOCK
7: (Unused)
8: (Unused)
D275AX-5 20-203
1
(5)
40908: Input signal of blade lever oil pressure switch

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40909: Transmission controller output signal

1: N-signal 1: ON
2: N-signal 2: ON
3: (Unused)
4: Back-up alarm relay: ON
5: Neutral safety relay: ON
6: (Unused)
7: (Unused)
8: (Unused)
40910: Steering 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)

1: Buzzer cancel switch: At
2: Buzzer cancel switch: At T
3: Information switch: At <
4: Information switch: At >
5: Service switch: ON
6: Pivot turn mode switch: ON
7: (Unused)
8: (Unused)
20-204 D275AX-5
1
(5)

1: (Unused)
2: (Unused)
3: (Unused)
4: Ripper lift RAISE oil pressure switch:
ON (Operated)
5: Ripper lift LOWER oil pressure switch:
ON (Operated)
6: Ripper TILT-IN oil pressure switch:
ON (Operated)
7: (Unused)
8: (Unused)

1: ACC signal: ON
2: Turbocharger timer signal: ON
3: Engine Li signal: ON
4: Monitoring signal: ON
5: N-signal 1: ON
6: N-signal 2: ON
7: (Unused)
8: (Unused)
40914: Output signal of steering controller

1: HSS FREE solenoid: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: Battery relay drive: ON
6: Sudden stop prevention valve: ON
7: (Unused)
8: (Unused)

1: Electrical intake air heater signal: ON
2: C-signal: ON
3: Air conditioner clutch signal: ON
4: Night lighting signal: ON
5: Hydraulic oil level switch signal: ON
6: (Unused)
7: (Unused)
8: (Unused)
D275AX-5 20-205
1
(5)
70100: SSC slip flag

1: Shoe slip ratio: Above 30%
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
70300: Input signal of blade lever knob switch

1: Blade lever tilt switch: DUAL
2: Blade lever tilt switch: SINGLE
3: Blade lever pitch switch: OFF
4: Blade lever pitch switch: ON
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
70304: 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)
70305: Input signal of ripper lever oil pressure switch

1: (Unused)
2: Ripper lift RAISE oil pressure switch:
ON (Operated)
3: Ripper lift LOWER oil pressure switch:
ON (Operated)
4: Ripper lift TILT-IN oil pressure switch:
ON (Operated)
5: Ripper lift TILT-OUT oil pressure switch:
ON (Operated)
6: (Unused)
7: (Unused)
8: (Unused)
20-206 D275AX-5
1
(5)
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be displayed
simultaneously.
★ Note that only codes and monitoring infor-
mation are displayed in this mode since the
usable display columns are limited. (Item
names and units cannot be displayed.)

i) Select “Dual display monitoring mode”
on the mode selection screen.
★ If the mode is selected, code (dR) is
ii) Display the monitoring code input screen
by operating buzzer cancel switch (4).
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operating
information switch (5), shift-up switch (6),
and shift-down switch (7).
ii) After inputting the codes, display the
monitoring screen by operating buzzer
cancel switch (4).
• [ ]: Enter input code.
★ If the input codes are normal, the
monitoring screen shown at right ap-
pears.
D275AX-5 20-207
1
★ If the input codes are abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
1: Code 1
2: Information 1
3: Code 2
4: Information 2
★ For the details, see the “MONITORING
MODE TABLE”.
4) When operating machine in monitoring

mode
position, gear speed display section (1) dis-
plays normally and the machine can be op-
erated normally.
parking brake lever to the FREE position
20-208 D275AX-5
1
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
TESTING AND ADJUSTING HANDLING OF
ADJUSTMENT
HIGH-VOLTAGE
METHOD
CIRCUIT
OF REPLACED
OF ENGINE CONTROLLER
HANDLING OF HIGH-VOLT- ADJUSTMENT METHOD OF

AGE CIRCUIT OF ENGINE REPLACED CONTROLLER
CONTROLLER
★ After the machine is assembled or transmission

controller or steering controller is replaced, ad-
just the system according to the following proce-
dure.
¤ 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. According-
ly, take a record of the next replacement periods
of the oils and filters.
★ Precautions for replacing a controller:
¤ The engine controller has a high-voltage circuit When replacing a controller, stop the machine in
(110 – 130V) to drive the fuel injector. This circuit a safe place and turn the starting switch off.
is connected to the wiring harness and connec-
tors between the engine controller and fuel injec- 1. Setting system in service mode
tor. Turn the starting switch on and set the monitor
★ Normally, the engine controller outputs the high panel in the “Adjustment mode” of the service
voltage to the fuel injector only while the engine mode.
is running and stops outputting if the engine
stops. 2. Adjusting steering controller
¤ If you touch the high-voltage circuit directly, you Select Steering controller specification set
may get an electric shock. To avoid this, observe (0002) and adjust the steering controller.
the following precautions. ★ Execute this code when only the transmis-
sion controller is replaced, too.
1. The following connectors are used in the high-
voltage circuit.
• Engine controller connector: ECN3
• Junction connector: E21
• Injector connectors:
CN1, CN2, CN3, CN4, CN5, CN6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector

related to the high-voltage circuit, be sure to turn
off the starting switch.
3. If a T-adapter is inserted in or connected to a

connector related to the high-voltage circuit for
troubleshooting, do not start the engine.
★ You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
D275AX-5 20-209
1
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
3. Adjusting transmission controller

Select Transmission controller specification set
(0003) and adjust the transmission controller.
★ Execute this code when only the steering
controller is replaced, too.
7. Turning power on again

Turn the starting switch off and on.
8. Checking error codes

1) Set the monitor panel in the “Electric system
4. Turning power on again error code display mode” of the service
Turn the starting switch off and on, then set the mode.
monitor panel in the “Adjustment mode” of the 2) See if any error code is being output current-
service mode again. ly. If any error code is not being output, de-
lete the all error codes.
5. Adjusting machine specification ★ If any error code is being output, remove its
Select Machine specification set (0004) and ad- cause by troubleshooting and execute steps
just the machine specification. 7 and 8 again.
★ 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 actu-
al operating hours. To solve this problem, deter-
mine the first replacement periods of the oils and
filters after the replacement of the controller ac-
cording to the replacement periods recorded be-
fore the replacement of the controller.
6. Adjusting brake potentiometer

Select Brake potentiometer initial set (0005) and
adjust the brake potentiometer.
20-210 D275AX-5
1
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC
TESTING AND ADJUSTING SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR ELEC-

TRIC SYSTEM
★ When carrying out troubleshooting for an electric 2. Engine controller

circuit related to the monitor panel, engine con- 1) Remove cover (3).
troller, transmission controller, or steering con-
troller, 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.
2) Insert or connect T-adapters in or to connec-

tors ECN1, ECN2, and ECN3 of engine con-
troller (4).
★ If the connectors cannot be disconnect-
ed and connected easily, remove the
controller from the floor frame.
★ Since the connectors are secured with
screws, loosen those screws before dis-
3) Insert or connect T-adapters in or to connec- connecting.
tors S01, S02, S03, and S04 of monitor pan- ★ When connecting the connectors again,
el (2). tighten their screws to the specified
torque.
3 Screw: 2.82Nm {0.288kgm}
D275AX-5 20-211
1
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC
TESTING AND ADJUSTING SYSTEM
3. Transmission controller 4. Steering controller

1) Remove cover (5). 1) Remove cover (5).
2) Insert or connect T-adapters in or to connec- 2) Insert or connect T-adapters in or to connec-

tors TMCN1, TMCN2, and TMCN3 of trans- tors STCN1, STCN2, and STCN3 of trans-
mission controller (6). mission controller (7).
★ If the connectors cannot be disconnect- ★ If the connectors cannot be disconnect-
ed and connected easily, remove the ed and connected easily, remove the
controller from the floor frame. controller from the floor frame.
★ Since the connectors are secured with ★ Since the connectors are secured with
screws, loosen those screws before dis- screws, loosen those screws before dis-
connecting. connecting.
★ When connecting the connectors again, ★ When connecting the connectors again,
tighten their screws to the specified tighten their screws to the specified
torque. torque.
3 Screw: 2.82Nm {0.288kgm} 3 Screw: 2.82Nm {0.288kgm}
20-212 D275AX-5
1
TESTING AND ADJUSTING HANDLING OF OPTIONAL DEVICES
HANDLING OF OPTIONAL DEVICES
★ D275AX-5 has connectors to install optional de- 4. Taking out C signal of starting switch
vices in its fuse box. When installing any optional If the C signal (starting signal) of the starting
device, receive the necessary signals and power switch is necessary to an optional device such
through those connectors without modifying the as the pre-lubricator, take it out through the fol-
wiring harness. lowing connector pin.
• CN-PRS (2-pole heavy duty wire connector)
1. Taking out ACC signal of starting switch ★ Remove the connector installed when the
If the ACC signal (ON signal) of the starting machine is shipped and connect pin 1 to the
switch is necessary to an optional device such starting signal to be output finally by the pre-
as the turbocharger timer, take it out through the lubricator and connect pin 2 to the input sig-
• Pin B of CN-ESD (3-pole heavy duty wire

following connector pin. nal from the starting switch.
connector) 5. Taking out external power source

★ A 20A fuse is installed on the upstream side If an external power source is necessary, take it
of this connector pin. through the following connectors.
• AUX1 (Plug connector)
2. Inputting engine controller holding signal • AUX2 (Plug connector)
If it is required to keep the engine running with ★ A 20A fuse is installed on the upstream side
the starting switch turned off for an optional de- of each of these connectors.
vice such as the turbocharger timer, connect the
• Pin A of CN-ESD (3-pole heavy duty wire

following connector pin to the chassis ground.
connector)
★ While this connector pin is connected to the
chassis ground, the starting switch works as
it is at the ON position even if it is at the OFF
position.
3. Inputting engine low-idling command

If it is required to keep the engine speed at low
idling for an optional device such as the engine
protector, connect the following connector pin to
• Pin C of CN-ESD (3-pole heavy duty wire

the chassis ground.
connector)
★ While this connector pin is connected to the
chassis ground, the engine speed is kept at
low idling, regardless of the position of the
fuel control dial.
D275AX-5 20-213
1
Pm CLINIC SERVICE
TESTING AND ADJUSTING PM CLINIC SERVICE
Model Serial No. Service meter

D275AX-5 h
User name Date of clinic Serviceman
Specifications
Blade Rear attachment Shoe width
Semi-U blade Multi-shank ripper 610 mm
U-blade Variable giant ripper 710 mm
Dual tilt blade Counterweight kg 810 mm
Operating conditions
Quarry, mine Construction Type of soil (specific gravity ) Type of work
Coal Construction, Rock Dozing %
Gold civil engineering Gravel Side cutting %
Limestone Roads Sand Ripping %
Tunnels Clay Travel %
Existence of abnormalities
Oil, water level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )
Engine coolant temperature Max. range Power train oil temperature Max. range Ambient temperature
Max.
Min.
Height above sea level
m
Operator's opinion
Visual check results
Service code history

E h E h
Content: Content:
E h E h
Content: Content:
20-214 D275AX-5
1
Pm-clinic
TESTING AND ADJUSTING measuring points for D275AX-5 (1/3)
PM CLINIC SERVICE
q1. Engine speed: Measuring engine speed (20-103 – 104 page)

Reference items of measurement procedure (Pages)
q2. Blow-by pressure: Measuring blow-by pressure (20-113 page)

q3. Engine oil pressure: Measuring engine oil pressure (20-114 page)
q4. Boost pressure: Measuring intake air pressure (boost pressure) (20-106 – 107 page)
q5. Exhaust temperature: Measuring extreme temperature (20-108 – 109 page)
D275AX-5 20-215
1
(5)
Pm-clinic
PM CLINIC SERVICE
q6. Items related to torque converter: Measuring power train oil pressure (20-123 – 130-1 page)
q7. Items related to transmission: Measuring power train oil pressure (20-123 – 130-1 page)
q8. Items related to steering: Measuring power train oil pressure (20-123 – 130-1 page)
20-216 D275AX-5
1
(5)
Pm-clinic
q9. Items related to HSS: Testing and adjusting HSS (20-131 – 134-1 page)
q10. Items related to work equipment: Testing and adjusting work equipment oil pressure, Testing and adjusting control circuit basic pres-
q11. Items related to fan: Measuring fan motor speed, Measuring fan circuit oil pressure (20-159 page and 20-159-1 page)
sure (20-145 – 148 page and 20-149 page)
D275AX-5 20-216-1
(5)
TESTING AND ADJUSTING SerialPM
NoCLINIC SERVICE
Pm CLINIC CHECK SHEET D275AX-5
Work order No. Date Service meter Serviceman
h
Item Measurement conditions Unit Standard value for new machine Service limit value Measurement results Pass Fail
Low idling 650 - 750 650 - 750
High idling Deceleration pedal depressed 850 - 950 850 - 950
Engine speed High idling (Deceleration cut-off mode) rpm 2100 - 2200 2100 - 2200
Torque converter stall 1570 - 1670 Min. 1510
Torque converter stall + work equipment relief 1530 - 1630 Min. 1450
kPa Max. 1.96 Max. 3.92
Blow-by pressure Torque converter stall <mmAq> <Max. 200> <Max. 400>
Engine
0.10 Min. 0.07

Engine at low idling <1.0> <Min. 0.7>
SAE10W
0.29 - 0.49 Min. 0.18
Engine oil Engine at high idling MPa <3.0 - 5.0> <Min. 1.8>
pressure <kg/cm2> 0.12 Min. 0.08
Engine at low idling
<1.2> <Min. 0.8>
SAE15W-40 SAE30
Engine at high idling 0.34 - 0.54 Min. 0.21
<3.5 - 5.5> <Min. 2.1>
kPa Min. 116.0 Min. 97.3
Boost pressure Torque converter stall <mmHq> <Min. 730>
<Min. 870>
Exhaust temperature Torque converter stall Max. 650 Max. 700
When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to "Both steering clutches release mode (Co mode)".
(Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
Max. 0.2 Max. 0.2
Inlet oil pressure <Max. 2> <Max. 2>
Outlet oil pressure Max. 0.2 Max. 0.2
<Max. 2> <Max. 2>
Engine at low idling
0-0 0-0
Lock-up clutch pressure <0 - 0> <0 - 0>
Transmission: 2.45 - 2.85 2.45 - 2.85
Torque converter
Stator clutch pressure Neutral <25.0 - 29.0> <25.0 - 29.0>

Oil temperature: 0.49 - 1.0 0.49 - 1.0
Inlet oil pressure <5.0 - 10.0> <5.0 - 10.0>
70-90 MPa
<kg/cm2> 0.39 - 0.59 0.39 - 0.59
Outlet oil pressure <4.0 - 6.0> <4.0 - 6.0>
Engine at high idling
Lock-up clutch pressure 0-0 0-0
<0 - 0> <0 - 0>
2.45 - 2.85 2.45 - 2.85
Stator clutch pressure <25.0 - 29.0> <25.0 - 29.0>
Lock-up clutch pressure 1.07 - 1.47 1.07 - 1.47
Raise engine speed, <11.0 - 15.0> <11.0 - 15.0>
Transmission: F1 when lock-up lamp
lights up 0-0 0-0
Stator clutch pressure <0 - 0> <0 - 0>
Engine at low idling 2.84 - 3.14 Min. 2.65
<29.0 - 32.0> <Min. 27.0>
Main relief pressure
3.14 - 3.43 Min. 2.94
Transmission: Engine at high idling <32.0 - 35.0> <Min. 30.0>
Neutral Engine at low idling
Lubricating oil
pressure 0.05 - 0.29 0.05 - 0.29
Transmission
Engine at high idling <0.5 - 3.0> <0.5 - 3.0>

F clutch pressure Engine at low idling MPa 2.84 - 3.14 Min. 2.65
Transmission: F3 <kg/cm2> <29.0 - 32.0> <Min. 27.0>
R clutch pressure 2.84 - 3.14 Min. 2.65
Transmission: R3 Engine at low idling <29.0 - 32.0> <Min. 27.0>
2.84 - 3.14 Min. 2.65
1st clutch pressure Transmission: F1 Engine at low idling <Min. 27.0>
<29.0 - 32.0>
Engine at low idling 2.84 - 3.14 Min. 2.65
2nd clutch pressure Transmission: F2 <29.0 - 32.0> <Min. 27.0>
3rd clutch pressure Engine at low idling 2.84 - 3.14 Min. 2.65
Transmission: F3 <29.0 - 32.0> <Min. 27.0>
2.84 - 3.14 Min. 2.26
Transmission: Engine at low idling <29.0 - 32.0> <Min. 23.0>
Left brake pressure
Steering brake
Neutral Engine at high idling 3.14 - 3.43 Min. 2.45

MPa <32.0 - 35.0> <Min. 25.0>
<kg/cm2> 2.84 - 3.14 Min. 2.26
Transmission: Engine at low idling <29.0 - 32.0> <Min. 23.0>
Right brake pressure
Neutral Engine at high idling 3.14 - 3.43 Min. 2.45
<32.0 - 35.0> <Min. 25.0>
Brake performance Engine at high idling, F2, brake actuated Machine must not move
D275AX-5 20-217
1
(5)
TESTING AND ADJUSTING SerialPM
NoCLINIC SERVICE
Pm CLINIC CHECK SHEET D275AX-5
h
PCCS lever (for travel) 38.2 - 41.7 38.2 - 41.7
HSS oil pressure
right FULL <390 - 425> <390 - 425>

HSS main relief pressure 38.2 - 41.7
PCCS lever (for travel) MPa 38.2 - 41.7
left FULL Engine at high idling <kg/cm2> <390 - 425> <390 - 425>
PCCS lever (for travel) 2.6 - 3.4 2.6 - 3.4
HSS charge relief pressure <27 - 35>
NEUTRAL <27 - 35>
Common use with work equipment PPC and fan pump control
HSS servo charge pressure at control initial pressure
Ripper lift 26.1 - 28.8 26.1 - 28.8
relief Engine at low <266 - 294> <266 - 294>
idling
Hydraulic components
Blade tilt relief 26.1 - 28.8 26.1 - 28.8

(single tilt only) <266 - 294> <266 - 294>
Work equipment pump
Ripper lift MPa 26.1 - 28.8 26.1 - 28.8
relief <kg/cm2> <266 - 294> <266 - 294>
Blade tilt relief Engine at high 26.1 - 28.8 26.1 - 28.8

(single tilt only) idling <266 - 294> <266 - 294>
Control circuit basic Lever: Neutral 3.43 - 3.92 3.23 - 3.92

pressure <30 - 40> <33 - 40>
Engine at low idling 8 - 15 Max. 20
Blade RAISE
Engine at high idling 3-5 Max. 6
Single tilt (left g right) Engine at low idling

Engine at high idling
3-5 Max. 7
Max. 3.5
2.3 - 3.3
Sec.
g right) Engine at low idling 5-8 Max. 10
Dual tilt (left
Engine at high idling 2.3 - 3.3 Max. 3.5
8 - 14 Max. 17
Ripper tilt (in g out) Engine at low idling
Engine at high idling 3-4 Max. 4.5
Hydraulic drift
Hydraulic oil temperature
Blade lift cylinder Engine stopped Max. 100 Max. 150

mm/5 min.
Ripper lift cylinder Max. 15 Max. 30
Engine at low 420 - 480 400
Fan speed rpm
Fan 100%
Fan
Engine at full 1000 - 1100 950

speed mode
Fan oil pressure MPa 16.17 - 19.11 16.17 - 19.11
Engine at full <kg/cm2> <165 - 195> <165 - 195>
Visual inspection of final drive drain plug Engine stopped There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
20-218 D275AX-5
1
(5)
TESTING AND
PmADJUSTING
CLINIC SerialPM
NoCLINIC SERVICE
UNDERCARRIAGE CHECK SHEET

D275AX-5
h
Measure the bushing temperature immediately after operations

Left side of machine
Measurement
results Pass Fail
Right side of machine

Measurement
results Pass Fail
Opening of track link Left track A: Clearance between links

Pin No. 1.4
Right track A: Clearance between links

Pin No. 1.4
D275AX-5 20-219
1
(5)
UNDERCARRIAGE
TESTING AND ADJUSTING TROUBLESHOOTING REPORT (NORMAL)
PM CLINIC SERVICE
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D275AX-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1042.4 1054.4
LINK PITCH
R
M L L=l/4 RH 1042.4 1054.4
LH 260.60 263.60
master pin M
master l
i 1.3 RH 260.60 263.60
LH 166.0 148.0
H
RH 166.0 148.0
LINK HEIGHT1.3
New Turned
BUSHIN d1 LH 90.5 82.0
G New Turned
d RH 90.5 82.0
D is the smallest d
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 88.0 30.0
H
0 RH 88.0 30.0
CARRIER
CARRIER LH 200.0 175.0
Front
RH 200.0 175.0
D LH 200.0 175.0
Rear
1.3 RH 200.0 175.0
IDLER
IDLER LH 21.0 33.5
Front
H RH 21.0 33.5
LH 21.0 33.5
Rear
1.3 RH 21.0 33.5
1 LH 255.0 195.0
2 LH 255.0 195.0
3 LH 255.0 195.0
4 LH 255.0 195.0
5 LH 255.0 195.0
6 LH 255.0 195.0
7 LH 255.0 195.0
TRACK ROLLER 8 LH 255.0 195.0
9 LH 255.0 195.0
10 LH 255.0 195.0
D 1 RH 255.0 195.0
h1 2 RH 255.0 195.0
h2
3 RH 255.0 195.0
D=2(h1- 4 RH 255.0 195.0
5 RH 255.0 195.0
6 RH 255.0 195.0
7 RH 255.0 195.0
8 RH 255.0 195.0
9 RH 255.0 195.0
1.3 10 RH 255.0 195.0
SPROCKET h1 LH 0.0 8.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 8.0
Remarks:
20-220 D275AX-5
1
UNDERCARRIAGE
TESTING AND ADJUSTING TROUBLESHOOTING REPORT PM
(IMPACT)
CLINIC SERVICE
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D275AX-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type IMPACT
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1042.4 1054.4
LINK PITCH
R
M L L=l/4 RH 1042.4 1054.4
LH 260.60 263.60
master pin M
master l
i 1.3 RH 260.60 263.60
LH 166.0 148.0
H
RH 166.0 148.0
LINK HEIGHT1.3
New Turned
BUSHIN d1 LH 90.5 84.5
G New Turned
d RH 90.5 84.5
D is the smallest d
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 88.0 30.0
H
0 RH 88.0 30.0
CARRIER
CARRIER LH 200.0 175.0
Front
RH 200.0 175.0
D LH 200.0 175.0
Rear
1.3 RH 200.0 175.0
IDLER
IDLER LH 21.0 33.5
Front
H RH 21.0 33.5
LH 21.0 33.5
Rear
1.3 RH 21.0 33.5
1 LH 255.0 195.0
2 LH 255.0 195.0
3 LH 255.0 195.0
4 LH 255.0 195.0
5 LH 255.0 195.0
6 LH 255.0 195.0
7 LH 255.0 195.0
TRACK ROLLER 8 LH 255.0 195.0
9 LH 255.0 195.0
10 LH 255.0 195.0
D 1 RH 255.0 195.0
h1 2 RH 255.0 195.0
h2
3 RH 255.0 195.0
D=2(h1- 4 RH 255.0 195.0
5 RH 255.0 195.0
6 RH 255.0 195.0
7 RH 255.0 195.0
8 RH 255.0 195.0
9 RH 255.0 195.0
1.3 10 RH 255.0 195.0
SPROCKET h1 LH 0.0 8.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 8.0
Remarks:
D275AX-5 20-221
1
TESTING AND ADJUSTING PM CLINIC SERVICE
20-222 D275AX-5
1
TROUBLESHOOTING 20
TROUBLESHOOTING
Points to remember when troubleshooting ........................................................................................... 20-302

Sequence of events in troubleshooting ................................................................................................. 20-303
Points to remember when carrying out maintenance ........................................................................... 20-304
Checks before troubleshooting ............................................................................................................... 20-307-5
Classification and procedures of troubleshooting ................................................................................. 20-308
Connector allocation drawing and electrical circuit diagram for each system ....................................... 20-311
Circuit drawing for monitor panel system (M circuit) ............................................................................. 20-322
Circuit drawing for engine controller system (E circuit) ......................................................................... 20-324
Circuit drawing for transmission controller system (T circuit) ................................................................ 20-326
Circuit drawing for steering controller system (S circuit) ....................................................................... 20-328
Connection table for connector pin numbers ........................................................................................ 20-330
D275AX-5 20-301
3
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. fl When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from fl The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302 D275AX-5
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible Step
causes.
Repair at jobsite
Hurray !
It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
TEW00189 failure?
TEW00190
D275AX-5 20-303
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1.
1. Points
POINTS to remenber when handling
TO REMEMBER WHENelectric equipment
HANDLING
ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
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.
2 Defective crimping or soldering of connec-

tors
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 plat-
ing at the joint will peel and cause improper
connection or breakage.
20-304 D275AX-5
3
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
4 High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity 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 sur-
face 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
D275AX-5 20-305
1
2) Removing, installing, and drying connectors and

wiring harnesses
· Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
★ Never pull with one hand.
2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
3 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-306 D275AX-5
1
• Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
TEW00200
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 po-
sition.
★ If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors
have 2 latches respectively, push them in until they
click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
D275AX-5 20-307
1
TROUBLESHOOTING POINTS TO REMENBER WHEN CARRYING OUT MAINTENANCE
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in wa-
ter 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 fol-

lows:
1 Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dry-
er to dry the connector.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-307-1 D275AX-5
3
3) Handling control box

1 The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2 Do not open the cover of the control box un-
less necessary.
3 Do not place objects on top of the control

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
6 Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand)
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
4. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.
D275AX-5 20-307-2
3
5. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure 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 re-
pairing the machine in rain or high winds, or plac-
es where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect 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 refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil fill-
er and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-307-3 D275AX-5
3
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 possi-
ble of the old hydraulic oil must be drained out.
(Do not drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants 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 equip-
ment, or changing the oil, use flushing oil to re-
move 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so
it is an extremely effective device.
D275AX-5 20-307-4
3
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

Checks before starting
4. Check oil level in damper case — Add oil

5. Check power train oil level — Add oil
6. Check engine oil level (engine oil pan level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check travel of brake pedal — Adjust
mechanical equipment
Electrical
10. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
Hydraulic,
13. Check for abnormal noise, smell — Repair

14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
Other check items
16. Check battery voltage (engine stopped) 20 - 30 V Replace

17. Check battery electrolyte level — Add or replace
Electrical equipment
18. Check for discolored, burnt, exposed wiring — Replace

19. Check for missing wiring clamps, hanging wire — Repair
20. Check for water leaking on wiring (pay particularly careful attention — Disconnect connector
to water leaking on connectors or terminals) and dry
21. Check for water on wiring — Replace
22. Check alternator voltage (engine running at 1/2 throttle or above) After running for Replace
several minutes:
27.5 - 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF) — Replace
20-307-5 D275AX-5
3
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Classification of Troubleshooting
Mode Explanation
Error code Troubleshooting when a service code is displayed
E Mode Troubleshooting of the electrical system
H Mode Troubleshooting of the hydraulic and mechanical systems
(Engine) Troubleshooting of the engine body (Refer to the Shop Manual for 140-3 Series Engine.)
Troubleshooting Procedures
When any phenomenon supposed to be a failure appeared on the machine, select a Troubleshooting No. ac-
cording to the procedures below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting Procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display a error code in the error code display mode
(electrical system, mechanical system) on the monitor display (EMMS).
Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code.
★ Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
★ When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trou-
bleshooting of the error code.)
2. Troubleshooting Procedures when error codes have been recorded:

When no action code is displayed on the monitor panel, check a error code in the error code display mode
(electrical system, mechanical system) on the monitor panel (EMMS).
When error codes have been recorded, execute a troubleshooting of the relevant [Error Code] in accor-
dance with the error code.
★ Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
★ When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trou-
bleshooting of the error code.)
3. Troubleshooting Procedures when no action code is displayed and error codes have not been re-
corded:
When error codes have not been recorded in the monitor panel (EMMS), a failure that the machine cannot
diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system.
In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out
of the table of “Phenomena supposed to be Failures and Troubleshooting No.” Then, execute the trouble-
shooting in the [E Mode] or [H Mode] related to the phenomenon.
20-308 D275AX-5
3
1
Phenomena supposed to be Failures and Troubleshooting No.
Troubleshooting
No. Phenomenon suppose to be Failure Error
E Mode H Mode (Engine)
Code
Phenomenon related to action code/error code
1 An action code is displayed on the monitor panel. Check the error code.
2 A error code is displayed in the error code display mode. ●
Phenomenon related to engine
3 The engine does not start smoothly. (Engine starting takes a time all the time.) S-1
4 The engine does not rotate. E-1 S-2a)
5 The engine does not start. The engine rotates but does not exhaust gas. S-2b)
6 The engine exhausts gas but does not rotate. S-2c)
7 The engine does not pick-up smoothly. (Poor follow-up performance) S-3
8 The engine stops during operation. S-4
9 The engine rotates abnormally. (Hunting) S-5
10 Insufficient output or no power S-6
11 Black exhaust (Imperfect combustion) S-7
12 Large oil consumption or blue exhaust S-8
13 Oil is contaminated fast. S-9
14 Large fuel consumption S-10
15 Oil mixes in coolant, spurts or water reduces. S-11
16 Engine oil pressure drops. S-12
17 Oil increases. S-13
18 Water temperature rises too high. (Overheat) S-14
19 An abnormal noise occurs. S-15
20 Large vibration S-16
21 The preheater does not work. E-2
Phenomenon related to power train
22 The power train has no power (no drawbar pull). H-1 S-6
23 The power train does not travel (in case of 2-spool or 3-spool). H-2
24 The power train does not start at all gear speeds. H-3
25 The power train travel forward or in reverse only H-4
26 Large time lag at any gear speed or at forward-reverse shifting H-5
27 Steering is not possible. (Left turn or right turn is impossible.) H-6
28 The steering speed is slow or the steering system has no power. H-7
29 The brake does not work. H-8
30 The torque converter does not lock-up. H-9
31 The power train oil is overheated. H-10
32 Abnormal noise around the HSS pump or the HSS motor H-11
Phenomenon related to work equipment
33 All the work equipment operates slowly. H-12
34 All the work equipment does not operate. H-13
35 The blade lift moves slowly or has no power. H-14
36 The blade tilt moves slowly or has no power. H-15
D275AX-5 20-309
1
Troubleshooting
No. Phenomenon suppose to be Failure Error
E Mode H Mode (Engine)
Code
37 The ripper lift moves slowly or has no power. H-16
38 The ripper tilt moves slowly or has no power. H-17
39 Large hydraulic drift of the blade lift H-18
40 Large hydraulic drift of the blade tilt H-19
41 Large hydraulic drift of the ripper lift H-20
The ripper pin puller cylinder does not operate.
42 E-3 H-21
(Giant ripper-mounted machine)
43 The blade pitcher does not operate. (Dual tilt-mounted machine) H-22
44 Abnormal noise from the work equipment pump H-23
Phenomenon related to monitor panel (Operator mode: Normal screen)
45 When the starting switch is set to ON, no light on the monitor panel comes on. E-4
When the starting switch is set to ON, all the lights on the monitor panel do
46 E-5
not go out.
47 When the starting switch is set to ON, the basic check items flash. E-6
48 While the engine is operating, the caution items flash. E-7
49 While the engine is operating, the emergency warning items flash. E-8
50 While the preheater is operating, the preheating pilot lamp does not come on. E-9
At the selecting time of dual tilt, the dual/single tilt selector lamp does not
51 E-10
come on. (Dual tilt-mounted machine)
At the locking-up of the torque converter, the torque converter lock-up display
52 E-11
lamp does not come on.
53 Indication of the engine water temperature gauge is abnormal. E-12
54 Indication of the power train oil temperature gauge is abnormal. E-13
55 Indication of the hydraulic oil temperature gauge is abnormal. E-14
56 Indication of the fuel gauge is abnormal. E-15
57 Indications of gear speed and engine speed are abnormal. E-16
58 Indication of the shift mode service meter is abnormal. E-17
59 The switch module cannot be operated. E-18
60 The warning lamp does not flash or does not go out. E-19
61 The alarm buzzer does not sound or does not stop. E-20
62 Auto shift down is not possible or is not released. E-21
63 Pivot turn is not possible or is not released. E-22
64 The alarm buzzer cannot be cancelled. E-23
65 The operator mode cannot be operated. E-24
Phenomenon related to monitor panel (Service mode: Special function screen)
66 The service mode does not operate. E-25
Others
67 The back-up alarm does not sound. E-26
The night light, the headlamp, the working lamp and the rear lamp on the pan-
68 E-27
el do not come on.
69 The air conditioner does not operate. E-28
20-310 D275AX-5
1
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR
TROUBLESHOOTING EACH SYSTEM
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIR-

CUIT DIAGRAM FOR EACH SYSTEM
TABLE OF CONNECTORS
★ Addresses show approximate positions of these devices in single view layout drawings of connectors and
electrical circuit diagrams of each system.
Connector Type of Number Address

Device name 3-dimensional
No. connector of pins M-circuit E-circuit T-circuit S-circuit
drawing
101 SWP 6 Intermediate connector C-1 H-7

201 SWP 6 Intermediate connector B-2 H-7
203 M 2 Right head lamp B-7 J-8
204 M 2 Left head lamp A-4
205 Terminal 1 Horn A-2
209 X 2 Intermediate connector A-6 J-8
214 DT-B 12 Intermediate connector N-3 D-8 G-3
215 DT-C 12 Intermediate connector N-2 D-6 E-3
216 DT-D 12 Intermediate connector N-3 H-3 E-3
217 DT 2 Caution buzzer P-1 A-4
218 4 Rear lamp switch N-5 B-1
219 4 Head lamp · Working lamp switch R-1 B-2
221 DT 2 Left working lamp F-1 L-8
223 DT 2 Left real lamp K-5 K-8
224 X 2 Pin puller solenoid valve K-7
241 DT 12 Intermediate connector C-7 H-7 J-9
242 DT 2 Right working lamp B-7 I-8
243 DT 2 Right rear lamp H-9 K-8
244 DT 2 Backup alarm J-9 L-3
262 X 2 Horn switch Q-8
263 X 2 Pin puller switch R-8
264 DT 4 Intermediate connector R-8
265 Terminal 1 Horn switch Q-7
266 Terminal 1 Horn switch Q-7
361 M 2 Front windshield washer motor I-3
362 M 2 Left windshield washer motor H-3
363 M 2 Right windshield washer motor I-3
364 M 2 Rear windshield washer motor H-3
406 DT 2 HSS charge oil pressure switch D-8 I-8
423 X 2 Fuel level sensor J-4 K-8
452 DT 2 Hydraulic oil temperature sensor AJ-7 H-8 K-7
453 DT 2 Torque converter oil temperature sensor AH-3 I-8
653 DT 2 Torque converter lockup solenoid valve AE-6 K-8
800 Plug 1 Intermediate connector (Service power source) N-9
801 Plug 1 Intermediate connector (Service power source) N-9
A/C X 1 Air conditioner compressor Y-7
AC1 17 Air conditioner control panel N-4
D275AX-5 20-311
1

drawing
ADH 4 Heater switch Q-1

ASD 4 Auto shift-down switch N-5 H-2
BB1 Relay 5 Front lamp relay M-8 G-3
BB2 Relay 5 Front lamp relay M-7 G-2
BB3 Relay 5 Working lamp relay M-8 G-2
BKA Relay 5 Backup alarm relay M-8 I-3
BRK DT 3 Brake pedal potentiometer Q-1 B-1
BUZ 3 Buzzer cancel switch N-6 B-2 F-2
C Terminal 1 Battery relay (M-terminal) E-1 L-1 A-1 L-2 L-1
CA1 3 CAN terminating resistor W-5 F-1 J-1 D-2 D-9
CA2 3 CAN terminating resistor O-6 B-3 K-9 I-2 E-2
CAN DT-D 12 Intermediate connector W-7 D-8
CB1 — 2 Circuit breaker (20A) M-9 J-2
CB3 — 2 Circuit breaker (20A) M-9 J-2 C-1 K-2
CB4 — 2 Circuit breaker (20A) M-9
CB6 — 2 Circuit breaker (20A) M-8 J-1 C-2 K-2 J-1
CN1 DT 2 Engine No. 1 injector Y-7 L-4
CN2 DT 2 Engine No. 2 injector Z-7 L-3
CN3 DT 2 Engine No. 3 injector Z-8 L-3
CN4 DT 2 Engine No. 4 injector AA-8 L-3
CN5 DT 2 Engine No. 5 injector AB-9 L-4
CN6 DT 2 Engine No. 6 injector AC-8 L-3
CN-1 Plug 1 Lamp outlet connector [Cab] H-9
CN-2 Terminal 1 Rear right speaker [Cab] H-9
CN-3 Terminal 1 Rear right speaker [Cab] H-9
CN-4 4 Rear wiper motor [Cab] G-9
CN-5 Terminal 1 Rear left speaker [Cab] G-9
CN-6 Terminal 1 Rear left speaker [Cab] G-9
CN-9 6 Front wiper motor [Cab] D-8
CN-10 9 Radio [Cab] I-9
CN-11 6 Left wiper switch [Cab] E-9
CN-12 6 Front wiper switch [Cab] E-9
CN-13 6 Right wiper switch [Cab] E-9
CN-14 6 Rear wiper switch [Cab] F-9
CN-15 2 Lamp switch [Cab] F-9
CN-17 4 Right door wiper motor [Cab] D-8
CN-18 4 Left door wiper motor [Cab] J-9
CN-19 M 4 Intermediate connector [Cab] I-4
CN-20 DT 1 Cab power source connector [Cab] U-1
CN-21 DT 1 Cab power source connector [Cab] T-1
CN-22 Terminal 2 Cigarette lighter [Cab] J-9
CN-23 4 Converter [Cab] G-9
CN-24 2 Intermediate connector [Cab] K-7
20-312 D275AX-5
1

drawing
CN-25 Plug 1 Revolving warning lamp outlet connector [Cab] I-9

CN-26 2 Revolving warning lamp switch [Cab] F-9
CN-81 2 Room lamp [Cab] E-8
CN-D 2 Accessory socket [Cab] K-8
CUR 3 Information switch N-6 B-3 F-2
DCL DT 3 Decelerator pedal potentiometer R-1 K-1
DL1 DT-D 12 Intermediate connector N-2 D-8 G-3 D-3
E21 24-31 31 Intermediate connector C-7 J-4
E22 24-31 31 Intermediate connector C-7 J-5 J-8 K-5
E51 24-31 31 Intermediate connector S-1 G-6 G-9 I-5 H-5
ECN1 DRC-26 24 Engine controller W-4 K-7 A-9
ECN2 DRC-26 40 Engine controller W-4 K-6 A-8 K-4 K-5
ECN3 DRC-26 40 Engine controller W-4 A-5 K-3 K-4
EGS SWP 6 Intermediate connector Q-1 G-7
ESD DT 3 Intermediate connector O-7 L-3
F1T DT 2 1st clutch ECMV (Fill switch) AG-8 K-6
F2T DT 2 2nd clutch ECMV (Fill switch) AG-7 K-5
F3T DT 2 3rd clutch ECMV (Fill switch) AF-7 K-5
FAC DT 2 Fan pump solenoid valve AH-2 K-8
FD5 DT 12 Intermediate connector V-2 J-4 B-1 J-2 K-2
FE2 24-23 23 Intermediate connector V-2 H-5
FFT DT 2 FWD clutch ECMV (Fill switch) AH-8 G-6 K-7
FLB DT 2 Left brake ECMV (Fill switch) AI-8 J-8
FLS X 4 Intermediate connector (For 232C) U-1 D-5
FRB DT 2 Left brake ECMV (Fill switch) AJ-7 K-8
FRT DT 2 REV clutch ECMV (Fill switch) AH-8 K-7
FS1 — — Fuse box 1 N-9 J-1 C-2 K-1 J-1
FS2 — — Fuse box 2 N-9 J-2 B-2
FS4 — — Fuse box 4 O-9 J-2 C-1 K-1 J-1
FSB 24-31 31 Intermediate connector S-1 G-5 G-2 I-5 H-4
FTU 4 Pivot turn switch N-5 F-2
G DT 2 Engine G speed sensor AB-3 L-4 K-6
GND Terminal — GND [Cab] J-4
GND1 Terminal — GND H-2 C-1 C-1 C-1
GND1 Terminal — GND N-4 D-1 H-2 E-1
GND1 Terminal — GND T-1
GND1 Terminal — GND [Cab] —
GND2 Terminal — GND [Cab] —
H Terminal 1 Battery relay (B-terminal) F-1 A-1 L-1 L-1
H01 Plug 1 Intermediate connector S-9 L-1
H01 Plug 1 Intermediate connector S-9
HHP DT 3 Hydraulic oil pressure sensor C-7 K-9
HT Terminal 1 Ribbon heater (C-terminal) AD-5 L-3 K-5
HT/A Terminal 1 Ribbon heater (A-terminal) AD-5 L-3 L-5
HT/B Terminal 1 Ribbon heater (B-terminal) AD-4 L-2 L-5
D275AX-5 20-313
1

drawing
KEY M 6 Starting switch O-7 B-3 K-9 H-2 E-2

M26 6 Air conditioner unit O-1
MFR DT 2 Pivot turn solenoid valve AI-3 K-8
NE DT 2 Engine Ne speed sensor AD-4 L-4 K-6
NSF Relay 5 Neutral safety relay M-7 G-3 D-1 I-3
NSW DT 3 Safety lock switch O-9 G-4 L-3 L-4
P03 DT 6 Pitch mode switch Q-8 E-2
PCV1 DT 2 Fuel supply pump PCV1 AC-3 L-2
PCV2 DT 2 Fuel supply pump PCV2 AB-2 L-2
PDS DT 2 Blade pitch solenoid valve D-8 K-9
PFUEL DT 3 Common rail fuel pressure sensor AC-3 K-8
PIM DT 3 Boost pressure sensor Z-7 K-8
PL1 24-31 31 Intermediate connector W-3 H-7
PL2 24-31 31 Intermediate connector W-3 G-8 H-8 H-7
PL4 DT12-B 12 Intermediate connector V-2 G-7 H-9
PL5 DT-A 12 Intermediate connector V-2 H-9 H-8
PPA DT 2 Blade dual solenoid valve D-8 K-9
PPR Relay 5 Pump power relay M-7 F-1
PRE DT 2 Pre-lubricator O-7 G-1 E-1 I-4
PRS DT 2 Pre-lubricator O-8 G-1 E-1 I-4
PSH Terminal 1 Engine oil pressure sensor (High pressure) AC-3 K-5 K-6
PSL Terminal 1 Engine oil pressure sensor (Low pressure) AD-3 K-5 K-7
PT1 DT 2 Pitch angle sensor D-1 L-8
PUPA DT 2 HSS pump solenoid valve (Right) AF-3 J-8
PUPB DT 2 HSS pump solenoid valve (Left) AE-3 I-8
PWR DT 2 Intermediate connector U-2 K-2 B-2 K-2 K-2
RHR Relay 5 Pre-heater relay N-7 G-1 F-1
RHT DT 3 Pre-heater timer O-8
RPD DT 2 Ripper LOWER oil pressure switch Q-8 E-8
RPU DT 2 Ripper RAISE oil pressure switch R-8 D-8
RTI DT 2 Ripper TILT-IN oil pressure switch Z-8 E-8
S01 AMP040 12 Monitor panel P-7 A-8 G-2 C-1
S02 M 2 Monitor panel O-6 A-7
S03 AMP070 20 Monitor panel R-7 A-7
S04 AMP070 12 Monitor panel R-7 A-5 J-9 G-2 D-1
S13 DT-A 12 Intermediate connector N-2 D-5 J-9 G-3 D-3
S1T DT 2 1st clutch ECMV (Solenoid valve) AF-6 K-6
S21 3 SSC initial jumper O-6 D-7
S24 Terminal 6 Service switch P-1 C-4 E-1
S2T DT 2 2nd clutch ECMV (Solenoid valve) AG-7 K-6
S3T DT 2 3rd clutch ECMV (Solenoid valve) AF-7 K-5
SDR Relay 5 Engine controller power relay N-7 E-1 L-3
SDS 2 Intermediate connector D-8
SFT DT 2 FWD clutch ECMV (Solenoid valve) AJ-3 K-7
SLB DT 2 Left brake ECMV (Solenoid valve) AI-8 J-8
20-314 D275AX-5
1

drawing
SRB DT 2 Right brake ECMV (Solenoid valve) AJ-7 J-8

SRT DT 2 REV clutch ECMV (Solenoid valve) AG-7 K-7
SS3 DT 4 Acceleration sensor D-1 L-8
ST DT 2 Starting motor AB-2 L-3 K-4
ST1 DT 3 HSS oil pressure A sensor — H-8
ST2 DT 3 HSS oil pressure B sensor — I-8
STB DT 2 Emergency stop prevention solenoid valve AI-8 K-8
STCN1 DRC-26 24 Steering controller W-5 E-8 A-9
STCN2 DRC-26 40 Steering controller V-7 E-8 H-1 C-1 A-7
STCN3 DRC-26 40 Steering controller V-8 F-8 H-1 D-1 A-4
STF X 4 Software writing connector (Steering controller) V-8 D-9
SW Terminal 1 Battery relay (BR-terminal) E-1 L-1 A-1 L-1 L-1
THL DT 3 Fuel temperature sensor AD-6 K-5
TL1 24-23 23 PPC lever · Fuel control dial unit W-5 K-2 E-2 B-1
TM1 DT 2 HSS speed sensor AJ-6 E-1 K-8
TMCN1 DRC-26 24 Transmission controller U-8 E-1 A-9 F-8
TMCN2 DRC-26 40 Transmission controller T-9 I-1 A-7 F-8
TMCN3 DRC-26 40 Transmission controller T-9 A-5 E-8
TMF X 4 Software writing connector (Transmission controller) U-8 F-2
TMV 24-23 23 Intermediate connector AH-8 J-7
TWH DT 2 Engine water temperature sensor (High temperature) AB-8 L-5 K-7
TWL DT 2 Engine water temperature sensor (Low temperature) AA-8 L-5 K-7
USB DT 2 Intermediate connector U-2 K-1 B-2 K-1 K-1
VHMS 2 Intermediate connector O-9
WLD X 2 Radiator water level sensor A-6 J-8
WLM X 2 Radiator water level sensor A-6 J-8
D275AX-5 20-315
1
CONNECTOR ARRANGEMENT DRAWING
20-316 D275AX-5
3
1
D275AX-5 20-317
3
1
20-318 D275AX-5
1
D275AX-5 20-319
3
1
20-320 D275AX-5
3
1
D275AX-5 20-321
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM

(M CIRCUIT)
20-322 D275AX-5
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
★ This circuit diagram was drawn by extracting the monitor panel system, the engine preheating, starting and
filling systems, the lighting system and the communication network system from the general electrical circuit
diagram.
D275AX-5 20-323
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM

(E CIRCUIT)
20-324 D275AX-5
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
★ This circuit diagram was drawn by extracting the engine controller system from the general electrical circuit
diagram.
D275AX-5 20-325
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM

(T CIRCUIT)
20-326 D275AX-5
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
★ This circuit diagram was drawn by extracting the transmission controller system from the general electrical
circuit diagram.
D275AX-5 20-327
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM

(S CIRCUIT)
20-328 D275AX-5
3
1
TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
★ This circuit diagram was drawn by extracting the steering controller system from the general electrical circuit
diagram.
D275AX-5 20-329
3
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
— —
• Grommet: red • Grommet: red
20-330 D275AX-5
1
SWP Type Connector

Number
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D275AX-5 20-331
1
SWP Type Connector

Number
Number
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-332 D275AX-5
1
M Type Connector
Number
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
D275AX-5 20-333
(6)
1
S Type Connector
Number
Number
8 799-601-7140
10
799-601-7150
(white)
12
799-601-7350
(white)
16
799-601-7330
(white)
20-334 D275AX-5
1
S Type Connector
Number
Number
10
—
(blue)
— —
12
799-601-7160
(blue)
16
799-601-7170
(blue)
D275AX-5 20-335
1
MIC Type Connector

Number
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 —
5 799-601-2710

9 799-601-2950

13 799-601-2720

20-336 D275AX-5
1
MIC Type Connector

Number
Number
17 799-601-2730

21 799-601-2740

—
D275AX-5 20-337
1
AMP040 Type Connector

Number
Number
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
12 799-601-7190

—
16 799-601-7210

—
20 799-601-7220

—
★ Terminal part number: 79A-222-3470 (for all numbers of pins).
20-338 D275AX-5
1
AMP070 Type Connector

Number
Number
10 799-601-7510
— Part number: 08195-10210
12 799-601-7520
— Part number: 08195-12210
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
20 799-601-7550
— Part number: 08195-20210
D275AX-5 20-339
1
L Type Connector
Number
Number
2 —
— —
PA Type Connector
Number
Number
9 —
— —
BENDIX (MS) Type Connector

Number
Number
10 799-601-3460
— —
20-340 D275AX-5
1
KES1 Automobile Type Connector

Number
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
D275AX-5 20-341
1
KES1 Automobile Type Connector

Number
Number
8 —
08027-10820 (Black) 08027-10870 (Black)
20-342 D275AX-5
1
F Type Connector
Number
Number
4 —
— —
D275AX-5 20-343
1
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-344 D275AX-5
1

Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
D275AX-5 20-345
1

Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-346 D275AX-5
1

Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
D275AX-5 20-347
(8)
1

Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-348 D275AX-5
1
DT Series connector
Number
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
D275AX-5 20-349
1
DT Series connector
Number
of Pins T-adapter
Part Number
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9080
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-350 D275AX-5
(6)
1
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D275AX-5 20-351
1
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
20-352 D275AX-5
3
1
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
D275AX-5 20-353
3
1
20-352 D275AX-5
1
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING WHEN
ERROR CODE IS DISPLAYED
(ERROR CODE)
Information described in troubleshooting list ........................................................................................... 20-405

Trouble code table ................................................................................................................................... 20-406
Error code 1500LO (Transmission clutch: See the list. (L1)) ................................................................. 20-407
Error code 15SAL1 (Forward clutch: See the list. (L1)) ......................................................................... 20-408
Error code 15SALH (Forward clutch: See the list. (LH)) ........................................................................ 20-409
Error code 15SBL1 (Reverse clutch: See the list. (L1)) ......................................................................... 20-410
Error code 15SBLH (Reverse clutch: See the list. (LH)) ........................................................................ 20-411
Error code 15SEL1 (Speed 1st clutch: See the list. (L1)) ...................................................................... 20-412
Error code 15SELH (Speed 1st clutch: See the list. (LH)) ..................................................................... 20-413
Error code 15SFL1 (Speed 2nd clutch: See the list. (L1)) ..................................................................... 20-414
Error code 15SFLH (Speed 2nd clutch: See the list. (LH)) .................................................................... 20-415
Error code 15SGL1 (Speed 3rd clutch: See the list. (L1)) ..................................................................... 20-416
Error code 15SGLH (Speed 3rd clutch: See the list. (LH)) .................................................................... 20-417
Error code 1800MW (Power train clutch: SLIP (MW)) ........................................................................... 20-418
Error code 2301L1 (Right brake: See the list. (L1)) ............................................................................... 20-419
Error code 2301LH (Right brake: See the list. (LH)) .............................................................................. 20-420
Error code 2302L1 (Left brake: See the list. (L1)) ................................................................................. 20-421
Error code 2302LH (Left brake: See the list. (LH)) ................................................................................ 20-422
Error code AB00MA (Alternator : Malfunction (MA)) ............................................................................. 20-423
Error code AD00L2 (Common rail: See the list. (L2)) ............................................................................ 20-423
Error code AD00MA (Common rail: Defective function (MA)) ................................................................ 20-424
Error code AD10L3 (Fuel supply pump: See the list. (L3)) .................................................................... 20-424
Error code AD10MA (Fuel supply pump: Defective function (MA)) ....................................................... 20-427
Error code AD10MB (Fuel supply pump: Function reduction (MB)) ...................................................... 20-427
Error code AD11KA (Fuel supply pump solenoid 1: Disconnection in wiring (KA)) ............................... 20-428
Error code AD11KB (Fuel supply pump solenoid 2: Disconnection in wiring (KB)) ............................... 20-429
Error code AD11KB (Fuel supply pump solenoid 1: Short circuit (KB)) ................................................. 20-430
Error code AD51KB (Fuel supply pump solenoid 2: Disconnection in short (KB)) ................................ 20-431
Error code ADA1KA (No.1 injector solenoid: Disconnection in wiring (KA)) .......................................... 20-432
Error code ADAZKB (No.1, 2, and 3 injector solenoids: Short (KB)) ..................................................... 20-433
Error code ADB1KA (No.2 injector solenoid: Disconnection in wiring (KA)) .......................................... 20-435
Error code ADC1KA (No.3 injector solenoid: Disconnection in wiring (KA)) .......................................... 20-436
Error code ADD1KA (No.4 injector solenoid: Disconnection in wiring (KA)) .......................................... 20-437
Error code ADDZKB (No.4, 5, and 6 injector solenoids: Short (KB)) ..................................................... 20-438
Error code ADE1KA (No. 5 fuel injector solenoid: Disconnection (KA)) ................................................ 20-440
Error code ADF1KA (No. 6 fuel injector solenoid: Disconnection (KA)) ................................................ 20-441
Error code B@BAZG (Engine oil: Oil Pressure reduction (ZG)) ............................................................ 20-442
Error code B@BCNS (Radiator coolant: Overheat (NS)) ...................................................................... 20-442
Error code B@BCZK (Radiator coolant: Level reduction (ZK)) ............................................................. 20-443
Error code B@CENS (Power tran oil: Overheat (NS)) ........................................................................... 20-443
Error code B@CHZG (HSS charge oil: Oil pressure reduction (ZG)) .................................................... 20-444
Error code B@HANS (Hydraulic oil: Overheat (NS)) ............................................................................. 20-444
Error code D110KA (Battery relay: Disconnection (KA)) ....................................................................... 20-445
Error code D110KB (Battery relay: Short circuit (KB)) .......................................................................... 20-446
Error code D130KA (Neutral safety relay: Disconnection (KA)) ............................................................. 20-447
Error code D130KB (Neutral safety relay: Short circuit (KB)) ................................................................ 20-449
Error code D161KA (Back-up alarm relay: Disconnection (KA)) ........................................................... 20-450
D275AX-5 20-401
3
1
TROUBLESHOOTING
Error code D161KB (Back-up alarm relay: Short circuit (KB)) ............................................................... 20-452
Error code D1D0KB (Engine controller load power supply relay: Short circuit (KB)) ............................. 20-454
Error code DAFRKR (Monitor panel can communication: Defective communication (KR)) ................... 20-456
Error code DAQ0KK (Transmission controller: Source voltage reduction (input) (KK)) .......................... 20-458
Error code DAQ0KT (Transmission controller: Abnormality in controller (KT)) ...................................... 20-459
Error code DAQ5KK (Transmission controller potentiometer power supply:
Source voltage reduction (input) (KK)) .................................................................................... 20-460
Error code DAQ6KK (Transmission controller source power supply:
Error code DAQ9KQ (Transmission controller type collation: Type select signal inconsistency (KQ)) ... 20-463
Error code DAQRKR (Transmission controller can communication:
Defective communication (Abnormality in objective component system) (KR)) ...................... 20-464
Error code DAQSKR (Transmission controller snet communication:
Error code DB20KT (Engine controller power supply: Abnormality in controller (KT)) ........................... 20-467
Error code DB22KK (Engine controller load power supply: Source voltage reduction (input) (KK)) ...... 20-469
Error code DB29KQ (Engine controller type select: Type select signal inconsistency (KQ)) ................. 20-471
Error code DB2AMA (Fuel injection amount adjustment switch signal: Malfunction (MA)) .................... 20-472
Error code DB2RKR (Engine controller can communication:
Error code DB30KK (Steering controller: Source voltage reduction (input) (KK)) .................................. 20-475
Error code DB30KT (Steering controller: Abnormality in controller (KT)) .............................................. 20-476
Error code DB35KK (Steering controller potentiometer power supply:
Error code DB36KK (Steering controller sensor power supply: Source voltage reduction (input) (KK)) 20-479
Error code DB39KQ (Steering controller type collation: Type select signal inconsistency (KQ)) ........... 20-481
Error code DB3RKR (Steering controller can communication:
Error code DB3SKR (Steering controller snet communication:
Error code DD11KB (Starting switch: Short circuit (KB)) ....................................................................... 20-485
Error code DD12KA (Shift up switch: Disconnection (KA)) .................................................................... 20-486
Error code DD12KB (Shift up switch: Short circuit (KB)) ....................................................................... 20-488
Error code DD13KA (Shift down switch: Disconnection (KA)) ............................................................... 20-490
Error code DD13KB (Shift down switch: Short circuit (KB)) ................................................................... 20-492
Error code DD14KA (Parking lever switch: Disconnection (KA)) ............................................................ 20-494
Error code DD14KB (Parking lever switch: Short circuit (KB)) ............................................................... 20-496
Error code DDE2L6 (Engine oil pressure switch: Refer to table (L6) ..................................................... 20-498
Error code DDN4LD (Ripper lift up pressure switch: Refer to table (LD) ............................................... 20-500
Error code DDN5LD (Ripper lift down pressure switch: Refer to table (LD) ........................................... 20-501
Error code DDN6LD (Ripper tilt in pressure switch: Refer to table (LD) ................................................ 20-502
Error code DDN7KA (Blade pitch switch: Disconnection (KA)) .............................................................. 20-503
Error code DDN7KB (Blade pitch Switch: Short Circuit (KB)) ................................................................ 20-505
Error code DDN9KA (Blade tilt switch: Disconnection (KA)) .................................................................. 20-507
Error code DDN9KB (Blade tilt switch: Short circuit (KB)) ..................................................................... 20-509
Error code DDQ2KA (Parking lever switch: Disconnection (KA)) ........................................................... 20-511
Error code DDQ2KB (Parking brake lever switch: Short circuit (KB)) .................................................... 20-513
Error code DDQ2L4 (Parking brake lever switch: See table (L4)) .......................................................... 20-515
Error code DGE2KX (Engine water temperature sensor (for high temperature):
Input signal is out of normal range (KX)) ................................................................................ 20-516
Error code DGE3L6 (Engine water temperature sensor (for low temperature): See table (L6)) ............ 20-517
Error code DGE4KX (Fuel temperature sensor: input signal is out of normal range (KX)) .................... 20-518
Error code DGS1KX (Hydraulic oil temperature sensor: input signal is out of normal range (KX)) ....... 20-519
Error code DH21KA (Work equipment pump oil pressure sensor: Disconnection (KA)) ....................... 20-520
20-402 D275AX-5
1
(5)
TROUBLESHOOTING
Error code DH21KB (Work equipment pump oil pressure sensor: Short circuit (KB)) .......................... 20-521
Error code DH30KX (Boost pressure sensor: Input is out of normal range (KX)) ................................. 20-522
Error code DH40KX (Common rail pressure sensor: Input is out of normal range (KX)) ...................... 20-524
Error code DHH3KA (Hss pump oil pressure sensor A: Disconnection (KA)) ....................................... 20-526
Error code DHH3KB (Hss pump oil pressure sensor A: Short circuit (KB)) ........................................... 20-527
Error code DHH4KA (Hss pump oil pressure sensor B: Disconnection (KA)) ....................................... 20-528
Error code DHH4KB (Hss pump oil pressure sensor B: Short circuit (KB)) ........................................... 20-529
Error code DK10KX (Fuel control dial: Input is out of normal range (KX)) ............................................ 20-530
Error code DK12KX (Deceleration potentiometer: Input is out of normal range (KX)) .......................... 20-532
Error code DK30KA (Steering potentiometer 1: Disconnection (KA)) ................................................... 20-534
Error code DK30KB (Steering potentiometer 1: Short circuit (KB)) ....................................................... 20-536
Error code DK30KX (Steering potentiometer 1: Input signal is out of normal range (KX)) .................... 20-537
Error code DK30KZ (Steering potentiometer 1: Disconnection or short circuit (KZ)) ............................ 20-537
Error code DK30L8 (Steering potentiometer 1: See table (L8)) ............................................................ 20-538
Error code DK31KA (Steering potentiometer 2: Disconnection (KA)) ................................................... 20-539
Error code DK31KB (Steering potentiometer 2: Short circuit (KB)) ....................................................... 20-541
Error code DK40KA (Brake potentiometer: Disconnection (KA)) .......................................................... 20-542
Error code DK40KB (Brake potentiometer: Short circuit (KB)) .............................................................. 20-544
Error code DK55KX (Forward-reverse potentiometer: Input signal is out of normal range (KX)) .......... 20-545
Error code DK55KZ (Forward-reverse potentiometer: Disconnection or short circuit (KZ)) .................. 20-545
Error code DK55L8 (Forward-reverse potentiometer: See table (L8)) ................................................... 20-546
Error code DK56KA (Forward-reverse potentiometer 1: Disconnection (KA)) ....................................... 20-547
Error code DK56KB (Forward-reverse potentiometer 1: Short circuit (KB)) .......................................... 20-549
Error code DK57KA (Forward-reverse potentiometer 2: Disconnection (KA)) ....................................... 20-550
Error code DK57KB (Forward-reverse potentiometer 2: Short circuit (KB)) .......................................... 20-552
Error code DK60KA (Acceleration sensor: Disconnection (KA)) ........................................................... 20-553
Error code DK60KB (Acceleration sensor: Short circuit (KB)) ............................................................... 20-554
Error code DKH1KA (Pitch angle sensor: Disconnection (KA)) ............................................................. 20-555
Error code DKH1KB (Pitch angle sensor: Short circuit (KB)) ................................................................ 20-556
Error code DLE3LC (Engine Ne speed sensor: See table (LC)) ........................................................... 20-557
Error code DLF1KA (Transmission output speed sensor: Disconnection (KA)) .................................... 20-559
Error code DLH1LC (Engine G speed sensor: See table (Lc)) .............................................................. 20-560
Error code DV00KB (Caution buzzer: Short circuit (KB)) ...................................................................... 20-561
Error code DW59KA (Blade dual selector solenoid: Disconnection (KA)) ............................................. 20-562
Error code DW59KB (Blade dual selector solenoid: Short circuit (KB)) ................................................ 20-563
Error code DW5AKA (Blade pitch selector solenoid: Disconnection (KA)) ............................................ 20-564
Error code DW5AKB (Blade pitch selector solenoid: Short circuit (KB)) ............................................... 20-565
Error code DWN1KA (Hss pump solenoid left: Disconnection (KA)) ..................................................... 20-566
Error code DWN1KB (Hss pump solenoid left: Short circuit (KB)) ......................................................... 20-567
Error code DWN2KA (Hss pump solenoid right: Disconnection (KA)) ................................................... 20-568
Error code DWN2KB (Hss pump solenoid right: Short circuit (KB)) ...................................................... 20-569
Error code DWN3KA (Sudden stop prevention solenoid: Disconnection (KA)) ..................................... 20-570
Error code DWN3KB (Sudden stop prevention solenoid: Short circuit (KB)) ......................................... 20-571
Error code DWN4KA (Hss free solenoid: Disconnection (KA)) .............................................................. 20-572
Error code DWN4KB (Hss free solenoid: Short circuit (KB)) ................................................................. 20-573
Error code DWN5KA (Fan pump solenoid: Disconnection (KA)) ........................................................... 20-574
Error code DWN5KB (Fan pump solenoid: Short circuit (KB)) .............................................................. 20-575
Error code DXH1KA (Lock-up solenoid: Disconnection (KA)) ............................................................... 20-576
Error code DXH1KB (Lock-up solenoid: Short circuit (KB)) ................................................................... 20-577
Error code DXH4KA (1st clutch ecmv: Disconnection (KA)) ................................................................. 20-578
Error code DXH4KB (1st clutch ecmv: Short circuit (KB)) ..................................................................... 20-579
Error code DXH5KA (2nd clutch ecmv: Disconnection (KA)) ................................................................ 20-580
Error code DXH5KB (2nd clutch ecmv: Short circuit (KB)) .................................................................... 20-581
Error code DXH6KA (3rd clutch ecmv: Disconnection (KA)) ................................................................. 20-582
D275AX-5 20-403
1
(5)
TROUBLESHOOTING
Error code DXH6KB (3rd clutch ecmv: Short circuit (KB)) ..................................................................... 20-583
Error code DXH7KA (Reverse clutch ecmv: Disconnection (KA)) .......................................................... 20-584
Error code DXH7KB (Reverse clutch ecmv: Short circuit (KB)) ............................................................. 20-585
Error code DXH8KA (Forward clutch ecmv: Disconnection (KA)) .......................................................... 20-586
Error code DXH8KB (Forward clutch ecmv: Short circuit (KB)) ............................................................. 20-587
Error code DXHBKA (Right brake ecmv: Disconnection (KA)) .............................................................. 20-588
Error code DXHBKB (Right brake ecmv: Short circuit (KB)) .................................................................. 20-589
Error code DXHCKA (Left brake ecmv: Disconnection (KA)) ................................................................. 20-590
Error code DXHCKB (Left brake ecmv: Short circuit (KB)) .................................................................... 20-591
20-404 D275AX-5
1
(5)
TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST

a The troubleshooting list and related circuit diagram summarize the following information. Understand their
contents well to advance troubleshooting.
Action code Error code
Trouble Trouble that appeared on machine
Panel display Panel display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of monitor
Action to be taken to protect the system and equipment when the monitor panel or controller detects a
panel or
trouble
controller
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or con-
appears on
troller (above)
machine
Related
Information related to a detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the assumed
cause (good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness is
disconnected.
• Grounding fault
2 A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
A harness not connected to the power (24V) circuit comes into
contact with the power (24V) circuit.
• Defective short
Possible causes Cause by which a trouble is as-
and standard A harness of an independent circuit abnormally comes into con-
sumed to be detected
tact with one of another circuit.
value in normal 3 (The order number indicates a
state serial number, not a priority se-
<Notes on troubleshooting>
quence.)
1Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
• When “male” or “female” is not indicated for a connector num-
ber, disconnect the connector, and insert the T-junction adapt-
4 er in both the male and female.
• When “male” or “female” is indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
only either the male or female.
2Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
shown below unless especially specified.
5 • 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.
D275AX-5 20-405
1
TROUBLESHOOTING TROUBLE CODE TABLE
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• Arrow ( ): Roughly indicates mounting place on machine.
TROUBLE CODE TABLE

a Regarding trouble code provided with instruction “Refer to table”, check it against table below.
Trouble Trouble
Contents of trouble Contents of trouble
code code
KA Disconnection L4 ON/OFF signals do not agree with each other
KB Short circuit L6 Operation state and stop state of engine do not agree with signals
KK Lowering of source voltage (Input) L8 Analog signals do not agree with each other
KQ Disagreement of model selection signals LC Speed signals do not agree with each other
Communication defective (Abnormality
KR LD Switch is pressed for long time
in objective component)
KT Internal defect of controller LH When command current is turned ON, fill signal is turned OFF
KX Out of input signal range MA Malfunction
KZ Disconnection or short circuit MB Lowering of function
L0 Double engagement MW Slip
When command current is turned OFF,
L1 NS Overheating
fill signal is turned ON
L2 Fuel pressure is too high ZG Lowering of oil pressure
L3 Objective part cannot be controlled ZK Lowering of level
20-406 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (L1))
ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (L1))
Action code Error code Transmission clutch: See the list. (LO)
Trouble
CALL E03 1500L0 (Transmission controller system)
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Connection error)
4Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Disconnection error)
5Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of
6[DXH6KA] and [DXH6KB]
trouble
7[15SFL1] and [15SGL1]
8[15SFLH] and [15SGLH]
9[15SAL1], [15SBL1], and [15SEL1]
:[15SALH] and [15SBLH]
;[15SALH] and [15SELH]
<[15SBLH] and [15SELH]
Action of • Flashes caution lamp and turns on caution buzzer.
controller • Limits operation of engine and transmission.
Problem that • The auto shift down function does not start.
appears on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, running is limited to F3 and R3.
Related
• Method of reproducing error code: Engine start + Run
information

Possible causes Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes.
and standard [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
value in normal [15SGLH]
state [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA],
[DXH8KB]
D275AX-5 20-407
4
TROUBLESHOOTING ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1))
Action code Error code Forward clutch: See the list. (L1)
Trouble
CALL E03 15SAL1 (Transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.
trouble
• Flashes caution lamp and turns on caution buzzer.
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
• Limits operation of engine and transmission.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on
• Once machine is stopped, running is limited to F1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing error code: Engine start + Neutral running

★ Prepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective forward clutch fill FFT (male) PCCS lever Resistance
1
switch (Internal short)
Between 4 – N Min. 1MΩ
chassis ground F (Forward) Max. 1Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective harness ground-
Possible causes without turning starting switch ON.
2 ing (Contact with ground cir-
and standard Wiring harness between TMCN1 (female) 8 –
cuit) Resistance Max. 1MΩ
value in normal FFT (female) 4 with chassis ground
state ★ Prepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective transmission con- TMCN1 PCCS lever Voltage
3
troller
Between 8 – N 20 – 30V
chassis ground F (Forward) Max. 1V
When no fault is detected in the electric system, the hydraulic pres-
Defective hydraulic pres-
4 sure system is assumed to be abnormal. Carry out the related trou-
sure system
bleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
20-408 D275AX-5
4
TROUBLESHOOTING ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH))
Action code Error code Forward clutch: See the list. (LH)
Trouble
CALL E03 15SALH (Transmission controller system)
Contents of
• The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + Forward running

aPrepare with starting switch OFF, then start the engine for trouble-
Defective forward clutch fill shooting.
1 switch (Internal disconnec- FFT (male) PCCS lever Resistance
tion in wiring) Between 1 – N Min. 1Mz
chassis ground F (Forward) Max. 1z
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting
Possible causes ness (Disconnection in wir- without turning starting switch ON.
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) 5 –
Resistance Max. 1z
value in normal connector) FFT (female) 1
state aPrepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective transmission con-
3 TMCN1 PCCS lever Voltage
troller
Between 5 – N 20 – 30V
chassis ground F (Forward) Max. 1V
sure system
D275AX-5 20-409
(8)
1
TROUBLESHOOTING ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1))
Action code Error code Reverse clutch: See the list. (L1)
Trouble
CALL E03 15SBL1 (Transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill
1 FRT (male) PCCS lever Resistance
Between 1 – N Min. 1Mz
chassis ground R (Reverse) Max. 1z
aPrepare with starting switch OFF, then carry out troubleshooting
and standard Wiring harness between TMCN1 (female) N –
cuit) Resistance Min. 1Mz
value in normal FFT (female) 1 with chassis ground
shooting.
troller
Between N – N 20 – 30V
chassis ground R (Reverse) Max. 1V
sure system
Circuit diagram related to transmission reverse clutch ECMV
20-410 D275AX-5
(8)
1
TROUBLESHOOTING ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH))
Action code Error code Reverse clutch: See the list. (LH)
Trouble
CALL E03 15SBLH (Transmission controller system)
Contents of
• The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
Problem that
appears on
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + Reverse running

Defective reverse clutch fill shooting.
1 switch (Internal disconnec- FRT (male) PCCS lever Resistance
tion in wiring) Between 1 – N Min. 1Mz
chassis ground R (Reverse) Max. 1z
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) N –
Resistance Max. 1z
value in normal connector) FRT (female) 1
shooting.
troller
Between N – N 20 – 30V
chassis ground R (Reverse) Max. 1V
sure system
D275AX-5 20-411
(8)
1
TROUBLESHOOTING ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1))
Action code Error code 1st clutch: See the list. (L1)
Trouble
CALL E03 15SEL1 (Transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
trouble
Problem that
appears on
• Once machine is stopped, running is limited to F1 and R1.
machine
• The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + F1 or R1 running

shooting.
Defective 1st clutch fill
1 F1T (male) PCCS lever Resistance
Between 1 – Other than F1/R1 Min. 1Mz
chassis ground F1·R1 Max. 1z
and standard Wiring harness between TMCN1 (female) M –
value in normal F1T (female) 1 with chassis ground
shooting.
troller
Between M – Other than F1/R1 20 – 30V
chassis ground F1·R1 Max. 1V
sure system
Circuit diagram related to transmission level 1 clutch ECMV
20-412 D275AX-5
(8)
1
TROUBLESHOOTING ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH))
Action code Error code Level 1 clutch: See the list. (LH)
Trouble
CALL E03 15SELH (Transmission controller system)
Contents of
• The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not start.
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information

Defective 1st clutch fill shooting.
1 switch (Internal disconnec- F1T (male) PCCS lever Resistance
tion in wiring) Between 1 – Other than F1/R1 Min. 1Mz
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) M –
Resistance Min. 1Mz
value in normal connector) F1T (female) 1
shooting.
troller
Between N – Other than F1/R1 20 – 30V
sure system
Circuit diagram related to transmission 1st clutch ECMV
D275AX-5 20-413
(8)
1
TROUBLESHOOTING ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1))
Action code Error code 2nd clutch: See the list. (L1)
Trouble
CALL E03 15SFL1 (Transmission controller system)
Contents of
• The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not operate.
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill
1 F2T (male) PCCS lever Resistance
Between 1 – Other than F2/R2 Min. 1Mz
and standard Wiring harness between TMCN1 (female) G –
shooting.
troller
Between G – Other than F2/R2 20 – 30V
sure system
Circuit diagram related to transmission 2nd clutch ECMV
20-414 D275AX-5
(8)
1
TROUBLESHOOTING ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH))
Action code Error code 2nd clutch: See the list. (LH)
Trouble
CALL E03 15SFLH (Transmission controller system)
Contents of
• The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T (male) PCCS lever Resistance
1
Between 1 – Other than F2/R2 Min. 1MΩ
chassis ground F2·R2 Max. 1Ω
Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) G –
Resistance Max. 1MΩ
shooting.
3
troller
Between G – Other than F2/R2 20 – 30V
sure system
D275AX-5 20-415
3
1
TROUBLESHOOTING ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1))
Action code Error code 3rd clutch: See the list. (L1)
Trouble
CALL E03 15SGL1 (Transmission controller system)
Contents of
• The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not operate.
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T (male) PCCS lever Resistance
1
Defective harness ground- without turning starting switch ON.
Possible causes
and standard Wiring harness between TMCN1 (female) $ –
shooting.
3
troller
Between $ – Other than F3/R3 20 – 30V
sure system
Circuit diagram related to transmission 3rd clutch ECMV
20-416 D275AX-5
4
TROUBLESHOOTING ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH))
Action code Error code 3rd clutch: See the list. (LH)
Trouble
CALL E03 15SGLH (Transmission controller system)
Contents of
• The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) $ –
Resistance Max. 1Ω
shooting.
3
troller
Between $ – Other than F3/R3 20 – 30V
sure system
D275AX-5 20-417
4
TROUBLESHOOTING ERROR CODE 1800MW (POWER TRAIN CLUTCH: SLIP (MW))
ERROR CODE 1800MW (POWER TRAIN CLUTCH: SLIP (MW))
Action code Error code Power train clutch slip

Trouble
E02 1800MW (Transmission controller system)
Contents of • At lock-up of the torque converter, the number of transmission rotations obtained from the number of
trouble engine rotations is different from the actual number of rotations by 200rpm or more.
Action of
controller
Problem that
appears on • The auto shift down function does not operate.
machine
• The number of engine rotations and the number of transmission rotations can be checked in monitor-
Related ing mode.
information (Code 01000: Number of engine rotations, code 31400: Number of transmission rotations)
• Method of reproducing error code: Engine start + Lock-up switch ON + Actual running

Power train clutch slip
★ Clutch slip was detected; check the cause and machine damage
1 (When the system is nor-
state, then repair the machine.
mal)
Possible causes
Defective engine rotation Check whether error codes [DLE3LC] and [DLH1LC] are displayed. If
and standard 2
sensor they are displayed, carry out the troubleshooting.
value in normal
state Defective transmission rota-Check whether error code [DLF1KA] is displayed. If it is displayed,
3
tion sensor system carry out the troubleshooting.
Internally trouble; troubleshooting is impossible.
4 (If no visible abnormality is detected on the machine, the controller
troller
may be used continuously.)
20-418 D275AX-5
3
1
TROUBLESHOOTING ERROR CODE 2301L1 (RIGHT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2301L1 (RIGHT BRAKE: SEE THE LIST. (L1))
Action code Error code Right brake: See the list. (L1)
Trouble
CALL E04 2301L1 (Steering controller system)
Contents of
• The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
trouble
controller • Limits operation of engine, transmission, and brake.
Problem that • The loose brake functions during running.
machine • 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.
Related
(Code 31521: Steering fill switch input state)
information
• Method of reproducing error code: Engine start + Parking lever release

★ Prepare with starting switch OFF. Engine start + Pivot turn switch
Defective right steering ON + Forward for troubleshooting.
1 brake fill switch FRB (male) PCCS lever Resistance
(Internal short) Between 1 – N (Neutral) Min. 1MΩ
chassis ground Right steering Max. 1Ω
Possible causes
and standard Wiring harness between STCN2 (female) O –
value in normal FRB (female) 1 with chassis ground
state ★ Prepare with starting switch OFF. Engine start + Pivot turn switch
ON + Forward for troubleshooting.
3 Defective steering controller STCN2 PCCS lever Voltage
Between O – N (Neutral) 20 – 30V
chassis ground Right steering Max. 1V
sure system
Circuit diagram related to right steering brake ECMV
D275AX-5 20-419
3
1
TROUBLESHOOTING ERROR CODE 2301LH (RIGHT BRAKE: SEE THE LIST. (LH))
ERROR CODE 2301LH (RIGHT BRAKE: SEE THE LIST. (LH))
Action code Error code Right brake: See the list. (LH)
Trouble
CALL E04 2301LH (Steering controller system)
Contents of
• The fill switch signal is not set off at output to the right steering brake solenoid circuit.
trouble
• The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start

Defective right steering ON + Forward for troubleshooting.
1 clutch fill switch FRB (male) PCCS lever Resistance
2
and standard ing or defective contact in Wiring harness between STCN2 (female) 2 –
value in normal connector) FRB (female) 4
Between 2 – N (Neutral) 20 – 30V
chassis ground Right steering Max. 1V
sure system
20-420 D275AX-5
4
TROUBLESHOOTING ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
Action code Error code Right brake: See the list. (L1)
Trouble
CALL E04 2302L1 (Steering controller system)
Contents of
• The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode.
Related
information

Defective left steering clutch ON + Forward for troubleshooting.
1 fill switch FRB (male) PCCS lever Resistance
Possible causes
and standard Wiring harness between STCN2 (female) < –
value in normal FLB (female) 4 with chassis ground
Between < – N (Neutral) 20 – 30V
chassis ground Left steering Max. 1V
sure system
Circuit diagram related to left steering brake ECMV
D275AX-5 20-421
4
TROUBLESHOOTING ERROR CODE 2302LH (LEFT BRAKE: SEE THE LIST. (LH))
ERROR CODE 2302LH (LEFT BRAKE: SEE THE LIST. (LH))
Action code Error code Left brake: See the list. (LH)
Trouble
CALL E04 2302LH (Steering controller system)
Contents of
• The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode.
Related
information

Defective left steering brake ON + Forward for troubleshooting.
1 fill switch FLB (male) PCCS lever Resistance
chassis ground Left steering Max. 1Ω
2
and standard ing or defective contact in Wiring harness between STCN2 (female) Y –
value in normal connector) FLB (female) 1
Between Y – N (Neutral) 20 – 30V
chassis ground Left steering Max. 1V
sure system
20-422 D275AX-5
3
1
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))
TROUBLESHOOTING ERROR
ERRORCODE
CODEAB00MA
AD00L2 (ALTERNATOR:
(COMMON RAIL:
MALFUNCTION
SEE THE LIST.(MA))
(L2))
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))

Trouble Alternator: Malfunction (MA) (Mechanical system)
— AB00MA
Contents of
• During rotation of engine, charge level caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, battery may be discharged.
machine
Related
• Method of reproducing error code: Start engine.
information

Defective battery charge It is suspected that problem causing defective battery charge is oc-
Possible causes
1 (When system is in normal curring at present or occurred in past. Investigate cause and damage
and standard
state) condition, and correct it.
value in normal
state Carry out troubleshooting of charge level caution lamp system in ac-
Defective charge level cau-
2 cordance with “During running of engine, emergency caution item
tion lamp system
flashes” in E mode.
ERROR CODE AD00L2 (COMMON RAIL: SEE THE LIST. (L2))
Action code Error code Common rail: See the list. (L2)
Trouble
E02 AD00L2 (Engine controller system)
Contents of
• The fuel pressure of common rail became high (level 1).
trouble
controller • Limits output for operation.
Problem that
appears on • Engine output reduces.
machine
• The fuel state (fuel pressure) of common rail can be checked in monitoring mode.
Related
(Code 36400: Common rail pressure)
information

Check the displayed error code. If another code is displayed, first car-
1 Defective related system
ry out troubleshooting for the code.
2 Inappropriate fuel The fuel used may be inappropriate; directly check it.
Defective electric system of
3 common rail pressure sen- Carry out troubleshooting for error code [DH40KX].
Possible causes sor
and standard
Defective mechanical sys-
value in normal The common rail pressure sensor is assumed to be defective me-
4 tem of common rail pres-
state chanically; directly check it.
sure sensor
The overflow valve may cause spring damage, sheet abrasion, or ball
5 Defective overflow valve
fixing; directly check it.
6 Clogged overflow pipe The overflow pipe is assumed to be clogged; directly check it.
The pressure limiter is assumed to be defective mechanically; directly
7 Defective pressure limiter
check it.
D275AX-5 20-423
1
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA))
ERROR
CODE
CODE
AD00MA
AD10L3
(COMMON
(FUEL SUPPLY
RAIL: DEFECTIVE
PUMP: SEEFUNCTION
THE LIST.(MA))
(L3))
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA))
Action code Error code Common rail: See the list. (MA)
Trouble
E02 AD00MA (Engine controller system)
Contents of
• The fuel pressure of common rail became high (level 2).
trouble
controller • Limits output and engine speed for operation.
Problem that
appears on • Engine output and speed reduces.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for error code [AD00L2].
state
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Action code Error code Fuel supply pump: See the list. (L3)
Trouble
CALL E03 AD10L3 (Engine controller system)
Contents of
• Non-pressure transmission (level 1) occurred in fuel supply pump.
trouble
controller • Limits output for operation.
Problem that
machine
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
Related
mode. (Code 36400: Common rail pressure)
information

Check the displayed error code. If another code is displayed, first car-
1 Defective related system
ry out troubleshooting for the code.
2 Inappropriate fuel The fuel used may be inappropriate; directly check it.
Defective low-pressure cir- The low-pressure circuit equipment is assumed to be defective; see
3
cuit equipment Note 2 for troubleshooting.
The filter strainer is assumed to be clogged; see Note 1 for trouble-
Possible causes 4 Clogged filter strainer
shooting.
and standard
Defective electric system of Carry out troubleshooting for error codes [AD11KA], [AD11KB],
value in normal 5
state fuel supply pump PCV [AD51KA], and [AD51KB].
6 Defective fuel supply pump of fuel supply pump
Defective common rail pres- The common rail pressure sensor is assumed to be defective; directly
7
sure sensor check it.
The pressure limiter is assumed to be defective mechanically; directly
8 Defective pressure limiter
check it.
The fuel injector is assumed to be defective; see Note 3 for trouble-
9 Defective fuel injector
shooting.
20-424 D275AX-5
3
1
TROUBLESHOOTING ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Note 1: Follow the procedure below to check, clean, and replace the filter and strainer.
1) Gauze filter: Disassemble and check. If the filter is clogged, clean it.
2) Gauze filter upstream strainer: If the gauze filter is clogged, also clean the upstream strainer.
3) Fuel filter: If abnormality is not yet recovered after steps 1) and 2), replace the fuel filter.
Note 2: When the low-pressure equipment is defective, check the following points:
1) Remaining fuel quantity
2) Feed pump fixing, abrasion, and filter clogging
3) Leak and clogging of low-pressure fuel pipe
4) Defective bypass valve function or other parts assembled erroneously (See the figure below.)
5) Clogged fuel filter
6) Fuel mix in oil pan (Fuel leak in head cover)
• Fuel low-pressure circuit pressure: 0.15 – 0.3MPa {1.5 – 3.0kg/cm2}
Figure: Overflow valve 1, bypass valve 2, and fuel inlet joint 3 mounting positions
• Overflow valve 1: Spring viewed from both holes
• Bypass valve 2: Spring viewed from nut hole side
• Fuel inlet joint 3: Gauze filter viewed from both holes
D275AX-5 20-425
3
1
TROUBLESHOOTING ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Note 3: When the fuel injector is defective, measure the fuel spill charge for decision.
¤ The temperature of spill fuel rises extremely (max. 90°C). Take care not to get burnt.
1) Disconnect the hose connected to the spill tube return set (in the rear of the engine).
2) Connect another hose to the end of the spill tube so that spill fuel can be poured in the container.
3) Start the engine and measure the spill fuel quantity per minute at stall for each engine speed.
★ Limit of fuel spill charge (6 cylinders in all)
Engine stall speed (rpm) Spill limit (cc/min.)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
20-426 D275AX-5
1
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))
ERRORCODE
CODE AD10MB
AD10MA (FUEL
(FUELSUPPLY
SUPPLYPUMP:
PUMP:FUNCTION
DEFECTIVEREDUCTION
FUNCTION (MA))
(MB))
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))
Action code Error code Fuel supply pump: Defective function (MA)
Trouble
CALL E03 AD10MA (Engine controller system)
Contents of
• An abnormal pressure occurred in the common rail fuel pressure.
trouble
Action of
• Runs in normal control state.
controller
Problem that
appears on • Engine output and speed reduces.
machine
Related
information

and standard
state
ERROR CODE AD10MB (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB))
Action code Error code Fuel supply pump: Function reduction (MB)
Trouble
E02 AD10MB (Engine controller system)
Contents of
• Non-pressure transmission (level 2) occurred in the fuel supply pump.
trouble
Action of
• Limits output and engine speed for operation.
controller
Problem that
machine
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
Related
mode. (Code 36400: Common rail pressure)
information

and standard
state
D275AX-5 20-427
3
1
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION
TROUBLESHOOTING IN WIRING (KA))
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN

WIRING (KA))
Action code Error code Fuel supply pump solenoid 1: Disconnection in wiring (KA)
Trouble
CALL E03 AD11KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in fuel supply pump solenoid 1 (PCV1).
trouble
Action of
• Limits engine and transmission operation.
controller
• Stops output to fuel supply pump solenoid 1 circuit.
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, running is limited to F1 and R1.
machine • If codes [AD51KA] and [AD51KB] are displayed at the same time, engine stops.
Related • The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 1.
information • Method of reproducing error code: Engine start

Defective fuel supply pump without turning starting switch ON.
1 solenoid 1 (Internal discon- PCV1 (male) Resistance
nection in wiring) Between 1 – 2 2.3 – 5.3z
Between 1 – chassis ground Min. 1Mz
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between ECN3 (female) B –
2 Resistance Max. 1z
Possible causes ing or defective contact in PCV1 (female) 1
and standard connector) Wiring harness between ECN3 (female) L –
Resistance Max. 1z
value in normal PCV1 (female) 2
state aPrepare with starting switch OFF, then carry out troubleshooting
Wiring harness between ECN3 (female) L –
PCV1 (female) 2 with chassis ground
without turning starting switch ON.
ECN3 (female) Resistance
4 Defective engine controller
Between B – L 2.3 – 5.3z
Between B L –
Min. 1Mz
chassis ground
Circuit diagram related to fuel supply pump solenoid 1
20-428 D275AX-5
(8)
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT
TROUBLESHOOTING (KB))
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))
Action code Error code Fuel supply pump solenoid 1: Short circuit (KB)
Trouble
CALL E03 AD11KB (Engine controller system)
Contents of
• Overcurrent flowed in fuel supply pump solenoid 1 (PCV1) circuit.
trouble
Action of
controller
appears on • Once machine is stopped, travel is limited to F1 and R1.
machine • When code [AD51KA] and [AD51KB] appear at the same time, engine stops.
Related • For troubleshooting of fuel supply pump solenoid 1, special adaptor (799-601-9430) is required.
information • Method of reproducing error code: Start engine.

1 solenoid 1 (Internal short PCV1 (male) Resistance
circuit) Between 4 – 5 2.3 – 5.3Ω
Between 4 – chassis ground Min. 1MΩ
Short circuit with chassis without turning starting switch ON.
2 ground in wiring harness
Wiring harness between ECN3 (female) % –
(Contact with ground circuit) Resistance Max. 1MΩ
Possible causes
and standard ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
value in normal
state Short circuit of wiring harness between ECN3
Hot short circuit in wiring
(female) % – PCV1 (female) 4 with chassis Voltage Max. 1V
3 harness
ground
(Contact with 24V circuit)
Short circuit of wiring harness between ECN3
(female) / – PCV1 (female) 5 with chassis Voltage Max. 1V
ground
4 Defective engine controller ECN3 (male) Resistance
Between % – / 2.3 – 5.3Ω
Between % / – chassis ground Min. 1MΩ
D275AX-5 20-429
4
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION
TROUBLESHOOTING IN WIRING (KA))
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN

WIRING (KA))
Action code Error code Fuel supply pump solenoid 2: Disconnection in wiring (KA)
Trouble
CALL E03 AD51KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in fuel supply pump solenoid 2 (PCV2).
trouble
Action of
controller

nection in wiring) Between 1 – 2 2.3 – 5.3Ω
ness (Disconnection in wir- Wiring harness between ECN3 (female) C –
Possible causes 2 Resistance Max. 1Ω
ing or defective contact in PCV2 (female) 1
and standard connector)
value in normal Wiring harness between ECN3 (female) M –
PCV2 (female) 2
state
cuit) Wiring harness between ECN3 (female) M –
Resistance Min. 1MΩ
Between C – M 2.3 – 5.3Ω
Between C M – chassis ground Min. 1MΩ
20-430 D275AX-5
3
1
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION
TROUBLESHOOTING IN SHORT (KB))
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN SHORT

(KB))
Action code Error code Fuel supply pump solenoid 2: Short (KB)
Trouble
CALL E03 AD51KB (Engine controller system)
Contents of
• Overcurrent occurred in fuel supply pump solenoid 2 (PCV2).
trouble
Action of
controller

nection in wiring) Between 4 – 5 2.3 – 5.3Ω
cuit) Wiring harness between ECN3 (female) & –
Possible causes Resistance Max. 1MΩ
PCV2 (female) 4
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state
Defective harness hot short Wiring harness between ECN3 (female) & –
3 Voltage Max. 1V
(Contact with 24V circuit) PCV2 (female) 4 with chassis ground
Wiring harness between ECN3 (female) 0 –
Voltage Max. 1V
Between & – 0 2.3 – 5.3Ω
Between & 0 – chassis ground Min. 1MΩ
D275AX-5 20-431
4
ERROR CODE ADA1KA (NO.1 INJECTOR SOLENOID: DISCONNECTION IN
TROUBLESHOOTING WIRING (KA))
ERROR CODE ADA1KA (NO.1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Action code Error code No.1 injector solenoid: Disconnection in wiring (KA)
Trouble
E02 ADA1KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in the No.1 injector solenoid (TWV#1) circuit.
trouble
controller • Stops output to the No.1 injector solenoid circuit.
Problem that
machine
Related
information

Defective No.1 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN1 (male) Resistance
in wiring)
Between 4 and 5 0.4 – 1.1Ω
and standard Disconnection in wiring har-
ness (Disconnection in wir- Wiring harness between ECN3 (female) ' –
value in normal 2 Resistance Max. 1Ω
ing or defective contact in CN1 (female) 4
state
connector) Wiring harness between ECN3 (female) 1 –
CN1 (female) 5
ECN3 (male) Resistance
Between ' and 1 0.4 – 1.1Ω
Circuit diagram related to No.1 injector solenoid
20-432 D275AX-5
4
TROUBLESHOOTING ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))
ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))
Action code Error code No.1, 2, and 3 injector solenoids: Short (KB)
Trouble
CALL E03 ADAZKB (Engine controller system)
Contents of • Overcurrent occurred in the No.1 injector solenoid (TWV#1), No.2 injector solenoid (TWV#2), or No.3
trouble injector solenoid (TWV#3).
Action of
• Limits engine and transmission operations.
controller
• Stops output to the No.1, 2, and 3 injector solenoid circuits.
machine • Engine output reduces extremely.
Related
information

Defective No.1 injector sole- CN1 (male) Resistance
1
noid (Internal short)
Between 4 – 5 0.4 – 1.1Ω
Between 4#5 – chassis ground Min. 1MΩ
2
Between 4 – 5 0.4 – 1.1Ω
Possible causes Defective No.3 injector sole- CN3 (male) Resistance
3
and standard noid (Internal short)
Between 4 – 5 0.4 – 1.1Ω
value in normal
state
Wiring harness between ECN3 (female) ' –
CN1 (female) 4 with chassis ground
4 ing (Contact with ground cir- Resistance Min. 1MΩ
cuit)
Wiring harness between ECN3 (female) ) –
Wiring harness between ECN3 (female) ( –
D275AX-5 20-433
4
TROUBLESHOOTING ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))

aPrepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Wiring harness between ECN3 (female) D –
Voltage Max. 1V
Wiring harness between ECN3 (female) N –
Voltage Max. 1V
Defective harness hot short Wiring harness between ECN3 (female) 6 –
5 Voltage Max. 1V
(Contact with 24V circuit) CN2 (female) 1 with chassis ground
Wiring harness between ECN3 (female) F –
Possible causes Voltage Max. 1V
and standard Wiring harness between ECN3 (female) 5 –
value in normal Voltage Max. 1V
state
Wiring harness between ECN3 (female) E –
Voltage Max. 1V
Resistance between (14) – (24) 0.4 – 1.1z
Resistance between (5), (6), (14),(15),
Min. 1Mz
(16) and (24) with chassis ground
Circuit diagram related to No.1, 2, and 3 injector solenoids
20-434 D275AX-5
(8)
ERROR CODE ADB1KA (NO.2 INJECTOR SOLENOID: DISCONNECTION IN
ERROR CODE ADB1KA (NO.2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Trouble
E02 ADB1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
Between 4#and 5 0.4 – 1.1Ω
ness (Disconnection in wir- Wiring harness between ECN3 (female) 9 –
state
connector) Wiring harness between ECN3 (female) ) –
CN2 (female) 5
Between 9 and ) 0.4 – 1.1Ω
D275AX-5 20-435
4
ERROR CODE ADC1KA (NO.3 INJECTOR SOLENOID: DISCONNECTION IN
ERROR CODE ADC1KA (NO.3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Trouble
E02 ADC1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
state
connector) Wiring harness between ECN3 (female) ( –
CN3 (female) 5
Between 8 and ( 0.4 – 1.1Ω
20-436 D275AX-5
4
ERROR CODE ADD1KA (NO.4 INJECTOR SOLENOID: DISCONNECTION IN
ERROR CODE ADD1KA (NO.4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Trouble
E02 ADD1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
state
connector) Wiring harness between ECN3 (female) = –
CN4 (female) 5
Between 3 and = 0.4 – 1.1Ω
D275AX-5 20-437
4
TROUBLESHOOTING ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))
ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))
Action code Error code No.4, 5, and 6 injector solenoids: Short (KB)
Trouble
CALL E03 ADDZKB (Engine controller system)
Contents of • Overcurrent occurred in the No.4 injector solenoid (TWV#4), No.5 injector solenoid (TWV#5), or No.6
trouble injector solenoid (TWV#6).
Action of
• Limits engine and transmission operations.
controller
• Stops output to the No.4, 5, and 6 injector solenoid circuits.
machine • Engine output reduces extremely.
Related
information

1
Between 4 – 5 0.4 – 1.1Ω
Between 4 5 – chassis ground Min. 1MΩ
2
Between 4 – 5 0.4 – 1.1Ω
Possible causes Defective No.6 injector sole- CN6 (male) Resistance
3
and standard noid (Internal short)
Between 4 – 5 0.4 – 1.1Ω
value in normal
state
Wiring harness between ECN3 (female) = –
Wiring harness between ECN3 (female) ; –
4 ing (Contact with ground cir- Resistance Min. 1MΩ
cuit)
Wiring harness between ECN3 (female) : –
Wiring harness between ECN3 (female) < –
20-438 D275AX-5
4
TROUBLESHOOTING ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))

★ Prepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Wiring harness between ECN3 (female) P –
Voltage Max. 1V
Wiring harness between ECN3 (female) Z –
Possible causes Voltage Max. 1V
and standard
Defective harness hot short Wiring harness between ECN3 (female) X –
value in normal 5 Voltage Max. 1V
state (Contact with 24V circuit) CN5 (female) 1 with chassis ground
Wiring harness between ECN3 (female) W –
Voltage Max. 1V
Wiring harness between ECN3 (female) O –
Voltage Max. 1V
Wiring harness between ECN3 (female) Y –
Voltage Max. 1V
Circuit diagram related to No.4, 5, and 6 injector solenoids
D275AX-5 20-439
3
1
ERROR CODE ADE1KA (NO. 5 FUEL INJECTOR SOLENOID: DISCONNECTION
TROUBLESHOOTING (KA))
ERROR CODE ADE1KA (NO. 5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code No. 5 fuel injector solenoid: Disconnection (KA)
Trouble
E02 ADE1KA (Engine controller system)
Contents of
• Disconnection occurred in No. 5 fuel injector solenoid (TWV#5) circuit.
trouble
controller • Stops output to No. 5 fuel injector solenoid circuit.
Problem that
appears on • Engine output lowers.
machine
Related
information

Defective No. 5 fuel injector without turning starting switch ON.
1 solenoid (Internal discon-
nection)
Between 1 – 2 0.4 – 1.1Ω
ness (Disconnection in wir- Wiring harness between ECN3 (female) X –
state
connector) Wiring harness between ECN3 (female) W –
CN5 (female) 2
Between X – W 0.4 – 1.1Ω
Circuit diagram related to No. 5 fuel injector solenoid
20-440 D275AX-5
1
ERROR CODE ADF1KA (NO. 6 FUEL INJECTOR SOLENOID: DISCONNECTION
ERROR CODE ADF1KA (NO. 6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code No. 6 fuel injector solenoid: Disconnection (KA)
Trouble
E02 ADF1KA (Engine controller system)
Contents of
• Disconnection occurred in No. 6 fuel injector solenoid (TWV#6) circuit.
trouble
controller • Stops output to No. 6 fuel injector solenoid circuit.
Problem that
appears on • Engine output lowers.
machine
Related
information

Defective No. 6 fuel injector without turning starting switch ON.
1 solenoid (Internal discon-
nection)
Between 1 – 2 0.4 – 1.1Ω
ness (Disconnection in wir- Wiring harness between ECN3 (female) O –
state
connector) Wiring harness between ECN3 (female) Y –
CN6 (female) 2
Between O – Y 0.4 – 1.1Ω
Circuit diagram related to No. 6 fuel injector solenoid
D275AX-5 20-441
3
1
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))
TROUBLESHOOTING ERROR ERROR
CODE B@BAZG
CODE B@BCNS
(ENGINE(RADIATOR
OIL: OIL PRESSURE
COOLANT:REDUCTION
OVERHEAT (NS))
(ZG))
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))

Trouble Engine oil: Oil pressure reduction (ZG) (Mechanical system)
— B@BAZG
Contents of
• During rotation of engine, engine oil pressure caution lamp flashes.
trouble
Action of
• Turns on caution buzzer. (Function of monitor panel)
controller
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related
information

Engine oil pressure reduc- It is suspected that problem causing engine oil pressure reduction is
Possible causes
1 tion (When system is in nor- occurring at present or occurred in past. Investigate cause and dam-
and standard
mal state) age condition, and correct it.
value in normal
state Carry out troubleshooting of engine oil pressure caution lamp system
Defective engine oil pres-
2 in accordance with “During running of engine, emergency caution
sure caution lamp system
item flashes” in E mode.
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS))

Trouble Radiator coolant: Overheat (NS) (Mechanical system)
— B@BCNS
Contents of
• During rotation of engine, engine water temperature caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
information

Engine water temperature It is suspected that problem causing engine water temperature over-
Possible causes
1 overheat (When system is in heat is occurring at present or occurred in past. Investigate cause and
and standard
normal state) damage condition, and correct it.
value in normal
state Defective engine water tem- Carry out troubleshooting of engine water temperature caution lamp
2 perature caution lamp sys- system in accordance with “During running of engine, emergency
tem caution item flashes” in E mode.
20-442 D275AX-5
4
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK))
TROUBLESHOOTING ERROR CODE
ERROR
B@BCZK
CODE(RADIATOR
B@CENS (POWER
COOLANT:
TRAN
LEVEL
OIL:REDUCTION
OVERHEAT (NS))
(ZK))
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK))

Trouble Radiator coolant: Level reduction (ZK) (Mechanical system)
— B@BCZK
Contents of
• When turning starting switch ON, radiator coolant caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
• Method of reproducing error code: Turn starting switch ON.
information

Radiator coolant level re- It is suspected that problem causing radiator coolant level reduction
Possible causes
1 duction (When system is in is occurring at present or occurred in past. Investigate cause and
and standard
value in normal
state Carry out troubleshooting of radiator coolant level caution lamp sys-
Defective radiator coolant
2 tem in accordance with “When turning starting switch ON, basic
level caution lamp system
check item flashes” in E mode.
ERROR CODE B@CENS (POWER TRAN OIL: OVERHEAT (NS))

Trouble Power train oil: Overheat (NS) (Mechanical system)
— B@CENS
Contents of
• During rotation of engine, power train oil temperature caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, power train may be damaged.
machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible causes
and standard
value in normal
state Defective power train oil Carry out troubleshooting of power train oil temperature caution lamp
2 temperature overheat cau- system in accordance with “During running of engine, emergency
tion lamp system caution item flashes” in E mode.
D275AX-5 20-443
4
ERROR CODE B@CHZG (HSS CHARGE OIL: OIL PRESSURE REDUCTION
ERROR CODE B@CHZG (HSS CHARGE OIL: OIL PRESSURE REDUCTION
(ZG))
TROUBLESHOOTING ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS))
(ZG))
ERROR CODE B@CHZG (HSS CHARGE OIL: OIL PRESSURE REDUCTION (ZG))

Trouble HSS charge oil: Oil pressure reduction (ZG) (Mechanical system)
— B@CHZG
Contents of
• During rotation of engine, HSS charge pressure caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, HSS pump or motor may be damaged.
machine
Related
information

HSS charge pressure re- It is suspected that problem causing HSS charge pressure reduction
Possible causes
1 duction (When system is in is occurring at present or occurred in past. Investigate cause and
and standard
value in normal
state Carry out troubleshooting of HSS charge pressure caution lamp sys-
Defective HSS charge pres-
2 tem in accordance with “During running of engine, emergency caution
sure caution lamp system
item flashes” in E mode.
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS))

Trouble Hydraulic oil: Overheat (NS) (Mechanical system)
— B@HANS
Contents of
• During rotation of engine, hydraulic oil caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil temperature It is suspected that problem causing hydraulic oil temperature over-
Possible causes
and standard
value in normal
state Defective hydraulic oil tem- Carry out troubleshooting of hydraulic oil temperature caution lamp
2 perature caution lamp sys- system in accordance with “During running of engine, emergency
tem caution item flashes” in E mode.
20-444 D275AX-5
4
TROUBLESHOOTING ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA))
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA))

Trouble Battery relay: Disconnection (KA) (Steering controller system)
— D110KA
Contents of
• Current does not flow when outputting it to battery relay circuit.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears 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.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing error code: Switch starting switch from ON to OFF.

Defective battery relay (In-
1 Battery relay Continuity
ternal disconnection)
Between terminals SW –
Continue
ground terminal
ness (Disconnection in wir- Wiring harness between STCN3 (female) 4 –
Possible causes 2 Resistance Max. 1Ω
ing or defective contact in battery relay SW terminal
and standard connector)
value in normal Wiring harness between battery relay ground
terminal – chassis ground
state
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring carry out troubleshooting.
3 harness (Contact with 24V Short circuit of wiring harness between STCN3
circuit) (female) 4 – battery relay terminal SW – KEY Voltage Max. 1V
(female) 4 with chassis ground
4 Defective steering controller
STCN3 (female) Continuity
Between 4 – chassis ground Continue
Circuit diagram related to battery relay
D275AX-5 20-445
3
1
TROUBLESHOOTING ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB))
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB))
Action code Error code Battery relay: Short circuit (KB)

Trouble
— D110KB (Steering controller system)
Contents of
• Abnormal current flowed to battery relay circuit when outputting it.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears 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.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing error code: Switch starting switch from ON to OFF.

Battery relay Continuity/resistance
Defective battery relay
1 Between terminals SW –
(Internal short circuit) Continue
ground terminal
Between terminal SW –
Min. 1MΩ
Possible causes chassis ground
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Short circuit with chassis without turning starting switch ON.
state 2 ground in wiring harness Short circuit of wiring harness between STCN3
(Contact with ground circuit) (female) 4 – battery relay terminal SW – KEY Resistance Min. 1MΩ
(female) 4 with chassis ground
3 Defective steering controller STCN3 Starting switch Voltage
Between 4 –
ON 20 – 30V
chassis ground
Circuit diagram related to battery relay
20-446 D275AX-5
3
1
TROUBLESHOOTING ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
Action code Error code Neutral safety relay: Disconnection (KA)

Trouble
E02 D130KA (Transmission controller system)
Contents of
• 24V is not generated when ground of neutral safety relay circuit is interrupted.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears 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)
Related
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position).
information
aThis error code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-
ondary side (contact side)

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with
1
(CB3) ground.
Defective neutral safety re- without turning starting switch ON.
2
lay (Internal disconnection) NSF (male) Resistance
Between 1 – 2 200 – 400z
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) 8 –
tion in wiring or defective NSF (female) 2
Possible causes contact in connector) Wiring harness between NSF (female) 1 –
and standard Resistance Max. 1z
CB3 (1)
value in normal
Short circuit with chassis Short circuit of wiring harness between
4 ground in wiring harness TMCN2 (female) 8 – NSF (female) 2 with Resistance Min. 1Mz
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between NSF
Resistance Min. 1Mz
(female) 1 – CB3 (1) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
Defective transmission con- TMCN2 Parking lever Voltage
5
troller
Between 8 – Lock position Max. 1V
chassis ground Free position 20 – 30V
D275AX-5 20-447
1
(5)
TROUBLESHOOTING ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
Circuit diagram related to neutral safety relay
20-448 D275AX-5
1
TROUBLESHOOTING ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))
Action code Error code Neutral safety relay: Short circuit (KB)
Trouble
E02 D130KB (Transmission controller system)
Contents of
• Abnormal current flowed in neutral safety relay circuit at the time of ground output.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears 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)
Related
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position).
information
aThis error code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-

Defective neutral safety re- without turning starting switch ON.
1
lay (Internal short circuit) NSF (male) Resistance
Between 1 – 2 200 – 400z
Possible causes carry out troubleshooting.
and standard
2 harness Short circuit of wiring harness between
value in normal
(Contact with 24V circuit) TMCN2 (female) 8 – NSF (female) 2 with Voltage Max. 1V
state
chassis ground
Defective transmission con- TMCN2 Parking lever Voltage
3
troller
Between 8 – Lock position Max. 1V
chassis ground Free position 20 – 30V
Circuit diagram related to neutral safety relay
D275AX-5 20-449
1
(5)
TROUBLESHOOTING ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Action code Error code Back-up alarm relay: Disconnection

Trouble
E01 D161KA (Transmission controller system)
Contents of
• 24V is not generated when ground output of neutral safety relay circuit is interrupted.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears 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)
Related • Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral posi-
information tion).
aThis error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-

If fuse is burnout, circuit probably has short circuit with chassis
1 Defective fuse FS4-1
ground.
Defective back-up alarm re- without turning starting switch ON.
2
lay (Internal disconnection) BKA (male) Resistance
Between 1 – 2 200 – 400z
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) H –
tion in wiring or defective BKA (female) 2
Possible causes contact in connector) Wiring harness between BKA (female) 1 –
Resistance Max. 1z
and standard FS4-1 outlet port
value in normal aPrepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Short circuit of wiring harness between
Short circuit with chassis
TMCN2 (female) H – BKA (female) 2 with Resistance Min. 1Mz
chassis ground
(Contact with ground circuit)
Short circuit of wiring harness between BKA
(female) 1 – FS4-1 outlet port with chassis Resistance Min. 1Mz
ground
5
troller
Between H – Neutral position 20 – 30V
chassis ground Reverse position Max. 1V
20-450 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Circuit diagram related to back-up alarm relay
D275AX-5 20-451
4
TROUBLESHOOTING ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Action code Error code Back-up alarm relay: Short circuit (KB)
Trouble
E01 D161KB (Transmission controller system)
Contents of
• Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears 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)
Related • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse posi-
information tion).
aThis error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-

Defective back-up alarm re- without turning starting switch ON.
1
lay (Internal short circuit) BKA (male) Resistance
Between 1 – 2 200 – 400z
Possible causes
and standard
2 harness (Contact with 24V Short circuit of wiring harness between
value in normal
circuit) TMCN2 (female) H – BKA (female) 2 with Voltage Max. 1V
state
chassis ground
3 TMCN2 Parking lever Voltage
troller
Between H – Neutral position 20 – 30V
chassis ground Reverse position Max. 1V
20-452 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Circuit diagram related to back-up alarm relay
D275AX-5 20-453
4
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY
TROUBLESHOOTING RELAY: SHORT CIRCUIT (KB))
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT
CIRCUIT (KB))
Action code Error code Engine controller load power supply relay: Short circuit (KB)
Trouble
CALL 04 D1D0KB (Engine controller system)
Contents of
• Voltage is generated in controller load power supply circuit when starting switch is turned OFF.
trouble
Problem that
appears on
• Once machine is stopped, it cannot travel any more.
machine
• Method of reproducing error code: Turn starting switch OFF.
Related
★ This error code detects abnormality in secondary side (contact side) of engine controller load power
information
supply relay, but not in primary side (coil side)

Defective engine controller without turning starting switch ON.
1 load power supply relay (In-
PPR (male) Resistance
ternal short circuit)
Between 3 – 5 Min. 1MΩ
Possible causes carry out troubleshooting.
and standard
2 harness (Contact with 24V Short circuit of wiring harness between ECN3
value in normal
circuit) (female) 1, 2, K – PPR (female) 3 with Voltage Max. 1V
state
chassis ground
with starting switch OFF or ON.
3 Defective engine controller ECN3 Starting switch Voltage
Between 1, 2, K – OFF position Max. 1V
chassis ground ON position Max. 8V
20-454 D275AX-5
3
1
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY:
TROUBLESHOOTING SHORT CIRCUIT (KB))
Circuit diagram related to engine controller
D275AX-5 20-455
4
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION:
TROUBLESHOOTING DEFECTIVE COMMUNICATION (KR))
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE

COMMUNICATION (KR))
Action code Error code Monitor panel CAN communication: Defective communication (KR)
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
• Monitor panel cannot recognize steering controller with CAN communication circuit.
trouble
Problem that • System may not operate normally.
machine • Once machine is stopped, travel is limited to F1 and R1.
Related
information

Wiring harness between S04 (female) 4, 5 –
Disconnection in wiring har- STCN2 (female) 9 – TMCN2 (female) 9 –
ness (Disconnection in wir- ECN2 (female) 9 – CA1 (female) $ – CA2 (fe-
1
ing or defective contact in male) $
connector) Wiring harness between S04 (female) 6 7 –
STCN2 (female) / – TMCN2 (female) /#–
ECN2 (female) / – CA1 (female) % – CA2 (fe-
male) %
Short circuit of wiring harness between S04
(female) 4, 5 – STCN2 (female) 9 – TMCN2
Short circuit with chassis Resistance Min. 1MΩ
(female) 9 – ECN2 (female) 9 – CA1 (female)
$ – CA2 (female) $ with chassis ground
Possible causes Short circuit of wiring harness between S04
and standard (female) 6, 7 – STCN2 (female) / – TMCN2
value in normal (female) / – ECN2 (female) / – CA1 (female)
state % – CA2 (female) % with chassis ground
(female) 4, 5 – STCN2 (female) 9 – TMCN2
Hot short circuit in wiring Voltage Max. 1V
(female) 9 – ECN2 (female) 9 – CA1 (female)
3 harness (Contact with 24V
$ – CA2 (female) $ with chassis ground
circuit)
hort circuit of wiring harness between S04 (fe-
male) 6, 7 – STCN2 (female) / – TMCN2
Voltage Max. 1V
(female) / – ECN2 (female) / – CA1 (female)
% – CA2 (female) % with chassis ground
Defective CAN terminal re- without turning starting switch ON.
4
sistance CA1 (male), CA2 (male) Resistance
Between $ – % 40 – 80Ω
If no problem is found in causes 1 to 4, it is suspected that monitor
Defective monitor panel or
5 panel or steering controller is defective. (Troubleshooting cannot be
defective steering controller
carried out since it is internal defect.)
20-456 D275AX-5
4
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION:
TROUBLESHOOTING DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to CAN communication
D275AX-5 20-457
4
ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: SOURCE VOLTAGE
TROUBLESHOOTING REDUCTION (INPUT) (KK))
ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: SOURCE VOLTAGE

REDUCTION (INPUT) (KK))
Action code Error code Transmission controller power supply: Source voltage reduction
Trouble
CALL E04 DAQ0KK (input) (KK) (Transmission controller system)
Contents of
• Source voltage of transmission controller is below 17V.
trouble
• Monitor panel may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
• Charge level (voltage) of battery can be checked in monitoring mode.
Related
(Code 03200: Battery voltage)
information

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with chas-
1
(CB3) sis ground.
If fusible link is burnout, circuit probably has short circuit with chassis
2 Defective fusible link (96A)
ground.
Disconnection in wiring har- Wiring harness between TMCN3 (female) 1,
Resistance Max. 1z
ness (Disconnection in wir- A – CB3 (1)
3
ing or defective contact in Wiring harness between CB3 (2) – fusible link
Resistance Max. 1z
connector) – battery relay terminal C
Possible causes
Wiring harness between TMCN3 (female) K
U V W – chassis ground
value in normal
TMCN3 (female) 1, A – CB3 (1) with chassis Resistance Min. 1Mz
ground
Short circuit of wiring harness between CB3
(2) – fusible link – battery relay terminal C with Resistance Min. 1Mz
chassis ground
Defective transmission con- carry out troubleshooting.
5
troller TMCN3 Voltage
Between 1, A – K, U, V, W 20 – 30V
20-458 D275AX-5
1
(5)
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN
TROUBLESHOOTING CONTROLLER (KT))
Circuit diagram related to transmission controller power supply
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN

CONTROLLER (KT))
Action code Error code Transmission controller: abnormality in controller (KT)

Trouble
E02 DAQ0KT (Transmission controller system)
Contents of
• Information of ROM (nonvolatile storage) of transmission controller is not normal.
trouble
controller • Sets default internal adjustment value.
Problem that
appears on • Gear shift feeling of transmission may become worse.
machine
Related
information

and standard Troubleshooting cannot be carried out since it is internal defect.
value in normal 1 (It is no problem even if you use controller unless no visible problem
troller
state appears on machine.)
D275AX-5 20-459
4
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER
TROUBLESHOOTING POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER POWER

SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Transmission controller potentiometer power supply: Source voltage
Trouble
CALL 03 DAQ5KK reduction (input) (KK) (Transmission controller system)
Contents of • Voltage of 5V power supply circuit of transmission controller sensor is below 4.5V or above 5.5V.
trouble • Abnormal current flowed in 5V power supply circuit of transmission controller sensor.
Action of
• Stops output to 5V power supply circuit if abnormal voltage flows
controller
machine • Once machine is stopped, travel is limited to F1 an R1.
Related
information

TL1 (male) Resistance
Defective forward-reverse Between L – J 2kz ± 20%
1 potentiometer (Internal Sensor 1 (FR3) Between L –
Min. 1Mz
short circuit) chassis ground
Between O – Q 2kz ± 20%
Sensor 2 (FR4) Between O –
Min. 1Mz
chassis ground
Possible causes aPrepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit with chassis without turning starting switch ON.
value in normal 2 ground in wiring harness
(Contact with ground circuit) TMCN1 (female) L – TL1 (female) L – TL1 Resistance Min. 1Mz
state
(female) O with chassis ground
3 harness (Contact with 24V Short circuit of wiring harness between
circuit) TMCN1 (female) L – TL1 (female) L – TL1
(female) O with chassis ground
Voltage Max. 1V
4
Between L – K 4.5 – 5.5V
20-460 D275AX-5
1
(5)
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER
TROUBLESHOOTING POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Circuit diagram related to transmission controller 5V power supply
D275AX-5 20-461
1
(5)
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER
TROUBLESHOOTING SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:

SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Transmission controller sensor power supply: Source voltage reduc-
Trouble
E01 DAQ6KK tion (input) (KK) (Transmission controller system)
Contents of • Voltage of 24V power supply circuit of transmission controller sensor is below 17V or above 30V.
trouble • Abnormal current flowed in 24V power supply circuit of transmission controller sensor.
Action of
• Stops output to 24V power supply circuit if abnormal voltage flows
controller
Problem that
appears on • Oil pressure of work equipment cannot be monitored in service mode.
machine
Related
information

It is internal defect if error code lights on (reset dis-
Defective work equipment
play) when disconnecting right connector.
large pump oil pressure HHP
1 aDisconnect connector with starting switch OFF, then
sensor (Internal short cir- connector
turn starting switch ON and carry out troubleshoot-
cuit)
ing.
Possible causes aPrepare with starting switch OFF, then carry out troubleshooting
value in normal
(Contact with ground circuit) TMCN1 (female) F – HHP (female) B with Resistance
state
Min. 1Mz
chassis ground
3
F–K 20 – 30V
Circuit diagram related to transmission controller 24V power supply
20-462 D275AX-5
1
(5)
ERROR CODE DAQ9KQ (TRANSMISSION CONTROLLER TYPE COLLATION:
TROUBLESHOOTING TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE DAQ9KQ (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE

SELECT SIGNAL INCONSISTENCY (KQ))
Action code Error code Transmission controller type collation/type select signal inconsistency
Trouble
CALL E04 DAQ9KQ (KQ) (Transmission controller system)
Contents of
• Internal spec. setting of transmission controller is inconsistent with spec. set signal.
trouble
Action of
• Stops all outputs to transmission controller.
controller
• Limits operation of engine, transmission, and brake.
Problem that • Machine does not operate at all.
machine • Once machine is stopped, it cannot travel any more.
Related
information

It is normal if error code lights on (reset display) after carrying out ad-
1 justment mode.
troller adjustment
• Adjustment code: 0003: Transmission controller spec.
Possible causes Disconnection in wiring har- ★ Prepare with starting switch OFF, carry out troubleshooting without
and standard ness (Disconnection in wir- turning starting switch ON.
2
value in normal ing or defective contact in Short circuit of wiring harness between
state connector) TMCN3 (female) # with chassis ground
3
Between # – chassis ground Max. 1V
Circuit diagram related to transmission controller type select
D275AX-5 20-463
4
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN
COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN
TROUBLESHOOTING OBJECTIVE COMPONENT SYSTEM) (KR))
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN COMMUNICATION:

DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Transmission controller CAN communication: Defective communication (Abnor-
Trouble
CALL E03 DAQRKR mality in objective component system) (KR) (Transmission controller system)
Contents of • Transmission controller cannot recognize monitor panel, steering controller, or engine controller with
trouble CAN communication circuit.
Related
information

STCN2 (female) V – TMCN2 (female) V –
ECN2 (female) V – CA1 (female) A – CA2 (fe-
Disconnection in wiring har-
Resistance Max. 1z
male) A
ness (Disconnection in wir-
1
ing or defective contact in
STCN2 (female) L – TMCN2 (female) L –
ECN2 (female) L – CA1 (female) B – CA2 (fe-
Resistance Max. 1z
male) B
(female) 1, 2 – STCN2 (female) V – TMCN2
Short circuit with chassis Resistance Min. 1Mz
(female) V – ECN2 (female) V – CA1 (female)
A – CA2 (female) A with chassis ground
Possible causes (female) 3, 4 – STCN2 (female) L – TMCN2
Resistance Min. 1Mz
and standard (female) L – ECN2 (female) L – CA1 (female)
value in normal B – CA2 (female) B with chassis ground
state aPrepare with starting switch OFF, then turn starting switch ON and
3 harness
(female) 3, 4 – STCN2 (female) L – TMCN2
Voltage Max. 1V
(female) L – ECN2 (female) L – CA1 (female)
B – CA2 (female) B with chassis ground
4
Between A – B 40 – 80z
Defective monitor panel, de- If no problem is found in causes 1 to 4, it is suspected that monitor
fective engine controller, de- panel, engine controller, transmission controller, or steering controller
5 fective transmission
controller or defective steer- is defective. (Troubleshooting cannot be carried out since it is internal
ing controller defect.)
20-464 D275AX-5
1
(5)
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN
D275AX-5 20-465
1
(5)
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER SNET
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER SNET COMMUNICATION:

Action code Error code Transmission controller SNET communication: Defective communication (Abnor-
Trouble
E01 DAQSKR mality in objective component system) (KR) (Transmission controller system)
Contents of
• Transmission controller cannot recognize S-NET.
trouble
Action of
• Takes no particular action.
controller
Problem that
appears on • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

ness (Disconnection in wir- without turning starting switch ON.
1
ing or defective contact in Wiring harness between TMCN2 (female) K –
Resistance Max. 1z
connector) S01 (female) 8
2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN2 (female) K – S01 (female) 8 with Resistance Min. 1Mz
chassis ground
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal 3 harness Short circuit of wiring harness between
state (Contact with 24V circuit) TMCN2 (female) K – S01 (female) 8 with Voltage Max. 1V
chassis ground
Defective monitor panel carry out troubleshooting.
4
(Switch module) S01 Voltage
Between 8 – chassis ground 6 – 9V
5
Between K – U 6 – 9V
Circuit diagram related to S-NET communication
20-466 D275AX-5
1
(5)
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
Action code Error code Engine controller: Abnormality in controller (KT)

Trouble
CALL E03 DB20KT (Engine controller system)
Contents of
• Problem occurred in engine controller.
trouble
Action of
• Cannot operate fuel injector solenoid well or stops output.
controller
Problem that • Engine may stop during operation or engine may not start.
Related
information

Possible causes Disconnection in wiring har-
and standard ness (Disconnection in wir-
1 Short circuit of wiring harness between
value in normal ing or defective contact in
state connector) ECN3 (female) A, U, V with chassis Resistance Max. 1z
ground
2 Defective engine controller Troubleshooting cannot be carried out since it is internal defect.
D275AX-5 20-467
(8)
1
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN
Circuit diagram related to engine controller power supply
20-468 D275AX-5
1
20
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY:
TROUBLESHOOTING SOURCE VOLTAGE REDUCTION (INPUT) (KK))
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE

VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Engine controller load power supply: Source voltage reduction (input)
Trouble
CALL E04 DB22KK (KK) (Engine controller system)
Contents of
• Load source voltage of engine controller is below 17V.
trouble
Problem that • Engine may stop during operation or engine may not start.
Related
information
aThis error code detects abnormality in secondary side (contact side) of engine controller load power
supply relay, but not in primary side (coil side)

If fuse is burnout, circuit probably has short circuit with chassis
1 Defective fuse (FS2-2)
ground.
ground.
aPrepare with starting switch OFF, turn starting switch ON and carry
Defective engine controller out troubleshooting.
3 load power supply relay If error code lights on (reset display) by replacing right
(Internal disconnection) connector with other relay, engine controller load power PPR
supply relay is defective.
Disconnection in wiring har- Wiring harness between ECN3 (female) 1, 2,
Resistance Max. 1z
ness (Disconnection in wir- K – PPR (female) 3
Possible causes 4
ing or defective contact in Wiring harness between PPR (female) 5 –
connector) FS2-2 outlet port
value in normal
state Wiring harness between FS2-2 inlet port – fus-
Resistance Max. 1z
ible link – battery relay terminal C
Short circuit with chassis (female) C, I – KEY (female) 1 with chassis Resistance Min. 1Mz
5 ground in wiring harness ground
(Contact with ground circuit) Short circuit of wiring harness between KEY
Resistance Min. 1Mz
(female) 5 – CB6 (1) with chassis ground
Wiring harness between CB6 (2) – fusible link
– battery relay terminal H
out troubleshooting.
ECN3 Voltage
Between 1, 2, K – A, U, V 20 – 30V
D275AX-5 20-469
1
(5)
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY:
Circuit diagram related to engine controller power supply
20-470 D275AX-5
1
(5)
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE
TROUBLESHOOTING SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL
INCONSISTENCY (KQ))
Action code Error code Engine controller type select: Type select signal inconsistency (KQ)
Trouble
CALL E03 DB29KQ (Engine controller system)
Contents of • Type select signal directly acquired by engine controller is inconsistent with type select signal acquired
trouble via communication.
Action of
• Controls it as default-set type.
controller
Problem that • Machine does not provide normal output.
Related
information

1
ing or defective contact in Wiring harness between ECN1 (female) 3 –
Possible causes Resistance Max. 1Ω
connector) chassis ground
and standard
★ Prepare with starting switch OFF, turn starting switch ON and carry
value in normal
state
ECN1 Voltage
Between 3 – chassis ground Max. 1V
Between G, M –
20 – 30V
chassis ground
Circuit diagram related to engine controller type select
D275AX-5 20-471
3
1
ERROR CODE DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH
TROUBLESHOOTING SIGNAL: MALFUNCTION (MA))
ERROR CODE DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:

MALFUNCTION (MA))
Action code Error code Fuel injection amount adjustment switch signal: Malfunction (MA)
Trouble
CALL E03 DB2AMA (Engine controller system)
Contents of
• Fuel injection amount adjustment switch is not set at correct position.
trouble
Problem that • Fuel injection amount adjustment setting cannot be changed.
Related
information

Possible causes Defective fuel injection
If both fuel injection amount adjustment switches 1 and 2 are set at
and standard 1 amount adjustment switch
[F], fuel injection amount adjustment switch setting is defective.
value in normal setting
state If no problem is found in above cause, it is suspected that engine con-
troller is defective.
20-472 D275AX-5
4
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION:
DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT
TROUBLESHOOTING SYSTEM) (KR))
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE

COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Engine controller CAN communication: Defective communication (Abnormality in
Trouble
CALL E03 DB2RKR objective component system) (KR) (Transmission controller and realer system)
Contents of • Engine controller cannot recognize transmission controller or steering controller with CAN communi-
trouble cation circuit.
Related
information

STCN2 (female) V – TMCN2 (female) V –
ECN2 (female) V – CA1 (female) A – CA2 (fe-
Resistance Max. 1z
male) A
1
connector) Wiring harness between S04 (female) 3, 4 –
Resistance Max. 1z
male) B
Possible causes
and standard Resistance Min. 1Mz
value in normal B – CA2 (female) B with chassis ground
state
3 harness
Voltage Max. 1V
4
Defective engine controller,
If no problem is found in causes 1 to 4, it is suspected that engine con-
defective transmission con-
5 troller, transmission controller, or steering controller is defective.
troller, or defective steering
(Troubleshooting cannot be carried out since it is internal defect.)
controller
D275AX-5 20-473
1
(5)
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION:
20-474 D275AX-5
1
(5)
ERROR CODE DB30KK (STEERING CONTROLLER: SOURCE VOLTAGE
TROUBLESHOOTING REDUCTION (INPUT) (KK))
ERROR CODE DB30KK (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION

(INPUT) (KK))
Action code Error code Steering controller power supply: Source voltage reduction (input)
Trouble
CALL E04 DB30KK (KK) (Steering controller system)
Contents of
• Source voltage of steering controller is below 17V.
trouble
• Monitor panel may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
Related
information

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with chas-
1
(CB1) sis ground.
ground.
Disconnection in wiring har- Wiring harness between STCN3 (female) 1 A
Resistance Max. 1z
ness (Disconnection in wir- – CB1 1
3
ing or defective contact in Wiring harness between CB1 (2) – fusible link
Resistance Max. 1z
Possible causes connector) – battery relay terminal C
and standard Wiring harness between STCN3 (female) K,
Resistance Max. 1z
value in normal U, V, W – chassis ground
Short circuit with chassis Short circuit of wiring harness between STCN3
Resistance Min. 1Mz
4 ground in wiring harness (female) 1, A – CB1 (1) with chassis ground
(Contact with ground circuit) Short circuit of wiring harness between CB1
(2)– fusible link – battery relay terminal C with Resistance Min. 1Mz
chassis ground
STCN3 Voltage
Between 1, A – K, U, V, W 20 – 30V
D275AX-5 20-475
1
(5)
ERROR CODE DB30KT (STEERING CONTROLLER: ABNORMALITY IN
Circuit diagram related to steering controller power supply
ERROR CODE DB30KT (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER

(KT))
Action code Error code Steering controller power supply: Abnormality in controller (KT)
Trouble
E01 DB30KT (Steering controller system)
Contents of
• Information of ROM (nonvolatile storage) of steering controller is not normal.
trouble
Action of
• Sets default internal adjustment value.
controller
Problem that
• Steering performance may be reduced.
appears on
• Brake performance may be reduced.
machine
Related
information

and standard Troubleshooting cannot be carried out since it is internal defect. (It is
value in normal 1 Defective steering controller no problem even if you use controller unless no visible problem ap-
state pears on machine.)
20-476 D275AX-5
4
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY:

SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Steering controller potentiometer power supply: Source voltage re-
Trouble
CALL E03 DB35KK duction (input) (KK) (Steering controller system)
Contents of • Voltage of 5V power supply circuit of steering controller sensor is below 4.5V or above 5.5V.
trouble • Abnormal current flowed in 5V power supply circuit of steering controller sensor.
Action of
• Stops output to 5V power supply circuit if abnormal voltage flows.
controller
Related
information

It is internal defect if error code lights on (reset display)
Defective brake potentiome- when disconnecting right connector. BRK
1
ter (Internal short circuit) aDisconnect connector with starting switch OFF, then connector
turn starting switch ON and carry out troubleshooting.
Defective acceleration sen- when disconnecting right connector. SS3
2
sor (Internal short circuit) aDisconnect connector with starting switch OFF, then connector
Defective steering potenti- Between A – G 2kz ± 20%
3 ometer (Internal short cir- Sensor 1 (ST1) Between A –
cuit) Min. 1Mz
chassis ground
Possible causes Between M – F 2kz ± 20%
and standard Sensor 2 (ST2) Between M –
Min. 1Mz
value in normal chassis ground
(female) L – TL1 (female) A – TL1 (female) M
Short circuit of wiring harness between STCN1
– BRK (female) C – SS3 (female) 1 with chas-
(Contact with ground circuit) Resistance Min. 1Mz
sis ground
(female) L – TL1 (female) A – TL1 (female) M
5 harness (Contact with 24V Short circuit of wiring harness between STCN1
– BRK (female) C – SS3 (female) 1 with chas-

circuit) Voltage Max. 1V
sis ground
STCN1 Voltage
Between L – K 4.5 – 5.5V
D275AX-5 20-477
1
(5)
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER
Circuit diagram related to steering controller 5V power supply
20-478 D275AX-5
1
(5)
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER SUPPLY:
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE

VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Steering controller sensor power supply: Source voltage reduction
Trouble
CALL E03 DB36KK (input) (KK) (Steering controller system)
Contents of • Voltage of 24V power supply circuit of steering controller sensor is below 17V or above 30V.
trouble • Abnormal current flowed in 24V power supply circuit of steering controller sensor.
Action of
• Stops output of 24V power supply circuit if abnormal voltage flows.
controller
Related
information

Defective blade pitch angle
when disconnecting right connector. PT1
1 sensor (Internal short cir-
aDisconnect connector with starting switch OFF, then connector
cuit)
Defective HSS oil pressure
when disconnecting right connector. ST1
2 sensor A (Internal short cir-
aDisconnect connector with starting switch OFF, then connector
cuit)
Possible causes It is internal defect if error code lights on (reset display)
Defective HSS oil pressure
and standard when disconnecting right connector. ST2
3 sensor B (Internal short cir-
value in normal aDisconnect connector with starting switch OFF, then connector
cuit)
state turn starting switch ON and carry out troubleshooting.
(female) F – PAS (female) C – ST1 (female) Resistance Min. 1Mz
Short circuit of wiring harness between STCN1
B – ST2 (female) B with chassis ground
STCN1 Voltage
Between F – K 20 – 30V
D275AX-5 20-479
1
(5)
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER SUPPLY:
Circuit diagram related to steering controller 24V power supply
20-480 D275AX-5
1
(5)
ERROR CODE DB39KQ (STEERING CONTROLLER TYPE COLLATION: TYPE
TROUBLESHOOTING SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE DB39KQ (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT

SIGNAL INCONSISTENCY (KQ))
Action code Error code Steering controller type collation: Type select signal inconsistency
Trouble
CALL E04 DB39KQ (KQ) (Steering controller system)
Contents of
• Internal spec. setting of steering controller is inconsistent with spec. set signal.
trouble
Action of
• Stops all outputs of steering controller.
controller
Related
information

It is normal if error code indicates P (reset display) after carrying out
Defective steering controller
1 adjustment mode.
adjustment
• Adjustment code: 0002 (Steering controller spec. set)
Possible causes Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting
and standard ness (Disconnection in wir- without turning starting switch ON.
2
value in normal ing or defective contact in Wiring harness between STCN3 (female) J –
Resistance Max. 1z
state connector) chassis ground
Prepare with starting switch OFF, turn starting switch ON and carry
STCN3 Voltage
Between J – chassis ground Max. 1V
Circuit diagram related to steering controller type select
D275AX-5 20-481
1
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION:
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE

COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Steering controller CAN communication: Defective communication (Abnormality
Trouble
CALL E03 DB3RKR in objective component system) (KR) (Steering controller system)
Contents of • Steering controller cannot recognize monitor panel, transmission controller, or engine controller with
trouble CAN communication circuit.
Related
information

Between wiring harness between S04 (female)
1, 2 – STCN2 (female) V – TMCN2 (female)
V – ECN2 (female) V – CA1 (female) A –
Resistance Max. 1z
CA2 (female) A
1
Resistance Max. 1z
male)
Possible causes (female) 3, 4 – STCN2 (female) L – TMCN2
Resistance Min. 1Mz
and standard
value in normal
state aPrepare with starting switch OFF, turn starting switch ON and carry
circuit)
Voltage Max. 1V
4
Defective monitor panel, de-
If no problem is found in causes 1 to 4, it is suspected that monitor
fective engine controller, de-
panel, engine controller, transmission controller, or steering controller
5 fective transmission
is defective.(Troubleshooting cannot be carried out since it is internal
controller or defective steer-
defect.)
ing controller
20-482 D275AX-5
1
(5)
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION:
D275AX-5 20-483
1
(5)
ERROR CODE DB3SKR (STEERING CONTROLLER SNET COMMUNICATION:
ERROR CODE DB3SKR (STEERING CONTROLLER SNET COMMUNICATION:

Action code Error code Steering controller SNET communication: Defective communication (Abnormali-
Trouble
E01 DB3SKR ty in objective component system) (KR) (Steering controller system)
Contents of
• Transmission controller cannot recognize S-NET.
trouble
Action of
• Takes no particular action.
controller
Problem that
appears on • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

1
ing or defective contact in Wiring harness between STCN2 (female) K –
Resistance Max. 1z
connector) S01 (female) 8
2 ground in wiring harness Short circuit of wiring harness between STCN2
(Contact with ground circuit) (female) K – S01 (female) 8 with chassis Resistance Min. 1Mz
ground
Possible causes aPrepare with starting switch OFF, turn starting switch ON and carry
and standard out troubleshooting.
value in normal 3 harness (Contact with 24V Short circuit of wiring harness between STCN2
state circuit) (female) K – S01 (female) 8 with chassis Voltage Max. 1V
ground
Defective monitor panel out troubleshooting.
4
Between 8 – chassis ground 6 – 9V
STCN2 Voltage
Between K – U 6 – 9V
Circuit diagram related to S-NET communication
20-484 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB))

Trouble Starting switch: Short circuit (KB) (Engine controller system)
CALL E04 DD11KB
Contents of
• Signal C of starting switch is input during running of engine.
trouble
Related
information

Defective adjustment of with starting switch OFF or ON.
1
steering controller KEY (male) Starting switch Resistance
Between 5 – 3 OFF Min. 1Mz
Possible causes
and standard Short circuit of wiring harness between ECN1
value in normal (female) J – NSF (female) 5 with chassis Voltage Max. 1V
state ground
circuit)
Short circuit of wiring harness between NSF
(female) 3 – KEY (female) 3 with chassis Voltage Max. 1V
ground
ECN1 Voltage
Between J – chassis ground Max. 1V
Circuit diagram related to starting switch signal C
D275AX-5 20-485
1
(8)
TROUBLESHOOTING ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))

Trouble Shift up switch: Disconnection (KA) (Transmission controller system)
E02 DD12KA
Contents of
• Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
trouble
controller • Recognizes that switch is not pressed.
Problem that
• Shift up is not possible.
appears on
• Auto shift down does not function.
machine
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
information (Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.

Shift up switch
TL1 (male)
Defective shift up switch OFF (Release) ON (Press)
1
(Internal disconnection)
N–U
Resistance between
Max. 1z Min. 1Mz
N–B
Resistance between
Min. 1Mz Max. 1z

Disconnection in wiring har- Wiring harness between TMCN1 (female) 6 – Resistance
ness (Disconnection in wir- TL1 (female) U
Max. 1z
2
ing or defective contact in Wiring harness between TMCN2 (female) [ –
TL1 (female) B
Resistance Max. 1z
connector)
Wiring harness between TMCN1 (female) 4,
@ – TL1 (female) N
Possible causes Resistance Max. 1z
and standard
value in normal aPrepare with starting switch OFF, turn starting switch ON and carry
state out troubleshooting.
TMCN1 (female) 6 – TL1 (female) U with

Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) [ – TL1 (female) B with

Voltage Max. 1V
chassis ground
Shift up switch
TMCN1,TMCN2
OFF (Release) ON (Press)
Defective transmission con- Voltage between
4
troller TMCN1 6 – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 [ – TMCN1 5 – 11V Max. 1V
4, @
20-486 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))
Circuit diagram related to shift up switch and shift down switch
D275AX-5 20-487
4
TROUBLESHOOTING ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))

Trouble Shift up switch: Short circuit (KB) (Transmission controller system)
E02 DD12KB
Contents of
• Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Shift up is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.

Shift up switch
TL1 (male)
Defective shift up switch OFF (Release) ON (Press)
1
N–U
Resistance between
Max. 1z Min. 1Mz
N–B
Resistance between
Min. 1Mz Max. 1z

TMCN1 (female) 6 – TL1 (female) U with

Possible causes Short circuit of wiring harness between
Resistance Min. 1Mz
and standard 2 ground in wiring harness
chassis ground
value in normal (Contact with ground circuit)
TMCN2 (female) [ – TL1 (female) B with

state Short circuit of wiring harness between
Resistance Min. 1Mz
chassis ground
Shift up switch
TMCN1,TMCN2
3
troller TMCN1 6 – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 [ – TMCN1 5 – 11V Max. 1V
4, @
20-488 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))
D275AX-5 20-489
4
TROUBLESHOOTING ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
Action code Error code Shift down switch: Disconnection (KA)

Trouble
E02 DD13KA (Transmission controller system)
Contents of
• Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
• Shift down is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
information (Code 40905:Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift down switch.

Shift down switch
TL1 (male)
Defective shift down switch OFF (Release) ON (Press)
1
D–V
Resistance between
Max. 1z Min. 1Mz
D–C
Resistance between
Min. 1Mz Max. 1z

Wiring harness between TMCN3 (female) I –
TL1 (female) V
Disconnection in wiring har- Resistance Max. 1z
2
ing or defective contact in Wiring harness between TMCN3 (female) S –
TL1 (female) C
Resistance Max. 1z
connector)
@ – TL1 (female) D
and standard
TMCN3 (female) I – TL1 (female) V with

Voltage Max. 1V
chassis ground
circuit)
TMCN3 (female) S – TL1 (female) C with

Voltage Max. 1V
chassis ground
Shift down switch
TMCN1, TMCN3
4
troller TMCN3 S – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN3 S – TMCN1 5 – 11V Max. 1V
4, @
20-490 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
D275AX-5 20-491
1
TROUBLESHOOTING ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))

Trouble Shift down switch: Short circuit (KB) (Transmission controller system)
E02 DD13KB
Contents of
• Signals of two systems of shift down switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Shift down is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.

Shift down switch
TL1 (male)
Defective shift down switch OFF (Release) ON (Press)
1
(Internal disconnection) Resistance between
D–V
Max. 1z Min. 1Mz
Resistance between
D–C
Min. 1Mz Max. 1z

TMCN3 (female) I – TL1 (female) V with
Possible causes Short circuit with chassis
Resistance Min. 1Mz
TMCN3 (female) S – TL1 (female) C with
state
Resistance Min. 1Mz
chassis ground
Shift down switch
TMCN1, TMCN3
3
troller TMCN3 I – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN3 S – TMCN1 5 – 11V Max. 1V
4, @
20-492 D275AX-5
(8)
1
TROUBLESHOOTING ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
D275AX-5 20-493
4
TROUBLESHOOTING ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code Error code Parking lever switch: Disconnection (KA)

Trouble
CALL E03 DD14KA (Transmission controller system)
Contents of
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
• Recognizes parking lever is in Free position.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1 and R1.
machine
aSignals 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).
Related
information
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking lever.
When error code [DD14KA] occurred alone

ness (Disconnection in wir- Wiring harness between TMCN1 (female) H –
ing or defective contact in branched point of circuit
connector) Wiring harness between TMCN1 (female) B –
branched point of circuit
and standard
value in normal
state
Parking lever
TMCN1
Defective transmission con- Free position Lock position
2
troller Between H –
Max. 1V 5 – 11V
chassis ground
Between B –
5 – 11V Max. 1V
chassis ground
When error codes [DD14KA] and [DDQ2KA] occurred at the same time
Parking lever switch Parking lever
1 NSW
(Internal disconnection) Free position Lock position
Between A – B Max. 1z Min. 1Mz
Between A – B
Possible causes
Min. 1Mz Max. 1z
and standard
harness between NSW (female) B –
state
Disconnection in wiring har- Wiring
Resistance Max. 1z
ness (Disconnection in wir- merged point of circuit
ing or defective contact in Wiring harness between NSW (female) C –
2
Resistance Max. 1z
connector) merged point of circuit
Wiring harness between NSW (female) A –
Resistance Max. 1z
chassis ground
20-494 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Possible causes Short circuit of wiring harness between NSW
and standard (female) % – TMCN1 (female) + – STCN2 (fe- Voltage Max. 1V
value in normal male) 8 with chassis ground
circuit)
state Short circuit of wiring harness between NSW
(female) & – TMCN1 (female) % – STCN2 (fe- Voltage Max. 1V
male) ( with chassis ground
Circuit diagram related to parking brake switch
D275AX-5 20-495
4
TROUBLESHOOTING ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
Action code Error code Parking lever switch: Short circuit (KB)
Trouble
CALL E03 DD14KB (Transmission controller system)
Contents of
• Signals of two systems of parking lever switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
controller
Problem that
appears on
machine
Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KB, DDQ2L4).
Related
information
(Code 40905: Transmission controller input signal 1)

1 NSW
Between A – B Min. 1Mz Max. 1z
Wiring harness between NSW (female) B –
and standard TMCN1 (female) H – STCN2 (female) 5 with Resistance Min. 1Mz
chassis ground
Wiring harness between NSW (female) C –
state
TMCN1 (female) B – STCN2 (female) E with Resistance Min. 1Mz
chassis ground
Parking lever
TMCN1
Defective transmission con- Free position Lock position
3
troller Between H –
Max. 1V 5 – 11V
chassis ground
Between B –
5 – 11V Max. 1V
chassis ground
20-496 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
D275AX-5 20-497
4
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE
TROUBLESHOOTING (L6)
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6)
Action code Error code Engine oil pressure switch: Refer to table (L6)
Trouble
CALL E03 DDE2L6 (Engine controller system)
Contents of
• Signals of engine oil pressure switch are inconsistent with engine state.
trouble
Problem that
appears on
machine
• Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.
Related
(Code 40900: Engine controller input signal 1)
information
• Method of reproducing error code: Turn starting switch ON or start engine.

Defective low engine oil without turning starting switch ON or by starting engine.
1 pressure switch (Internal PSL Engine Resistance
disconnection/short circuit) Between terminal – Stop Max. 1Ω
chassis ground Min. 600rpm Min. 1MΩ
Defective high engine oil without turning starting switch ON or by starting engine.
2 pressure switch (Internal PSH Engine Resistance
disconnection/short circuit) Between terminal – Stop Max. 1Ω
chassis ground Min. 1,300rpm Min. 1MΩ
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wir- Wiring harness between ECN1 (female) . –
3 Resistance Max. 1Ω
value in normal ing or defective contact in PSL
state connector) Wiring harness between ECN1 (female) ( –
PSH
(Contact with ground circuit) Resistance Min. 1MΩ
(female) . – PSH with chassis ground
without turning starting switch ON or by starting engine.
ECN1 Engine Voltage
5 Defective engine controller Between . – chassis Stop Max. 1V
ground Min. 600rpm 20 – 30V
Between ( – chassis Stop Max. 1V
ground Min. 1,300rpm 20 – 30V
20-498 D275AX-5
4
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE
TROUBLESHOOTING (L6)
Circuit diagram related to low engine oil pressure switch & high engine oil pressure switch
D275AX-5 20-499
4
ERROR CODE DDN4LD (RIPPER LIFT UP PRESSURE SWITCH: REFER TO
TROUBLESHOOTING TABLE (LD)
ERROR CODE DDN4LD (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Ripper lift UP pressure switch: Refer to table (LD).
Trouble
— DDN4LD (Steering control system)
Contents of
• Signals from ripper lift UP pressure switch was continuously ON for 60 seconds.
trouble
Action of
• Recognizes ripper lift UP pressure switch is turned OFF.
controller
Problem that
appears on • Shoe slip control (SSC) does not operate normally.
machine
• Input state (ON/OFF) from ripper lift UP pressure switch can be checked in monitoring mode.
Related (Code 40912: Steering controller input signal 3)
information • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least
60 seconds.)

Defective lever operation If error code lights on (reset display) even after carrying out reset, it is
1
(Electric system is normal.) suspected that lever operation causing error was performed in past.
Defective ripper lift UP pres- carry out troubleshooting.
2 sure switch (Internal short RPU (male) Ripper lever Resistance
circuit) Neutral Min. 1Mz
Between 1 – 2
Possible causes UP Max. 1z
and standard aPrepare with starting switch OFF, then carry out troubleshooting
(Contact with ground circuit) (female) 3 – RPU (female) 1 with chassis Resistance Min. 1Mz
ground
4 Defective steering controller STCN1, STCN2 Ripper lever Voltage
Between STCN2 3 – Neutral 5 – 11V
STCN1 4, @ UP Max. 1V
Circuit diagram related to ripper lift UP pressure switch
20-500 D275AX-5
1
(5)
ERROR CODE DDN5LD (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO
ERROR CODE DDN5LD (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO TABLE
(LD)
Action code Error code Ripper lift DOWN pressure switch: Refer to table (LD).
Trouble
Contents of
• Signals from ripper lift DOWN pressure switch was continuously ON for 60 seconds.
trouble
Action of
• Recognizes ripper lift DOWN pressure switch is OFF.
controller
Problem that
machine
• Input state (ON/OFF) from ripper lift DOWN pressure switch can be checked in monitoring mode.
Related (Code 40912: Steering controller input signal 3)
60 seconds.)

1
Defective ripper lift DOWN carry out troubleshooting.
2 pressure switch (Internal RPD (male) Ripper lever Resistance
short circuit) Neutral Min. 1Mz
Between 1 – 2
Possible causes DOWN Max. 1z
(Contact with ground circuit) (female) N – RPD (female) 1 with chassis Resistance Min. 1Mz
ground
4 Defective steering controller STCN1 Ripper lever Voltage
Between STCN1 N – Neutral 5 – 11V
4, @ UP Max. 1V
Circuit diagram related to ripper lift DOWN pressure switch
D275AX-5 20-501
1
(5)
ERROR CODE DDN6LD (RIPPER TILT IN PRESSURE SWITCH: REFER TO
ERROR CODE DDN6LD (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Ripper tilt IN pressure switch: Refer to table (LD).
Trouble
Contents of
• Signals of ripper tilt IN pressure switch was continuously ON for 60 seconds.
trouble
Action of
• Recognizes ripper tilt IN pressure switch is OFF.
controller
Problem that
machine
• Input state (ON/OFF) from ripper tilt IN pressure switch can be checked in monitoring mode.
Related (Code 70305: Ripper lever pressure switch input signal)
60 seconds.)

1
Defective ripper tilt IN pres- carry out troubleshooting.
2 sure switch (Internal short RTI (male) Ripper lever Resistance
circuit) Neutral Min. 1Mz
Between 1 – 2
Possible causes Tilt IN Max. 1z
(Contact with ground circuit) (female) H – RTI (female) 1 with chassis Resistance Min. 1Mz
ground
4 Defective steering controller STCN1 Ripper lever Voltage
Between STCN1 H – Neutral 5 – 11V
4, @ Tilt IN Max. 1V
Circuit diagram related to ripper tilt IN pressure switch
20-502 D275AX-5
1
(5)
TROUBLESHOOTING ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
Action code Error code Blade pitch switch: Disconnection (KA)

Trouble
E02 DDN7KA (Transmission controller system)
Contents of
• Signals of two systems of blade pitch switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
appears on • Blade pitch does not function. (Operating blade pitch causes tilt operation.)
machine
Related • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal 1)
• Method of reproducing error code: Turn starting switch ON (and operate blade pitch switch).

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Release) ON (Press)
1
Max. 1z Min. 1Mz
1–5
Resistance between
Min. 1Mz Max. 1z
1–2
Disconnection in wiring har- Wiring harness between TMCN2 (female) E –
Resistance Max. 1z
ness (Disconnection in wir- P03 (female) 5
2
ing or defective contact in Wiring harness between TMCN2 (female) 5 –
Resistance Max. 1z
connector) P03 (female) 2
@ – P03 (female) 1
and standard
TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1V
chassis ground
Blade pitch switch
TMCN1, TMCN2
4
troller TMCN2 E – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 5 – TMCN1 5 – 11V Max. 1V
4, @
D275AX-5 20-503
(8)
1
TROUBLESHOOTING ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
Circuit diagram related to blade pitch switch & blade tilt switch
20-504 D275AX-5
1
TROUBLESHOOTING ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))

Trouble Blade pitch switch: Short circuit (KB) (Transmission controller system)
E02 DDN7KB
Contents of
• Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
appears on • Blade pitch does not function (Operating blade pitch causes tilt operation.)
machine
Related • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input)
• Method of reproducing error code: Turn starting switch ON and operate blade pitch switch.

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Release) ON (Press)
1
Max. 1z Min. 1Mz
1–5
Resistance between
Min. 1Mz Max. 1z
1–2
and standard TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1V
TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1V
chassis ground
Blade pitch switch
TMCN1, TMCN2
3
troller TMCN2 E – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 5 – TMCN1 5 – 11V Max. 1V
4, @
D275AX-5 20-505
(8)
1
TROUBLESHOOTING ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
20-506 D275AX-5
1
TROUBLESHOOTING ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))

Trouble Blade tilt switch: Disconnection (KA) (Transmission controller system)
E01 DDN9KA
Contents of
• Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
• Recognizes switch is set at SINGLE side.
controller
Problem that
appears on • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
Related • Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
• Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch).

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1z Min. 1Mz
3–6
Resistance between
Min. 1Mz Max. 1z
3–4
Disconnection in wiring har- Wiring harness between TMCN2 (female) Y – Resistance
Max. 1z
ness (Disconnection in wir- P03 (female) 6
2
ing or defective contact in Wiring harness between TMCN2 (female) O –
Resistance Max. 1z
connector) P03 (female) 4
Possible causes Wiring harness between TMCN1 (female) 4,
Resistance Max. 1z
@ – P03 (female) 3
and standard
TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1V
chassis ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
4
troller TMCN2 Y – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 O – TMCN1 5 – 11V Max. 1V
4, @
D275AX-5 20-507
1
(5)
TROUBLESHOOTING ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
20-508 D275AX-5
1
TROUBLESHOOTING ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))

Trouble Blade tilt switch: Short circuit (KB) (Transmission controller system)
E01 DDN9KB
Contents of
• Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
• Recognizes switch is set at SINGLE side.
controller
Problem that
appears on • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
Related • Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input state)
• Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch).

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1z Min. 1Mz
3–6
Resistance between
Min. 1Mz Max. 1z
3–4
TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1V
chassis ground
TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1V
chassis ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
3
troller TMCN2 Y – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 O – TMCN1 5 – 11V Max. 1V
4, @
D275AX-5 20-509
1
(5)
TROUBLESHOOTING ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
20-510 D275AX-5
1
TROUBLESHOOTING ERROR CODE DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code Error code Parking lever switch: Disconnection (KA)

Trouble
CALL E03 DDQ2KA (Transmission controller system)
Contents of
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
controller
Problem that
appears on
machine
Depending on where problem occurs, related codes may be displayed at the same time. (Related
code: DD14KA, DDQ2L4).
Related
information
(Code 40907: Blade lever knob switch input signal)
When error code [DDQ2KA] occurred alone

ing or defective contact in branched point of circuit
connector) Wiring harness between STCN2 (female) E –
branched point of circuit
and standard
value in normal
state
Parking lever
STCN2
Free position Lock position
Between 5 –
Max. 1V 5 – 11V
chassis ground
Between E –
5 – 11V Max. 1V
chassis ground
When error codes [DDQ2KA] and [DD14KA] occurred at the same time
1 NSW
Between A – B
Possible causes
Min. 1Mz Max. 1z
and standard
harness between NSW (female) B –
state
Disconnection in wiring har- Wiring
Resistance Max. 1z
ness (Disconnection in wir- merged point of circuit
ing or defective contact in Wiring harness between NSW (female) C –
2
Resistance Max. 1z
connector) merged point of circuit
Wiring harness between NSW (female) A –
Resistance Max. 1z
chassis ground
D275AX-5 20-511
1
(5)
TROUBLESHOOTING ERROR CODE DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
(female) B – TMCN1 (female) H – STCN2 (fe- Voltage Max. 1V

Possible causes Short circuit of wiring harness between NSW
and standard
circuit)
state
(female) C – TMCN1 (female) B – STCN2 (fe- Voltage Max. 1V
Short circuit of wiring harness between NSW
male) E with chassis ground
20-512 D275AX-5
1
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB))
Action code Error code Parking brake lever switch: Short circuit (KB)
Trouble
CALL E03 DDQ2KB (Steering controller system)
Contents of
• Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously.
trouble
Action of
• Recognizes that parking brake lever is at FREE position.
controller
Problem that
appears on
machine
aSince parking brake switch signal is used by both transmission controller and steering controller, re-
lated codes may be displayed simultaneously, depending on troubled part. (Related codes: DD14KB,
DDQ2L4)
Related
• NO and NC signals of both switch systems are for detecting operation and error respectively.
information
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.
(Code 40907: Blade control lever knob switch input signal)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever.
When error codes [DDQ2KA] and [DD14KA] are displayed simultaneously

Defective parking brake le- Parking brake lever
1 ver switch (Internal short cir- NSW
At FREE At LOCK
Between A – B
cuit)
Max. 1z Min. 1Mz
Between A – B Min. 1Mz Max. 1z
(female) B – TMCN1 (female) H – STCN2 (fe- Resistance Min. 1Mz

Short circuit of wiring harness between NSW
(female) C – TMCN1 (female) B – STCN2 (fe- Resistance Min. 1Mz

state Short circuit of wiring harness between NSW
male) E with chassis ground

Parking brake lever
STCN2
At FREE At LOCK
Between 5 –
Max. 1V 5 – 11V
chassis ground
Between E –
5 – 11V Max. 1V
chassis ground
D275AX-5 20-513
1
(5)
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT
20-514 D275AX-5
4
TROUBLESHOOTING ERROR CODE DDQ2L4 (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
ERROR CODE DDQ2L4 (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
Action code Error code Parking brake lever switch: See table (L4)
Trouble
CALL E03 DDQ2L4 (Steering controller system)
Contents of • Switch input signal of steering controller disagrees with communication signal from transmission con-
trouble troller.
Problem that
appears on
machine
★ 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, de-
pending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR, DD14KA,
Related
DD14KB, DDQ2KA, DDN4LD, DDN5LD)
information
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.
(Code 40907: Parking brake lever switch input signal)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever.

See if error codes [DAFRKR], [DB2RKR], [DB3RKR], and [DAQRKR]
Defective CAN communica-
Possible causes 1 are displayed. If they are displayed, carry out troubleshooting for them
tion signal system
and standard first.
value in normal See if error codes [DD14KA], [DD14KB], [DDQ2KA], and [DDQ2KB]
state Defective parking brake le-
2 are displayed. If they are displayed, carry out troubleshooting for them
ver switch signal system
first.
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
D275AX-5 20-515
4
ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR
TROUBLESHOOTING HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH

TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
Action code Error code Engine water temperature sensor (for high temperature): Input signal
Trouble
CALL E03 DGE2KX is out of normal range (KX) (Engine controller system)
Contents of
• High engine water temperature sensor signal is out of normal range.
trouble
Action of
• Fixes water temperature signal output for monitor panel at 90%.
controller
Problem that • Monitor panel does not display engine water temperature normally.
• Engine water temperature (temperature) can be checked in monitoring mode.
Related
(Code 04102: Engine water temperature (High temperature side))
information

Defective high engine water without turning starting switch ON.
temperature sensor (Inter- TWH Resistance
1
nal disconnection or short
circuit) Between 4 – 5 3.5k – 90kΩ
Between 4, 5 – chassis ground Min. 1MΩ
Possible causes ing or defective contact in TWH (female) 4
and standard connector) Wiring harness between ECN2 (female) @ –
value in normal TWH (female) 5
state ★ Prepare with starting switch OFF, then carry out troubleshooting
3 ground in wiring harness Short circuit of wiring harness between ECN2
(Contact with ground circuit) (female) 4 – TWH (female) 4 with chassis Resistance Min. 1MΩ
ground
4 Defective engine controller ECN2 (female) Resistance
Between 4 – @ 3.5k – 90kΩ
Between 4, @ – chassis ground Min. 1MΩ
Circuit diagram related to high engine water temperature sensor
20-516 D275AX-5
4
ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR LOW
TROUBLESHOOTING TEMPERATURE): SEE TABLE (L6))
ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR LOW

TEMPERATURE): SEE TABLE (L6))
Action code Error code Engine water temperature sensor (for low temperature): See table
Trouble
E02 DGE3L6 (L6) (Engine controller system)
Contents of
• Low engine water temperature sensor signal is not input.
trouble
Action of
controller
Problem that
• Exhaust gas color is bad at low temperature.
appears on
• Engine does not start easily at low temperature.
machine
• Engine water temperature (temperature) can be checked in monitoring mode.
Related
(Code 04104: Engine water temperature (Low temperature side))
information

Defective low engine water without turning starting switch ON.
temperature sensor (Inter-
1 TWL (male) Resistance
nal disconnection or short
Between 4 – 5 0.3k – 9kΩ
circuit)
ness (Disconnection in wir- Wiring harness between ECN2 (female) > –
Possible causes ing or defective contact in TWL (female) 4
value in normal TWL (female) 5
(Contact with ground circuit) (female) > – TWL (female) 4 with chassis Resistance Min. 1MΩ
ground
Between > – @ 0.3k – 9kΩ
Between >, @ – chassis ground Min. 1MΩ
Circuit diagram related to low engine water temperature sensor
D275AX-5 20-517
4
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS
TROUBLESHOOTING OUT OF NORMAL RANGE (KX))
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF

NORMAL RANGE (KX))
Action code Error code Fuel temperature sensor: Input signal is out of normal range (KX)
Trouble
E01 DGE4KX (Engine controller system)
Contents of
• Fuel temperature sensor signal is out of normal range.
trouble
Action of
• Operates with normal control.
controller
Problem that
appears on • Engine output lowers a little at low temperature.
machine
Related • Fuel temperature (temperature) can be checked in monitoring mode. (Code 04204: Fuel temperature)
information • Method of reproducing error code: Turn starting switch ON or start engine.

Defective fuel temperature without turning starting switch ON.
1 sensor (Internal disconnec- THL (male) Resistance
tion or short circuit) Between 4 – 5 0.3k – 9kΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) *#–
Possible causes ing or defective contact in THL (female) 4
value in normal THL (female) 5
(Contact with ground circuit) (female) * – THL (female) 4 with chassis Resistance Min. 1MΩ
ground
Between * – @ 0.3k – 9kΩ
Between *, @ – chassis ground Min. 1MΩ
Circuit diagram related to fuel temperature sensor
20-518 D275AX-5
4
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT
TROUBLESHOOTING SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS

OUT OF NORMAL RANGE (KX))
Action code Error code Hydraulic oil temperature sensor: Input signal is out of normal range
Trouble
— DGS1KX (KX) (Transmission controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
• Does not take any particular action.
controller
Problem that
appears on • Hydraulic oil temperature gauge of monitor panel may not display normally.
machine
• Hydraulic oil temperature (temperature) can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information

Defective hydraulic oil tem- without turning starting switch ON.
perature sensor (Internal
1 452 (male) Resistance
disconnection or short cir-
Between 1 – 2 3.5k – 90kz
cuit)
Between 1 – chassis ground Min. 1Mz
ness (Disconnection in wir- Wiring harness between TMCN2 (female) D –
ing or defective contact in 452 (female) 1
connector) Wiring harness between TMCN2 (female) K –
Resistance Max. 1z
452 (female) 2
Possible causes
value in normal
state 3 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN2 (female) D – 452 (female) 1 with Resistance Min. 1Mz
chassis ground
Short circuit with power out troubleshooting.
4 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) TMCN1 (female) D – 452 (female) 1 with Voltage Max. 1V
chassis ground
Defective transmission con- TMCN1 (female) Resistance
5
troller
Between D – K 1k – 50kz
Between D – chassis ground Min. 1Mz
Circuit diagram related to hydraulic oil temperature sensor
D275AX-5 20-519
1
(5)
ERROR CODE DH21KA (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:
TROUBLESHOOTING DISCONNECTION (KA))
ERROR CODE DH21KA (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:

DISCONNECTION (KA))
Action code Error code Work equipment pump oil pressure sensor: Disconnection (KA)
Trouble
E01 DH21KA (Transmission controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
appears on • Work equipment pump oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment pump oil sensor)
information

Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out
1
system troubleshooting for it first.
Defective work equipment out troubleshooting.
2 pump oil pressure sensor
HHP Voltage
(Internal trouble)
Between & – $ 0.5 – 6.0V
Possible causes ness (Disconnection in wir- Wiring harness between TMCN1 (female) ) –
and standard ing or defective contact in HHP (female) %
value in normal connector) Wiring harness between TMCN1 (female) < –
state HHP (female) &
(Contact with ground circuit) TMCN1 (female) < – HHP (female) & with Resistance Min. 1MΩ
chassis ground
Defective transmission con- out troubleshooting.
5
troller TMCN1 (female) Voltage
Between < – . 0.5 – 6.0V
Circuit diagram related to work equipment pump oil pressure sensor
20-520 D275AX-5
4
ERROR CODE DH21KB (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:
TROUBLESHOOTING SHORT CIRCUIT (KB))
ERROR CODE DH21KB (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT
CIRCUIT (KB))
Action code Error code Work equipment pump oil pressure sensor: Short circuit (KB)
Trouble
E01 DH21KB (Transmission controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor circuit is above 6.0V
trouble
Action of
controller
Problem that
appears on • Work equipment pump oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment pump oil pressure sensor)
information

Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out
1
Defective work equipment out troubleshooting.
2 pump oil pressure sensor
HHP Voltage
Between C – A
(Internal trouble)
Possible causes 0.5 – 6.0V
and standard ★ Prepare with starting switch OFF, turn starting switch ON and carry
value in normal Short circuit with power out troubleshooting.
state 3 source in wiring harness
TMCN1 (female) 9 – HHP (female) C with
(Contact with 24V circuit) Voltage Max. 1V
chassis ground
Defective transmission con- out troubleshooting.
4
troller TMCN1 (female) Voltage
Between 9 – K 0.5 – 6.0V
Circuit diagram related to work equipment pump oil pressure sensor
D275AX-5 20-521
3
1
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF
TROUBLESHOOTING NORMAL RANGE (KX))
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL

RANGE (KX))
Action code Error code Boost pressure sensor: Input is out of normal range (KX)
Trouble
E02 DH30KX (Engine controller system)
Contents of
• Boost pressure sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on • Machine is not affected seriously.
machine
• Special adapter (799-601-9420) is necessary for troubleshooting for boost pressure sensor.
Related • Boost pressure (pressure) can be checked in monitoring mode.
information (Code 36500: Boost pressure)

Defective boost pressure PIM Voltage
1
sensor (Internal trouble)
Between 4 – 6 4.6 – 5.4V
Between 5 – 6 0.3 – 5.7V
Disconnection in wiring har- Wiring harness between ECN2 (female) , –
ness (Disconnection in wir- PIM (female) 4
2
ing or defective contact in Wiring harness between ECN2 (female) - –
connector) PIM (female) 5
Wiring harness between ECN2 (female) @ –
Possible causes PIM (female) 6
value in normal without turning starting switch ON.
(female) , – PIM (female) 4 with chassis Resistance Min. 1MΩ
Short circuit with chassis ground
(Contact with ground circuit) (female) - – PIM (female) 5 with chassis Resistance Min. 1MΩ
ground
(female) @ – PIM (female) 6 with chassis Resistance Min. 1MΩ
ground
4 Defective engine controller ECN2 Voltage
Between , – @ 4.6 – 5.4V
Between - – @ 0.3 – 5.7V
20-522 D275AX-5
4
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF
TROUBLESHOOTING NORMAL RANGE (KX))
Circuit diagram related to boost presure sensor
D275AX-5 20-523
4
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT
TROUBLESHOOTING OF NORMAL RANGE (KX))
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF

NORMAL RANGE (KX))
Action code Error code Common rail pressure sensor: Input is out of normal range (KX)
Trouble
CALL E03 DH40KX (Engine controller system)
Contents of
• Common rail pressure sensor signal is out of normal range.
trouble
Problem that
appears on
machine
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail pressure sensor.
Related • Common rail pressure (pressure) can be checked in monitoring mode.
information (Code 36400: Common rail pressure)

Defective common rail pres- out troubleshooting.
1 sure sensor (Internal trou- PFUEL Voltage
ble) Between 1 – 3 4.6 – 5.4V
Between 2 – 3 0.3 – 5.7V
Disconnection in wiring har- Wiring harness between ECN2 (female) I –
ness (Disconnection in wir- PFUEL (female) 1
2
ing or defective contact in Wiring harness between ECN2 (female) ^ –
connector) PFUEL (female) 2
Wiring harness between ECN2 (female) ] –
Possible causes PFUEL (female) 3
state Short circuit of wiring harness between N2 (fe-
male) I – PFUEL (female) 1 with chassis Resistance Min. 1MΩ
Short circuit with chassis ground
(Contact with ground circuit) (female) ^ – PFUEL (female) 2 with chassis Resistance Min. 1MΩ
ground
(female) ] – PFUEL (female) 3 with chassis Resistance Min. 1MΩ
ground
Between I – ] 4.6 – 5.4V
Between ^ – ] 0.3 – 5.7V
20-524 D275AX-5
3
1
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT
Circuit diagram related to common rail presure sensor
D275AX-5 20-525
4
ERROR CODE DHH3KA (HSS PUMP OIL PRESSURE SENSOR A:
ERROR CODE DHH3KA (HSS PUMP OIL PRESSURE SENSOR A: DISCONNECTION

(KA))
Action code Error code HSS pump oil pressure sensor A: Disconnection (KA)
Trouble
CALL E03 DHH3KA (Steering controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor A circuit is below 0.5V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (A side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor A can be checked in monitoring mode.
Related
(Code 50503: Voltage of HSS pump oil pressure sensor A)
information

Defective 24V power source See if error code [DB36KK] is displayed. If it is displayed, carry out
1
Defective HSS pump oil out troubleshooting.
2 pressure sensor A (Internal
ST1 Voltage
Between C – A
trouble)
0.5 – 6.0V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) F –
and standard ing or defective contact in ST1 (female) (B)
value in normal connector) Wiring harness between STCN1 (female) J –
ST1 (female) C
state Resistance Max. 1z

(Contact with ground circuit) (female) J – ST1 (female) C with chassis Resistance Min. 1Mz
ground
STCN1 Voltage
Between J – K 0.5 – 6.0V
Circuit diagram related to HSS pump oil pressure sensor A
20-526 D275AX-5
(8)
1
ERROR CODE DHH3KB (HSS PUMP OIL PRESSURE SENSOR A: SHORT
TROUBLESHOOTING CIRCUIT (KB))
ERROR CODE DHH3KB (HSS PUMP OIL PRESSURE SENSOR A: SHORT CIRCUIT (KB))
Action code Error code HSS pump oil pressure sensor A: Short circuit (KB)
Trouble
CALL E03 DHH3KB (Steering controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor A circuit is above 6.0V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (A side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor A can be checked in monitoring mode.
Related
(Code 50503: Voltage of HSS pump oil pressure sensor A)
information

1
Defective HSS pump oil out troubleshooting.
2 pressure sensor A (Internal
ST1 Voltage
Between C – A
trouble)
Possible causes 0.5 – 6.0V
and standard aPrepare with starting switch OFF, turn starting switch ON and carry
value in normal Short circuit with power out troubleshooting.
state 3 source in wiring harness hort circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) J – ST1 (female) C with chassis Voltage Max. 1V
ground
STCN1 Voltage
Between J – K 0.5 – 6.0V
Circuit diagram related to HSS pump oil pressure sensor A
D275AX-5 20-527
(8)
1
20
ERROR CODE DHH4KA (HSS PUMP OIL PRESSURE SENSOR B:
ERROR CODE DHH4KA (HSS PUMP OIL PRESSURE SENSOR B: DISCONNECTION

(KA))
Action code Error code HSS pump oil pressure sensor B: Disconnection (KA)
Trouble
CALL E03 DHH4KA (Steering controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor B circuit is below 0.5V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (B side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor B can be checked in monitoring mode.
Related
(Code 50504: Voltage of HSS pump oil pressure sensor B)
information

1
Defective HSS pump oil carry out troubleshooting.
2 pressure sensor B (Internal
ST2 Voltage
trouble)
Between & – $ 0.5 – 6.0V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) ) –
and standard ing or defective contact in ST2 (female) %
value in normal connector) Wiring harness between STCN1 (female) ' –
state ST2 (female) &
(Contact with ground circuit) (female) ' – ST2 (female) & with chassis Resistance Min. 1MΩ
ground
STCN1 (female) Voltage
Between ' – . 0.5 – 6.0V
Circuit diagram related to HSS pump oil pressure sensor B
20-528 D275AX-5
4
ERROR CODE DHH4KB (HSS PUMP OIL PRESSURE SENSOR B: SHORT
ERROR CODE DHH4KB (HSS PUMP OIL PRESSURE SENSOR B: SHORT CIRCUIT (KB))
Action code Error code HSS pump oil pressure sensor B: Short circuit (KB)
Trouble
CALL E03 DHH4KB (Steering controller system)
Contents of
• Signal voltage of HSS pump oil pressure sensor B circuit is above 6.0V.
trouble
Action of
controller
Problem that • HSS pump oil pressure (B side) cannot be monitored.
• Input (Voltage) from HSS pump oil pressure sensor B can be checked in monitoring mode.
Related
(Code 50504: Voltage of HSS pump oil pressure sensor B)
information

1
Defective HSS pump oil carry out troubleshooting.
2 pressure sensor B (Internal
ST2 Voltage
trouble)
Possible causes Between & – $ 0.5 – 6.0V
value in normal Short circuit with power carry out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) ' – ST2 (female) & with chassis Voltage Max. 1V
ground
STCN1 (female) Voltage
Between ' – . 0.5 – 6.0V
Circuit diagram related to HSS pump oil pressure sensor B
D275AX-5 20-529
4
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL
TROUBLESHOOTING RANGE (KX))
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE
(KX))
Action code Error code Fuel control dial: Input is out of normal range (KX)
Trouble
CALL E03 DK10KX (Engine controller system)
Contents of
• Signal voltage of fuel control dial circuit is below 0.5V or above 4.5V.
trouble
Action of
• Continues controlling with signal of decelerator pedal potentiometer.
controller
Problem that
appears on
machine
• Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
Related
(Code 03000: Voltage of fuel control dial)
information

Defective fuel control dial TL1 (male) Resistance
1 (Internal disconnection or
Between 5 – 7 4.0 – 6.0kΩ
short circuit)
Between 5 – 6 0.25 – 7.0kΩ
Between 6 – 7 0.25 – 7.0kΩ
Disconnection in wiring har- Wiring harness between ECN2 (female) < –
ness (Disconnection in wir- TL1 (female) 5
2
ing or defective contact in Wiring harness between ECN2 (female) # –
connector) TL1 (female) 6
TL1 (female) 7
value in normal Short circuit with chassis
(female) < – TL1 (female) 5 with chassis Resistance Min. 1MΩ
state 3 ground in wiring harness
ground
(female) # – TL1 (female) 6 with chassis Resistance Min. 1MΩ
ground
Short circuit with power
(female) < – TL1 (female) 5 with chassis Voltage Max. 1V
4 source in wiring harness
ground
(female) # – TL1 (female) 6 with chassis Voltage Max. 1V
ground
Between < – 6 4.6 – 5.4V
Between # – 6 0.5 – 4.5V
20-530 D275AX-5
4
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL
TROUBLESHOOTING RANGE (KX))
Circuit diagram related to fuel control dial
D275AX-5 20-531
4
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL

RANGE (KX))
Action code Error code Fuel control dial: Input is out of normal range (KX)
Trouble
CALL E03 DK12KX (Engine controller system)
Contents of
• Signal voltage of deceleration potentiometer circuit is below 0.3V or above 4.5V.
trouble
Action of
• Continues controlling with signal of fuel control dial.
controller
Problem that
appears on
machine
• Inputting from deceleration potentiometer (Voltage) can be checked in monitoring mode.
Related
(Code 50101: Voltage of deceleration potentiometer)
information

Defective deceleration po- DCL (male) Resistance
1 tentiometer (Internal dis-
Between $ – & 4.0 – 6.0kΩ
connection or short circuit)
Between $ – % 0.25 – 7.0kΩ
Between % – & 0.25 – 7.0kΩ
Disconnection in wiring har- Wiring harness between ECN2 (female) < –
ness (Disconnection in wir- DCL (female) $
2
ing or defective contact in Wiring harness between ECN2 (female) ? –
connector) DCL (female) %
DCL (female) &
value in normal Short circuit with chassis
(female) < – DCL (female) $ with chassis Resistance Min. 1MΩ
state 3 ground in wiring harness
ground
(female) = – DCL (female) % with chassis Resistance Min. 1MΩ
ground
Short circuit with power
(female) < – DCL (female) $ with chassis Voltage Max. 1V
4 source in wiring harness
ground
(female) = – DCL (female) % with chassis Voltage Max. 1V
ground
Between < – 6 4.6 – 5.4V
Between ? – 6 0.3 – 4.5V
20-532 D275AX-5
4
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT
Circuit diagram related to decel potentiometer
D275AX-5 20-533
4
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION (KA))
Action code Error code Steering potentiometer 1: Disconnection (KA)

Trouble
CALL E03 DK30KA (Steering controller system)
Contents of
• Signal voltage of steering potentiometer 1 system (ST1) is below 0.5V.
trouble
Action of
• Continues controlling with signal of steering potentiometer 2 system (ST2).
controller
Problem that
appears on
machine
• Input (Voltage) from steering potentiometer 1 (ST1) can be checked in monitoring mode.
Related
(Code 50300: Voltage of steering potentiometer 1)
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).

Defective 5V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
source system troubleshooting for it first.
Defective steering potenti- TL1 (male) Resistance
2 ometer 1 (Internal discon-
Between $ – * 2kΩ ± 20%
nection or short circuit)
Between + – $
Between + – *
and standard ness (Disconnection in wir- Wiring harness between STCN1 (female) / –
value in normal ing or defective contact in TL1 (female) $
state connector) Wiring harness between STCN1 (female) 5 –
TL1 (female) +
(Contact with ground circuit) (female) 5 – TL1 (female) + with chassis Resistance Min. 1MΩ
ground
STCN1 Voltage
Between 5 – . 0.5 – 4.5V
20-534 D275AX-5
4
Circuit diagram related to steering potentiometer
D275AX-5 20-535
4
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))
Action code Error code Steering potentiometer 1: Short circuit (KB)

Trouble
CALL E03 DK30KB (Steering controller system)
Contents of
• Signal voltage of steering potentiometer 1 system (ST1) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Between $ – * 2kΩ ± 20%
Possible causes Between + – $
and standard Between + – *
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state Short circuit with power carry out troubleshooting.
3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) 5 – TL1 (female) + with chassis Voltage Max. 1V
ground
STCN1 Voltage
Between 5 – . 0.5 – 4.5V
20-536 D275AX-5
4
ERROR CODE
ERROR CODE DK30KX
DK30KX (STEERING(STEERING POTENTIOMETER
POTENTIOMETER 1:OFINPUT
1: INPUT SIGNAL IS OUT NORMALSIGNAL IS
RANGE (KX))
TROUBLESHOOTING ERROR CODE DK30KZ (STEERING POTENTIOMETER 1:OUT OF NORMAL
DISCONNECTION RANGE
OR SHORT (KX))
CIRCUIT (KZ))
ERROR CODE DK30KX (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF

NORMAL RANGE (KX))
Action code Error code Steering potentiometer 1: Input signal is out of normal range (KX)
Trouble
CALL E04 DK30KX (Steering controller system)
Contents of • Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and error
trouble codes [DK31KA] and [DK31KB] are displayed simultaneously.
Problem that
appears on
machine
• Input (Voltage) from steering potentiometers can be checked in monitoring mode.
Related (Code 50300: Voltage of steering potentiometer 1)
information (Code 50301: Voltage of steering potentiometer 2)

and standard
value in normal Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
ERROR CODE DK30KZ (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT

CIRCUIT (KZ))
Action code Error code Steering potentiometer 1: Disconnection or short circuit (KZ))
Trouble
CALL E04 DK30KZ (Steering controller system)
• When starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal, then
Contents of
either of error codes [DK30KA] and [DK30KB] and error codes [DK31KA] and [DK31KB] are displayed
trouble
simultaneously.
Problem that
appears on
machine

and standard
state
D275AX-5 20-537
4
TROUBLESHOOTING ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8))
ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8))
Action code Error code Steering potentiometer 1: See table (L8)

Trouble
CALL E03 DK30L8 (Steering controller system)
Contents of • Total signal voltage of each of steering potentiometer 1 system (ST1) and 2 system (ST2) is below
trouble 4.41V or above 5.59V.
Action of
• Continues controlling with signal of normal one of steering potentiometer 1 system (ST1) and 2 (ST2).
controller
Problem that
appears on
machine

and standard
state
20-538 D275AX-5
4
ERROR CODE DK31KA (STEERING POTENTIOMETER 2: DISCONNECTION (KA))
Action code Error code Steering potentiometer 2: Disconnection (KA)

Trouble
Contents of
• Signal voltage of steering potentiometer 2 system (ST2) is below 0.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
Between 0 – ) 2kΩ ± 20%
Between ( – 0
Between ( – )
and standard ness (Disconnection in wir- Wiring harness between STCN1 (female) / –
value in normal ing or defective contact in TL1 (female) 0
state connector) Wiring harness between STCN1 (female) , –
TL1 (female) (
(Contact with ground circuit) (female) , – TL1 (female) ( with chassis Resistance Min. 1MΩ
ground
STCN1 Voltage
Between , – . 0.5 – 4.5V
D275AX-5 20-539
4
20-540 D275AX-5
4
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))
Action code Error code Steering potentiometer 2: Short circuit (KB)

Trouble
Contents of
• Signal voltage of steering potentiometer 2 system (ST2) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
Defective steering potenti- TL1 (male) Voltage
Between 0 – ) 2kΩ ± 20%
Possible causes Between ( – 0
and standard Between ( – )
(Contact with 24V circuit) (female) , – TL1 (female) ( with chassis Resistance Max. 1V
ground
STCN1 Voltage
Between , – . 0.5 – 4.5V
D275AX-5 20-541
4
TROUBLESHOOTING ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
Action code Error code Brake potentiometer: Disconnection (KA)

Trouble
Contents of
• Signal voltage of brake potentiometer circuit is above 4.5V.
trouble
Action of
• Does not control with signal of brake potentiometer (Brake can be operated with pedal).
controller
Problem that • Brake control performance of brake pedal lowers.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiom- BRK (male) Resistance
Between A – C
2 eter (Internal disconnection
4.0 – 6.0kΩ
Between A – B
or short circuit)
0.25 – 7.0kΩ
Between B – C 0.25 – 7.0kΩ
and standard ness (Disconnection in wir- Wiring harness between STCN1 (female) L –
ing or defective contact in BRK (female) C
state connector) Wiring harness between STCN1 (female) 3 –
BRK (female) B

(Contact with ground circuit) (female) 3 – BRK (female) B with chassis Resistance Min. 1MΩ
ground
STCN1 Voltage
Between 3 – B 0.5 – 4.5V
20-542 D275AX-5
(8)
1
TROUBLESHOOTING ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
Circuit diagram related to brake potentiometer
D275AX-5 20-543
4
TROUBLESHOOTING ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
Action code Error code Brake potentiometer: Short circuit (KB)

Trouble
Contents of
• Signal voltage of brake potentiometer circuit is below 0.5V or above 4.5V.
trouble
Action of
• Does not control with signal of brake potentiometer (Brake can be operated with pedal).
controller
Problem that • Brake control performance of brake pedal lowers.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiome- BRK (male) Resistance
2 ter (Internal disconnection
$–& 4.0 – 6.0kΩ
or short circuit)
Possible causes $–% 0.25 – 7.0kΩ
and standard %–& 0.25 – 7.0kΩ
(Contact with 24V circuit) (female) 6 – BRK (female) % with chassis Voltage Max. 1V
ground
STCN1 Voltage
Between 6 – % 0.5 – 4.5V
Circuit diagram related to brake potentiometer
20-544 D275AX-5
4
ERROR
ERROR CODE DK55KXCODE DK55KX (FORWARD-REVERSE
(FORWARD-REVERSE POTENTIOMETER:
POTENTIOMETER: INPUT SIGNAL INPUT
IS OUT OF NORMAL RANGE (KX))
TROUBLESHOOTING SIGNAL IS OUT
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: OF NORMAL
DISCONNECTION RANGE
OR SHORT (KX))
CIRCUIT (KZ))
ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS

OUT OF NORMAL RANGE (KX))
Action code Error code Forward-reverse potentiometer: Input signal is out of normal range
Trouble
CALL E04 DK55KX (KX) (Transmission controller system)
Contents of • Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and
trouble either of error codes [DK57KA] and [DK57KB] are displayed simultaneously.
Problem that
appears on
machine
• Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
Related
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
state
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR

SHORT CIRCUIT (KZ))
Action code Error code Forward-reverse potentiometer: Disconnection or short circuit (KZ))
Trouble
CALL E04 DK55KZ (Transmission controller system)
• When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnor-
Contents of
mal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
trouble
[DK57KB] are displayed simultaneously.
Problem that
appears on
machine
Related • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
information verse travel).

and standard
state
D275AX-5 20-545
3
1
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE
TROUBLESHOOTING (L8))
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))
Action code Error code Forward-reverse potentiometer: See table (L8)

Trouble
CALL E03 DK55L8 (Transmission controller system)
Contents of • Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is
trouble below 4.41V or above 5.59V.
Action of • Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3) and
controller 2 (FR4).
Problem that
appears on
machine
Related
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
state
20-546 D275AX-5
1
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1:
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION

(KA))
Action code Error code Forward-reverse potentiometer 1: Disconnection (KA)

Trouble
CALL E03 DK56KA (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 1 system (FR3) is below 0.5V.
trouble
Action of
• Continues controlling with signal of forward-reverse potentiometer 2 system (FR4).
controller
Problem that
appears on
machine
• Input (Voltage) from forward-reverse potentiometer 1 (FR3) can be checked in monitoring mode. (Code
Related 50200: Voltage of forward-reverse potentiometer 1)
information • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
Defective forward-reverse without turning starting switch ON.
Between L – J
potentiometer 1 (Internal
2
disconnection or short cir- 2kΩ ± 20%
cuit) Between K – L
Between K – J
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) L –
ing or defective contact in TL1 (female) L
state connector) Wiring harness between TMCN1 (female) 2 –
TL1 (female) K

(Contact with ground circuit) TMCN1 (female) 2 – TL1 (female) K with
chassis ground
5
Between 2 – K 0.5 – 4.5V
D275AX-5 20-547
3
1
Circuit diagram related to forward-reverse potentiometer
20-548 D275AX-5
4
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 1: Short circuit (KB)

Trouble
CALL E03 DK56KB (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 1 system (FR3) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
potentiometer 1 (Internal TL1 (male) Resistance
2
disconnection or short cir- Between / – - 2kΩ ± 20%
Possible causes cuit) Between . – /
and standard Between . – -
(Contact with 24V circuit) TMCN1 (female) 5 – TL1 (female) . with Resistance Max. 1V
chassis ground
4
Between 5 – . 0.5 – 4.5V
D275AX-5 20-549
4
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION

(KA))
Action code Error code Forward-reverse potentiometer 2: Disconnection (KA)

Trouble
CALL E03 DK57KA (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 2 system (FR4) is below 0.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

Defective 5V sensor power ★ See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
2
disconnection or short cir- Between 2 – 4 2kΩ ± 20%
cuit) Between 3 – 2
Between 3 – 4
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) / –
value in normal ing or defective contact in TL1 (female) 2
state connector) Wiring harness between TMCN1 (female) , –
TL1 (female) 3
(Contact with ground circuit) TMCN1 (female) , – TL1 (female) 3 with Resistance Min. 1MΩ
chassis ground
5
Between , – . 0.5 – 4.5V
20-550 D275AX-5
4
D275AX-5 20-551
4
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 2: Short circuit (KB)

Trouble
CALL E03 DK57KB (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 2 system (FR4) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

ness (Disconnection in wir- See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
ing or defective contact in troubleshooting for it first.
connector)
2
Possible causes disconnection or short cir- Between 2 – 4 2kΩ ± 20%
and standard cuit) Between 3 – 2
value in normal Between 3 – 4
state ★ Prepare with starting switch OFF, then turn starting switch ON and
Short circuit with power carry out troubleshooting.
(Contact with 24V circuit) TMCN1 (female) , - TL1 (female) 3 with Voltage Max. 1V
chassis ground
4
Between , - . 0.5 – 4.5V
20-552 D275AX-5
4
TROUBLESHOOTING ERROR CODE DK60KA (ACCELERATION SENSOR: DISCONNECTION (KA))
ERROR CODE DK60KA (ACCELERATION SENSOR: DISCONNECTION (KA))

Trouble Acceleration sensor: Disconnection (KA) (Steering controller system)
E01 DK60KA
Contents of
• Signal voltage of acceleration sensor is below 0.5V.
trouble
Action of
• Turns shoe slip control (SSC) function OFF.
controller
Problem that
appears on • Even if shoe slips, engine speed does not change.
machine
• Input (Voltage) from acceleration sensor can be checked in monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

1
Defective acceleration sen- carry out troubleshooting.
2
sor (Internal trouble) SS3 Voltage
Between 5 – 6 0.75 – 4.25V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) / –
and standard ing or defective contact in SS3 (female) 4
value in normal connector) Wiring harness between STCN1 (female) 4 –
state SS3 (female) 5
(Contact with ground circuit) (female) 4 – SS3 (female) 5 with chassis Resistance Min. 1MΩ
ground
STCN1 Voltage
Between 4 – . 0.75 – 4.25V
Circuit diagram related to acceleration sensor
D275AX-5 20-553
4
TROUBLESHOOTING ERROR CODE DK60KB (ACCELERATION SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DK60KB (ACCELERATION SENSOR: SHORT CIRCUIT (KB))

Trouble Acceleration sensor: Short circuit (KB) (Steering controller system)
E01 DK60KB
Contents of
• Signal voltage of acceleration sensor is above 4.7V.
trouble
Action of
• Turns shoe slip control (SSC) function OFF.
controller
Problem that
appears on • Even if shoe slips, engine speed does not change.
machine
• Input (Voltage) from acceleration sensor can be checked in monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

1
Defective acceleration sen- carry out troubleshooting.
2
sor (Internal trouble) SS3 Voltage
Possible causes Between 5 – 6 0.75 – 4.25V
state 3 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) STCN1 (female) 4 – SS3 (female) 5 with Voltage Max. 1V
chassis ground
STCN1 Voltage
Between 4 – . 0.75 – 4.25V
Circuit diagram related to acceleration sensor
20-554 D275AX-5
4
TROUBLESHOOTING ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA))
ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA))

Trouble Pitch angle sensor: Disconnection (KA) (Steering controller system)
CALL E03 DKH1KA
Contents of
• Signal voltage of pitch angle sensor is below 0.15V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope and when machine is steered on level place.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of pitch angle sensor)
information

1
Defective pitch angle sensor carry out troubleshooting.
2
(Internal trouble) PT1 Voltage
Between % – $ 0.15 – 4.85V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) ) –
and standard ing or defective contact in PT1 (female) &
value in normal connector) Wiring harness between STCN1 (female) & –
state PT1 (female) %
(Contact with ground circuit) (female) & – PT1 (female) % with chassis Resistance Min. 1MΩ
ground
STCN1 Voltage
Between & – . 0.15 – 4.85V
Circuit diagram related to pitch angle sensor
D275AX-5 20-555
4
TROUBLESHOOTING ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))

Trouble Pitch angle sensor: Short circuit (KB) (Steering controller system)
CALL E03 DKH1KB
Contents of
• Signal voltage of pitch angle sensor is above 4.85V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope and when machine is steered on level place.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of pitch angle sensor)
information

1
Defective pitch angle sensor carry out troubleshooting.
2
(Internal trouble) PT1 Voltage
Possible causes Between % – $ 0.15 – 4.85V
state 3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) & – PT1 (female) % with chassis Voltage Max. 1V
ground
STCN1 Voltage
Between & – . 0.15 – 4.85V
Circuit diagram related to pitch angle sensor
20-556 D275AX-5
4
TROUBLESHOOTING ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
Action code Error code Engine Ne speed sensor: See table (LC)
Trouble
CALL E03 DLE3LC (Engine controller system)
Contents of
• Cylinders cannot be identified by signal of engine NE speed sensor.
trouble
Problem that • Engine speed may become unstable or engine may stop.
Related • Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor.

Defective engine Ne speed without turning starting switch ON.
1 sensor (Internal disconnec- NE (male) Resistance
tion or short circuit) Between 1 – 2 85 – 210Ω
ness (Disconnection in wir- Wiring harness between ECN2 (female) Z –
ing or defective contact in NE (female) 1
connector) Wiring harness between ECN2 (female) P –
NE (female) 2
and standard
(female) Z – NE (female) 1 with chassis Resistance Min. 1MΩ
ground
(female) P – NE (female) 2 with chassis Resistance Min. 1MΩ
ground
Between Z – P 85 – 210Ω
Between Z, P – chassis ground Min. 1MΩ
D275AX-5 20-557
(8)
1
TROUBLESHOOTING ERROR CODE DLE3LE (ENGINE NE SPEED SENSOR: SEE TABLE (LE))
Circuit diagram related to engine Ne speed sensor
20-558 D275AX-5
4
ERROR CODE DLF1KA (TRANSMISSION OUTPUT SPEED SENSOR:
ERROR CODE DLF1KA (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION

(KA))
Action code Error code Transmission output speed sensor: Disconnection (KA)
Trouble
E01 DLF1KA (Transmission controller system)
Contents of
• Signal is not input from transmission output speed sensor.
trouble
controller • Assumes that transmission output speed is 0rpm.
Problem that
• Transmission speed cannot be monitored.
appears on
• Traction force cannot be calculated.
machine
• Input (rpm) from transmission output speed sensor can be checked in monitoring mode.
Related
(Code 31400: Transmission speed
information
• Method of reproducing error code: Start engine and travel machine actually.

Defective transmission out- carry out troubleshooting.
put speed sensor (Internal
1 TM1 (male) Resistance
disconnection or short cir-
cuit) Between 1 – 2 500 – 1,000Ω
ness (Disconnection in wir- Wiring harness between TMCN2 (female) T –
Possible causes ing or defective contact in TM1 (female) 1
and standard connector) Wiring harness between TMCN2 (female) ] –
value in normal TM1 (female) 2
(Contact with ground circuit) TMCN2 (female) T – TM1 (female) 1 with Resistance Min. 1MΩ
chassis ground
4 TMCN2 (female) Resistance
troller
Between T – ] 500 – 1,000Ω
Between T – chassis ground Min. 1MΩ
Circuit diagram related to transmission output speed sensor
D275AX-5 20-559
(8)
1
TROUBLESHOOTING ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC))
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC))
Action code Error code Engine G speed sensor: See table (LC)
Trouble
CALL E03 DLH1LC (Engine controller system)
Contents of
• Signal of engine G speed sensor does not match to signal of engine Ne speed sensor.
trouble
Problem that
appears on
machine
Related • Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor.

Defective engine G speed carry out troubleshooting.
1 sensor (Internal disconnec- G (male) Resistance
tion or short circuit) Between 4 – 5 1.4k – 3.5kΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) < – G
ing or defective contact in (female) 4
connector) Wiring harness between ECN2 (female) 2 – G
Possible causes (female) 5
(female) < – G (female) 4 with chassis Resistance Min. 1MΩ
ground
(female) 2 – G (female) 5 with chassis Resistance Min. 1MΩ
ground
Between < – 2 1.4k – 3.5kΩ
Between <, 2 –
Min. 1MΩ
chassis ground
Circuit diagram related to engine G speed sensor
20-560 D275AX-5
4
TROUBLESHOOTING ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB))
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB))

Trouble Caution buzzer: Short circuit (KB) (Monitor panel system)
E01 DV00KB
Contents of
• Abnormal current flowed when caution buzzer circuit output ground signal.
trouble
Action of • Flashes caution lamp.
controller • Stops caution buzzer circuit from outputting ground signal.
Problem that
appears on • Caution buzzer does not sound.
machine
Related • Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for
information 1 second).

Defective caution buzzer without turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between 1 – 2 200Ω
Possible causes Short circuit with power carry out troubleshooting.
and standard 2 source in wiring harness
Short circuit of wiring harness between 217 (fe-
value in normal (Contact with 24V circuit) Voltage Max. 1V
male) 1 – S03 (female) H with chassis ground
state
S03 Caution buzzer Voltage
3 Defective monitor panel
When turned OFF 20 – 30V
Between H –
When turned ON
chassis ground Max. 3V
(sounding)
Circuit diagram related to caution buzzer
D275AX-5 20-561
3
1
ERROR CODE DW59KA (BLADE DUAL SELECTOR SOLENOID:
ERROR CODE DW59KA (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code Blade dual selector solenoid: Disconnection (KA)
Trouble
E01 DW59KA (Transmission controller system)
Contents of
• When signal is output to blade dual selector solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to blade dual selector solenoid circuit.
controller
Problem that
appears on • Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
• Output (Current) to blade dual selector solenoid can be checked in monitoring mode.]
Related
(Code 70600: Blade dual solenoid drive current)
information
• Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- without turning starting switch ON.
1 tor solenoid (Internal short
PPA (male) Resistance
circuit)
Between 4 – 5 10 – 40Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) 4 –
Possible causes ing or defective contact in PPA (female) 4
and standard connector) Wiring harness between TMCN3 (female) 0 –
value in normal PPA (female) 5
(Contact with 24V circuit) TMCN3 (female) 4 – PPA (female) 4 with Voltage Max. 1V
chassis ground
4
troller TMCN3 (female) Resistance
Between 4 – 0 10 – 40Ω
Circuit diagram related to blade dual selector solenoid
20-562 D275AX-5
4
ERROR CODE DW59KB (BLADE DUAL SELECTOR SOLENOID: SHORT
ERROR CODE DW59KB (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade dual selector solenoid: Short circuit (KB)
Trouble
E01 DW59KB (Transmission controller system)
Contents of
• When signal is output to blade dual selector solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to blade dual selector solenoid circuit.
controller
Problem that
appears on • Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
• Output (Current) to blade dual selector solenoid can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- without turning starting switch ON.
1 tor solenoid (Internal short PPA (male) Resistance
circuit) Between 4 – 5 10 – 40Ω
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal 2 ground in wiring harness Short circuit of wiring harness between
state (Contact with ground circuit) TMCN3 (female) 4 – PPA (female) 4 with Resistance Min. 1MΩ
chassis ground
3
troller
Between 4 – 0 10 – 40Ω
Circuit diagram related to blade dual selector solenoid
D275AX-5 20-563
4
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID:
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch selector solenoid: Disconnection (KA)
Trouble
E02 DW5AKA (Transmission controller system)
Contents of
• When signal is output to blade pitch selector solenoid circuit, any current does not flow.
trouble
controller • Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
• Output (Current) to blade pitch selector solenoid can be checked in monitoring mode.
Related
(Code 31625: Blade pitch solenoid drive current)
information
• Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short
PDS (male) Resistance
circuit)
Between 4 – 5 10 – 40Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) > –
Possible causes ing or defective contact in PDS (female) 4
value in normal PDS (female) 5
(Contact with 24V circuit) TMCN3 (female) > – PDS (female) 4 with Voltage Max. 1V
chassis ground
4
Between > – 0 10 – 40Ω
Circuit diagram related to blade pitch selector solenoid
20-564 D275AX-5
4
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch selector solenoid: Short circuit (KB)
Trouble
E02 DW5AKB (Transmission controller system)
Contents of
• When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
trouble
controller • Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
• Output (Current) to blade pitch selector solenoid can be checked in monitoring mode.
Related
information
• Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short PDS (male) Resistance
circuit) Between 4 – 5 10 – 40Ω
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal 2 ground in wiring harness Short circuit of wiring harness between
state (Contact with ground circuit) TMCN3 (female) > – PDS (female) 4 with Resistance Min. 1MΩ
chassis ground
3
troller
Between > – 0 10 – 40Ω
Between > – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch selector solenoid
D275AX-5 20-565
4
ERROR CODE DWN1KA (HSS PUMP SOLENOID LEFT: DISCONNECTION
ERROR CODE DWN1KA (HSS PUMP SOLENOID LEFT: DISCONNECTION (KA))
Action code Error code HSS pump solenoid left: Disconnection (KA)
Trouble
CALL E03 DWN1KA (Steering controller system)
Contents of
• When signal is output to HSS pump solenoid left circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS pump solenoid left circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid left can be checked in monitoring mode.
Related (Code 50602, 50600: Left HSS solenoid output current)
information • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to
left).

Defective HSS pump sole- without turning starting switch ON.
1 noid left (Internal discon-
PUPB (male) Resistance
nection)
Between 4 – 5 10 – 20Ω
Possible causes ing or defective contact in PUPB (female) 4
and standard connector) Wiring harness between STCN3 (female) 6 –
value in normal PUPB (female) 5
(Contact with 24V circuit) (female) 2 – PUPB (female) 4 with chassis Voltage Max. 1V
ground
STCN3 Resistance
Between 2 – 6 10 – 20Ω
Circuit diagram related to HSS pump solenoid left
20-566 D275AX-5
4
TROUBLESHOOTING ERROR CODE DWN1KB (HSS PUMP SOLENOID LEFT: SHORT CIRCUIT (KB))
ERROR CODE DWN1KB (HSS PUMP SOLENOID LEFT: SHORT CIRCUIT (KB))
Action code Error code HSS pump solenoid left: Short circuit (KB)
Trouble
CALL E03 DWN1KB (Steering controller system)
Contents of
• When signal was output to HSS pump solenoid left circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to HSS pump solenoid left circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid left can be checked in monitoring mode.
Related (Code 50602, 50600: Left HSS solenoid output current)
left).

1 noid left (Internal short cir- PUPB (male) Resistance
cuit) Between 4 – 5 10 – 20Ω
Possible causes (Contact with ground circuit) (female) 2 – PUPB (female) 4 with chassis Resistance Min. 1MΩ
and standard ground
Short circuit in wiring har-
Short circuit in wiring harness between STCN3
3 ness (with another wiring
(female) 2 – PUPB (female) 4 with wiring har-
harness) Resistance Min. 1MΩ
ness between STCN3 (female) 6 – PUPB (fe-
male) 5
4 Defective steering controller STCN3 Resistance
Between 2 – 6 10 – 20Ω
Circuit diagram related to HSS pump solenoid left
D275AX-5 20-567
4
ERROR CODE DWN2KA (HSS PUMP SOLENOID RIGHT: DISCONNECTION
ERROR CODE DWN2KA (HSS PUMP SOLENOID RIGHT: DISCONNECTION (KA))
Action code Error code HSS pump solenoid right: Disconnection (KA)
Trouble
Contents of
• When signal is output to HSS pump solenoid right circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS pump solenoid right circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid right can be checked in monitoring mode.
Related (Code 50603, 50601: Right HSS solenoid output current)
right).

1 noid right (Internal discon-
PUPA (male) Resistance
nection)
Between 4 – 5 10 – 20Ω
ness (Disconnection in wir- Wiring harness between STCN3 (female) < –
Possible causes ing or defective contact in PUPA (female) 4
value in normal PUPA (female) 5
(Contact with 24V circuit) (female) < – PUPA (female) 4 with chassis Voltage Max. 1V
ground
STCN3 Resistance
Between < – 6 10 – 20Ω
Circuit diagram related to HSS pump solenoid right
20-568 D275AX-5
4
ERROR CODE DWN2KB (HSS PUMP SOLENOID RIGHT: SHORT CIRCUIT
ERROR CODE DWN2KB (HSS PUMP SOLENOID RIGHT: SHORT CIRCUIT (KB))
Action code Error code HSS pump solenoid right: Short circuit (KB)
Trouble
Contents of
• When signal was output to HSS pump solenoid right circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to HSS pump solenoid right circuit.
controller
Problem that
appears on
machine
• Output (Current) to HSS pump solenoid right can be checked in monitoring mode.
Related (Code 50603, 50601: Right HSS solenoid output current)
right).

1 noid right (Internal short cir- PUPA (male) Resistance
Possible causes (Contact with ground circuit) (female) Y – PUPA (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
(female) Y – PUPA (female) 1 with wiring har-
ness between STCN3 (female) 3 – PUPA (fe-
male) 2
Between Y – 3 10 – 20Ω
Between Y – chassis ground Min. 1MΩ
Circuit diagram related to HSS pump solenoid right
D275AX-5 20-569
3
1
ERROR CODE DWN3KA (SUDDEN STOP PREVENTION SOLENOID:
ERROR CODE DWN3KA (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION

(KA))
Action code Error code Sudden stop prevention solenoid: Disconnection (KA)
Trouble
Contents of
• When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
trouble
Problem that • Brake is applied lightly during travel.
• Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- without turning starting switch ON.
1 vention solenoid (Internal
STB (male) Resistance
disconnection)
Between 1 – 2 5 – 25Ω
Possible causes ing or defective contact in STB (female) 1
and standard connector) Wiring harness between STCN3 (female) M –
value in normal STB (female) 2
(Contact with 24V circuit) (female) 7 – STB (female) 1 with chassis Voltage Max. 1V
ground
STCN3 Resistance
Between 7 – M 5 – 25Ω
Circuit diagram related to sudden stop prevention solenoid
20-570 D275AX-5
1
ERROR CODE DWN3KB (SUDDEN STOP PREVENTION SOLENOID: SHORT
ERROR CODE DWN3KB (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT

(KB))
Action code Error code Sudden stop prevention solenoid: Short circuit (KB)
Trouble
Contents of
• When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
trouble
• Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- without turning starting switch ON.
1 vention solenoid (Internal STB (male) Resistance
short circuit) Between 1 – 2 5 – 25Ω
Possible causes (Contact with ground circuit) (female) 7 – STB (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
(female) 7 – STB (female) 1 with wiring har-
ness between STCN3 (female) M – STB (fe-
male) 2
Between 7 – M 5 – 25Ω
Circuit diagram related to sudden stop prevention solenoid
D275AX-5 20-571
3
1
TROUBLESHOOTING ERROR CODE DWN4KA (HSS FREE SOLENOID: DISCONNECTION (KA))
ERROR CODE DWN4KA (HSS FREE SOLENOID: DISCONNECTION (KA))
Action code Error code HSS free solenoid: Disconnection (KA)

Trouble
E01 DWN4KA (Steering controller system)
Contents of
• When signal is output to HSS free solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS free solenoid circuit.
controller
Problem that
appears on • Machine cannot make pivot turn.
machine
• Output (Voltage) to HSS free solenoid can be checked in monitoring mode.
Related (Code 31626: HSS free solenoid drive current)
information • Method of reproducing service code: Start engine and turn pivot turn switch ON and travel and steer
fully.

Defective HSS free solenoid without turning starting switch ON.
1
(Internal disconnection) MFR (male) Resistance
Between 1 – 2 5 – 25Ω
Possible causes ing or defective contact in MFR (female) 1
value in normal MFR (female) 2
(Contact with 24V circuit) (female) 8 – MFR (female) 1 with chassis Voltage Max. 1V
ground
STCN3 (female) Resistance
Between 8 – 3 5 – 25Ω
Circuit diagram related to HSS free solenoid
20-572 D275AX-5
1
TROUBLESHOOTING ERROR CODE DWN4KB (HSS FREE SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DWN4KB (HSS FREE SOLENOID: SHORT CIRCUIT (KB))
Action code Error code HSS free solenoid: Short circuit (KB)
Trouble
E01 DWN4KB (Steering controller system)
Contents of
• When signal was output to HSS free solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to HSS free solenoid circuit.
controller
Problem that
appears on • Machine cannot make pivot turn.
machine
• Output (Voltage) to HSS free solenoid can be checked in monitoring mode.
Related (Code 31626: HSS free solenoid drive current)
information • Method of reproducing service code: Start engine and turn pivot turn switch ON and travel and steer
fully.

Defective HSS free solenoid MFR (male) Resistance
1
(Internal short circuit)
Between 1 – 2 5 – 25Ω
Possible causes (Contact with ground circuit) (female) 8 – MFR (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
3 ness (with another wiring Short circuit in wiring harness between STCN3
(female) 8 – MFR (female) 1 with wiring har-
ness between STCN3 (female) W – MFR (fe-
male) 2
Between 8 – 3 5 – 25Ω
Circuit diagram related to HSS free solenoid
D275AX-5 20-573
3
1
TROUBLESHOOTING ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION (KA))
ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION (KA))
Action code Error code Fan pump solenoid: Disconnection (KA)

Trouble
E01 DWN5KA (Transmission controller system)
Contents of
• When signal is output to fan pump solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump solenoid without turning starting switch ON.
1
(Internal disconnection) FAC (male) Resistance
Between 1 – 2 15 – 25Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) G –
Possible causes ing or defective contact in FAC (female) 1
and standard connector) Wiring harness between TMCN3 (female) M –
value in normal FAC (female) 2
(Contact with 24V circuit) TMCN3 (female) G – FAC (female) 1 with Voltage Max. 1V
chassis ground
4
Between G – M 15 – 25Ω
Circuit diagram related to fan pump solenoid
20-574 D275AX-5
1
TROUBLESHOOTING ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Fan pump solenoid: Short circuit (KB)
Trouble
E01 DWN5KB (Transmission controller system)
Contents of
• When signal was output to fan pump solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump solenoid FAC (male) Resistance
1
(Internal short circuit)
Between 1 – 2 15 – 25Ω
Possible causes (Contact with ground circuit) TMCN3 (female) G – FAC (female) 1 with Resistance Min. 1MΩ
and standard chassis ground
Short circuit in wiring harness between
harness) TMCN3 (female) G – FAC (female) 1 with wir-
ing harness between TMCN3 (female) M –
FAC (female) 2
Defective transmission con- TMCN3 Resistance
4
troller
Between G – M 15 – 25Ω
Between G – chassis ground Min. 1MΩ
Circuit diagram related to fan pump solenoid
D275AX-5 20-575
3
1
TROUBLESHOOTING ERROR CODE DXH1KA (LOCK-UP SOLENOID: DISCONNECTION (KA))
ERROR CODE DXH1KA (LOCK-UP SOLENOID: DISCONNECTION (KA))
Action code Error code Lock-up solenoid: Disconnection (KA)

Trouble
E01 DXH1KA (Transmission controller system)
Contents of
• When signal is output to torque converter lock-up solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to torque converter lock-up solenoid circuit.
controller
Problem that
appears on • Torque converter is not locked-up.
machine
• Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
Related
(Code 31627: Torque converter lock-up solenoid drive current)
information
• Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine.

Defective torque converter without turning starting switch ON.
1 lock-up solenoid (Internal
653 (male) Resistance
short circuit)
Between 1 – 2 30 – 80Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) \ –
Possible causes ing or defective contact in 653 (female) 1
and standard connector) Wiring harness between TMCN3 (female) M –
value in normal 653 (female) 2
(Contact with 24V circuit) TMCN3 (female) \ – 653 (female) 1 with Voltage Max. 1V
chassis ground
4
Between \ – M 30 – 80Ω
Circuit diagram related to torque converter lock-up solenoid
20-576 D275AX-5
1
TROUBLESHOOTING ERROR CODE DXH1KB (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DXH1KB (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))

Trouble Lock-up solenoid: Short circuit (KB)(Transmission controller system)
E01 DXH1KB
Contents of
• When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to torque converter lock-up solenoid circuit.
controller
Problem that
appears on • Torque converter is not locked-up.
machine
• Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
Related
(Code 31627: Torque converter lock-up solenoid drive current)
information
• Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine.

Defective torque converter without turning starting switch ON.
1 lock-up solenoid (Internal 653 (male) Resistance
Possible causes (Contact with ground circuit) TMCN3 (female) \ – 653 (female) 1 with Resistance Min. 1MΩ
Short circuit in wiring harness between
harness) TMCN3 (female) \ – 653 (female) 1 with wir-
ing harness between TMCN3 (female) M – 653
(female) 2
4
troller
Between \ – M 30 – 80Ω
Between \ – chassis ground Min. 1MΩ
Circuit diagram related to torque converter lock-up solenoid
D275AX-5 20-577
3
1
TROUBLESHOOTING ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 1st clutch ECMV: Disconnection (KA)

Trouble
CALL E03 DXH4KA (Transmission controller system)
Contents of
• When signal is output to 1st clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that • Automatic shift-down function does not work.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in F1 or R1.

Defective 1st clutch sole- without turning starting switch ON.
1
noid (Internal short circuit) S1T (male) Resistance
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) E –
Possible causes ing or defective contact in S1T (female) 1
value in normal S1T (female) 2
(Contact with 24V circuit) TMCN3 (female) E – S1T (female) 1 with Voltage Max. 1V
chassis ground
Defective transmission con- without turning starting switch ON.
4
Between E – 3 5 – 15Ω
20-578 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 1st clutch ECMV: Short circuit (KB)
Trouble
CALL E03 DXH4KB (Transmission controller system)
Contents of
• When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that • Automatic shift-down function does not work.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information

Defective 1st clutch sole- S1T (male) Resistance
1
noid (Internal short circuit)
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) E – S1T (female) 1 with Resistance Min. 1MΩ
3 ness (with another wiring Short circuit in wiring harness between
TMCN3 (female) E – S1T (female) 1 with wir-
ing harness between TMCN3 (female) 3 –
S1T (female) 2
4
troller
Between E – 3 5 – 15Ω
Between E – chassis ground Min. 1MΩ
D275AX-5 20-579
(6)
1
TROUBLESHOOTING ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 2nd clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to 2nd clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole- without turning starting switch ON.
1
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Z –
and standard connector) Wiring harness between TMCN3 (female) C –
(Contact with 24V circuit) TMCN3 (female) Z – S2T (female) 1 with Voltage Max. 1V
chassis ground
4
Between Z – C 5 – 15Ω
20-580 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 2nd clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole- S2T (male) Resistance
1
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) Z – S2T (female) 1 with Resistance Min. 1MΩ
TMCN3 (female) Z – S2T (female) 1 with wir-
ing harness between TMCN3 (female) C –
S2T (female) 2
4
troller
Between Z – C 5 – 15Ω
Between Z – chassis ground Min. 1MΩ
D275AX-5 20-581
(6)
1
TROUBLESHOOTING ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 3rd clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to 3rd clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole- without turning starting switch ON.
1
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) 5 –
(Contact with 24V circuit) TMCN3 (female) 5 – S3T (female) 1 with Voltage Max. 1V
chassis ground
4
Between 5 – 3 5 – 15Ω
20-582 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 3rd clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole- S3T (male) Resistance
1
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) 5 – S3T (female) 1 with Resistance Min. 1MΩ
TMCN3 (female) 5 – S3T (female) 1 with wir-
ing harness between TMCN3 (female) 3 –
S3T (female) 2
4
troller
Between 5 – 3 5 – 15Ω
D275AX-5 20-583
(6)
1
TROUBLESHOOTING ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Reverse clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to reverse clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch so- without turning starting switch ON.
1
lenoid (Internal short circuit) SRT (male) Resistance
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) O –
Possible causes ing or defective contact in SRT (female) 1
value in normal SRT (female) 2
(Contact with 24V circuit) TMCN3 (female) O – SRT (female) 1 with Voltage Max. 1V
chassis ground
4
Between O – C 5 – 15Ω
20-584 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Reverse clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch so- SRT (male) Resistance
1
lenoid (Internal short circuit)
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) O – SRT (female) 1 with Resistance Min. 1MΩ
TMCN3 (female) O – SRT (female) 1 with wir-
SRT (female) 2
4
troller
Between O – C 5 – 15Ω
Between O – chassis ground Min. 1MΩ
D275AX-5 20-585
(6)
1
TROUBLESHOOTING ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Forward clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to forward clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch so- without turning starting switch ON.
1
lenoid (Internal short circuit) SFT (male) Resistance
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Y –
Possible causes ing or defective contact in SFT (female) 1
value in normal SFT (female) 2
(Contact with 24V circuit) TMCN3 (female) Y – SFT (female) 1 with Voltage Max. 1V
chassis ground
4
Between Y – C 5 – 15Ω
20-586 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Forward clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch so- SFT (male) Resistance
1
lenoid (Internal short circuit)
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) Y – SFT (female) 1 with Resistance Min. 1MΩ
TMCN3 (female) Y – SFT (female) 1 with wir-
SFT (female) 2
4
troller
Between Y – C 5 – 15Ω
Between Y – chassis ground Min. 1MΩ
D275AX-5 20-587
(6)
1
TROUBLESHOOTING ERROR CODE DXHBKA (RIGHT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE DXHBKA (RIGHT BRAKE ECMV: DISCONNECTION (KA))
Action code Error code Right brake ECMV: Disconnection (KA)

Trouble
CALL E04 DXHBKA (Steering controller system)
Contents of
• When signal is output to right steering brake solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to right steering brake solenoid circuit.
controller
• Limits operation of engine, transmission and brake.
• Output (Current) to right steering brake solenoid can be checked in monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing service code: Turn starting switch ON and release parking brake lever.

Defective right steering without turning starting switch ON.
1 brake solenoid (Internal
SRB (male) Resistance
short circuit)
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between STCN3 (female) E –
Possible causes ing or defective contact in SRB (female) 1
and standard connector) Wiring harness between STCN3 (female) C –
value in normal SRB (female) 2
(Contact with 24V circuit) (female) E – SRB (female) 1 with chassis Voltage Max. 1V
ground
Between E – C 5 – 15Ω
20-588 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXHBKB (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHBKB (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
Action code Error code Right brake ECMV: Short circuit (KB)
Trouble
CALL E04 DXHBKB (Steering controller system)
Contents of
• When signal was output to right steering brake solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to right steering brake solenoid circuit.
controller
• Output (Current) to right steering brake solenoid can be checked in monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing service code: Start engine and release parking brake lever.

Defective right steering without turning starting switch ON.
1 brake solenoid (Internal SRB (male) Resistance
Possible causes (Contact with ground circuit) (female) E – SRB (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
(female) E – SRB (female) 1 with wiring har-
ness between STCN3 (female) C – SRB (fe-
male) 2
Between E – C 5 – 15Ω
Between E – chassis ground Min. 1MΩ
D275AX-5 20-589
(6)
1
TROUBLESHOOTING ERROR CODE DXHCKA (LEFT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE DXHCKA (LEFT BRAKE ECMV: DISCONNECTION (KA))
Action code Error code Left brake ECMV: Disconnection (KA)

Trouble
CALL E04 DXHCKA (Steering controller system)
Contents of
• When signal is output to left steering brake solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to left steering brake solenoid circuit.
controller
• Limits operation of engine, transmission and brake.
• Output (Current) to left steering brake solenoid can be checked in monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing service code: Turn starting switch ON and release parking brake lever.

Defective left steering brake without turning starting switch ON.
1 solenoid (Internal short cir-
SLB (male) Resistance
cuit)
Between 1 – 2 5 – 15Ω
Possible causes ing or defective contact in SLB (female) 1
and standard connector) Wiring harness between STCN3 (female) C –
value in normal SLB (female) 2
(Contact with 24V circuit) (female) 5 – SLB (female) 1 with chassis Voltage Max. 1V
ground
Between 5 – C 5 – 15Ω
20-590 D275AX-5
(6)
1
TROUBLESHOOTING ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
Action code Error code Left brake ECMV: Short circuit (KB)
Trouble
CALL E04 DXHCKB (Steering controller system)
Contents of
• When signal was output to left steering brake solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to left steering brake solenoid circuit.
controller
• Output (Current) to left steering brake solenoid can be checked in monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing error code: Start engine and release parking brake lever.

Defective left steering brake without turning starting switch ON.
1 solenoid (Internal short cir- SLB (male) Resistance
Possible causes (Contact with ground circuit) (female) 5 – SLB (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
(female) 5 – SLB (female) 1 with wiring har-
ness between STCN3 (female) C – SLB (fe-
male) 2
Between 5 – C 5 – 15Ω
D275AX-5 20-591
(6)
1
TROUBLESHOOTING ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
20-592 D275AX-5
4
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)

E-1 The engine does not start. ............................................................................................................... 20-603
E-2 The preheater does not operate. (Manual preheating function) ....................................................... 20-605
E-3 The ripper pin puller cylinder does not operate. ............................................................................... 20-607
E-4 The monitor panel does not come on at all when the starting switch is turned ON. ........................ 20-608
E-5 When the starting switch is turned ON, the monitor panel completely remains lighted
and does not go out. ......................................................................................................................... 20-609
E-6 When the starting switch is turned on, the basic check items flash. ................................................ 20-610
E-7 While the engine is operating, any caution item flashes. ................................................................. 20-611
E-8 While the engine is operating, the emergency warning item flashes. .............................................. 20-613
E-9 While the preheater is operating, the preheating pilot lamp does not come on. .............................. 20-617
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on.
(Dual tilt-mounted machine) ........................................................................................................... 20-619
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp
does not come on. .......................................................................................................................... 20-619
E-12 The engine water temperature gauge does not indicate normally. ................................................ 20-620
E-13 Indication of the power train temperature gauge is abnormal. ....................................................... 20-621
E-14 The hydraulic oil temperature gauge does not indicate normally. .................................................. 20-622
E-15 Indication of the fuel gauge is abnormal. ....................................................................................... 20-623
E-16 Indications of gear speed and engine speed are abnormal. .......................................................... 20-624
E-17 Indication of the shift mode service meter is abnormal. ................................................................. 20-624
E-18 The switch module cannot be operated. ........................................................................................ 20-625
E-19 The warning lamp does not flash or does not go out. .................................................................... 20-626
E-20 The alarm buzzer does not sound or does not stop. ...................................................................... 20-627
E-21 Auto shift down is not possible or is not released. ......................................................................... 20-628
E-22 Pivot turn is not possible or is not released. .................................................................................. 20-629
E-23 The alarm buzzer cannot be cancelled. ......................................................................................... 20-630
E-24 The operator mode cannot be operated. ....................................................................................... 20-631
E-25 The service mode cannot be operated. ......................................................................................... 20-632
E-26 The back-up alarm does not sound. .............................................................................................. 20-634
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel
do not come on. ............................................................................................................................. 20-635
E-28 The air conditioner does not operate. ............................................................................................ 20-639
D275AX-5 20-601
4

★ Troubleshooting lists and related circuit diagrams contain the following information all together. Understand
the contents carefully and troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to problems occurred or troubleshooting
information

<Described contents>
• Standard value in normal state required to judge the assumed
cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is
disconnected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
2 A harness not connected to the power (24V) circuit comes into
contact with the power (24V) circuit.
• Defective short
Possible causes Cause by which a trouble is as-
A harness of an independent circuit abnormally comes into con-
and standard sumed to be detected
tact with one of another circuit.
value in normal (The order number indicates a
state serial number, not a priority se-
<Notes on troubleshooting>
quence.)
4Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
3 shown below unless especially specified.
• When “male” or “female” is not indicated for a connector num-
ber, disconnect the connector, and insert the T-junction adapt-
er in both the male and female.
• When “male” or “female” is indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
only either the male or female.
5Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
4 shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• Arrow (⇔): Roughly indicates mounting place on machine.
20-602 D275AX-5
4
TROUBLESHOOTING E-1
E-1 THE ENGINE DOES NOT START.
Trouble • The engine does not start.

• The engine start circuit has the neutral safety function, and the engine does not start unless the park-
ing lever is set to the lock position.
Related
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when
information
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.

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24V Min. 1.26
★ Prepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective starting switch (in- KEY (male) Switch position Resistance
2
OFF Min. 1MΩ
Between 5 and 3
START Max. 1Ω
★ Prepare with the starting switch OFF, then start the engine and car-
ry out troubleshooting.
Defective neutral safety re-
3 If the engine starts in accordance with the engine starting arrange-
lay (internal disconnection)
ment after the neutral safety relay (NSF) is replaced with another one
while the starting switch is set to OFF, the relay is defective.
★ Prepare with the starting switch OFF, then turn the starting switch
Defective alternator (inter- ON and carry out troubleshooting.
4
nal short-circuit) Alternator Voltage
Between Terminal R and ground Max. 1V
Possible causes Starting motor Voltage
and standard Electric power supply : between
20 – 30V
value in normal Terminal ST/B and ground
state Detective starting motor (in- Charge : between ST 2 and
5 Max. 1V
ternal defect) ground
Starting : between ST 1 and
20 – 30V
ground
When the voltages of electric power supply, for charging and starting
are normal but the starting motor does not rotate, the starting motor
is defective.
Disconnection in wiring har- without turning the starting switch ON.
ness (disconnection in wir- Wiring harness between KEY (female) 3 and
ing or defective contact in NFS (female) 3
connector) Wiring harness between NSF (female) 5 and
ST (female) 1
ON and carry out troubleshooting.
Hot short circuit of wiring Hot short circuit of wiring harness between al-
ternator R terminal and ST (female) 2 or
TMCN1 (female) E or S04 (female) 9 with
ground (Note : While a hot short circuit occurs,
the battery charge level lamp comes on when
the starting switch is turned ON.)
D275AX-5 20-603
3
1
TROUBLESHOOTING E-1
Engine start/charge-related circuit diagram
20-604 D275AX-5
1
TROUBLESHOOTING E-2
E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION)
Trouble • The preheater does not operate. (Manual preheating function)

★ This troubleshooting describes the procedures to be followed when the manual preheating function
cannot heat the electrical intake air heater mounting section. (When the preheating lamp only does
not come on, carry out the troubleshooting of “The preheating lamp does not come on.”)
Related • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
information available. When either function is performed, the preheating lamp comes on.
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” hen the
starting switch is turned ON, the main electric power supply system supposed to be out of order. So,
inspect the main electric power supply system.

Defective starting switch (In-
1 KEY (male) Switch position Resistance
OFF Min. 1MΩ
Between 5 and 2
HEAT Max. 1Ω
★ Prepare with the starting switch OFF, then set the starting switch to
HEAT and carry out troubleshooting.
Heater relay Voltage
Electric power supply : between
Defective heater relay (inter- 20 – 30V
2 Terminal HT/A (A) and ground
nal defect)
Signal : between Terminal HT (C)
20 – 30V
and ground
Possible causes When the both voltages of electric power supply and signal are nor-
and standard mal and no operating sound is caused, the heater relay is defective.
value in normal ★ Prepare with the starting switch OFF, then carry out troubleshooting
state without turning the starting switch ON.
Defective electrical intake
3
air heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
Wiring harness between FS4-4 output – RHR
(female) 5
Wiring harness between RHR (female) 3 and
ness (Disconnection in wir- Resistance Max. 1Ω
4 KEY (female) 2 or heater relay HT (C)
connector) Wiring harness between battery relay c termi-
nal and starting motor, or heater relay A termi- Resistance Max. 1Ω
nal
Wiring harness between heater relay HT/B (B)
terminal and electrical intake air heater
D275AX-5 20-605
3
1
TROUBLESHOOTING E-2
Engine preheat-related circuit diagram
20-606 D275AX-5
4
TROUBLESHOOTING E-3
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.
Trouble • The ripper pin puller cylinder does not operate.

Related
information

When the fuse is blown, a ground fault may have possibly occurred to
the circuit.
Defective pin puller switch without turning the starting switch ON.
2 (Internal disconnection or 263 (male) Switch Resistance
short circuit) Pull Max. 1Ω
Between 4 and 5
Press Min. 1MΩ
Defective pin puller solenoid without turning the starting switch ON.
3 (Internal disconnection or 224 (male) Resistance
short circuit) Between 4 and 5 10 – 80Ω
Between 4 and ground Min. 1MΩ
Possible causes ★ Prepare with the starting switch OFF, then carry out troubleshooting
and standard without turning the starting switch ON.
value in normal Disconnection of wiring har- Wiring harness between FS4-1 outlet and 263 Resistance
Max. 1Ω
state ness (Disconnection in wir- (female) 4
4
ing or defective contact in Wiring harness between 263 (female) 5 and
connector) 224 (female) 4
Wiring harness between 224 (female) 5 and
ground
Ground fault of wiring har-
Between wiring harness related to FS4-1 (out-
5 ness (Contact with ground Resistance Min. 1MΩ
let side) and ground
circuit)
Between wiring harness (between 263 (fe-
male) 5 and 224 (female) 4) and ground
Hot short circuit of wiring ON and carry out troubleshooting.
circuit) Between wiring harness (between 263 (fe-
Voltage Max. 1V
Circuit diagram related to ripper pin puller solenoid
D275AX-5 20-607
4
TROUBLESHOOTING E-4
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH
IS TURNED ON.
Trouble • The monitor panel does not come on at all when the starting switch is turned ON.
Related • When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for 2 sec.

Defective circuit breaker When the circuit breaker is cut off, the circuit may have possibly been
1
(CB2) short-circuited with ground.
Disconnection of wiring har- without turning the starting switch ON.
ness (Disconnection in wir- Wiring harness between S03 (female) 4 5
ing or defective contact in and CB2 outlet
Possible causes connector) Wiring harness between S03 (female) 6 7
and standard Resistance Max. 1Ω
and ground
value in normal
state ★ Prepare with the starting switch OFF, then carry out troubleshooting
3 ness (Contact with ground
Between wiring harness related to CB2 (outlet
circuit) Resistance Min. 1MΩ
side) and ground
Defective monitor panel ON and carry out troubleshooting.
4
(Gauge/lamp module) S03 Voltage
Between 4 5 and 6 7 20 – 30V
Circuit diagram related to monitor panel electric power supply
20-608 D275AX-5
4
TROUBLESHOOTING E-5
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL
COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
• When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
Trouble
out.
Related • When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for 2 sec. and go out.

and standard
Defective monitor panel
value in normal 1 This internal defect cannot be diagnosed.
state (Gauge/lamp module)
D275AX-5 20-609
4
TROUBLESHOOTING E-6
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH.
Trouble • The radiator water level caution lamp flashes.

Related
• When any basic check items are detected to be abnormal before the engine starts, they will flash.
information

A drop of radiator water level (main radiator or sub radiator) was de-
Drop of radiator water level
1 tected, inspect the radiator water levels. (The lamp flashes when the
(when the system is normal)
level is below the specified level.)
aPrepare with the starting switch OFF, then carry out troubleshooting
The main radiator water lev- without turning the starting switch ON.
2 el sensor is defective. WLM (male) Radiator water level Resistance
(Internal disconnection) Normal level Max. 1z
Between 1 and 2
Lower level Min. 1Mz
The sub radiator water level without turning the starting switch ON.
3 sensor is defective. WLD (male) Radiator water level Resistance
Possible causes (Internal disconnection) Normal level Max. 1z
and standard Between 1 and 2
value in normal Lower level Min. 1Mz
state aPrepare with the starting switch OFF, then carry out troubleshooting
Disconnection of wiring har- Wiring harness between S03 (female) A and
Resistance Max. 1z
ness (Disconnection in wir- WLM (female) 1
4
ing or defective contact in Wiring harness between WLM (female) 2 and
Resistance Max. 1z
connector) WLD (female) 1
Wiring harness between WLD (female) 2 and
Resistance Max. 1z
ground
aPrepare with the starting switch OFF, then turn the starting switch
5 CN1 Radiator water level Voltage
(Gauge/lamp module)
Between A and Normal level Max. 1V
ground Lower level 20 – 20V
Circuit diagram related to radiator water caution lamp
20-610 D275AX-5
(8)
1
TROUBLESHOOTING E-7
E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES.
Trouble • The battery charge level caution lamp flashes.

Related
• When any abnormality is detected during engine operation, the relevant caution item will flash.
information

Defective alternator (insuffi-
1 Alternator Engine speed Voltage
cient power generation)
Between Terminal R Min. medium speed
20 – 30V
and ground (half)
Disconnection of wiring har- ★ Prepare with the starting switch OFF, then carry out troubleshooting
ness (Disconnection in wir- without turning the starting switch ON.
2
Possible causes ing or defective contact in Wiring harness between S04 (female) 9 and
and standard connector) alternator R terminal
state Ground fault of wiring har- without turning the starting switch ON.
3 ness (Contact with ground Between wiring harness (between S04 (fe-
circuit) male) 9 and alternator R terminal, or TMCN 1 Resistance Min. 1MΩ
(female) E) and ground
4 S04 Voltage
(Gauge/lamp module)
Between 9 and Min. medium speed
20 – 30V
ground (half)
D275AX-5 20-611
3
1
TROUBLESHOOTING E-7
Engine start/charge-related circuit diagram
20-612 D275AX-5
4
TROUBLESHOOTING E-8
E-8 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES.
Trouble (1) • The engine oil pressure caution lamp flashes.

• When any abnormality is detected during engine operation, the relevant emergency warning item will
Related
sound the alarm buzzer.
information
• The engine oil pressure switch signal is received from the engine controller through communication.

Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de-
1
(when the system is normal) tected.
The engine oil low pressure without turning the switch ON or after starting the engine.
2 switch is defective. PSL Engine Resistance
(Internal short circuit) Between terminal and Stop Max. 1Ω
ground Min. 600rpm Min. 1MΩ
The engine oil high pres- without turning the switch ON or after starting the engine.
3 sure switch is defective. PSH Engine Resistance
(Internal short circuit) Between terminal and Stop Max. 1Ω
Possible causes ground Min. 1,300rpm Min. 1MΩ
and standard ★ Prepare with the starting switch OFF, then carry out troubleshooting
value in normal without turning the starting switch ON.
state Ground fault of wiring har-
Between wiring harness (between ECN1 (fe-
male) . and PSL) and ground
circuit)
etween wiring harness (between ECN1 (fe-
male) ( and PSH) and ground
without turning the switch ON or after starting the engine.
ECN1 Engine Voltage
5 Defective engine controller Between . and Stop Max. 1V
ground Min. 600rpm 20 – 30V
Between ( and Stop Max. 1V
ground Min. 1,300rpm 20 – 30V
6 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch
D275AX-5 20-613
4
TROUBLESHOOTING E-8
Trouble (2) • The engine water temperature caution lamp flashes.

Related sound the alarm buzzer.
information • The engine water temperature caution lamp flashes or goes out as it links with indication on the engine
water temperature gauge.

Overheated engine water As overheated engine water was detected, check the engine water tempera-
1 temperature (when the sys- ture. (When the water temperature is over 102ºC, the lamp flashes. When the
tem is normal) water temperature is over 108ºC, the lamp flashes and the buzzer sounds.)
Check the indication on the engine water temperature gauge. If the
indication is abnormal, carry out the troubleshooting of “Indication on
the engine water temperature gauge is abnormal.”
aWater temperatures are guides for select-
ing indications.
Possible causes
The engine water tempera-
and standard
ture sensor system is defec- Water temperature
value in normal 2
tive. (Engine controller gauge
state
system)
White range/
Water temperature Red range
Green range
lamp
Goes out. Flashes.
When Causes 1 and 2 are not applicable, the monitor panel is sup-
3 posed to be defective. (This is an internal defect, which cannot be
(Gauge/lamp module)
troubleshot.)
Trouble (3) • The power train oil temperature caution lamp flashes.
information • The power train oil temperature caution lamp flashes or goes out as it links with indication on the power
train oil temperature gauge.

Overheated oil temperature As an overheated power train oil temperature was detected, check the
1 of power train (when the power train oil temperature. (When the oil temperature is over 130ºC,
system is normal) the lamp flashes.)
Check the indication on the power train oil temperature gauge. If the
indication is abnormal, carry out the troubleshooting of “Indication on
the power train oil temperature gauge is abnormal.”
aOil temperatures are guides for selecting
indications.
Possible causes
and standard The power train oil tempera-
value in normal 2 ture sensor system is defec- Oil temperature gauge
state tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
(Gauge/lamp module)
troubleshot.)
20-614 D275AX-5
1
(5)
TROUBLESHOOTING E-8
Trouble (4) • The hydraulic oil temperature caution lamp flashes.

information • The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydrau-
lic oil temperature gauge.

Overheated hydraulic oil As an overheated hydraulic oil temperature was detected, check the
1 temperature (when the sys- hydraulic oil temperature. (When the oil temperature is over 130°C,
tem is normal) the lamp flashes.)
Check the indication on the engine water temperature gauge. If the in-
dication is abnormal, carry out the troubleshooting of “Indication on
the hydraulic oil temperature gauge is abnormal.”
★ Oil temperatures are guides for selecting
indications.
Possible causes
and standard The hydraulic oil tempera-
value in normal 2 ture sensor system is defec- Oil temperature gauge
state tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
(Gauge/lamp module)
troubleshot.)
D275AX-5 20-615
4
TROUBLESHOOTING E-8
Trouble (5) • The HSS charge pressure caution lamp flashes.

Related • When any abnormality is detected during engine operation, the relevant emergency warning item will
information sound the alarm buzzer.

Drop of HSS charge pres-
Check the HSS charge pressure as the drop of HSS charge pressure
1 sure (when the system is
is detected.
normal)
The HSS charge oil pres- 406 (male) HSS charge pressure Resistance
2 sure switch is defective. Less than 0.8MPa
Min. 1Mz
(Internal disconnection) {Less than 8kg/cm2}
Between 1 and 2
Possible causes Min. 1.4MPa
Max. 1z
and standard {Min. 14kg/cm2}
value in normal aPrepare with the starting switch OFF, then carry out troubleshooting
Wiring harness between S03 (female) E and
circuit) Resistance Min. 1Mz
406 (female) 1 and ground.
S03 HSS charge pressure Voltage
4 Less than 0.8MPa
(Gauge/lamp module) 20 – 30V
Between E and {Less than 8kg/cm2}
ground Min. 1.4MPa
Max. 1V
{Min. 14kg/cm2}
Circuit diagram related to HSS charge oil pressure switch
20-616 D275AX-5
(8)
1
TROUBLESHOOTING E-9
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES
NOT COME ON.
Trouble • While the preheater is operating, the preheating pilot lamp does not come on.
★ This troubleshooting describes the procedures to be followed when the preheating lamp doe not come
on. (When the preheater mounting section is not heated, carry out the troubleshooting of “The pre-
Related
heater does not work.”)
information
• 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.

1
ing or defective contact in Wiring harness between S03 (female) < and
connector) heater relay HT/B (B) terminal
Possible causes without turning the starting switch ON.
and standard
2 ness (Contact with ground Between wiring harness between S03 (female)
value in normal circuit) < and heater relay HT/B (B) terminal and Resistance Min. 1MΩ
state
ground
3 S03 Voltage
(Gauge/lamp module)
Between < and ON Max. 1V
ground HEAT 20 – 30V
D275AX-5 20-617
4
TROUBLESHOOTING E-9
Engine preheat-related circuit diagram
20-618 D275AX-5
4
TROUBLESHOOTING E-9
E-10, E-11
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR
LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)
• At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-mounted
Trouble
machine)
• Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does not
Related
operate normally, the electrical system on the machine side or the hydraulic/mechanical system is sup-
information
posed to be out of order. So, troubleshoot the relevant system.)

and standard
value in normal Defective monitor panel
(Gauge/lamp module)
state
E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER

LOCK-UP DISPLAY LAMP DOES NOT COME ON.
Trouble • At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on.
• Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lock-
Related
up does not operate normally, the electrical system on the machine side or the hydraulic/mechanical
information
system is supposed to be out of order. So, troubleshoot the relevant system.)

and standard
(Gauge/lamp module)
state
D275AX-5 20-619
4
TROUBLESHOOTING E-12
E-12 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble (1) • The engine water temperature gauge does not indicate normally.
• Signals of the engine water high temperature sensor are received from the engine controller through
Related communication.
information • When any abnormality occurred in the engine hot water temperature sensor system, the failure code
[DGE2KX] is displayed sometimes.

The engine water high tem- without turning the starting switch ON.
perature sensor is defective.
1 TWH (male) Resistance
(Internal disconnection or
Between 4 and 5 3.5k – 90kΩ
short circuit)
Between 4 5 and ground Min. 1MΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) 4 and
ing or defective contact in TWH (female) 4
connector) Wiring harness between ECN2 (female) @ and Resistance Max. 1Ω
TWH (female) 5 Resistance Max. 1Ω
Possible causes
Ground fault of wiring har- without turning the starting switch ON.
value in normal 3 ness (Contact with ground
state circuit) Between wiring harness (between ECN2 (fe-
male) 4 and TWH (female) 4) and ground
circuit) Between wiring harness (between ECN2 (fe-
Voltage Max. 1V
male) 4 and TWH (female) 4) and ground
Between 4 and @ 3.5k – 90kΩ
Between 4 @ and ground Min. 1MΩ
(Gauge/lamp module)
Circuit diagram related to engine water high temperature sensor
20-620 D275AX-5
4
E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.
Trouble • Indication of the power train temperature gauge is abnormal.

Related
information

The power train oil tempera- Torque converter oil
453 (male) Resistance
ture sensor is defective. temperature
1
(Internal disconnection or About 3.8k –
Between 1 and 2
short circuit) about 80kΩ
10 – 100°C
Between 1 and
Min. 1MΩ
ground
ness (Disconnection in wir- Wiring harness between S04 (female) B and Resistance Max. 1Ω
2
Possible causes connector) Wiring harness between 453 (female) 1 and Resistance Max. 1Ω
and standard
ground Resistance Max. 1Ω
value in normal
Between wiring harness (between S04 (fe-
male) B and 453 (female) 1) and ground
Between wiring harness (between S04 (fe-
male) B and 453 (female) 1) and ground
Defective monitor panel Torque converter oil
5 S04 (female) Resistance
(Gauge/lamp module) temperature
Between B and About 3.8k –
10 – 100°C
ground about 80kΩ
Circuit diagram related to power train oil temperature sensor
D275AX-5 20-621
3
1
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble • The hydraulic oil temperature gauge does not indicate normally.
• Signals of the hydraulic oil temperature sensor are received from the transmission controller through
Related communication.
information • When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.

The hydraulic oil tempera- without turning the starting switch ON.
ture sensor is defective. (In-
1 452 (male) Resistance
ternal disconnection or
Between 4 and 5 3.5k – 90kΩ
short circuit)
ness (Disconnection in wir- Wiring harness between TMCN1 (female) '
ing or defective contact in and 452 (female) 4
connector) Wiring harness between TMCN1 (female) .
and 452 (female) 5
Possible causes
and standard Ground fault of wiring har-
value in normal 3 ness (Contact with ground
state Between wiring harness (between TMCN1 (fe-
male) ' and 452 (female) 4) and ground
Hot short circuit of wiring
Between wiring harness (between TMCN1 (fe-
male) ' and 452 (female) 4) and ground
5
troller
Between ' and . 3.5k – 90kΩ
Between ' and ground Min. 1MΩ
(Gauge/lamp module)
Circuit diagram related to hydraulic oil temperature sensor
20-622 D275AX-5
4
E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL.
Trouble • Indication of the fuel gauge is abnormal.

Related
information

Defective fuel level sensor. without turning the starting switch ON.
1 (Internal disconnection or 423 (male) Remained fuel level Resistance
short circuit) Between 4 and 5 Full About 4Ω
(ground) Empty About 85Ω
ness (Disconnection in wir- Wiring harness between S04 (female) # and
connector) Wiring harness between 423 (female) 5 and
ground
and standard
state 3 ness (Contact with ground
circuit) Between wiring harness (between S04 (fe-
male) # and 423 (female) 4) and ground
circuit) Between wiring harness (between S04 (fe-
Voltage Max. 1V
male) # and 423 (female) 4) and ground
5 S04 (female) Remained fuel level Resistance
(Gauge/lamp module)
Between # and Full About 4Ω
ground Empty About 85Ω
Circuit diagram related to fuel level sensor
D275AX-5 20-623
4
TROUBLESHOOTING E-16, E-17
E-15
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.
Trouble • Indications of gear speed and engine speed are abnormal.

Related • Signals of gear speed and engine speed are received from the transmission controller and the engine
information controller through communication.

and standard
value in normal 1 This is an internal defect, which cannot be troubleshot.
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.
Trouble (1) • During engine operation, the service meter does not advance.
Related • The service meter measures time according to engine drive signals (alternator voltage and engine oil
information pressure).

When the battery charge level caution lamp flashes during engine op-
1 Defective alternator system eration, carry out the troubleshooting of “While the engine is operat-
Possible causes
ing, caution items flash.”
and standard
The engine oil pressure When the engine oil pressure caution lamp flashes during engine op-
value in normal
state 2 sensor system is defective. eration, carry out the troubleshooting of “While the engine is operat-
(Engine controller system) ing, emergency warning items flash.”
(Gauge/lamp module)
Trouble (2) • Shift mode and service meter are not displayed at all.
Related
information

and standard
(Gauge/lamp module)
state
20-624 D275AX-5
4
E-18 THE SWITCH MODULE CANNOT BE OPERATED.
Trouble (1) • Though the switch is used, lamps do not change.

Related
information

and standard
state (Switch module)
Trouble (2) • Though the switch is used, the system setting does not change.
Related
• Switch module signals are transmitted to each controller through communication.
information

Possible causes 1
ing or defective contact in Wiring harness between S01 (female) 8 and
connector) STCN2 (female) K, or TMCN2 (female) K
value in normal
state
Defective monitor panel ry out the troubleshooting.
2
Between 8 and ground 6 – 9V
Circuit diagram related to S-NET Communication
D275AX-5 20-625
3
1
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
Trouble • The warning lamp does not flash or does not go out.
Related
information

and standard
20-626 D275AX-5
1
E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.
Trouble • The alarm buzzer does not sound or does not stop.
Related • When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other fail-
information ure codes are displayed.

Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possibly
1
(CB2) occurred in the circuit.
Defective alarm buzzer (In- without turning the starting switch ON.
2 ternal disconnection or 217 (male) Resistance
short circuit) Between 1 and 2 200Ω
Possible causes ness (Disconnection in wir- Wiring harness between S03 (female) H and
and standard ing or defective contact in 217 (female) 1
value in normal connector) Wiring harness between 217 (female) 2 and
state CB2 outlet
circuit) Between wiring harness related to CB2 (outlet
side) and ground
Defective monitor panel S03 Alarm buzzer Voltage
5
(Gauge/lamp module) At stop 20 – 30V
Between H and
At operation
ground Max. 3V
(sounding)
Circuit diagram related to alarm buzzer
D275AX-5 20-627
3
1
E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.
Trouble • Auto shift down is not possible or is not released.

Related
Defective auto shift down switch (Internal disconnection or short circuit)
information

Defective auto shift down without turning the starting switch ON.
1 switch (Internal disconnec- ASD (male) Auto shift down switch Resistance
tion or short circuit) OFF (0) Min. 1MΩ
Between 2 and 3
ON (1) Max. 1Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) ]
ing or defective contact in and ADS (female) 3
Possible causes connector) Wiring harness between ADS (female) 2 and
and standard ground
circuit) Between wiring harness (between TMCN3 (fe-
male) ] and ASD (female) 3) and ground
4 TMCN3 Auto shift down switch Voltage
troller
Between ] and OFF (0) 20 – 30V
ground ON (1) Max. 3V
When Causes 1 to 4 are not applicable, the transmission control sys-
5 tem is supposed to be out of order. (Since the system is defective, the
trol system
control system cannot be troubleshot.)
Circuit diagram related to auto shift down switch
20-628 D275AX-5
3
1
E-22 PIVOT TURN IS NOT POSSIBLE OR IS NOT RELEASED.
Trouble • Pivot turn is not possible or is not released.

Related
information

Defective pivot turn switch without turning the starting switch ON.
1 (Internal disconnection or FTU (male) Pivot turn switch Resistance
short circuit) OFF (0) Min. 1MΩ
Between 2 and 3
ON (1) Max. 1Ω
ness (Disconnection in wir- Wiring harness between STCN2 (female) C
ing or defective contact in and FTU (female) 3
Possible causes connector) Wiring harness between FTU (female) 2 and
and standard ground
circuit) Between wiring harness (between STCN2 (fe-
male) C and FTU (female) 3) and ground
4 Defective steering controller STCN2 Pivot turn switch Voltage
Between C and OFF (0) 20 – 30V
ground ON (1) Max. 3V
When Causes 1 to 4 are not applicable, the steering control system
Defective steering control
5 is supposed to be out of order. (Since the system is defective, the con-
system
trol system cannot be troubleshot.)
Circuit diagram related to pivot turn switch
D275AX-5 20-629
3
1
E-23 THE ALARM BUZZER CANNOT BE CANCELLED.
Trouble • The alarm buzzer cannot be cancelled.

Related
information

Defective buzzer cancel BUZ (male) Buzzer cancel switch Resistance
1 switch (Internal disconnec- OFF (0) Min. 1Mz
Between 1 and 2
tion or short circuit) Max. 1z
OFF (0) Min. 1Mz
Between 1 and 3
Max. 1z
Disconnection of wiring har- Wiring harness between STCN2 (female) Z
Resistance Max. 1z
ness (Disconnection in and BUZ (female) 2
2
wiring or defective contact Wiring harness between STCN2 (female) P
in connector) and BUZ (female) 3
and standard
Wiring harness between BUZ (female) 1 and
value in normal Resistance Max. 1z
ground
state
Between wiring harness (between STCN2 (fe-
3 ness (Contact with ground Resistance Min. 1Mz
male) Z and BUZ (female) 2) and ground
circuit)
Resistance Min. 1Mz
male) P and BUZ (female) 3) and ground
ON and carry out the troubleshooting.
STCN2 Buzzer cancel switch Voltage
4 Defective steering controller Between Z and OFF (0) 20 – 30V
ground Max. 1V
Between P and OFF (0) 20 – 30V
ground Max. 1V
Circuit diagram related to buzzer cancel switch
20-630 D275AX-5
(8)
1
E-24 THE OPERATOR MODE CANNOT BE OPERATED.
Trouble • The operator mode cannot be operated.

Related
information

Since the buzzer cancel switch system is supposed to be out of order,
Defective buzzer cancel
1 carry out the troubleshooting of “The alarm buzzer cannot be can-
switch system
celled.”
Defective information switch CUR (male) Information switch Resistance
2 (Internal short circuit or dis- OFF (0) Min. 1Mz
Between 1 and 2
connection) Max. 1z
OFF (0) Min. 1Mz
Between 1 and 3
Max. 1z
Disconnection of wiring har- Wiring harness between STCN2 (female) F
Resistance Max. 1z
Possible causes ness (Disconnection in wir- and CUR (female)
3
and standard ing or defective contact in Wiring harness between STCN2 (female) 6
value in normal connector) and CUR (female) 3
state Wiring harness between CUR (female) 1 and
Resistance Max. 1z
ground
4 ness (Contact with ground Resistance Min. 1Mz
male) F and CUR (female) 2) and ground
circuit)
Resistance Min. 1Mz
male) 6 and CUR (female) 3) and ground
STCN2 Buzzer cancel switch Voltage
5 Defective steering controller Between F and OFF (0) 20 – 30V
ground Max. 1V
Between 6 and OFF (0) 20 – 30V
ground Max. 1V
Circuit diagram related to information switch
D275AX-5 20-631
(8)
1
E-25 THE SERVICE MODE CANNOT BE OPERATED.
Trouble • The service mode cannot be operated.

Related
information

Since the buzzer cancel switch system is supposed to be out of order,
Defective buzzer cancel
1 carry out the troubleshooting of “The alarm buzzer cannot be can-
switch system
celled.”
Since the information switch system is supposed to be out of order,
Defective information switch
2 carry out the troubleshooting of “The operator mode cannot be can-
system
celled.”
3
Defective service switch (In- without turning the starting switch ON.
4 ternal short circuit or dis- S24 Service switch Resistance
connection) Between 5 and 6, OFF Min. 1MΩ
Between 8 and 9 ON Max. 1Ω
Wiring harness between CB6 outlet and S24
Disconnection of wiring har- Resistance Max. 1Ω
Possible causes 6
and standard ness (Disconnection in wir-
5 Wiring harness between S24 9 and ground Resistance Max. 1Ω
value in normal ing or defective contact in
connector) Wiring harness between S03 (female) ) and
state Resistance Max. 1Ω
S24 5
Wiring harness between STCN1 (female) 9
and S24 8
Between wiring harness related to CB6 (outlet
side) and ground
Defective monitor panel S03 Service switch Voltage
7
(Gauge/lamp module)
Between ) and OFF Max. 1V
ground ON 20 – 30V
8 Defective steering controller STCN1 Service switch Voltage
Between 9 and OFF 20 – 30V
ground ON Max. 1V
20-632 D275AX-5
4
Circuit diagram related to service switch
D275AX-5 20-633
4
E-26 THE BACK-UP ALARM DOES NOT SOUND.
Trouble • The back-up alarm does not sound.

Related • When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure code
information is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed.

When the fuse is blown, a ground fault may have probably occurred
in the circuit.
Defective back-up relay (in- When the relay is replaced with another relay while the starting switch
2
ternal disconnection) 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.
Possible causes
Disconnection of wiring har- Wiring harness between FS4-1 outlet and BKA
ness (Disconnection in wir- (female) 6
value in normal 3
ing or defective contact in Wiring harness between BKA (female) 8 and
state Resistance Max. 1Ω
connector) 244 (female) 5
ground
Between wiring harness related to FS4-1 (out-
circuit)
Between wiring harness (between BKA (fe-
Defective back-up alarm (in- When Causes 1 to 4 are not applicable, the back-up alarm is sup-
5
ternal defect) posed to be defective.
Circuit diagram related to back-up alarm
20-634 D275AX-5
4
E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP
ON THE PANEL DO NOT COME ON.
Trouble(1) • None of the night light, the headlamp, the working lamp and the rear lamp on the panel comes on.
Related
information

in the circuit.
★
Disconnection of wiring har- Prepare with the starting switch OFF, then carry out troubleshooting
2
ing or defective contact in Wiring harness between FS2-5 outlet and cir-
connector) cuit branching point
Possible causes ★ Prepare with the starting switch OFF, then carry out troubleshooting
and standard without turning the starting switch ON.
value in normal Between wiring harness related to FS2-5 (out-
state Resistance Min. 1MΩ
Ground fault of wiring har- Between wiring harness (between 219 (fe-
3 ness (Contact with ground male) 2 and S01 (female) @, S01 (female) 1,
circuit) S03 (female) 8, BB2 (female) 1 or BB3 (fe-
male) 1) and ground
Between wiring harness (between 218 (fe-
male) 3 and 223 (female) 1 or 243 (female) Resistance Min. 1MΩ
1) and ground
Trouble(2) • None of the night light, the headlamp and the working lamp on the panel comes on.
Related
information

Headlamp and working without turning the starting switch ON.
1 lamp switch (international 219 (male) Switch Resistance
disconnection) OFF Min. 1MΩ
Between 2 and 3
Possible causes ON Max. 1Ω
value in normal without turning the starting switch ON.
state Wiring harness between 219 (female) 3 and
Ground fault of wiring har- Resistance Max. 1Ω
circuit branching point
circuit) Resistance Max. 1Ω
BB2 (female) 1 or BB3 (female) 1
Wiring harness between BB2 (female) 2 or
BB3 (female) 1 and ground
D275AX-5 20-635
3
1
Trouble(3) • Only the night light on the panel does not comes on. (whole or part)
Related
information

1 Defective night lamp (blown) The night lamp is supposed to be defective. Check if the bulb is blown.
Wiring harness between S01 (female) @ and
circuit branching point
Disconnection of wiring har- Wiring harness between S01 (female) 2 and Resistance
Max. 1Ω
ness (Disconnection in wir- ground
2
ing or defective contact in Wiring harness between S02 (female) 1 and
connector) circuit branching point
Possible causes Wiring harness between S03 (female) 8 and
and standard circuit branching point
value in normal Wiring harness between S03 (female) 3, 4
state and ground
Defective monitor panel Between S01 @
3
(Switch module) and 2
Light switch ON 20 – 30V
Between S02 1
and ground
Defective monitor panel ON and carry out troubleshooting.
4
(Gauge/lamp module) Between S03
Light switch ON 20 – 30V
8 and 3, 4
Trouble(4) • Only the headlamp does not comes on. (Both right and left, or one side only)
Related
information

1 Defective headlamp (blown) The headlamp is supposed to be defective. Check if the bulb is blown.
2
Defective headlamp relay When the relay is replace with another relay while the starting switch
3
(Internal disconnection) is set to OFF and the headlamp comes on after the starting switch is
turned ON and the light switch is turned ON, the headlamp relay
(BB2) is defective.
Possible causes
and standard
value in normal Disconnection of wiring har- without turning the starting switch ON.
state ness (Disconnection in wir- Wiring harness between CB5 outlet and BB2
connector) Wiring harness between BB2 (female) 5 and
203 (female) 1 or 204 (female) 1
Ground fault of wiring har- Between wiring harness related to CB5 (outlet
5 ness (Contact with ground side) and ground
circuit) Between wiring harness (between BB2 (fe-
1) and ground
20-636 D275AX-5
3
1
Trouble(5) • Only the working lamp does not comes on. (Both right and left, or one side only)
Related
information

Defective working lamp The working lamp is supposed to be defective. Check if the bulb is
1
(blown) blown.
in the circuit.
Defective working lamp re- When the relay is replace with another relay while the starting switch
3
lay (Internal disconnection) is set to OFF and the headlamp comes on after the starting switch is
turned ON and the light switch is turned ON, the working lamp relay
Possible causes (BB3) is defective.
value in normal Disconnection of wiring har- without turning the starting switch ON.
state ness (Disconnection in wir- Wiring harness between Fs2-4 outlet and BB3
connector) Wiring harness between BB3 (female) 8 and
Ground fault of wiring har- Between wiring harness related to FS2-4 (out-
5 ness (Contact with ground let side) and ground
circuit) Between wiring harness (between BB3 (fe-
4) and ground
Trouble(6) • Only the rear lamp does not comes on. (Both right and left, or one side only)
Related
information

The working lamp is supposed to be defective. Check if the bulb is
1 Defective rear lamp (blown)
blown.
Defective rear lamp switch ON and carry out troubleshooting.
Possible causes 2 (international disconnec- 218 (male) Switch Resistance
and standard tion) OFF Min. 1MΩ
value in normal Between 5 and 6
ON Max. 1Ω
ness (Disconnection in wir- Wiring harness between 218 (female) 5 and
ing or defective contact in circuit branching point
connector) Wiring harness between 218 (female) 6 and
D275AX-5 20-637
4
Circuit diagram related to night light, headlamp, working lamp and rear lamp on panel
20-638 D275AX-5
4
E-28 THE AIR CONDITIONER DOES NOT OPERATE.
Trouble (1) • No air flow

Related
information

1
Defective blower main relay without turning the starting switch ON.
2
(coil side) CN-R1 (male) Resistance
Between (1) and (2) 240 ± 40Ω
Defective blower main relay ON and carry out troubleshooting.
3
(contact side) CN-R1 Voltage
Between (6C) and ground 20 – 30V
Defective blower Hi relay without turning the starting switch ON.
4
Between (1) and (2) 240 ± 40Ω
Defective blower Hi relay ON and carry out troubleshooting.
5
(contact side) The relay is in order when the motor rotates after the starting switch
is turned ON and the blower Hi switch is turned on.
Defective blower Mi relay without turning the starting switch ON.
Possible causes 6
and standard
Between (1) and (2) 240 ± 40Ω
value in normal
state ★ Prepare with the starting switch OFF, then turn the starting switch
Defective blower Mi relay ON and carry out troubleshooting.
7
(contact side) The relay is in order when the motor rotates after the starting switch
is turned ON and the blower Mi switch is turned on.
8 Defective blower motor
The motor is in order when it rotates after the starting switch is turned
ON and the blower Lo switch is turned on.
Wiring harness between CN-R3 (female) (0B),
CN-AC1 (female) (0C), CN-R (female) (0D) or Resistance Max. 1Ω
CN-R2 (female) (0E) and ground
Wiring harness between CN-B(female) (10A)
Disconnection of wiring har- Resistance Max. 1Ω
and CN-R1 (female) (10B)
9 Wiring harness between CN-B (female) (11A)
connector) and CN-R2 (female) (11B) or CN-R (female) Resistance Max. 1Ω
(11C)
Wiring harness between CB4 outlet and CN-
AC1 (female) (13C), CN-R1 (female) (13D), Resistance Max. 1Ω
CN-R2 (female) (13E) or CN-R3 (female) (13H)
Wiring harness between CN-R1 (female) (14A)
and CN-AC1 (female) (14B)
D275AX-5 20-639
3
1

ness (Disconnection in wir- Wiring harness between CN-R3 (female) (17A)
Possible causes ing or defective contact in and CN-AC1 (female) (17B)
and standard connector) Wiring harness between CN-R2 (female) (18A)
value in normal and CN-AC1 (female) (18B)
state When Causes 1 to 9 are not applicable, the control panel is supposed
10 Defective control panel
to be defective.
When any cause cannot be specified, failure phenomenon may have
Different failure phenome-
11 been mistaken. Carry out the troubleshooting of “Cooling is not pos-
non
sible.”
20-640 D275AX-5
4
Trouble (2) • Cooling is not possible.

Related
information

1 Defective pressure switch CN-P Blower switch Voltage
Between (26A) and
ON 20 – 30V
ground
Defective compressor without turning the starting switch ON.
2
clutch relay (coil side) CN-R4 (male) Resistance
Between (1) and (2) 240 ± 40Ω
Defective compressor ON and carry out troubleshooting.
3
clutch relay (contact side) CN-R4 Voltage
Between (9B) and ground 20 – 30V
Defective condenser relay ON and carry out troubleshooting.
4
(contact side) CN-R5 Voltage
Between (7B) and ground 20 – 30V
5 Defective thermistor
CN-AC1 (male) Resistance
Possible causes Between (15B) and (16C) Max. 3,500Ω
value in normal Defective condenser blower without turning the starting switch ON.
state 6
resistor Condenser blower resistor Resistance
Between terminals 2.8Ω ± 5%
★ Turn the starting switch on and carry out the troubleshooting.
7 Defective condenser motor The motor is in order if it is rotating when the air conditioner is
switched ON.
★ Start the engine and carry out the troubleshooting.
Defective compressor mag-
8 The compressor magnet clutch is supposed to be out of order, so in-
net clutch
spect it directly.
★ Start the engine and carry out the troubleshooting.
9 Defective compressor
The compressor is supposed to be out of order, so inspect it directly.
Wiring harness between CB4 outlet and CN-
R5 (female) (6B) or CN-R4 (female) (6D)
Disconnection of wiring har- Wiring harness between CN-R5 (female) (7B)
ness (Disconnection in wir- and ARC (female) 5
10
ing or defective contact in Wiring harness between CN-R4 (female) (9B)
connector) and 351 (female) 4
Wiring harness between CB4 outlet and CN-R
(female) (131)
Wiring harness between CN-T (female) (15A)
and CN-AC1 (female) (15B)
D275AX-5 20-641
4

Disconnection of wiring har- Wiring harness between CN-P (female) (19A)
ness (Disconnection in wir- and CN-R4 (female) (19C)
and standard 10
ing or defective contact in Wiring harness between CN-P (female) (26A)
value in normal Resistance Max. 1Ω
connector) and CN-AC1 (female) (26B)
state
Wiring harness between ARC (female) 4 and
ground
When Causes 1 to 10 are not applicable, the control panel is sup-
11 Defective control panel
posed to be defective.
20-642 D275AX-5
4
Circuit diagram related to air conditioner
D275AX-5 20-643
4
20-644 D275AX-5
4
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)

H-1 No travel power (No drawbar pull) ................................................................................................... 20-703
H-2 Machine does not move (At 2nd or 3rd speed) ................................................................................ 20-704
H-3 Machine does not move in any speed range ................................................................................... 20-705
H-4 Machine travels only in one direction forward or in reverse ............................................................. 20-706
H-5 When gear is shifted or travel direction is changed, large time lag is made .................................... 20-707
H-6 Machine does not turn (Not turned rightward or leftward) ............................................................... 20-708
H-7 Steering speed or power is low ........................................................................................................ 20-708
H-8 Brake does not work ........................................................................................................................ 20-709
H-9 Torque converter does not lock-up ................................................................................................... 20-709
H-10 Overheat of power train oil temperature ......................................................................................... 20-710
H-11 Abnormal sound around HSS pump or HSS motor ....................................................................... 20-711
H-12 All work equipment speeds are slow ............................................................................................. 20-712
H-13 work equipment does not move ..................................................................................................... 20-713
H-14 Blade lift speed is slow or lacks power .......................................................................................... 20-713
H-15 Blade tilt speed is slow or lacks power .......................................................................................... 20-714
H-16 Ripper lift speed is slow or lacks power ......................................................................................... 20-714
H-17 Ripper tilt speed is slow or lacks power ........................................................................................ 20-715
H-18 Excessive hydraulic drift of blade lift .............................................................................................. 20-715
H-19 Excessive hydraulic drift of blade tilt .............................................................................................. 20-716
H-20 Excessive hydraulic drift of ripper lift .............................................................................................. 20-716
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ................................ 20-717
H-22 Blade pitch does not work (Dual tilt attachment machine) ............................................................. 20-717
H-23 Abnormal sound comes out from around work equipment pump .................................................. 20-717
D275AX-5 20-701
4

★ Troubleshooting lists contain the following information all together. Understand the contents carefully and
troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to problems occurred or troubleshooting
information
Possible causes Cause supposed to have caused

2
and standard failure <Contents>
value in normal (The sequence shows reference • Standard values in normal state for judging possible causes
state numbers and does not mean pri- • Remarks for making judgment
3 ority.)
20-702 D275AX-5
4
TROUBLESHOOTING H-1
H-1 NO TRAVEL POWER (NO DRAWBAR PULL)
Trouble • There is no travel power. (No drawbar pull).

Related
• Confirm that the oil quantity on the power train is normal before troubleshooting.
information

★ Prepare with starting switch OFF, then drive the engine in high
idling mode for troubleshooting.
1 Defective engine
Measurement conditions Number of engine rotations
F3 stall 1,510rpm
2 Defective power train pump The power train pump is assumed to be defective; directly check it.
Internally defective torque Original pressure of Torque converter
3 PCCS lever
converter torque converter delivery pressure
0.49 – 1.0MPa 0.49 ± 0.1MPa
Full neutral
{5 – 10kg/cm2} {5 ± 1kg/cm2}
Transmission main relief
PCCS lever
pressure
Full neutral Min. 2.94MPa {Min. 30kg/cm2}
Defective set pressure of
4 transmission main relief ★ Prepare with the starting switch OFF, then carry out troubleshooting
valve and internal defect without turning the starting switch ON.
Possible causes Directly check that the spring length and the number of shims are nor-
and standard mal and also that the spool rotates smoothly.
value in normal • Free length of large spring: 122mm
state • Free length of small spring: 108mm
• Number of shims: 6
★ Prepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting.
Transmission clutch Clutch pressure
Defective transmission FWD Min. 2.65MPa {Min. 27kg/cm2}
5
valve (ECMV) function REV Min. 2.65MPa {Min. 27kg/cm2}
1ST Min. 2.65MPa {Min. 27kg/cm2}
2ND Min. 2.65MPa {Min. 27kg/cm2}
3RD Min. 2.65MPa {Min. 27kg/cm2}
6 Defective brake valve Parking lever Left brake pressure Right brake pressure
Min. 2.45MPa Min. 2.45MPa
Free
{Min. 25kg/cm2} {Min. 25kg/cm2}
If the result of the troubleshooting in cause 5 is abnormal, the parking
Defective parking lever or
7 lever or brake pedal linkage is not assumed to be adjusted normally.
brake pedal linkage
Directly check it.
Internally defective trans- The transmission is assumed to be defective internally; directly check
8
mission it.
D275AX-5 20-703
3
1
TROUBLESHOOTING H-2
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)
Trouble • Machine does not move. (At 2nd or 3rd speed)

Related • Confirm that the oil quantity on the power train is normal before troubleshooting.
information • Confirm that the transmission main relief pressure is normal before troubleshooting. (See H-1.)

1 PCCS lever
0.49 – 1.0MPa 0.49 ± 0.1MPa
Full neutral
{5 – 10kg/cm2} {5 ± 1kg/cm2}
Possible causes Defective transmission
2 Transmission clutch Clutch pressure
and standard valve (ECMV) function
value in normal
state 3RD Min. 2.65MPa {Min. 27kg/cm2}
Internally defective trans- The transmission clutch (2nd or 3rd speed) is assumed to be defec-
3
mission clutch tive internally; directly check it.
Defective parking brake The parking brake function is assumed to be defective (dragged);
4
function (Drag) check the linkage valves.
★ Move to a flat place, and start the engine for troubleshooting.
Defective brake function
5 If the machine does not run by low idling + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting “Brake does not work.”)
Internally defective trans- The transmission is assumed to be defective internally; directly check
6
mission it.
20-704 D275AX-5
1
TROUBLESHOOTING H-3
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE
Trouble • Machine does not move in any speed range.

Related
information

PCCS lever
pressure
Defective and Internally de-
2 fective set pressure of trans- ★ Prepare with the starting switch OFF, then carry out troubleshooting
mission main relief valve without turning the starting switch ON.
Directly check that the spring length and the number of shims are nor-
mal and also that the spool rotates smoothly.
• Free length of large spring: 122mm
• Free length of small spring: 108mm
mode for troubleshooting. (Before this, confirm that the transmis-
Possible causes
sion main relief pressure is normal.)
and standard
value in normal Transmission clutch Clutch pressure
state 3
valve (ECMV) function
REV Min. 2.65MPa {Min. 27kg/cm2}
Internally defective trans- The transmission clutch (2nd or 3rd speed) is assumed to be defec-
4
mission clutch tive internally; directly check it.
★ Move to a flat place, and drive the engine in high idling mode for
troubleshooting. (Before this, confirm that the transmission main re-
lief pressure is normal.)
Brake hydraulic pressure
Brake pedal
5 Defective brake function (left/right)
Release Min. 2.45MPa {Min. 25kg/cm2}
Pedal 0 {0}
When the hydraulic pressure is abnormal, carry out troubleshooting
“Brake does not work.”
D275AX-5 20-705
3
1
TROUBLESHOOTING H-4
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE
Trouble • Machine travels only in one direction Forward or in reverse.

Related
information

PCCS lever
pressure
valve or internal defect without turning the starting switch ON.
Possible causes mal and also that the spool rotates smoothly.
and standard • Free length of large spring: 122mm
value in normal • Free length of small spring: 108mm
state • Number of shims: 6
mode for troubleshooting. (Before this, confirm that the transmis-
Defective transmission sion main relief pressures is normal.)
3 Transmission clutch Clutch pressure
FWD Min. 2.65MPa {Min. 27kg/cm2}
Defective transmission When the troubleshooting in cause 3 is abnormal, the clutch seal is
4
clutch seal assume to be defective; directly check it.
Internally defective trans- The transmission clutch (forward or backward) is assumed to be de-
5
mission clutch fective internally; directly check it.
20-706 D275AX-5
3
1
TROUBLESHOOTING H-5
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG
IS MADE
Trouble • Time lag is excessive when shifting gear or changing direction.

Related
information

PCCS lever
pressure
Full neutral Min. 2.94MPa{Min. 30kg/cm2}
valve or internal defect without turning the starting switch ON.
mal and also that the spool rotates smoothly.
• Free length of large spring: 122mm
• Free length of small spring: 108mm
Possible causes
and standard ★ Prepare with starting switch OFF, then drive the engine in low idling
value in normal mode for troubleshooting. (Before this, confirm that the transmis-
state sion main relief pressure is normal.)
Transmission clutch Clutch pressure
3
Defective transmission When the troubleshooting in cause 3 is abnormal, the clutch seal is
4
clutch seal assume to be defective; directly check it.
Internally defective trans- The transmission clutch is assumed to be defective internally; directly
5
mission clutch check it.
★ Move to a flat place, then start the engine for troubleshooting.
6 If the machine does not run by low idling + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting “Brake does not work.”)
D275AX-5 20-707
3
1
TROUBLESHOOTING H-6, H-5
H-7
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)
Trouble • Machine does not turn. (The machine does not turn leftward or rightward.)
Related
• Confirm that the oil quantity for function is normal before troubleshooting.
information

★ Prepare with starting the engine, then drive the engine in high idling
Defective set pressure or mode for troubleshooting.
defective function of self-
Original pressure of control
1 pressure reducing valve PCCS lever
circuit
(HSS servo charge pres-
sure) 3.23 – 3.92MPa
Neutral
{33 – 40kg/cm2}
Possible causes
2 defective function of HSS PCCS lever Charge relief pressure
and standard
charge relief valve 2.6 – 3.4MPa
value in normal Neutral
state {27 – 35kg/cm2}
Defective function of HSS The HSS pump solenoid valve function is assumed to be defective; di-
3
pump solenoid valve rectly check it.
Defective function of pivot The pivot turn solenoid valve is assumed to be defective; directly
4
turn solenoid valve check it.
Defective function of pivot The function of the pivot turn valve is assumed to be defective; directly
5
turn valve check it.
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
6 out troubleshooting “Abnormal Sound around HSS Pump or HSS Mo-
peripheral equipment
tor.”
H-7 STEERING SPEED OR POWER IS LOW
Trouble • Steering speed or power is insufficient.

Related
information

1 defective function of HSS PCCS lever HSS main relief pressure
main relief valve 38.2 – 41.7MPa
Left or right stroke end
{390 – 425kg/cm2}
circuit
Possible causes (HSS servo charge pres-
and standard sure) 3.23 – 3.92MPa
Neutral
{33 – 40kg/cm2}
value in normal
state Prepare with starting the engine, then drive the engine in high idling
Defective set pressure or
3 defective function of HSS PCCS lever
circuit
charge relief valve
2.6 – 3.4MPa
Neutral
{27 – 35kg/cm2}
Defective function of HSS The HSS pump solenoid valve function is assumed to be defective; di-
4
pump solenoid valve rectly check it.
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
5 out troubleshooting “Abnormal Sound in HSS Pump or HSS Motor
peripheral equipment
Periphery.”
20-708 D275AX-5
4
H-5
H-8 BRAKE DOES NOT WORK
Trouble • Brake does not work.

information • Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)

Defective brake valve func- Brake pedal Brake hydraulic pressure
1
tion Min. 2.45MPa
Possible causes At release
{Min. 25kg/cm2}
and standard
value in normal At pedaling 0 {0}
state Defective adjustment of If the troubleshooting in cause 1 is abnormal, the adjustment of the
2
brake pedal linkage brake pedal linkage is assumed to be abnormal; directly check it.
If the troubleshooting in cause 1 is abnormal, the brake seal is as-
3 Defective brake seal
sumed to be defective; directly check it.
Slipped or abrasive brake The brake disk plate is assumed to be slipped or abrasive; directly
4
disk plate check it.
H-9 TORQUE CONVERTER DOES NOT LOCK-UP
Trouble • Torque converter does not lock-up.

information • Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)

Defective torque converter
2 Torque converter Lock-up clutch pressure
lock-up valve function
1.27 ± 0.2MPa
Possible causes At lock-up
{13 ± 2kg/cm2}
and standard
value in normal Defective lock-up clutch If the troubleshooting in cause 2 is abnormal, the lock-up clutch seal
3
seal is assumed to be defective; directly check it.
state
Internally defective lock-up The lock-up clutch is assumed to be defective internally; directly
4
clutch check it.
Internally defective torque idling mode for troubleshooting.
5
converter Measurement conditions Number of engine rotations
F3 stall 1,510rpm
D275AX-5 20-709
4
TROUBLESHOOTING H-10
H-10 OVERHEAT OF POWER TRAIN OIL TEMPERATURE
Trouble • The oil temperature of the power train overheats.

• Confirm that the value of the oil temperature of the power train matches the actual oil temperature be-
Related
fore troubleshooting. (If they do not match, carry out troubleshooting “Abnormal Power Train Oil tem-
information
perature.”) Confirm that the main relief pressure for transmission is normal before troubleshooting.
(See H-1.)

The engine cooling system is assumed to be defective or the engine
1 Defective engine system
output is assumed to be increased; see the Shop Manual: Engine.
Defective power train pump ★ The power train pump is assumed to be defective or aired from the
2
or air from suction circuit suction circuit; directly check it.
3 PCCS lever
Possible causes
0.49 – 1.0MPa 0.49 ± 0.1MPa
and standard Full neutral
{5 – 10kg/cm2} {5 ± 1kg/cm2}
value in normal
state Defective transmission The transmission clutch is assumed to be defective internally
4
clutch function (Slip) (slipped); directly check it.
★ Prepare with starting the engine for troubleshooting.
1. Use the blades and ripper to float the machine from the ground.
5 2. Convert the drive position while low-idling.
(Drag)
3. If the track shoe does not rotate, brake drag occurs. (Carry out
troubleshooting "Brake does not work.")
★ Prepare with starting the engine for troubleshooting.
6 Carry out F3 stall. If the machine does not stop completely, brake slip
(Slip)
occurs.
20-710 D275AX-5
4
H-11 ABNORMAL SOUND AROUND HSS PUMP OR HSS MOTOR
Trouble • An abnormal sound occurs in the HSS pump or HSS motor periphery.
Related
• Confirm that the oil quantity on the hydraulic oil tank is normal before troubleshooting.
information

1 defective function of HSS PCCS lever HSS main relief pressure
main relief valve 38.2 – 41.7MPa
Left or right stroke end
{390 – 425kg/cm2}
circuit
(HSS servo charge pres-
sure) 3.23 – 3.92MPa
Possible causes Neutral
{33 – 40kg/cm2}
and standard
value in normal ★ Prepare with starting the engine, then drive the engine in high idling
state Defective set pressure or mode for troubleshooting.
3 defective function of HSS PCCS lever Charge relief pressure
charge relief valve 2.6 – 3.4MPa
Neutral
{27 – 35kg/cm2}
The clamp of the HSS charge pipe is assumed to be loosened or the
4 Defective HSS charge pipe
O ring is assumed to be damaged; directly check it.
Internally defective HSS
5 The HSS pump is assumed to be defective internally; directly check it.
pump
Internally defective HSS
6 The HSS motor is assumed to be defective internally; directly check it.
motor
Internally defective work The work equipment pump is assumed to be defective internally; di-
7
equipment pump rectly check it.
D275AX-5 20-711
4
H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW
Trouble • All work equipment speeds are slow.

Related
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information

Defective PTO (pump drive The PTO pump drive unit of the work equipment is assumed to be de-
1
unit of work equipment) fective; directly check it.
Defective work equipment The pump of the work equipment is assumed to be defective; directly
2
pump check it.
Defective unload valve func-
3 Work equipment lever Unload pressure
tion
2.45 – 3.82MPa
Full neutral
{25 – 39kg/cm2}
Possible causes
and standard
Defective set pressure or idling mode for troubleshooting.
value in normal
state 4 defective function of main Work equipment lever Main relief pressure
relief valve 27.44 ± 1.37MPa
Stroke end
{280 ± 14kg/cm2}
Defective function of self-
5 pressure reducing valve Work equipment lever
circuit
(PPC original pressure)
3.23 – 3.92MPa
Full neutral
{33 – 40kg/cm2}
Internally defective PPC When the troubleshooting in cause 5 is abnormal, the PPC valve is
6
valve assumed to be defective internally; directly check it.
20-712 D275AX-5
3
1
H-14
H-13 WORK EQUIPMENT DOES NOT MOVE
Trouble • Work equipment does not move.

Related
information

Defective PTO (Pump drive The PTO pump drive unit of the work equipment is assumed to be de-
1
unit of work equipment) fective; directly check it.
Defective work equipment The work equipment pump is assumed to be defective; directly check
2
pump it.
Defective unload valve func-
3 Work equipment lever Unload pressure
tion
2.45 – 3.82MPa
Possible causes Full neutral
{25 – 39kg/cm2}
and standard
value in normal ★ Prepare with starting switch OFF, then drive the engine in high
state Defective set pressure or idling mode for troubleshooting.
4 defective function of main Work equipment lever Main relief pressure
relief valve 27.44 ± 1.37MPa
Stroke end
{280 ± 14kg/cm2}
Defective function of self-
5 pressure reducing valve Work equipment lever
circuit
(PPC original pressure)
3.23 – 3.92MPa
Full neutral
{33 – 40kg/cm2}
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER
Trouble • Blade lift speed is slow or lacks power.

Related • Confirm whether the blade is remodeled.
information • When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Lift.”

Defective PPC valve func-
Possible causes 1 Blade lever PPC valve output pressure
tion
and standard 3.14 – 3.92MPa
Lift stroke end
value in normal {32 – 40kg/cm2}
state Defective function of blade The spool function of the blade lift operation valve is assumed to be
2
lift operation 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.
D275AX-5 20-713
3
1
H-12
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER
Trouble • Blade tilt speed is slow or lacks power.

information • When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Tilt.”

Possible causes 1 Blade lever PPC valve output pressure
tion
and standard 3.82 – 4.12MPa
Lift stroke end
value in normal {39 – 42kg/cm2}
state Defective function of blade The spool function of the blade tilt operation valve is assumed to be
2
tilt operation 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
H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
Trouble • Ripper lift speed is slow or lacks power.

Related • Confirm whether the ripper is remodeled.
information • When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting “High Hydraulic
Drift Rate of Ripper Lift.”

1 Ripper lever PPC valve output pressure
tion
3.82 – 4.12MPa
Lift stroke end
Possible causes {39 – 42kg/cm2}
and standard Defective function of ripper The spool function of the ripper lift operation valve is assumed to be
value in normal 2
lift operation valve (Spool) defective; directly check it.
state The suction valve of the ripper lift operation valve is assumed to be
Defective function of ripper
defective; directly check it.
3 lift operation valve (suction
★ Replace the suction valve in the head with one at the bottom, and
valve)
observe how the phenomenon changes.
The ripper lift cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper lift cylinder
20-714 D275AX-5
4
H-18
H-17 RIPPER TILE SPEED IS SLOW OR LACKS POWER
Trouble • Ripper tile speed is slow or lacks power.

Related • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information • Confirm whether the ripper is remodeled.

1 Ripper lever PPC valve output pressure
tion
3.82 – 4.12MPa
Tilt stroke end
Possible causes {39 – 42kg/cm2}
and standard Defective function of ripper The spool function of the ripper tilt operation valve is assumed to be
value in normal 2
tilt operation valve (Spool) defective; directly check it.
state The suction valve of the ripper tilt operation valve is assumed to be
Defective function of ripper
defective; directly check it.
3 tilt operation valve (Suction
★ Replace the suction valve in the head with one at the bottom, and
valve)
observe how the phenomenon changes.
The ripper tilt cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper tilt cylinder
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT
Trouble • Excessive hydraulic drift of blade lift.

information • Confirm that no oil leaks the circuits in the work equipment before troubleshooting.

Prepare with starting the engine, then stop the engine for trouble-
shooting.
Follow the procedure below for troubleshooting. If the hydraulic drift
Possible causes speed becomes high, the spool seal of the blade lift operation valve
Defective seal of blade lift is assumed to be defective.
and standard 1
operation valve (Spool) 1. Prop up the machine using the blade lift, and lift the front of the
value in normal
state machine.
2. Stop the engine, and release the safety lock lever.
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; directly
2
cylinder check it.
D275AX-5 20-715
4
H-12
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT
Trouble • Excessive hydraulic drift of blade tilt.


★ Prepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the blade tilt operation valve
Defective seal of blade tilt is assumed to be defective.
Possible causes 1
operation valve (Spool) 1. Prop up the machine using the blade tilt, and lift the right of the
and standard machine.
value in normal
2. Stop the engine, and release the safety lock lever.
state
3. Set the blade lever to the right tilt side, and confirm how the phe-
nomenon changes.
Defective seal of blade tilt idling mode for troubleshooting.
2
cylinder Blade tilt cylinder Cylinder leak quantity
Right tilt stroke end 16cc/min
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT
Trouble • Excessive hydraulic drift of ripper lift.

Related • Confirm whether the ripper is remodeled.

★ Prepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the ripper lift operation valve
Defective seal of ripper lift (Hi) is assumed to be defective.
Possible causes 1
operation valve (Spool) 1. Prop up the machine using the blade tilt, and lift the rear of the
and standard
machine.
value in normal 2. Stop the engine, and release the safety lock lever.
state 3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of ripper lift idling mode for troubleshooting.
2
cylinder Ripper lift cylinder Cylinder leak quantity
Lowering stroke end 16cc/min
20-716 D275AX-5
4
TROUBLESHOOTING H-21, H-22, H-12
H-23
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT
MACHINE)
Trouble • The ripper pin puller cylinder does not work.

Related
• Confirm that the main relief pressure for transmission is normal before troubleshooting.
information

Possible causes
Defective function of pin Pin puller working
and standard 1 Pin puller switch Measurement position
puller solenoid pressure
value in normal
state Push-in Cylinder bottom side Min. 2.45MPa
Pull-in Cylinder head side {Min. 25kg/cm2}
Internally defective pin pull- The pin puller cylinder is assumed to be defective internally; directly
2
er cylinder check it.
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)
Trouble • The blade pitch does not work.

Related
information

Defective function of blade
The spool of the blade pitch operation valve is assumed to be defec-
1 pitch selection solenoid
Possible causes tive; directly check it.
valve
and standard
Defective function of blade
value in normal The function of the blade pitch cylinder is assumed to be defective; di-
state 2 pitch operation valve
rectly check it.
(Spool)
Defective function of blade The function of the blade pitch selection solenoid valve is assumed to
3
pitch cylinder be defective; directly check it.
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP
Trouble • Abnormal noise from around work equipment pump.

Related
information

1 Inappropriate oil The oil used is assumed to be inappropriate; directly check it.
Possible causes Clogged hydraulic oil tank The strainer of the hydraulic oil tank is assumed to be clogged; direct-
2
and standard strainer ly check it.
value in normal Air is assumed to be inhaled in the suction circuit of the work machine
state 3 Air inhaled in suction circuit
pump; directly check the pipes.
Internally defective work The work equipment pump is assumed to be defective internally; di-
4
equipment pump rectly check it.
D275AX-5 20-717
4
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL ................. 30- 5 REMOVAL AND INSTALLATION OF

Removal and installation of assemblies 30- 5 FUEL TANK ASSEMBLY ............................ 30- 35
Special tools ......................................... 30- 5 Removal ................................................ 30- 35
Removal of parts .................................. 30- 5 Installation ............................................. 30- 36
Installation of parts ............................... 30- 5 REMOVAL AND INSTALLATION OF
Sketches of special tools ...................... 30- 5 MAIN RADIATOR ASSEMBLY ................... 30- 37
Disassembly and assembly of Removal ................................................ 30- 37
assemblies ........................................... 30- 6 Installation ............................................. 30- 39
Special tools ......................................... 30- 6 REMOVAL AND INSTALLATION OF
Disassembly ......................................... 30- 6 SUB-RADIATOR ASSEMBLY .................... 30- 40
Assembly .............................................. 30- 6 Removal ................................................ 30- 40
Sketches of special tools ...................... 30- 6 Installation ............................................. 30- 41
PRECAUTIONS WHEN CARRYING OUT REMOVAL AND INSTALLATION OF
OPERATION ............................................... 30- 7 HYDRAULIC OIL COOLER ASSEMBLY .... 30- 42
SPECIAL TOOL LIST ................................. 30- 8-1 Removal ................................................ 30- 42
REMOVAL AND INSTALLATION OF Installation ............................................. 30- 43
FUEL SUPPLY PUMP ASSEMBLY ........... 30- 9 REMOVAL AND INSTALLATION OF
Special tools ......................................... 30- 9 RADIATOR GUARD ASSEMBLY ............... 30- 44
Removal ............................................... 30- 9 Removal ................................................ 30- 44
Installation ............................................ 30- 11 Installation ............................................. 30- 46
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
FUEL INJECTOR ASSEMBLY ................... 30- 13 ENGINE ...................................................... 30- 47
Removal ............................................... 30- 13 Special tools .......................................... 30- 47
Installation ............................................ 30- 16 Removal ................................................ 30- 47
REMOVAL AND INSTALLATION OF Installation ............................................. 30- 51
NOZZLE TIP ............................................... 30- 19 REMOVAL AND INSTALLATION OF
Special tools ......................................... 30- 19 DAMPER ASSEMBLY ................................ 30- 53
Removal ............................................... 30- 19 Special tools .......................................... 30- 53
Installation ............................................ 30- 20 Removal ................................................ 30- 53
Sketch of special tool ........................... 30- 21 Installation ............................................. 30- 56
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF
ENGINE FRONT SEAL .............................. 30- 22 DAMPER ASSEMBLY ................................ 30- 57
Special tools ......................................... 30- 22 Special tools .......................................... 30- 57
Removal ............................................... 30- 22 Disassembly .......................................... 30- 58
Installation ............................................ 30- 22 Assembly .............................................. 30- 60
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
ENGINE REAR SEAL ................................. 30- 24 POWER TRAIN UNIT ASSEMBLY ............. 30- 62
Special tools ......................................... 30- 24 Removal ................................................ 30- 62
Removal ............................................... 30- 24 Installation ............................................. 30- 66
Installation ............................................ 30- 24 DISCONNECTION AND CONNECTION OF
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY ............. 30- 67
CYLINDER HEAD ASSEMBLY .................. 30- 26 Disconnection ....................................... 30- 67
Special tool ........................................... 30- 26 Connection ............................................ 30- 74
Removal ............................................... 30- 26 Connection diagram of centralized
Installation ............................................ 30- 31 oil pressure pick-up hoses .................... 30- 76
D275AX-5 30-1
4c
2 c
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF

PTO ASSEMBLY ......................................... 30- 79 TRACK FRAME ASSEMBLY ....................... 30-161
Disassembly .......................................... 30- 79 Special tool ............................................ 30-161
Assembly .............................................. 30- 82 Removal ................................................ 30-161
DISASSEMBLY AND ASSEMBLY OF Installation ............................................. 30-164
TORQUE CONVERTER ASSEMBLY .......... 30- 86 Sketch of special tool ............................ 30-165
Disassembly .......................................... 30- 86 REMOVAL AND INSTALLATION OF
Assembly .............................................. 30- 90 IDLER ASSEMBLY ...................................... 30-166
DISASSEMBLY AND ASSEMBLY OF Removal ................................................ 30-166
TORQFLOW TRANSMISSION Installation ............................................. 30-166
ASSEMBLY ................................................. 30- 96 DISASSEMBLY AND ASSEMBLY OF
Special tools .......................................... 30- 96 IDLER ASSEMBLY ...................................... 30-167
Disassembly .......................................... 30- 96 Special tools .......................................... 30-167
Assembly .............................................. 30-104 Disassembly .......................................... 30-167
DISASSEMBLY AND ASSEMBLY OF Assembly ............................................... 30-168
HSS CASE ASSEMBLY .............................. 30-115 Sketch of special tool ............................ 30-170
Special tools .......................................... 30-115 REMOVAL AND INSTALLATION OF
Disassembly .......................................... 30-115 RECOIL SPRING ASSEMBLY .................... 30-171
Assembly .............................................. 30-123 Special tools .......................................... 30-171
REMOVAL AND INSTALLATION OF Removal ................................................ 30-171
SCAVENGING PUMP ................................. 30-135 Installation ............................................. 30-174
Removal ................................................ 30-135 DISASSEMBLY AND ASSEMBLY OF
Installation ............................................. 30-135 RECOIL SPRING ASSEMBLY .................... 30-175
REMOVAL AND INSTALLATION OF Special tools .......................................... 30-175
HSS PUMP ASSEMBLY ............................. 30-136 Disassembly .......................................... 30-175
Removal ................................................ 30-136 Assembly ............................................... 30-175
Installation ............................................. 30-137 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY .................... 30-177
WORK EQUIPMENT AND HSS CHARGE Special tools .......................................... 30-177
PUMP ASSEMBLY ..................................... 30-138 Removal ................................................ 30-177
Removal ................................................ 30-138 Installation ............................................. 30-178
Installation ............................................. 30-139 Sketch of special tool ............................ 30-179
FAN PUMP ASSEMBLY ............................. 30-140 TRACK ROLLER ASSEMBLY ..................... 30-180
Removal ................................................ 30-140 Special tools .......................................... 30-180
Installation ............................................. 30-141 Disassembly .......................................... 30-180
REMOVAL AND INSTALLATION OF Assembly ............................................... 30-181
POWER TRAIN AND LUBRICATING Sketch of special tool ............................ 30-183
OIL PUMP ASSEMBLY ............................... 30-142 REMOVAL AND INSTALLATION OF
Removal ................................................ 30-142 CARRIER ROLLER ASSEMBLY ................. 30-184
Installation ............................................. 30-143 Removal ................................................ 30-184
REMOVAL AND INSTALLATION OF Installation ............................................. 30-184
HSS MOTOR ASSEMBLY .......................... 30-144 DISASSEMBLY AND ASSEMBLY OF
Removal ................................................ 30-144 CARRIER ROLLER ASSEMBLY ................. 30-185
Installation ............................................. 30-144 Special tools .......................................... 30-185
REMOVAL AND INSTALLATION OF Disassembly .......................................... 30-185
FINAL DRIVE ASSEMBLY .......................... 30-145 Assembly ............................................... 30-186
Special tools .......................................... 30-145 Sketch of special tool ............................ 30-188
Removal ................................................ 30-145 REMOVAL AND INSTALLATION OF
Installation ............................................. 30-146 1ST BOGIE ASSEMBLY ............................. 30-189
Sketch of special tool ............................ 30-147 Special tools .......................................... 30-189
FINAL DRIVE ASSEMBLY .......................... 30-148 Installation ............................................. 30-191
Special tools .......................................... 30-148 Sketch of special tool ............................ 30-194
Disassembly .......................................... 30-148
Assembly .............................................. 30-153
30-2 D275AX-5
! 2!

2ND, 3RD AND 4TH BOGIE ASSEMBLY .. 30-195 HYDRAULIC CYLINDER ASSEMBLY ........ 30-244
Special tools ......................................... 30-195 Special tools .......................................... 30-244
Removal ............................................... 30-195 Disassembly .......................................... 30-244
Installation ............................................ 30-197 Assembly .............................................. 30-247
Sketch of special tool ........................... 30-201 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY .................................... 30-251
BOGIE ASSEMBLY .................................... 30-203 Removal ................................................ 30-251
Special tools ......................................... 30-203 Installation ............................................. 30-252
Disassembly ......................................... 30-203 DISASSEMBLY AND ASSEMBLY OF
Assembly .............................................. 30-203 RIPPER ASSEMBLY .................................. 30-253
Sketch of special tool ........................... 30-206 Disassembly .......................................... 30-253
EXPANDING AND INSTALLING TRACK Assembly .............................................. 30-255
SHOE ASSEMBLY ..................................... 30-207 REMOVAL AND INSTALLATION OF
Check before expanding track ROPS GUARD ............................................ 30-257
shoe assembly ..................................... 30-207 Removal ................................................ 30-257
Expanding track shoe Installation ............................................. 30-257
assembly (Normal) ............................... 30-207 REMOVAL AND INSTALLATION OF
Expanding track shoe assembly ........... 30-208 OPERATOR'S CAB ASSEMBLY ................ 30-258
Installation ............................................ 30-209 Removal ................................................ 30-258
WHOLE DISASSEMBLY AND WHOLE Installation ............................................. 30-259
ASSEMBLY OF TRACK REMOVAL AND INSTALLATION OF
SHOE ASSEMBLY ..................................... 30-210 FLOOR FRAME ASSEMBLY ...................... 30-260
Special tools ......................................... 30-210 Special tools .......................................... 30-260
Whole disassembly .............................. 30- 211 Removal ................................................ 30-260
Whole assembly ................................... 30-213 Installation ............................................. 30-263
Dimensions table of fitting jig of REMOVAL AND INSTALLATION OF
link press .............................................. 30-225 TRANSMISSION CONTROLLER
Disassembly of 1 link in the field .......... 30-226 ASSEMBLY ................................................. 30-265
Assembly of 1 link in the field ............... 30-227 Removal ................................................ 30-265
DISASSEMBLY of master link .............. 30-229 Installation ............................................. 30-265
Assembly of master link ....................... 30-230 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF STEERING CONTROLLER ASSEMBLY .... 30-266
PIVOT SHAFT ASSEMBLY ........................ 30-232 Removal ................................................ 30-266
Special tools ......................................... 30-232 Installation ............................................. 30-266
Removal ............................................... 30-232 REMOVAL AND INSTALLATION OF
Installation ............................................ 30-232 ENGINE CONTROLLER ASSEMBLY ........ 30-267
REMOVAL AND INSTALLATION OF Removal ................................................ 30-267
EQUALIZER BAR ASSEMBLY .................. 30-233 Installation ............................................. 30-267
Special tools ......................................... 30-233 REMOVAL AND INSTALLATION OF
Removal ............................................... 30-233 ENGINE HOOD ASSEMBLY ...................... 30-268
Installation ............................................ 30-234 Removal ................................................ 30-268
Sketch of special tool ........................... 30-236 Installation ............................................. 30-269
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
EQUALIZER BAR BUSHING ..................... 30-237 FAN DRIVE ASSEMBLY ............................ 30-270
Special tools ......................................... 30-237 Removal ................................................ 30-270
Disassembly ......................................... 30-237 Installation ............................................. 30-270
Assembly ............................................. 30-237 REMOVAL AND INSTALLATION OF FAN MOTOR
REMOVAL AND INSTALLATION OF ASSEMBLY (Serial No. 20001 – 20030) ........... 30-271
WORK EQUIPMENT CONTROL Removal ................................................ 30-271
VALVE ASSEMBLY .................................... 30-239 Installation ............................................. 30-271
Removal ............................................... 30-239 REMOVAL AND INSTALLATION OF FAN MOTOR
Installation ............................................ 30-241 ASSEMBLY (Serial No.: 20031 and up) ............ 30-272
WORK EQUIPMENT CONTROL Installation ............................................. 30-272
VALVE ASSEMBLY .................................... 30-243
Assembly .............................................. 30-243
D275AX-5 30-3
4c
2 c
30-4 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF
ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS
• Special tools that are deemed necessary for re- • Except where otherwise instructed, install parts
moval or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with q 1 mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
": Special tools which cannot be substitut- are intended for.
ed, should always be used. • Marks shown in the INSTALLATION Section
# Special tools which are very useful if stand for the following.
available, can be substituted with com- ¤ This mark indicates safety-related pre-
mercially available tools. cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly ★ This mark gives guidance or precau-
2This mark stands for a specific coating

developed for this model. tions when doing the procedure.
R: Tools with upgraded part numbers, re-
3This mark indicates the specified

modeled from already available tools agent to be used.
for other models.
Blanks: Tools already available for other torque.
models, used without any modifica-
tion. 5 This mark indicates an amount of oil or
3) Circle mark (!) in sketch column: water to be added.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketch- SKETCHES OF SPECIAL TOOLS
es for Special Tools.
• Various special tools are illustrated for the con-
★ Part No. of special tools starting with 79*T
venience of local manufacture.
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
¤ This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
D275AX-5 30-5
2! !
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS ASSEMBLY
• Special tools which are deemed ncessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Section
kind of information. are explained and listed below.
1) Neccessity ¤ This mark indicates safety-related pre-
": Special tools which cannot be substitut- cautions which must be followed when
ed, should always be used. doing the work.
# Special tools which are very useful if ★ This mark gives guidance or precau-
2This mark stands for a specific coating

available, can be substituted with com- tions when doing the procedure.
mercially available tools.
3This mark indicates the specified

2) Distinction of new and existing special tools agent to be used.
N: Tools with new part numbers, newly
developed for this model. torque.
R: Tools with upgraded part numbers, re-
modeled from already available tools 5 This mark indicates an amount of oil or
for other models. water to be added.
Blanks: Tools already available for other
models, used without any modifica- SKETCHES OF SPECIAL TOOLS
tion. • Various special tools are illustrated for the con-
3) Circle mark (!) in sketch column: venience of local manufacture.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketch-
es for Special Tools.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
¤ This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
30-6 D275AX-5
! 2!
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
s Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions (mm)
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
D275AX-5 30-7
2
4cc
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
2. PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect se-
curely.
• 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 hy-
draulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. PRECAUTIONS WHEN COMPLETING THE OPERATION

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassem-
bling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-8 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

s Tools with number 799T-999-9999 cannot be supplied (they are items to be locally manufactured).
s Necessity: Cannot be substituted, should always be installed (used)
z: Extremely useful if available, can be substituted with commercially available part.
s New/removed; N ...... Tools with new part numbers, newly developed for this model
R ...... Tools with upgraded part numbers, remodeled from items already available for other models.
Blank ......Tools already available for other models, used without any modification
s Tools marked 9 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS)
New/remodel
Sketch
Qty
Component Symbol Part No. Part Name Nature of work, remarks
795-471-1500 Remover 1
e795-471-1520 eblock 1 Removal of fuel supply
e795-471-1530 ebolt
A1
1 pump assembly
e01435-01070 ebolt 2
Removal, installation
795-521-1110 Push tool 1
790-101-5221 Grip 1 Installation of Engine front
A2
01010-51225 Bolt 1 seal
Engine assembly
01010-31640 Bolt 3
795-931-1210 Sleeve 1
795-931-1220 Sleeve 1 Installation of Engine rear
A3
01050-31625 Bolt 3 seal
01050-31645 Bolt 3
A4 790-331-1110 Wrench 1 Tighten of cylinder head bolt
A5 795T-471-1550 Wrench 1 9 Removal, Installation of nozzle tip
791-612-1100 Installer 1 Removal, installation
Damper assembly B 790-101-4200 Puller (294kN {30ton}) 1 Press fitting of bearing
790-101-1102 Hydraulic pump 1

Disassembly, assembly
TORQFLOW transmission Checking actuation of pis-

D 799-301-1600 Oil leak tester 1
assembly ton
791-622-1110 Bracket 1
Removal, Installation of
1 01010-62095 Bolt 1
HSS case assembly E Brake-carrier assembly
01016-61690 Bolt 1
2 796-550-1301 Wrench 1 Removal, Installation of lock nut
790-337-1032 Lifting tool 1
791-627-1320 Shackle 2 Removal, Installation of fi-

1
791T-627-1810 Plate 1 9 nal drive assembly
01010-82090 Bolt 2
791-627-1400 Remover 1
Pulling out sprocket bear-
2 790-101-2102 Puller 1
ing
Final drive assembly J 790-101-1102 Pump 1
791-627-1600 Remover 1
Removal of planetary gear
3 790-101-2102 Puller 1
shaft
790-101-1102 Pump 1
791-627-1200 Remover 1
4 790-101-2102 Puller 1 Removal of hub assembly
790-101-1102 Pump 1
D275AX-5 30-8-1
4c c
New/remodel
Sketch
Qty
791-627-1300 Installer 1
5 790-101-2102 Puller 1 Press fitting of hub bearing
790-101-1102 Pump 1
Final drive assembly J 791-627-1500 Installer 1
Press fitting of cover bear-
6 790-101-2102 Puller 1
ing
790-101-1102 Pump 1
7 791-627-1280 Installer 1 Installation of floating seal
791T-630-1310 Plate 1 N 9
791-630-1220 Rod 4
790-101-2510 Block 2
790-101-2570 Plate 4
1 Press fitting of bushing
01643-31445 Washer 4
Idler assembly 01580-01411 Nut 4
790-101-2102 Puller (294kN {30ton}) 1
790-101-1102 Pump 1
3 791-630-1240 Push tool 1 Press fitting of seal guide
4 791-601-1000 Oil pump 1 Filling with oil
790-401-1700 Lifting tool 1
Removal, installation Disassembly, assembly Removal, installation Disassembly, assembly Disassembly, assembly
790-401-1761 Adapter 1 Installation of No.1track
5
790-401-1540 Shackle 2 roller assembly
790-401-1770 T-bolt 2
6 791T-630-1320 Plate 1 N 9 Press fitting of bushing
7 791T-630-1330 Push tool 1 N 9 Installation of floating seal
Track roller assembly
8 791-651-1510 Installer 1 Press fitting of seal guide
L
14 791T-630-1380 Bracket 4 9 Secure bogie assembly
10 790-102-1891 Nut wrench 1 Removal, Installation of nut

Carrier roller assembly
12 791T-630-2410 Push tool 1 N 9 Press fitting of seal guide
Track frame assembly 14 791T-630-1380 Bracket 6 9 Secure bogie assembly

791-630-1360 Spacer 1 N
790-101-2310 Block 1
790-101-2360 Plate 2
No. 2, 3, 4 Bogie assembly
15 790-445-4130 Screw 2 Removal of shaft, ring
791-112-1180 Nut 2
790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
30-8-2 D275AX-5
c 4c
New/remodel
Sketch
Qty
790-201-2760 Spacer 1 N
791-630-1370 Adapter 1
790-434-1060 Screw 2
16 01580-13024 Nut 2 Removal of shaft, ring
01643-33080 Washer 1
790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
17 796-230-1120 Recoil spring assembly 1 Installation of floating seal
Check the airtight of the
18 790-701-3000 Seal checker 1
floating seal
No. 2, 3, 4 Bogie assembly
1 N 9
Adjustment procedure for
19 791T-630-1390 Guide
cartridge pin hole
790-101-2310 Block 1
790-445-4130 Screw 2
796T-470-1130 Plate 1 9
Press fitting of cartridge
20 790-101-2360 Plate 2
pin assembly
791-112-1180 Nut 2
L 790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
790-101-2310 Block 1
790-445-4130 Screw 2
796T-470-1130 Plate 1 9
Press fitting of cartridge
20 790-101-2360 Plate 2
Bogie assembly pin assembly
791-112-1180 Nut 2
790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
Removal, installation Removal, installation
790-401-1700 Lifting tool 1 Removal, Installation of

22
790-401-1761 Adapter 1 track roller assembly
No.1 Bogie assembly
791-630-1860 Bracket 1
Pull up of No.1Bogie as-
23
791-630-1870 Bracket 1 sembly
791-730-1110 Bolt 6
Disassembly of Idler yoke,
1 01580-12722 Nut 6
recoil cylinder
01643-32780 Washer 6
791-630-1100 Installer 1
2 790-101-1600 Cylinder (686kN {70ton}) 1 Press fitting of bushing
Recoil spring assembly M 790-101-1102 Pump 1
791-685-8502 Compressor 1
790-201-2780 Spacer 1
Disassembly, assembly of
3 791-635-3160 Extension 1
Recoil spring assembly
790-101-1600 Cylinder (686kN {70ton}) 1
790-101-1102 Pump 1
D275AX-5 30-8-3
4
4cc
New/remodel
Sketch
Qty
791T-650-1930 Spacer 1 N 9
792-900-1520 Plate 1
791-520-4140 Screw 1
790-101-2470 Adapter 1
Equalizer bar assembly N1 Removal of center pin
790-101-2540 Washer 1
791-112-1180 Nut 1
790-101-2102 Puller (294kN {30ton}) 1
791-650-1800 Remover 1
Equalizer bar bushing N2 790-101-2102 Puller (294kN {30ton}) 1
spherical bushing
1 790-401-1700 Lifting tool 1
pivot shaft assembly
Pivot shaft assembly P 791-650-1700 Installer 1
2 790-101-4200 Puller (294kN {30ton}) 1 Press fitting of seal
1 791-646-7531 Plug remover 1 Removal of pin plug
2 791-660-7460 Pin brush 1 Cleaning of pin hole
3 791-646-7900 Push tool 1 Press fitting of pin plug
4 791-932-1110 Push tool 1 Press fitting of pin plug
790-701-3000 Seal checker 1
5 Supply oil
791-601-1000 Pump 1
Installation of seal assem-
6 791-632-1070 Installer 1 N
bly
791-680-9802 Remover & installer 1
791-680-1520 Guide 1
7 790-101-4200 Puller (294kN {30ton}) 1 Disassembly of a link
790-101-4300 Cylinder (1470kN {150ton}) 1
Track shoe assembly R
790-101-1102 Pump 1
791-632-1500 Push tool assembly 1 N
e791-632-1420 eAdapter 1 N
e791-632-1430 eRing 1 N
e791-632-1440 ePlate 1 N
e791-632-1450 eRing 1 N
8 e791-632-1460 ePush tool 1 N Assembly of a link
e791-632-1470 eAdapter 1 N
e791-632-1480 eSpring 1 N
e791-685-5730 eBar 1
e01252-30650 eBolt 1
e01580-01210 eNut 1
30-8-4 D275AX-5
c 4c
New/remodel
Sketch
Qty
791-632-1400 Push tool assembly 1 N

e791-632-1410 eAdapter 1 N
e791-632-1430 eRing 1 N
e791-632-1440 ePlate 1 N
e791-632-1450 eRing 1 N
9 e791-632-1460 ePush tool 1 N Assembly of a link
e791-632-1470 eAdapter 1 N
e791-632-1480 eSpring 1 N
e791-685-5730 eBar 1
e01252-30650 eBolt 1
e01580-01210 eNut 1
791-632-1490 Push tool 1 N
10 Assembly of a link
791-685-5740 Push tool 1
790-434-1110 Adapter 1
790-434-1610 Guide 1
11
195-32-61210 Bolt 1
01010-51440 Bolt 2
790-101-4300 Cylinder (1470kN {150ton}) 1
12
790-101-1102 Pump 1
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
Track shoe assembly R 791-685-9550 Nut 1
791-685-9560 Bolt 4
13
790-434-1110 Adapter 1
01010-51030 Bolt 1
04530-12030 Eyebolt 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1 Disassembly of a single
791-685-9540 Rod 1 link
14
791-685-9550 Nut 1
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9550 Nut 2
791-685-9560 Bolt 4
791-126-0150 Adapter 1
791-680-5520 Guide 1
15
791-126-0140 Pusher 1
790-434-1110 Adapter 1
01010-51030 Bolt 1
04530-12030 Eyebolt 1
791-685-9620 Extension 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790101-1102 Pump 1
D275AX-5 30-8-5
4c c
New/remodel
Sketch
Qty
791-680-1630 Spacer 1
Disassembly of a single
16 790-101-4200 Puller (294kN {30ton}) 1
link
790-101-1102 Pump 1
791-680-5543 Adapter (for pin) 1
791-680-9630 Adapter (for bush) 1
17
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
18 790-434-1130 Guide 1
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
19 791-126-0150 Adapter 1
01010-51030 Bolt 1
791-685-9620 Extension 1
791-680-5543 Adapter 1
791-680-5551 Guide 1
Track shoe assembly R
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1 Assembly of a single link
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
791-126-0150 Adapter 1
20
01010-51030 Bolt 1
791-685-9620 Extension 1
791-680-5551 Guide 1
790-434-1140 Adapter 1
791-680-9630 Adapter 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
790-101-4200 Puller (294kN {30ton}) 1
21
790-101-1102 Pump 1
22 790-434-1160 Guide 1
30-8-6 D275AX-5
c 4c
New/remodel
Sketch
Qty
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9540 Rod 3
791-685-9550 Nut 4
791-685-9560 Bolt 1
Track shoe assembly R 23 791-126-0150 Adapter 1 Assembly of a single link
790-434-1150 Guide 1
790-434-1110 Adapter 1
01010-51030 Bolt 1
790-434-1160 Guide 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
790-502-1003 Cylinder repair stand 1 Disassembly, assembly of
1
790-101-1102 Pump 1 hydraulic cylinder
790-102-2303 Wrench 1 Removal and assembly of
2
790-102-3802 Wrench 1 round head
790-102-4300 Wrench 1 Removal and assembly of
3
790-102-4310 Pin 2 round head
790-201-1702 Push tool kit 1
e790-101-5021 eClip
For press fitting coil bush-
1
e01010-50816 eBolt
ing
1
e790-201-1831 ePush tool
4 Disassembly, assembly
1 (Blade lift)
e790-201-1851 ePush tool 1 (Blade tilt, ripper lift)
e790-201-1841 ePush tool 1 (Ripper tilt)
Hydraulic cylinder assembly U 790-201-1500 Push tool kit 1
e790-101-5021 eClip 1 For press fitting dust seal
e01010-50816 eBolt 1
e790-201-1640 ePlate
5
1 (Blade lift)
e790-201-1650 ePlate 1 (Blade tilt)
e790-201-1660 ePlate 1 (Ripper lift, ripper tilt)
6 790-720-1000 Expander 1 Expansion of piston ring
796-720-1670 Ring 1 (Blade lift)
07281-01279 Clamp 1 (Blade lift)
796-720-1690 Ring 1 (Blade tilt, ripper lift)
7
07281-01919 Clamp 1 (Blade tilt, ripper lift)
796-720-1680 Ring 1 (Blade tilt)
07281-01589 Clamp 1 (Blade tilt)
799-703-1200 Service tool kit 1
799-703-1100 Vacuum pump (100W) 1

Related to air conditioner X 799-703-1110 Vacuum pump (220W) 1 Charging with freon gas
799-703-1120 Vacuum pump (240W) 1
799-703-1400 Gas leak detector 1
D275AX-5 30-8-7
4c c
REMOVAL AND INSTALLATION OF FUEL
DISASSEMBLY AND ASSEMBLY SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION

OF FUEL SUPPLY PUMP
ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch
795-471-1500 Remover " 1

• 795-471-1520 • Block 1
A1
• 795-471-1530 • Bolt 1
• 01435-01070 • Bolt 2
REMOVAL
¤ Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Drain the cooling water.
8. Disconnect fuel supply pump wiring connectors
6Cooling ¬
water: Approx. 130¬ (5) and (6) and engine G speed sensor wiring
connector (7).
2. Release the residual pressure from the fuel sys-
tem. For details, see TESTING AND ADJUST- 9. Remove fuel filter bracket (8).
ING, Releasing residual pressure from fuel ★ Move the fuel filter bracket aside.
system.
10. Remove common rail cover (9).
3. Open the left side cover of the engine.
4. Remove side cover (1).
11. Remove brackets (10) and (11) and 4 caps (12).
12. Remove fuel filter tubes (13) and (14).

5. Remove bracket (2) and move it aside so that it
will not be an obstacle to removal of the fuel sup-
ply pump assembly.
6. Remove the 2 clamps of 2 water separator drain
hoses (3).
7. Remove water pump tube (4).
D275AX-5 30-9
2! !
13. Remove fuel tube (15) and lubrication tubes (16) 18. Remove nut (23) and washer (24).
and (17). ★ Take care not to drop the nut and washer in
the engine.
14. Disconnect fuel tube (18) and fuel hose (19).
19. Remove filler gauge (25) and high-pressure

15. Disconnect sub-radiator outlet hose (20). pipes (26) and (27).
16. Remove 3 nuts (21) and the water pump assem-

bly.
20. Remove cover (28) and bracket (29).
30-10 D275AX-5
! 2!
21. Set tool A1.

3 Eye joint bolt of fuel filter tube:
14.8 - 19.6 Nm {1.5 - 2.0 kgm}
(Supply pump side)
24.5 - 34.3 Nm {2.5 - 3.5 kgm}

(Fuel filter side)
3 Eye-joint bolt of fuel tube (15):

14.8 - 19.6 Nm {1.5 - 2.0 kgm}
(Supply pump side)
22. Remove 4 mounting bolts. Then, using tool A1, 9.8 - 1.27 Nm {1.0 - 1.3 kgm}
remove fuel supply pump assembly (30). (Block side)
3 Eye-joint bolt of lubrication tube (16):
★ Take care not to drop key (31).
★ Do not remove tool A1 until the fuel supply
pump assembly is installed again. (If tool A1 7.9 - 12.7 Nm {0.8 - 1.3 kgm}
is removed, the idler gear and fuel supply
(Supply pump side)
pump drive gear may be meshed incorrectly.)
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
(Cylinder block side)
3 Eye-joint bolt of lubrication tube (17):

19.6 - 29.4 Nm {2.0 - 3.0 kgm}
3 Clamp of lubrication tube:

9.8 ± 1Nm {1.0 ± 0.1kgm}
★ Set insertion length "c" of hose "a" and tube

"b" to the following value.
• Insertion length "c" of outlet hose: 50 mm
3 Clamp of outlet hose:
883 ± 49 Nm {90 ± 5 kgm}
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
3 Water pump tube coupling nut:

14.7 - 18.6 Nm {1.5 - 1.9 kgm}
D275AX-5 30-11
2! !
¤ Contact of the high-pressure pipes with elec-

3 Mounting nut of fuel supply pump drive tric wiring around them is dangerous. After
gear: assembling, check that the distance be-
tween the pipes and the wiring is at least 10
176 - 196 Nm {18 - 20 kgm} mm. If it is not, increase it to 10 mm or more
• Installation procedure for fuel supply pump and by moving the wiring.
tubes ¤ Do not bend and reuse the high-pressure
pipes or use them for other parts.
6. Tighten upper and lower clamps securely in the

order of (31), (32), and (33).
★ Before tightening the stays, bend the rubber.
3 Clamp bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
7. Tighten the stays securely in the installation or-

der of the upper and lower clamps.
1. Install and tighten supply pump (30), bracket • Refilling with water
(29), and high-pressure pipes (26) and (27) with Add water through the water fillers of the main
fingers. radiator and sub-radiator to the specified level.
Run the engine to circulate the water through the
2. Tighten high-pressure pipes (26) and (27) se- system. Then, check the water level again.
5Cooling water: Approx. 130¬

curely.
3 Sleeve nut:
¬
39.2 - 58.8 Nm {4 - 6 kgm} • Bleeding air

(Common rail side) Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
39.2 - 49 Nm {4 - 5 kgm} fuel circuit.
(Supply pump side)
3. Tighten suction pump (30) securely.

★ When tightening, apply LOCTITE.
4. Tighten bracket (29) securely.
5. Tighten the stays and upper and lower clamps of

high-pressure pipe clamps (31), (32), and (33)
with fingers.
¤ The high-pressure pipe clamps are very im-
portant parts. If they are loosened or their
rubber parts are hardened or they are re-
moved and the engine is kept used, the con-
tact parts of the high-pressure pipes may be
worn and the pipes may be broken by vibra-
tion. Accordingly, be sure to use the genuine
high-pressure pipe clamps and tighten them
to the specified torque.
30-12 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF FUEL INJECTOR
DISASSEMBLY AND ASSEMBLY ASSEMBLY

OF FUEL INJECTOR
ASSEMBLY
REMOVAL 15. Remove the 4 bracket mounting bolts, water sep-
arator (17), and bracket.
nal of the battery.
1. Remove the engine hood. For details, see RE- 17. Remove the 4 bracket mounting bolts, fuel filter
MOVAL OF ENGINE HOOD. (20), and bracket.
2. Loosen the hose clamp and disconnect Koma- 18. Remove corrosion resistor tubes (21) and (22).
clone hose (1).
19. Remove the 4 bracket mounting bolts, corrosion
3. Remove the 4 mounting bolts and bracket (2). resistor (23), and bracket.
4. Disconnect dust indicator hose (3).
5. Loosen 2 hose clamps and disconnect tube (4).
6. Remove 2 bands (5) and air cleaner assembly

(6).
7. Remove the 4 mounting bolts and bracket (7).
8. Remove corrosion resistor tubes (8) and (9).
9. Remove oil tubes (10) and (11).
10. Remove the 4 bracket mounting bolts, oil filter

(12), and bracket.
11. Close the fuel supply valve.
12. Disconnect priming pump hose (13) and water

separator hose (14).
13. Disconnect 2 drain hoses (15).
14. Remove the 2 priming pump mounting bolts and

priming pump (16).
D275AX-5 30-13
2! !
20. Remove the 12 mounting bolts and 4 nuts, then ★ To disconnect fuel injector connector "c", in-
lift off bracket (24). sert flat-head screwdriver 1 in stepped part
★ If any shims are inserted, check their quanti- "a" and move it in direction "X", pressing
ty and positions. stopper "b".
4 Bracket: 50 kg d: Fuel injector wiring side
25. Disconnect fuel supply pump wiring connectors

E41 (31) and E42 (32).
21. Disconnect intermediate wiring connectors 101
(25), E21 (26), and E22 (27).
22. Remove the 2 mounting bolts and bracket (28).
23. Disconnect the wire clamp and remove wire (29).

★ When disconnecting the wire clamp, take
care not to drop the spacer held under the
clamp.
24. Disconnect wiring connector E31 (30).

★ The photo shows removal of No. 1.
30-14 D275AX-5
! 2!
26. Remove head cover (33).
32. Loosen sleeve nut (43).

27. Loosen locknut (34) and adjustment screw (35).
★ Loosen the locknut so that an excessive

force will not be applied to the push rod, then
loosen the adjustment screw by 2 - 3 turns.
33. Remove the mounting bolts of fuel injector as-

sembly (38) and put a small-sized L-lever under
connection (44) and pry the fuel injector assem-
bly out slowly.
★ Never hold the solenoid valve above the in-
28. Remove the 3 mounting bolts and remove rocker jector with priers, etc.
arm (36). ★ Loosen the bolts used to install high-pres-
sure pipe clamps No. 1 - No. 6 near the injec-
29. Remove rubber cap (37). tor to the manifold.
★ Remove the sleeve of the high-pressure pipe
on the injector side and pull out the injector,
keeping the high-pressure pipe end off the
hollow of the injector.
30. Remove 2 upper solenoid valve nuts (39) of fuel

injector assembly (38) and pull out spring clamp
(40).
31. Disconnect clamp (41) and move fuel injector

wiring (42) aside.
D275AX-5 30-15
2! !
INSTALLATION
moval. ★ After tightening the locknut, adjust the valve
clearance. For details, see TESTING AND
ADJUSTING, Adjusting valve clearance.
3 Komaclone hose clamp: 3 Locknut:53 - 64.7 Nm {5.4 - 6.6 kgm}
10.8 - 16.5 Nm {1.1 - 2.7 kgm}
★ Check that the ball of the adjustment screw

is fitted to the push rod socket and tighten
3 Dust indicator hose mounting nut: the mounting bolts.
17.6Nm {1.8kgm} 3 Rocker arm mounting bolt:

93 - 103 Nm {9.5 - 10.5 kgm}
3 Hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgm} 3 Terminal nut:
1.8 - 2.2 Nm {0.18 - 0.22 kgm}
3 Band mounting bolt:

★ Check that the O-rings are fitted to both in-
9.8 - 11.76 Nm {1.0 - 1.2 kgm} jector side and sleeve nut side.
★ After sleeve nut (43) catches the threads of
the injector, turn it 2 turns with fingers, then
3 Eye-joint bolt of corrosion resistor

tighten it with a spanner.
★ Control the tightening torque with torque
tube: wrench (2) of spanner type.
24.5 - 34.3 Nm {2.5 - 3.5 kgm} 3 Sleeve nut:
39.2 - 49 Nm {4 - 5 kgm}
★ If sleeve nut (43) does not catch the threads,
3 Eye-joint bolt of priming pump hose: push its end with a small spanner and turn its
hexagonal part with the torque wrench.
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
3 Eye-joint bolt of fuel filter tube:

14.8 - 19.6 Nm {1.5 - 2.0 kgm}
(Supply pump side)
24.5 - 34.3 Nm {2.5 - 3.5 kgm}

(Fuel filter side)
3 Head cover mounting bolt:

14.7 - 34.3 Nm {1.5 - 3.5 kgm}
30-16 D275AX-5
! 2!
★ After tightening the sleeve nut, check that the

O-ring is not projected from the sleeve nut
end.
3) Fit the ball washer to bolt (46) and tighten

them into holder (45) with fingers. Insert
high-pressure pipe sleeve (47) through the
fuel high-pressure pipe insertion part and
tighten it with fingers, matching it to injection
★ When installing the high-pressure pipe, (44). Tighten bolt (46) of holder (45) secure-
check the paper seal of the joint (Part "a": ly.
Part of 2 mm from the end) for visible length- ★ Apply engine oil to the spherical part of the
wise slit "b" and spot "c" and check part "d" ball washer (to fit the ball washer).
(End of taper seal: Part of 2 mm from the 3 Holder mounting bolt:
end) for stepped-type wear (fatigue) which
your nail can feel. If any of those defects 58.8 - 73.5 Nm {6.0 - 7.5 kgm}
may cause fuel leakage, replace the high-
pressure pipe.
★ Check that there is not dirt in the injector

sleeve.
1) Fit the gasket and O-ring to the fuel injector
and apply engine oil (SAE 30) to them.
2) Insert holder (45) in fuel injector assembly
(38). Direct the injector connection toward
the fuel high-pressure pipe insertion hole
and insert the fuel injector assembly and
holder together.
D275AX-5 30-17
2! !
★ It is difficult to insert the wiring connector af-

ter the O-ring is fitted to it.
4) Take out wiring connector (48) through the
connector insertion opening with O-ring (49)
removed. Fit O-ring (49) and apply engine
oil (SAE30) and install connector holder (50),
then push them in and secure connector
holder (50) with mounting bolt (51).
5) Install wiring terminal (52) to the terminal of

fuel injector assembly (38). Tighten 2 nuts
(39) and insert wire holder clamp (40) in the
injector connection, then install wire clamp
(41) with the bolt.
3 Terminal nut:
1.8 - 2.2 Nm {0.18 - 0.22 kgm}
★ Tense the wires and press them against the
injector body.
30-18 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP

OF NOZZLE TIP
★ [EPA Regulation] 3. Using 19-mm deep socket 3 , loosen retaining
In a country where EPA Regulation is applied, re- nut (4).
place the nozzle of the common rail engine by
the assembly. In a country where EPA Regula-
tion is not applied, however, only the nozzle tip
can be replaced according to the following pro-
cedure.
★ All the nozzles shown in the following photos are
for the 125 Series engine. The removal and in-
stallation procedures for them can be applied as
they are, however.
SPECIAL TOOLS
Sym- Ne- New/Re-
Part No. Part name cessity Q'ty model Sketch
bol 4. Remove retaining nut (4) from injector assembly
A5 795T-471-1550 Wrench " 1 ! (3).
5. Lift up and remove nozzle assembly (5) vertical-
ly.
REMOVAL ★ Do not remove tip guide (6). (The tip guide
1. Hold tool A5 with vice 1 . cannot be disassembled.)
★ Do not hold the injector directly with the vice. ★ Take care that dirt will not stick to the parts.
2. Set injector assembly (3) to tool A5.
D275AX-5 30-19
2! !
INSTALLATION 5. Install nozzle assembly (3) and tighten retaining

nut (2) with the fingers.
1. Hold tool A5 with vice 1 .
★ Do not hold the injector directly with the vice.
6. Set 19-mm deep socket 2 to a torque wrench

2. Set injector assembly (1) to tool A5. and tighten the retaining nut according to the fol-
lowing procedure.
3. Clean the lower body and the threads of retain- ★ Apply rust-preventive oil to the nozzle body.
ing nut (2) thoroughly with parts cleaner and 1) Tighten the retaining nut to 88.3 Nm {9.0
blow air against them. kgm}.
2) Make match marks (6) on retaining nut
(2) and lower body (5).
3) Tighten the retaining nut by 45° (Angle
tightening).
4. Install new nozzle assembly (3), matching it to

the dowel pin of tip guide (4).
★ Take care not to drop the tip.
30-20 D275AX-5
! 2!
Sketch of special tool

Note: We will not be liable for any result caused by a special tool made according to this drawing.
A5 Wrench
D275AX-5 30-21
2! !
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

OF ENGINE FRONT SEAL
SPECIAL TOOLS INSTALLATION
Sym- Ne- New/Re- • Carry out installation in the reverse order to re-
moval.
795-521-1110 Push tool " 1
790-101-5221 Grip " 1
A2
01010-51225 Bolt " 1 ★ Match the taper pin of the damper pulley and
" tighten the 6 mounting bolts.
3 Mounting bolt:
01050-31640 Bolt 3
REMOVAL
1. Remove the radiator guard assembly. For de- 245 - 309 Nm {25 - 31.5 kgm}
tails, see REMOVAL OF RADIATOR GUARD
ASSEMBLY. • Installation procedure for front seal (2)
★ Before installing the seal, make sure that the
2. Sling damper pulley (1) temporarily and remove end corners and lip sliding surfaces of the
the mounting bolts. crankshaft and housing are free from flaw,
burr, fin, and rust.
3. Lift off damper pulley (1). ★ When installing the seal, do not apply oil or
grease to the shaft and seal lip. Wipe off the
oil from the shaft.
★ Never remove the inside plastic cylinder of
the replacement seal before installing the
seal.
4. Remove front seal (2).
30-22 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
1) Bring the large inside diameter side of plastic

inside cylinder (3) to the end of crankshaft
(4).
★ Take care not to mistake the installing di-
rection.
2) Hold the metal ring of seal (2) with both

hands and push it in firmly as if you are pass-
ing over the large inside diameter side of the
plastic inside cylinder.
3) After pushing in seal (2), remove plastic in-

side cylinder (3).
★ When removing the inside cylinder, take
care not to damage the seal lip.
4) Tighten the bolts of tool A2 evenly to press fit

seal (2) until the end of tool A2 reaches the
end of crankshaft (4).
★ When press fitting the seal, take care not
to damage the lip on the PTO side with
the tool set, etc.
★ After press fitting the seal, remove the
red sealant layer from its periphery.
D275AX-5 30-23
2! !
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

OF ENGINE REAR SEAL
SPECIAL TOOLS 4. Remove rear seal (2).
Sym- Ne- New/Re-
795-931-1210 Sleeve jig " 1

795-931-1220 Sleeve jig " 1
A3
01050-31625 Bolt " 3
01050-31645 Bolt " 3
REMOVAL
1. Remove the damper assembly. For details, see
REMOVAL OF DAMPER ASSEMBLY.
2. Using hanging bolt 1 , sling the flywheel assem-

bly temporarily.
INSTALLATION
• Carry out installation in the reverse order to
removal.
★ Tighten the 6 flywheel mounting bolts in the

order of 1 - 6 as shown below.
3. Remove the 6 mounting bolts and lift off flywheel

assembly (1).
4 Flywheel assembly: 60 kg
30-24 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
3) After pushing in seal (2), remove plastic in-

• Installation procedure for rear seal (2) side cylinder (3).
★ Before installing the seal, make sure that ★ When removing the inside cylinder, take
the end corners and lip sliding surfaces care not to damage the seal lip.
of the crankshaft and housing are free
from flaw, burr, fin, and rust.
★ When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
★ Never remove the inside plastic cylinder
of the replacement seal before installing
the seal.
4) Tighten the bolts of tool A3 evenly to press fit

seal (2) until the end of tool A3 reaches the
end of crankshaft (4).
5) Using the 2 types of the bolts of tool A3,
tighten seal (2).
i) Tighten until the bolt 45 mm long stops.
ii) Tighten until the bolt 25 mm long stops.
1) Bring the large inside diameter side of plastic ★ When press fitting the seal, take care not
inside cylinder (3) to the end of crankshaft to damage the lip on the PTO side with
(4). the tool set, etc.
★ Take care not to mistake the installing di- ★ After press fitting the seal, remove the
rection.
2) Hold the metal ring of seal (2) with both

hands and push it in firmly as if you are pass-
ing over the large inside diameter side of the
plastic inside cylinder.
D275AX-5 30-25
2! !
REMOVAL AND INSTALLATION OF CYLINDER
DISASSEMBLY AND ASSEMBLY HEAD ASSEMBLY

OF CYLINDER
HEAD ASSEMBLY
SPECIAL TOOL 5. Loosen the hose clamp and disconnect Koma-
clone hose (5).
Sym- Ne- New/Re-
A4 790-331-1110 Wrench # 1 6. Remove bracket (6).
7. Remove 2 bands (7) and air cleaner assembly

(8).
REMOVAL
nal of the battery.
1. Remove the engine hood assembly. For details,

see REMOVAL OF ENGINE HOOD ASSEM-
BLY.
2. Remove main radiator drain cover (1) sub-radia-

tor drain cover (2) and drain the cooling water.
6 Cooling water: Approx. 130¬

¬¬
9. Remove water drain tube (10).
10. Remove the mounting bolts of muffler bracket

(11).
★ Sling the muffler assembly temporarily, then
remove the mounting bolts.
3. Loosen 2 hose clamps (3).
4. Loosen the hose clamp and disconnect dust in-

dicator hose (4).
30-26 D275AX-5
! 3!
2
11. Lift off muffler assembly (12).
4 Muffler assembly: 30 kg
19. Install 2 hanging bolts 1 and 2 guide bolts 2

and lift off turbocharger and exhaust manifold as-
sembly (21).
12. Disconnect 2 hose clamps (13). 4 Turbocharger and exhaust manifold
assembly: 30 kg
13. Loosen 2 hose clamps (14).
14. Remove tube (15) and bracket together.
15. Remove heat insulation panel (16).
20. Remove air cleaner bracket (22).
21. Remove oil tubes (23) and (24).
22. Remove bracket (25).

16. Remove bracket (17). ★ Remove the oil filter and bracket together.
17. Disconnect turbocharger lubrication tube inlet 23. Disconnect priming pump hose (26) and water
(18) and turbocharger lubrication tube outlet separator hose (27).
(19).
24. Disconnect 2 drain hoses (28).
18. Remove the mounting bolts and exhaust mani-
fold assembly (20). 25. Remove priming pump (29).
D275AX-5 30-27
3
2! !
26. Remove water separator assembly (30). 32. Remove the mounting bolts and nuts and lift off
★ Remove the water separator assembly and bracket (39).
bracket together. ★ If any shims are inserted, check their quanti-
ty and positions.
4 Bracket: 50 kg

★ Remove the fuel filter and bracket together.
33. Remove the tube bracket and tube clamp, then
remove engine oil supply tube (40) and damper
oil supply tube (41).
34. Remove aftercooler tubes (42) and (43).

★ Remove the corrosion resistor and bracket
together.

(44), E21 (45), and E22 (46).
30-28 D275AX-5
! 2!
37. Disconnect boost pressure sensor wiring con-

nector (48).
★ To disconnect fuel injector connector "c", in-

sert flat-head screwdriver 3 in stepped part
38. Disconnect intermediate wiring connectors E41 "a" and move it in direction "X", pressing
(49) and E42 (50). stopper "b".
b: Fuel injector wiring side
39. Disconnect 3 electrical intake air heater ground
wires.
43. Remove the mounting bolts. Using hanging bolt

40. Disconnect electrical intake air heater relay ter- (4), lift off air intake manifold assembly (56).
minal (52).
4 Air intake manifold assembly: 70kg
41. Disconnect fuel return temperature sensor wir-

ing connector (53).
42. Disconnect the wire clamp, wire (54), and fuel in-
jector wiring connector (55).
★ When disconnecting the wire, take care not
to drop the spacer installed under the clamp
bolt.
D275AX-5 30-29
2! !
44. Remove 5 high-pressure pipe clamps (57). 49. Pull out push rod (64).
50. Remove the mounting bolts and cylinder head

assembly (65).
45. Remove cooling water tube (58) and fuel spill

tube (59).
46. Remove rubber cap (60) and high-pressure pipe

(61).
47. Remove head cover (62).
48. Remove fuel injector assembly (63). For details,

see Removal of fuel injector assembly.
30-30 D275AX-5
! 2!
INSTALLATION
• Carry out installation in the reverse order to re- 3 Eye-joint bolt of priming pump hose:
moval. 24.5 - 34.3 Nm {2.5 - 3.5 kgm}
3 Hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm} 3 Eye-joint bolt of fuel filter tube:
14.8 - 19.6 Nm {1.5 - 2.0 kgm}
(Supply pump side)
3 Dust indicator hose mounting nut: 24.5 - 34.3 Nm {2.5 - 3.5 kgm}
17.6 Nm {1.8 kgm} (Fuel filter side)
3 Komaclone hose clamp: 3 Eye-joint bolt of corrosion resistor

10.8 - 26.5 Nm {1.1 - 2.7 kgm} tube:
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
3 Band mounting bolt: 3 Coupling bolt of aftercooler tube:

9.8 - 11.76 Nm {1.0 - 1.2 kgm} 14.7 - 18.6 Nm {1.5 - 1.9 kgm}
3 U-clamp nut of aftercooler tube:

10.8 - 26.5 Nm {1.1 - 2.7 kgm}
3 Water drain tube:
39.2 - 49 Nm {3 - 4 kgm}
Installation procedure for exhaust manifold assembly
1) Fit the gaskets to both sides of the electrical
intake air heater.
★ Install the gasket, then tighten the mounting 2) Install the wiring harness to the electrical in-
bolts of the exhaust manifold assembly in the take air heater and couple them with the ex-
order of 1 - N as shown below.
3 Mounting bolt of exhaust manifold as-
haust manifold.
3) Tighten the mounting bolts of the exhaust
sembly: 59 - 74 Nm {6 - 7.5 kgm} manifold assembly in the order of 1 - N as
shown below.
3 Mounting bolt of exhaust manifold as-
sembly: 59 - 74 Nm {6 - 7.5 kgm}
D275AX-5 30-31
3
2! !
7. Tighten high-pressure pipe side clamp (57)

• Assembly procedure for common rail injec- securely.
tion pipe (Between common rail and injector) 3 Clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}
1. Install high-pressure pipe (61).
3 Sleeve nut: 39.2 - 49 Nm {4 - 5 kgm} 8. Tighten stay (69) securely.
★ Precautions for installing sleeve nut on
injector side
1) Insert the sleeve nut in the head hole
from outside.
★ Check that the O-rings are fitted to both
injector side and sleeve nut side.
2) After sleeve nut (43) catches the threads
of the injector, turn it 2 turns with fingers,
then tighten it with a spanner.
★ Control the tightening torque with a
torque wrench of spanner type.
3 Sleeve nut:
39.2 - 49 Nm {4 - 5 kgm}
★ If the sleeve nut does not catch the
threads, push its end with a small span-
ner and turn its hexagonal part with the
torque wrench.
★ After tightening the sleeve nut, check
that the O-ring is not projected from the
sleeve nut end.
2. Tighten the stay and upper and lower clamps
of high-pressure pipe clamp (57) with fin-
gers.
3. Tighten upper and lower clamps (57) secure-
ly.
★ Bend the rubber first.
3 Clamp bolt: 9.8 ± 1 Nm {1 ± 0.1 kgm}
3 Eye-joint bolt of cooling water tube:

4. Tighten the stay securely.
5. Tighten the stay and upper and lower clamps
of high-pressure pipe side clamp (57) with 9.8 - 12.7 Nm {1.0 - 1.3 kgm}
3 Eye-joint bolt of fuel spill tube:

fingers.
6. Install high-pressure pipe clamp (66) and
gate frame (67) temporarily. 8 - 9.8 Nm {0.8 - 1.0 kgm}
1) Tighten high-pressure pipe clamp (66)
securely first.
2) Install gate frame (67) to special bolt (68)
securely.
3 Clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
30-32 D275AX-5
! 3!
2
2 Mounting bolt:
★ When installing the high-pressure pipe, Lubricant containing molybdenum
check the paper seal of the joint (Part "a":
Part of 2 mm from the end) for visible length- disulfide (LM-P)
wise slit "b" and spot "c" and check part "d" ★ A special socket is required to tighten the
(End of taper seal: Part of 2 mm from the head bolts.
3 Cylinder head mounting bolt:
end) for stepped-type wear (fatigue) which
your nail can feel. If any of those defects
may cause fuel leakage, replace the high- 1st time: 137 - 157 Nm {14 - 16 kgm}
pressure pipe. 2nd time: 284 - 294 Nm {29.0 - 30.0 kgm}
3rd time:
i) When using tool A4
Using an angle tightening wrench (tool
A4), retighten each bolt by 90° + 30°
0 in
the order of 1 - 6.
3 Head cover mounting bolt:

14.7 - 34.3 Nm {1.5 - 3.5 kgm}
• Before tightening the cylinder head mounting

bolts, check the following matter.
★ If the mounting bolts are longer than the fol-
lowing using limits or they have been tight-
ened 5 times (there are 5 punch marks on
them), do not reuse them but replace them.
1) Measure stem length "e" of each mount-
ing bolt and check that the result is less
than the using limit.
2) Using limit of bolt
• Short bolt: Must be shorter than
170.8 mm.
• Long bolt: Must be shorter than
205.8 mm.
D275AX-5 30-33
2! !
ii) When not using tool A4

Make marks on the all bolts and cylinder
head, then retighten each bolt by 90°
+ 30°
0 in the order of 1 - 6 .
★ After tightening bolts 1 - 6, tighten bolt
7 to 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}.
• Refilling with water

Add water through the water fillers of the main
radiator and sub-radiator to the specified level.
system. Then, check the water level again.
5 ¬
Cooling water: Approx. 130¬
30-34 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY

OF FUEL TANK ASSEMBLY
REMOVAL 6. Remove plate (6).
nal of the battery.
1. Remove step (1).
7. Disconnect fuel level sensor wiring connector

423 (7).
8. Disconnect 3 fuel hoses (8).
4. Close the fuel supply valve.
5. Remove drain hose clamp (4) and drain block

(5).
9. Remove 4 mounting bolts (9).
D275AX-5 30-35
2! !
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
10. Lift off fuel tank assembly (10).
4Fuel tank assembly:

390 kg (When empty)
1,100 kg (When full)
INSTALLATION
moval.
30-36 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY MAIN RADIATOR ASSEMBLY

OF MAIN RADIATOR
ASSEMBLY
REMOVAL 5. Remove the mounting bolts and open guard (3).
6. Remove the mounting bolts and open undercov-
nal of the battery.
er (4).
4
Engine undercover: 250 kg
6 ¬
2. Remove radiator upper cover (1).
7. Disconnect oil cooler hose (5) and radiator outlet

hose (6).
★ Disconnect the hose and tube together.
3. Raising the radiator upper cover, disconnect
head lamp wiring connector 209 (2).
4. Lift off the radiator upper cover.
D275AX-5 30-37
2! !
8. Disconnect oil cooler hose (7) and radiator inlet

hose (8).
★ Disconnect the hose and tube together.
13. Remove baffles (19) and (20).
14. Remove mounting bolts (21) (4 pieces on each

9. Disconnect wiring connectors (WLM) (9) and side).
(WLD) (10) and 2 clamps (11).
10. Disconnect reservoir hose (12), aeration hose

(13), and radiator inlet hose (14).
15. Lift off main radiator assembly (22).

4 Main radiator assembly: 310 kg
11. Remove 10 radiator mounting bolts (15) and

(16).
• (15): 2 pieces on each side
• (16): 3 pieces on each side
12. Remove baffles (17) and (18).
30-38 D275AX-5
! 2!
INSTALLATION
moval.
3 Reservoir hose clamp:

34 ± 5 Nm {3.4 ± 0.5 kgm}
"b" to the following values.
Hoses (12) and (13): Min. 25 mm
Hose (14): 60 mm
★ The rubber plates of the baffles must be in

contact with the radiator tank.


¬
D275AX-5 30-39
2! !
REMOVAL AND INSTALLATION OF SUB-
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY

OF SUB-RADIATOR ASSEMBLY
REMOVAL 5. Remove the mounting bolts and open undercov-
er (3).
4 Engine undercover: 250 kg

nal of the battery.

¬
6. Disconnect sub-radiator outlet hose (4).
3. Raising the radiator upper cover, disconnect

head lamp wiring connector (CN-209) (2).
30-40 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF SUB-
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
7. Remove 4 mounting bolts (5) (2 pieces on each INSTALLATION

side of the lower part).
★ Or, remove the 2 lower bolts (1 piece on each
moval.
side).

Hoses (4) and (11): 50 mm
8. Disconnect wiring connector (WLD) (6) and

clamp (7).
9. Disconnect hose clamp (8) and reservoir hoses

(9) and (10).
3 Reservoir hose clamp:

10. Disconnect sub-radiator inlet hose (11).
11. Remove 4 mounting bolts (12). 34 ± 5 Nm {3.4 ± 0.5 kgm}

Hoses (9) and (10): Min. 25 mm (See the
above illustration)

¬
12. Lift off sub-radiator assembly (13).

4 Sub-radiator assembly: 75 kg
D275AX-5 30-41
2! !
REMOVAL AND INSTALLATION OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY OIL COOLER ASSEMBLY

OF HYDRAULIC OIL COOLER
ASSEMBLY
er (3).
4
nal of the battery.
1. Drain the hydraulic oil.
6Hydraulic oil: Approx. 130¬
6. Disconnect aeration hose (4).
7. Disconnect main radiator inlet hose (5).

★ Drain the cooling water to a degree that it will
not leak when the radiator inlet hose is dis-
3. Raising the radiator upper cover, disconnect connected.
head lamp wiring connector (CN-209) (2).
30-42 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY OIL COOLER ASSEMBLY
9. Disconnect hose clamp (7) and hydraulic oil INSTALLATION

cooler hose (8).
★ Disconnect the upper end of the hydraulic oil
moval.
cooler hose.

Hose (4): Min. 25 mm
Hose (5): 60 mm
10. Remove bracket (9) and disconnect hydraulic oil

cooler hose (10).
• 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.
5Hydraulic tank: Approx. 130¬

¬
11. Remove the 4 upper and lower mounting bolts

and lift off hydraulic oil cooler assembly (11).
4 Hydraulic oil cooler assembly: 35 kg
D275AX-5 30-43
2! !
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD ASSEMBLY

OF RADIATOR GUARD
ASSEMBLY
er (4).
4
nal of the battery.
6 ¬
2. Drain the hydraulic oil.
6 Hydraulic oil: Approx. 130¬
3. Remove the engine hood. For details, see RE-

MOVAL OF ENGINE HOOD ASSEMBLY.
4. Remove both side covers (1).

7. Disconnect main radiator outlet hose (5), oil
cooler hose (6), cooler hose (7), and sub-radia-
tor outlet hose (8).
5. Remove cap (2) and shim (3) from the blade lift
cylinder.
★ Check the thickness and quantity of the in-
serted shims.
★ Run the engine and retract the piston rod ful-
ly and bind it with wires so that it will not
come out.
★ Bind the piston rod on the opposite side sim-
ilarly.
30-44 D275AX-5
! 2!
8. Disconnect fan motor hoses (9), (10), and (11), 13. Sling the radiator guard assembly temporarily
blade lift cylinder hoses (12) and (13), oil cooler and remove the lock bolt (23) and pull out left
hose (14), and main radiator inlet hose (15). rear pin (24).
★ Remove the lock bolt and pin on the right
side similarly.
9. Disconnect wiring connector 201 (16).
10. Disconnect sub-radiator inlet hose (17), aeration 14. Remove lock plate (25).
hose (18), and main radiator inlet hose (19).
15. Pull out left front pin (26).
★ Remove the lock plate and pin on the right
11. Remove cover (20) and disconnect hydraulic oil side similarly.
cooler hose (21).
12. Remove condenser assembly (22).

★ Do not disconnect the hoses from the con-
denser assembly. Remove only the mount-
ing bolts and move the hoses aside.
16. Lift off radiator guard assembly (27).

★ Take care extremely not to damage the radi-
ator core, etc.
4 Radiator guard assembly: 2,450 kg
D275AX-5 30-45
2! !
INSTALLATION
★ Tighten the locknut so that clearance "e" be-
tween the radiator guard and nut will be in
moval.
the following range.
Clearance "e": 3 - 5 mm
• Install the blade lift cylinder according to the
1) Sling the blade lift cylinder temporarily.
2) Run the engine and extend the piston
rod slowly to couple it with the blade as-
sembly by cap (2) at the lift cylinder end.
3) Adjust clearance "a" at the mating face of
the cap to the following value with shims.
• Standard clearance "a": 0.2 - 0.5 mm
• Standard shim thickness: 4 mm
★ Check that the shims rotate smoothly.


¬

5
★ Set insertion length "d" of hose "b" and tube
"c" to the following value. ¬
Hydraulic tank: Approx. 130¬
Hoses (8) and (17): 50 mm
Hose (19): 60 mm
30-46 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE

OF ENGINE
SPECIAL TOOLS
Sym- Ne- New/Re-
799-703-1200 Service tool kit " 1
Vacuum pump
799-703-1100 " 1
(100 V)
Vacuum pump
799-703-1110 " 1
X (220 V)
Vacuum pump
799-703-1120 " 1
(240 V)
Gas leak
799-703-1400 " 1
tester
REMOVAL
5. Disconnect radiator outlet hose (6) and radiator
¤ Disconnect the cable from the negative (–) termi- inlet hose (7).
nal of the battery. ★ Plug the openings so that dirt will not enter
★ For the method of changing the fuel injection then piping.
amount adjustment after replacement of the en-
gine assembly or engine controller, ask your Ko- 6. Disconnect sub-radiator outlet hose (8) from the
matsu distributor. sub-water pump.

¬

3. Remove floor covers (1) and (2) and step covers

(3) and (4).
7. Remove the bolt and open inspection cover (9).

er (5).
D275AX-5 30-47
2! !
8. Disconnect ground wire (10). 12. Disconnect wire clamp (16).

★ Remove the cover and leave it as it is.
9. Disconnect heater hose (11), then disconnect

tube (12) from the main water pump.
10. Disconnect air condenser hoses (13) and (14). 14. Disconnect intermediate wiring connectors 101
(18), E21 (19), and E22 (20).
★ Using tool X, collect new Freon gas (R134a)
before disconnecting the air conditioner hos-
es.
15. Remove the hose clamp and disconnect heater

hoses (21) and (22) and air conditioner hoses
11. Disconnect starting motor wiring harness (15). (23) and (24).
★ Close the heater hose valve on the engine
side.
30-48 D275AX-5
! 2!
16. Remove cover (25). 19. Disconnect wire (29).
17. Loosen the hose clamp and remove hose (26). 20. Remove plate (30) and remove 3 partition
mounting bolts (31).
★ Remove the plate and partition mounting
bolts on the right side similarly.
18. Disconnect wiring connectors PT1 (27) and SS3

(28).
21. Lift off partition (32).

★ After removing the partition, take out cover
(17) which has been removed.
4 Partition: 140 kg
D275AX-5 30-49
2! !
22. Sling universal joint assembly (33) temporarily. 27. Loosen the hose clamps and disconnect Koma-
clone hose (37).
23. Remove the mounting bolts and lift off the univer-
sal joint assembly. 28. Remove bracket (38).
4 Universal joint assembly: 30 kg
29. Disconnect sub-radiator inlet hose (39), aeration

hose (40), and main radiator inlet hose (41) and
24. Close the fuel supply valve. remove reservoir tank (42).
★ Remove the reservoir tank and bracket to-
25. Disconnect fuel supply hose (34). gether.
26. Disconnect fuel return hoses (35) and (36).

30. Disconnect intermediate wiring connector 201
(43).
30-50 D275AX-5
! 3!
2
31. Remove 4 front and rear engine mounting bolts

(44) and (45).
★ Install each hose so that it will not be twisted.

★ When installing the air conditioner hoses,
32. Lift off engine assembly (46). take care that dirt, dust, and water will not
★ Before lifting off the engine assembly, check enter them.
that the all wires and pipes are disconnect- ★ Before tightening each air conditioner hose
ed. connector, check that the O-ring is fitted to it.
4 Engine assembly: 2,050 kg ★ Apply compressor oil (Showa-Shell, Sniso
4G or 5G) sufficiently to the O-rings.
3 Tightening torque for refrigerant gas

pipes
INSTALLATION
Thread size : Tightening torque
16X1.5 11.8-14.7Nm {1.2-1.5kgm}
moval.
22X1.5 19.6-24.5Nm {2-2.5kgm}
★ For the method of changing the fuel injection
amount adjustment after replacement of the en- 24X1.5 29.4-34.3Nm {3-3.5kgm}
gine assembly or engine controller, ask your Ko-
matsu distributor.

Insertion length "c" of outlet hose: 50 mm
3 Outlet hose clamp:
883 ± 48 Nm {90 ± 51 kgm}
D275AX-5 30-51
2! !

98.10 - 123 Nm {10 - 12.5 kgm}
3 Eye-joint bolt of fuel return hose:

24.5 - 34.3 Nm {2.5 - 3.5 kgm}
3 Komaclone hose clamp:

10.8 - 26.5 Nm {1.1 - 2.7 kgm}
★ Set insertion length "d" of hose "b" and tube

"c" to the following value.
Hoses (39): 50 mm
Hose (41): 60 mm
3 Engine mounting bolt:

824 - 1,030 Nm {84 - 105 kgm}


¬
• Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
30-52 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY DAMPER ASSEMBLY

OF DAMPER ASSEMBLY
SPECIAL TOOLS 5. Disconnect starting motor wiring harness (3),
then disconnect wire clamp (4) from the partition.
Sym- Ne- New/Re-
Service tool 6. Remove cover (5).

799-703-1200 " 1
kit ★ Remove the cover and leave it as it is.
Vacuum
799-703-1100 " 1
pump (100 V)
Vacuum
X 799-703-1110 " 1
pump (220 V)
Vacuum
799-703-1120 " 1
pump (240 V)
Gas leak
799-703-1400 " 1
tester
REMOVAL
2. Remove the mounting bolt and open the under-

cover.
(6), E21 (7), and E22 (8).
4Power train undercover: 320 kg
3. Drain the damper chamber oil.
6 ¬
Damper chamber oil:1.5¬
4. Remove step covers (1) and (2).
8. Remove the hose clamp and disconnect heater

hoses (9) and (10) and air conditioner hoses (11)
and (12).
side.
★ Using tool X, collect new Freon gas (R134a)
before disconnecting the air conditioner hos-
es.
D275AX-5 30-53
2! !
9. Remove cover (13). 12. Disconnect wire (17).
10. Loosen the hose clamp and remove hose (14). 13. Remove plate (18) and remove partition mount-
ing bolts (19).
★ Remove the plate and partition mounting
bolts on the right side similarly.
11. Disconnect wiring connectors PT1 (15) and SS3

(16).
14. Lift off partition (20).

★ After removing the partition, take out cover
(5) which has been removed.
4 Partition: 140 kg
30-54 D275AX-5
! 2!
15. Sling universal joint assembly (21) temporarily.

21. Using 2 forcing screws 2 , lift off damper cover
16. Remove the mounting bolts and lift off the univer- assembly.
sal joint assembly. 4 Damper cover assembly: 55 kg
22. Using hanging bolt 3 , sling damper assembly

(26) and remove the mounting bolts.
17. Disconnect breather hose (22) and remove it
and oil level detection pipe (23) together.
23. Using 2 forcing screws 4 , lift off the damper as-

sembly.
18. Using hanging bolt 1 , sling damper cover as-
sembly (24) temporarily. 4 Damper assembly: 75 kg
19. Disconnect ground wire (25).
20. Remove the mounting bolts of damper cover as-

sembly (24).
D275AX-5 30-55
2! !
INSTALLATION
★ When installing the damper cover assembly,
degrease the shaft spline and apply dry lu-
moval.
bricant A and leave it as it is for 2 - 3 minutes.
Then, apply extreme pressure lithium grease
containing molybdenum B to the shaft
spline.
take care that dirt, dust, and water will not Molybdenum disulfide
A Sumiko, lubricant
enter them. dry lubricant
★ Before tightening each air conditioner hose Extreme pressure lithi- • Kyodo Yushi, Molylex No. 2
connector, check that the O-ring is fitted to it. B um grease containing • Showa-Shell, Letinax AM
★ Apply compressor oil (Showa-Shell, Sniso molybdenum • Nihon Sekiyu Molytex
3 Tightening torque for refrigerant gas

3 Damper assembly mounting bolt:
pipes
Thread size : Tightening torque 98.10 - 123 Nm {10 - 12.5 kgm}
16×1.5 11.8-14.7Nm {1.2-1.5kgm}
22×1.5 19.6-24.5Nm {2-2.5kgm} • Refilling with oil.
24×1.5 29.4-34.3Nm {3-3.5kgm}
5Damper chamber oil:1.5¬

¬ (SAE30CD)
3 Drain plug: 58.8 - 78.5 Nm {6 - 8 kgm}
3 Level plug:
98.10 - 123 Nm {10 - 12.5 kgm}
3 Damper cover assembly mounting

127 - 177 Nm {13 - 18 kgm}
bolt:98.10 ∼ 123Nm {10 ∼ 12.5kgm}

30-56 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY OF
DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY
SPECIAL TOOLS
Sym- Ne- Q'ty New/Re- Sketch
Part No. Part name cessity
bol model
791-612-1100 Installer " 1
Puller
790-101-4200 (294kN " 1
B
{30ton})
Hydraulic
790-101-1102 " 1
pump
D275AX-5 30-57
2! !
DISASSEMBLY 3) Bearing and oil seal

i) Remove oil seal (9) from cover (2), then
1. Disassembly of damper cover assembly (1).
remove inner race (7-3) of bearing (7).
1) Coupling
Remove bolt (3) from cover (2), then remove
holder (4) and coupling (5).
ii) Remove inner races (7-4) and (7-5) of

bearing (7) from cover (2).
2) Shaft
i) Set damper cover assembly (1) on block
1.
ii) Push out shaft (6) by hitting it with a plas-
tic hammer from the output side.
★ Shaft (6) comes out together with inner
race (7-1) and oil seal (8) of bearing (7).
iii) Remove the O-ring from shaft (6), then

remove collar (7-2) and inner race (7-1)
of bearing (7).
30-58 D275AX-5
! 2!
2. Disassembly of damper assembly (2)

1) Remove bolts (11) and flange (12).
2) Remove outer body (13), inner body (14),
and cushion (15).
3) Pull plug (17) out of flange (16).
★ Perform this procedure only when the plug
needs to be replaced.
D275AX-5 30-59
2! !
ASSEMBLY
1. Assembly of damper assembly (10)
1) Set flange (16) and outer body (13) to cylin-
der 1 , matching their bolt holes, and install
inner body (14).
2 Mating faces of flange and outer body:
2 Inside of outer body: Grease (G2-LI)
2 Cushion contact surface of inner
body: Grease (G2-LI)
4) Fill with grease.

Fill part a of the inner body with 80 g of
grease.
2 Grease:
Molybdenum disulfide
A Sumiko, lubricant
dry lubricant‹
Extreme pressure lithi- • Kyodo Yushi, Molylex No. 2
B um grease containing • Showa-Shell, Letinax AM
molybdenum • Nihon Sekiyu Molytex
2) Install cushion (15).

★ Apply grease (G2-LI) all over the cushion.
★ After installing the cushion, fill the clearance
between the inner body and outer body (16
places) with grease of 30%.
2. Assembly of damper cover assembly (1)

1) Using push tool 2 , press fit outer races (7-
4) and (7-5) of bearing (7) to cover (2).
3) Install flange (12) and secure it with bolts

(11).
3 Flange mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm}
30-60 D275AX-5
! 2!
2) Press fit inner race (7-1) of bearing (7) to 5) Fit oil seals (8) and (9) to cover assembly (2).
shaft (6) with tool B. 2 Press fitting face of oil seal:
2 Oil seal lip: Grease (G2-LI)
★ Apply the gasket sealant thinly to the oil seal
surface and wipe off projected part.
3) Install collar (7-2) and O-ring to shaft (6).
6) Install coupling (5) and holder (4) and secure

them with bolts (3).
3 Coupling mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
4) Set cover (2) to shaft (6). Using tool B, press

fit bearing inner race (7-3).
D275AX-5 30-61
2! !
REMOVAL AND INSTALLATION OF POWER TRAIN
DISASSEMBLY AND ASSEMBLY UNIT ASSEMBLY

OF POWER TRAIN
UNIT ASSEMBLY
REMOVAL
nal of the battery.
1. Drain the oil.
6 Hydraulic tank: Approx. 130¬
6 Power train case: Approx. 90¬
2. Remove the floor frame assembly. For details,

see REMOVAL OF FLOOR FRAME ASSEM- 9. Remove cover (6).
BLY.
3. Remove the fuel tank assembly. For details, see

REMOVAL OF FUEL TANK ASSEMBLY.
4. Remove the undercover.

4 Power train undercover: 320 kg
5. Disconnect intermediate wiring connector FE2

(1) from bracket (2).

10. Disconnect the following 4 oil filter hoses.
• (7): Power train oil filter inlet hose
• (8): Power train oil filter outlet hose
• (9): Steering oil filter inlet hose
• (10): Steering oil filter outlet hose
7. Disconnect wire clamp (3).
8. Disconnect fan pump discharge hose (4) and

drain hose (5).
30-62 D275AX-5
! 2!
11. Disconnect 4 hose clamps (11) and (12). 16. Disconnect the following 4 self-pressure reduc-
ing valve hoses.
12. Disconnect the following 4 ripper hoses. • (22): hose (Port P1)
• (13): Ripper tilt hose (port A5) • (23): hose (Port PC)
• (14): Ripper tilt hose (port B5) • (24): hose (Port PR)
• (15): Ripper lift hose (port A4) • (25): hose (Port LS)
• (16): Ripper lift hose (port B4)
17. Remove oil level detection pipe for the power

13. Disconnect intermediate wiring connector 241 train (26).
(17).
18. Remove power train oil supply pipe (27).
14. Disconnect work equipment pump tube coupling

(18).
15. Disconnect charge pump hose (19), HSS pump

hose (20) and HSS motor hose (21).
D275AX-5 30-63
2! !
19. Remove pin puller block (28). 24. Disconnect torque converter outlet hose (34)
★ Un disconnect hose. and transmission inlet hose (35).
20. Disconnect oil cooler hoses (29) and (30). 25. Loosen the hose clamp and disconnect tube
(36).
21. Disconnect cooler hose (31) and drain hose (32).
26. Remove the mounting bolts and final drive shaft

22. Sling universal joint assembly (33) temporarily. cover (37).
★ Remove the final drive shaft cover on the op-
23. Remove the mounting bolts and lift off universal posite side similarly.
joint assembly (33).
30-64 D275AX-5
! 2!
27. Pull out drive shaft (38) according to the follow- 30. Remove left (42) and right (43) mounting bolts
ing procedure. on the front side.
Using forcing screw 1, pull out the drive shaft
until the spline on the steering case side comes
off.
★ If the shaft is difficult to pull out, raise the
shoe grouser with a jack and find out a posi-
tion where the shaft is pulled out easily.
★ Pull out the drive shaft on the opposite side
similarly.
31. Lift off the power train unit assembly (44).
4 Power train unit assembly: 2,650 kg
28. Remove 2 covers (39) on both sides.
29. Loosen coupling clamp (40) and move seal (41)

outward.
D275AX-5 30-65
2! !
INSTALLATION
moval.

98.10 - 123 Nm {10 - 12.5 kgm}
★ Clamp the peak of the coupling seal securely

and set the clamp threads in parallel with the
cap mounting seat.
★ When installing the power train unit as-

sembly, take care extremely not to dam-
age seal (41).
• Refilling with oil

¬

¬
• Bleeding air
Bleed air from the fan pump. For details, see
fan pump.
30-66 D275AX-5
! 2!
DISCONNECTION AND CONNECTION OF
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT ASSEMBLY
DISCONNECTION AND
CONNECTION OF
POWER TRAIN UNIT
ASSEMBLY
DISCONNECTION 5. Disconnect left brake oil pressure pick-up hose.
1. Draining oil
• (5): Left brake oil pressure pick-up hose
Before setting the power train unit assembly to
(Color band: White)
the block, drain the oil from the PTO case and
steering case.
2. Sling and set power train unit assembly (1) to

block 1.
4 Power train unit assembly: 2,650 kg
6. Disconnect the following 2 torque converter out-

let oil pressure pick-up hoses.
• (6): Torque converter outlet oil pressure pick-
up hose (Color band: White/Red)
• (7): Torque converter inlet oil pressure pick-
up hose (Color band: Blue)
4. Disconnect steering oil filter (3) and pwer train oil

filter (4).
D275AX-5 30-67
2! !
7. Disconnect right brake oil pressure pick-up hose 10. Disconnect EPC valve main pressure hoses (18)
(8). and (19).
• (8): Right brake oil pressure pick-up hose
(Color band: Yellow) 11. Disconnect charge pump hose (20).
8. Disconnect the following 6 HSS motor hoses. 12. Disconnect hose (21) between the HSS motors
• (9): Drain hose (Port T1) and hose (22) between the drain collecting block.
• (10): (Pilot hose (Port P) ★ Disconnect the hoses from the HSS motor
• (11): From charge filter hose (Port C) end and drain collecting block end.
• (12): To cooler hose (Port CD)
• (13): HSS pump hose (Port PA) 13. Remove pivot turn solenoid (23).
• (14): HSS pump hose (Port PB) ★ Remove the solenoid and bracket together.
9. Disconnect pin puller solenoid valve hoses (15)

and (16) and steering lubrication oil supply hose
(17).
30-68 D275AX-5
! 2!
14. Disconnect the following 5 transmission oil pres-

sure pick-up hoses.
• (24): Transmission forward oil pressure pick-

up hose (Color band: Blue/White)
• (25): Transmission 2nd gear speed oil pres-
sure pick-up hose (Color band: Yellow/
White)
• (26): Transmission reverse oil pressure pick-
up hose (Color band: Blue/Red)
• (27):Transmission 3rd gear speed oil pres-
sure pick-up hose (Color band: Black/Yellow)
• (28): Transmission 1st gear speed oil pres-
17. Disconnect the following 4 hoses.
sure pick-up hose (Red)
• (39), (40): HSS pump hose (Port Pd2 )
• (41): Work equipment pump hose (Port PA2)
• (42): Work equipment pump hose (Port
PLS1)
15. Disconnect the following 3 torque converter oil

pressure pick-up hoses.
• (29): Torque converter T/M pressure pick-up
hose (Color band: Transparent)
18. Remove 4 hose clamps (43) and oil pressure
• (30): Torque converter S/C pressure pick-up
pick-up bracket assembly (44).
hose (Color band: Yellow/Blue)
★ After removing the hose clamps, remove the
• (31): Torque converter L/U pressure pick-up
disconnected hoses, too.
hose (Color band: Red/Yellow)
★ Remove the oil pressure pick-up bracket as-
sembly and oil pressure pick-up hose togeth-
er.

• (32): Charge pump hose (Port PA2)
• (33): Work equipment pump hose (Port PA1)
• (34): HSS pump hose (Port PA)
• (35): HSS pump hose (Port PB)
• (36): HSS pump hose (Port Pd1)
• (37): HSS pump hose (Port PCD)
• (38): HSS pump hose (Port PC)
D275AX-5 30-69
2! !
19. Disconnect hydraulic oil temperature sensor wir- 22. Disconnect HSS pump solenoid valve wiring
ing connector 452 (45) and sudden stop preven- connectors PUPA (49) and PUPB (50).
tion solenoid wiring connector STB (46).
23. Disconnect fan pump solenoid valve wiring con-

20. Disconnect pivot turn changeover solenoid wir- nector FAC (51), torque converter lockup sole-
ing connector MFR (47). noid valve wiring connector 653 (52), and torque
converter oil temperature sensor wiring connec-
tor 453 (53).
21. Remove cooler bypass valve and drain collecting

block (48).
★ Remove the block without disconnecting the 24. Disconnect the following 8 wiring connectors.
hoses. • (55): TM1 bevel gear speed sensor
• (56): ST1 (HSS oil pressure sensor)
• (57): ST2 (HSS oil pressure sensor)
• (58): FRB (Right brake ECMV fill switch)
• (59): SRB (Right brake ECMV solenoid)
• (60): FLB (Left brake ECMV fill switch)
• (61): SLB (Left brake ECMV solenoid)
25. Disconnect the wire clamp and wires (62) and

(63).
30-70 D275AX-5
! 2!
26. Remove plate (64) and disconnect road (65). 32. Disconnect suction tube (75) and remove block
(76).
27. Remove brackets (66) and (67) and hose bracket

(68).
33. Remove the 2 mounting bolts and lift off work

equipment and HSS charge pump assembly
(77).
28. Disconnect HSS motor gear lubrication tube
4
(69). Work equipment and HSS charge
pump assembly: 75 kg
29. Disconnect suction tubes (70) and (71).
30. Disconnect scavenging pump suction tube (72).
31. Disconnect pump drive gear lubrication tube (73)

and remove transmission lubrication tube (74).
D275AX-5 30-71
2! !
34. Remove the 2 mounting bolts and lift off HSS

pump assembly (78).
4 HSS pump assembly: 110 kg
35. Remove hose bracket (79).
36. Remove the 4 mounting bolts and scavenging

pump (80).

motor assembly (84).
4 HSS motor assembly: 65 kg
37. Remove the 2 mounting bolts and lift off power

train and lubricating oil pump assembly (81).
4 Power train and lubricating oil pump

assembly: 30 kg
41. Remove torque converter oil temperature sensor

block (85) and pull out 2 sleeves (86).
38. Remove pump drive gear lubrication tube (73)

and tube (82).
39. Remove the 4 mounting bolts and fan pump as-

sembly (83).
4 Fan pump assembly: 30 kg
30-72 D275AX-5
! 2!
42. Remove torque converter valve assembly (87) 45. Loosen the 6 mounting bolts and remove retain-
and pull out the sleeve. er (90) by using 2 forcing screws 2 .
★ Check the quantity and thickness of inserted
shims (91).

case assembly (88).
46. Remove snap ring (92).
4 HSS case assembly: 1,000 kg
47. Set PTO, torque converter, and transmission as-

sembly (93) with the PTO side up.
44. Remove coupling (89).
D275AX-5 30-73
2! !
48. Remove the 19 mounting bolts and lift off PTO CONNECTION
assembly (94).
• Carry out connection in the reverse order to dis-
connection.
4 PTO assembly: 400 kg
★ The adapters of the oil pressure hoses have

respective collar codes. (For details, see
CONNECTION DIAGRAM OF CENTRAL-
IZED OIL PRESSURE PICK-UP HOSE)
★ Layout of oil pressure pick-up hose block.

1) Upper line: (7) (R), (6) (FWD), (30) (TM),
(31) (SC), (29) (LU), (24) (OUT), (26) (IN)
2) Lower line: (27) (3RD), (25) (2ND), (28) (F1),
(8) (RB), (–) (RC), (5) (LB), (–) (LC)
49. Sling the torque converter assembly temporarily

and remove 11 mounting bolts (95).
★ Adjust the brake pedal. For details, see

TESTING AND ADJUSTING, Adjusting
50. Lift off torque converter assembly (96). brake pedal and parking brake lever.
4 Torque converter assembly: 160 kg 3 Eye-joint bolt:

34.3 - 44.2 Nm {3.5 - 4.5 kgm}
3 Mounting bolt:
44.1 - 54 Nm {4.5 - 5.5 kgm}
★ Adjust the shims for the retainer according to

the following procedure.
1) Install retainer (90) and secure the 6 mount-
ing bolts to the following torque without in-
serting any shim.
2 Oil seal: Grease (G2-LI)
3 Mounting bolt: 9.8 Nm {1 kgm}
30-74 D275AX-5
! 3!
2
2) Using a thickness gauge, measure clear-

ance "a" between retainer (90) and PTO
housing (97).
★ Apply lubricant containing molybdenum

disulfide (LM-P) to part "P" of the PTO input
shaft and grease (G2-LI) to spline "b".
★ Measure clearance "a" at 5 places on the pe-

riphery (A, B, C, and D) and obtain the aver-
age.
2 Mounting bolt:
Thread tightener (LT-2)
3) Select shim thickness. 3 Mounting bolt:

0
• Shim thickness = a –0.05 mm 98.10 - 123 Nm {10 - 12.5 kgm}
• Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
• Standard shim thickness: 0.5 mm
4) Insert a shim of the selected thickness and
tighten the mounting bolts of retainer (90) to
the specified torque.
2 Mounting bolt:
3 Mounting bolt:
58.8 - 73.6 Nm {6.0 - 7.5 kgm}
★ Select the shims so that their thickness and
quantity on both sides will be the same.
★ Insert the shims so that they will not block the
forcing tap hole of the retainer as shown be-
low.
D275AX-5 30-75
3
2! !
CONNECTION DIAGRAM OF CENTRALIZED OIL PRESSURE PICK-UP HOSES
30-76 D275AX-5
! 3!
2

(Color band: White)

• (7): Torque converter inlet oil pressure pick-up

hose (Color band: (Blue)

(Color band: Yellow)
• (24): Transmission FORWARD oil pressure

pick-up hose (Color band: Blue/White)
• (25): Transmission 2ND oil pressure pick-up

hose (Color band: Yellow/White)
• (26): Transmission REVERSE oil pressure

pick-up hose (Color band: Blue/Red)
• (27): Transmission 3RD oil pressure pick-up

hose (Color band: Black/Yellow)
• (28): Transmission 1ST oil pressure pick-up

hose (Color band: Red)
• (29): Torque converter TM oil pressure pick-up

hose (Color band: Not attached)
• (30): Torque converter SC oil pressure pick-up

• (31): Torque converter LU oil pressure pick-up

D275AX-5 30-77
3
2! !

(Color band: White)

• (7): Torque converter inlet oil pressure pick-up

hose (Color band: (Blue)

(Color band: Yellow)
• (24): Transmission FORWARD oil pressure

pick-up hose (Color band: Blue/White)
• (25): Transmission 2ND oil pressure pick-up

hose (Color band: Yellow/White)
• (26): Transmission REVERSE oil pressure

pick-up hose (Color band: Blue/Red)
• (27): Transmission 3RD oil pressure pick-up

hose (Color band: Black/Yellow)
• (28): Transmission 1ST oil pressure pick-up

hose (Color band: Red)
• (29): Torque converter TM oil pressure pick-up

hose (Color band: Not attached)
• (30): Torque converter SC oil pressure pick-up

• (31): Torque converter LU oil pressure pick-up

30-78 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY PTO ASSEMBLY

OF PTO ASSEMBLY
DISASSEMBLY ii) Remove bearing inner race (3B) and
bearing (6) from gear (7).
1. Lubrication tube
Remove shaft lubrication tube (1).
3. Hydraulic/HSS charge pump and power train/

lubrication pump drive gear, cover assembly
2. HSS pump/fan pump drive gear, cover as- 1) Remove mounting bolts, then using forcing
sembly screws and guide bolts, remove pump drive
1) Remove mounting bolts, then using forcing gear and cover assembly (8).
screws and guide bolts, remove pump drive
gear and cover assembly (2).
2) Disassemble pump drive gear and cover as-

sembly as follows.
2) Remove bearing outer race and roller (3A) i) Remove cover (9) from gear and bearing
from PTO case. (10).
3) Disassemble pump drive gear and cover as-
sembly as follows.
i) Remove cover (4) from gear and bearing
(5).
D275AX-5 30-79
2! !
ii) Remove 2 bearings (11) from gear (12). 3) Remove snap ring (15), then remove bearing
(16).
4. Scavenging pump drive gear

1) Remove snap ring (13). 5. Idler gear assembly
1) Remove plate (17).
2) Knock drive gear (14) out from snap ring end

to remove. 2) Remove mounting bolts, then using forcing
screws (1) and guide bolts (2), remove shaft
(18).
30-80 D275AX-5
! 2!
★ Bearing (19) and spacer (20) separate 7. Sleeve

from shaft (18) and gear (21) comes off. Remove sleeve (29) from PTO case.
★ If the bearing is to be used again, do not
change the combination with the outer
race. Keep as a set in a safe place.
3) Remove 2 outer races (22) and snap ring
(23) from gear (21).
8. Magnet assembly
1) Remove mounting bolts, then remove cover
(30).
6. Input shaft bearing

1) Knock input shaft bearing and race assem-
bly (24) out from inside PTO case to remove.
2) Remove spacer (25) and outer race (26).
2) Remove 2 springs (31) and 2 magnet as-

semblies (32).
3) Remove 2 bearings (28) from race (27).

★ If the bearing is to be used again, do not
change the combination with the outer
race. Keep as a set in a safe place.
D275AX-5 30-81
2! !
ASSEMBLY 2. Sleeve
Install sleeve (29) to PTO case.
★ Clean all parts, check that there is no dirt or
★ Install the sleeve with the chamfered side
damage, and coat the sliding surfaces of all parts
facing the inside of the PTO case.
with engine oil before assembling.
★ Expand fit the sleeve.
★ After press fitting the bearing, drop approx. 6 cc
of oil (EO30-CD or EO10-CD) on the bearing,
and rotate it 10 times.
★ When expand fitting the bearing, before cooling
with dry ice, drop approx. 6 cc of oil (EO30-CD or
EO10-CD) on the bearing, and rotate it 10 times.
★ Check that the snap ring is fitted securely in the
groove.
1. Magnet assembly
1) Assemble 2 magnet assemblies (32) and 2
springs (31) to PTO case.
3. Input shaft bearing

★ Match the production No. and set No. on the
bearing and spacer, and be sure to use them
as a set.
1) Using push tool 3 , press fit outer race (26)
to PTO case.
2) Install cover (30).
2) Using push tool 4 , press fit 2 bearings (28)

to race (27).
30-82 D275AX-5
! 2!
3) Assemble input shaft bearing and race as-

sembly (24) to PTO case.
2 Surface of inside circumference of
race:
Molybdenum disulphide lubri-
cant (LM-P)
4) Assemble spacer (25).
5) Using push tool 5 , press fit outer race (26).
5) Install spacer (20).

6) Install bearing (19) to gear, then press fit
bearing by fitting plate (17).
2 Mounting bolt:
3 Mounting bolt:
245.0 - 308.7 Nm
{25.0 - 31.5 kgm}
4. Idler gear
★ Match the production No. and set No. on the
bearing and spacer, and be sure to use them
as a set.
1) Install snap ring (23) to gear (21).
2) Using push tool 6 , press fit 2 outer races
(22) to gear (21).
7) Install mounting bolts of shaft (18).
3) Fit O-ring, then using 3 guide bolts 7 , insert

shaft to position shown in diagram.
★ If shaft (18) is inserted fully, is will be-
come impossible to install the idler gear.
2 O-ring: Grease (G2-LI)
4) Hold down shaft from outside of case, then
using push tool 8 , press fit bearing (19) to
gear.
D275AX-5 30-83
2! !
5. Scavenging pump drive gear 6. Hydraulic/HSS charge pump and power train/
1) Press fit bearing (16) to PTO case. lubrication pump drive gear, cover assembly
2) Install snap ring (15). 1) Using push tool 0 , press fit 2 bearings (11)
to gear (12).
3) Hold down inner race end of bearing with

push tool 9 , and press fit drive gear (14). 2) Using push tool A , press fit gear and bear-
ing (10) to cover (9).
4) Install snap ring (13).
3) Fit O-ring and install pump drive gear and

cover assembly (8) to PTO case.
2 Mounting bolt:
3 Mounting bolt:
98.0 - 122.5 Nm {10.0 - 12.5 kgm}
30-84 D275AX-5
! 2!
7. HSS pump/fan pump drive gear, cover as- 8. Lubrication tube

sembly Install shaft lubrication tube (1).
1) Using push tool B , press fit bearing (6) to
gear (7).
2) Using push tool C , press fit bearing inner
race (3B) to gear (7).
3) Using push tool D , press fit gear and bear-

ing (5) to gear (4).
4) Using push tool E , press fit bearing outer
race and roller (3A) to PTO case.
5) Fit O-ring and install pump drive gear and

cover assembly (2) to PTO case.
2 Mounting bolt:
3 Mounting bolt:
98.0 - 122.5 Nm {10.0 - 12.5 kgm}
D275AX-5 30-85
2! !
DISASSEMBLY AND ASSEMBLY OF TORQUE
DISASSEMBLY AND ASSEMBLY CONVERTER ASSEMBLY

OF TORQUE CONVERTER
ASSEMBLY
DISASSEMBLY 3. Disassembly of drive case, housing assem-
bly
1. Input shaft 1) Remove snap ring (5), then remove spacer
1) Remove mounting bolts, then using eyebolts (6).
1 , remove input shaft (1).
2) Using 2 forcing screws 3 , remove bearing

2) Remove 2 seal rings (2) from input shaft (1). (7) from turbine end.
2. Drive case, housing assembly 3) Remove mounting bolts, then using eyebolts
1) Remove 36 mounting bolts (3) between drive 4 , remove housing (8).
case and pump, then using eyebolts 2 , re-
move drive case and housing assembly (4).
30-86 D275AX-5
! 2!
4) Remove 2 seal rings (9) from housing (8).
4. Stator
5) Remove lock-up clutch piston (10). 1) Remove snap ring (16).
6) Remove 2 seal rings (11) from lock-up clutch
piston (10).
2) Remove stator and boss (17).
7) Remove 2 lock-up clutch discs (12) and lock-

up clutch plate (13).
3) Remove boss (18) from stator (19).
8) Using eyebolts 5 , raise drive case (14) and

remove from turbine and gear (15).
D275AX-5 30-87
2! !
4) Remove snap ring (20).
2) Remove stator clutch piston (27).

5. Pump 3) Remove seal ring (28) from stator clutch pis-
1) Remove pump assembly (21) from stator ton (27).
clutch assembly (22). 4) Remove 5 pins (29) and 10 springs (30),
then remove 2 stator clutch discs (31) and
stator clutch plate (32) from housing (33).
2) Remove mounting bolts, then remove retain-

er (23) and outer race (24) from pump (25).
5) Disassemble housing and shaft assembly as
follows.
i) Using forcing screws 6 , remove shaft
and bearing assembly (34).
6. Stator clutch assembly

1) Loosen 3 mounting bolts slowly and discon-
nect housing and shaft assembly (26).
30-88 D275AX-5
! 2!
ii) Remove snap ring (35), then remove vii) Remove snap ring (44), then remove
bearing (36) from shaft (37). bearing (45) from shaft (46).
iii) Remove seal ring (38) from shaft (37). viii) Remove seal ring (47) from shaft (46).
iv) Remove bushing (39) from shaft (37).
ix) Remove seal ring (48) from housing (43).

v) Remove snap ring (40), then remove
gear (41).
vi) Remove shaft and bearing assembly

(42) from housing (43).
D275AX-5 30-89
2! !
ASSEMBLY 4) Using push tool 7 , press pit shaft and bear-

★ Clean all parts, check that there is no dirt or ing assembly (42) to housing (43) with press.
with engine oil before installing.
groove.
1. Assembly of stator clutch assembly

1) Using push tool 6 , press fit bearing (45) to
shaft (46) with press. 5) Using push tool (8), press fit bearing (36) to
shaft (37).
7) Install bushing (39) to shaft (37).
★ Expand fit the bushing.
8) Install seal ring (38) to shaft (37).
★ Fit the seal ring securely to the shaft with
grease.
2 Seal ring: Grease (G2-LI)
2) Install snap ring (44) to shaft (46).

3) Install seal ring (47) to shaft (46).
grease.
9) Install shaft and bearing assembly (34) to

housing (43).
30-90 D275AX-5
! 2!
10) Turn over housing assembly, then fit gear

(41) and install snap ring (40).
14) Install 5 pins (29).

15) Install 2 stator clutch discs (31) and stator
11) Install seal ring (48) to housing (43). clutch plate (32).
★ The seal ring must be installed facing in
the correct direction. Assemble as
2 Outside circumference of seal
ring: Grease (G2-LI)
12) Install seal ring (28) to stator clutch piston
(27).
13) Install stator clutch piston (27) to housing. 16) Install 10 springs (30).
2 Seal ring contact surface:
Grease (G2-LI)
D275AX-5 30-91
2! !
17) Set housing (33) on top and install 3 mount- 2. Pump

ing bolts “a”. 1) Press fit outer race (24) to pump (25).
★ Tighten the 3 mounting bolts uniformly in 2) Install retainer (23) to pump.
turn. 2 Mounting bolt:
2 Mounting bolt: Thread tightener (LT-2)
Thread tightener (LT-2) 3 Mounting bolt:
3 Mounting bolt: 58.8 - 73.6 Nm {6.0 - 7.5 kgm}
98.0 - 122.5 Nm {10.0 - 12.5 kgm}
3) Install pump assembly (21) to stator clutch

18) Before installing pump, insert 11 mounting assembly (22).
bolts (b) of torque converter assembly and
transmission assembly in bolt holes.
3. Snap ring
Install snap ring (20) to shaft.
30-92 D275AX-5
! 2!
4. Stator 5. Assembly of drive case and housing

1) Install boss (18) to stator (19). 1) Set turbine and gear (15) on block 9 .
2 Mounting bolt:
3 Mounting bolt:
58.8 - 73.6 Nm {6.0 - 7.5 kgm}
2) Using eyebolts 5 , set drive case (14) on top

of turbine and gear (15).
2) Install stator and boss (17).
3) Install 2 lock-up clutch discs (12) and lock-up

clutch plate (13) to case (14).
3) Install snap ring (16) to shaft.
D275AX-5 30-93
2! !
4) Install 2 seal rings (11) to lock-up clutch pis- 7) Using eyebolts 4 , raise housing (8) and in-
ton (10). stall to drive case.
★ The seal ring must be installed facing in ★ Lower the housing gradually and align
the correct direction. Assemble as the 3 holes in the top surface of the pis-
shown in the diagram. ton with the protruding pins on the inside
2 Outside circumference of seal of the housing.
ring: Grease (G2-LI) ★ Or, install the piston to the housing, then
support the piston so that it does not fall
out, and install the housing.
2 Mounting bolt:
3 Mounting bolt:
98.0 - 122.5 Nm {10.0 - 12.5 kgm}
5) Install lock-up clutch piston (10).
8) Using eyebolts 2 , install drive case and

housing assembly (4).
★ Align pump plug (48) with the oil groove
in the drive case when installing.
2 Mounting bolt:
3 Mounting bolt:
6) Install 2 seal rings (9) to housing (8). 49.0 - 58.8 Nm {5.0 - 6.0 kgm}
3 Plug:
14.7 - 19.6 Nm {1.5 - 2.0 kgm}
30-94 D275AX-5
! 2!
9) Using push tool 0 , push bearing (7) with

press and press fit.
10) Fit spacer (6) and install snap ring (5).
6. Input shaft
1) Install 2 seal rings to shaft (1).
grease.
2) Using eyebolts 1 , install input shaft (1).

2 Mounting bolt:
3 Mounting bolt:
98.0 - 122.5 Nm {10.0 - 12.5 kgm}
D275AX-5 30-95
2! !
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY

OF TORQFLOW TRANSMISSION
ASSEMBLY
SPECIAL TOOLS 3. Transmission control valve assembly
1) Remove 5 pressure detection nipples (126).
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch 2) Remove cover (3).
Oil leak
D 799-301-1600 " 1
testerll
DISASSEMBLY
★ Store the discs and plates in a flat place to pre-
vent them from becoming deformed.
1. Elbow
Remove elbow (1).
3) Remove wiring connector (136) from cover.

4) Remove cover (137).
2. Main relief valve assembly

Remove main relief valve assembly (2).
5) Remove flanges (138) and (139) and sleeves

(140) and (141).
30-96 D275AX-5
! 2!
6) Remove 4 mounting bolts (4), then remove 2) Remove 13 tie bolts (8) used to tighten trans-
transmission control valve assembly (5). mission case.
★ Do not remove 2 connecting bolts (6) ★ Do not remove 4 tie bolts (9) not used to
connecting the top and bottom control tighten transmission case.
valve.
3) Using eyebolts 2 , remove transmission

4. Sleeve case (10).
Remove sleeve (7).
6. Tie bolts
5. Transmission case Remove 4 remaining tie bolts (9).
1) Set input shaft end at top and put on block 1 .
D275AX-5 30-97
2! !
7. Input shaft, front cover, No. 1 carrier assem- vi) Remove snap ring (142), then remove
bly bearing (143) from front cover (19).
1) Using eyebolts 3 , remove input shaft, front vii) Remove seal ring (121).
cover, and No. 1 carrier assembly (11).
viii) Remove spacer (144).

2) Disassemble input shaft, front cover, and No. ix) Remove snap ring (20), then knock input
1 carrier assembly as follows. shaft (21) out from torque converter end,
i) Remove snap ring (12), then remove No. and remove from No. 1 carrier assembly
2 sun gear (13). (118).
ii) Remove snap ring (14). x) Remove bearing (117) from input shaft
iii) Remove snap ring (15), then remove No. (21).
1 sun gear (16) and spacer (17). xi) Remove seal ring (158) from input shaft.
iv) Remove snap ring (18).

v) Using push tool 7 , push input shaft and
No. 1 carrier assembly, and remove from
front cover (19).
30-98 D275AX-5
! 2!
3) Disassemble No. 1 carrier assembly as fol-

lows. 3) Remove seal ring (145) from No. 1 housing
i) Remove snap ring (22) from No. 1 carrier (33).
assembly, then remove No. 1 ring gear 4) Remove seal ring (146) from No. 1 piston
(23). (34).
ii) Remove shaft (24) and ball (28).
★ Be careful not to lose the ball.
iii) Remove 2 thrust washers (25), needle
bearing (27), and planetary gear (26).
10. No. 2 discs, plates, springs, guide pins

1) Remove 6 guide pins (35).
2) Remove 12 No. 2 springs (36).
3) Remove 48 springs (37), 8 No. 2 discs (38),
8. No. 1 discs, plates, springs and 7 No. 2 plates (39).
and 6 No. 1 plates (32).
9. No. 1 housing assembly

1) Using eyebolts 4 , remove No. 1 housing
(33).
2) Remove No. 1 piston (34) from No. 1 hous-
ing.
D275AX-5 30-99
2! !
11. Sleeves
Remove 17 sleeves (40). 5) Remove snap ring (44).
6) Using push tool 8 , push No. 2 carrier as-
sembly (45), and remove from No. 2 housing
12. Lubrication relief valve (46).
Remove lubrication relief valve (41) and spring
(120).
7) Remove snap ring (58), then remove bearing

(59) from No. 2 housing (46).
13. No. 2 housing, No. 2 carrier assembly 8) Remove seal ring (57).
1) Using eyebolts 5 , remove No. 2 housing
and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
3) Remove seal ring (147) from No. 2 housing

(46).
4) Remove seal ring (148) from No. 2 piston
(43).
30-100 D275AX-5
! 2!
9) Disassemble No. 2 carrier assembly as fol- 15. No. 3 ring gear

lows. Remove No. 3 ring gear (64).
i) Remove spacer (47) and No. 2 ring gear
(48) from No. 2 carrier assembly.
ii) Remove shaft (50) and ball (54).
16. No. 3, No. 4 carrier assembly

1) Using eyebolts 9 , remove No. 3 and No. 4
carrier assembly (65).
iv) Remove snap ring (55), then remove ring

gear (56).
14. No. 3 discs, plates, springs

D275AX-5 30-101
2! !
2) Disassemble No. 3 and No. 4 carrier assem-

bly as follows.
i) Remove seal ring (66)
ii) Using round bar, knock pin (67) into shaft
(68).
iii) Using round bar, knock No. 4 shaft (68)
out from No. 3 carrier and remove.
★ Pull the pin out from the shaft.
iv) Remove 2 thrust washers, needle bear-
ing (71), and No. 4 planetary gear (70).
v) Remove No. 3 shaft (72) and ball (76).
vi) Remove 2 thrust washers (73), needle
bearing (75), and No. 3 planetary gear
(74).
vii) Remove snap ring (156), then remove 18. No. 4 discs, plates, springs, guide pins
bearing (157). 1) Remove 6 guide pins (83).

1) Using eyebolts 0 remove No. 3 housing
(77).
2) Remove No. 3 piston (78). 19. No. 5 carrier, No. 4 ring gear assembly
1) Remove 8 mounting bolts (84).
2) Remove No. 5 carrier and No. 4 ring gear as-
sembly (85).

(77).
4) Remove seal ring (150) from No. 3 piston
(78).
30-102 D275AX-5
! 2!
3) Disassemble No. 5 carrier and No. 4 ring 3) Remove seal ring (151) from No. 4 housing
gear as follows. (94).
i) Remove shaft (86) and ball (90). 4) Remove seal ring (152) from No. 4 piston
★ Be careful not to lose the ball. (95).
ii) Remove 2 thrust washers (87), needle
bearing (89), and planetary gear (88)
from No. 5 carrier (93).

iii) Remove snap ring (91), then remove No. and 4 No. 5 plates (98).
4 ring gear (92) from No. 5 carrier (93).

1) Using eyebolts A , remove No. 4 housing
(94).
2) Remove No. 4 piston (95).
D275AX-5 30-103
2! !
22. No. 5 ring gear

Remove No. 5 ring gear (100).
23. Spacer, No. 4 sun gear, bearing

2) Remove spacer (102), No. 4 sun gear (103),
and bearing and spacer (104).
24. No. 5 sun gear

Remove No. 5 sun gear (105).

25. No. 5 piston
1) Remove snap ring (110), then remove bear-
Remove No. 5 piston (106).
ing (111) from No. 5 housing.
2) Remove snap ring (112), then remove bear-
ing (113) from No. 5 housing.
3) Remove cage (114).
4) Remove seal rings (115) and (116) from
cage (114).
26. Seal rings

(109).
2) Remove seal ring (154) from No.5 piston
(106).
ASSEMBLY
27. Output shaft, spacer groove.
1) Remove spacer (108). ★ Coat the blind plugs with thread tightener (LT-2),
2) Remove snap ring (155), then remove output then after assembling, caulk 2 places on diago-
shaft (107) from No. 5 housing (109). nally opposite sides.
30-104 D275AX-5
! 2!
1. No. 5 housing assembly 3) Install spacer (108) to shaft (107).

1) Install seal rings (116) and (115) to cage
(114).
2) Install cage (114) to No. 5 housing (109).
3) Using push tool (12), press fit bearing (113)
to No. 5 housing with press.
3. Seal ring
1) Install seal ring (154) to No. 5 piston (106).
4) Install snap ring (112). 2 Seal ring: Grease (G2-LI)
5) Install snap ring (110). 2) Install seal ring (153) to No. 5 housing (109).
6) Using push tool C , press fit bearing (111) ★ The seal ring must be installed facing in
until it contacts snap ring (110). the correct direction. Assemble as
2. Output shaft, spacer

1) Install snap ring (155) to output shaft (107).
2) Support inner side of bearing (111) of No. 5
housing with tool D , then using push tool E ,
press fit output shaft with press.
★ Press fit bearing (111) until it contacts
snap ring (155).
D275AX-5 30-105
2! !
4. No. 5 piston
Install No. 5 piston (106).
5. No. 5 sun gear

Install No. 5 sun gear (105).
6. No. 5 ring gear

Install No. 5 ring gear (100).

2Seal ring: Grease (G2-LI)
2) Install seal ring (151) to No. 4 housing (94).
7. Bearing, No. 4 sun gear, spacer shown in the diagram.
1) Using push tool F , press fit bearing (156) to 2Seal ring: Grease (G2-LI)
spacer (157).
2) Install bearing and spacer (104).
3) Install No. 4 sun gear (103) and spacer
(102).
3) Install No. 4 piston (95) to No. 4 housing (94).

4) Using eyebolts A , install No. 4 housing (94).
★ Check that the spring is fitted securely in
the groove.

1) Install guide pin (83).
2) Install 4 No. 5 plates (98), 3 No. 5 discs (97),
and 18 springs (99).
3) Install 12 springs (96).
★ Free length of spring: 70 mm
30-106 D275AX-5
! 2!
10. No. 5 carrier, No. 4 ring gear assembly

1) Assemble No. 5 carrier and No. 4 ring gear
assembly as follows.
i) Set No. 4 ring gear (92) to No. 5 carrier
(93), and install snap ring (91).

2) Install 12 No. 4 springs (79).
ii) Assemble needle bearing (89) to plane-
tary gear (88), put 2 thrust washers (87)
in contact on both sides, and set to No. 5
carrier (93).
★ Be careful not to damage or dent the
thrust washers.
iii) Install shaft (86) and ball (90).
★ Check that the gear rotates smoothly.

2) Using guide bolt G , install No. 5 carrier and ★ The seal ring must be installed facing in
No. 4 ring gear assembly (85). the correct direction. Assemble as
2 Mounting bolt: shown in the diagram.
Thread tightener (LT-2) 2 Seal ring: Grease (G2-LI)
3 Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
D275AX-5 30-107
2! !
3) Install No. 3 piston (78) to No. 3 housing (77). 2) ALign meshing of gears, then using eyebolts
4) Using eyebolts 0 , install No. 3 housing (77). (9), install No. 3 and No. 4 carrier assembly
★ Check that the spring is fitted securely in (65).
the groove.
14. No. 3 ring gear

Install No. 3 ring gear (64).
13. No. 3, No. 4 carrier assembly

1) Assemble No. 3 and No. 4 carrier assembly
as follows.
i) Assemble needle bearing (75) to No. 3
planetary gear (74), put 2 thrust washers
(73) in contact on both sides, and set to
No. 3 carrier.
thrust washers.
ii) Install No. 3 shaft (72) and ball (76).
iii) Assemble needle bearing (71) to No. 4 15. No. 3 discs, plates, springs
planetary gear (70), put 2 thrust washers 1) Install 5 No. 3 plates (63), 4 No. 3 discs (62),
(69) in contact on both sides, and set to and 24 springs (61).
No. 4 carrier. 2) Install 12 No. 4 springs (60).
thrust washers.
iv) Install No. 4 shaft (68).
v) Check that the position of the pin holes
matches, then install pin (67) to No. 4
shaft (68).
30-108 D275AX-5
! 2!
16. No. 2 housing, No. 2 carrier assembly 2) Using push tool H , press fit bearing (59) to
1) Assembly No. 2 carrier assembly as follows. No. 2 housing (46).
i) Set ring gear (56) to No. 2 carrier (45),
and install snap ring (55).
3) Using push tool I , press fit No. 2 housing

ii) Assemble needle bearing (53) to plane- (46) to No. 2 carrier assembly (45).
tary gear (52), put 2 thrust washers (51) ★ Push the bearing inner race to press fit.
carrier.
thrust washers.
iii) Install shaft (50) and ball (54).
iv) Install No. 2 ring gear (48).

v) Install spacer (47).
★ Install with the cut side facing the carrier.
D275AX-5 30-109
2! !

1) Install guide pins (35).

9) Using eyebolts 5 , install No. 2 housing and
No. 2 carrier assembly (42).

17. Sleeves
Install 17 sleeves (40).
18. Lubrication relief valve

Install lubrication relief valve (41) and spring
(120).
30-110 D275AX-5
! 2!

4) Using eyebolts 4 , align No. 2 piston (34)
with guide pin position, then install No. 1
housing (33).
the groove.
4) Using push tool K press fit bearing outer

end of input shaft (21) to No. 1 carrier as-
sembly (118).
21. Input shaft, No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as follows.
i) Assemble needle bearing (27) to plane-
tary gear (26), put 2 thrust washers (25)
carrier.
thrust washers.
ii) Install shaft (24) and ball (28).
★ Check that the gear rotates smooth-
ly. 5) Install spacer (17).
iii) Set No. 1 ring gear (23) to No. 1 carrier, 6) Fit No. 1 sun gear and install snap ring (15)
and install snap ring (22). to input shaft.
2) Install seal ring (158) to input shaft (21).

3) Using push tool J , press fit bearing (117) to
input shaft (21) with press.
D275AX-5 30-111
2! !
8) Fit No. 2 sun gear (13) and install snap ring 24. Front cover
(12) to input shaft. 1) Using push tool L , press fit bearing (143) to
front cover (19).
9) Align meshing of No. 2 sun gear and No. 1

planetary gear, then using eyebolts 3 , in- 2) Install snap ring (142).
stall input shaft and No. 1 carrier assembly 3) Install seal ring (121) to front cover (19).
(119). 2 Seal ring: Grease (G2-LI)
22. Spacer
4) Using eyebolts 6 , install front cover (19).
Install spacer (144).
the groove.
30-112 D275AX-5
! 2!
5) Using push tool M , press fit inner side of 27. Transmission case
bearing (143) inside front cover (19). 1) Fit O-ring, then using eyebolts 2 , install
6) Install snap ring (18). transmission case (10).
25. Tie bolts

Install 4 tie bolts (9).
3 Tie bolt:
2) Install remaining 13 tie bolts (8).
3 Tie bolt:
156.8 - 176.4 Nm {16.0 - 18.0 kgm}
156.8 - 176.4 Nm {16.0 - 18.0 kgm}
26. Piston actuation check

28. Sleeve
Using tool D, check stroke and actuation condi-
Fit O-ring and install sleeve (7).
tion of each clutch piston.
Piston Standard stroke (mm)
No.1 6
No.2 8.8
No.3 6.4
No.4 6.4
No.5 6
D275AX-5 30-113
2! !
29. Transmission control valve assembly 5) Fit gasket and install cover (3).
1) Fit O-ring and install transmission control 6) Install 5 pressure detection nipples (126).
valve assembly (5).
3 Mounting bolt: 44.1 - 53.9 Nm
{4.5 - 5.5 kgm}
30. Main relief valve assembly

Install main relief valve assembly (2).
3 Mounting bolt:
2) Fit O-ring and install sleeves (140) and 44.1 - 53.9 Nm {4.5 - 5.5 kgm}
(141), and sleeves (138) and (139).
31. Elbow
Install elbow (1).
3) Fit gasket and install cover (137).
★ Coat both the cover and transmission
case with gasket sealant.
2 Cover:
4) Fit wiring connector (136) to cover (137).
3 Mounting bolt:
39.6 - 42.4 Nm {4.0 - 4.3 kgm}
30-114 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY HSS CASE ASSEMBLY

OF HSS CASE ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
791-622-1110 Bracket " 1

1 01010-62095 Bolt " 1
E
01016-61690 Bolt " 1
2 791-550-1301 Wrench " 1
DISASSEMBLY
1. Drain hose, joint
1) Remove drain hose (1). 3. Disassembly of brake, carrier assembly
2) Remove joint (2). 1) Remove flange (5) and plate (6).
2. Brake, carrier assembly 2) Loosen 4 hexagonal socket head bolts (7)

1) To install tool E1 perpendicularly, use block uniformly, then using eyebolts 3 , remove
1 and jack 2 , and set HSS case assembly brake case (8).
at an angle of 15°. ★ The case is being pushed by the brake
spring, so loosen uniformly a little at a
time.
3) Remove bearing (9A) from brake case (8).
2) Remove 16 mounting bolts, then using tool

E1, remove brake and carrier assembly (4).
★ Do not remove the 4 hexagon socket
head bolts.
★ Remove the brake and carrier assembly
on the opposite side in the same way.
D275AX-5 30-115
2! !
4) Remove brake spring (10), piston (11), and

cylinder (12).
9) Remove ring (20), then remove ring gear

5) Remove brake drum, disc, and plate assem- 10) Disassemble carrier assembly as follows.
bly (13). i) Remove snap ring (23).
6) Remove 7 discs (14), 6 plates (15), and 7 ii) Remove shaft (24) and ball (25).
springs (86) from brake drum (16). ★ Be careful not to lose the ball.
7) Remove mounting bolts, then remove carrier

assembly (18) from hub (17).
8) Remove gear assembly (19) from hub (17).
30-116 D275AX-5
! 2!
11) Remove bearing (9B) from hub (17). ii) Remove pin (35).
12) Remove snap ring (29), then remove stopper
(30) from hub (17).
iii) Hold with press so that bevel pinion does

not move, and use tool E2 to remove
4. Bevel pinion assembly locknut (36).
1) Using guide bolt 4 and forcing screws 5 ,
remove bevel pinion assembly (31) and
shims (32).
★ Check the number and thickness of the
shims, and keep in a safe place.
iv) Support cage (37), and use push tool 6

to remove bevel pinion and bearing (38).
2) Disassemble bevel pinion as follows.

i) Remove plate (34).
D275AX-5 30-117
2! !
v) Remove bearing (39A).

vi) Remove outer races (39B) and (40B)
from cage (37).
6. HSS motor housing assembly

1) Using eyebolts 7 , remove HSS motor hous-
ing assembly (44).
vii) Remove spacer (41) and bearing (40A)
from bevel pinion (42).
5. Transmission output speed sensor

Remove transmission output speed sensor (43)
together with flange.
★ When removing the transmission output

speed sensor from the flange and replacing
it, measure distance L between the flange
and the tip of the speed sensor. When re-
placing the speed sensor, install so that the
installation dimension of the speed sensor is
L ± 0.2 mm.
30-118 D275AX-5
! 2!
2) Disassemble HSS motor assembly as fol- v) Remove snap ring (52).

lows. vi) Using puller 9 , remove gear and bear-
i) Remove mounting bolts, then remove ing assembly (53).
holder (45).
ii) Using push tool 8 , remove shaft (46)
and ball (47).
iii) Remove gear and bearing assembly
(48).
vii) Remove 2 bearings (54) from gear (55).
7. Steering control valve assembly

1) Remove 3 sleeves (56).
★ Remove on the opposite side in the
same way.
iv) Remove 2 bearings (49) and collar (50)
from gear (51).
D275AX-5 30-119
2! !
2) Remove mounting bolts, then using eyebolts

0 , remove steering control valve assembly
(57).
2) Using puller A , remove gear and bearing

assembly (61).
3) Remove 2 sleeves (58) from HSS case.
3) Remove snap ring (62) and spacer (83), then

remove bearing (63) from gear (64).
8. Sun gear
Remove sun gear (59).
4) Using puller B , remove bearing (65).
9. Gear, bearing
30-120 D275AX-5
! 2!
10. HSS motor output gear, shaft 3) Remove outer race (73) from right cage (71).
1) Remove mounting bolts, then remove plate
(66) and gear (67).
★ Remove on both the left and right sides.
2) Knock out shaft (68) with plastic hammer
and remove.
★ Bearing inner race (69) at one end will
come off and the bearing inner race at
the other end will remain on the shaft.
4) Using forcing screws D , disconnect retainer

(74) from case.
5) Remove forcing screws D , then using eye-
bolts E , remove retainer (74).
3) Remove bearing (70) from left side of case.
6) Remove bearing (70) from retainer (74).
11. Bevel gear shaft, bevel gear assembly

1) Set with right side of HSS case at top.
2) Remove mounting bolts, then using forcing
screws C , remove right cage (71) and
shims (72).
D275AX-5 30-121
2! !
7) Hook wire to bevel gear and shaft assembly iv) Using puller G , remove bearing (80)
(75) and remove. from shaft (77).
8) Disassemble bevel gear and shaft assembly

as follows.
i) Remove 2 seal rings (76) from shaft (77). 12. Left cage
Remove mounting bolts, then using forcing
screws H and guide bolt I , remove left cage
(81) and shims (82).
ii) Using puller F , remove bearing (78)

from shaft (77).
iii) Remove bevel gear (79) from shaft (77).
13. Tube
Remove tube (84).
30-122 D275AX-5
! 2!
ASSEMBLY 3. Bevel gear shaft, bevel gear assembly

1) Set with right side of HSS case at top.
2) Assemble bevel gear and shaft assembly as
follows.
i) Using push tool J , press fit bearing (80)
to shaft (77).
groove.
★ Coat the blind plugs with thread tightener (LT-2),
then after assembling, caulk 2 places on oppo-
site sides.
1. Tube
1) Install tube (84).
ii) Install bevel gear (79) to shaft (77).
3 Mounting nut:
215.6 - 274.4 Nm {22 - 28 kgm}
iii) Using push tool K , press fit bearing (78)
to shaft (77).
2. Left cage
Using guide bolt I , install shims (82) and left
cage (81).
★ Assemble the same amount and thickness of
shims (82) that was removed.
• Standard shim thickness: 2 mm iv) Install 2 seal rings (76) to shaft (77).
• Types of shim thickness: 2 Seal ring: Grease (G2-LI)
0.1 mm, 0.2 mm, 0.5 mm
{10 - 12.5 kgm}
D275AX-5 30-123
2! !
3) Hook wire to bevel gear and shaft assembly 6) Using push tool M , press fit outer race (73)
(75) and install to HSS case. to cage (71).
★ Be careful not to damage the seal rings
of the shaft.
7) Using guide bolt N , install right cage (71)

and shims (72).
4) Press fit bearing (70) to retainer (74). ★ Assemble the same amount and thick-
ness of shims (72) that was removed.
• Types of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
3 Mounting bolt:
98.1 - 122.6 Nm
{10 - 12.5 kgm}
5) Using eyebolts E and guide bolt L , install

retainer (74).
3 Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
30-124 D275AX-5
! 2!
8) Set HSS case assembly horizontally.

9) Adjust preload of cage bearing.
• Push tip of tooth of bevel gear (79) with
push-pull scale O and measure rotating
torque of bevel gear shaft.
★ Standard value for rotating torque (cen-
ter of bevel gear shaft):
3.9 - 4.9 Nm {0.4 - 0.5 kgm}
(At tip of bevel gear tooth:
21.6 - 27.4 N {2.2 - 2.4 kg})
★ When measuring the rotating torque, ro-
tate the bevel gear thoroughly (10 - 20
times) before measuring.
★ If the rotating torque is not within the iv) nstall cage (37) to bevel pinion (42).
standard value, adjust the shim thick- v) Using push tool R , press fit bearing
ness at the left and right cages as fol- (39A) with press.
lows:
If value is LOW, ADD shims
If value is HIGH, REMOVE shims
vi) Hold with press so that bevel pinion does

not move, and use tool E2 to tighten lock-
nut (36).
★ Rotate the cage while tightening.
★ After tightening the locknut, check that
4. Bevel pinion the bevel pinion rotates smoothly.
1) Assemble bevel pinion as follows. 2 Locknut:
i) Using push tool P , press fit bearing Thread tightener (LT-2)
3 Locknut:
(40A) to bevel pinion (42) with press.
ii) Install spacer (41).
392 - 441 Nm {40 - 45 kgm}
iii) Using push tool Q , press fit outer race

(39B) to cage (37).
★ Press fit outer race (40B) in the same
way.
D275AX-5 30-125
2! !
vii) After tightening locknut, turn locknut in

direction of loosening to a point where 1
of 5 pin insertion holes in pinion shaft
and 1 of 8 pin insertion holes in locknut
are aligned.
• Angle to loosen: 0 - 9°
viii) Install pin (35) in aligned hole.
5. Adjusting backlash, tooth contact

1) Adjusting backlash
i) Put probe of dial gauge S in contact with
tooth face at tip of bevel gear.
ii) Fix bevel pinion in position, and read
scale when bevel gear is moved back-
ward and forward (in direction of rota-
ix) Fit plate (34). tion).
2 Mounting bolt: • Standard value of backlash:
Thread tightener (LT-2) 0.25 - 0.33 mm
3 Mounting bolt:
★ Measure at 3 places on diametrically op-
posite sides.
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
2) Using guide bolt 4 , install bevel pinion as-

sembly (31) and shims (32).
★ Assemble the same amount and thick-
ness of shims (32) that was removed.
• Types of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
3 Mounting bolt:
98.1 - 122.6 Nm
{10 - 12.5 kgm}
30-126 D275AX-5
! 2!
iii) If the result of the measurement shows 2) Adjusting tooth contact

that the backlash is not correct, adjust as Testing
follows. i) Coat the tooth face of the bevel pinion
★ When adjusting the shim thickness, add lightly with red lead (minium), then rotate
or remove shims on the left or right sides. the bevel gear forward and backward
However, to prevent the preload of the and inspect the tooth contact pattern left
bearing from changing, always keep the on the bevel gear teeth.
same total thickness of shims on the left ii) The standard value for the tooth contact
and right. (Adjust by moving shims from is as follows
one side to the opposite side.) (from tip of bevel pinion tooth)
• When backlash is too small: a. Center of tooth contact: 20 - 40 % of
Reduce the shim thickness on the right tooth width (from small end)
side of the chassis and add the same b. Width of tooth contact: 30 - 50 % of
shim thickness to the left side. (Move the tooth width
bevel gear in direction A.) c. Center of tooth contact: 35 - 65 % of
tooth height (from root of tooth)
d. Width of tooth contact: 60 - 80 % of
tooth height
In addition, check that there is no strong
contact at the tip or root of the teeth or at
the big and small ends.
★ If the gears are adjusted to this pattern,
the tooth contact will be correct when
load is applied.
• When backlash is too large:

Reduce the shim thickness on the left
side of the chassis and add the same
shim thickness to the right side. (Move
the bevel gear in direction B.)
D275AX-5 30-127
2! !
Adjusting 6. HSS motor output gear, shaft

If the result of the inspection shows that the 1) Press fit bearing (70) to left side of case.
correct tooth contact is not being obtained,
adjust again as follows.
i) When bevel pinion is too far from center
line of bevel gear:
Contact is at the small end of the convex
tooth face of the bevel gear and at the big
end of the concave tooth face.
• Adjust the shim thickness at the bevel
pinion end and move the bevel pinion in
direction A.
Or, adjust the shim thickness and move
the bevel gear in direction B.
After adjusting, check the tooth contact
pattern and backlash again. 2) Using push tool, press fit bearing inner race
(69) to shaft (68).
★ Install only one end of the shaft.
★ Press fit until distance a from the end
face of the shaft to the bearing is 26 mm.
ii) When 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. 3) Insert shaft (68) and fit bearing inner race
• Correct as follows: (69) from opposite side.
Adjust the shim thickness at the bev- 4) Using push tool T , press fit bearing inner
el pinion end and move the bevel pin- race (69).
ion in direction A. ★ Hold down the shaft from the opposite
Or, adjust the shim thickness and end and press fit the bearing inner race.
move the bevel gear in direction B.
After adjusting, check the tooth con-
tact pattern and backlash again.
30-128 D275AX-5
! 2!
5) Install gear (67) and plate (66).

★ Install on both the left and right sides.
2 Mounting bolt:
3 Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
8. Sun gear
Fit spacer (93) and install sun gear (59).
7. Gear, bearing
1) Using push tool U , press fit bearing (65).
9. Steering control valve assembly

1) Install 2 sleeves (58) to HSS case.
2) Using push tool V , press fit bearing (63) to

gear (64).
3) Install snap ring (62) and spacer (83).
4) Fit gear and bearing (61), then using push

tool W , press fit bearing inner side.
D275AX-5 30-129
2! !
2) Fit O-ring to HSS case end, then using guide 2) Using push tool Z , press fit gear and bear-
bolt X and eyebolts 0 , install steering con- ing assembly (53) to housing.
trol valve assembly (57).

3) Install 3 sleeves (56).
★ Install on the opposite side in the same
way.
4) Using push tool [ , press fit bearing (49) to

gear (51).
5) Assemble collar (50), and press fit other
bearing (49) in same way as Item 4).
10. HSS motor housing assembly

1) Assemble HSS motor housing assembly as
follows.
i) Using push tool Y , press fit 2 bearings
(54) to gear (55) with press.
30-130 D275AX-5
! 2!
6) Install gear and bearing assembly (48) to

housing, fit ball (47) to shaft (46), then using
push tool \, press fit shaft (46).
11. Transmission speed sensor

Install transmission speed sensor (43).
★ Install the stamped mark [HSS UP] at the ro-
7) Install holder (45). tation sensor flange portion so that it faces
2 Mounting bolt: the top of the HSS case.
Thread tightener (LT-2) ★ Adjust the transmission speed sensor. For
3 Mounting bolt:
details, see TESTING AND ADJUSTING,
Adjusting transmission speed sensor.
98.1 - 122.6 Nm {10 - 12.5 kgm}
12. Assembly of brake, carrier assembly

8) Using eyebolts 7 , install HSS motor hous-
★ Use the same procedure to assemble on
ing assembly (44).
both the left and right sides.
★ Check that there are no dents, rust, oil,
1) Fit stopper (30) to hub (17), and install snap
grease, or moisture on the mating sur-
ring (29).
face of both the case and housing.
2) Using push tool ] , press fit bearing (9B).
★ Coat both the case and housing with
gasket sealant, and make sure that there
is no gap in the sealant film.
2 Housing mounting surface:
3 Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
D275AX-5 30-131
2! !
3) Assemble carrier assembly as follows. viii) Install brake drum (16) to hub (17).
i) Assemble needle bearing (27) to plane- ix) Install 7 springs (86), 6 plates (15), and 7
tary gear (28), put 2 thrust washers (26) discs (14).
in contact on both sides, and set to carri-
er.
thrust washers.
ii) Install shaft (24) and ball (25).
iii) Install snap ring (23).
4) Install seal rings (87) and (88) to cylinder

(12).
iv) Install 2 bushings (85) to gear (22).

v) Set gear (22) to ring gear (21), and install
ring (20).
5) Install cylinder (12), piston (11), and brake

spring (10).
★ Install stamped mark A facing the posi-
tion shown in the diagram.
vi) Install gear assembly (19) to hub (17).

vii) Install carrier assembly (18) to hub (17).
3 Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
30-132 D275AX-5
! 2!
6) Using push tool ^ , press fit bearing (9A) to

brake case (8).
7) Install bushing (89) and collar (90).
11) Install plate (6).

3Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
8) Install guide bolt $1 to cylinder (12).
12) Fit O-ring and install flange (5).
3 Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
9) Fit O-ring, then using eyebolts 3 , install

brake case (8).
10) Using push tool $2 , push inner side of bear-
ing (9A) and press fit with press.
★ After press fitting with the press, install 4
hexagon socket head bolts.
★ After removing from the press, fully tight-
en the hexagon socket head bolts uni-
formly.
D275AX-5 30-133
3
2! !
13. Brake, carrier assembly 15. Cover

1) To install tool E1 perpendicularly, use block If cover (91) at rear of HSS case has been re-
1 and jack 2 , and set HSS case assembly moved, install new gasket.
(3) at an angle of 15°. ★ Coat both surfaces of the gasket with gasket
sealant.
2 Gasket: Gasket sealant (LG-1)
★ Tighten connector bracket (92) of the trans-
mission output speed sensor with the cover
mounting bolts.
2) Fit O-ring, then using tool E1, install brake

and carrier assembly (4).
{10.0 - 12.5 kgm}
14. Drain hose, joint

1) Install joint (2).
2) Install drain hose (1).
30-134 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY SCAVENGING PUMP

OF SCAVENGING PUMP
REMOVAL INSTALLATION
1. Remove inspection cover (1). • Carry out installation in the reverse order to re-
moval.
• Refilling with oil (Power train case)

5 ¬
Power train case: Approx. 90¬
2. Drain the power train oil.
3. Remove tube (2).
4. Remove the 5 mounting bolts and scavenging

pump assembly (3).
D275AX-5 30-135
2! !
DISASSEMBLY AND ASSEMBLY HSS PUMP ASSEMBLY

OF HSS PUMP ASSEMBLY
REMOVAL 5. Remove floor plate (6).
nal of the battery. 4 Floor plate: 35 kg

er (1).
6. Disconnect wiring connectors PUPA (7) and

PUPB (8).
7. Disconnect HSS pump hoses (9), (10), (11).

• (9): Pump hose port PCD
• (10): Pump hose port PC
• (11): Drain hose port Pd1
3. Disconnect wiring connectors DCL (3) and BRK
(4).
4. Disconnect brake linkage (5) from the turnbuck-

le.
★ Before disconnecting the linkage, measure
its installed length.
30-136 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY HSS PUMP ASSEMBLY
8. Disconnect hose clamps (12), (13), and (14). 12. Lift off HSS pump assembly (20).
★ Install wires to the HSS pump assembly and
connect 2 nylon rings to them. Sling the ny-
lon rings taken out of both sides of the oper-
ator's cab to lift off the HSS pump assembly
slowly.
4 HSS pump assembly: 110 kg
9. Disconnect drain hose ports Pd2 (17) and (18).
10. Disconnect 2 pump hose, (17) and (18).

• (17): Pump hose (Port PB)
• (18): Pump hose (Port PA)
INSTALLATION
moval.

brake pedal and parking brake lever.
11. Remove 2 HSS pump mounting bolts (19). • Bleeding air

Bleed air from the HSS pump. For details, see
HSS pump.
D275AX-5 30-137
2! !
REMOVAL AND INSTALLATION OF WORK
DISASSEMBLY AND ASSEMBLY EQUIPMENT AND HSS CHARGE PUMP ASSEMBLY

OF WORK EQUIPMENT AND
HSS CHARGE PUMP ASSEM-
BLY
REMOVAL 5. Remove floor plate (6).
¤ Disconnect the cable from the negative (–) termi- 4 Floor plate: 35 kg
nal of the battery.
er (1).
6. Disconnect the hose clamps and hose plates (7),

(8), (9), (10), (11), and (12).
7. Disconnect suction tube (13) and discharge

hose (14).
8. Remove the mounting bolts and charge pump

assembly (15).
(4). 9. Disconnect suction tubes (16) and (17).
4. Disconnect brake linkage (5) from the turnbuck- 10. Disconnect load pressure input hose (18).
le.
30-138 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY EQUIPMENT AND HSS CHARGE PUMP ASSEMBLY
11. Disconnect 2nd pump pressure signal hose (19),

discharge hose (20), and drain hose (21).
12. Remove the 2 mounting bolts and lift off work

equipment pump assembly (22).
4 Work equipment pump assembly: 75 kg
INSTALLATION
moval.

D275AX-5 30-139
2! !
DISASSEMBLY AND ASSEMBLY FAN PUMP ASSEMBLY

OF FAN PUMP ASSEMBLY
REMOVAL
nal of the battery.
er (1).
5. Remove plate (6).

★ Plate (6) may be removed together with op-
erator's seat sliding plate (5).
2. Remove mounting nuts (2) and operator's seat

assembly (3).
4 Operator's seat assembly: 40kg

(9).

le.
9. Remove floor plate (11).
4
3. Disconnect plate (4).
Floor plate: 35 kg
4. Remove the mounting bolts and operator's seat
sliding plate (5).
★ Operator's seat sliding plate (5) may be re-
moved together with plate (6).
4 Operator's seat sliding plate (5):

25 kg
4 Operator's seat sliding plate (5) and
plate (6): 40 kg
30-140 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY FAN PUMP ASSEMBLY
10. Disconnect hose clamps (12), (13), and (14). INSTALLATION

moval.

• Bleeding air
Bleed air from the fan pump. For details, see
fan pump.
11. Disconnect wiring connectors FAC (15).
12. Disconnect EPC valve main pressure hoses (16)

and (17).
13. Disconnect suction tube (18).
14. Disconnect discharge hose (19) and drain hose

(20).
15. Remove the 4 mounting bolts and fan pump as-

sembly (21).
4 Fan pump assembly: 30 kg
D275AX-5 30-141
2! !
DISASSEMBLY AND ASSEMBLY AND LUBRICATING OIL PUMP ASSEMBLY

OF POWER TRAIN AND LUBRI-
CATING OIL PUMP ASSEMBLY
REMOVAL
nal of the battery.
er (1).

★ Plate (6) may be removed together with op-
erator's seat sliding plate (5).
2. Remove mounting nuts (2) and operator's seat

assembly (3).
4 Operator's seat assembly: 40kg

(9).

le.
3. Disconnect plate (4). its installed length.
9. Remove floor plate (11).
4
4. Remove the mounting bolts and operator's seat
Floor plate: 35 kg
sliding plate (5).
★ Operator's seat sliding plate (5) may be re-
moved together with plate (6).
4 Operator's seat sliding plate (5): 25 kg
4 Operator's seat sliding plate (5) and
plate (6): 40 kg
30-142 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY AND LUBRICATING OIL PUMP ASSEMBLY
10. Disconnect suction tube (12). INSTALLATION

moval.

11. Disconnect hose clamps (13) and (14).
12. Disconnect discharge hoses (15), (16).
13. Remove the 2 mounting bolts and lift off power

train and lubricating oil pump assembly (17).
4 Power train and lubricating oil pump
assembly: 30 kg
D275AX-5 30-143
2! !
DISASSEMBLY AND ASSEMBLY HSS MOTOR ASSEMBLY

OF HSS MOTOR ASSEMBLY
¤ Disconnect the cable from the negative (–) termi- Carry out installation in the reverse order to removal.
nal of the battery.
1. Remove the fuel tank assembly. For details, see

REMOVAL OF FUEL TANK ASSEMBLY.
2. Disconnect wiring connectors ST1 (1) and ST2

(2).

• (3): Drain hose (Port T1)
• (4): Pilot hose (Port P)
• (5): Charge filter hose (Port C)
• (6): Cooler hose (Port CD)
• (7): HSS pump hose (Port PA)
• (8): HSS pump hose (Port PB)

motor assembly (9).
4 HSS motor assembly: 65 kg
30-144 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY

OF FINAL DRIVE ASSEMBLY
Special tools 6. Remove the 3 final drive bolts and install tool J1.
Sym- Part No. Part name
Neces-
Q'ty
New/Re-
Sketch
bol sity model
790-337-1032 Lifting tool " 1 7. Using tool J1, sling final drive assembly (5) tem-
791-627-1320 Shackle " 2
porarily.
J1
791T-627-1810 Plate " 1 !
01010-82090 Bolt " 2
REMOVAL
1. Expand the track shoe assembly. For details,
see EXPANDING TRACK SHOE ASSEMBLY.
2. Raise the machine body with a jack or the ripper

and set stand 1 under the frame.
3. Remove guards (1) and (2).

4 Guard (2): 30 kg 8. Remove inside mounting bolts (6) of the final
drive assembly.

9. Remove the mounting bolts and lift off the final
drive assembly.
5. Using a forcing screw, pull out the drive shaft (4).
★ Remove the sprocket teeth first so that the
★ If the shaft cannot be pulled out, raise the
mounting bolts can be removed easily.
shoe grouser with a jack and move the
sprocket forward or in reverse until the shaft 4 Sprocket tooth: 25 kg
can be pulled out. 4 Final drive assembly: 1,700 kg
★ Pull out the shaft until it comes in contact
with the sprocket.
D275AX-5 30-145
2! !
INSTALLATION
moval.
3 Mounting bolt:
456 - 569 Nm {46.5 - 58 kgm}
3 Mounting bolt:
1,160 - 1,440 Nm {118 - 147 kgm}
3 Sprocket tooth mounting bolt:

1,080 - 1,270 Nm {110- 130 kgm}
• Refilling with oil (Final drive case)

5Final drive case: Approx. 40¬

¬（E030-CD）
）
30-146 D275AX-5
! 2!
Sketch of special tool

Plate J1
D275AX-5 30-147
2! !
DISASSEMBLY AND
ASSEMBLY OF
FINAL DRIVE ASSEMBLY
SPECIAL TOOLS 3. Cover
Using hanging bolt 1 , remove cover (4).
Sym- Ne- New/Re-
791-627-1400 Remover " 1

2 790-101-2102 Puller " 1
790-101-1102 Pump " 1
791-627-1600 Remover " 1
3 790-101-2102 Puller " 1
790-101-1102 Pump " 1
791-627-1200 Remover " 1
4 790-101-2102 Puller " 1
J
790-101-1102 Pump " 1
791-627-1300 Installer " 1
5 790-101-2102 Puller " 1
790-101-1102 Pump " 1 4. Hub
791-627-1500 Installer " 1 1) Remove plate (5).
6 790-101-2102 Puller " 1
2) Using hanging bolt 2 , remove hub (6).
790-101-1102 Pump " 1
7 791-628-1280 Installer " 1
DISASSEMBLY
1. Draining oilì
Remove the drain plug and drain the oil from the
final drive case.
6 Final drive case: 40¬
5. Sprocket assembly
2. Sprocket, wear guard, and plate
1) Remove holder (7).
1) Set the final drive assembly on a block with
the sprocket side up.
2) Remove the mounting bolts and sprocket (1).
3) Remove wear guard (2) and plate (3).
30-148 D275AX-5
! 2!
2) Using tool J2, disconnect sprocket hub as-

sembly (8) and bearing (9).
3) Using hanging bolt 3 , remove sprocket hub
assembly (8).
6. Cover assembly
1) Using a hanging bolt, remove cover assem-
bly (15).
2) Disassemble the cover assembly according

4) Remove bearing (10) from the sprocket hub to the following procedure.
assembly. i) Remove floating seal cover (16).
ii) Remove floating seal (17) from floating
seal cover (16).
★ Store the floating seal in a safe place so
that it will not be damaged.
5) Turn over the sprocket hub assembly and re-

move floating seal cover (11) and outer races
(12) and (13).
6) Remove floating seal (14) from floating seal
cover (11).
★ Store the floating seal in a safe place so
that it will not be damaged.
D275AX-5 30-149
2! !
iii) Remove spacer (18), bearing (19), and

spacer (20).
4) Remove bearing outer race (26D).

5) Remove spacer (26E) and snap ring (26F).
iv) Remove the plate and ring gear (21).
7. Carrier assembly
1) Using hanging bolt 4 , remove carrier as-
sembly (22).
6) Remove collar (27) and bearing (28) from

the carrier.
2) Disassemble the carrier assembly according

i) Remove holder (23).
ii) Using tool J3, remove planetary gear
shaft (24).
3) Remove planetary gear (25), bearings (26A)

and (26B), and spacer (26C).
30-150 D275AX-5
! 2!
8. Sun gear shaft assembly

1) Remove sun gear shaft assembly (29).
5) Remove 2 outer races (39) from hub (40).
2) Remove the mounting bolts and holders (30)

and (31) from the sun gear shaft assembly.
3) Remove inner race (32).
4) Using push tool 5 , remove sun gear shaft
(34) from sun gear (33).
6) Remove the mounting bolts and shaft as-

sembly (41) from the case.
7) Disassemble the shaft assembly according
i) Remove collar (42).
ii) Remove bearing (43) and collar (44).
9. Hub and shaft assembly
1) Remove gear (35).
2) Remove the mounting bolts and plate (36).
3) Using tool J4, remove hub assembly (37).

4) Remove bearing (38).
D275AX-5 30-151
2! !
10. Cage assembly 12. Outer race and oil seal

1) Using hanging bolt 6 , remove cage assem- 1) Using puller 9 , remove outer race (54).
bly (45). 2) Remove oil seals (55) and (56).
2) Remove shim (46).
★ Check the thickness and quantity of the
inserted shims, then store them.
3) Disassemble the cage assembly according

i) Using puller 7 , remove outer race (47).
ii) Remove oil seals (48) and (49).
11. Gear assembly

1) Remove gear assembly (50).
2) Using puller 8 , remove bearings (51) and
30-152 D275AX-5
! 2!
ASSEMBLY 3. Gear assembly

1) Using push tool C , press fit bearings (52)
★ Clean the all parts and check them for dirt or
and (51) to gear (53).
damage before installing..
★ Coat sliding surfaces of each part with engine oil • Press fitting force for bearing:
before installing. 0.9 - 2.6 kN {9 - 25 tons}
2) Install gear assembly (50).
★ Check that each snap ring is fitted to the groove
★ Lower and install the gear assembly
securely.
slowly so that the oil seal lip will not be
damaged.
1. Oil seal
1) Using push tools 0 and A , install oil seals
(56) and (55).
★ Install the lower oil seal with the pressure
receiving side down and the upper oil
seal with the pressure receiving side up.
★ Apply gasket sealant thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal fitting surface:
4. Cage assembly
1) Assemble the cage assembly according to
i) Using push tools D and E , install oil
seals (49) and (48).
★ Install the lower oil seal with the pressure
receiving side down and the upper oil
seal with the pressure receiving side up.
★ Apply gasket sealant thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal fitting surface:
2. Outer race
Using push tool B , press fit outer race (54).
• Press fitting force for outer race:
1 - 13 kN {0.1 - 1.3 tons}
D275AX-5 30-153
2! !
2) Using push tool F , press fit outer race (47).

• Press fitting force for bearing:
1 - 13 kN {0.1 - 1.3 tons}
3) Using hanging bolt 6 , install case assembly

(45).
4) Adjust the clearance of the pinion bearing

i) Tighten mounting bolts C, D, G, and H of
cage A evenly, then loosen them.
3 Mounting bolt:
49 Nm {5 kgm}
ii) Tighten mounting bolts C, D, G, and H of
cage A evenly again.
3 Mounting bolt:
20 Nm {2 kgm}
iii) Under this condition, measure clearanc-
es "a" and "b" between cage A and case
B with thickness gauge.
iv) Set shim thickness "c" from the total of
clearances "a" and "b", referring to Table
1.
v) Install the shim set in step iv) to cage A
and tighten the 6 mounting bolts of cage
A evenly.
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
30-154 D275AX-5
! 2!
Table 1
a + b (mm) Number of shims to use Total
Thickness
Not less Not more of shims
t=0.15 t=0.5 t=1.0
than than (mm)
3.05 3.15 5 1 1.75
3.15 3.25 2 1 1 1.80
3.25 3.35 9 1 1.85
3.35 3.45 6 1 1.90
3.45 3.55 3 1 1 1.95
3.55 3.65 2 2.00
3.65 3.75 7 1 2.05
3.75 3.85 4 1 1 2.10
3.85 3.95 1 2 2.15
3.95 4.05 8 1 2.20
4.05 4.15 5 1 1 2.25
4.15 4.25 2 2 2.30 2) Install the O-ring and shaft assembly (41) to
4.25 4.35 9 1 2.35 the case.
2 Mounting bolt:
4.35 4.45 6 1 1 2.40
4.45 4.55 3 2 2.45
3 Mounting bolt:
4.55 4.65 1 2 2.50
4.65 4.75 7 1 1 2.55
4.75 4.85 4 2 2.60
4.85 4.95 1 1 2 2.65
235 - 285 Nm {23.5 - 29.5 kgm}
4.95 5.05 8 1 1 2.70
5.05 5.15 5 2 2.75
5.15 5.25 2 1 2 2.80
5.25 5.35 9 1 1 2.85
5.35 5.45 6 2 2.90
5.45 5.55 3 1 2 2.95
5.55 5.65 3 3.00
5.65 5.75 7 2 3.05
5.75 5.85 4 1 2 3.10
5.85 5.95 1 3 3.15
5.95 6.05 8 2 3.20
6.05 6.15 5 1 2 3.25
6.15 6.25 2 3 3.30
6.25 6.35 9 3 3.35
6.35 6.45 6 1 2 3.40
6.45 6.55 3 3 3.45
3) Using push tool H , press fit 2 outer races
6.55 6.65 1 3 3.50
6.65 6.75 7 1 2 3.55 (39) to hub (40).
6.75 6.85 4 3 3.60 • Press fitting force for outer race:
6.85 6.95 1 1 3 3.65 2 - 16 kN {0.2 - 1.6 tons}
6.95 7.05 8 1 2 3.70
7.05 7.15 5 3 3.75
7.15 7.25 2 1 3 3.80
7.25 7.35 9 1 2 3.85
5. Hub and shaft assemblyy

1) Assemble the shaft assembly according to
i) Install collar (44).
ii) Using push tool G , press fit bearing
(43).
11 - 32 kN {1.1 - 3.2 tons}
iii) Install collar (42).
D275AX-5 30-155
2! !
4) Set hub assembly (37) and bearing (38) to

the shaft.
5) Using push tool J5, press fit bearing (38).
11 - 32 kN {1.1 - 3.2 tons}
iii) Install spacer (26C) and bearings (26B)

and (26A) to planetary gear (25), then
set them to the carrier.
★ Direct the planetary gear end having
a projection out of the machine body.
6) Install gear (35) to hub (40).

2 Mounting bolt:
3 Mounting bolt:
235 - 285 Nm {23.5 - 29.5 kgm}
2 Mounting bolt:
3 Mounting bolt:
235 - 285 Nm {23.5 - 29.5 kgm}
iv) Using tool J3, press fit planetary gear
shaft (24).
★ Match the holes of the bearing and
spacer and press fit the shaft slowly.
v) Install holder (23).
2 Mounting bolt:
Thread tightenere (LT-2)
3 Mounting bolt:
455 - 565 Nm {46.5 - 58 kgm}
★ After tightening the holder bolts, check
that the gear turns lightly.
6. Carrier assembly
1) Assemble the carrier assembly according to
★ Since each bearing of the planetary gear
is an assembly, match the identification
marks of the inner race, outer race, and
spacer when assembling.
i) Install snap ring (26F) and spacer (26E)
to the planetary gear.
ii) Using push tool I , press fit 2 bearing
outer races (26D).
• Press fitting force for outer race:
5 - 20 kN {0.5 - 2 tons}
30-156 D275AX-5
! 2!
vi) Using push tool J , press fit bearing (28)

to the carrier.
0 - 12 kN {0 - 1.2 tons}
vii) Install collar (27).
8. Carrier assembly
Using hanging bolt 4 , install carrier assembly
(22).
7. Sun gear shaft assembly

1) Using push tool K , press fit sun gear shaft
(34) to sun gear (33) with a press.
• Press fitting force for shaft:
103 - 156 kN {10.5 - 15.9 tons}
2) Install holder (31).
2 Mounting bolt:
3) Using push tool L , press fit inner race (32)
to sun gear shaft (34).
• Press fitting force for inner race: 9. Cover assembly
13 - 25 kN {1.3 - 2.6 tons} 1) Install ring gear (21) and plate.
★ Install the gear with the cut end in.
2 Mounting bolt:
3) Using tool J6, press fit bearing (19).
11 - 53 kN {1.1 - 5.4 tons}

2 Mounting bolt:
5) Install sun gear shaft assembly (29).
D275AX-5 30-157
2! !
5) Using tool J7, press fit floating seal (17) to 10. Sprocket hub assembly
floating seal cover (16). 1) Using tool J7, press fit floating seal (14) to
★ Degrease the O-ring and O-ring fitting floating seal cover (11).
surfaces thoroughly and dry them before ★ Degrease the O-ring and O-ring fitting
installing. surfaces thoroughly and dry them before
★ After installing the floating seal, check installing.
that its slant is within 1mm. ★ After installing the floating seal, check
that its slant is within 1mm.
6) Install the O-ring and floating seal cover (16).

★ Set the outside cut part of the floating 2) Using push tool M press fit outer races (13)
seal cover down. and (12).
17 - 36 kN {1.7 - 3.7 tons}
7) Using a hanging bolt, install the O-ring and

cover assembly (15).
★ The mating faces of the case and cover 3) Install the O-ring and floating seal cover (11).
must be free from bruise, rust, oil,
grease, dirt, and water.
3 Mounting bolt:
455 - 565 Nm {46.5 - 58 kgm}
30-158 D275AX-5
! 2!
4) Set bearing (9) to sprocket hub assembly (8).
11. Hub
5) Using hanging bolt 3 , set sprocket hub as- 1) Using hanging bolt 2 , install hub (6).
sembly (8) to the cover. 2) Install plate (5).
2 Mounting bolt:
★ Check that the sliding surfaces of the
floating seal are free from dirt and apply
3 Mounting bolt:
engine oil to them thinly.
6) Using tool J6, press fit bearing (9).
★ Press fit the bearing, turning the sprock- 235 - 285 Nm {23.5 - 29.5 kgm}
et hub assembly.
11 - 53 kN {1.1 - 5.4 tons}
12. Cover
Using hanging bolt 1 , install the O-ring and cov-
er (4).
3 Mounting bolt:
235 - 285 Nm {23.5 - 29.5 kgm}

2 Mounting bolt:
3 Mounting bolt:
235 - 285 Nm {23.5 - 29.5 kgm}
D275AX-5 30-159
2! !
13. Sprocket, wear guard, and plate

3 Mounting bolt:
455 - 565 Nm {46.5 - 58 kgm}
2) Install wear guard (2).
3 Mounting bolt:
785 - 980 Nm {80 - 100 kgm}
3) Install sprocket (1).
3 Mounting bolt:
1078 - 1274 Nm {110 - 130 kgm}
14. Refilling with oil (Final drive case)

Tighten the drain plug and add oil through the oil
filler.
★ After installing the final drive assembly to the
machine body, check the oil level finally in the
specified position.
3 Drain plug:
127 - 176 Nm {13 - 18 kgm}
5 Final drive case: 40¬
30-160 D275AX-5
! 2!
30 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY TRACK FRAME ASSEMBLY

OF TRACK FRAME ASSEMBLY
SPECIAL TOOL 2) Set stands 2 on both sides of the front main
frame of the machine body.
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch 3) Set hydraulic jack 3 under the center of the
L14 791T-630-1380 Bracket " 6 ! equalizer bar and raise the front part of the
machine body.
4) Set a block under the raised front part of the
REMOVAL track frame to secure safety during work.
★ After setting stands 1 and 2 , set the jacks
1. Remove the blade assembly. For details, see or ripper again as auxiliary supports.
REMOVAL OF BLADE ASSEMBLY.

3. Using tool L14, secure the bogie assembly.
5. Temporarily sling the track frame assembly to be

removed.
4. Raise the machine body according to the follow-

ing procedure.
1) Raise the machine body with a jack or the
ripper and set stands 1 under both sides of
the frame to float the rear part of the machine
body.
D275AX-5 30-161
2! !
7. Remove the mounting nuts and cover (2). 12. Remove cover (8).
8. Disconnect grease tube (3).

13. Disconnect hose (9) on the bottom side of the

blade cylinder and hose (10) on the head side.
★ Perform this step for only the right side of the
10. Pull out pin (5). single tilt specification or both track frames of
★ If the equalizer bar hole is not aligned with the dual tilt specification.
the track frame hole, the pin cannot be pulled
out easily. Accordingly, adjust the slinging 14. Remove the mounting bolts and pull out cover
height of the track frame when pulling out the (11).
pin. ★ Take care since hoses are connected inside
¤ If the track frame assembly on the opposite the cover.
side is raised before the pin is pulled out,
support it with a block.
11. Remove guards (6) and (7).

4 Guard (7): 30 kg
30-162 D275AX-5
! 2!
15. Disconnect hoses (12) and (13) connected in- 18. Remove spacer (16).
side cover (11) pulled out and remove cover (11).
single tilt specification or both track frames of
the dual tilt specification.
19. Remove the mounting bolts and disconnect cov-

er (17) from the track frame.

★ There are 2 mounting bolts on the track
frame side and 6 on the pivot shaft side.
★ Take care not to damage the O-ring.
★ Prepare an oil container to receive the oil
from the pivot shaft case.
6 ¬
Pivot shaft case: 10¬
20. Lift off track frame assembly (18).

4 Track frame assembly: 5,050 kg
17. Remove seal (15) and cover (14) together.

single tilt specification or both track frames of
the dual tilt specification.
D275AX-5 30-163
2! !
INSTALLATION
★ Degrease the fitting face of the seal and ap-
ply gasket sealant (LG-6) to it.
moval.
★ Do not install the track frame with torsional
deformation left in seal (19).
Installation procedure for cover (4)
1) Tighten the mounting bolts of cover (4) with
fingers.
2) Install cover (2) and secure it with the nuts.
3) Tighten the mounting bolts of cover (4) se-
curely.
4) Install grease tube (3).
2 Bushing contact surface of pivot shaft:

Lubricant containing molybdenum
disulfide (LM-P)
★ When replacing the pivot shaft bushing
of the track frame assembly, press fit a
new bushing with the bushing mating
face up.
¤ When aligning the pin holes, never insert
your fingers in the pin holes. • Refilling with oil (Pivot shaft case)
★ Direct the grease holes of the pins down. Add oil through the oil filler to the specified level.
• Left pin: Outside of machine body 3 Plug: 127-177Nm {13-18kgm}
• Right pin: Inside of machine body
2 Equalizer bar side bushing: 5 ¬ (EO30-CD)
Pivot shaft case: 10¬
Grease (G2-LI)
★ When fitting the seal, degrease the fitting

face and apply gasket sealant (LG-6) to it.
★ Do not fit the seal with torsional deformation
left in it.
30-164 D275AX-5
! 2!
SKETCH OF SPECIAL TOOL

Bracket L14
D275AX-5 30-165
2! !
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

OF IDLER ASSEMBLY
1. Remove the blade assembly. For details, see • Carry out installation in the reverse order to re-
REMOVAL OF BLADE ASSEMBLY. moval.

see EXPANDING TRACK SHOE ASSEMBLY. ★ Install both idler assemblies with the oil sup-
ply plugs directed to the left.
3. Remove covers (1) and (2). ★ Tighten the idler cap mounting bolts in the
following order.
Tightening order:
1) 2 bolts on "a" side
2) 2 bolts on "b" side
3) 2 bolts on "a" side
4) Tighten the all bolts to the specified
torque.
2 Mounting bolt:
3 Mounting bolt:
1,180 - 1,470 Nm {120 - 150 kgm}
4. Sling idler assembly (3) temporarily and remove ★ After tightening the idler cap mounting bolts,
cap (4). check that clearance "c" between the idler
cab bottom and the yoke is 0.
5. Lift off idler assembly (3).
4 Idler assembly: 340 kg
30-166 D275AX-5
! 2!
DISASSEMBLY AND ASSEM-

BLY OF IDLER ASSEMBLY
SPECIAL TOOLS 6. Using puller 4 , remove seal guide (6), retainer
(7), and plate (8).
Sym- Ne- New/Re-
791T-630-1310 Plate " 1 N !

791-630-1220 Rod " 4
790-101-2510 Block " 2
790-101-2570 Plate " 4
1 01643-31445 Washer " 4
01580-01411 Nut " 4
L
Puller
790-101-2102 (294kN " 1
{30ton})
790-101-1102 Pump " 1
2 791-515-1520 Installer " 1
3 791-630-1240 Push tool " 1 7. Remove seal guides (2) and (6) from retainers
4 791-601-1000 Oil pump " 1 (3) and (7).
DISASSEMBLY
1. Remove the oil filler plug and drain the oil.
6 ¬ (G0140)
Idler: 0.8 ∼ 0.9¬
2. Set idler assembly (1) to block 1 .
3. Remove the mounting bolts, then remove seal

guide (2), retainer (3), and plate (4), using forc-
ing screw 2 .
8. Remove floating seals (9) from seal guides (2)
and (6).
★ Keep the floating seals so that they will not
be damaged.

and (7).
be damaged.
4. Turn over the idler assembly.
5. Remove the mounting bolts, then remove shaft

(5) and retainer, using hanging bolt 3 .
D275AX-5 30-167
2! !
10. Remove bushing (11) from idler (12).
3. Fit the O-ring and install retainer (3) and plate (4)
to the idler.
ASSEMBLY
damage.
1. Set bushing (11) and tool L1 to idler (12) to press

fit bushing (11).
★ Center the bushing with a plastic hammer
first, then press fit it with the puller.
★ Press fit the bushing so that distance "a"
from the idler end to the bushing top will be
as follows.
• Press fitting distance "a": 17 ± 0.5 mm
4. Using hanging bolt 3 , set idler (12) to shaft (5).
★ Set a block (about 200 mm) under the idler.
5. Turn over the idler assembly.

★ Bind the shaft with wires so that it will not
drop.
6. Fit the O-ring and install retainer (7) and plate (8)
to the idler.
2. Using tool L2, install floating seals (10) to retain-

ers (3) and (7).
★ When installing the floating seals, thoroughly
degrease and dry the contact surfaces of
them and O-rings (hatched portion). Take
care that dirt will not stick to the contact sur-
faces of the floating seals.
★ After installing each floating seal, check that
its slant is within 1mm and its projection "a"
is 7 - 11 mm.
30-168 D275AX-5
! 2!
7. Using tool L2, install floating seals (9) to seal 9. Using tool L4, supply the specified quantity of oil
guides (2) and (6). and tighten the oil filler plug.
★ For precautions for installing the floating
seals, see ★ in step 2 above. 5Idler: 0.8 - 0.9¬
¬ {G0140}
3 Oil filler plug:
156.8 - 254.8 Nm {16 - 26 kgm}
8. Set seal guide (2) to the shaft and press fit seal
guide (2) by using tools L1 and L3.
• Press fitting force for seal guide:
49 - 83.4 kN {5 - 8.5 tons}
★ Press fit the seal guide so that distance "b"

from the shaft end to the seal guide top will
be as follows.
• Press fitting distance "b": 96 ± 0.2 mm
★ Turn over the idler assembly and press fit
seal guide (6) on the opposite side similarly.
D275AX-5 30-169
2! !

Bracket L1
30-170 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF RECOIL
DISASSEMBLY AND ASSEMBLY SPRING ASSEMBLY

OF RECOIL SPRING ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
791-730-1110 Bolt " 6

1 01580-12722 Nut " 6
01643-32780 Washer " 6
M 791-630-1100 Installer " 1
Cylinder
2 790-101-1600 (686kN " 1
{70ton})
790-101-1102 Pump " 1
REMOVAL 6. Remove covers (4).

★ Remove both inside and outside covers.
¤ Never stand in front of the idler yoke to pre- 7. Using hanging bolt 1 , pull out pin (5).
vent danger.
2. Using an oil pump, drain the oil from the recoil

cylinder.
6 ¬
Recoil spring chamber: Approx. 83¬
4. Loosen mounting bolts (2) of the guide plate.
8. Lift off idler and recoil spring assembly (6).

★ Set the assembly on the level by using lever
blocks, etc. and remove it so carefully that
the oil seal on the track frame will not be
damaged.
4 Idler and recoil spring assembly:
2,300 kg
5. Remove the mounting bolts and lift off trunnion

(3).
4 Trunnion: 60 kg
D275AX-5 30-171
2! !
9. Disconnect recoil spring assembly (8) from idler

yoke assembly (7) according to the following pro-
cedure.
1) Lower idler yoke assembly (8) to the ground
and sling recoil cylinder assembly (7).
★ At this time, check that the welded parts of
recoil cylinder assembly (7) are not dam-
aged.
★ Protect the chromium-plated bushing by cov-
ering it with cloths.
¤ If the loosening torque does not lower after

steps 2) and 3) above, recoil spring set bolt
(10) may be broken or shaft end nut (11) may
have come off. Since the idler yoke assem-
bly can jump out forward in this case, remove
the bolts according to the following proce-
dure.
¤ Do not stand in front of the idler yoke and at
the rear of the recoil cylinder until the idler
yoke assembly and recoil cylinder assembly
2) Loosen idler yoke assembly mounting bolts are disassembled and the recoil spring is
(9) gradually in the diagonal order. taken out and the safety is confirmed.
¤ Never stand in front of the idler yoke and at
the rear of the recoil cylinder to prevent dan-
ger.
i) Prepare the following parts (Tool M1).

• Bolt 2 (6 pieces): 791-730-1110
• Nut 3 (6 pieces): 01580-12722
¤ Since the installed load of about 372,700 N • Washer 4 (6 pieces): 01643-32780 (Re-
ii) Remove the 6 bolts marked with q and in-

{38,000 kg} for the recoil spring is applied to used)
the idler yoke, do not loosen the mounting
bolts suddenly but loosen them gradually un- stall bolts 2 , nuts 3 , and washers 4 .
til clearance "a" between the idler yoke and
recoil spring becomes 8 - 12 mm.
3) Check that the loosening torque of the bolts
has lowered suddenly and the installed load
for the recoil spring is not applied to the bolts,
remove the all bolts.
★ If the loosening torque increases (If the in-
stalled load for the recoil spring is applied)
during the work, stop the work and remove
the bolts according to the following proce-
dure.
30-172 D275AX-5
! 2!
★ Check that dimension L is less than 361 mm. 11. Supply grease through lubricator (13) and re-
★ Tighten bolts 2 until they come in contact move cylinder (14) and piston assembly (15).
with the bottom of the yoke threads.
marked with q.
iii) Remove the 12 bolts other than the ones
iv) Secure bolts 2 with a spanner and loosen 2

nuts on a diagonal line simultaneously and
gradually.
★ Take care that the load will not be applied to
only 1 bolt.
v) Loosen nuts 3 until the recoil spring is ex-
panded fully and the loosening torque on
them lowers totally, then remove bolts 2 .
12. Disassemble piston assembly (15) according to

i) Remove wear ring (16) from the piston.
ii) Remove snap ring (17) and packing (18).
★ If clearance "b" becomes 186 mm, the spring

is expanded fully.
13. Lift off recoil spring assembly (19).

4 Recoil spring assembly: 355 kg
10. Remove ring (12).
D275AX-5 30-173
2! !
14. Remove holder (20) from the recoil spring as-

sembly. ★ If the recoil spring set bolt is broken or the
shaft end nut has come off, assemble ac-
cording to Assembly of recoil spring assem-
bly.
2 Idler yoke assembly mounting bolt:

3Idler yoke assembly mounting bolt:
1,150 - 1,440 Nm {118 - 147 kgm}
★ Supply grease to the cylinder to prevent air

15. Remove bushing (21).
from staying in the cylinder according to the
i) Supply grease of about 0.9 ¬ into the cylin-
der.
ii) Set the cylinder with the drain hole up and
loosen the lubricator.
iii) Push in the piston until it is stopped by the
stopper to discharge air and excessive
grease.
iv) Tighten the lubricator.
3 Lubricator: 59 - 88 Nm {6 - 9 kgm}
★ Using tool M2, press fit bushing (21).

Press fitting force:
INSTALLATION
44.1 - 228.3 kN {4.5 - 23.3 tons}
2 Case to press fit:
moval.
★ Adjust the clearance of the idler. For details,

see TESTING AND ADJUSTING, Adjusting
clearance of idler.
2 Cover mounting bolt:

3 Cover mounting bolt:
245 - 309 Nm {25 - 31.5 kgm}
¤ When aligning the pin holes, never insert • Refilling with oil
your fingers in the pin holes. Pour engine oil (EO30) in the spring chamber up
★ Before inserting the pin, align the recoil cyl- to the center.
3 Plug: 127 - 177 Nm {13 - 18 kgm}
inder hole with the track frame hole.
5 Recoil spring chamber (Each side):

¬
Approx. 83¬
30-174 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY OF RECOIL

BLY OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS 3. Release the oil pressure gradually to reduce the
spring tension to 0 (zero).
Sym- Ne- New/Re-
791-685-8502 Compressor " 1 4. Remove rear pilot (5), spacer (6), bolt (7), and pi-
790-201-2780 Spacer " 1
lot (8) from spring (4).
791-635-3160 Extension " 1
M 3
Cylinder
790-101-1600 (686kN " 1
{70ton})
790-101-1102 Pump " 1
DISASSEMBLY
1. Set recoil spring assembly (1) to tool M3.
¤ Since the installed load of the spring is large
and dangerous, set the spring assembly se-
curely.
★ Installed load of spring:
372,700 N {38,000 kg}
ASSEMBLY
1. Install pilot (8), bolt (7), spacer (6), and rear pilot
(5) to spring (4) and set them to M3.
¤ Since the installed load of the spring is large
and dangerous, set each part securely.
2. Apply oil pressure gradually and compress the

spring to the standard length.
★ Installed length of spring "a":
Approx. 1,045 mm
★ Installed load of spring:
272,700 N {38,000 kg}
2. Apply oil pressure gradually and compress the
spring and remove lock plate (2) and nut (3).
D275AX-5 30-175
2! !
DISASSEMBLY AND ASSEMBLY OF RECOIL
3. Install nut (3) to bolt (7), then install lock plate (2).
★ When securing the recoil spring mounting
nut, make clearance "b" (0 - 1.0 mm) be-
tween lock plate (2) and nut (3) and fix lock
plate (2) and bolt (7) together.
2 Lock plate mounting bolt:
4. Release the oil pressure gradually to reduce the

spring tension to 0 (zero), then remove recoil
spring assembly (1) from tool M3.
30-176 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY TRACK ROLLER ASSEMBLY

OF TRACK ROLLER ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
790-401-1700 Lifting tool " 1

790-401-1761 Adapter " 1
5
L 790-401-1540 Shackle " 2
790-401-1770 T-bolt " 2
14 791T-630-1380 Bracket " 4 !
REMOVAL
1. Loosen the track shoe tension. For details, see
EXPANDING TRACK SHOE ASSEMBLY. Note 2: Sling and secure 1st bogie assembly (1)
with a lever block, etc.
2. Install tool L14 and secure bogie assembly (1). A fixing tool can not be used for the 1st
bogie assembly.
★ When removing track roller assembly (2), se-

cure the related bogie assemblies according 3. Operate the blade and ripper to raise the ma-
to the following table. chine body until track roller assembly (2) is float-
Track roller Bogie assembly to be ed above the track shoe.
assembly to be secured with tool ★ Operate the blade and ripper slowly with the
removed
engine at low speed.
Location Related bogie
1st roller Note 1 2nd bogie
4. Loosen the mounting bolts of roller cap (3).
2nd roller 2nd bogie Note 2
3rd roller 2nd bogie 3rd bogie ★ Loosen both inside and outside mounting
4th roller 3rd bogie 2nd bogie bolts.
5th roller 3rd bogie 4th bogie ★ Do not remove the mounting bolts.
6th roller 4th bogie 3rd bogie
7th roller 4th bogie –
Note 1: Set block 1 to prevent 1st bogie assem-
bly (1) from lowering.
A fixing tool can not be used for the 1st
bogie assembly.
D275AX-5 30-177
2! !
5. Operate the blade and ripper to lower the ma- 3 Roller cap mounting bolt:
chine body. 824 - 1,030 Nm {84 - 105 kgm}
★ Operate the blade and ripper slowly.
6. Remove the mounting bolts and roller cap.

★ Take care not to damage the dowel pin.
7. Operate the blade and ripper to raise the ma-

chine body until track roller assembly (2) is sep-
arated from the bogie.
Types of track roller assembly

S: Track roller assembly (Single flange)
D: Track roller assembly (Double flange)
★ Install the track roller assembly with the oil
filler plug out.
8. Pull track roller assembly (2) out of the machine

body.
4 Track roller assembly (Single frange):

150 kg
4 Track roller assembly (Double frange):
165 kg
INSTALLATION
moval.
When installing the 1st track roller assembly (sin-

Install the track roller assembly according to the fol- gle flange) by using tool L5;
lowing procedure. 1) Set tool L5 under the track roller assembly.
1. Set the track roller assembly on the track shoe. 2) Sling 1st track roller assembly (2) and set it
★ irect the oil filler of the track roller assembly to the track frame.
out of the machine body.
2. Lower the machine body until the roller cap bolts

can be installed and install roller cap (3) tempo-
rarily.
★ Direct roller cap protector "a" out of the bo-
gie.
3. Align dowel pin (4) with the dowel pin hole of the
track roller and tighten roller cap bolts (3).
★ Take care not to break the dowel pin.
2 Roller cap mounting bolt:
30-178 D275AX-5
! 2!

Bracket L14
D275AX-5 30-179
2! !
DISASSEMBLY AND ASSEMBLY OF TRACK
DISASSEMBLY AND ASSEMBLY ROLLER ASSEMBLY

BLY OF TRACK ROLLER
ASSEMBLY
SPECIAL TOOLS 6. Using a press, remove seal guide (6), retainer
(7), and plate (8) from the shaft.
Sym- Ne- New/Re-
6 791T-630-1320 Plate " 1 N ! 7. Remove seal guides (2) and (6) from the retain-
7 791T-630-1330 Push tool " 1 N !
ers (3) and (7).
L
8 791-651-1510 Installer " 1
9 791-601-1000 Oil pump " 1
DISASSEMBLY
6 ¬
Track roller: Approx. 0.75 - 0.85¬
2. Set track roller assembly (1) to block 1 .
3. Remove the mounting bolts and remove seal

guide (2), retainer (3), and plate (4) together by
and (6).
using forcing screw 2 .
be damaged.
4. Turn over the track roller assembly.
5. Remove the mounting bolts and remove shaft (5)
and (7).
and retainer together by using hanging bolt 3 .
be damaged.
10. Remove 2 bushings (11) from roller (12).
30-180 D275AX-5
! 2!
ASSEMBLY 5. Using tool L7, install floating seals (9) to seal

guides (2) and (6).
damage.
them (hatched portion) and O-rings. Take
1. Set roller (12) to a press and press fit bushing
(11) by using tool L6.
★ Center the bushing with a plastic hammer
first, then press fit it with the press.
★ Press fit the bushing so that distance "a"
is 7 - 11 mm.
from the roller end to the bushing top will be
as follows.
• Press fitting distance "a": 17 ± 0.5 mm
• Press fitting force for bushing:
29 - 132 kN {3 - 13.5 tons}
2. Set shaft (5) to the roller.
6. Using tool L8, press fit seal guide (2) to the shaft.
• Press fitting force for seal guide:
39 - 69 kN {4 - 7 tons}
3. Using tool L7, install floating seals (10) to retain-

ers (3) and (7).
them (hatched portion) and O-rings. Take
its slant is within 1mm.
4. Fit the O-ring and install retainers (3) and (7) and
plates (4) and (8) to the roller.
★ Check that the plates can be turned smooth-
ly with hand.
D275AX-5 30-181
2! !
★ Press fit the seal guide so that distance "c"

be as follows.
Press fitting distance "c": 64.2 ± 0.2 mm
★ After press fitting the seal guide, check that
its slant from the shaft is less than 0.4 mm.
★ Turn over the track roller assembly and press
fit seal guide (6) on the opposite side similar-
ly.
7. Using tool L9, supply the specified quantity of oil

and tighten the oil filler plug.
5 ¬（G0140）
Track roller: 0.75 - 0.85¬ ）
3 Oil filler plug:
156.8 - 254.8 Nm {16 - 26 kgm}
30-182 D275AX-5
! 2!

Plate L6
Bush tool L7
D275AX-5 30-183
2! !
REMOVAL AND INSTALLATION OF CARRIER

OF CARRIER ROLLER ASSEM-
BLY
REMOVAL
EXPANDING TRACK SHOE ASSEMBLY.
2. Using hydraulic jack 1 , raise the track shoe.
3. Lift off carrier roller assembly (1).

4 Carrier roller assembly: 60 kg
INSTALLATION
moval.
2 Carrier roller assembly mounting bolt:

30-184 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY OF CARRIER

BLY OF CARRIER ROLLER
ASSEMBLY
SPECIAL TOOLS 7. Remove bearing outer race (7) from the roller.
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch 8. Using puller 3 , remove seal guide (8) and bear-
10 790-102-1891 Nut wrench " 1 ing inner race (9) together.
11 791-675-1510 Installer " 1
L
12 791T-630-2410 Push tool " 1 N !
13 791-601-1000 Oil pump " 1
DISASSEMBLY
★ Drain the oil, turning the shaft.
6 ¬
Carrier roller: Approx. 0.6 - 0.7¬
2. Set carrier roller assembly (1) to block 1 .

9. Remove floating seal (10) from seal guide (8).
3. Remove the mounting bolts and cover (2).
4. Remove ring (3).
10. Using push tool 4 , remove seal guide (11).
11. Remove floating seal (12) from seal guide (11).

5. Using tool L10, remove nut (4).
6. Using puller 2 , remove the fitted part of the seal

guide. Using hanging bolts, remove bearing (5)
and roller (6) together.
D275AX-5 30-185
2! !
ASSEMBLY
damage.
1. Using push tool 5 , press fit bearing inner race

(9).
2. Using push tool 6 , press fit bearing outer race

(7).
7. Fit the O-ring and install cover (2).
3. Set roller (6) and bearing inner race (5) to the

shaft.
4. Using push tool 7 , press fit bearing inner race

(5) to the shaft.
8. Using tool L11, install floating seal (10) to seal
★ Press fit the bearing inner race, turning the
guide (8).
roller. Continue press fitting until the roller
becomes heavy to turn.
is 7 - 11 mm.
5. Using tool L10, tighten nut (4).

3 Nut: 98 Nm {10 kgm}
★ After the nut is tightened, if the nut hole is not
aligned with the shaft hole, align them by
loosening the nut.
6. Install ring (3).

★ Check that the end play (the clearance be-
tween the bearing and nut) is 0 - 0.22 mm.
30-186 D275AX-5
! 2!
9. Fit the O-ring and install seal guide (8), matching 12. Using tool L13, supply the specified quantity of
it to the dowel pin. oil and tighten the oil filler plug.
5 Carrier roller: 0.6 - 0.7 ¬ (GO140)

3 Oil filler plug:
157 - 255 Nm {16 - 26 kgm}
10. Using tool L11, install floating seal (12) to seal

guides (11).
★ For precautions for installing the floating
seal, see ★ in step 8 above.
11. Using tool L12, press fit seal guide (11).

★ Press fit the seal guide so that distance "b"
be 160 ± 0.2 mm.
★ After press fitting the seal guide, check that
its slant from the shaft is less than 0.4 mm.
D275AX-5 30-187
2! !

Push tool L12
30-188 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF 1ST
DISASSEMBLY AND ASSEMBLY BOGIE ASSEMBLY
REMOVAL AND INSTALLA-

TION OF 1ST
BOGIE ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
14 791T-630-1380 Bracket " 2 !

790-401-1700 Lifting tool " 1
22
L 790-401-1761 Adapter " 1
791-630-1860 Bracket " 1
23
791-630-1870 Bracket " 1
REMOVAL
1. Remove the undercover.
8. Set tool L22 and remove roller caps (3).
2. Using tool L14, secure 2nd bogie assembly (1).
9. Using tool L22, remove track roller assembly (6).

3. Expand the track shoe assembly. For details, ★ When removing the track roller assembly,
see EXPANDING TRACK SHOE ASSEMBLY. balance it.
4 Track roller assembly: 150 kg
chine body until the track roller of 2nd bogie as-
sembly (1) is floated above the track link.
¤ Set stands or blocks under the front and rear
parts of the frame so that the machine body
will not lower.
5. Set block 1 between the 1st track roller and 2nd

track roller so that 1st bogie assembly (2) will not
lower.
6. Loosen the mounting bolts of roller caps (3) by
about 20 mm.
★ Loosen both inside and outside bolts.
7. Hit the end of shaft (4) with a plastic hammer to
disconnect the track roller from the bogie.
★ Take care not to damage dowel pin (5).
D275AX-5 30-189
2! !
3) Remove floating seals (10) from the end fac-

11. Using tool L23, sling and hold the 1st bogie. es of rings (9) and (12).
be damaged.
12. Pull out the shaft and ring.

1) Set tool L15.
2) Push shaft (8) with tool L15 to push out ring 4) Set pulling out tool L16.
(9) to the opposite side.
★ When the ring is pushed out, it interferes with
the idler. To prevent this, supply grease to
the lubricator to push out the idler cushion
assembly forward.
• Pushing force (Reference):
275 - 490 kN {28 - 50 tons}
30-190 D275AX-5
! 2!
5) Pull out spacer (11) and rings (12) and (13). INSTALLATION
• Pulling out force (Reference):
1. Assemble the cartridge pin.
275 - 490 kN {28 - 50 tons}
1) Using tool L17, install floating seals (10) to

6) Remove spacer (11).
rings (9) and (12) and install floating seal
7) Remove spacer (14) and floating seal (14)
(15) to the opposite side of ring (12) and ring
between rings (12) and (13).
(13).
be damaged.

8) Remove the shaft and rings from the bogie them and O-rings (hatched portion). Take
on the opposite side according to steps 1) - care that dirt will not stick to the contact sur-
7) above. faces of the floating seals.
13. Sling 1st bogie (16) and pull it out. its slant is within 1mm and its projection "a"
★ When the 1st bogie is removed, it interferes is 3 - 5 mm.
with 2nd bogie assembly (1). To prevent this,
lower the 2nd bogie assembly.
4 Bogie assembly: 100 kg
D275AX-5 30-191
2! !
2) Install spacer (11) and ring (12) to shaft (8) ¤ When aligning the pin holes, never insert
and ring (9). your fingers in the pin holes.
3) Install spacer (14) to ring (12) and press fit
ring (13) with tool 2 . 4. Support 1st bogie (16) with hydraulic jack 2 and
• Press fitting force for ring (13): remove guide tool L19 and sling tool L23.
4.9 - 35.3 kN {0.5 - 3.6 tons}
2 Between shaft (8) - ring (13):
Lubricant containing
molybdenum disulfide (LM-P)
5. Insert cartridge pin assembly (17) in the pin hole.

★ Insert the cartridge pin assembly with arrow
"b" on its end face up (in the mounting state
on the machine body).
4) Using tool L18, check the airtightness of the
6. Using tool L20, press fit cartridge pin assembly
floating seal.
(17).
2. Using the tool, sling and install 1st bogie (16).

★ Keep 2nd bogie assembly (1) lowered.
★ Sling 1st bogie (16) and put it in from the
front side and set it in position.
3. Align the pin holes of the track frame and bogie

assembly and insert guide tool L19.
30-192 D275AX-5
! 2!
★ Press fit the cartridge pin assembly to the

machined surface “c” of the bogie.
5 Outside surface of pin:

disulfide (LM-P)
★ Press fitting force for cartridge pin assembly:
275 - 490 kN {28 - 50 tons}
11. Install covers (7).

★ Install 2 covers, outside and inside ones.
7. Using tool L21, supply the specified quantity of

oil to the cartridge pin assembly.
★ Oil supply pressure: 0.49 MPa {5kg/cm2}
5 Cartridge pin assembly (81 - 95% of

full level): 61 - 71 cc (GO-140)
12. Using tool L22, sling and set track roller assembly (6).
★ When setting the track roller assembly, bal-
ance it.
4 Track roller assembly: 150 kg
8. Press fit the cartridge pin assembly on the oppo-

site side according to steps 5 - 7 above.
9. Raise 2nd bogie assembly (1) with a hydraulic

jack and install fixing tool L14.
10. Set block 1 between 1st bogie (16) and 2nd bo-
gie assembly (1) so that 1st bogie (16) will not
lower.
D275AX-5 30-193
2! !
13. Install roller cap (3) and secure it with the bolts 14. Align the dowel pin holes and tighten the bolts.
temporarily. 2 Roller cap mounting bolt:
★ Direct roller cap protectors "b" out of the bogie. Thread tightener (LT-2)
824 - 1,030 Nm {84 - 105 kgm}
15. Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track shoe tension.

Bracket L14
30-194 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF 2ND, 3RD AND
DISASSEMBLY AND ASSEMBLY 4TH BOGIE ASSEMBLY
REMOVAL AND INSTALLA-

TION OF 2ND, 3RD AND
4TH BOGIE ASSEMBLY
SPECIAL TOOLS 3. Using tool L14, secure bogie assembly (1).
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch 4. Remove cover (2).
14 791T-630-1380 Bracket " 2 ! ★ Remove the cover on the opposite side, too.
791-630-1360 Spacer " 1 N
790-101-2310 Block " 1
790-101-2360 Plate " 2
790-445-4130 Screw " 2
15 "
791-112-1180 Nut 2
Puller
790-101-4000 (490kN " 1
{50ton})
790-101-1102 Pump " 1
790-201-2760 Spacer " 1 N
791-630-1370 Adapter " 1
790-434-1060 Screw " 2
01580-13024 Nut " 2
16
01643-33080 Washer " 1 chine body until the track roller is floated above
L Puller the track link.
790-101-4000 (490kN " 1
{50ton}) ¤ Set a block between the track roller and track
790-101-1102 Pump " 1 link so that the machine body will not lower.
17 796-230-1120 Installer " 1
18 790-701-3000 Seal checker " 1 6. Set steel plate 4 on the track shoe and block 3 .
19 791T-630-1390 Guide " 1 N ! ★ Set block 3 according to the height of the
790-101-2310 Block " 1
track link.
790-445-4130 Screw " 2
7. Operate the blade and ripper to lower the ma-
796T-470-1130 Plate " 1 !
chine body until the track roller of the bogie as-
790-101-2360 Plate " 2
20 791-112-1180
sembly comes in contact with steel plate 4 .
Nut " 2 ★ Operate the blade and ripper slowly.
Puller
790-101-4000 (490kN " 1
{50ton})
790-101-1102 Pump " 1
21 791-601-1000 Oil pump " 1
REMOVAL
EXPANDING TRACK SHOE ASSEMBLY.
2. Remove the undercovers.

★ Remove the following undercovers which will
be obstacles to removal of the bogie assem-
bly.
D275AX-5 30-195
2! !
8. Remove the shaft and ring. 4) Set pulling out tool L16.
1) Set tool L15.
2) Push shaft (3) with tool L15 to push out ring
(4) to the opposite side.
• Pushing force (Reference):
275 - 490 kN {28 - 50 tons}
5) Pull out spacer (6) and rings (7) and (8).

• Pulling out force (Reference):
275 - 490 kN {28 - 50 tons}
6) Remove spacer (6).

7) Remove spacer (9) and floating seal (10) be-
tween rings (7) and (8).
3) Remove floating seals (5) from the ends of ★ Keep the floating seals so that they will
rings (4) and (7). not be damaged.
★ Keep the floating seals so that they will
not be damaged.
30-196 D275AX-5
! 2!
8) Remove the shaft and rings from the bogie INSTALLATION

on the opposite side according to steps 1) -
1. Assemble the cartridge pin assembly.
7) above.

chine body until the bogie assembly can be
pulled out.
¤ Set a block between the track roller and track link
of the bogie which will not be removed so that the
machine body will not lower.
10. Sling bogie assembly (1) and slide it out on steel

plate 4 and remove it.
4 Bogie assembly: 550 kg
1) Using tool L17, install floating seals (5) to

rings (4) and (7) and install floating seal (10)
to the opposite side of ring (7) and ring (8).

is 3 - 5 mm.
D275AX-5 30-197
2! !
2) Install spacer (6) and ring (7) to shaft (3) and 2. Lift off bogie assembly (1) onto block 3 and
ring (4). steel plate 4 .
3) Install spacer (9) to ring (7) and press fit ring
(8) with tool 5 .
• Press fitting force for ring (8):
4.9 - 35.3 kN {0.5 - 3.6 tons}
2 Between shaft (3) - ring (8):
disulfide (LM-P)
3. Apply lever block 6 between the guard of bogie

assembly (1) and that of the bogie assembly on
the opposite side.
4. Slide bogie assembly (1) on the steel plate with

lever block 6 to the mounting position.
4) Using tool L18, check the airtightness of the

floating seal.

chine body.
6. Adjustment procedure for cartridge pin hole.

1) Set block 2 and hydraulic jack 7 on the rear
side of the machine body.
30-198 D275AX-5
! 2!
2) Set stand 1 and hydraulic jack 7 on the

front side of the machine body.
5) Insert guide tool L19 in the pin hole.
3) Operate front and rear hydraulic jacks 7 to

lower the machine body and install fixing tool
L14 to bogie assembly (1).
7. Insert cartridge pin assembly (11) in the pin hole.

★ Insert the cartridge pin assembly with arrow
"b" on its end face up (in the mounting state
on the machine body).
4) Adjust front and rear hydraulic jacks 7 to
align the pin holes of the track frame and bo-
gie assembly.
your fingers in the pin holes.
★ If the pin holes cannot be aligned by adjust-
ing the front and rear hydraulic jacks, align
them by slinging the front part of the opposite
track or applying a hydraulic jack to the bogie
assembly.
D275AX-5 30-199
2! !
8. Using tool L20, press fit cartridge pin assembly

(11).
★ Press fit the cartridge pin assembly to ma-
chined surface "c" of the bogie.
disulfide (LM-P)
★ Press fitting force for cartridge pin assembly:
275 - 490 kN {28 - 50 tons}
10. Press fit the cartridge pin assembly on the oppo-

site side according to steps 6-5) - 9 above.
11. Install cartridge pin assembly covers (2) and

tighten the bolts.
★ Install 2 covers, outside and inside ones.
12. Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track shoe tension.
9. Using tool L21, supply the specified quantity of

5 Cartridge pin assembly

(81 - 95% of full level):
61 - 71 cc (GO-140)
30-200 D275AX-5
! 2!

Bracket L14
Guide L19
D275AX-5 30-201
2! !
Plate L20
30-202 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY OF BOGIE

BLY OF BOGIE ASSEMBLY
SPECIAL TOOLS 3. Cartridge pin assembly
Remove cartridge pin assembly (4) according to
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch the procedure in REMOVAL OF BOGIE ASSEM-
790-101-2310 Block " 1 BLY.
790-445-4130 Screw " 2
★ See step 8.
796T-470-1130 Plate " 1 !
790-101-2360 Plate " 2
20 "
L 791-112-1180 Nut 2
Puller
790-101-4000 (490kN " 1
{50ton})
790-101-1102 Pump " 1
21 791-601-1000 Oil pump " 1
DISASSEMBLY
1. Track roller assembly
1) Turn over bogie assembly (1). 4. Bogie
2) Remove the roller cap and lift off 2 track roller Disconnect inner bogie (5) and outer bogie (6).
assemblies (2).
150 kg
165 kg
ASSEMBLY
1. Assembly of cartridge pin assembly
Assemble the cartridge pin assembly according
to the procedure in INSTALLATION OF BOGIE
ASSEMBLY.
2. Cover ★ See step 1.
Remove cover (3).
D275AX-5 30-203
2! !
2. Bogie 4. Refilling with oil

Set inner bogie (5) to outer bogie (6). Using tool L21, supply the specified quantity of
3. Cartridge pin assembly
5
1) Set tool L20.
Cartridge pin assembly (81 - 95% of
full level): 61 - 71 cc (GO-140)
2) Press fit cartridge pin assembly (4).

★ Press fit the cartridge pin assembly with the
cover. 5. Cartridge pin assembly (Opposite side)
★ Insert the cartridge pin assembly with arrow Press fit the cartridge pin assembly on the oppo-
"a" on its end face up (in the mounting state site side according to steps 3 - 4 above.
on the machine body). ★ After press fitting the cartridge pin assembly,
★ Press fit the cartridge pin assembly to the adjust it so that the inner bogie can slide
machined surface of the bogie. lightly.
Lubricant containing molybdenum 6. Covers
disulfide (LM-P) Install covers (3).
★ Press fitting force for cartridge pin assembly: ★ Install 2 covers, outside and inside ones.
275 - 490 kN {28 - 50 tons}
30-204 D275AX-5
! 2!
7. Track roller assembly

1) Sling 2 track roller assemblies (2) and set
them on the bogie.
★ Install the track roller assemblies with the oil
fillers out.
150 kg
165 kg
2) Install the roller caps to track roller assem-

blies (2) and secure them with the mounting
bolts.
★ Direct roller cap protectors "b" out of the bo-
gie.
824 - 1,030 Nm {84 - 105 kgm}
D275AX-5 30-205
2! !

Plate L20
30-206 D275AX-5
! 2!
EXPANDING AND INSTALLING
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY

TRACK SHOE ASSEMBLY
CHECK BEFORE EXPANDING TRACK EXPANDING TRACK SHOE ASSEMBLY
SHOE ASSEMBLY (NORMAL)
¤ Since it may be very dangerous to expand the ★ If CHECKING BEFORE REMOVAL OF TRACK
track shoe assembly, check the following items in SHOE ASSEMBLY shows that there is no abnor-
advance. mality, do as follows.
¤ Do not loosen the lubricator more than 1 turn. If
the grease does not come out well, move the 1. Set master link (3) in position.
machine forward and in reverse. ★ Bring the master link above the idler (just be-
hind the center).
1. Remove cover (1) and loosen lubricator (2) of the ★ Set blocks [1] and [2] at the front end of the
adjustment cylinder to discharge the grease. idler and between the carrier rollers so that
the mating faces of the master link will not
¤ Do not loosen the lubricator more than 1
open until the master bolt is removed.
turn.
2. Relieve track shoe tension.

2. After the shoe is loosened, perform EXPAND-
¤ Never loosen lubricator (1) more than one
ING TRACK SHOE ASSEMBLY (NORMAL).
turn.
3. If the track shoe is not loosened by the above ★ If the track is not relieved by loosening the lu-
work, perform EXPANDING TRACK SHOE AS- bricator, move the machine backwards and
SEMBLY (WHEN TRACK FRAME HAS INTER- forwards.
NAL TROUBLE).
★ The track frame may have an internal trouble
(damage of the recoil spring or recoil spring
set bolt, fall of the shaft end nut, etc.)
3. Remove track shoe (2).

★ 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.
D275AX-5 30-207
2!
(5) !
★ If a bolt is turned forcibly while it cannot be 2. Loosen the track shoe.

turned lightly, the threads of it and master ¤ Do not loosen the lubricator more than 1
link (3) may be damaged. turn.
★ If the track shoe is not loosened by loosening
the lubricator, move the machine forward
and in reverse to discharge the grease.
★ Check that the all grease has been dis-
charged.
4. Raise tip of master link, move machine towards

rear slowly, and lay out track shoe assembly (4).
★ Length of track : Approx. 10.5 m
¤ To prevent danger, never stand in front of the
idler yoke assembly.
3. Move the machine slowly forward against large
block 3 or a wall (or the blade of another ma-
chine of the similar size of the machine to be re-
paired, if available) to press the track shoe on the
idler side. When the recoil spring and track shoe
are distorted, stop and apply the brake. At this
time, set the master link between the idler and
front carrier roller.
★ For safe work, apply lever block 4 1between
the carrier roller support and link.
EXPANDING TRACK SHOE ASSEMBLY

(When a trouble is inside the track frame)
★ If any abnormality is detected by CHECK BE-
FORE EXPANDING TRACK SHOE ASSEMBLY,
perform the following procedure.
¤ If the track shoe is removed while the track frame
has an internal trouble, it may spring back. Even
if the track shoe is removed, the idler may jump
4. Remove track shoe (4) and disconnect master
out, and that can cause a serious result. Accord-
link (3).
ingly, expand the track shoe according to the fol-
lowing procedure.
5. Move the machine slowly in reverse to expand
track shoe assembly.
1. Remove the work equipment. For details, see
REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
30-208 D275AX-5
! (5)!
2
INSTALLATION
• Carry out expansion (normal) in the reverse or-
der to removal.
★ Adjust the track shoe tension. For details,

see TESTING AND ADJUSTING, Testing
and adjusting track shoe tension.
★ Tighten the shoe mounting bolts for the mas-

ter link in the following order.
2 Shoe mounting bolt:
Anti-seizure agent
(Maruzen MOLYMAX No. 2 or equivalent)
3 Shoe mounting bolt:
1st time: 490 ± 49 Nm {50 ± 50 kgm}
32nd time: Retighten by 180° ± 10°
★ Tighten the all 4 bolts with fingers until the
master link mating faces are fitted.
★ If the bolts are tightened forcibly before the
master link mating faces are fitted, the
threads of the bolts and master link may be
damaged.
D275AX-5 30-209
2! !
WHOLE DISASSEMBLY AND WHOLE
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRACK SHOE ASSEMBLY
WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF

TRACK SHOE ASSEMBLY
SPECIAL TOOLS
Sym- Part No. Part name
Ne- Q'ty New/Re- Sketch Sym- Part No. Part name
Ne- Q'ty New/Re- Sketch
bol cessity model bol cessity model
1 791-646-7531 Plug remover " 1 791-685-9560 Bolt " 4
2 791-660-7460 Pin brush " 1 790-434-1120 Adapter " 1
Push tool (For 01010-51030 Bolt " 1
3 791-646-7900 large plug) " 1
04530-12030 Eyebolt " 1
Push tool (For 13 Cylinder
4 791-932-1110 small plug) " 1
790-101-4300 (1,470 kN " 1
790-701-3000 Seal checker " 1 {150ton})
5 791-601-1000 Oil pump " 1 Hydraulic
790-101-1102 " 1
pump
6 791-632-1070 Installer " 1 N
791-685-9540 Rod " 1
Remover and 14
791-680-9802 " 1 791-685-9550 Nut " 1
installer
791-680-1520 Guide " 1 791-685-9510 Frame " 1
Puller (294kN 791-685-9520 Frame " 1
790-101-4200 " 1 791-685-9530 Rod " 1
{30ton}
7 791-685-9550 Nut " 2
Cylinder
790-101-4300 (1,470 kN " 1 791-685-9560 Bolt " 4
{150ton}) 791-126-0150 Adapter " 1
Hydraulic 791-680-5520 Guide " 1
790-101-1102 " 1
pump
791-126-0140 Pusher " 1
Push tool 15 790-434-1120
791-632-1500 " 1 N Adapter " 1
assembly
01010-51030 Bolt " 1
• 791-632-1420 • Adapter " 1 N
04530-12030 Eyebolt " 1
• 791-632-1430 • Ring " 1 N
791-685-9620 Extension " 1
• 791-632-1440 • Plate " 1 N
• 791-632-1450 • Ring " 1 N Cylinder
8 • 790-101-4300 (1,470 kN " 1
791-632-1460 • Push tool " 1 N {150ton})
• 791-632-1470 • Adapter " 1 N Hydraulic
• 791-632-1480 • Spring " 1 N 790-101-1102 " 1
pump
• 791-685-5730 • Bar " 1 R 791-680-1630 Spacer "
R • 01252-30650 • Bolt " 1 Puller (294kN
790-101-4200 " 1
• 01580-01210 • Nut " 1 16 {30ton})
Push tool Hydraulic
791-632-1400 " 1 N 790-101-1102 " 1
assembly pump
• 791-632-1410 • Adapter " 1 N 791-680-5541
Adapter (For
" 1
• 791-632-1430 • Ring " 1 N pin)
• 791-632-1440 • Plate " 1 N Adapter (For
791-680-9630 " 1
bushing)
• 791-632-1450 • Ring " 1 N 17
9 • 791-632-1460 Puller (294kN
• Push tool " 1 N 790-101-4300 " 1
{30ton})
• 791-632-1470 • Adapter " 1 N Hydraulic
• 791-632-1480 • Spring " 1 N 790-101-1102 " 1
pump
• 791-685-5730 • Bar " 1 18 790-434-1130 Guide " 1
• 01252-30650 • Bolt " 1 791-685-9510 Frame " 1
• 01580-01210 • Nut " 1 791-685-9520 Frame " 1
791-632-1490 Push tool " 1 N 791-685-9530 Rod " 1
10 791-685-5740 Push tool " 1 791-685-9540 Rod " 1
790-434-1110 Adapter " 1 791-685-9550 Nut " 3
790-434-1610 Guide " 1 791-685-9560 Bolt " 4
11 195-32-61210 Bolt (Shoe bolt
" 1 791-126-0150 Adapter " 1
may be used) "
19 01010-51030 Bolt 1
01010-51440 Bolt " 2
791-685-9620 Extension " 1
Cylinder
791-680-5541 Adapter " 1
790-101-4300 (1,470 kN " 1
{150ton}) 791-680-5550 Guide " 1
12
Hydraulic Cylinder
790-101-1102 " 1 790-101-4300 (1,470 kN " 1
pump
{150ton})
791-685-9510 Frame " 1
Hydraulic
791-685-9520 Frame " 1 790-101-1102 " 1
13 791-685-9530 pump
Rod " 1
791-685-9550 Nut " 1
30-210 D275AX-5
! 2!
WHOLE DISASSEMBLY
Sym- Ne- New/Re-
Part No. Part name Q'ty Sketch
bol cessity model
1. Removal of shoe
791-685-9510 Frame # 1
Sling the shoe assembly and set it with the shoe
791-685-9520 Frame # 1
791-685-9530 Rod # 1
up on the floor and remove the shoe by using a
791-685-9540 Rod # 1 shoe bolt impact wrench.
791-685-9550 Nut # 3 ★ If a shoe bolt is not loosened after it is un-
791-685-9560 Bolt # 4 screwed by 1 turn (If its torque is not reduced
791-126-0150 Adapter # 1 to 0), loosen the other bolts first, and it will be
01010-51030 Bolt # 1 removed smoothly.
20 791-685-9620 Extension # 1 ★ If a shoe bolt is turned forcibly while its
791-680-5550 Guider # 1 torque is not 0, bolt and link will adhere to
790-434-1140 Adapter # 1 each other and they will need to be repaired.
791-680-9630 Adapter # 1
★ When moving the shoe assembly, take care
Cylinder
790-101-4300 (1,470kN # 1 not to damage the master link.
{150ton}) ★ If it is obliged to cut a shoe nut with gas, keep
790-101-1102
Hydraulic
# 1
the seal temperature below 80°C to prevent
pump thermal deterioration of the seal and take
Puller
790-101-4200 (294kN # 1
measures to prevent the spatters from enter-
R 21 {30ton}) ing through the clearances among the links.
Hydraulic
790-101-1102 # 1
pump
22 790-434-1160 Guide # 1
791-685-9510 Frame # 1
791-685-9520 Frame # 1
791-685-9530 Rod # 1
791-685-9540 Rod # 1
791-685-9550 Nut # 3
791-685-9560 Bolt # 4
791-126-0150 Adapter # 1
23 790-434-1150 Guide # 1
790-434-1120 Adapter^ # 1
01010-51030 Bolt # 1
790-434-1160 Guide # 1
Cylinder 2. Disassembly of link
790-101-4300 (1,470kN # 1
{150ton}) 1) Set the link assembly on a link press (Tool
Hydraulic R7) and hit it with a hammer so that the
790-101-1102 # 1
pump bushing will be fitted to the jaw.
★ When disassembling the track shoe, see "Parts
judgment guide, Undercarriage, Lubricated
track" and "Parts judgment guide, Undercar-
riage, Reversing procedure for lubricated track".
D275AX-5 30-211
3
2! !
★ If the link tread, outside of the bushing, etc.

are worn, adjust the height of the jaw or
guide plate and align the pin and bushing
with the disassembly jig so that the link hole
will not be damaged during disassembly
work.
★ If the pin and bushing are not aligned well,
the link hole may be damaged and the pin
and bushing may be broken during disas-
sembly work.
3) Return the left cylinder and operate the right

cylinder to pull out the pin and bushing from
the right link simultaneously.
★ Using tool R1, drive the small plug of the pin

inward after the disassembly work so that the
workplace will not become dirty.
4) Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides and feed the next 1 set of the link as-
sembly to the jaw.
★ If the bushing ends and sealing surfaces are
damaged, oil will leak. Accordingly, handle
them carefully.
★ Since the broken wedge link has sharp edg-
es, take care not to cut your hands with them.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
★ Check the pulling out force of the pin and
bushing to see if the necessary press fitting
force for the pin and bushing can be obtained
when reversed and assembled again.
★ The wedge link is broken with a bang. This
sound does not indicate abnormality.
30-212 D275AX-5
! 2!
3. Inspection ★ Precautions for storage

Check the parts for the following items to see if 1) Store the seal without removing it from the link
they can be used for a lubricated track or a so that the counterbore portion will not be rusted
grease-filled track, then examine them generally and take care not to damage the seal lip.
and determine to use them for a lubricated track 2) Apply rust-preventive oil to the pin and bushing
or grease-filled track. fitting parts, shoe mating surface, and master
★ For judgment of reuse of the parts, see link mating surface of the link.
"Parts judgment guide, Undercarriage, Lu- 3) When storing, apply rust-preventive oil to the all
bricated track". surfaces of the pin, bushing, and spacer. Take
care not to damage the ends of the bushing in
1) Check the parts visually for damage. If a particular.
part seems to be damaged, check it by dye
penetrant test or magnaflux inspection. If it
has any crack, it cannot be used again. Dis-
card it.
WHOLE ASSEMBLY
When recycling for lubricated track
2) Measure the outside diameter of the press
fitting parts of the pin and bushing and the in- 1. Preparation work
side diameter of the pin and bushing fitting 1) Cleaning seal assembly
parts of the link with a micrometer and a cyl- Remove the seal assembly from the link and
inder gauge to see if the allowable fitting al- divide it into the seal ling and load ring, then
lowance is obtained. When using the pin, clean them.
bushing, and link for a lubricated track, how- ★ Since the seal ring and load ring are deterio-
ever, secure the standard fitting allowance rated easily by the cleaning liquid (trichloro-
between the pin and link. ethylene etc.), clean them quickly. After
★ If the allowable fitting allowance is not ob- cleaning them, wipe off the cleaning agent
tained, replace the parts with new ones. from them.
★ For the dimensional criteria, see MAINTE-
NANCE STANDARD.
D275AX-5 30-213
2! !
2) When reusing the pin, chamfer its end cor- iv) Drive in the bar with a hammer.
ners smoothly with a grinder. Remove the ★ Driving distance "a" from pin end: 10 ± 1 mm
nodules sticking to the press fitting parts with ★ If the chamfered part of the pin hole has
the grinder, too. been worn, chamfer it with a small-sized
★ If the ends are worn and sharpened, they grinder (grindstone tip angle: 45°- 60°) so
may scuff the press fitting parts and cause oil that the plug will not be damaged.
leakage. ★ Coat the plug with GO90 and drive it with the
small diameter end ahead.
3) If the link, pin, bushing, and spacer are dirty,

clean them. Remove the nodules sticking to 5) Installation of seal assembly
the link and bushing with the grinder, too. Clean the counterbore portion of the link
carefully and push in the seal to the bottom
★ Since these parts rust easily, clean them just by using tool R6.
before assembling them. ★ If oil is sticking to the counterbore portion of
★ Do not polish the bushing ends. If they are the link or seal assembly, the seal will turn
polished, oil may leak. and its sealing performance will lower. Ac-
4) If the large plug was pulled out, drive it in by cordingly, do not apply any oil. When insert-
using tool R3. ing the seal in the counterbore portion, take
★ Using tool R2, clean the pin hole in ad- care that oil not stick to the seal and counter-
vance. bore portion.
i) Insert the plug through the plug insertion

window into the guide hole.
ii) Push the bar with the hand until the plug
stops.
iii) Push the plug with the bar to press the
guide against the pin.
30-214 D275AX-5
! 2!
6) Adjust the dimensions of the press fitting jig

of the link press to keep the projection of the
pin and bushing constant and keep the in-
stalled dimensions of the seal within the
standard range.
★ For the standard dimensions, see DIMEN-
SIONS TABLE OF FITTING JIG OF LINK
PRESS.
★ If the pin end (part P) or link sides (parts Q
and R) are worn, add the dimensions of the
worn parts when adjusting the standard di-
mensions so that the projections of the pins
and bushings on both sides will be even.
2) Press fit the master links on both bushing
sides to the bushing with the shoe fitting fac-
es up.
★ At this time, use the master links on the pin
side as supports.
★ Press fitting force for bushing:
137 - 274 kN {14 - 28 tons}
7) Adjust the relief pressure of the link press so

that the pressing force of the press will not
exceed the standard value.
★ If the pressing force is too strong, the spacer
will be pressed forcibly against the bushing.
As a result, the spacer may be broken and it
and bushing may be worn abnormally.
★ Pushing force of pin and bushing: 3) Using the shoe bolt hole pitch gauge, press
735 kN {75 tons} fit the master links until the distance between
Pushing force ≈ 1.8 x Average pressure the shoe bolt holes of both links is the stan-
(Adjust the relief pressure of the link press to dard value.
set the press cutting force.) ★ Remove the all steel chips caused by press
fitting of the bushing with compressed air.
2. Assembly of link
1) Apply oil (GO90) to the mating surfaces of 4) Turn over the master links and check that
the pin and bushing with a clean brush and they are press fitted in parallel.
assemble them, then set them before the jaw
of the link press.
★ When reusing (reversing) the bushing, set
the worn outside surface of the bushing on
the shoe fitting side of the link (set the bush-
ing with the worn outside surface up on the
link press).
D275AX-5 30-215
2! !
5) Measure the projections of the bushing on 8) Set the right link and install the spacer to the
both sides with a depth gauge. pin.
★ Adjust the press fitting jig of the link press so ★ Check that the seal surface and bushing end
that the projections on both sides will be are free from dirt and apply oil (GO90) to
even. them with a clean cloth or brush.
★ When installing the spacer, wipe it with a
clean cloth.
6) Send the master links and set the next pin

and bushing.
★ When reusing a pin, install it so that its side 9) Set the right jig on the receiving side and the
hole will be the link tread side similarly to a left one on the pushing side and press fit the
new one. If it is not installed so, its strength pin and bushing simultaneously.
may be lowered. Accordingly, indicate the di- ★ If the pin and bushing have play when they
rection of the side hole on the end face to are press fitted, the seal may come off the
prevent a mistake. link. To prevent this, press fit smoothly. If the
seal comes off the link, stop press fitting and
set the seal to the link correctly, then start
press fitting again.
★ Press fitting force for pin and bushing:
284 - 519 kN {29 - 53 tons}
7) Apply gasket sealant (198-32-19890) to the

pin fitting parts of the links to prevent oil from
oozing out of the scuffed parts of the pin fit-
ting parts.
30-216 D275AX-5
! 2!
10) Using the spacer for fine adjustment, press 13) Press fit until the link, spacer, and bushing
fit the pin and bushing until the pin end is fit- are fitted together.
ted to the bottom of the receiving jig. ★ Actually, you cannot see from outside if the
★ Adjust the depth of the receiving jig hole so above parts are fitted. Accordingly, control
that the projections of the pin on both sides the hydraulic pressure of the link press. Set
will be even. the relief pressure to a proper level and
heighten the hydraulic pressure to that level.
For setting of the relief pressure, see PREP-
ARATION WORK.
★ Check that adjacent 2 links can turn around
each other.
11) Set the left link and install the spacer to the
pin.
★ Apply oil similarly to the right link.
14) Using a shoe bolt hole pitch gauge, measure

the distance between the shoe bolt holes
and check that the result is within the stan-
dard range.
★ If the distance between the shoe bolt holes is
longer than the standard range, disassemble
and check for abnormality, then press fit
again.
★ If the distance between the shoe bolt holes is
shorter than the standard range and the
shoe cannot be installed, the spacer or bush-
12) Set the left jig on the receiving side and the ing end may be worn more than the allow-
right one on the pushing side and press fit able limit. In this case, disassemble and
the left link. replace the parts.
★ When press fitting, take care that both seals
and spacers will not come off.
Press fitting force for link:
284 - 519 kN {29 - 53 tons}
D275AX-5 30-217
2! !
15) Install the ring to jig R8. 18) Using jig R10, push in the ring.
Pushing force for ring:
245 - 304 kN {25 - 31 tons}
16) Align the jig with plug hole and push it slowly
until a click is heard.
★ A click is heard when the ring slides down on 19) After each link is assembled, bleed air from
the jig and fits to the pin. the pin by using tool R5 and check the seal-
ing performance.
★ 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, disassem-
ble and check the seal. If the seal is free
from abnormality, assemble again.
17) Using jig R9, insert the ring in the pin groove
on the opposite side similarly.
30-218 D275AX-5
! 2!
20) Using tool R5, supply oil (G090) until the oil
supply pressure rises to 196 - 294 kPa {2 - 3
kg/cm2}.
★ In a cold or very cold district, supply Komatsu
genuine oil (150-09-19270 or 195-32-61990)
having better low-temperature characteris-
tics instead of G090.
★ If the oil pressure is heightened too much, it
has bad effects on the seal. Take care.
22) Assemble the master link on the pin side at

last.
★ 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
★ Supply oil so that depth L of the hollow of the a torque wrench.
pin hole will be in the following range when 2 Shoe bolt: Lubricant containing
the link is left with the small plug side up molybdenum disulfide (LM-P)
3 Shoe bolt (Regular link)
(when the link assembly is placed on its side)
for 30 minutes.
Initial torque:
Dimension L: 50 - 80 mm
784 ± 78 Nm {80 ± 8 kgm}
3 Retightening angle: 120°° ± 10°°
21) After supplying oil, drive in the small plug to

the specified position, using tool R4.
★ Apply G090 around the small plug.
★ Drive in the plug to the following depth.
Driving depth from end: 7.5 ± 1 mm
D275AX-5 30-219
2! !
2) When installing a double track, place the as-

sembled double shoes on a level place in 1
line with the shoe side up.
3) Pull pin-side master link (1) and bushing-
side master link (2) together and set them to
each other by the mating faces.
4) Place shoe (3) on the links and fits the mat-
ing faces of the links.
5) Check that shoe bolts (4) can be tightened
easily, then connect the links with the master
bolts.
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will be
press fitted smoothly.
2 Shoe bolt:
Anti-friction compound (LM-P)
3 Shoe bolt (Master link)
Initial torque:
490 ± 49 Nm {50 ± 5 kgm}
3 Retightening angle: 180°° ± 10°°
★ Tighten the bolts in the order of 1 - 4 .
When recycling for grease-filled track
1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link and
divide it into the seal ling and load ring, then
clean them.
★ Since the seal ring and load ring are deterio-
rated easily by the cleaning liquid, clean
them quickly. After cleaning them, wipe off
the cleaning agent from them.
30-220 D275AX-5
! 2!
3) Drive in the large and small plugs by using

tools R3 and R5.
i) Insert each plug through the plug inser-
tion window into the guide hole.
★ Apply oil to each plug.
ii) Push the bar with the hand until the plug
stops.
iii) Push the plug with the bar to press the
guide against the pin.
iv) Drive in the bar with a hammer.
★ Driving distance "a" from pin end:
Small plug: 7.5 ± 1 mm
Large plug: 10 ± 2 mm
★ If the plugs were not pulled out when the 7) Adjust the dimensions of the press fitting jig
shoe was disassembled, reuse them as they of the link press to keep the projection of the
are. pin and bushing constant and keep the in-
4) If the outside of the pin, surfaces of the spac- stalled dimensions of the seal within the
er, and ends and inside of the bushing are standard range.
dirty, clean them. ★ For the standard dimensions, see DIMEN-
5) Apply grease to the outside of the pin and SIONS TABLE OF FITTING JIG OF LINK
surfaces of the spacer. PRESS.
6) Installation of seal assembly

Clean the counterbore portion of the link
carefully and push in the seal to the bottom
by using tool R6.
★ If grease is sticking to the counterbore por-
tion of the link or seal assembly, the seal will
turn and its sealing performance will lower.
Accordingly, do not apply any oil.
D275AX-5 30-221
2! !
2. Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and assem-
ble them, then set them before the jaw of the
link press.
★ When reusing (reversing) the bushing, set
the worn outside surface of the bushing on
the shoe fitting side of the link (set the bush-
ing with the worn outside surface up on the
link press).
5) Measure the projections of the bushing on

both sides with a depth gauge.
★ Adjust the press fitting jig of the link press so
that the projections on both sides will be
even.
2) Press fit the master links on both bushing

sides to the bushing with the shoe fitting fac-
es up.
★ At this time, use the master links on the pin
side as supports.
137 - 274 kN {14 - 28 tons}
6) Send the master links and set the next pin

and bushing.
★ When reusing a pin, install it so that its side
hole will be the link tread side similarly to a
new one. If it is not installed so, its strength
may be lowered. Accordingly, indicate the di-
rection of the side hole on the end face to
prevent a mistake.
★ If the outside of the pin is worn, install it so
that the un-worn surface will be on the trac-
tion side. In this case, install the pin so that
its side hole will be the link tread side, too.
3) Using the shoe bolt hole pitch gauge, press
fit the master links until the distance between
the shoe bolt holes of both links is the stan-
dard value.
★ Remove the all steel chips caused by press
fitting of the bushing with compressed air.
4) Turn over the master links and check that

they are press fitted in parallel.
30-222 D275AX-5
! 2!
7) Set both links and operate both pushing jigs 9) Install the ring to jig R8.
to press fit the pin and bushing simulta-
neously.
★ If the pin and bushing have play when they
are press fitted, the seal may come off the
link. To prevent this, press fit smoothly. If the
seal comes off the link, stop press fitting and
set the seal to the link correctly, then start
press fitting again.
★ Pushing force of pin and bushing: 735 kN
{75 tons}
Pushing force ≈ 1.8 x Average pressure
(Adjust the relief pressure of the link press to
set the press cutting force.)
10) Align the jig with pin hole and push it slowly
until a click is heard.
Using jig R9, install the ring on the opposite
side similarly.
★ A click is heard when the ring slides down on
the jig and fits to the pin.
8) Using a shoe bolt hole pitch gauge, measure

the distance between the shoe bolt holes.
When the distance is in the standard range,
stop press fitting.
11) Using jig R10, push in the ring.

Pushing force for ring:
245 - 304 kN {25 - 31 tons}
12) Assemble the master link on the pin side at

last.
★ Check that the master links on both sides are
press fitted in parallel.
D275AX-5 30-223
2! !
3. Installation of Shoe 2 Shoe bolt: Lubricant containing mo-

1) Set the link assembly on the bed and install lybdenum disulfide (LM-P)
the shoe with a shoe bolt impact wrench and 3 Shoe bolt (Master link)
a torque wrench.
2 Shoe bolt: Lubricant containing mo-
Initial torque:
490± 49 Nm {50 ± 5 kgm}
lybdenum disulfide (LM-P) 3 Retightening angle: 180°° ± 10°°
3 Shoe bolt (Regular link) ★ Tighten the bolts in the order of 1 - 4 .
Initial torque:
784 ± 78 Nm {80 ± 8 kgm}
3 Retightening angle: 120°° ±10°°
2) When a 2-piece track is used, place the as-

sembled 2 shoes on a level place in 1 line
with the shoe side up.
side master link (2) together and set them to
each other by the mating faces.
4) Place shoe (3) on the links and fits the mat-
5) Check that shoe bolts (4) can be tightened
easily, then connect the links with the master
bolts.
30-224 D275AX-5
! 3!
2
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
Unit: mm
Precaution
Dimensions of jig 1. The link receiving faces of jaw (5) must be verti-
cal.
a 4.2 2. Replaceable wear plate (6) is desirable.
b 2.0
c 44.5
Adjust the dimensions of the press fitting jig of

the link press to keep the projection of the pin
and bushing constant and keep the installed di-
mensions of the seal within the standard range.
D275AX-5 30-225
2! !
DISASSEMBLY OF 1 LINK IN THE FIELD 4. Set tool R15 and apply oil pressure to pull out pin
(3).
¤ Only how to use the tools is explained below.
★ After the cylinder reaches the stroke end, in-
For details of disassembly and assembly, see
stall extension tool R15 between the adapter
WHOLE DISASSEMBLY (OR ASSEMBLY) OF
and guide, then repeat the work.
TRACK SHOE.
1. Using 2 bolts (2), install tool R11 to link (1).
★ As 2 bolts (2) for this step, 2 track bolts may
be used.
5. Set tool R16 and spacer 1 at the center of roller

tread side of the link to be disassembled and ap-
ply oil pressure to the puller to open the link by
"a" (5 - 6 mm) to disconnect it.
2. Assemble tools R12 and R13, then sling them to-
gether and set them on the track.
3. Insert the rod of tool R14 from the cylinder side

and install it with 2 nuts.
★ Install the rod through the hole of link (1).
30-226 D275AX-5
! (5)!
2
ASSEMBLY OF 1 LINK IN THE FIELD 3. Set link (4) on the opposite side and support it
with tool R18.
1. Assembly of link sub-assembly
1) Set tool R17 to the link end and press fit
bushing (1).
137 - 274 kN {14 - 28 tons}
4. Set tools R19 and R20 as for pin pulling work

and press the pin end “c” with tool R19 and the
bushing end “d” with tool R20 alternately.
★ Press fitting force for pin:
2) Set tool R17 to the link end (on the pin side) 147 - 245 kN {15 - 25 tons}
and press fit pin (2). ★ Press fitting force for bushing:
★ Set the pin with side hole "a" toward link 137 - 274 kN {14 - 28 tons}
tread "b".
147 - 245 kN {15 - 25 tons}
5. Using tool R21 as for disassembly, push link (5)

on the bushing side open.
2. Set link sub-assembly (3) to the link to be con-

nected.
D275AX-5 30-227
2!
(5) !
6. Set pin-side link (6) to bushing-side link (5) and

connect them by tool R22, then remove tool R21.
7. Set tool R19 to pin (7) side and press fit pin (7),
using tool R23.
2 Pin fitting hole of link:
Gasket sealant (198-32-19890)
Cylinder: b
Frame side: e
★ Set the pin with the side hole toward the link
tread.
299 - 490 kN {30 - 50 tons}
8. Using tools R8, R9, and R10, install the ring.

★ For the procedure, see ASSEMBLY OF
LINK.
30-228 D275AX-5
! (5)!
2
DISASSEMBLY OF MASTER LINK

★ For the method of using tool R7, see DISAS-
SEMBLY OF 1 LINK IN THE FIELD.
1. Removal of track shoe assembly

Remove the track shoe assembly from the track
frame. For details, see EXPANDING TRACK
SHOE ASSEMBLY.
2. Removal of master link

1) Cutting and removal of master link on bush-
ing side with gas
Cut the parts marked with gas and re-
move the parts marked . Move master
links (5) and (6) in the direction of and to
pull them out. Then, push pins (8) and (9)
out of regular link (7) in the directions of
and with a press.
Necessary special tools:
1. Gas cutting machine
2. Tool R7
2) Removal of master link on pin side

Cut the parts marked with gas and re-
move the parts marked . Push pin (10)
out of link (11) in the direction of with a
press. Then, pull pin (10) and link (12) to-
gether out of bushing (13).
Necessary special tools:
1. Gas cutting machine
2. Tool R7
D275AX-5 30-229
3
2! !
ASSEMBLY OF MASTER LINK 2) Set spacer (3) and seal assembly (4) to the
counterbore of the link of the connecting
★ For the method of using tool R7, see DISAS-
part.
SEMBLY OF 1 LINK IN THE FIELD.
1. Assembly of bushing-side link

1) Press fit bushing-side master link (1) to
bushing (2) with a press.
★ When press fitting both master links,
take care that they will be in parallel with
each other.
★ Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1 184.15 ± 0.7
L2 234.95 ± 0.7 3) Match the pin hole and bushing hole to each
Drill 30 in other and connect the pin and bushing with
D1
diameter guide pin 1 .
D2 27 × 2.0
4) Press fit pin (5) with tool R7 and install bush-

ing-side master link (1).
2 Apply gasket sealant (198-32-
2. Installation of bushing-side link
1) Expand the center of the link tread with tool
R7 as shown in the figure. (Expand the link 19890) to the pin hole of the link.
end by 10 mm.) ★ Set the pin with its side hole on the link tread
a: 5 mm side.
30-230 D275AX-5
! 2!
5) Using tools R7, R8, R9, and R10, install the 2) Pass pin (10) through bushing (9) and set
ring. and press fit pin-side master links (11) from
★ For the procedure, see ASSEMBLY OF both sides with tool R7.
LINK. 3) Using tools R7, R8, R9, and R10, install the
ring.
6) Install the shoe to the link of the connecting ★ For the procedure, see steps 9) - 12) in
part. Assembly of link.
7) Drive large plug (6) with tool R3 and supply 4) Drive large plug (13) with tool R3 and supply
oil with tool R5, then drive small plug (7) with oil with tool R5, then drive small plug (14)
tool R4. with tool R4.
★ When press fitting both master links,
take care that they will be in parallel with
each other (Bushing side and pin side).
★ Do not damage the mating surfaces of
the master links and end faces of the
bushing.
★ 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.
4. Connection of master links

1) When a 2-piece track is used, place the as-
sembled 2 shoes on a level place in 1 line
with the shoe side up.
side master link (16) together and set them
to each other by the mating faces.
3) Place the shoe on the links and fits the mat-
3. Assembly of pin-side link 4) Check that the shoe bolts can be tightened
1) Set spacer (3) and seal assembly (4) to the easily, then connect the links with the master
counterbore of the master link. bolts.
2 Shoe bolt:
Lubricant containing molybde-
num disulfide (LM-P)
3 Shoe bolt (Master link)
Initial torque:
490 ± 49 Nm {50 ± 5 kgm}
Retightening angle: 180°° ± 10°°
D275AX-5 30-231
3
2! !
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT ASSEMBLY

OF PIVOT SHAFT ASSEMBLY
SPECIAL TOOLS INSTALLATION
Sym- Ne- New/Re- • Carry out installation in the reverse order to re-
moval.
1 790-401-1700 Lifting tool " 1
791-650-1700 Installer " 1
Puller ★ Using tool P2, press fit seal (2) to the pivot
P 790-101-4200 (294kN " 1 shaft.
2 Press fitting face of seal:
2
{30ton})
Hydraulic
790-101-1102 " 1
pump Gasket sealant (LG-6)
★ Check that press fitting distance "a" of the
seal from the shaft end is as follows.
REMOVAL • Press fitting distance "a":
493.5 ± 1.0 mm
1. Remove the track frame assembly. For details,
see REMOVAL OF TRACK FRAME ASSEM-
BLY.
2. Using tool P1, sling pivot shaft assembly (1) tem-

porarily.
3. Remove the mounting bolts. Using forcing screw

1 , pull out pivot shaft assembly.
4 Pivot shaft assembly: 145 kg
4. Remove seal (2) and cover (3).
30-232 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF EQUALIZER
DISASSEMBLY AND ASSEMBLY BAR ASSEMBLY

OF EQUALIZER
BAR ASSEMBLY
SPECIAL TOOLS 4. Remove mounting nuts and cover (2).
Sym- Ne- New/Re-
791T-650-1930 Spacer " 1 N !

5. Disconnect grease tube (3).
792-900-1520 Plate " 1
791-520-4140 Screw " 1 6. Remove cover (4).
790-101-2470 Adapter " 1
790-101-2540 Washer " 1
N 1
791-112-1180 Nut " 1
Puller
790-101-2102 (294kN " 1
{30ton})
Hydraulic
790-101-1102 " 1
pump
REMOVAL
1. Remove the engine undercover and power train
undercover.
4
7. Pull out side pin (5).
★ If the equalizer bar hole is not aligned with
4 Power train undercover: 320 kg the track frame hole, the pin cannot be pulled
out easily. Accordingly, adjust the height of
2. Set stand 1 and hydraulic jack 2 under the ra- the equalizer bar side with hydraulic jack 2 .
diator guard. ★ Remove the pin on the opposite side by re-
peating steps 3 - 7.
D275AX-5 30-233
2! !
8. Operate hydraulic jack 2 slowly to lower the ma- 13. Sling equalizer bar (8) and lower it, bypassing
chine body until the equalizer bar touches both both track frames.
track frames. ¤ After remove the equalizer bar, do not lower
the machine body.
4
9. Disconnect lubrication tube (6).
Equalizer bar: 275 kg
10. Remove lock plate (7).
11. Using tool N1, remove center pin (8).

INSTALLATION
★ If the equalizer bar hole is not aligned with
the main frame hole, the pin cannot be pulled • Carry out installation in the reverse order to re-
out easily. Accordingly, adjust the height of moval.
the main frame side with the hydraulic jack.
Installation procedure for cover (2)

1) Tighten the 5 mounting bolts of cover (4)
lightly.
2) Install cover (2) and secure it with the 2 nuts.
3) Tighten the mounting bolts of cover (4) per-
manently.
4) Install grease tube (3).
12. Operate the blade to raise the front part of the

machine body and set a hydraulic jack under the
radiator guard.
30-234 D275AX-5
! 2!

★ Before installing the side pin, operate the hy-
draulic jack to adjust the main frame height
and align the equalizer bar hole with the
track frame hole.
★ Set the grease holes of the pins in the follow-
ing directions.
• Left pin: Outside of machine body
• Right pin: Inside of machine body
2 Equalizer bar side bushing:
Grease (G2-LI)

★ Before installing the center pin, sling the
equalizer bar and align the equalizer bar hole
with the main frame hole.
2 Equalizer bar center bushing and
main frame bushing: Grease (G2-LI)
D275AX-5 30-235
2! !

Spacer N1
30-236 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR BUSHING

BLY OF EQUALIZER BAR
BUSHING
SPECIAL TOOLS 3) Using tool N2, remove spherical bushing (5)
from equalizer bar (6).
Sym- Ne- New/Re-
bol Part No. Part name cessity Q'ty model Sketch ★ Remove the parts on the opposite similarly.
791-650-1800 Remover " 1
Puller
790-101-2102 (294kN " 1
N 2
{30ton})
Hydraulic
790-101-1102 " 1
pump
DISASSEMBLY
1. Center bushing
Remove center bushing (1).
ASSEMBLY
1. Side bushing
1) Set spherical bushing (5) and tool N2 and
press fit spherical bushing (5) to equalizer
bar (6).
2. Side bushing
1) Remove ring (2) and seal (3).
2) Remove ring (4).
★ Install the spherical bushing as shown in the

figure.
i) Set bushing end "a" on the level.
ii) Install the bushing with grease hole "b"
slant.
D275AX-5 30-237
2! !
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR BUSHING
2) Install ring (4).

3) Using a press, press fit seal (3) and ring (2).
2 Part "c" between side bushing and
seal:
Supply 0.3 liters of grease (G2-LI)
(on each side).
★ Install the ring and seal so that they will be
flush with the equalizer bar.
2 Seal lip: Grease (G2-LI)
2. Center bushing
Using the press, press fit center bushing (1).
30-238 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY EQUIPMENT CONTROL VALVE ASSEMBLY

OF WORK EQUIPMENT CON-
TROL VALVE ASSEMBLY
REMOVAL 4. Disconnect 3 PPC hose clamps and plate (5).
nal of the battery.
¤ Lower the work equipment to the ground and re-
lease the residual pressure from the piping, re-
fe r r i n g t o T E S T I N G A N D A D J U S T I N G ,
Releasing residual pressure from work equip-
ment cylinders. Then, set the safety lock lever in
the LOCK position.
★ Plug the disconnected pipes and hoses to pre-
vent foreign matter from entering them.
★ Put tags to the disconnected pipes to prevent a
mistake in re-connecting them.
5. Disconnect hydraulic tank return hose (6).
1. Drain the oil from the hydraulic tank.
6. Disconnect blade PPC hose (7) and ripper PPC
6 Hydraulic tank: Approx. 130 ¬ hose (8).
• (7): Coupler (Color band: Blue)
2. Remove covers (1), (2), and (3) from the right
• (8): Coupler (Color band: Blue)
side of the machine body.
3. Disconnect hydraulic oil pressure sensor wiring

connector HHP (4).
D275AX-5 30-239
2! !
7. Disconnect PPC hoses (9) on the right side. 9. Disconnect accumulator hose (PPC main pres-
sure port) (11).
★ There 5 PPC hoses in the dual tilt machine
and 4 in the single tilt machine.
The PPC hoses are as follows from the top
(Dual tilt machine).
• Ripper tilt BACK hose
(Color band: Brown) (Coupler) (Port PA5)
• Ripper lift LOWER hose
(Color band: Black) (Coupler) (Port PA4)
• LEFT tilt cylinder hose
(Color band: Yellow) (Port PA3)
• Blade lift LOWER hose
(Color band: Not colored) (Port PA2)
• RIGHT tilt cylinder hose
(Color band: Brown) (Coupler) (Port PA1) 10. Remove accumulator bracket (12).
8. Disconnect PPC hoses (10) on the left side.
★ There 5 PPC hoses in the dual tilt machine

and 4 in the single tilt machine.
The PPC hoses are as follows from the top (Dual
tilt machine).
• Ripper tilt BACK hose
(Color band: White) (Coupler) (Port PB5)
• Ripper RAISE hose
(Color band: Not colored) (Coupler) (Port
PB4)
• LEFT tilt cylinder hose
(Color band: Green) (Port PB3)
• Blade lift RAISE hose
(Color band: Black) (Coupler) (Port PB2)
• RIGHT tilt cylinder hose
(Color band: White) (Port PB1)
30-240 D275AX-5
! 2!
11. Disconnect the work equipment hoses. 16. Remove the 4 mounting bolts. Using hanging
★ There are 10 work equipment hoses for the bolt 1 , lift off work equipment control valve as-
dual tilt machine and 8 for the single tilt ma- sembly (20).
4
chine. Work equipment control valve assem-
• Hoses (13) are as follows from the top (Dual bly: 155 kg
tilt machine).
Ripper tilt IN hose (Port A5)
Ripper lift LOWER hose (Port A4)
LEFT tilt cylinder hose (Port A3)
Blade lift LOWER hose (Port A2)
RIGHT tilt cylinder hose (Port A1)
• Hoses (14) are as follows from the top (Dual
tilt machine).
Ripper tilt BACK hose (Port B5)
Ripper lift RAISE hose (Port B4)
LEFT tilt cylinder hose (Port B3)
Blade lift RAISE hose (Port B2)
RIGHT tilt cylinder hose (Port B1)
INSTALLATION
moval.
,
★ Since the connecting positions of the PPC
hoses are indicated by their band colors,
check the band colors when connecting
those hoses.
• PPC hose band colors (Dual tilt machine)
12. Disconnect work equipment pump hoses (Port
P1) (15) and (Port PC) (16).
13. Disconnect PPC main pressure hose (Port PR)

(17).
14. Disconnect drain hose (Port TS) (18).
15. Disconnect work equipment pump hose (Port

LS) (19).
• PPC hose band colors (Single tilt machine)
D275AX-5 30-241
2! !

• Bleeding air
Bleed air from the piping. For details, see TEST-
ING AND ADJUSTING, Bleeding air from work
equipment cylinders.
30-242 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY OF WORK

BLY OF WORK EQUIPMENT
CONTROL VALVE ASSEMBLY
★ This chapter deals only with precautions to be
followed when reassembling the DISASSEMBLY
AND ASSEMBLY OF WORK EQUIPMENT
CONTROL VALVE ASSEMBLY.
★ Only the precautions for assembling the work
equipment control valve assembly are described
below.
★ For the tightening torque for each part, see
STRUCTURE AND OPERATION, Maintenance
standard.
ASSEMBLY
damage. Coat their sliding surfaces with en-
gine oil before installing.
★ When assembling the suction valve, check
that the spring is installed in the sleeve nor-
mally.
★ When assembling a relief valve or a plug,
check that the cut part of the backup ring is
closed and apply grease (G2-LI) to the pe-
riphery of the backup ring.
★ After installing the main relief valve assem-
bly, adjust it. For details, see TESTING AND
ADJUSTING, Testing and adjusting work
equipment oil pressure.
D275AX-5 30-243
2! !
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY

BLY OF HYDRAULIC
CYLINDER ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
Cylinder repair
790-502-1003 " 1
1 stand
790-101-1102 Pump " 1
Other than
790-102-2303 Wrench " 1
2 blade lift
790-102-3802 Wrench Blade lift " 1
790-102-4300 Wrench Ripper lift " 1
3
790-102-4310 Pin Ripper tilt " 2
790-201-1702 Push tool kit " 1
•790-101-5021 • Grip 1
3. Piston rod assembly
•01010-50816 • Bolt 1
4 •790-201-1831 Blade lift 1
• Blade lift cylinder
1) Set the cylinder assembly to tool U1.
• Push Blade tilt
• 790-201-1851
tool Ripper lift
1 2) Using a hydraulic pump or a power wrench
and tool U2, remove head assembly (8).
•790-201-1841 Ripper tilt 1
U 3) Pull piston rod assembly (9) out of cylinder
790-201-1500 Push tool kit " 1
(10).
• 790-101-5021 • Grip 1
★ Put an oil pan under the cylinder to re-
• 01010-50816 • Bolt 1 ceive the oil.
5 • 790-201-1640 Blade lift 1
• 790-201-1650 Blade tilt 1
• Plate
Ripper lift
• 790-201-1660 1
Ripper tilt
6 790-720-1000 Expander " 1
796-720-1670 Ring " 1
Blade lift
07281-01279 Clamp " 1
796-720-1690 Ring Blade tilt " 1
7
07281-01919 Clamp Ripper lift " 1
796-720-1680 Ring " 1
Ripper tilt
07281-01589 Clamp " 1
DISASSEMBLY
1. Cylinder tube
Remove the cylinder tube.
2. Quick drop valve

• Perform this procedure for only the blade
lift cylinder.
1) Remove quick drop valve (1).
2) Disassemble the quick drop valve assembly
i) Remove block (2).
ii) Remove spring (3), spacer (4), valves (5)
and (6), and collar (7).
30-244 D275AX-5
! 2!
• Blade tilt cylinder, ripper lift cylinder, and

ripper tilt cylinder
1) Remove the mounting bolt and disconnect
head assembly (11).
2) Pull piston rod assembly (12) out of cylinder
(13).
★ Put an oil pan under the cylinder to receive
the oil.
• Ripper lift and ripper tilt cylinders

1) Set piston rod assembly (12) to tool U1.
4. Piston assembly
• Blade lift cylinder and blade tilt cylinder
1) Remove the mounting bolts and 2 spacers
(14).
2) Remove 4 valves (15).
3) Remove piston assembly (16) from piston
rod (17).
4) Remove retainer (18). 2) Remove lock screw (24) of piston assembly
(23).
• Screw size: M12 x Pitch 1.75
5) Disassemble the piston assembly according

i) Remove wear rings (19).
★ The blade lift cylinder has 2 wear
rings and the dual tilt cylinder has 1
wear ring.
ii) Remove piston ring (20) from the piston.
★ Do not remove 2 seats (21) and valve
(22).
D275AX-5 30-245
2! !
★ If screw (24) is crushed so much that it 5. Head assembly

cannot be removed, tighten it and cut 1) Remove head assembly (8) or (11) from pis-
threads of the screw hole, then remove it. ton rod (17) or (25).
3) Using tool U3, remove piston assembly (23) 2) Disassemble the head assembly according
from piston rod (25). to the following procedure.
i) Remove O-ring and backup ring (29).
ii) Remove snap ring (30) and dust seal
(31).
iii) Remove packing (32), buffer ring (33),
and bushing (34).
4) Disassemble the piston assembly according

i) Remove backup ring and O-ring (26).
ii) Remove wear ring (27).
iii) Remove piston ring (28).
6. O-ring and backup ring
lift cylinder and blade tilt cylinder.
Remove O-ring and backup ring (35) from
piston rod (17).
30-246 D275AX-5
! 2!
ASSEMBLY
★ Take care not to damage the packings, dust
seals, O-rings, etc.
★ Clean each part and block the piping ports and
pin holes so that dirt will not enter them.
1. O-ring and backup ring

• Perform this procedure for only the blade lift
cylinder and blade tilt cylinder.
Install O-ring and backup ring (35) to piston rod
(17).
★ When installing the backup ring, warm it in
water at 50 - 60°C.
2) Install the O-ring and head assembly (8) or
(11) to piston rod (17) or (25).
2. Head assembly
1) Assemble the head assembly according to
the following procedure. 3. Assembly of piston assembly
i) Using tool U4, press fit bushing (34). 1) Set piston ring (28) to tool U6 and turn the
ii) Install buffer ring (33) and packing (32). handle of the tool by 8 - 10 turns to expand
iii) Using tool U5, install dust seal (31) the piston ring.
iv) Install snap ring (30). 2) Remove piston ring (28) from tool U6 and in-
v) Install O-ring and backup ring (29). stall it to the piston.
★ When installing the backup ring, 3) Using tool U7, shrink piston ring (28).
warm it in water at 50 - 60°C.
D275AX-5 30-247
2! !
4) Install wear ring (27). ii) Install screw (24).

5) Install backup ring and O-ring (26). ★ Before installing the screw, degrease and dry
★ When installing the backup ring, warm it in it well.
water at 50 - 60°C. ★ After installing the screw, bend 4 places of
the periphery of the screw.
2 Threads:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 - 73.6 Nm {6 - 7.5 kgm}
4. Piston assembly
• Ripper lift cylinder and ripper tilt cylinder
1) Install piston assembly (23) to piston rod (25)
and set them to tool U1.
3) When either or both of piston rod (25) and

piston assembly (23) are new, install them
i) Using tool U3, tighten piston assembly
(23).
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
ii) Make 1 screw hole to install the screw.
★ Apply the drill to the groove in the threads
between the piston and piston rod and cut
threads horizontally.
2) When reusing piston rod (25) and piston as-
• Thread cutting dimensions (mm):
sembly (23), install them according to the fol-
Tap drill diameter: 10.3
lowing procedure.
Tap drill depth: 27
★ Remove burrs and fins from the threads with
Tap size: 12 x 1.75
a file.
Tapping depth: 20
★ Clean the parts thoroughly and remove met-
iii) After making the screw hole, remove
al chips and dirt.
chips and dirt and clean thoroughly.
i) Using tool U3, tighten piston assembly
(23) in piston rod (25) until the screw
holes are matched.
30-248 D275AX-5
! 2!
iv) Install screw (24). 5. Piston rod assembly

★ Before installing the screw, degrease and dry • Blade tilt cylinder, ripper lift cylinder, and
it well. ripper tilt cylinder
★ After installing the screw, bend 4 places of 1) Insert piston rod assembly (12) in the cylin-
the periphery of the screw. der (13).
2 Threads: ★ Push in the piston rod to the stroke end.
Adhesive 2 Sealing part: Grease (G2-LI)
(LOCTITE No. 262 or equiva- 2) Tighten the mounting bolts of head assembly
lent)
3 Screw:
(11).
3 Mounting bolt (Ripper tilt):
58.9 - 73.6 Nm {6 - 7.5 kgm} 250 ± 24.5 Nm {25.5 ± 2.5 kgm}
3 Mounting bolt
(Blade tilt, ripper lift):
343 ± 34.3 Nm {35 ± 3.5 kgm}
• Blade lift cylinder and blade tilt cylinder

1) Install retainer (18) and piston assembly (16)
to piston rod (17).
2) Install 4 valves (15). • Blade lift cylinder
3) Install 2 spacers (14). 1) Set cylinder (10) to tool U1.
★ Clean and degrease the piston and threads 2) Install piston rod assembly (9) to cylinder
of the mounting bolts thoroughly. (10).
★ After tightening the mounting bolts, leave ★ Push in the piston rod to the stroke end.
them for about 30 minutes. 2 Sealing part: Grease (G2-LI)
2 Apply hardener (LOCTITE Primer 3) Using tool U2, tighten head assembly (8).
3 Head assembly:
T or equivalent) to the piston and
6 mounting bolts, then apply ad-
1,010 ± 2.9 Nm {103 ± 0.3 kgm}
hesive (LOCTITE No. 262 or
equivalent) to the piston and 6
mounting bolts by 0.5 - 0.7 cc
each.
3 Mounting bolt:
98.1 - 122.6 Nm {10 - 12.5 kgm}
D275AX-5 30-249
2! !
6. Quick drop valve

lift cylinder.
1) Assemble the quick drop valve assembly ac-
i) Install collar (7), valves (6) and (5), spac-
er (4), and spring (3).
ii) Install block (2).
2) Install quick drop valve assembly (1).
30-250 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY BLADE ASSEMBLY

OF BLADE ASSEMBLY
REMOVAL 3. Using plate (3), fix the lift cylinder assembly to
the radiator guard.
¤ Lower the work equipment to a level place and
★ Bind the piston rod with wires so that it will
set blocks 1 under both straight frames secure-
not come out.
ly.
4. Similarly, disconnect the lift cylinder assembly on

1. Remove cap (1) from the lift cylinder.
the opposite side from the blade.
★ Check the quantity and thickness of the in-
¤ After stopping the engine, release the residual
serted shims.
pressure from the piping, referring to TEST AND
hydraulic circuit.
5. Remove both covers (4).
6. Disconnect hose (5).

★ Plug the openings so that dirt will not enter
the piping.
★ Hose (5) is connected to only the right side
of the single-tilt machine and to both sides of
the dual-tilt machine.
2. Sling lift cylinder assembly (2) temporarily. Start 7. Remove both trunnion caps (6).
the engine and retract the piston rod fully.
D275AX-5 30-251
2! !
DISASSEMBLY AND ASSEMBLY BLADE ASSEMBLY
8. Remove blade assembly (7).

★ Start the engine and move the machine in re- ★ Adjust height "b" and width "c" of both
verse slowly to disconnect the blade assem- straight frames to the following values with
bly from the trunnion. block 1 , etc.
• Trunnion height "b": Approx. 860 mm
• Frame width "c": Approx. 2,930 mm
INSTALLATION
moval.
★ Adjust clearance "a" at the mating face of the

cap to the following value with shims and
check that the shims rotate smoothly.
★ After installing the blade, adjust its tilting dis-
tance, referring to TESTING AND ADJUST-
ING, Adjusting blade.
• Bleeding air
Bleed air from the work equipment cylinders. For
details, see TESTING AND ADJUSTING, Bleed-
ing air from work equipment cylinders.
★ Adjust the shims of the trunnion, referring to

blade.
30-252 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY RIPPER ASSEMBLY

BLY OF RIPPER ASSEMBLY
DISASSEMBLY 5. Set stand 2 between the arm and beam.
1. Remove right step (1).
6. Sling lift cylinder assembly (3) temporarily.
7. Remove the lock plate and pin (4).

★ Start the engine and retract the piston rod
fully and lower it onto the arm.
8. Sling tilt cylinder assembly (5) temporarily.
9. Remove the lock plate and pin (6).

★ Start the engine and retract the piston rod
fully and lower it onto the lift cylinder assem-
bly.
2. Set block 1 and drive the machine over it and

lower the blade.
¤ Lock the brake securely.
3. Sling shank (2) temporarily and operate the pin

puller cylinder to pull out the pin.
★ The pin puller cylinder is installed to only the
giant ripper machine.
4. Start the engine and raise the ripper assembly

fully, then lower and remove shank (2) gradually.
4 Shank (Multi-shank ripper): ★ Remove the pins on the opposite side simi-
350 kg (1 piece) larly.
4 Shank (Giant ripper): 500 kg
10. Sling beam (7) temporarily and remove the lock
plate.
11. Using forcing screw 3 , pull out both pins (8).
12. Lift off beam (7).

4 Beam: 1,750 kg
D275AX-5 30-253
2! !
¤ Release the residual pressure from the work

equipment cylinders, referring to TESTING AND
work equipment cylinders.
13. Disconnect tilt cylinder hose (9) and lift cylinder

hose (10).
18. Sling arm (13) and remove the lock plate.
19. Using forcing screw 4 , pull out both pins (14).
14. Sling tilt cylinder assembly (5) temporarily and

remove the lock plate and pin (11).
15. Lift off tilt cylinder assembly (5).

4 Tilt cylinder assembly: 160 kg
★ Remove the tilt cylinder assembly on the op-
posite side similarly.
20. Lift off arm (13).

4 Arm: 750 kg
16. Sling lift cylinder assembly (3) temporarily and

remove pin (12).
17. Lift off lift cylinder assembly (3).

4 Lift cylinder assembly: 185 kg
★ Remove the lift cylinder assembly on the op-
posite side similarly.
30-254 D275AX-5
! 2!
ASSEMBLY 6. Connect lift cylinder hose (10) and tilt cylinder

hose (9).
1. Set a stand under arm (13) and set arm (13) in
position.
2. Install pins (14) to both sides and secure them

with the lock plates.
★ When installing the tilt cylinder hose, set the

angle between the hose adapter and cylin-
der to "a" (50°) at the all 4 places.
3. Set lift cylinder assembly (3) in position and in-

stall pin (12).
★ After installing the lift cylinder assembly, low-
er it onto the arm.
★ Install the lift cylinder on the opposite side
similarly.
★ When installing tilt cylinder hose (9) to the

machine rear block, set the angle between
the hose adapter and machine rear block (in
the longitudinal direction) to "b" (10°) at the
all 4 places.
★ When installing the tilt cylinder hose clamp,
set the distance between the machine body
rear block adapter and the tilt cylinder hose
4. Set tilt cylinder assembly (5) in position.
clamp to "c" (560 mm).
5. Install pin (11) and secure it with the lock plate.
★ After installing the tilt cylinder assembly, low-
er it onto the lift cylinder assembly.
★ Install the tilt cylinder on the opposite side
similarly.
D275AX-5 30-255
2! !
7. Set beam (7) in position. 17. Pass a wire through the shank holder and raise
shank (2) slowly to align it with the pin hole.
8. Install pins (8) to both sides and secure them ¤ When aligning the pin holes, never insert
with the lock plates. your fingers in the pin holes.
18. Operate the pin puller cylinder to insert the pin.

★ The pin puller cylinder is installed to only the
giant ripper machine.
19. Raise the blade and lower the machine body

from block 1 .
9. Sling tilt cylinder assembly (5) temporarily.
10. Start the engine and extend the piston rod to

align the pin holes.
11. Install pin (6) and secure it with the lock plate. 20. Install right step cover (1).
★ Install the pin on the opposite side similarly.
12. Sling lift cylinder assembly (3) temporarily.
13. Start the engine and extend the piston rod to

align the pin holes.
14. Install pin (4) and secure it with the lock plate.
★ Install the pin on the opposite side similarly.
ÅD
• Bleeding air
★ Bleed air from the work equipment cylinders.
For details, see TESTING AND ADJUST-
ING, Bleeding air from work equipment cylin-
der.
★ Supply grease (G2-LI) to each connecting
pin.
15. Set block 1 and drive the machine over it and

lower the blade.
¤ Lock the brake securely.
16. tart the engine and raise the ripper assembly ful-
ly.
30-256 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ROPS GUARD

OF ROPS GUARD
REMOVAL
1. Sling the ROPS guard temporarily and remove
mounting bolts (1).
2. Lift off ROPS guard (2).

4 ROPS guard: 700 kg
INSTALLATION
moval.
3 Mounting bolt:
1,180 - 1,470 Nm {120 - 150 kgm}
D275AX-5 30-257
2! !
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB ASSEMBLY

OF OPERATOR'S CAB ASSEM-
BLY
REMOVAL 5. Remove covers (6) and (7).
6. Remove step (8) and covers (9) and (10).
nal of the battery.
★ Remove these parts from both sides.
1. Remove the ROPS guard. For details, see RE-
MOVAL OF ROPS GUARD.
2. Open operator's cab left cover (1).
7. Remove mounting bolts (11) under the opera-

tor's cab.
★ Remove the bolts from both sides.
3. Disconnect intermediate wiring connectors (CN-

19) (2) and cab power supply connectors (CN-
20) (3) and (CN-21) (4).
★ After disconnecting the connectors, pull out
the wires from inside of the operator's cab.
4. Disconnect 4 windshield washer hoses (5).
★ After disconnecting the hoses, pull out them

from inside of the operator's cab.
8. Remove mounting bolts (12) on the front side

and mounting bolts (13) inside the operator's
cab.
30-258 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB ASSEMBLY
9. Remove cigarette lighter cover (14) and discon- INSTALLATION

nect accessory socket wiring connector CN-D.
• Carry out installation in the reverse order to
removal.
10. Remove garnishes (15), (16), and (17).
★ When connecting the windshield washer

hoses, match the colors of their bands.
11. Remove mounting bolts (18) inside the opera-

tor's cab.
★ Remove the mounting bolts from both sides
and rear side.
12. Lift off operator's cab assembly (19).

4 Operator's cab assembly: 420 kg
D275AX-5 30-259
2! !
REMOVAL AND INSTALLATION OF FLOOR FRAME

OF FLOOR FRAME ASSEMBLY
SPECIAL TOOLS
Sym- Ne- New/Re-
Service tool
799-703-1200 " 1
kit
Vacuum
799-703-1100 pump " 1
(100 V)
Vacuum
X 799-703-1110 pump " 1
(220 V)
Vacuum
799-703-1120 pump " 1
(240 V)
799-703-1400
Gas leak
" 1
4. Remove left cover (8), armrest (9), and right cov-
tester er (10).
REMOVAL
nal of the battery.
¤ Lower the work equipment to the ground and re-
lease the residual pressure from the piping, re-
fe r r i n g t o T E S T I N G A N D A D J U S T I N G ,
Releasing residual pressure from work equip-
ment cylinders.
1. Remove the operator's cab. For details, see RE-

MOVAL OF OPERATOR'S CAB. 5. Remove bracket (11).
2. Remove covers (1), (2), (3), and (4).

(5), E21 (6), and E22 (7).
30-260 D275AX-5
! 2!
7. Disconnect wiring connectors DCL (13) and 12. Lift off floor plate (17).
4
BRK (14). Flower plate: 35kg

le.
13. Disconnect brake lever linkage (19).
9. Remove the mounting bolts of lower plate (16).
10. Remove the mounting bolts of floor plate (17).
14. Remove cover (20) and duct hose (21).

★ Loosen the bracket of receiver tank.
11. Lift off operator's seat assembly (18).

★ Remove the operator's seat assembly and
lower plate (16) together.
4 Operator's seat assembly: 100 kg
D275AX-5 30-261
2! !
15. Disconnect receiver tank hose (23) and air con- 20. Disconnect 5 blade PPC hoses (37), 5 ripper
ditioner compressor hose (24). PPC hoses (38), and accumulator hose (39).
★ Before disconnecting the air conditioner
hose, collect the refrigerant gas (R134a) by
using tool X.
16. Disconnect heater hoses (25) and (26).

side.
★ Plug the disconnected hoses.
21. Disconnect floor front support ground wire (40)

on the right side of the machine body.
18. Disconnect intermediate wiring connectors PWR

(28), USB (29), PL4 (30), PL5 (31), PL1 (32),
PL2 (33), and FE2 (34).
22. Disconnect 2 front mount bolts (41).
23. Remove 5 rear mount bolts (42) from each side.
19. Disconnect wiring connectors PPA (35) and

PDS-b (36).D
30-262 D275AX-5
! 2!
24. Lift off floor frame (43).

4 Floor frame: 550 kg ★ Since the connecting positions of the PPC
hoses are indicated by their clamp colors,
check the clamp colors when connecting
those hoses.
• Blade PPC hose clamp colors
(Dual tilt machine)
Green (44): Solenoid valve hose (Outside of
machine body)
Yellow (45): Solenoid valve hose (Inside of
machine body)
Not colored (46): Work equipment control
valve hose (port PA2)
Black (47): Work equipment control valve
hose (port PB2)
Blue (48): Drain centralized block hose (Rear
side of machine body)
INSTALLATION • Ripper PPC hose clamp colors
(Dual tilt machine)
Brown (49): Work equipment control valve
moval.
hose (port PA5)
hose (port PA4)
White (51): Work equipment control valve
hose (port PB5)
brake pedal and parking lever.
valve hose (port PB4)
Blue (53): Drain centralized block hose
(Front side of machine body)
take care that dirt, dust, and water will not
• Clamp colors between block and work
enter them.
equipment control valve (Dual tilt machine)
★ Before tightening each air conditioner hose
Yellow (54):Work equipment control valve
connector, check that the O-ring is fitted to it.
hose
★ Apply compressor oil (Showa-Shell, Suniso
Brown (55):Work equipment control valve
hose
Green (56):Work equipment control valve
hose
hose
3 Tightening torque for refrigerant gas pipes

Thread size : Tightening torque
16-1.5 11.8-14.7Nm {1.2-1.5kgm}
22-1.5 19.6-24.5Nm {2-2.5kgm}
24-1.5 29.4-34.3Nm {3-3.5kgm}
D275AX-5 30-263
2! !
★ Hose clamp colors seen from the right of the

machine body are shown.
• Blade PPC hose clamp colors

(Single tilt machine)
valve hose
hose
Green (58): Work equipment control valve
hose
Yellow (59): Work equipment control valve
hose
• Ripper PPC hose clamp colors
(Single tilt machine)
Brown (49): Work equipment control valve
hose
hose
hose
valve hose
★ Hose clamp colors seen from the right of the

machine body are shown.

30-264 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROLLER ASSEMBLY

OF TRANSMISSION CONTROL-
LER ASSEMBLY
REMOVAL
nal of the battery.
1. Remove operator's seat rear cover (1).
2. Disconnect 3 wiring connectors TMCN1,

TMCN2, and TMCN3 of the transmission con-
troller assembly.
3. Remove the mounting bolts and transmission

controller assembly (2).
INSTALLATION
moval.
3 Screw: 2.82 Nm {0.288 kgm}
D275AX-5 30-265
2! !
REMOVAL AND INSTALLATION OF STEERING
DISASSEMBLY AND ASSEMBLY CONTROLLER ASSEMBLY

OF STEERING CONTROLLER
ASSEMBLY
REMOVAL
nal of the battery.
1. Remove operator's seat rear cover (1).
2. Disconnect 3 wiring connectors STCN1, STCN2,

and STCN3 of the steering controller assembly.
3. Remove the mounting bolts and steering control-

ler assembly (2).
INSTALLATION
moval.
3 Screw: 2.82 Nm {0.288 kgm}
30-266 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF ENGINE
DISASSEMBLY AND ASSEMBLY CONTROLLER ASSEMBLY

OF ENGINE CONTROLLER
ASSEMBLY
REMOVAL
nal of the battery.
1. Remove operator's seat left rear cover (1).
2. Disconnect 3 wiring connectors ECN1, ECN2,

and ECN3 of the engine controller assembly.
3. Remove the mounting bolts and engine control-

ler assembly (2).
INSTALLATION
moval.
★ For the method of changing the fuel injection
amount adjustment after replacement of the en-
gine assembly or engine controller, ask your Ko-
matsu distributor.
3 Screw: 2.82 Nm {0.288 kgm}
D275AX-5 30-267
2! !
DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY

OF ENGINE HOOD ASSEMBLY
REMOVAL 4. Remove both side plates (3).
5. Remove both covers (4).
nal of the battery.
6. Open the left inspection cover of engine hood as-
1. Remove mounting bolt of radiator top cover (1). sembly (5).
2. Raise the radiator top cover and disconnect

7. Loosen the clamp and disconnect air conditioner
head lamp wiring connector 209 (2).
duct hose (6).
3. Lift off the radiator top cover.

★ Loosen the bracket of receiver tank (8) and
move it a side.
30-268 D275AX-5
! 2!
DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY
9. Lift off engine hood assembly (9).

★ Open the 5 locks on both sides before lifting
up the engine hood assembly.
4 Engine hood assembly: 210 kg
INSTALLATION
moval.
D275AX-5 30-269
2! !
DISASSEMBLY AND ASSEMBLY FAN DRIVE ASSEMBLY

OF FAN DRIVE ASSEMBLY
REMOVAL 4. Sling fan drive assembly (6) temporarily and re-
move the mounting bolts.
1. Drain the oil from the hydraulic tank.
6
5. Sling fan drive assembly (6) temporarily and re-
Hydraulic tank: Approx. 130¬ move the mounting bolts.
4 Fan drive assembly: 135 kg
2. Remove the mounting bolts and open fan guard
(1).
3. Disconnect fan motor hoses (2), (3), and (4) and INSTALLATION
remove plate (5).
★ Plug the openings so that dirt will not enter
moval.
the piping.
★ If plate (5) is not an obstacle to removal of
3 Upper mounting bolt:

the fan drive assembly, it does not need to be
removed.
235 - 285 Nm {23.5 - 29.5 kgm}
5Hydraulic tank: Approx.130¬
30-270 D275AX-5
! 2!
REMOVAL AND INSTALLATION OF FAN MOTOR

OF FAN MOTOR ASSEMBLY
Serial No. 20001 – 20030 • Carry out installation in the reverse order to re-
1. Remove the fan drive assembly. For details, see moval.
REMOVAL OF FAN DRIVE ASSEMBLY.
2. Remove bolt (1). 3 Mounting bolt:

147 - 196 Nm {15 - 20 kgm}
s Wipe all dirt off the tapered surfaces of the

fitting parts of fan motor shaft and fan.
3. Using puller 1 , remove fan (2).
4. Remove the 4 mounting bolts and fan motor as-

sembly (3).
4 Fan motor assembly: 40 kg
D275AX-5 30-271
4
2c
REMOVAL AND INSTALLATION OF FAN MOTOR

OF FAN MOTOR ASSEMBLY
Serial No.: 20031 and up 5. Remove the 4 mounting bolts and fan motor as-
sembly (4).
REMOVAL
4 Fan motor assembly: 40 kg
1. See the fan motor assembly. For details, see
REMOVAL OF FAN MOTOR.
2. Remove the mounting bolts and lock plate (1).
INSTALLATION
3. Remove nut (2). moval.
Be sure to align the hole of lock plate (1) by ro-

tating nut (2) in the tightening direction.
3 Mounting nut (2):

441 - 539 Nm {45 - 55 kgm}
s After tightening the nut, check dimension "d"
shown in the figure below.
e MIN: 1.2 mm
e MAX: 3.0 mm
4. Using puller (1), remove fan (3).
s Wipe off dirt from the engaging portions of

the fan motor and fan, and then degrease
those parts.
30-272 D275AX-5
4c
2
20-718 D275AX-5
4
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................. 90- 2

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................. 90- 3
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM ........................................ 90- 5
DIAGRAM FOR ELECTRICAL CIRCUIT (1/4) ........................................................................................ 90- 7
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER ......................................................... 90- 15
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB .................................................................................. 90- 16
D275AX-5 90-1
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Torque converter case 40. Sudden brake prevention valve

2. Transmission oil pan 41. Parking brake valve
3. Steering case oil pan 42. Pilot filter
4. Power train oil strainer 43. Pin puller cylinder
5. Power train pump (SAR100) 44. Last-chance filter
6. Steering lubricating oil pump (SAR50) A. Torque converter lock-up clutch pressure pick-up
7. Power train oil filter port
Cracking pressure: 0.29 MPa {3.0 kg/cm2} B. Torque converter stator clutch pressure pick-up
8. Main relief valve port
Set pressure: 3.2 ± 0.1 MPa {32.7 ±1 kg/cm2} C. Main relief pressure pick-up port
9. Torque converter relief valve D. Torque converter relief pressure pick-up port
Set pressure: E. 1st clutch pressure pick-up port
0.98 ± 0.05 MPa {10.2 ± 0.5 kg/cm2} F. 2nd clutch pressure pick-up port
10. Torque converter G. 3rd clutch pressure pick-up port
11. Torque converter lock-up changeover valve H. F clutch pressure pick-up port
12. Torque converter lock-up solenoid valve J. R clutch pressure pick-up port
13. Lock-up clutch modulating valve K. Left brake pressure pick-up port
Set pressure: 1.3 +0.1
0 MPa {13 +10 kg/cm2} L. Right brake pressure pick-up port
14. Stator clutch modulating valve
Set pressure: 2.6 ± 0.1MPa {27 ± 1kg/cm2}
15. Lock-up clutch
Set pressure: 1.3 +0.1
0 MPa {13 +10 kg/cm2}
16. Stator clutch
17. PTO lubrication
18. Stator clutch lubrication
19. Oil cooler
20. Steering lubricating oil filter
Cracking pressure: 0.29 MPa {3.0 kg/cm2}
21. Transmission lubrication
22. Transmission lubrication valve
Cracking pressure:
0.29 ± 0.03 MPa {3.0 ± 0.3 kg/cm2}
23. Scavenging pump (BAR(3)140)
24. Steering lubrication
25. 1st clutch modulating valve (ECMV)
26. 2nd clutch modulating valve (ECMV)
27. 3rd clutch modulating valve (ECMV)
28. F clutch modulating valve (ECMV)
29. R clutch modulating valve (ECMV)
30. Fill switch
Operating pressure: 0.27 MPa {2.7kg/cm2}
30A. Fill switch
Operating pressure:
1.68 MPa {17.1kg/cm2}
31. 1st clutch
32. 2nd clutch
33. 3rd clutch
34. F clutch
35. R clutch
36. Left brake ECMV
37. Right brake ECMV
38. Left brake
39. Right brake
90-2 D275AX-5
POWER TRAIN HYDAULIC CIRCUIT DIAGRAM
D275AX-5 90-3
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM
★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D275AX-5 90-5
DIAGRAM FOR ELECTRICAL CIRCUIT (1/4)
D275AX-5 90-7
D275AX-5 90-9
D275AX-5 90-11
D275AX-5 90-13
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER
D275AX-5 90-15
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB
90-16 D275AX-5

D275 Ax-5 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D275 Ax-5 PDF

Uploaded by

Copyright:

Available Formats

SEBM025508

Machine model Serial number

D275AX-5 20001 and up

• D275AX-5 mount the SDA6D140E-3 engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ....... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

90 OTHERS ............................................................................................ 90-1

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

q 00- 1 (8) 10- 8 10-54 (5) 10- 99 10-141 (4)

10-186 10-250 20-122 (5) 20-176 (5) 20-308 (6)

30- 51 (2) 30- 111 (2) 30-170 (2) 30-229 (3)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.